TH360B & TH560B

Telehandler Service Manual

31200264
S/N TBH00100 & After
S/N TBP00100 & After

Section Title Manual No.

Service Manual Contents 31200265

Torque Specifications 31200268

Engine
Disassembly & Assembly Engine Supplement 31200299

Power Train
Systems Operation, Testing & Adjusting Power Train 31200270
Disassembly & Assembly Power Train 31200300

Vehicle Systems
Schematic Hydraulic System 31200304
Systems Operation, Testing & Adjusting Hydraulic System 31200302
Systems Operation, Testing & Adjusting Steering System 31200273
Systems Operation, Testing & Adjusting Brake System 31200274
Machine Components Specs Machine Systems 31200306
Disassembly & Assembly Machine Systems 31200308

Electrical Systems
Schematic - TH360B Electrical System 31200310
Schematic - TH560B Electrical System 31200311
Machine Troubleshooting Hydrostatic Transmission 31200279
Electronic Control System
Systems Operation, Testing & Adjusting LSI System 31200280
Systems Operation, Testing & Adjusting Monitoring System 31200281

31200265 A
31200268
December 15, 2006

Specifications
Torque Specifications - TH220B, TH330B,
TH360B, TH560B & TH580B Telehandlers
S/N TBF00100 & After
S/N TBG00100 & After
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200268 1
Table of Contents
Table of
Table of Contents
Specifications Section
General Information .............................................. 3
Introduction to Torque ...................................... 3
Torque-Turn ..................................................... 3
Torque Sequence ............................................ 3
Metric (ISO) Fasteners .......................................... 4
Metric (ISO) Nuts and Bolts ............................. 4
Metric (ISO) Taperlock Studs........................... 4
Metric (ISO) Machine Screws .......................... 4
Hex Button Head Screw and Set
Screw ............................................................... 4
English (SAE) Fasteners ....................................... 5
English (SAE) Nuts and Bolts .......................... 5
English (SAE) Taperlock Studs........................ 5
English (SAE) Machine Screws ....................... 5
Hex Button Head Screw and Set Screws......... 6
Ground Engaging Tool (G.E.T.) Fasteners ........... 6
Installation of Fittings ............................................ 7
Installation of Split Flange Couplings ............... 7
Installation of Adjustable STOR Fittings........... 8
Straight Thread O-Ring Fittings ............................ 8
Plugs ................................................................... 10
Straight Thread O-Ring Plugs (Hex Drive)..... 10
Straight Thread O-Ring Plugs (Socket Drive) 11
Drain Plugs with Straight Thread .................. 11
Straight Thread O-Ring Plugs (Mechanical Joint
Tube Assemblies) .......................................... 11
O-Ring Face Seal Fittings ................................... 12
Bulkhead Nuts ..................................................... 12
Flare Fittings ....................................................... 13
37 Degree Flare Fitting .................................. 13
45 Degree Flare and 45 Degree Inverted Flare
Fittings ........................................................... 13
Air Conditioning Fittings ...................................... 14
Air Brake Fittings ................................................. 14
Tapered Pipe Thread Fittings.............................. 14
Miscellaneous Fittings ......................................... 15
Hi Duty Tube Fittings (Shear Sleeve)............. 15
SAE Flareless Fittings.................................... 15
Flex Fittings.................................................... 15
Hose Clamps....................................................... 15
Worm Drive Band Type Clamps..................... 15
Constant Torque Hose Clamps...................... 16
2 31200268
Table of Contents
31200268 3
Specifications Section

Specifications Section Torque-Turn

The torque-turn method is used when precise control
General Information over clamping force is required. There is an initial
torque and an additional turn. The initial torque is
required to bring all parts of the joint into contact. The
additional turn provides the desired clamping force.
Ensure that all fasteners have been torqued before you
Mismatched or incorrect fasteners can result in perform the additional turns. Turn the fastener
damage or malfunction, or personal injury. according to the specified amount. The specified
Take care to avoid mixing metric dimensioned fasteners amount will normally be equal to or greater than 90°.
and inch dimensioned fasteners. The specified amount will normally be in 30°
increments. Turns of 120° or 180° are preferred. Turns
Introduction to Torque of 120° or 180° are easily measured by the points of
the hex head of the fastener. Lubrication may be
"Torque" is measured in terms of force and distance. specified in order to reduce the effort that is required for
Force is the amount of pushing or pulling applied at the the final turn. The use of the torque-turn method will
end of the lever. Distance is the length of the lever that allow the following:
is being used. Torque values are given in the following
• Increase the life of the fastener.
units: NEWTON meters (Nm), pound inches (lb in), and
pound feet (lb ft) • Maximize the potential clamping force of a fastener.
This manual is intended to provide the operator with a
reference. This manual will provide the standard torque Typical applications are the following:
settings for the following: bolts, nuts, plugs, fittings, and • Track bolts
clamps.
• Sprocket bolts
Exceptions to these torques are given in the Service
Manual, if necessary. • Connecting rod bolts
Be sure to use a torque wrench that has the proper • Engine Cylinder Heads
range. Torque wrenches must be used properly in • Drive Shaft bolts
order to ensure that the correct torque is applied.
Always use a smooth pull for torque wrenches. Do not Note: Too much tension on the bolt will cause the bolt to
jerk a torque wrench. Do not use adapters that change be stretched beyond the point of yield. The bolt will be
the length of the torque wrench. For the correct use of permanently stretched. The bolt will loosen the grip on
your torque wrench, refer to the instructions that were the parts that are being fastened. If the bolt is
packaged with your torque wrench. tightened again, the bolt will break. Do not reuse bolts
that have been permanently stretched.
Prior to installation of any hardware, ensure that
components are in near new condition. Bolts and
threads must not be worn or damaged. Threads must Torque Sequence
not have burrs or nicks. Hardware must be free of rust Unless the bolt tightening sequence is specified by the
and corrosion. Clean reused fasteners with a Service Manual, the fasteners should be tightened in a
noncorrosive cleaner. Lightly lubricate the threads of cross pattern. Use Step 1 through Step 5 unless the
reused fasteners. Lightly lubricate the mating surface of tightening sequence is specified:
the head of reused fasteners. Other applications for
lubricating fasteners may also be specified in the 1. Hand tighten all fasteners. Larger fasteners may
Service Manual. The Service Manual may also specify require the use of a small hand wrench.
the use of sealants and compounds. 2. Torque all fasteners to 40% of full torque.
Note: Do not use sealants that are not specified in 3. Torque all fasteners to 70% of full torque.
the Service Manual. Do not use compounds that 4. Torque all fasteners to full torque by using a cross
are not specified in the Service Manual. Clean old pattern. Large flanges may require additional
compound from the bolt and from the hole before passes.
installation.
5. Apply at least one final full torque to all fasteners
in a clockwise direction until all torque is uniform.
Large flanges may require additional passes.
Note: Final torque may be a turn.
4 31200268
Specifications Section

Metric (ISO) Fasteners

Metric (ISO) Nuts and Bolts

Illustration 2 g00908932

Table 3

Thread Size
Torque
mm
Illustration 1 g00909614
M1.6 0.10 ±0.01 Nm (0.9 ±0.1 lb in)

Note: The following table has the recommended M2 0.15 ±0.01 Nm (1.3 ±0.1 lb in)
standard torque values for Metric nuts and bolts for use M2.5 0.35 ± 0.05 Nm (3.1 ±0. 4 lb in)
on Perkins engines.
M3 0.50 ± 0.05 Nm (4.4 ±0. 4 lb in)
Table 1
M4 1.70 ± 0.25 Nm (15.0 ± 2.2 lb in)
Thread Size
Torque M5 2.25 ± 0.25 Nm (19.9 ± 2.2 lb in)
mm
M6 5 Nm (44 lb in)
M8 22 Nm (16 lb ft) Hex Button Head Screw and Set
M10 44 Nm (32 lb ft) Screw
M12 78 Nm (60 lb ft)
M14 124 Nm (90 lb ft)
M16 177 Nm (130 lb ft)
M18 200 Nm (150 lb ft)
M20 400 Nm (300 lb ft)
M24 790 Nm (580 lb ft) Illustration 3 g01186742

Note: The difference between Caterpillar standard Table 4

torque values and Perkins standard torque values are Thread Size
due to different classes of fasteners. Caterpillar uses Torque
mm
class 10.9 fasteners. Perkins uses class 8.8 fasteners.
M3 .6± .1 Nm (5 ± 0.9 lb in)
The different class of fasteners have different tensile
strengths. M4 2± .3 N m ( 1 8 ± 3 l b i n )
M5 4± .5 Nm (35 ± 4 lb in)
Metric (ISO) Taperlock Studs M6 6± 1 N m ( 5 5 ± 9 l b in)
Note: The following table has the recommended M8 15 ±3 Nm (11 ± 2 lb ft)
standard torque values for metric nuts and bolts for use
M10 30 ± 7 Nm (22 ± 5 lb ft)
on Perkins engines.
Table 2
M12 50 ± 10 Nm (37 ± 7 lb ft)
M14 80 ± 15 Nm (60 ± 11 lb ft)
Thread Size
Torque
mm M16 125 ± 20 Nm (90 ± 15 lb ft)
M6 5 Nm (44 lb in)
M20 250 ± 40 Nm(185 ± 30 lb ft)
M8 11 Nm (97 lb in)
425 ± 50 Nm
M10 18 Nm (13 lb ft) M24
(310 ± 37 lb ft)
M12 25 Nm (18 lb ft) 850 ± 100 Nm
M30 (620 ± 75 lb ft)

Metric (ISO) Machine Screws M36

1500 ± 200 Nm
(1100 ± 150 lb ft)
31200268 5
Specifications Section

English (SAE) Fasteners English (SAE) Taperlock Studs

Table 6
English (SAE) Nuts and Bolts
Thread Size
Standard Torque
Inch
1/4 8 ± 3 Nm (6 ± 2 lb ft)
5/16 17 ± 5 Nm (13 ± 4 lb ft)
3/8 35 ± 5 Nm (26 ± 4 lb ft)
7/16 45 ± 10 N m ( 3 3 ± 7 lb ft)
Illustration 4 g00908911
1/2 65 ± 10 N m ( 4 8 ± 7 lb ft)
Table 5
5/8 110 ±20 N m ( 8 0 ± 15 lb ft)
Thread Size 3/4 170 ± 30 N m ( 1 2 5 ±2 2 lb ft)
Torque
Inch
7/8 260 ±40 N m ( 1 9 0 ± 30 lb ft)
1/4 12 ± 3 N m ( 9 ± 2 lb ft)
1 400 ± 60 Nm (300 ± 44 lb ft)
5/16 25 ± 6 Nm (18 ± 4 lb ft)
1 1/8 525 ± 60 Nm (390 ± 44 lb ft)
3/8 47 ± 9 Nm (35 ± 7 lb ft)
1 1/4 750 ± 80 Nm (550 ± 60 lb ft)
7/16 70 ± 15 N m ( 5 0 ± 11 lb ft)
1 3/8 950 ± 125 Nm(700±90 lb ft)
1/2 105 ±20 N m ( 7 5 ± 15 lb ft)
1 1/2 1200 ± 150Nm(880± 110 lb ft)
9/16 160 ± 30 N m ( 1 2 0 ±2 2 lb ft)
5/8 215 ±40 N m ( 1 6 0 ± 30 lb ft)
3/4 370 ± 50 Nm (275 ± 37 lb ft)
7/8 620 ± 80 Nm (460 ± 60 lb ft) English (SAE) Machine Screws
1 900 ± 100 Nm(660±75 lb ft)
1 1/8 1300 ± 150Nm(960± 110 lb ft)
1 1/4 1800 ± 200 Nm (1320 ± 150 lb ft)
1 3/8 2400 ± 300 Nm (1780 ± 220 lb ft)
1 1/2 3100 ± 350 Nm (2280 ± 260 lb ft)

Illustration 5 g00908932

Table 7

Thread Size
Torque
No.
0-80 0.10 ±0.01 Nm (0.9 ±0.1 lb in)
1-64 0.15 ±0.01 Nm (1.3 ±0.1 lb in)
2-56 0.25 ± 0.02 Nm (2.2 ± 0.2 lb in)
3-48 0.35 ± 0.05 Nm (3.1 ± 0.4 lb in)
4-40 0.50 ± 0.05 Nm (4.4 ± 0.4 lb in)
5-40 0.70 ± 0.10 Nm (6.2 ± 0.9 lb in)
6-32 0.90 ± 0.10 Nm (8.0 ± 0.9 lb in)
8-32 1.70 ± 0.25 Nm (15.0 ± 2.2 lb in)
10-24 2.25 ± 0.25 Nm (19.9 ± 2.2 lb in)
12-24 3.40 ± 0.60 Nm (30.1 ± 5.3 lb in)
6 31200268
Specifications Section

Hex Button Head Screw and Set Ground Engaging Tool (G.E.T.)
Screws Fasteners
Ground Engaging Tools (G.E.T.) are secured by many
types of bolts. Refer to Table 9 for the correct torque for
the following combinations of fasteners for G.E.T.:
• plow bolts and nuts
• hex head bolts and nuts
Illustration 6 g01186972
Table 9

Table 8 Thread Size Torque(1)

Thread Size Inch Nm lb ft

Torque
inch 5/8 inch 270 ± 40 200 ± 30
#4 &#5 .6± .1 N m ( 5 ± 0 . 9 lb in) 3/4 inch 475 ± 60 350 ± 45
#6 & #8 2± . 3 N m ( 1 8 ± 3 lb in) 7/8 inch 750 ± 90 550 ± 65
#10 &#12 4± . 5 N m ( 3 5 ± 4 lb in) 1 inch 1150 ± 150 850 ± 110
1/4 6± 1 N m ( 5 5 ± 9 lb in) 1 1/4 inch 2300 ± 300 1700 ± 220
5/16 13±3Nm(115±27 lbin)
(1) These values are only for Caterpillar bolts for cutting edges.
3/8 25±6Nm(18±4 lb ft)
7/16 40±8Nm(20±6 lb ft)
1/2 60 ± 1 2 N m ( 4 4 ±9 l b f t )
9/16 85 ± 1 5 N m ( 6 5 ± 11 lb ft)
5/8 11 5 ±2 0 N m ( 8 5 ± 15 lb ft)
200 ± 40 Nm
3/4
(150 ± 30 lb ft)
325 ± 40 Nm
7/8
(240 ± 30 lb ft)
500 ± 65 Nm
1
(370 ± 48 lb ft)
700 ± 90 Nm
1 1/8
(520 ± 65 lb ft)
1000 ± 125 Nm
1 1/4
(740 ± 90 lb ft)
1300 ± 150 Nm
1 3/8
(960 ± 110 lb ft)
1700 ± 200 Nm
1 1/2
(1260 ± 150 lb ft)
31200268 7
Specifications Section

• Tapered Pipe Thread (NPT and NPTF)

• 37 Degree Flare Fitting
Personal injury can result when installing plow bolts. • 45 Degree Flare Fitting
The appropriate safety equipment must be worn when • 45 Degree Inverted Flare Fitting
striking the plow bolts. To avoid injury to your eyes and
ears, wear protective glasses and hearing protection • Split Flange Coupling
during this procedure.
Installation of Split Flange
Couplings
1. For a metal tube to hose installation, install the
tube and tighten all bolts finger tight at the rigid
end.
2. Install the hose and tighten all bolts finger tight.
Illustration 7 g00909058 3. Put the hose in a position so that the hose does
Plow bolts must be installed properly. Refer to the not make contact with the machine or with another
following procedure for the correct installation of plow hose.
bolts.

1. Clean all surfaces that contact the bolt. Remove

all occurrences of the following conditions:rust,
paint, nicks, and burrs
2. Tighten the nut to the correct torque. Refer to
Table 9 for the correct torque.
3. Use a hammer to strike the head of the bolt. The
bolt must be struck with significant force.
Note: The head of the bolt may be recessed below the
mounting surface. Use a suitable punch in order to
transfer the hammer blow to the bolt head. Illustration 8 g00906528
4. Tighten the nut to the correct torque. Refer to 4. Tighten the bolts on both connections to the
Table 9 for the correct torque. proper torque. Follow the prescribed torque
sequence for split flange connections. Refer to
Illustration 8. Add the measurement of gap (A) to
the measurement of gap (B). The total must not
Installation of Fittings exceed 4.0 mm (0.16 inch).
Note: The tightening sequence of the fasteners that 5. Start the engine.
attach a tube assembly or hose assembly to the 6. Move the implement control levers to all of the
machine is very critical to the proper function of the positions.
machine. The sealing surfaces of the tube assembly or
hose assembly should be secured squarely. The 7. Look at the hose during movement of the
sealing surfaces of the tube assembly or hose assembly implement. Ensure that the hose is not in contact
should be tightened to the serviced component (control with the machine or with other hoses.
valve, cylinder, hydraulic motor, etc). Perform this Note: For hoses that cross an articulation hitch, check
procedure prior to the final tightening of any clamps or for contact during articulation. For hoses that connect to
clips that are used in order to fasten the tube the steering system, check for contact during steering.
assembly or the hose assembly to the machine. 8. Shut off the engine.
Fittings have different connections. Fittings may have 9. If the hose contacts other hoses or the machine
two completely different ends. Be sure to use the during the test, loosen the bolts and reposition
proper torque for the end of the fitting that is used. The the hose. Repeat steps 3 through 8 until there is
following list contains some common types of fittings. no contact.
• Straight Thread O-Ring (STOR)
• Adjustable Straight Thread O-Ring (STOR)
• O-Ring Face Seal (ORFS)
8 31200268
Specifications Section

Installation of Adjustable STOR • Excessive tightening can expand a loose ferrule

into the nut. This will cause the ferrule to lock up in
Fittings the nut and the nut will not function properly.
This type of fitting is used in many applications. One • Excessive tightening can split the nut on the end of
end of the fitting will be an adjustable STOR fitting. The the tube or can split the ferrule.
other end will be different. Always use the same
• Excessive tightening can gall or excessive
installation procedure for the STOR end. Adjustable
tightening can strip the threads of the nut.
STOR fittings can be positioned before tightening.
Note: If the above conditions occur due to excessive
tightening, the damaged fluid connector must be
scrapped and the fluid connectors must be replaced.

Straight Thread O-Ring Fittings

Illustration 9 g00906575
Elbow Body Assembly Illustration 10 g00911924
(1) End that connects to the tube or hose. (2) Fitting body. (3) Locknut. (4)
Backup washer. (5) O-ring seal. (6) End that is assembled to the mating part.
Note: For torques for plugs, refer to Specifications,
"Plugs".
1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far away from the threads as possible. Hold
these components in this position. Turn the fitting Note: Straight Thread O-Ring fittings for medium
into the mating part. Turn the fitting until backup pressure usage will have shorter threaded ends than
washer (4) contacts the surface of the mating part. high pressure fittings. The torque value for medium
Note: Excessive use of the wrench will distort the pressure Straight Thread O-Ring fittings will be lower
washer. Distortion of the washer will prevent proper than the torque values that are required for Straight
sealing. Thread O-Ring fittings for high pressure fittings.

2. Put the fitting assembly in the correct position,

loosen fitting (2) until the correct assembly position
is achieved. Do not loosen the fitting more than
360 degrees. Install the tube or hose hand tight in
order to verify the orientation of the fitting. Tighten
the fitting (2) to the torque that is shown in the
correct chart for the fitting that is used. Tighten
locknut (3) to the torque that is shown in the correct
chart for the fitting that is used. Use a backup
wrench, when the locknut is tightened.
Note: Torque the fitting prior to the locknut.

Note: If the fitting is not adjustable, the hex on the body

replaces the locknut. To install this type of fitting, tighten
the hex against the face of the mating part.

Excessive tightening of the connectors can cause

failure. Connectors that are under tightened can also
cause failures. The following failures occur:
31200268 9
Specifications Section

Table 10 Table 11

Ferrous Straight Thread O-Ring Fittings Torques for

Mating with Ferrous Materials High Pressure use with
Ferrous Straight Thread O-Ring Fitting Torques for
O-Ring Face Seal Fittings
Mating with Ferrous Materials Medium Pressure use
with 37° Flare Fittings Nominal Outer Standard
Thread Size
Diameter of the Torque Tolerance
Nominal Outer Standard Inch
Thread Size Tube (+10% - 0%)
Diameter of the Torque Tolerance
Inch
Tube (+10% - 0%) 4.76 mm (0.188 12 + 2 Nm
3/8 - 24
inch) (9 + 1 lb ft)
3.18 mm (.125 8 + 1 Nm
5 / 16 - 2 4
inch) (6 + 1 lb ft) 6.35 mm (0.250 22 + 2 Nm
7/16 - 20
inch) (16+ 1 lb ft)
4.76 mm (.188 13 + 1.5 Nm
3/8 - 24
inch) (10 + 1.1 lb ft) 7.94 mm (0.312 30 + 3 Nm
1/2 - 20
inch) (22 + 2 lb ft)
6.35 mm (.250 17 + 2 Nm
7/16 - 2 0
inch) (13+ 1.5 lb ft) 9.52 mm (0.375 48 + 5 Nm
9/16 - 18
inch) (35 + 4 lb ft)
7.94 mm (.312 28 + 3 Nm
1/2 - 20
inch) (21 + 2 lb ft) 12.7 mm (0.500 82 + 8 Nm
3/4 - 16
inch) (60 + 6 lb ft)
9.52 mm (.375 34 + 3 Nm
9/16 - 18
inch) (25 + 2 lb ft) 15.88 mm (0.625 140 + 14 Nm
7/8 - 14
inch) (105+ 10 lb ft)
12.70 mm (.500 55 + 6 Nm
3/4 - 16
inch) (41 + 4 lb ft) 19.05 mm (0.750 190 + 15 Nm
1 1/16- 12
inch) (140+ 11 lb ft)
Ferrous Straight Thread O-Ring Fitting Torques for
Mating with Ferrous Materials Medium Pressure use 22.22 mm (0.875 250 + 20 Nm
1 3/16 - 12
with 37° Flare Fittings inch) (185+ 15 lb ft)
Ferrous Straight Thread O-Ring Fittings Torques for
Nominal Outer Standard
Thread Size Mating with Ferrous Materials High Pressure use with
Diameter of the Torque Tolerance
Inch O-Ring Face Seal Fittings
Tube (+10% - 0%)
Nominal Outer Standard
15.88 mm (.625 80 + 8 Nm Thread Size
7/8 - 14 Diameter of the Torque Tolerance
inch) (60 + 6 lb ft) Inch
Tube (+10% - 0%)
19.05 mm (.750 100 + 10 Nm
1 1/16- 12
inch) (75 + 7 lb ft) 25.40 mm (1.000 300 + 30 Nm
1 5/16 - 12
inch) (220 + 22 lb ft)
22.22 mm (.875 135 + 13 Nm
1 3/16 - 12
inch) (100+ 10 lb ft) 31.75 mm (1.250 350 + 35 Nm
1 5/8 -12
inch) (260 + 26 lb ft)
25.40 mm (1.000 150 + 15 Nm
1 5/16 - 12
inch) (110+ 11 lbft) 38.10 mm (1.500 415 + 40 Nm
1 7/8 - 12
inch) (305 + 30 lb ft)
31.75 mm (1.250 290 + 25 Nm
1 5/8 - 12
inch) (215+ 18 lb ft)
Note: Use 50 percent of the torque values from Table 11
38.10 mm (1.500 325 + 30 Nm when the fitting or the port material is nonferrous.
1 7/8 - 12
inch) (240 + 22 lb ft)
50.80 mm (2.000 420 + 40 Nm
2 1/2 - 12
inch) (310 + 30 lb ft)

Note: Use 50 percent of the torque values from Table 10

when the fitting or the port material is nonferrous.
Note: Straight Thread O-Ring fittings for high pressure
usage will have longer threaded ends than medium
pressure fittings. The torque value for high pressure
Straight Thread O-Ring fittings will be higher than the
torque values that are required for Straight Thread O-
Ring fittings for medium pressure fittings.
10 31200268
Specifications Section

Table 142
Plugs
Metric Ferrous Straight Thread O-Ring Fittings Torques
for Mating with Ferrous Materials
Straight Thread O-Ring Plugs (Hex
Ref Nominal Standard Drive)
Outer Diameter of Thread Size Torque Tolerance
the Tube (+10% -0%)

10.5 + 1 Nm
4 mm M8X 1
(95 + 9 lb in)
2 1 + 2 Nm
5 mm M10X 1
(15+ 1.5 lb ft)
37 + 3 Nm Illustration 11 g00911999
6 mm M12X 1.5
(27 + 2 lb ft)
47 + 4 Nm Table 13
8 mm M14X 1.5
(35 + 3 lb ft) Thread Size Torque
58 + 6 Nm Inch Tolerance (+10% - 0%)
10 mm M16X 1.5
(43 + 4 lb ft) 5/16 9+ 1 Nm (80 + 9 lb in)
75 + 7 Nm
12 mm M18X 1.5 3/8 17+ 1.5 N m ( 13 + 1 lb ft)
(55 + 5 lb ft)
7/16 23 + 2 N m ( 1 7 + 1.5 lb ft)
105 + 10 Nm
16 mm M22X 1.5
(75 + 7 lb ft) 1/2 28 + 3 Nm(21 + 2 lb ft)
180 + 15 Nm 9/16 34 + 3 Nm (25 + 2 lb ft)
20 mm M27X2
(135+ 11 lb ft)
3/4 60 + 6 Nm (44 + 4 lb ft)
225 + 20 Nm
22 mm M30X2 7/8 115 + 10 N m ( 8 5 + 7lbft)
(165+ 15 lb ft)
325 + 30 Nm 1 1/16 140+ 14N m (10 5 + 10 lb ft)
25 mm M33X2
(240 + 22 lb ft)
1 3/16 190+ 19N m (14 0 + 14 lb ft)
350 + 35 Nm
30 mm M42X2 1 5/16 210 + 20Nm(155 + 15 lb ft)
(260 + 26 lb ft)
1 5/8 290 + 25Nm(215 + 18 lb ft)
440 + 40 Nm
38 mm M48X2
(320 + 30 lb ft) 1 7/8 325 + 30 Nm (240 + 22 lb ft)
525 + 50 Nm 2 1/2 420 + 40 Nm (310 + 30 lb ft)
50 mm M60X2
(390 + 37 lb ft)
Note: Use 50 percent of the torque values from Table 13
Note: Use 50 percent of the torque values from 12 when the fitting or the port material is nonferrous.
when the fitting or the port material is nonferrous.
31200268 11
Specifications Section

Straight Thread O-Ring Plugs Table 15

Type of Thread Size Torque Tolerance
(Socket Drive) Plug Inch (+10% - 0%)
1/2 - 13 20 + 5 N m ( 1 5 + 4 lb ft)
5/8 - 11 35 + 5 Nm (26 + 4 lb ft)

A 3/4 - 12 3/4 - 16 50 + 5 Nm (37 + 4 lb ft)

7/8 - 14 1 1/8- 12 70+ 1 5 N m ( 5 2 + 11 lb ft)

Illustration 12 g00912006 1 5/16 - 12 1 1/2 -

90+ 15Nm(66 + 11 lb ft)
B 12
Note: The socket may be hexagonal or a square recessed 2 - 12 125+ 15 Nm (92+ 11 lb ft)
drive.
1 1/8- 12 70+ 1 5 N m ( 5 2 + 11 lb ft)
Table 14 C
1 5/16 - 12 90+ 15Nm(66 + 11 lb ft)
Thread Size Torque
Inch Tolerance (+10% - 0%) 1/2 - 20 11 + 4 N m ( 9 7 + 35lbin)

5/16 5 + 1 Nm (44 + 9 lb in) 7/8 -14 55 + 7 N m ( 4 1 + 5 lb ft)

D
3/8 11 + 1 Nm(97 + 9 lb in) 1 3/8 -13 90 + 15 N m ( 6 6 + 11 lb ft)

7/16 16+ 1 . 5 N m ( 1 2 + 1 lb ft) 1 1/2 - 12 110+ 15Nm(81 + 11 lb ft)

1/2 20 + 2 N m ( 1 5 + 1.5 lb ft) Note: Use 50% of the values in Table 15 when either the
9/16 35 + 3.5 Nm (26+ 3 lb ft) plug or the port material is nonferrous.

3/4 70 + 7 Nm (50 + 5 lb ft)

Straight Thread O-Ring Plugs
7/8 100+ 10 Nm (75 + 7 lb ft)
(Mechanical Joint Tube Assemblies)
1 1/16 170+ 1 5N m (1 2 5 + 11 lb ft)
1 3/16 215 + 20Nm(160 + 15 lb ft)
1 5/16 270 + 25 Nm (200 + 18 lb ft)
1 5/8 285 + 25Nm(210 + 18 lb ft)
1 7/8 370 + 35 Nm (275 + 26 lb ft)
2 1/2 415 + 40 Nm (305 + 30 lb ft)

Drain Plugs with Straight Thread

Illustration 14 g00912010

Note: When you tighten the plug, the torque must not
be transmitted to the joint between the tube and the
Illustration 13 g00912008 elbow.
Note: Plug (A), plug (B) and plug (C) are used with a gasket. Conical seal plug
(D) does not use a gasket.
12 31200268
Specifications Section

Table 16
Bulkhead Nuts
Thread Size
Torque
Inch
7/8 125 ± 15 N m ( 92 ± 11 lb ft)
1 1/16 175 ± 15Nm(130± 11 lb ft)
1 3/16 250±20Nm(185± 15 lb ft)
1 1/4 250±20Nm(185± 15 lb ft)
1 5/16 370±20Nm(275± 15 lb ft)
1 5/8 420 ± 25 Nm (310 ±20 lb ft)
1 7/8 525 ± 35 Nm (390 ±25 lb ft)
2 1/2 900 ± 50 Nm (665 ±40 lb ft)
Illustration 16 g00909138
Bulkhead connector (ORFS) (1) and bulkhead nut (1A).
Note: The bulkhead connector may have different
O-Ring Face Seal Fittings connections. The type of fluid connection does not affect
the torque for nut (1A).
Note: When you assemble the fluid connection, do not
use the bulkhead nut (1A) as leverage for a backup
wrench. Use the hex on the body (1) of the connector for
leverage.
Table 2018

Thread Size
Torque
Inch
5/16 6± 1 Nm (53 ± 9 lb in)
3/8 8± 1 Nm (71 ± 9 lb in)
7/16 14 ± 1.5 N m ( 1 0 ± 1 lb ft)
Illustration 15 g00906427
1/2 17 ±2 N m ( 1 3 ± 1.4 lb ft)
O-ring face seal fitting (ORFS fitting)
(1) O-ring face seal connector 9/16 22 ±2 N m ( 1 6 ± 1.4 lb ft)
(1A) O-ring groove
(2) O-ring seal 11/16 31 ± 3 Nm (23 ± 2 lb ft)
(3) Nut for the O-ring face seal
3/4 37 ± 4 Nm (27 ± 3 lb ft)
Table 17 13/16 40 ± 4 Nm (30 ± 3 lb ft)
Ferrous ORFS Fitting 7/8 44 ± 4 Nm (32 ± 3 lb ft)
Thread Size Thread Size
Standard Torque for Nut (3) Torque
Inch Inch
9/16 - 18 25 + 3 Nm (18 + 2 lb ft) 1 61 ± 6 Nm (45 ± 4 lb ft)
11/16 - 16 40 + 4 Nm (30 + 3 lb ft) 1 1/16 70 ± 7 Nm (52 ± 5 lb ft)
13/16 - 16 55 + 5 Nm (41 + 4 lb ft) 1 3/16 91 ± 10 N m ( 6 7 ± 7 lb ft)
1 - 14 86 +8 Nm (65 + 6 lb ft) 1 5/16 113 ± 10 N m ( 8 3 ± 7 lb ft)
1 13/16 - 12 125 + 15 Nm (90 + 11 lb ft) 1 7/16 125 ± 12 N m ( 9 2 ± 9 lb ft)
1 7/16 - 12 165 + 15 Nm (120 + 11 lb ft) 1 5/8 150 ± 15 N m ( 11 0 ± 11 lb ft)

1 11/16 - 12 200 + 20 Nm (150 + 15 lb ft) 1 11/16 150 ± 15 N m ( 11 0 ± 11 lb ft)

2 - 12 245 + 20 Nm (180 + 15 lb ft) 1 7/8 155 ± 15 N m ( 11 5 ± 11 lb ft)

2 170 ± 17 N m ( 1 2 5 ± 13 lb ft)
2 1/2 220 ±20 N m ( 1 6 0 ± 15 lb ft)

Note: Bulkhead nuts are designed to secure fluid

connectors firmly in position.
31200268 13
Specifications Section

Flare Fittings Note: Use 50 percent of the torque values from Table 21
when the fitting or the port material is nonferrous.
The torques in Table 21 are for 37 degree flare fittings.
The torques in Table 22 are for 45 degree flare fittings
and 45 degree inverted flare fittings. 45 Degree Flare and 45 Degree
Inverted Flare Fittings
37 Degree Flare Fitting I

llustration 18 g01185492
Illustration 17 g01185483 (1) 45 Degree Inverted Flare Fittings. (2) 45 Degree Flare Fittings.
(1) 37 degree flare fitting. (2) Swivel nuts. Table 20
Table 19
45 Degree Flare Fittings and 45 Degree
Nuts for 37 Degree Flare Fittings Inverted Flare Fittings
Nominal Outer
Nominal Outer Standard Torque Thread Size
Thread Size Diameter of the Standard Torque
Diameter of the Tolerance Inch
Inch Tube
Tube (+ 10% - 0%)
3.18 mm 5.0 ± 1.5 Nm
5/16
3.18 mm 5.0 + 1 Nm (.125 inch) (44 ± 13 lbin)
5/16
(.125 inch) (44 + 9 lb in)
4.76 mm 8.0 ± 1.5 Nm
3/8
4.76 mm 11 + 1 Nm (.188 inch) (70 ± 13 lbin)
3/8
(.188 inch) (100 + 9 lb in)
6.35 mm 11 ± 2 Nm
7/16
Nuts for 37 Degree Flare Fittings (.250 inch) (100 ± 18 lbin)
7.94 mm 17 ± 3 Nm
Nominal Outer Standard Torque 1/2
Thread Size (.312 inch) (13 ± 2 lbft)
Diameter of the Tolerance
Inch 9.52 mm 30 ± 3 Nm
Tube (+ 10% - 0%) 5/8
(.375 inch) (22 ± 2 lb ft)
6.35 mm 16 + 1.5 Nm
7/16 11.11 mm 30 ± 3 Nm
(.250 inch) (12+ 1.1 lb ft) 11/16
(.438 inch) (22 ± 2 lb ft)
7.94 mm 20 + 2 Nm
1/2 12.70 mm 38 ± 4 Nm
(.312 inch) (15+ 1.5 lb ft) 3/4
(.500 inch) (28 ± 3 lb ft)
9.52 mm 27 + 3 Nm
9/16 15.88 mm 50 ± 5 Nm
(.375 inch) (20 + 2 lb ft) 7/8
(.625 inch) (37 ± 4 lb ft)
12.70 mm 58 + 6 Nm
3/4 19.05 mm 90 ± 8 Nm
(.500 inch) (43 + 4 lb ft) 1 1/16
(.750 inch) (65 ± 6 lb ft)
15.88 mm 74 + 7 Nm
7/8 22.22 mm 100 ± 10 Nm
(.625 inch) (55 + 5 lb ft) 1 1/4
(.875 inch) (75 ± 7 lb ft)
19.05 mm 108 + 10 Nm
1 1/16
(.750 inch) (80 + 7 lb ft)
22.22 mm 135 + 13 Nm
1 3/16
(.875 inch) (100+ 10 lb ft)
25.40 mm 156 + 15 Nm
1 5/16
(1.000 inch) (115+ 11 lb ft)
31.75 mm 217 + 20 Nm
1 5/8
(1.250 inch) (160+ 15 lb ft)
38.10 mm 251 + 25 Nm
1 7/8
(1.500 inch) (185+ 18 lb ft)
50.80 mm 339 + 30 Nm
2 1/2
(2.000 inch) (250 + 22 lb ft)
14 31200268
Specifications Section

Air Conditioning Fittings Table 22

Nominal Turn Tightening
Outer Torque
Diameter of Nonmetallic Copper
the Tube Tubing Tubing
6.35 mm 11 ± 3 Nm (8
3 2
(0.250 inch) ± 2 lb ft)
9.53 mm 20 ± 3 Nm
4 2
(0.375 inch) (15 ± 2 lb ft)
12.70 mm 35 ±6 Nm
4 2
(0.500 inch) (26 ± 4 lb ft)
15.88 mm 40 ± 6 Nm
3 1/2 3
(0.625 inch) (30 ± 4 lb ft)

Illustration 19 g01185521
19.05 mm 50 ±6 Nm
3 1/2 3
(0.750 inch) (37 ± 4 lb ft)
(1) O-ring seal. (2) 45 degree flare fitting.

Note: Clean the connectors and the seals and

Table 21 lubricate the connectors and seals by using
Air Conditioning Fittings Refrigerant Mineral Oil. This is a special oil that is
compatible with R-134a.
O-Ring 45 Degree Flare Fitting
Thread Size Fitting End End
Inch Torque for
Torque
Torque for
Steel Tubes
Aluminum Tapered Pipe Thread Fittings
Tubes
Torque is based on the diameter of the thread. The
14 ±4 Nm 30 ± 3 Nm 23 ±3 Nm
5/8- 18 torque values are identical for coarse threads and fine
(10 ±3 lbft) (22 ± 2 lb ft) (17 ±2 lbft)
threads.
27 ±4 Nm 52 ± 5 Nm 33 ±4 Nm
3/4 - 16
(20 ± 3 lb ft) (38 ± 4 lb ft) (24 ± 4 lb ft)
Note: The following table has the recommended
standard torque value for tapered pipe thread fitting for
7/8 - 14 1 - 40 ± 4 Nm 60 ± 7 Nm 38 ±4 Nm use on all Caterpillar equipment and Mitsubishi
14 (30 ± 3 lb ft) (44 ± 5 lb ft) (28 ± 3 lb ft) engines. Use Table 23 as a general recommendation
1 1/16-14
45 ± 5 Nm 75 ± 8 Nm 50 ±5 Nm only. Actual values may vary due to variations in the
(33 ± 4 lb ft) (55 ± 6 lb ft) (37 ± 4 lb ft) material of the connector. Actual values may vary due
to variations in the characteristics of the threads.

Table 23
Air Brake Fittings
Tapered Pipe Thread Fittings
Diameter of the Standard Torque
Pipe Thread
Threads with 5P-
(Inch) Threads without
3413 Pipe
Pipe Sealant
Sealant
1/16 10Nm(90 lb in) 1 0Nm ( 90 lb in)
1/8 16 Nm (12 lb ft) 16 Nm (12 lb ft)
Illustration 20 g00909062

Put nut (1) and sleeve (2) over the tube. Push the tube 1/4 20 Nm (15 lb ft) 25 Nm (18 lb ft)
into the counterbore of the fitting body as far as 3/8 35 Nm (26 lb ft) 45 Nm (33 lb ft)
possible. There are two methods that may be used to 1/2 45 Nm (33 lb ft) 60 Nm (44 lb ft)
tighten the nut. Tighten the nut with one of two
methods. 3/4 60 Nm (44 lb ft) 75 Nm (55 lb ft)

• Tighten nut (1) to the torque that is specified in 1 75 Nm (55 lb ft) 90 Nm (65 lb ft)
Table 22. 1 1/4 95 Nm (70 lb ft) 110Nm(80 lb ft)
• Tighten nut (1) by the number of turns that is 1 1/2 110 Nm (80 lb ft) 130Nm(95lb ft)
specified in Table 22. The number of turns is for
the turns after the nut is finger tight. 2 130 Nm (95 lb ft) 160 Nm (120 lb ft)
31200268 15
Specifications Section

Note: Use 50 percent of the torque values from Table 25 be next to the nut. Push the tube into the counterbore
when the fitting, the plug, or the port material is of the fitting body as far as possible. Tighten the nut
nonferrous. until a sudden increase in torque is felt. Next, tighten
Note: Use 50 percent of the torque values from Table 25 the fitting for an additional 1/6 to 1/3 turn in order to
when a tapered thread is mated with a straight thread. seat the sleeve.

Flex Fittings
Miscellaneous Fittings
Hi Duty Tube Fittings (Shear Sleeve)

Illustration 23 g00909645

Put nut (1) and sleeve (2) over the tube and push the
tube into the counterbore of the fitting body as far as
possible. Tighten the nut until the nut is against the hex
part of the fitting body.
Illustration 21 g00909648

Put nut (1) over the tube and push the tube into the
counterbore of the fitting body as far as possible. Turn
the nut with a wrench until a small decrease in torque is Hose Clamps
felt. The small decrease in torque indicates that the
sleeve (1A) has been broken off of the nut. Hold the Worm Drive Band Type Clamps
tube in order to prevent the tube from turning. Tighten
the nut for an additional 1 1/2 turns.

SAE Flareless Fittings

Illustration 24 g00910017
Illustration 22 g00909647
Table 24
Installing a New Flareless Fitting
Width (A) of Clamp Torque for New Hose
Put nut (1) and sleeve (2) over the tube. The head end
of the sleeve should be next to the nut. The head end 7.9 mm (0.31 inch) 0.9 ± 0.2 N m ( 8 ± 2 lb in)
has a shoulder. The nut will be seated against this 13.5 mm (0.53 inch) 4.5 ± 0.5 N m ( 4 0 ± 4 lb in)
shoulder when the nut is tightened. Push the tube into
15.9 mm (0.63 inch) 7.5 ± 0.5 N m ( 6 5 ± 4 lb in)
the counterbore of the fitting body as far as possible.
Turn nut (1) clockwise until the sleeve grips the tube. Width (A) of Clamp Torque for Reused Hose(1)
The sleeve must prevent all movement of the tube. 7.9 mm (0.31 inch) 0.7 ± 0.2 N m ( 6 ± 2 lb in)
Tighten the nut for an additional 1 1/4 turns. The sleeve
should be seated and the sleeve should give a locking 13.5 mm (0.53 inch) 3.0 ± 0.5 N m ( 2 7 ± 4 lb in)
action. 15.9 mm (0.63 inch) 4.5 ± 0.5 N m ( 4 0 ± 4 lb in)
Installing a Used Flareless Fitting (1) Use this value when the hose is reused. The clamp may be
new or reused.
Less turns are required for a used fitting. Put nut (1) and
sleeve (2) over the tube. The head of the sleeve should
16 31200268
Specifications Section

Constant Torque Hose Clamps

Use a constant torque hose clamp in place of any
worm drive band type clamp. Ensure that the constant
torque hose clamp is the same size as the worm drive
band type clamp. Due to extreme temperature
changes, the hose will heat set. Heat setting can
cause worm drive band type clamps to loosen. Loose
hose clamps can result in leaks. There have been
reports of component failures that have been caused
by worm drive band type clamps that have loosened.
The constant torque hose clamp will help prevent these
failures.

Illustration 25 g00906389
(1) Constant Torque Hose Clamp (Belleville Washer)
(2) Constant Torque Hose Clamp (Tee bolt and Spring)

Use a torque wrench for proper installation of all

constant torque hose clamps. There are two types of
constant torque hose clamps: Belleville washer (1) and
Tee bolt and spring (2)
When the constant torque hose clamp (Belleville
washer) (1) is assembled correctly, the Belleville
washers (1A) are nearly collapsed flat. The proper
torque for screw (1B) is based on the diameter (B) of
the clamp. Refer to the following table for the correct
torque.
Table 25

Diameter (B) Standard Torque

Up to 50.8 mm (2 inch) 7.5±0.5Nm(65±5 lb in)
Greater than 50.8 mm
11 ± 1 Nm(95± 10 lb in)
(2 inch)

The correct torque for the constant torque hose clamp

(tee bolt and spring) (2) is 7.5 ± 1 Nm (65 ± 10 lb in).
31200268 17
Index Index

A S
Air Brake Fittings................................................................ 14 Specifications Section .......................................................... 3
Air Conditioning Fittings ..................................................... 14 Straight Thread O-Ring Fittings ........................................... 8

B T
Bulkhead Nuts.................................................................... 12 Table of Contents................................................................. 1
Tapered Pipe Thread Fittings............................................. 14
E
English (SAE) Fasteners
English (SAE) Machine Screws ...................................... 5
English (SAE) Nuts and Bolts ......................................... 5
English (SAE) Taperlock Studs ...................................... 5
Hex Button Head Screw and Set Screws ....................... 6
English (SAE) Fasteners...................................................... 5

F
Flare Fittings ...................................................................... 13
37 Degree Flare Fittings ............................................... 13
45 Degree Flare and 45 Degree Inverted Flare Fittings 13

G
General Information ............................................................. 3
Introduction to Torque..................................................... 3
Torque Sequence ........................................................... 3
Torque-Turn.................................................................... 3
Ground Engaging Tool (G.E.T.) Fasteners .......................... 6

H
Hose Clamps...................................................................... 15
Constant Torque Hose Clamps .................................... 16
Worm Drive Band Type Clamps ................................... 15

I
Important Safety Information.................................................ii
Installation of Fittings ........................................................... 7
Installation of Adjustable STOR Fittings ......................... 8
Installation of Split Flange Couplings.............................. 7

M
Metric (ISO) Fasteners......................................................... 4
Hex Button Head Screw and Set Screw......................... 4
Metric (ISO) Machine Screws ......................................... 4
Metric (ISO) Nuts and Bolts............................................ 4
Metric (ISO) Taperlock Studs ......................................... 4
Miscellaneous Fittings........................................................ 15
Flex Fittings .................................................................. 15
Hi Duty Tube Fittings (Shear Sleeve) ........................... 15
SAE Flareless Fittings .................................................. 15

O
O-Ring Face Seal Fittings .................................................. 12

P
Plugs .................................................................................. 10
Drain Plugs with Straight Thread.................................. 11
Straight Thread O-Ring Plugs (Hex Drive) ................... 10
Straight Thread O-Ring Plugs (Mechanical Joint Tube
Assemblies) .................................................................. 11
Straight Thread O-Ring Plugs (Socket Drive)............... 11
18 31200268
Index
Manufactured by JLG under license from Caterpillar
31200299
December 15, 2006

Disassembly and
Assembly

TH360B, TH560B and TH580B Telehandlers

Engine Supplement
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200299 1
Table of Contents
Table of
Table of Contents Engine Mount (Rear) - Install ................. 23
Disassembly and Assembly Section Installation Procedure ........................ 23
Battery - Remove and Install ................... 3 Engine Enclosure - Remove and Install . 23
Removal Procedure............................. 3 Removal Procedure ........................... 23
Installation Procedure.......................... 4 Installation Procedure ........................ 24
Alternator - Remove and Install ............... 4 Engine - Remove ................................... 25
Removal Procedure............................. 4 Removal Procedure ........................... 25
Installation Procedure.......................... 5 Engine - Install ....................................... 28
Electric Starting Motor -Remove and Installation Procedure ........................ 28
Install ....................................................... 5
Removal Procedure............................. 5
Installation Procedure.......................... 5
Air Cleaner - Remove .............................. 6
Removal Procedure............................. 6
Air Cleaner - Install .................................. 7
Installation Procedure.......................... 7
Muffler - Remove and Install.................... 8
Removal Procedure............................. 8
Installation Procedure.......................... 8
Expansion Tank - Remove and Install..... 9
Removal Procedure............................. 9
Installation Procedure........................ 10
Radiator - Remove ................................ 10
Removal Procedure........................... 10
Radiator - Disassemble ......................... 12
Disassembly Procedure .................... 12
Radiator - Assemble .............................. 13
Assembly Procedure ......................... 13
Radiator - Install .................................... 13
Installation Procedure........................ 13
Fan Guard - Remove and Install ........... 15
Removal Procedure........................... 15
Transmission Oil Cooler -Remove......... 15
Removal Procedure........................... 15
Transmission Oil Cooler -Install............. 16
Installation Procedure........................ 16
Refrigerant Condenser -Remove and
Install ..................................................... 17
Removal Procedure........................... 17
Installation Procedure........................ 18
Refrigerant Compressor -Remove and
Install ..................................................... 19
Removal Procedure........................... 19
Installation Procedure........................ 19
Engine Mount (Front) - Remove ............ 20
Removal Procedure........................... 20
Engine Mount (Front) - Install ................ 21
Installation Procedure........................ 21
Engine Mount (Rear) - Remove............. 22
Removal Procedure........................... 22
2 31200299
Table of Contents
31200299 3
Disassembly and Assembly Section

Disassembly and
Assembly Section
Battery - Remove and Install
Removal Procedure
Start By:
a. If equipped, turn the battery disconnect switch to the OFF
position. Refer to Operation and Maintenance Manual,
"Battery Disconnect Switch (if equipped) ".
Illustration 2 g00909220
2. Pull back the terminal cover (1) in order to
disconnect positive cable (2). Pull back the
terminal cover (3) in order to disconnect negative
Batteries give off flammable fumes that can cable (4).
explode resulting in personal injury.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.
Do not smoke when checking battery electrolyte
levels.
Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
Always wear eye protection when starting a
machine with jump start cables.
Improper jump start procedures can cause an
explosion resulting in personal injury.
Illustration 3 g00909235
Always connect the positive (+) to positive (+) and
3. Remove nuts (5), the washers and hold down
the negative (-) to negative (-).
bracket (6).
Jump start only with an energy source with the
same voltage as the stalled machine.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.

Illustration 4 g00909831
4. With the aid of a second person or with the aid of
a suitable lifting device, remove battery (7). The
weight of the battery is approximately 25 kg (55 lb).
Remove studs (8).
Illustration 1 g00909832
1. The following procedure shows the removal of the
front battery which is an attachment. Use the same
procedure when you are removing the rear battery.
4 31200299
Disassembly and Assembly Section

Installation Procedure

Illustration 8 g00909220
4. Connect positive cable (2) and slide terminal cover
Illustration 5 g00909832 (1) into position. Connect Negative cable (4) and
1. The following procedure shows the installation of slide terminal cover (3) into position.
the front battery which is an attachment. Use the End By:
same procedure when you are installing the rear
a. If equipped, turn the battery disconnect switch to the ON
battery.
position. Refer to Operation and Maintenance Manual,
"Battery Disconnect Switch (if equipped)".

Alternator - Remove and Install

Removal Procedure
Start By:
a. Turn the battery disconnect switch to the OFF position.
Refer to Operation and Maintenance Manual, "Battery
Disconnect Switch (if equipped)". If the machine is not
equipped with a battery disconnect switch, disconnect
the battery cables from the battery and insulate the
battery clamps.
Illustration 6 g00909831
1. Put identification marks on all wires for installation
2. Install studs (8). With the aid of a second person purposes.
or with the aid of a suitable lifting device, install
battery (7). The weight of the battery is
approximately 25 kg (55 lb).

Illustration 9 g00908444
2. Remove belt (1) from alternator (2). Refer to
Operation and maintenance Manual, "Belts -
Illustration 7 g00909235
Inspect/Adjust/Replace".
3. Install hold down bracket (6), nuts (5), and the
washers. 3. Disconnect wires (3) and positive cable (4).
4. Remove bolt (5), the washer, nut (6), bolt (7) and
the washers before removing alternator (2) from
the machine.
31200299 5
Disassembly and Assembly Section

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 11 g00908447
2. Disconnect positive cable (2) from starter motor (1).
Lift the plastic cap (not shown) in order to access
screw (3) and disconnect wire (4).

Illustration 10 g00908444
2. Position alternator (2) onto the machine. Install
bolt (7), nut (6) and washers. Install bolt (5) and
the washer.
3. Connect wires (3) and positive cable (4) to
alternator (2).
4. Install belt (1) from alternator (2). Refer to
Operation and maintenance Manual, "Belts -
Inspect/Adjust/Replace".
End By:
a. Turn the battery disconnect switch to the ON position.
Refer to Operation and Maintenance Manual, "Battery
Disconnect Switch (if equipped)". If the machine is not
equipped with a battery disconnect switch and the
battery was disconnected, remove the insulation from
the battery clamps and install the battery cables onto the
battery.

Illustration 12 g00908460
Electric Starting Motor -Remove 3. Remove bolt (5) in order to disconnect ground
and Install cable (6).
4. Remove bolts (7) and remove starter motor (1)
Removal Procedure from the engine.

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
Accidental machine starting can cause injury or worn or damaged, use new Caterpillar parts for
death to personnel working on the machine. replacement.
To avoid accidental machine starting, turn the battery
disconnect switch to the OFF position and remove
the key. If the machine is not equipped with a battery
disconnect switch, disconnect the battery cables
from the battery and tape the battery clamps.
Place a do not operate tag at the battery disconnect
switch location to inform personnel that the
machine is being worked on.
1. Put identification marks on all wires for installation
purposes.
6 31200299
Disassembly and Assembly Section

Air Cleaner - Remove

Removal Procedure

Illustration 15 g00909117
1. Disconnect inlet duct (2) from air cleaner assembly
Illustration 13 g00908460
(1).
2. Position starter motor (1) onto the engine and
install bolts (7).
3. Position ground cable (6) and install bolt (5).

Illustration 16 g00909118
2. Remove hose clamp (3) and disconnect inlet hose
(4) from air cleaner assembly (1).

Illustration 14 g00908447
4. Install screw (3) in order to connect wire (4). Close
the plastic cap (not shown). Connect positive cable
(2) to starter motor (1).
End By:
a. Turn the battery disconnect switch to the ON position.
Refer to Operation and Maintenance Manual, "Battery
Disconnect Switch (if equipped)". If the machine is not
equipped with a battery disconnect switch and the
battery was disconnected, remove the insulation from
the battery clamps and install the battery cables onto the
battery.

Illustration 17 g00909119
3. Disconnect hose (5) from air cleaner assembly (1).
31200299 7
Disassembly and Assembly Section

Illustration 18 g00909120 Illustration 21 g00909123

2. Position air cleaner assembly (1) on the engine and
install bolts (7), nuts (6) and the washers.

Illustration 19 g00909121
4. Remove nuts (6), bolts (7) and the washers
before removing air cleaner assembly (1) from the Illustration 22 g00909124
engine. 3. Connect hose (5) to air cleaner assembly (1).

Air Cleaner - Install

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 23 g00909125
4. Connect inlet hose (4) to air cleaner assembly (1)
and install hose clamp (3).

Illustration 20 g00909122
8 31200299
Disassembly and Assembly Section

2. Remove clamp (4) which connects exhaust pipe (5)

to muffler (6).

Illustration 24 g00909126
5. Connect inlet duct (2) to air cleaner assembly (1).

Muffler - Remove and Install Illustration 27 g00914595

Removal Procedure

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact
skin.

Illustration 28 g00914606
3. Remove bolts (7) and the washers before sliding
muffler (6) away from exhaust pipe (5). Remove the
muffler from the machine.

Installation Procedure

Illustration 25 g00914593
1. Remove bolts (1) and the washers in order to
remove cover (2) and exhaust shield (3).

Illustration 29 g00914606

Illustration 26 g00914594
The photograph is from the top side of the muffler
31200299 9
Disassembly and Assembly Section

Expansion Tank - Remove and

Install
Removal Procedure

At operating temperature, the engine coolant is hot

and under pressure.
Steam can cause personal injury.
Illustration 30 g00914595 Check the coolant level only after the engine has
1. Position muffler (6) and then slide the muffler onto been stopped and the fill cap is cool enough to
exhaust pipe (5) before installing bolts (7) and the touch with your bare hand.
washers.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
Illustration 31 g00914594 mandates.
The photograph is from the top side of the muffler.
1. Drain the coolant from the radiator into a suitable
2. Install clamp (4) which connects exhaust pipe (5) to container so that the level of the coolant in the
muffler (6). radiator is below the level of the expansion tank.
The capacity of the cooling system is
approximately 27.5 L (7.3 US gal). Refer to the
appropriate Operation and Maintenance Manual.

Illustration 32 g00914593
3. Position exhaust shield (3) with cover (2) and
install bolts (1) with the washers.

Illustration 33 g00914256
2. Loosen the hose clamp and disconnect hose (6)
from expansion tank (3).
3. Disconnect hose (4) from filler cap (5).
10 31200299
Disassembly and Assembly Section

4. Connect hose (1) and hose (2) to expansion tank

(3) and tighten the hose clamps.
5. Fill the cooling system. The capacity of the cooling
system is approximately 27.5 L (7.3 US gal).
Refer to the appropriate Operation and
Maintenance Manual.

Radiator - Remove
Removal Procedure
Start By:
Illustration 34 g00914264 a. Remove the access plate.
4. Loosen the hose clamps and disconnect hose (1)
and hose (2) from expansion tank (3).
5. Remove bolts (7) and the washers in order to
remove expansion tank (3).
At operating temperature, the engine coolant is hot
and under pressure.
Installation Procedure
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
Illustration 35 g00914264 compartment or disassembling any component
1. Position expansion tank (3) and install bolts (7) containing fluids.
and the washers. Dispose of all fluids according to local regulations and
2. Connect hose (6) to expansion tank (3) and mandates.
tighten the hose clamp. 1. Put identification marks on all hoses for installation
purposes. Plug all hoses. This helps to prevent
fluid loss, and this helps to keep contaminants
from entering the system.
2. Drain the coolant from the cooling system into a
suitable container for storage or disposal. The
capacity of the cooling system is approximately
27.5 L (7.3 US gal). Refer to the appropriate
Operation and Maintenance Manual.

Illustration 36 g00914256
3. Disconnect hose (4) from filler cap (5).
31200299 11
Disassembly and Assembly Section

Illustration 37 g00912426 Illustration 40 g00912779

3. If equipped, release latch (1) in order to remove 6. Loosen the hose clamp and disconnect hose (6)
condenser (2) from radiator (3). Tilt the condenser from radiator (3).
and remove the condenser from the mounts at the
base of the radiator. Move the condenser aside.
Note: Do not disconnect the hose to the condenser.
The radiator can be removed without discharging the
refrigerant.

Illustration 41 g00912775
7. Remove bolts (7) and the washer from both sides
of shroud (8).

Illustration 38 g00912772

4. Loosen the hose clamp and disconnect hose (top)

(4) from radiator (3).

Illustration 42 g00912780
8. Remove bolts (9), the washers, bolt (10), the
washer and mount (11) in order to remove bracket
(12) from radiator (3) and the chassis.

Illustration 39 g00912773
5. Loosen the hose clamp and disconnect hose
(bottom) (5) from the radiator.
12 31200299
Disassembly and Assembly Section

Radiator - Disassemble
Disassembly Procedure
Start By:
a. Remove the radiator from the machine. Refer to
Disassembly and Assembly, "Radiator - Remove".

Illustration 43 g00912781
9. Remove bolt (13), the washers, mount (14), bolt
(15) and the washer in order to remove bracket
(16) from radiator (3) and the chassis.

Illustration 46 g00913571
1. Remove bolts (1) and the washers in order to
remove bracket (2) from radiator (3).

Illustration 44 g00912782
10. Remove bolts (17), the washers and the nuts that
secure radiator (3) to the chassis.
11. With the aid of a second person, remove radiator
(3) from the machine.

Illustration 47 g00913572
2. Remove bolts (4) and the washers in order to
remove bracket (5) from radiator (3).

Illustration 45 g00912783
12. Remove mounts (18) from the chassis.

Illustration 48 00913575
31200299 13
Disassembly and Assembly Section

3. Remove bolts (6) and the washers in order to

remove mounting bracket (7) from radiator core
(3).
4. Remove bolts (8) and the washers in order to
remove mounting bracket (9) from radiator core
(3).

Radiator - Assemble
Assembly Procedure

Illustration 51 g00913595
4. Position bracket (2) onto the front of radiator (3)
and install bolts (1) with the washers.
End By:
a. Install the radiator onto the machine. Refer to
Disassembly and Assembly, "Radiator - Install".

Radiator - Install
Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 49 00913593
1. Position mounting bracket (9) onto radiator (3) and
install bolts (8) with the washers.
2. Position mounting bracket (7) onto radiator (3) and
install bolts (6) with the washers.

Illustration 52 g00912841
2. Install mounts (18) into the chassis.

Illustration 50 g00913594
3. Position bracket (5) onto the front of radiator (3)
and install bolts (4) with the washers.

Illustration 53 g00912843
14 31200299
Disassembly and Assembly Section

3. With aid of a second person, lift radiator (3) into

position. Install bolts (17), the washers and the nuts
that secure the radiator to the chassis.

Illustration 57 g00912853
7. Connect hose (6) to radiator (3) and tighten the
hose clamp.
Illustration 54 g00912846
4. Install bolt (13), the washer, mount (14), bolt (15)
and the washer in order to secure bracket (16) to
radiator (3) and the chassis.

Illustration 58 g00912861
8. Connect hose (bottom) (5) to radiator (3) and
tighten the hose clamp.

Illustration 55 g00912848
5. Install bolts (9), the washer, bolt (10), the washer
and mount (11) in order to secure bracket (12) to
radiator (3) and the chassis.

Illustration 59 g00912860
9. Connect hose (top) (4) to radiator (3) and tighten
the hose clamp.

Illustration 56 g00912849
6. Install bolts (7) and the washers into both sides of
shroud (8).
31200299 15
Disassembly and Assembly Section

Installation Procedure

Illustration 60 g00912875
10. If equipped, Install condenser (2) into the mounts
at the base of radiator (3) before you fasten latch
(1).
11. Fill the cooling system. The capacity of the cooling
system is approximately 27.5 L (7.3 US gal).
Refer to the appropriate Operation and
Maintenance Manual. Illustration 62 g00909977
End By: 1. Position fan guard (2) on shroud (3) and install
a. Install the access plate. bolts (1) and the washers.

Fan Guard - Remove and Install Transmission Oil Cooler -

Remove
Removal Procedure
Removal Procedure
Start By:
a. Remove the access plate.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered, oil is cool before removing any
components or lines. Remove the oil filler cap only
Illustration 61 g00909977
when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
1. Remove bolts (1) and the washers in order to
remove fan guard (2) from shroud (3).

At operating temperature, the engine coolant is hot

and under pressure.
Steam can cause personal injury.
16 31200299
Disassembly and Assembly Section

Check the coolant level only after the engine has Note: The following procedure will give additional
been stopped and the fill cap is cool enough to information that is required to install an oil cooler for the
touch with your bare hand. high ambient temperature cooling arrangement.
Remove the fill cap slowly to relieve pressure. Remove Components
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put Identification marks on all hoses for installation
purposes. Plug all hoses. This helps to prevent
fluid loss, and this helps to keep contaminants
from entering the system.
2. Drain the coolant from the cooling system into a
suitable container for storage or disposal. The Illustration 64 g00987113
capacity of the cooling system is approximately 1. Loosen the hose clamp and remove hose (1) from
27.5 L (7.3 US gal). Refer to the appropriate radiator (2).
Operation and Maintenance Manual. 2. Remove all hose clips and any cable straps which
secure hose (3).
3. Loosen the hose clamp and disconnect hose (3)
from water pump (4).
4. Loosen the hose clamp and disconnect hose (3)
from expansion tank (5) before removing the hose
from the machine.
Install Components

Illustration 63 g00910188
3. From the underside of the machine, loosen the
hose clamps and disconnect hoses (1) from oil
cooler (2).
4. Loosen the hose clamps and disconnect hoses
(3) from oil cooler (2).
5. Remove bolts (4) and the washer in order to
remove oil cooler (2) from the machine.

Transmission Oil Cooler -Install

Installation Procedure
Oil Cooler (High Ambient Temperature Illustration 65 g00987125

Cooling Arrangement) 1. The following steps show the location of all hoses to
be installed with the high ambient temperature
cooling arrangement. Refer to Parts Manual, "Lines
31200299 17
Disassembly and Assembly Section

Gp - Coolant" for the part numbers for all Refrigerant Condenser -

components.
2. Connect a new hose (3) to expansion tank (5) and
Remove and Install
tighten the hose clamp.
3. Connect hose (3) to water pump (4) and tighten Removal Procedure
the hose clamp.
4. Install all hose clips and any cable straps which
secure hose (3).
Note: A new hose clamp (6) is installed as part of the Personal injury can result from contact with
installation procedure for the oil cooler. Refer to refrigerant.
Disassembly and Assembly, "Transmission Oil Cooler -
Contact with refrigerant can cause frost bite. Keep
Install".
face and hands away to help prevent injury.
5. Connect a new hose (1) to radiator (2).
Protective goggles must always be worn when
Note: A new hose clamp (6) is installed as part of the refrigerant lines are opened, even if the gauges
installation procedure for the oil cooler. Refer to indicate the system is empty of refrigerant.
Disassembly and Assembly, "Transmission Oil Cooler -
Always use precaution when a fitting is removed.
Install".
Slowly loosen the fitting. If the system is still under
Transmission Oil Cooler pressure, release it slowly in a well ventilated area.
1. Clean all parts and inspect all parts. If any parts are Personal injury or death can result from inhaling
worn or damaged, use new Caterpillar parts for refrigerant through a lit cigarette.
replacement. Inhaling air conditioner refrigerant gas through a lit
cigarette or other smoking method or inhaling
fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm
or death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning
system.
1. Recover the air conditioner refrigerant from the air
conditioner system. The correct charge is 0.8 kg
(1.8 lb).
Illustration 66 g00910194
2. At the underside of the machine, position oil cooler
(2) and install bolts (4) and the washers.
3. Connect hoses (3) and tighten the hose clamps.
4. Connect hoses (1) and tighten the hose clamps.
5. Fill the cooling system. The capacity of the cooling
system is approximately 27.5 L (7.3 US gal).
Refer to the appropriate Operation and
Maintenance Manual.

Illustration 67 g00910214
2. Disconnect two hoses (1) from condenser (2).
18 31200299
Disassembly and Assembly Section

Illustration 68 g00910954 Illustration 71 g00910954

1. Install condenser (2) into mount (4). Tilt the
condenser toward the rear of the machine and
fasten latch assembly (3).

Illustration 69 g00910955
3. Release latch assembly (3). Tilt condenser (2)
toward the front of the machine before removing the
condenser. Illustration 72 g00910214
2. Connect two hoses (1) to condenser (2).
Installation Procedure 3. Charge the air conditioner system. The correct
charge is 0.8 kg (1.8 lb).

Illustration 70 g00945940
31200299 19
Disassembly and Assembly Section

Refrigerant Compressor -
Remove and Install
Removal Procedure
Start By:
a. Recover the air conditioner refrigerant from the air
conditioner system. The correct charge is 0.8 kg
(1.8 lb).
b. Remove the air cleaner. Refer to Disassembly and
Assembly, "Air Cleaner - Remove".
c. Remove the fan drive belt. Refer to
Operation and Maintenance Manual, "Belts - Illustration 73 g00921116
Inspect/Adjust/Replace". 2. Remove bolt (1), the washers, the nut, the lower
half of mount (2) and plate (3). This will enable
access to the rear of refrigerant compressor (4).

Personal injury can result from contact with

refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when
refrigerant lines are opened, even if the gauges
indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still under
pressure, release it slowly in a well ventilated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette. Illustration 74 g00921516
3. Disconnect two tubes (5) from refrigerant
Inhaling air conditioner refrigerant gas through a lit
compressor (4).
cigarette or other smoking method or inhaling
fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm
or death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning
system.
1. Put identification marks on all hose, on all tubes
and on all wires for installation purposes. Plug all
hoses and tubes. This helps prevent fluid loss, and
this helps to keep contaminants from entering the
system. Illustration 75 g00921517

4. Disconnect harness (6) from refrigerant

compressor (4).
5. Remove four bolts (7) and the washers in order
to remove refrigerant compressor (4) from the
machine.

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
20 31200299
Disassembly and Assembly Section

c. Charge the air conditioner system. The correct

charge is 0.8 kg (1.8 lb).

Engine Mount (Front) - Remove

Removal Procedure
Start By:
a. Remove the hood and the rear cover panel. Refer to
Disassembly and Assembly, "Engine Enclosure - Remove
and Install".

Illustration 76 g00921517
2. Position refrigerant compressor (4) onto the
machine and install four bolts (7) and the washers. Personal injury or death can result from improper
3. Connect harness (6) for refrigerant compressor lifting or blocking.
(4). When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
1. The following procedure is used to remove the
engine mount from the right side of the machine.
Use the same procedure to remove the engine
mount from the left side of the machine.
Illustration 77 g00921516
4. Connect two tubes (5) to refrigerant compressor
(4).

Illustration 79 g00921569
2. Remove bolt (1), the washers, the nut, the lower
half of mount (2) and washers (3).
Illustration 78 g00921116

5. Position the lower half of mount (2) and plate (3)

before installing bolts (1), the washers and the nut.
Tighten the nut and the bolt to a torque of 775 ± 20
Nm (572 ± 15 lb ft).
End By:
a. Install the fan drive belt. Refer to Operation
and Maintenance Manual, "Belts -
Inspect/Adjust/Replace".
b. Install the air cleaner. Refer to Disassembly and
Assembly, "Air Cleaner- Install".
31200299 21
Disassembly and Assembly Section

Illustration 80 g00921570
Engine Mount (Front) - Install
Installation Procedure
1. The following procedure is used to install the
engine mount on the right side of the machine.
Use the same procedure to install the engine
mount on the left side of the machine.
2. Clean all parts and inspect all parts. If any parts
are worn or damaged, use new Caterpillar parts
for replacement.

Illustration 81 g00921670
3. Attach a suitable lifting chain to the bracket on the
rear side of the engine and to a suitable hoist.
4. Use the hoist to carefully lift the engine until
bracket (4) is just clear of the upper half of mount
(2).
5. Remove four nuts (5) and the washers in order to
remove mounting bracket (4) from engine block
(6).

Illustration 83 g00921905
3. The engine is supported by a suitable hoist and
suitable lifting chain. Refer to Disassembly and
Assembly, "Engine Mount (Front) - Remove".

Illustration 82 g00921668
6. Remove the upper half of mount (2) from chassis
(7).

Illustration 84 g00921904
4. Install the upper half of mount (2) into chassis (7).

Illustration 85 g00921906
22 31200299
Disassembly and Assembly Section

5. Position mounting bracket (4) onto engine block

(6) and install four nuts (5) and the washers.
6. Use the hoist and lower the engine and bracket
(4) onto the upper half of mount (2). Remove the
hoist and lifting chain.

Illustration 87 g00984274
1. Attach a suitable lifting chain to the bracket on the
engine and to a suitable hoist. Take up the tension
on the chain but do not try to lift the engine at this
time.
Illustration 86 g00921907
7. Install the lower half of mount (2), washers (3), bolt
(1), the washer and the nut. Tighten the bolt to a
torque of 220 ± 20 Nm (162 ± 15 lb ft).
End By:
a. Install the hood and the rear cover panel. Refer to
Disassembly and Assembly, "Engine Enclosure -
Remove and Install".

Engine Mount (Rear) - Remove

Removal Procedure
Illustration 88 g00984278
Start By:
a. Remove the hood. Refer to Disassembly and
Assembly, "Engine Enclosure - Remove and
Install".
b. Remove the air cleaner. Refer to Disassembly and
Assembly, "Air Cleaner - Remove".

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
Illustration 89 g00984279
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a 2. Remove bolt (1), two washers (2), nut (3), washer
component. Install blocks or stands before (4), the lower half of mount (5) and sleeve (6).
performance of any work under a heavy 3. Use the hoist to carefully lift the engine and the
component. transmission until bracket (7) is just clear of the
Approximate weights of the components are upper half of mount (5). The combined weight of
shown. Clean all surfaces where parts are to be the engine and the transmission is approximately
installed. 780 kg (1720 lb).
4. Remove four bolts (8) and the washers in order
to remove bracket (7). Remove the upper half of
mount (5) from the engine frame.
31200299 23
Disassembly and Assembly Section

Engine Mount (Rear) - Install 3. Install the upper half of mount (5) into the engine
frame. Position bracket (7) onto the engine and
install four bolts (8) and the washers.
Installation Procedure 4. Use the hoist to carefully lower the engine until
1. Clean all parts and inspect all parts. If any parts are bracket (7) is seated on the upper half of mount
worn or damaged, use new Caterpillar parts for (5).
replacement. 5. Install sleeve (6), the lower half of mount (5),
washer (4), bolt (1), two washers (2) and nut
(3). Tighten the nut and the bolt to a torque of
775 ± 20 Nm (572 ± 15 lb ft).
6. Remove the lifting chain.
End By:
a. Install the air cleaner. Refer to Disassembly and
Assembly, "AirCleaner- Install".
b. Install the hood. Refer to Disassembly and
Assembly, "Engine Enclosure - Remove and
Install".

Engine Enclosure - Remove and

Illustration 90 g00984296 Install
2. The suitable lifting chain was attached to the
bracket on the engine in the removal procedure in
order to support the engine and the transmission. Removal Procedure
Refer to Disassembly and Assembly, "Engine
Mounts (Rear) - Remove". The combined weight of
the engine and the transmission is approximately
780 kg (1720 lb).
Personal injury or death can result from improper
lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
Hood
Illustration 91 g00984278

Illustration 93 g00919246
Illustration 89 g00984279
24 31200299
Disassembly and Assembly Section

1. Raise hood (1). Attach a suitable nylon lifting

around the hood and to a suitable hoist. Take up the
tension in order to support the hood.

Illustration 97 g00919671
2. Remove bolts (3) and the washers in order to
remove front panel (4) from the machine.
Illustration 94 g00919286
2. Disconnect gas spring assembly (2) from bracket (3). Installation Procedure
Panel Group

Illustration 95 g00919669
3. Remove bolts (4) and the washers which secure
hood (1) to mounting brackets (5).
Illustration 98 g00919671
4. Use the hoist and remove hood (1) from the
1. Position front panel (4) and install bolts (3) with the
machine. The weight of the hood is approximately
washers.
28 kg (62 lb).
Panel Group

Illustration 99 g00919670
2. Position front panel (2) and install bolts (1) with the
Illustration 96 g00919670 washers.
1. Remove bolts (1) and the washers in order to
remove rear panel (2) from the machine.
31200299 25
Disassembly and Assembly Section

Hood Engine - Remove

Removal Procedure
Start By:
a. Remove the transmission. Refer to the appropriate Service
Manual for more information.
b. Remove the expansion tank. Refer to Disassembly
and Assembly, "Expansion Tank - Remove and
Install".

Personal injury or death can result from improper

Illustration 100 g00919246
lifting or blocking.
1. Attach a suitable nylon lifting around hood (1) and to
a suitable hoist. Lift the hood into position on the When a hoist or jack is used to lift any part or
machine. The weight of the hood is approximately component, stand clear of the area. Be sure the
28 kg (62 lb). hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
Illustration 101 g00919669 containing fluids.
2. Align hood (1) with mounting brackets (5) and Dispose of all fluids according to local regulations and
install bolts (4) with the washers in order to secure mandates.
the hood.
1. Put identification marks on all hoses, on all lines
and on all wires for installation purposes. Plug all
hoses and all lines. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.

Illustration 102 g00919286

3. Connect gas spring assembly (2) to bracket (3).
4. Remove the nylon lifting sling and the hoist before
closing the hood.

Illustration 103 g00983900

2. Pull back the terminal covers in order to disconnect
positive cables (1) and negative cables (2) from
batteries (3). Tie the cables onto the engine with a
26 31200299
Disassembly and Assembly Section

suitable cable strap as the cables are removed with the cable over the engine and remove all cable
the engine. straps and clips that secure the cable.

Illustration 104 g00983901

Illustration 107 g00983904
3. Loosen the hose clamps in order to disconnect two 6. Disconnect electrical connector (13) for sensor (14)
hoses (4) from fuel filter/water separator (5). Trace for the hydraulic oil filter from harness (15). Remove
the hoses over the rear of the engine and remove nut (16) and the washer in order to disconnect the
all clamps or all cable straps that are attached. harness from engine frame (17).
Make a note of the location of the clamps and
straps for installation purposes.

Illustration 108 g00983908

7. Loosen the two hose clamps in order to disconnect
Illustration 105 g00983902
heater hoses (18) from thermostat housing (19).
4. Loosen the retaining nut in order to disconnect Move the hoses aside.
hose (6) from fuel filter (7). Trace the hoses over
the rear of the engine and remove all clamps or all
cable straps that are attached. Make a note of the
location of the clamps and straps for installation
purposes.

Illustration 109 g00983909

8. Loosen the hose clamp in order to disconnect
hose (20) from water pump (21). Disconnect hose
(22) (if equipped) from accumulator (23) for the air
conditioner.
Illustration 106 g00983903
5. Remove pin (8) in order to disconnect cable (9)
from the lever on fuel pump (10). Loosen two nuts
(11) and remove the cable from bracket (12). Trace
31200299 27
Disassembly and Assembly Section

Illustration 110 g00983910 Illustration 113 g00983912

9. Remove nut (24) and the washer in order to 11. Remove two bolts (29), the washers, the nuts, the
disconnect ground cable (25) from the engine lower half of mounts (30) and washer (31) that
frame (17). disconnect electrical connector (26) in secured the engine to the engine frame.
order to disconnect harness (15). Note: The rear mount which is for the engine and for the
transmission is removed in the removal procedure for
the transmission. Refer to the appropriate Service
Manual for more information.

Illustration 111 g00983911

10. Remove nut (27) and the washer in order to
disconnect the positive cable which is part of
harness (15) from terminal block (28). The terminal Illustration 114 g00983941
block is located on the side of the chassis which is 12. Attach a suitable double chain lifting sling to the
near to the exhaust muffler. lifting brackets on the front and on the rear of the
engine and to a suitable hoist. Use the hoist to
carefully lift the engine out of the engine frame and
away from the machine. Be careful not to catch on
any loose hoses or wires on removal. The weight of
the engine is approximately 450 kg (992 lb).

Illustration 112 g00983945

28 31200299
Disassembly and Assembly Section

Engine - Install
Installation Procedure

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
Illustration 117 g00983912
component. Install blocks or stands before
performance of any work under a heavy 3. Install two bolts (29), the washers, the nuts, the
component. lower half of mounts (30) and washer (31). This will
secure the engine to the engine frame. Tighten the
Approximate weights of the components are
bolts to a torque of 220 ± 20 Nm (162 ± 15 lb ft).
shown. Clean all surfaces where parts are to be
installed. Note: The rear mount which is for the engine and for
the transmission is installed in the installation
1. Clean all parts and inspect all parts. If any parts are procedure for the transmission. Refer to the appropriate
worn or damaged, use new Caterpillar parts for Service Manual for more information.
replacement.

Illustration 118 g00983911

Illustration 115 g00983941 4. Install nut (27) and the washer in order to connect
2. Attach a suitable double chain lifting sling to the the positive cable which is part of harness (15)
lifting brackets on the front and on the rear of the from terminal block (28). The terminal block is
engine and to a suitable hoist. Use the hoist to located on the side of the chassis which is near to
carefully lift the engine toward the machine and into the exhaust muffler.
the engine frame. Be careful not to catch on any
loose hoses or wires on installation. The weight of
the engine is approximately 450 kg (992 lb).

Illustration 119 g00983910

5. Install nut (24) and the washer in order to connect
ground cable (25) to the engine frame (17).
Connect electrical connector (26) to harness (15).
Illustration 116 g00983945
31200299 29
Disassembly and Assembly Section

Illustration 120 g00983909 Illustration 123 g00983903

6. Connect hose (22) (if equipped) to accumulator (23) 9. Route cable (9) over the engine to fuel pump (10).
for the air conditioner. Connect hose (20) to water Install the cable into bracket (12) and tighten two
pump (21) and tighten the hose clamp. nuts (11). Align the cable with the lever on the fuel
pump and install pin (8).

Illustration 121 g00983908 Illustration 124 g00983902

7. Connect heater hoses (18) to thermostat housing 10. Route hose (6) over the engine to the fuel filter.
(19) and tighten the hose clamp. Connect the hose and tighten the retaining nut.
Install all cable straps and clips that were removed
and noted in the removal procedure.

Illustration 122 g00983904

8. Install nut (16) and the washer in order to connect
Illustration 125 g00983901
the harness to engine frame (17). Connect
electrical connector (13) for sensor (14) for the 11. Connect two hoses (4) to fuel filter/water separator
hydraulic oil filter to harness (15). (5) and tighten the hose clamps. Install all cable
straps and clips that were removed and noted in the
removal procedure.
30 31200299
Disassembly and Assembly Section

Illustration 126 g00983900

12. Connect positive cables (1) and negative cables (2)
to battery's (3) and install the terminal covers.
End By:
a. Install the expansion tank. Refer to Disassembly
and Assembly, "Expansion Tank - Remove and
Install".
b. Install the transmission. Refer to the appropriate Service
Manual for more information.
31200299 31
Index Index

A M
Air Cleaner - Install Muffler - Remove and Install
Installation Procedure..................................................... 7 Installation Procedure ..................................................... 8
Air Cleaner - Install............................................................... 7 Removal Procedure ........................................................ 8
Air Cleaner - Remove Muffler - Remove and Install ................................................ 8
Removal Procedure........................................................ 6
R
Air Cleaner - Remove........................................................... 6
Alternator - Remove and Install............................................ 4 Radiator - Assemble
Installation Procedure..................................................... 5 Assembly Procedure..................................................... 13
Removal Procedure........................................................ 4 Radiator - Assemble........................................................... 13
Radiator - Disassemble
B Disassembly Procedure................................................ 12
Battery - Remove and Install Radiator - Disassemble...................................................... 12
Installation Procedure..................................................... 4 Radiator - Install
Removal Procedure........................................................ 3 Installation Procedure ................................................... 13
Battery - Remove and Install................................................ 3 Radiator - Install ................................................................. 13
Radiator - Remove
D
Removal Procedure ...................................................... 10
Disassembly and Assembly Section .................................... 3 Radiator - Remove ............................................................. 10
E Refrigerant Compressor -Remove and Install
Installation Procedure ................................................... 19
Electric Starting Motor -Remove and Install
Removal Procedure ...................................................... 19
Installation Procedure..................................................... 5
Refrigerant Compressor -Remove and Install .................... 19
Removal Procedure........................................................ 5
Refrigerant Condenser -Remove and Install ...................... 17
Electric Starting Motor -Remove and Install......................... 5
Installation Procedure ................................................... 18
Engine - Install ................................................................... 28
Removal Procedure ...................................................... 17
Installation Procedure................................................... 28
Engine - Remove T
Removal Procedure...................................................... 25 Table of Contents................................................................. 1
Engine - Remove ............................................................... 25 Transmission Oil Cooler -Install
Engine Enclosure - Remove and Install Installation Procedure ................................................... 16
Installation Procedure................................................... 24 Transmission Oil Cooler -Install ......................................... 16
Removal Procedure...................................................... 23 Transmission Oil Cooler -Remove
Engine Enclosure - Remove and Install ............................. 23 Removal Procedure ...................................................... 15
Engine Mount (Front) - Install Transmission Oil Cooler -Remove ..................................... 15
Installation Procedure................................................... 21
Engine Mount (Front) - Install............................................. 21
Engine Mount (Front) - Remove
Removal Procedure...................................................... 20
Engine Mount (Front) - Remove......................................... 20
Engine Mount (Rear) - Install
Installation Procedure................................................... 23
Engine Mount (Rear) - Install ............................................. 23
Engine Mount (Rear) - Remove
Removal Procedure...................................................... 22
Engine Mount (Rear) - Remove ......................................... 22
Expansion Tank - Remove and Install
Installation Procedure................................................... 10
Removal Procedure........................................................ 9
Expansion Tank - Remove and Install ................................. 9

F
Fan Guard - Remove and Install
Installation Procedure................................................... 15
Removal Procedure...................................................... 15
Fan Guard - Remove and Install ........................................ 15

I
Important Safety Information.................................................ii
32 31200299
Index
Manufactured by JLG under license from Caterpillar
31200270
December 15, 2006

Power Train System

Testing & Adjusting

TH220B, TH330B, TH360B, TH560B and

TH580B Telehandler
S/N TBF00100 & After
S/N TBG00100 & After
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200270 1
Table of Contents
Table of
Table of Contents Transmission Charge Pump .................. 24
Systems Operation Section Modulating Valve (Transmission)........... 24
Graphic Color Codes ............................... 3 Solenoid Valves (Transmission)............. 24
Introduction.............................................. 4 Directional Solenoids ......................... 24
General Information................................. 5 Speed or Synchronized Solenoids..... 25
Location of Electrical Components .......... 6 Torque Converter ................................... 26
Transmission Neutralizer Switch ......... 7 Transmission.......................................... 28
Parking Brake Switch .......................... 7 Clutch Operation................................ 31
Service Brake Pressure Switch ........... 7 Operation of the Synchronizers ......... 32
Transmission Direction Control Lever Synchronizer for the Third Speed and
(Power Shuttle Transmission) ............. 8 Fourth Speed ..................................... 35
Transmission Speed Selector Limits ................................................. 37
(Powersynchro Transmission)............. 8 Cooler (Hydraulic Oil)............................. 38
Differential Lock Switch (if Equipped... 8 Transmission Control (Shift Lever)......... 38
Transmission Oil Temperature Sensor 8 Powersynchro Transmission.............. 39
Torque Converter Output Sensor for the Power Shuttle Transmission .............. 39
Temperature of the Oil ........................ 8 Transmission Power Flow ...................... 40
Engine Speed Sensor ......................... 8 Examples of Power Flow Through the
Torque Converter Output Speed Transmission ..................................... 42
Sensor ................................................. 8 Differential Lock Control (If Equipped) ... 44
Transmission Intermediate Speed Front Axle and Rear Axle ....................... 46
Sensors ............................................... 9 Final Drives........................................ 46
Transmission Output Speed Sensor ... 9 Hydraulic Schematic (Power Train
Shift Rail Sensors................................ 9 System) .................................................. 48
Electronic Control Module ................... 9 Neutral (Power Shuttle Transmission)48
Modulating Valve for the Neutral (Powersynchro Transmission)49
Synchronizers...................................... 9 Neutral into First Gear (Start of shift). 50
Solenoid Valves................................. 10 Neutral Into First Gear (End of Shift)
Transmission Neutralizer Override (FORWARD)...................................... 51
Switch................................................ 10 Configuration Parameters ...................... 53
Location of Hydraulic Components........ 10 Testing and Adjusting Section
Transmission Charge Pump.............. 11 Transmission Shift Rail -Calibrate.......... 55
Torque Converter .............................. 11 Machine Preparation.......................... 55
Hydraulic Oil Cooler .......................... 11 Transmission Fill - Calibrate................... 62
Electrical Input Components.................. 12 Machine Preparation.......................... 62
Sensors ............................................. 12 Torque Converter Stall - Test................. 69
Switches ............................................ 14 Introduction ........................................ 69
Transmission Control ........................ 15 Required Tools .................................. 69
Electronic Control Module ..................... 16 Test Procedure .................................. 69
Inputs................................................. 16 Measurement of the Stall Speed ....... 70
Outputs.............................................. 16 Transmission Pressures - Test and
Input/Output....................................... 16 Adjust ..................................................... 70
Electrical Output Components............... 20 Pressure Test Points for the
Synchronizer Solenoids..................... 21 Powersynchro Transmission.............. 71
Directional Solenoids......................... 21 Pressure Test Points for the Power
Instrument Cluster ............................. 21 Shuttle Transmission ......................... 72
Data Link ............................................... 22 Oil Level Check.................................. 72
CAT Data Link ................................... 22 Torque Converter Inlet Pressure ....... 72
CAN Data Link................................... 22 Regulated Pump Pressure................. 73
Electrical Schematic .............................. 22
2 31200270
Table of Contents

Operating Pressures of Clutches and

Synchronizers ....................................74
Differential Pinion Bearing -Adjust..........75
Introduction ........................................75
Required Tools...................................75
Procedure ..........................................76
Differential Backlash and Bearings -
Adjust .....................................................81
Front Axle Differential ........................81
Rear Axle Differential .........................84
Tooth Contact Pattern ........................85
Axle Housing and Bearing Preload -
Adjust .....................................................87
Introduction ........................................87
Adjustment Procedure .......................88
31200270 3
Systems Operation Section

Systems Operation (M) Light Gray...........................................Surface color

Note: The information that is covered in this manual
Section may not require all of the colors in Illustration 1.

Graphic Color Codes

Illustration 1 g01023555

(A) Red.................................................High pressure oil

(B) Red Stripes and White Stripes
.....................................................First pressure reduction
(C) Red Crosshatch............Second pressure reduction
(D) Pink.....................................Third pressure reduction
(E) Orange.................Pilot, signal or torque converter oil
(F) Orange Stripes and White Stripes................Reduced
pilot, signal or torque converter oil
(G) Blue ........................................................Trapped oil
(H) Green ..................................Tank, sump or return oil
(I) Brown ..................................................Lubricating oil
(J) Orange Crosshatch...........Second reduction in pilot,
signal or torque converter oil
(K) Yellow....................Moving or activated components
(L) Purple........................................Pneumatic pressure
4 31200270
Systems Operation Section

Introduction

Illustration 2 g00902881

This module discusses the features and operation of

the power train. The following Telehandlers are
covered in this module:
TH220B
TH330B
TH360B
TH560B
TH580B

The power train for these machines has the

following main components:
• Torque converter
• Transmission
• Front axle differential and rear axle differential
• Final drives for the front axle and final drives for
the rear axle
31200270 5
Systems Operation Section

General Information

Illustration 3 g00889520
1. Torque converter
2. Engine
3. Transmission
4. Front axle differential
5. Rear axle differential
6. Drive shaft (front axle)
7. Drive shaft (rear axle)
8. Final drive (front axle)
9. Final drive (rear axle
)
The power train consists of the following main Final drives (8) for the front axle and final drives (9)
components: for the rear axle - Power is transferred to the final
drives for the front axle and to the final drives for the
rear axle from differentials (4) and (5). The final drives
Torque converter (1) - The torque converter in the front axle and in the rear axle have planetary
transfers power from engine (2) to transmission (3). gears. The planetary gears provide the secondary
The torque converter and the transmission are bolted as reduction.
a unit to the flywheel housing on the engine.
The torque converter and the transmission have a
common hydraulic system for operation, for
Transmission (3) - The transmission has spur gears lubrication, and for cooling. The transmission case and
and helical gears that are in constant mesh on all the hydraulic tank serve as an oil reservoir. Oil flow
shafts in order to provide a range of forward speeds through the system is provided by a pump that is
and reverse speeds. The speed range and the direction mounted on the casing for the transmission.
(forward and reverse) are selected when the clutches Machines are equipped with one of the following
and synchronizers lock specific gears to the shafts. transmission arrangements:
• Power Shuttle transmission with four speeds
Front axle differential (4) and rear axle differential
• Powersynchro transmission arrangement with four
(5) - Power is directed to the differentials from the speeds
transmission via drive shafts (6) and (7). Each of the
• Powersynchro transmission arrangement with five
differentials has a ring gear and a pinion (bevel gear
speeds
set) in order to provide the primary reduction. The
differential for the front axle can be locked in order to
improve traction on adverse ground conditions.
6 31200270
Systems Operation Section

Note: The five speed Powersynchro transmission is an

option on some machines. Your machine may not have
this option. The transmissions with five speeds and the
transmissions with four speeds are identical except for
the added components for the fifth speed. The Power
Shuttle transmission is identical to the Powersynchro
transmission with the exception of the mechanism for
shifting the transmission.
Note: This machine must be serviced by a technician.
The technician must be familiar with Caterpillar
Electronic Technician (ET). A number of parameters
can be installed and modified through the configuration
screen. The configuration of the machine may appear
as a interlock. The clutches and the synchronizers for
the Powersynchro transmission are engaged by oil
pressure. The oil pressure is controlled by solenoid
valves that are mounted on the transmission.

Location of Electrical
Components
The power train consists of the following electrical
components:
Illustration 4 g00877529
• Transmission neutralizer switch
1. Transmission neutralizer switch
• Parking brake switch 2. Parking brake switch
• Service brake pressure switch 3. Service brake pressure switch
4. Transmission direction control lever (Power Shuttle
• Transmission direction control lever (Power Shuttle transmission)
transmission)
5. Transmission speed selector (powersynchro
• Transmission speed selector (Powersynchro transmission )
transmission) 6. Differential lock switch
• Differential lock switch 7. Transmission oil temperature sensor
8. Oil temperature sensor for the torque converter output
• Transmission oil temperature sensor
9. Engine speed sensor
• Torque converter oil temperature sensor 10. Torque converter output speed sensor
• Engine speed sensor 11. Transmission intermediate speed sensor
12. Transmission output speed sensor
• Torque converter output speed sensor
13. Position sensor for the shift rail (first gear and second
• Transmission intermediate speed sensor gear)
• Transmission output speed sensor 14. Position sensor for the shift rail (third gear and fourth
gear)
• Position sensor for the shift rail (first gear and 15. Position sensor for the shift rail (fifth gear)
second gear) 16. Electronic control module
• Position sensor for the shift rail (third gear and 17. Modulating valve
fourth gear) 18. First gear (solenoid valve)
• Position sensor for the shift rail (fifth gear) 19. Second gear (solenoid valve)
20. Third gear (solenoid valve)
• Electronic Control Module (ECM)
21. Fourth gear (solenoid valve)
• Modulating valve 22. Fifth gear (solenoid valve (if equipped))
• Solenoid valves 23. Forward clutch solenoid valve
24. Reverse clutch solenoid valve
• Transmission neutralizer override switch
25. Solenoid valve for the differential lock
26. Transmission neutralizer override switch
31200270 7
Systems Operation Section

neutralizer switch is located on the top of the

transmission shift lever. The neutralizer switch allows
the operator to neutralize the transmission during
transmission shifts.

Parking Brake Switch

Illustration 5 g00884241

Powersynchro Transmission (Four Speed)

(7)Transmission oil temperature sensor (Torque Converter outlet)
(8)The oil temperature sensor for the torque converter output
(9)Engine speed sensor
(10)Torque converter output speed sensor
(11)Transmission intermediate speed sensor Illustration 8 g00907218
(12)Transmission output speed sensor Parking brake switch (2) is located inside the housing for
(13)Position sensor for the shift rail (first gear and second gear) the parking brake on the brake mechanism. The
(14)Position sensor for the shift rail (third gear and fourth gear) parking brake switch sends a signal to the ECM when the
parking brake is applied.

Service Brake Pressure Switch

Illustration 6 g00890792
(15) Position sensor for the shift rail (fifth gear)

Transmission Neutralizer Switch Illustration 9 g00903938

Service brake pressure switch (3) is located on the end
of the brake cylinder. Remove the cover from the front
of the cab in order to gain access to the service brake
pressure switch. The service brake pressure switch
sends a signal to the ECM in order to neutralize the
transmission when the brakes are applied.

Illustration 7 g00877559

Machines with a Power Shuttle transmission are

equipped with transmission neutralizer switch (1). The
8 31200270
Systems Operation Section

Transmission Direction Control Differential Lock Switch (if

Lever (Power Shuttle Transmission) Equipped

Illustration 10 g00877616 Illustration 12 g00890801

Lever (4) for the transmission direction control is Differential Lock switch (6) is located on the cab floor. In
located on the left side of the steering column. The order to gain access to the foot switch, lift the floor mat
transmission direction control lever controls the of the cab. The differential lock switch sends a signal to
direction of the machine. the ECM in order to activate the differential lock.

Transmission Speed Selector Transmission Oil Temperature

(Powersynchro Transmission) Sensor
Transmission oil temperature sensor (7) is located on
the transmission housing next to the forward and
reverse solenoids. Refer to Illustration 5. The
transmission oil temperature sensor sends a signal to
the ECM regarding the temperature of the transmission
oil.

Torque Converter Output Sensor for

the Temperature of the Oil
Torque converter oil temperature sensor (8) is located on
the transmission housing next to the transmission
intermediate speed sensors. The torque converter oil
Illustration 11 g00877617 temperature sensor sends a signal to the ECM
regarding the temperature of the torque converter oil.
Lever (5) for the transmission speed selector is located
on the left side of the steering column. The Engine Speed Sensor
transmission speed selector sends a signal to the
ECM in order to control the speed and direction of the Engine speed sensor (9) is located at the interface of
machine. the torque converter housing and the engine. Refer to
Illustration 5. The engine speed sensor sends a signal
to the ECM regarding the speed of the engine.

Torque Converter Output Speed

Sensor
Torque converter output speed sensor (10) is located on
the transmission housing in front of the torque
converter. Refer to Illustration 5. The torque converter
output speed sensor sends a signal to the ECM
regarding the speed of the torque converter.
31200270 9
Systems Operation Section

Transmission Intermediate Speed Electronic Control Module

Sensors
The transmission intermediate speed sensors (11) are
located on the transmission housing. Refer to
Illustration 5. The transmission intermediate speed
sensors send signals to the ECM regarding the speed
of the transmission shafts.

Transmission Output Speed Sensor

Transmission output speed sensor (12) is located on
the transmission housing above the yoke for the drive
shaft to the front axle. Refer to Illustration 5. The
transmission output speed sensor sends a signal to the
ECM regarding the output speed of the transmission.

Shift Rail Sensors

The position sensors for the shift rails are located on
the housing for the Powersynchro transmission. Refer
to Illustration 5. The position sensors for the shift rails Illustration 13 g00987344
send signals to the ECM regarding the position of the
shift rails. Electronic control module (16) is mounted under the
engine hood. The electronic control module is required
Machines with four speeds are equipped with the
for machines with Powersynchro transmission or the
following position sensors for the shift rails:
Power Shuttle transmission. The ECM controls the
• Position sensor (13) for the shift rail (first gear and operation of the power train.
second gear)
• Position sensor (14) for the shift rail (third gear and Modulating Valve for the
fourth gear)
Synchronizers
Machines with five speeds are equipped with the
following position sensors for the shift rails:
• Position sensor (13) for the shift rail (first gear and
second gear)
• Position sensor (14) for the shift rail (third gear and
fourth gear)
• Position sensor (15) for the shift rail (fifth gear)

Illustration 14 g00947395

Modulating valve (17) for the powersynchro

transmission is mounted on the front of the
transmission. The modulating valve receives a signal
from the ECM in order to control the oil pressure that is
sent to the shift rails.
10 31200270
Systems Operation Section

Solenoid Valves Transmission Neutralizer Override

Switch

Illustration 15 g00947389

Illustration 17 g01007364
The transmission neutralizer override switch (26) is
located on the left side of the dash panel. When the
brakes are applied the transmission is neutralized in
order to provide more hydraulic power to the
implement system. The transmission neutralizer
override switch may be used to prevent the
transmission from neutralizing when the brakes are
applied.
Reference: See Systems Operation/Testing and
Adjusting, "Electrical Input Components" for more
information on the electrical components.
Illustration 16 g00947390

Powersynchro Transmission with Five Speeds Location of Hydraulic

(18)First gear (solenoid valve) Components
(19)Second gear (solenoid valve)
(20)Third gear (solenoid valve)
The power train consists of the following hydraulic
components:
(21)Fourth gear (solenoid valve)
(22)Fifth gear (solenoid valve (if equipped))
• Transmission charge pump
(23)Forward clutch (solenoid valve) • Torque converter
(24)Reverse clutch (solenoid valve) • Hydraulic oil cooler
(25)Differential lock (solenoid valve)

The solenoid valves receive signals from the ECM in

order to control the oil that is sent to the transmission
clutches, the differential lock and the shift rails.
31200270 11
Systems Operation Section

Torque Converter

Illustration 20 g00908442

Torque converter (2) is located at the interface

between the engine and the transmission. The torque
converter hydraulically connects the engine to the
transmission.

Hydraulic Oil Cooler

Illustration 18 g00877618
(1)Transmission charge pump
(2)Torque converter
(3)Hydraulic oil cooler

Transmission Charge Pump

Illustration 21 g00903965
Hydraulic oil cooler (3) is located inside the engine
enclosure to the right of the transmission. The
hydraulic oil cooler cools the hydraulic oil.

Illustration 19 g00884634

Transmission charge pump (1) is mounted on the rear

of the transmission. The transmission charge pump
supplies oil to the torque converter and the solenoid
valves in the power train.
12 31200270
Systems Operation Section

Electrical Input Components

Illustration 22 g00991197

Block Diagram of Input Components Pulse Width Modulated Sensor (PWM)

This type of sensor produces a digital signal with a duty
Sensors cycle that varies as the condition changes. The
Sensors provide information to the ECM about frequency of this signal is constant.
changing conditions. The sensor signal changes
proportionally to the changing conditions. The
following type of sensor signals are recognized by the
machine ECM.
Frequency - This type of sensor produces a signal
that varies in frequency as the condition changes.
31200270 13
Systems Operation Section

Speed Sensors Transmission Output Speed Sensor

Illustration 24 g00899623
The transmission output speed sensor (12) is used in
order to measure the output speed of the transmission.
The value that is measured is used in order to control
both upshifts and downshifts. The sensor is an input to
the ECM. The sensor connects to contact J1-2 and
contact J1-3.

Temperature Sensor (Torque Converter)

Illustration 23 g00899619

Engine Speed Sensor

The engine speed sensor (14) is used to measure the
speed of the engine. The sensor is an input to the
ECM. The sensor connects to contact J1-17 and contact
J1-18.

Torque Converter Output Speed Sensor

The torque converter output speed sensor (11) is used
in order to measure the speed at the output of the Illustration 25 g00991230
torque converter. The value that is measured is
compared with the value of the engine speed signal The torque converter oil temperature sensor (2) is an
from the engine speed sensor in order to calculate the input to the ECM. The information from the torque
ratio of the torque converter output speed. The sensor converter oil temperature sensor is sent to the
is an input to the ECM. The sensor connects to contact instrument cluster for display. The sensor connects to
J1-15 and contact J1-16. the ECM through contacts J1-22 and contact J1-45.

Transmission Intermediate Speed Sensor

The transmission intermediate speed sensor (13) is
used in order to measure the intermediate shaft speed
of the transmission. The sensor is an input to the ECM.
The sensor connects to contact J1-6 and contact J1-7.
14 31200270
Systems Operation Section

Temperature Sensor (Transmission and Switches

Hydraulic Oil)
Switches provide an open signal, a ground signal, or a
+battery signal to the inputs of the ECM. Switches are
open or closed.
• When a switch is open, no signal is provided to the
corresponding input of the ECM. This "no signal"
condition is also called "floating".
• When a switch is closed, a ground signal or a
+battery signal is provided to the corresponding
input of the ECM.
Switch (Parking Brake)

Illustration 26 g00991216
The hydraulic oil temperature sensor (1) is an input to
the ECM. The sensor provides an input signal to the
ECM and the signal is also sent to the instrument
cluster. The sensor connects to the ECM through
contacts J1-11, J1-21 and J1-36.

Sensor (Shift Rail 1), Sensor (Shift Rail 2),

and Sensor (Shift Rail 3)

Illustration 28 g00899639

The parking brake switch (9) tells the ECM that the
operator has the parking brake lever in the PARK
position. When the operator places the parking brake
lever in the PARK position, the normally closed circuit is
open and the normally open circuit is closed to ground.
Illustration 27 g00901162
When the lever is NOT in the PARK position, the
normally closed circuit is closed to ground and the
The sensors for the shift rails detect the position of the normally open circuit is open. The switch connects to
shift rails. The sensors send a signal to the ECM the ECM through contacts J2-52 and contact J2-53.
regarding the position of the rails. The ECM will
determine if the transmission has been neutralized by
the position of the rails. The sensors connect to the
ECM through the following contacts: J2-49, J2-50, J2-
51, J1-44, and J1-45.
31200270 15
Systems Operation Section

Transmission Neutralizer Override Switch Switch (Transmission Neutralizer)

Illustration 30 g00940274

The transmission neutralizer switch (8) will deactivate

the direction clutch solenoid in order to temporarily
place the transmission in neutral. The transmission will
remain in the neutral position while the switch is held.
When the switch is released, the transmission is placed
Illustration 29 g00901157
back into gear. The switch is used to neutralize the
transmission, so the user can change gears. The switch
The transmission neutralizer override switch (7) will is located on the transmission shift lever. The switch
deactivate the direction clutch solenoid in order to connects to the ECM through contacts J2-58.
temporarily place the transmission in neutral. When the
top of the switch is pushed in, the transmission is
automatically neutralized when the service brake
Transmission Control
pressure sensor detects a rise in the brake system Transmission Direction Control Lever
pressure. The transmission is engaged when the brake
system pressure decreases. This allows a higher The transmission direction control lever (3) contains
engine speed for improved hydraulic performance two switch inputs that are connected to the battery and
when you operate the machine implements. This also two switch inputs that are connected to ground. When
prevents premature brake wear. The switch is located the transmission direction control lever is in the
on the dash panel. The switch connects to the ECM forward position, the output for the forward direction is
through contacts J1-33. closed to ground and the output for the forward
direction is closed to the battery. When the
Switch (Service Brake Pressure) transmission direction control lever is not in the
The service brake pressure switch (10) is used to forward position both of the outputs are open. When
monitor the pressure in the service brake system. The the transmission direction control lever is in the
service brake pressure switch sends a signal to the reverse position, the output for the reverse direction is
ECM and the ECM neutralizes the transmission when closed to ground and the output for the reverse
the pressure reaches a set point. The ECM will engage direction is closed to the battery. When the
the transmission when the pressure decreases below a transmission direction control lever is not in the
set point. The set points for both the disengagement reverse position both of the outputs are open. When the
and the re-engagement are parameters that can be transmission direction control lever is in the neutral
changed by using ET. The switch is located on the position, all four of the inputs should be open. The
brake cylinder. The switch connects to the ECM transmission direction control lever connects to the
through contacts J2-42. ECM through contacts J2-59, J2-60, J1-24, and J1-25.
16 31200270
Systems Operation Section

Transmission Speed Selector Outputs

The speed and the direction of the machine are The ECM responds to decisions by sending electrical
determined by the position of the transmission speed signals to the outputs. The outputs can create an
selector and the position of the speed selector. The action or the outputs can provide information to the
transmission speed selector sends information about operator or the service technician. The outputs of the
the requested speed to the machine ECM over the machine ECM are listed in table 1 and table 2.
CAT data link.
Input/Output
Electronic Control Module
The CAT data link is used in order to provide a
connection for the service tool for troubleshooting ,
testing, and calibrations. The data link is bidirectional.
The data link allows the ECM to receive information.
The data link allows the ECM to send information.

Illustration 31 g00785019

Electronic Control Module (ECM). The control is used for both the
manual and the powersynchro transmissions.
The electronic control module (ECM) makes decisions
that are based on input information and memory
information. After the ECM receives the input
information, the ECM sends a corresponding response
to the outputs. The inputs and outputs of the ECM are
connected to the machine harness by two 70 contact
connectors (J1 and J2). The ECM is located on the
right side of the machine inside the engine
compartment. The ECM sends the information to the
Caterpillar Electronic Technician on the CAT data link.
Note: The ECM is not serviceable. The ECM must be
replaced if the ECM is damaged. Replace the ECM if a
failure is diagnosed.

Inputs
The inputs describe the status of the machine
systems. Two types of inputs exist. The inputs can be
either a switch type or a sensor type. Switches provide
an open, a ground, or a + battery signal to the inputs of
the controller. Sensors (frequency, PWM or voltage)
provide a changing signal to the sensor inputs of the
controller. The inputs to the ECM are listed in table 1
and table 2.
31200270 17
Systems Operation Section

Table 1 (Table 1, contd.)

Contact Description J1(1) Contact Description J1(1)

No. (2) Function Type No.(2) Function Type
1 Key Switch ON Key Switch ON Transmission Oil Temp
21 5V Sensor Return
Sensor Return
Transmission Output
2 Diff Speed 1 + Torque Converter Temp
Speed Sensor + 22 Analog Pass 1
Sensor
Transmission Output
3 Diff Speed 1 - Shuttle Reverse Duality
Speed Sensor- 24 Switch To Battery
Input (4)
Transmission Intermediate
6 Diff Speed 3 + Shuttle Forward Duality
Speed Sensor 1 + (3) 25 Switch To Battery
Input (4)
29 Engine Coolant Sensor Analog
Transmission Intermediate
7 Diff Speed 3 -
Speed Sensor 1 - (3) 30 Fuel Level Sensor Analog

10 Cat Data Link + CDL + 32 Location Code Enable Switch To Ground

Transmission Oil Transmission Neutralizer

11 5V Sensor Supply 33 Override Switch (moved Switch To Ground
Temperature Supply
from J2-51)
12 Backup Alarm Relay 2A ON
Transmission Oil Filter
35 Switch To Ground
13 Machine Ground Battery - Bypass Switch
Converter Output Speed Transmission Oil
15 Diff Speed 5 + 36 Analog
Sensor + Temperature Sensor
Converter Output Speed 38 Unswitched Battery + Battery
16 Diff Speed 5 -
Sensor -
39 Unswitched Battery + Battery
17 Engine Speed Sensor + Diff Speed 6 +
40 Left Stabilizer Raise Switch To Ground
18 Engine Speed Sensor - Diff Speed 6 -
41 Left Stabilizer Hold Switch To Ground
20 Cat Data Link - CDL -
42 Left Stabilizer Lower Switch To Ground
Transmission Oil Temp
21 5V Sensor Return
Sensor Return 43 Boom Retracted Switch Switch To Ground
Torque Converter Temp
22 Analog Pass 1 45 Switch To Ground Return 8V Sensor Return
Sensor
47 Unswitched Battery + Battery
Shuttle Reverse Duality
24 Switch To Battery
Input ( Transmission - Speed
48 PWM
Clutch 1 (3)
Shuttle Forward Duality
25 Switch To Battery
Input C9 Transmission - Speed
49 PWM
Clutch 2 (3)
29 Engine Coolant Sensor Analog
Transmission - Speed
30 Fuel Level Sensor Analog 50 PWM Return
Clutch 1-4 returns(3)
32 Location Code Enable Switch To Ground Transmission - Speed
51 PWM
Transmission Neutralizer Clutch 3 (3)
33 Override Switch (moved Switch To Ground Transmission - Speed
from J2-51) 52 PWM
Clutch 4 (3)
Transmission Oil Filter
35 Switch To Ground 54 Fwd/Rev Clutch Return PWM Return
Bypass Switch
Rear Axle Lock & Auxiliary
Transmission Oil 55 PWM Return
36 Analog Diverter Valve Return
Temperature Sensor
57 Machine Ground - Battery -
38 Unswitched Battery + Battery
Transmission - Speed
58 PWM
Clutch 5 (3)

(continued)
18 31200270
Systems Operation Section

(Table 1, contd)
(Table 2, contd)
Contact Description J1(1)
No.(2) Function Type Contact Description J2(1)
Transmission No.(2) Function Type
59 Synchronizer Modulation PWM
16 LSI Sensor PWM
Valve (3)
Speed Clutch 5 and Inlet Air Filter Restriction
17 Switch To Ground
Transmission Switch
60 PWM Return
Synchronizer Modulation 20 MSS Lamp Driver 300 mA Sink
Valve Returns (3)
21 MSS Lamp Driver 300 mA Sink
63 Hydraulic Lockout Switch - Switch To Ground
Enable 23 Auxiliary 2 Select Switch Switch To Ground

Hydraulic Lockout Switch - 24 Rear Axle Align Switch Switch To Ground

64 Switch To Ground
Disable
25 Steer Mode Switch - Front Switch To Ground
65 Rear Axle Lock Solenoid PWM
26 Steer Mode Switch - Circle Switch To Ground
66 Auxiliary Diverter Valve PWM
27 Steer Mode Switch - Crab Switch To Ground
67 Transmission - Clutch PWM 28 Front Axle Align Switch Switch To Ground
Forward
29 Right Stabilizer Raise Switch To Ground
68 Transmission - Clutch PWM
Reverse 30 Right Stabilizer Hold Switch To Ground

69 10 Volt PHS Valve Power 10 Volt Power 31 Right Stabilizer Lower Switch To Ground
Supply
Joystick Longitudinal
70 Machine Ground (-) Battery - 32 PWM
Command

(1) The ECM responds to an active input only when all Joystick Thumb Slider
33 PWM
Command
the necessary conditions are satisfied.
Quick Coupler Switch -
(2) The connector contacts that are not listed are not 36 Switch To Ground
Engage
used.
Quick Coupler Switch -
(3) Machines equipped with a Power Synchro 37 Switch To Ground
Disengage
Transmission
Quick Coupler Switch -
(4) Machines equipped with manual transmissions 38 Switch To Ground
Parity
Table 2 Differential Lock Engaged
39 Switch To Ground
Switch
Contact Description J2(1)
40 Joystick Lateral Command PWM
No.(2) Function Type
41 Auxiliary (+) Switch To Ground
1 Key Switch Start Neutral Start IN
Service Brake Pressure
3 Quick Coupler Relay 2A On/Off
42 Switch (Transmission Switch To Ground
5 Circle Steer Relay 2A On/Off Neutralizer)
6 Crab Steer Relay 2A On/Off 43 Engine Oil Pressure PWM

7 Start Relay 2A On/Off Right Stabilizer Pressure

44 Switch To Ground
Switch
8 Relay Returns Return
Left Stabilizer Pressure
9 Continuous Flow LED 300mA Sink 1 45 Switch To Ground
Switch
10 Frame Level Interlock Relay 300mA Sink 2 46 Trigger Parity Switch To Ground
Rear Axle Lock Return Side 47 Boom Critical Angle Switch Switch To Ground
11 300mA Sink 3
Relay
48 Aux Parity Switch To Ground
12 Engine Run Relay 300mA Sink 4
13 PHS Address Out 300mA Sink 5
(Table 2, contd)
14 Alternator R-Terminal R-Terminal
15 Continuous Flow Switch Switch To Ground Contact Description J2(1)
No.(2) Function Type
31200270 19
Systems Operation Section

49 Shift Rail Position Sensor 1 (3) PWM

50 Shift Rail Position Sensor 2 (3) PWM

51 Shift Rail Position Sensor 3 (3) PWM

Parking Brake Switch -

52 Switch To Ground
ENGAGED
Parking Brake Switch -
53 Switch To Ground
DISENGAGED
54 Boom Lowered Switch Switch To Ground
55 PHS Address (IN) Switch To Ground
Neutralizer Switch
58 Switch To Ground
(Transmission) (4)
59 Shuttle Control FWD (4) Switch To Ground
60 Shuttle Control REV (4) Switch To Ground
Boom Critical Angle Switch
61 Switch To Ground
Parity
62 Auxiliary - Switch to ground
64 CAN B+(Instr) J1939 CAN B +
65 CAN B-(Instr) J1939 CAN B -
67 CAN A+ (PHS Valve Stack) CAN A +
68 CAN A- (PHS Valve Stack) CAN A-

(1) The ECM responds to an active input only when all

the necessary conditions are satisfied.
(2) The connector contacts that are not listed are not
used.
(3) Machines equipped with a Power Synchro
Transmission
(4) Machines equipped with manual transmissions
20 31200270
Systems Operation Section

Electrical Output Components

Illustration 32 g00899165
31200270 21
Systems Operation Section

Table 3

Solenoid Function
This solenoid controls the
Transmission Solenoid 1
reverse direction clutch.
This solenoid controls the
Transmission Solenoid 2
forward direction clutch.
This solenoid engages the
Transmission Solenoid 3
first synchronizer.
This solenoid engages the
Transmission Solenoid 4
second synchronizer.
This solenoid engages the
Transmission Solenoid 5
third synchronizer.
This solenoid engages the
Transmission Solenoid 6
fourth synchronizer.
This solenoid engages the
Transmission Solenoid 7
fifth synchronizer.
Illustration 33 g01009007
The transmission solenoids use a combination of
proportional solenoids and on/off solenoids.
Directional Solenoids
The directional solenoids are proportional solenoids.
The proportional solenoids allow better shift • Solenoid Valve 1 (Reverse)
modulation.
• Solenoid Valve 2 (Forward)
The speed or synchronizer solenoids will be on/off
• Modulation Valve (Synchronizer)
solenoids.
The synchronizer modulation valve aids in the shifting of
the transmission.

Synchronizer Solenoids
• Solenoid Valve 3 (Synchronizer 1)
• Solenoid Valve 4 (Synchronizer 2)
• Solenoid Valve 5 (Synchronizer 3)
• Solenoid Valve 6 (Synchronizer 4)
• Solenoid Valve 7 (Synchronizer 5)

Illustration 34 g00899201

Instrument Cluster
The instrument cluster is used in order to inform the
operator of the status of the transmission system.
Standard information will include the following
information about the transmission.
• Actual gear and direction
• Action alarm and lamp
• Diagnostic information that relates to the
transmission
22 31200270
Systems Operation Section

Data Link CAN Data Link

The CAN Data Link is used in order to aid the
machine ECM with the control of the transmission. The
CAN data link is used for communication with the
display module.

Electrical Schematic
This is a simplified schematic of the power train
system for the machine ECM. This schematic does not
show all possible harness connectors. Always see the
Electrical System Schematic in the Service Manual for
the machine for an accurate schematic of a particular
machine.

Illustration 35 g00991545

CAT Data Link

The data link is an input and an output of the ECM. The
data link is designed to communicate with other
electronic control modules through the machine
harness. The data link is not a visible component. The
data link consists of internal ECM circuits and the
connecting harness wiring. The data link is
bidirectional. The data link allows the ECM to receive
information and the data link allows the ECM to send
information.
Caterpillar Electronic Technician (ET) also
communicates with other ECM modules through the
data link. The ET will list the other ECM modules and
the available diagnostic information.
Note: All electronic control modules (ECM) that use the
data link have a module identifier (MID). The MID is
listed for each module:
Machine ECM ...................................................................039

Shift Lever...........................................................................117
31200270 23
Systems Operation Section

Illustration 36 g00991166
24 31200270
Systems Operation Section

Transmission Charge Pump on one side of the pump. The crescent separates the
ring gear and the rotor on the other side of the pump.
The pump creates oil flow from the inlet port to the
outlet port by trapping oil in the spaces between the
rotor, the teeth on the ring gear and the crescent.
Seal (7) - The seal prevents oil from escaping
between rotating sleeve (1) and housing (6).

Modulating Valve
(Transmission)
The modulating valve that is used for controlling the
clutches and the synchronizer solenoids is a
proportional pressure reducing valve. The valve
reduces the system pressure in an inverse proportion to
the current that is supplied to the valve solenoid. When
no current is supplied, the outlet port is connected to
the tank and the supply is cut off. The valve is pilot
operated. The force of the solenoid acts on a small
pilot stage. This force allows the main control spool to
be hydraulically operated. The relatively low force of
the solenoid is magnified in order to enable a relatively
large flow through the valve.
Note: The maximum oil pressure that will flow through
the valve is always reduced. The valve reduces the
system pressure by about 150 kPa (22 psi).
Illustration 37 g00889728
(1) Sleeve
(2) Pump drive shaft (transmission)
Solenoid Valves (Transmission)
(3) Ball bearing
The transmission solenoids are a combination of
(4) Rotor
(5) Ring Gear
proportional solenoids and on/off solenoids.
(6) Housing The transmission direction control will energize the
(7) Seal solenoids in order to control the direction of the output
shaft. The transmission direction control also energizes
The charge pump for the torque converter and the the solenoids in order to control the speeds in the
transmission is a crescent type gear pump that is powersynchro transmission.
driven by the pump drive shaft of the transmission. The Reference: See Systems Operation/Testing and
clearances between the components within the charge Adjusting, "Location of Electrical Components" for more
pump are very small in order to keep losses in efficiency information on the location of the solenoids.
to a minimum. The solenoids control the following functions on
the machine:
The charge pump consists of the following main • Forward/Reverse Clutches
components:
• Gear Selection (powersynchro transmission)
Sleeve (1) - The sleeve is splined to pump drive shaft
• Fifth Gear Selection (if equipped)
(2) of the transmission. The sleeve which has external
tangs rotates with the pump drive shaft on ball bearing
(3). Directional Solenoids
Rotor (4) - Tangs on the outside of sleeve (1) drive the The directional solenoids are proportional solenoids.
ring gear. The proportional solenoids allow better directional
Ring Gear (5) - Rotor (4) is meshed with the rotor. As clutch pressure modulation as the solenoids are
the rotor and the ring gear rotate inside housing (6), oil energized in order to achieve smooth gear changes.
is drawn through the inlet. The oil is then forced past a
crescent and out of the outlet.
Crescent (not shown) - Ring gear (5) is offset from
rotor (4), and the teeth of these components only mesh
31200270 25
Systems Operation Section

Speed or Synchronized Solenoids

The speed solenoids or synchronized solenoids are
on/off solenoids. The speed solenoids and the
synchronized solenoids are used on the powersynchro
transmission in order to control the output direction and
gear.
26 31200270
Systems Operation Section

Torque Converter

Illustration 38 g00889374
(1) Housing (4) Impeller (7) Stator
(2) Engine flywheel (5) Turbine (8) Sleeve
(3) Drive plate (6) Transmission input shaft (9) Gear

The torque converter hydraulically connects the Systems Operation/Testing and Adjusting,
engine to the transmission. There is no direct "Transmission Charge Pump" for further information.
mechanical connection between the engine and the The torque converter has the following main
transmission. components:
When the machine works against a load, the torque Housing (1) - The housing is connected to engine
converter can multiply the torque from the engine in flywheel (2) through drive plate (3).
order to send a higher torque to the transmission. The
oil for the operation of the torque converter is supplied Impeller (4) - The impeller, which is connected to
by the charge pump for the transmission. Refer to housing (1), rotates with engine flywheel (2) at engine
speed. When the housing and the impeller turn, oil is
31200270 27
Systems Operation Section

directed toward the outside of the impeller and against

the blades of turbine (5).
Turbine (5) - The force of the oil that contacts the
turbine blades causes the turbine and input shaft (6)
for the transmission to rotate. The rotation of the input
shaft provides power to the transmission.
Stator (7) - The stator is splined to sleeve (8) which is
bolted to the torque converter casing. Oil is directed
back to impeller (4) through the stator vanes which
causes the torque to increase.
Gear (9) - The gear which is splined to impeller (4)
rotates at engine speed in order to supply power to the
fan drive shaft.
28 31200270
Systems Operation Section

Transmission

Illustration 39 g00886406
31200270 29
Systems Operation Section

(1) Input shaft (13) Forward clutch (25) First gear

(2) Torque Converter (14) Forward primary gear (26) First gear
(3) Gear (15) Reverse clutch (27) Second gear
(4) Gear (16) Reverse primary gear (28) Second gear
(5) Fan drive shaft (17) Reverse idler shaft (29) Third gear
(6) Gear (18) Gear (30) Third gear
(7) Gear (19) Gear (31) Fourth gear
(8) Pump drive shaft (20) Countershaft (32) Fifth gear
(9) Gear (21) Fourth gear (33) Synchronizer (first/second speeds)
(10) Gear (22) Synchronizer (fifth speed) (34) Synchronizer (third speed and fourth
(11) Forward/Reverse shaft (23) Fifth gear speed)
(12) Input drive gear (24) Output shaft

Pump drive shaft (8) - Gear (9) that is on the pump

drive shaft for the implement pump is driven by gear (6)
on the fan drive shaft. Gear (9) is splined to the pump
drive shaft in order to provide drive to the pump drive
shaft. Power is transferred from gear (7) to gear (10)
that rotates on the pump drive shaft. The pump drive
shaft rotates at engine speed. A needle bearing is
located between gear (10) and the pump drive shaft in
order to allow the gear to rotate independently of the
pump drive shaft.
Forward/Reverse shaft (11) - Input drive gear (12)
that is splined to the forward/reverse shaft meshes with
gear (10) on the pump drive shaft. Power is transferred
Illustration 40 g00886748
from gear (10) to the forward/reverse shaft via input
Reverse Idler Shaft (Shown Outside of the Transmission for Clarity)
drive gear (12).
Note: The transmission that is shown in Illustration 39 is Forward clutch (13) - When the forward clutch is
a transmission with five speeds. The fifth gear (23) is engaged, forward primary gear (14) is locked to the
removed when the machine has only four speeds. forward/reverse shaft. When the forward clutch is not
Also, synchronizer (22) is replaced by a spacer, and engaged, forward primary gear (14) can rotate freely on
fifth gear (32) is replaced by a spacer. two needle bearings on the forward/reverse shaft. Refer
to "Clutch Operation" for more information on the
operation of the forward clutch.
The transmission consists of the following main Reverse clutch (15) - When the reverse clutch is
components: engaged, reverse primary gear (16) is locked to the
Input shaft (1) - Power from torque converter (2) is forward/reverse shaft. When the reverse clutch is not
transferred to the input shaft which causes the input engaged, reverse primary gear (16) can rotate freely on
shaft to rotate. Gear (3) is splined to the input shaft, and two needle bearings on the forward/reverse shaft. Refer
gear (4) rotates freely on the input shaft at the engine to "Clutch Operation" for more information on the
speed. operation of the reverse clutch.
Fan drive shaft (5) - The fan drive shaft is splined to Reverse idler shaft (17) - Gear (18) on the reverse
gear (6) which meshes with gear (4) on the input shaft. idler shaft meshes with reverse primary gear (16).
Power is transferred from gear (4) to gear (6) in order to When reverse clutch (15) is engaged, power from the
cause the fan drive shaft to rotate. Gear (7) meshes reverse primary gear is transferred to the reverse idler
with gear (3) on the input shaft. Power is transferred shaft via gear (18). The power in the reverse idler shaft
from gear (3) to gear (7) in order to cause gear (7) to is transferred to gear (19).
rotate on the fan drive shaft. A needle bearing is
located between gear (7) and the fan drive shaft in
order to allow the gear to rotate independently of the
fan drive shaft.
30 31200270
Systems Operation Section

Countershaft (20) - Forward primary gear (14) and

gear (19) mesh with fourth gear (21) on the
countershaft. If the forward clutch is engaged, power is
transferred from the forward primary gear to the fourth
gear on the countershaft. The reverse idler shaft will
rotate freely in this case. If the reverse clutch is
engaged, power is transferred from gear (19) to the
fourth gear on the countershaft. Forward primary gear
will rotate freely in this case. The countershaft has four
gears that are integral to the shaft, a fifth gear (if
equipped) that rotates on two needle bearings, and a
synchronizer (if equipped). When the synchronizer (22)
is engaged, fifth gear (23) is locked to the countershaft.

Output shaft (24) - The countershaft and the output

shaft have the following gear sets that are in constant
mesh:
• First gear (25) on the countershaft with first gear
(26) on the output shaft
• Second gear (27) on the countershaft with second
gear (28) on the output shaft
• Third gear (29) on the countershaft with third gear
(30) on the output shaft
• Fourth gear (21) on the countershaft with fourth
gear (31) on the output shaft
• Fifth gear (23) (if equipped) on the countershaft
with fifth gear (32) (if equipped) on the output shaft
• The required gear ratio is selected by locking the
specific gear sets to the respective shafts by
engaging one of the following synchronizers:
• Synchronizer (33) for the first/second speed that is
on the output shaft
• Synchronizer (34) for the third/fourth speed that is
on the output shaft
• Synchronizer (22) (if equipped) for the fifth speed
that is on the countershaft
Refer to Systems Operation/Testing and Adjusting,
"Transmission Power Flow" for information on the
clutches and the synchronizers that are engaged for
each speed.
31200270 31
Systems Operation Section

Clutch Operation

Illustration 41 g00886075
(11) Forward/reverse shaft (38) Clutch piston (44) Needle bearings
(14) Forward primary gear (39) Clutch pack (45) Spring
(16) Reverse primary gear (40) Outer discs (46) Needle bearings
(35) Seal rings (41) Inner discs (47) Spring retainer
(36) Control oil passage (42) Backing plate (48) Circlip
(37) Drum shaft assembly (43) Snap ring

The two clutches on the forward/reverse shaft operate corresponding splines in drum shaft assembly (37).
in an identical manner. The forward clutch and the The discs are stacked alternately until six inner discs
reverse clutch have the following main and six outer discs are installed. The discs are held in
components: position by backing plate (42) and snap ring (43).
Seal rings (35) - Three seal rings are located on the The hub of forward primary gear (14) and the hub of
end of forward/reverse shaft (11). Control oil is reverse primary gear (16) have external splines which
connected to each clutch through a series of passages engage with the internal splines of inner discs (41). The
which are formed in the housings of the torque inner discs and the primary gears which run on needle
converter and the transmission. Control oil is bearings (44) are free to increase in speed and free to
connected to a control oil passage (36) in the forward/ rotate in the opposite direction to the outer discs
reverse shaft. The control oil is prevented from leaking provided that there is no oil pressure in that specific
by seal rings (35). clutch.
Drum shaft assembly (37) - Each clutch pack is Clutch piston (38) - When the clutch is engaged,
installed in a drum shaft assembly which has internal control oil pressure is transmitted into the area behind
splines. A section of the bore of drum shaft assembly is the clutch piston. The oil pressure forces the clutch
smooth in order to allow operation of clutch piston (38). piston and clutch discs (40) and (41) against backing
Clutch pack (39) - The clutch packs consist of outer plate (42) in order to form a solid connection. The drive
discs (40) with external splines on the outer diameter can then be transmitted from drum shaft assembly (37)
and inner discs (41) with internal splines on the inner to the hub of forward primary gear (14) or reverse
diameter. The outer discs are made from steel and the primary gear (16).
inner discs (friction) are made from steel and a paper
based material. An outer disc is installed first against
clutch piston (38), and an inner disc is then installed.
The external splines on the outer disc engage with
32 31200270
Systems Operation Section

Spring (45) - The spring is located on spring guide

(46) between spring retainer (47) and clutch piston
(38). The spring is held under compression by circlip
(48). The spring force is used to move clutch piston
(38) away from clutch discs (40) and (41) in order to
disengage the clutch. Oil from behind the clutch piston
flows back through control oil passage (36) when the
clutch is disengaged.
When pressure is relieved from the clutch, drum shaft
assembly (37) can rotate with outer discs (40) at a
different speed to the forward primary gear (14) or
reverse primary gear (16) and inner discs (41). Also,
when pressure is relieved from the clutch, the drum
shaft assembly can rotate with the outer discs in the
opposite direction to the forward primary gear or
reverse primary gear and the inner discs.

Operation of the Synchronizers

The synchronizer for the first speed and second
speed, and the synchronizer for the third speed and
fourth speed are two-way synchronizers. The
synchronizer assemblies and the shift rails can be
operated manually or the synchronizer assemblies and
the shift rails can be operated by solenoids. The
operation of the synchronizer assemblies and the shift
rails depends on the type of transmission on the
machine. Each of these synchronizers can lock one of
two output gears to the output shaft at a time. The
synchronizer for the fifth speed can only lock the fifth
gear to the countershaft. All three of the synchronizers
are actuated with forks and a shift rail. The shift rails
have a steel ball and spring detents in order to hold the
NEUTRAL position and the GEAR positions. The first/
second synchronizer use a double clutch. The third/
forth synchronizer and the fifth synchronizer use a
single cone clutch. The synchronizer assemblies are all
strut type. The following text explains the operation of
the synchronizer assemblies.
31200270 33
Systems Operation Section

Synchronizer for the First Speed and

Second Speed

Illustration 42 g00886407

Synchronizer for the First/Second speed

(24) Output shaft (53) Connecting block (58) Friction ring
(26) First gear (54) Strut (59) Inner cone
(28) Second gear (55) Spring (60) Plate
(49) Hub (56) Detent pin
(50) Sleeve (57) Outer cone
of the sleeve provides a location for fork (51) which is
attached to shift rail (52).
Connecting blocks (53) - Three connecting blocks
are located between hub (49) and sleeve (50). The
connecting blocks are positioned around the sleeve at
120 degree intervals. The connecting blocks connect
the inner cone to the outer cone.
Struts (54) - Three struts are also located between
hub (49) and sleeve (50). Each strut is positioned
directly opposite one of the connecting blocks (53).
Each of the three struts have a spring (55) and detent
pin (56). The head of the detent pin sits in a groove on
Illustration 43 g00887427 the inside of sleeve (50).
Output Shaft (Shown Outside of the Transmission for Clarity)
Two outer cones (57) - Each outer cone sits in a
(51) Fork
circular channel on the side of hub (49). The outer
(52) Shift rail
cones are driven by lugs which engage in slots in the
The synchronizer contains the following main
hub. The outer cones also have teeth on the
components:
circumference which can engage with the internal teeth
Hub (49) - The hub is splined to output shaft (24). The of the sleeve.
outer radius of the hub also has splines.
Two friction rings (58) - Each friction ring which sits
Sleeve (50) - Splines on the internal radius of the between the inner cone and the outer cone (57) can
sleeve are interlocked with the splines on the outer rotate independently of the cones. The friction ring
radius of hub (49). A groove around the circumference drives the plate (60) via lugs.
34 31200270
Systems Operation Section

Two inner cones (59) - Each inner cone sits inside Sleeve (50) rides over the top of detent pins (56) so
friction ring (58) and interlocks with connecting blocks that no force is transmitted to struts (54).
(53) to the outer cones. The pressure to the clutch is controlled by a
Two Plates (60) - Each plate (60) fits over an inner proportional pressure reducing valve. When the
cone (59), a friction ring (58) and an outer cone (57). synchronizer is engaged, the output gear is locked to
The location lugs of friction rings (58) are interlocked the output shaft. Power flows through the system
with the alignment slots of the adjacent plate (60). components in the following order:
Each plate (60) is also splined with an output gear that • Output gear
is on the output shaft.
• Synchronizer
When the synchronizer is not engaged, the
following components rotate with the output gear: • Output shaft
• Plate (60)
• Friction ring (58)
When the synchronizer is not engaged, the
following components rotate with the output shaft:
• Hub (49)
• Inner cone (59)
• Outer cone (57)
• Connecting blocks (53)
• Strut (54)
• Detent pins (56)
• Springs (55)
• Sleeve(50)
When a transmission speed is selected the solenoid on
the gear valve is switched on. Oil flows into the
actuator at the opposite end of the shift rail. The shift
rail (52) moves in a direction that is parallel to the
output shaft. Fork (51), which is attached to the shift
rail, exerts a force on sleeve (50) and the sleeve
begins to move toward the output gear. As sleeve (50)
moves toward output gear detent pins (56) are
dragged by the groove in sleeve (50). This causes
struts (54) to move until the struts contact outer cone
(57). The modulating valve drops the pressure initially.
The pressure then ramps up to a predetermined level.
When the surfaces of the struts and the surfaces of the
cones come together outer cone (57) will rotate by half
a tooth. The chamfers of the teeth on sleeve (50)
contact the chamfers of the teeth on outer cone (57).
The force on sleeve (50) is now transmitted to the
cones by these tooth chamfers. Further movement of
sleeve (50) is blocked by the interaction of the
synchronising torque and the indexing torque of the
chamfers on the tooth. The friction that is created
causes the speed of the output gear and the speed of
output shaft (24) to become equal. Zero synchronising
torque will result if the speed of the output gear is equal
to the speed of the output shaft. The chamfers on the
teeth are now able to rotate outer cone (57) by half a
tooth. Sleeve (50) will then move up over the teeth on
the outer cone and up to plate (60). The teeth on
sleeve (50) will engage with the teeth on plate (60).
This action will fix the output gear to output shaft (24).
31200270 35
Systems Operation Section

Synchronizer for the Third Speed and

Fourth Speed

Illustration 44 g00888146
Synchronizer for the Third/Fourth Speed
(24) Output shaft (50) Sleeve (61) Plate
(30) Third gear (54) Strut (62) Steel ball
(31) Fourth gear (55) Spring
(49) Hub (57) Outer cone

The synchronizer for the third/fourth speed has the

following components that operate in the same
way as the synchronizer for the first/second speed:
• Sleeve (50)
• Strut (54)
• Springs (55)
• Outer cone (57)
• Hub (49)

Illustration 45 g00888421
The synchronizer for the third/fourth speed has the
Output Shaft (Shown Outside of the Transmission for Clarity)
(63) Shift rail
following components that operate in a different
(64) Fork
way to the synchronizer for the first/second speed:
The synchronizer for the third/fourth speed operates on Plates (61) - The plate (61) for the third speed is
the same principles as the synchronizer for the first/ splined to third gear (30) on output shaft (24). The
second speed, but it does not include all of the same plate (61) for the fourth speed is splined to fourth gear
components. The components that are not used in the (31) on output shaft (24). The plates (61) have an
synchronizer for the third/fourth speed are the friction inner cone that is machined into the inner
rings and the connecting blocks. circumference of the plates (61). The plates (61) also
have teeth around the outer circumference.
36 31200270
Systems Operation Section

When third speed or fourth speed is selected, shift rail

(62) moves in a direction that is parallel to the output
shaft. Fork (63), which is attached to the shift rail,
exerts a force on sleeve (50) in order to initiate the
engagement of the synchronizer. The synchronizer for
the third speed and fourth speed operates in the same
way as the synchronizer for the first/second speed. The
frictional force that is required to equalize the speed of
the output shaft and the speed of the output gear is
produced between outer cone (57) and the inner cone
on plate (61).
Steel balls (62) - The three steel balls will operate in the
same way as the detent pins on the synchronizer for the
first/second speed. The steel balls sit in a groove on
the inside of outer ring (50). This action causes the
struts to move.
Synchronizer for the Fifth Speed (If
Equipped)
The synchronizer for the fifth speed operates on the
same principles as the synchronizer for the third/fourth
speed. However, the synchronizer for the fifth speed
has the following differences to the synchronizer for the
third/fourth speed:
• The fifth speed cannot be selected manually.
• The fifth gear is engaged and disengaged
automatically when the transmission is in fourth
gear.
• The synchronizer for the fifth speed operates on
one side instead of two sides.
• The synchronizer operates on the countershaft
instead of the output shaft.
• The actuator is held hydraulically in the
DISENGAGED position.
31200270 37
Systems Operation Section

Illustration g00886408
Synchronizer for the Fifth Speed
(20) Countershaft (50) Sleeve (57) Outer cone
(32) Fifth gear (54) Strut (61) Plate
(49) Hub (55) Spring (62) Steel ball
The fifth speed is automatically selected by the
machine when the output shaft reaches a set speed.
Shift rail (65) and forks (66) move outer ring (50) in
order to engage the synchronizer, and the fifth gear is
then locked to the countershaft. Power is transferred
through the system components in the following
order:
• Countershaft
• Synchronizer for the fifth speed
• Fifth gear on the countershaft
• Fifth gear on the output shaft
Illustration 47 g00888072
• Output shaft
(65) Shift rail
(66) Fork
The synchronizer for the fifth speed operates in the Limits
same way as the top half of the synchronizer for the
Several limits have been incorporated into the control
third/fourth speed. The synchronizer for the fifth speed
system of the transmission. The limits prevent
is only able to lock the fifth gear to the shaft.
damage to the power train. The limits also prevent
overspeed of the engine.
• Transmission shifting through the gears will be
prevented when the torque converter has stalled.
• When a direction change from fourth gear forward
or fifth gear forward is received, this will be limited.
The ECM will change down the gears to third gear
in order to reach a suitable speed before changing
direction.
38 31200270
Systems Operation Section

• Shifting down causing engine overspeed will be Transmission Control (Shift

limited . Once the speed drops the shift will be
allowed. Lever)
• The ECM will allow directional changes at any
speed in third gear. Excessive numbers of
directional changes at any speed in third gear is
limited. Excessive numbers of directional changes
at any speed in third gear could damage the
integrity of the system.
• The machine has a downshift inhibitor in order to
prevent the engine from over-speeding. The ECM
will detect the current speed. The ECM will stop
the operator from selecting a lower gear while the
machine is coasting down a hill.
• The machine has a inhibitor on shifting for
protection from rollback in order to prevent the Illustration 49 g00890358
machine from rolling back between shifts on a The transmission direction control is a sealed,
slope if the torque converter is near a stall. If nonserviceable unit which is mounted to the steering
the transmission output speed and the torque column. Movement of the control lever energizes
converter ratio fall below the limit, the ECM will solenoid valves for the direction clutches of the
not allow a downshift. The ECM will shift to the transmission.
requested gear when the limit has passed. The control lever has the following positions:
• FORWARD (F)
Cooler (Hydraulic Oil)
• NEUTRAL (N)
• REVERSE (R)
The control lever is pushed upward in order to travel in
a forward direction and the control lever is pulled
downward in order to travel in a reverse direction.
The transmission control lever sends a signal to the
machine ECM. The ECM interprets the signal as either
forward, neutral or reverse.
The transmission control lever needs to be in
NEUTRAL position before the engine will start.
When the ECM detects the transmission control lever in
the REVERSE position the ECM energizes the back up
Illustration 48 g00907373
alarm.
Oil from the torque converter flows into the hydraulic oil
When the control lever is in the NEUTRAL position a
cooler. The cooled oil then flows into the transmission
switch in the control group is closed and this
housing.
completes a circuit between the engine start switch and
Refer to Systems Operation/Testing and Adjusting, the start relay. The switch opens when the control lever is
"Location of Hydraulic Components" for the location of in any other position which will prevent the engine from
the oil cooler. being started.
When the control lever is in the REVERSE position, a
switch in the control closes. This activates the backup
alarm and warning light of the machine.
A switch that is located below the parking brake control
is open in order to prevent the power to the
transmission control if the parking brake is not fully
disengaged.
A pressure switch that is located in the service brake
line is connected in series with a switch that is located
on the dash panel. When the switch on the dash panel
is in the ON position, the application of the service
31200270 39
Systems Operation Section

brake prevents the power supply to the transmission Power Shuttle Transmission
control which neutralizes the transmission. This control
is intended for use with a machine that is equipped
with a work tool. The control ensures that full engine
power is available for operating the hydraulics when the
machine is held stationary with the service brake.

Powersynchro Transmission

Illustration 51 g00890363
On machines with a Power Shuttle transmission, the
transmission speed is selected by pressing
transmission neutralizer switch (2) and holding the
transmission neutralizer switch in order to neutralize the
transmission. Then moving the transmission speed
lever to one of the four available travel speeds. A
Illustration 50 g01007367 mechanical linkage transfers the movement of the
On machines with a powersynchro transmission, the transmission speed lever to the transmission in order to
required transmission speed is selected by rotating the engage the required speed. The shift pattern for the
barrel of the control lever. The corresponding solenoid transmission speed lever is shown in Illustration 52.
valve on the transmission is energized in order to
select the desired transmission speed.

The following transmission speeds are available

when the control lever is in the FORWARD
position:
• First speed
• Second speed
• Third speed
• Fourth speed
Your machine may also be equipped with an Illustration 52 g00846950
automatic fifth speed. Machines that are equipped with The following transmission speeds are available
this feature will automatically shift into fifth speed when when the control lever is in either the FORWARD
the appropriate ground speed is reached. Fifth speed position or the REVERSE position:
cannot be manually selected by the operator.
• First speed
• Second speed
The following transmission speeds are available
when the control lever is in the REVERSE position: • Third speed
• First speed • Fourth speed
• Second speed
• Third speed
40 31200270
Systems Operation Section

Transmission Power Flow

Illustration 53 g01007675
(1) Input shaft (12) Reverse idler shaft (23) Fourth gear (output shaft)
(2) Gear (13) Gear (24) Fifth gear (output shaft)
(3) Gear (14) Fourth gear (countershaft) (25) Output shaft
(4) Fan drive shaft (15) Countershaft (F) Forward clutch
(5) Gear (16) First gear (countershaft) (R) Reverse clutch
(6) Pump drive shaft (17) Second gear (countershaft) (X) Synchronizer for the first
(7) Input drive gear (18) Third gear (countershaft) speed and second speed
(8) Forward/Reverse shaft (19) Fifth gear (countershaft) (Y) Synchronizer for the third
(9) Forward primary gear (20) First gear (output shaft) speed and fourth speed
(10) Reverse primary gear (21) Second gear (output shaft) (Z) Synchronizer for the
(11) Gear (22) Third gear (output shaft) fifth speed

Table 4 and Table 5 show the engagements of the

clutches and the synchronizers for different speed
selections.
31200270 41
Systems Operation Section

Table 4

FORWARD DIRECTION
Engaged Clutches and
Selected Speed
Synchronizers
Neutral None
Forward clutch (F) and
First Speed Forward synchronizer (X) with first
gear (20)
Forward clutch (F) and
Second Speed Forward synchronizer (X) with
second gear(21)
Forward clutch (F) and
Third Speed Forward synchronizer (Y) with third
gear (22)
Forward clutch (F) and
Fourth Speed Forward (1) synchronizer (Y) with fourth
gear (23)
Forward clutch (F) and
Fifth Speed Forward (if
synchronizer (Z) with fifth
equipped) (1)
gear (19)
(1) Forward direction only

Table 5

REVERSE DIRECTION
Engaged Clutches and
Selected Speed
Synchronizers
Neutral None
Reverse clutch (R) and
First Speed Reverse synchronizer (X) with first
gear (20)
Reverse clutch (R) and
Second Speed Reverse synchronizer (X) with
second gear(21)
Reverse clutch (R) and
Third Speed Reverse synchronizer (Y) with third
gear (22)
Fourth Speed Reverse Reverse clutch (R) and
(Power Shuttle synchronizer (Y) with third
Transmission ) gear (23)
42 31200270
Systems Operation Section

Examples of Power Flow Through

the Transmission
First Speed Forward

Illustration 54 g00886981
When first speed forward is selected, synchronizer (X)
locks first gear (20) to output shaft (25). Also, forward
clutch (F) is hydraulically actuated in order to lock
forward primary gear (9) to forward/reverse shaft (8).
Power will flow through components in the following
order:
• Input shaft (1)
• Gear (2)
• Gear (3)
• Gear (5)
• Input drive gear (7)
• Forward/Reverse shaft (8)
• Forward clutch (F)
• Forward primary gear (9)
• Fourth gear (countershaft) (14)
• Countershaft (15)
• First gear (countershaft) (16)
• First gear (output shaft) (20)
• Synchronizer (X)
• Output shaft (25)
31200270 43
Systems Operation Section

Second Speed Reverse

Illustration 55 g00886984

When second speed reverse is selected, synchronizer

(X) locks second gear (21) to output shaft (25). Also,
reverse clutch (R) is hydraulically actuated in order to
lock reverse primary gear (10) to forward/reverse shaft
(8).
Power will flow through components in the following
order:
• Input shaft (1)
• Gear (2)
• Gear (3)
• Gear (5)
• Input drive gear (7)
• Forward/Reverse shaft (8)
• Reverse clutch (R)
• Reverse primary gear (10)
• Gear (11)
• Reverse idler shaft (12)
• Gear (13)
• Fourth gear (countershaft) (14)
• Countershaft (15)
• Second gear (countershaft) (17)
• Second gear (output shaft) (21)
• Synchronizer (X)
• Output shaft (25)
44 31200270
Systems Operation Section

Fifth Speed Forward (If Equipped)

Illustration 56 g00886983
When fifth speed forward is selected, synchronizer (Z) Differential Lock Control (If
locks fifth gear (19) to countershaft (15). Also, forward
clutch (F) is hydraulically actuated in order to lock Equipped)
forward primary gear (9) to forward/reverse shaft (8).
The action of the differential can cause the drive to be
Power will flow through components in the following lost in adverse ground conditions if the resistance
order: under one wheel is low. In these circumstances, all the
• Input shaft (1) drive will be transferred to the wheel with the least
• Gear (2) resistance. For example, if one wheel sinks into soft
ground all drive may be transferred to the opposite
• Gear (3) wheel which will spin due to having a lower resistance.
• Gear (5)
• Input drive gear (7) The differential for the front axle has an arrangement
which allows the differential to be locked and the
• Forward/Reverse shaft (8)
mechanism enables the axle shafts of the universal
• Forward clutch (F) joints to be locked together. Both wheels can then
• Forward primary gear (9) rotate at the same speed and torque regardless of
different ground resistance between the wheels.
• Fourth gear (countershaft) (14)
• Countershaft (15)
• Synchronizer (Z)
• Fifth gear (countershaft) (19)
• Fifth gear (output shaft) (24)
• Output shaft (25)
31200270 45
Systems Operation Section

The differential lock is controlled in the following

way:
• The differential lock is engaged by oil pressure
when the foot switch is held down.
• The differential lock is disengaged by spring force
when the foot switch is released.

The foot switch for the differential lock control

operates a solenoid valve. Oil is supplied to the
solenoid valve from the charge pump for the
transmission. Refer to Systems Operation/Testing and
Illustration 57 g00833493 Adjusting, "Location of Hydraulic Components" for the
location of the solenoid valve forthe differential lock.
The differential lock is controlled by a two-position foot
switch that is located on the floor of the operator station.

Illustration 58 g00907223
Differential lock actuator
(1) Fork (3) Piston (5) Spring
(2) Spring (4) Shaft (6) Switch

Fork (1) is located on shaft (4) in the differential

housing. When the switch on the floor of the operator
compartment is pressed oil pressure is supplied to the
solenoid valve. Oil pressure from the solenoid valve
exerts pressure on piston (3). The piston moves the
shaft and the fork against springs (2) and (5). This
movement engages the differential lock.

When shaft (4) contacts switch (6) an input is sent to the

ECM. The ECM then sends an input through a CAN
data link to the dash panel. A light on the dash panel will
illuminate when the differential is engaged.
46 31200270
Systems Operation Section

Illustration 59 g00907323 Illustration 60 g00908446

Differential lock (1) Inner end of the Shaft Assembly
(1) Fork (8) Slots (2) Outer end of the Shaft Assembly
(7) Collar (9) Side gear (3) Bearing
Fork (1) moves collar (7) axially across the differential. (4) Gear
Four pins that are located in the collar engage in slots (5) Carrier
(8) in side gear (9) of the differential in order to engage (6) Ring gear
(7) Flange
the differential lock.
(8) Stud
In normal operation, the differential is unlocked and the (9) Flange
axle shafts are free to rotate at different speeds. The (10) Nut
wheel speed is governed by the resistance at the (11) Knuckle
wheel.
Fork (1) and collar (7) are held clear of the differential by
springs (2) and (5) when the differential is unlocked.
Refer to Illustrations 58 and 59.

Front Axle and Rear Axle

S/N TBF00100 & After
S/N TBG00100 & After
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After

Final Drives
The final drives provide the final gear reduction to the
road wheels. The components that are shown in
Illustration 60 are located at each side of the axle.
31200270 47
Systems Operation Section

The final drives have the following main

components:
• Gears
• Carrier
• Ring gear
• Flange
Gears (4) - The gears are splined to the end of shaft (2)
and the gears are in constant mesh with ring gear (6).
Carrier (5) - The carrier contains gears (4) that rotate
on pins in the carrier. The carrier is secured to the flange
(9) by studs (8).
Ring Gear (6) - The ring gear is held stationary by the
flange (7) which is splined to knuckle (11).
Flange (9) - The flange is supported on knuckle (11)
by bearings (3). Flange (7) and flange (9) are retained
on knuckle (11) by nut (10).
The shaft assembly rotates gears (4). Gears (4) will
then attempt to rotate ring gear (6). Since ring gear (6)
is held stationary, gears (4) rotate inside ring gear (6) in
order to turn carrier (5) in the same direction as the
shaft assembly. Because the distance that is travelled
by the gears is relative to the size of the gears, a gear
reduction is provided between the speed of the shaft
assembly and the carrier which turns flange (9).
48 31200270
Systems Operation Section

Hydraulic Schematic (Power

Train System)
Neutral (Power Shuttle
Transmission)

Illustration 61 g01003710
(1) Machine electronic control module (ECM) (10) Oil cooler (19) Filter
(2) Parking brake switch (11) Scavenge pump (20) Forward clutch solenoid
(3) Neutralizer switch (Gear selector lever) (12) Reverse clutch solenoid (21) Engine speed sensor
(4) Transmission output speed (13) Differential lock switch (22) Transmission and hydraulic oil
(5) Torque converter output speed (14) Differential lock solenoid temperature
(6) Torque converter inlet relief valve (16) Return screen (23) Torque converter outlet (oil temperature)
(7) Transmission lube (17) Pump (24) Neutralizer switch (brake pedal)
(9) Torque converter (18) Differential lock actuator (25) Pressure regulator

The direction clutches for the Power Shuttle The pressure regulator sets the maximum pressure in
transmission are controlled by the Machine "ECM". The the clutch packs.
ECM will control the engagement of the clutch pressure When the operator pushes the differential lock switch,
for the FORWARD and the REVERSE Positions. The the differential lock solenoid is energized. Some of the
operator will need to release the parking brake before pump flow is then sent to the differential lock actuator. A
the transmission will shift. The operator will then select pressure switch in the differential lock actuator signals
a transmission gear. The operator will then move the the Machine "ECM" that the differential lock is in the
shuttle lever to the FORWARD or to the REVERSE ENGAGED Position. The Machine "ECM" then
Position. The machine ECM will then control the illuminates the indicator for the differential lock on the
engagement of the clutch pressure through the use of display in the cab.
the appropriate proportional clutch solenoid.
The scavenge pump sends oil from the transmission
During shifts, the clutches are released when the case back to the hydraulic tank.
operator pushes the neutralizer button on the
transmission shifter.
31200270 49
Systems Operation Section

Neutral (Powersynchro
Transmission)

Illustration 62 g01003719
(1) Machine electronic control module (ECM) (12) Reverse clutch solenoid (22) Transmission and Hydraulic oil
(2) Parking brake switch (13) Differential lock switch temperature
(3) Neutralizer switch (Gear selector lever) (14) Differential lock solenoid (23) Torque converter outlet (oil temperature)
(4) Transmission output speed (15) Synchronizer modulation solenoid (24) Transmission (Intermediate shaft
(5) Torque converter output speed (16) Return screen speed)
(6) Torque converter inlet relief valve (17) Pump (25) Pressure regulator
(7) Transmission lube (18) Differential lock actuator (26) Gear selector lever
(8) Solenoid for the Synchronizer (19) Filter (27) Shift rail position sensor 1
(9) Torque converter (20) Forward clutch solenoid (28) Shift rail position sensor 2
(10) Oil cooler (21) Engine speed sensor (29) Shift rail position sensor 3
(11) Scavenge pump

The Powersynchro transmission uses "ON/OFF"

Synchronizer solenoids that are controlled by the
Machine "ECM" in order to move the shift rails. The
synchronizers in the transmission are then activated in
order to select the appropriate gear. The modulation of
the pressure that is sent to the Synchronizer solenoids
is controlled by the Synchronizer Modulation Solenoids.
50 31200270
Systems Operation Section

Neutral into First Gear (Start of shift)

Illustration 63 g01003728
(1) Machine electronic control module (ECM) (12) Reverse clutch solenoid (22) Transmission and Hydraulic oil
(2) Parking brake switch (13) Differential lock switch temperature
(3) Neutralizer switch (Gear selector lever) (14) Differential lock solenoid (23) Torque converter outlet (oil temperature)
(4) Transmission output speed (15) Synchronizer modulation solenoid (24) Transmission (Intermediate shaft
(5) Torque converter output speed (16) Return screen speed)
(6) Torque converter inlet relief valve (17) Pump (25) Pressure regulator
(7) Transmission lube (18) Differential lock actuator (26) Gear selector lever
(8) Synchronizer solenoids (19) Filter (27) Shift rail position sensor 1
(9) Torque converter (20) Forward clutch solenoid (28) Shift rail position sensor 2
(10) Oil cooler (21) Engine speed sensor (29) Shift rail position sensor 3
(11) Scavenge pump

When you are shifting into a gear, the sensors for the The modulation valve for the synchronizer begins to
shift rail will check in order to ensure that the shift rails ramp up the pressure to a set value which starts
are in the neutral position. The modulation valve for the moving the shift rail and the synchronizer toward the
synchronizer is energized and the pressure is dropped appropriate gear. When the Machine "ECM" detects the
to approximately 455 kPa (66 psi) in order to limit the appropriate ratio between the intermediate shaft speed
speed of the movement of the synchronizer. The and the output shaft speed, the synchronizer for the
appropriate synchronizer for the solenoid is energized modulation valve is de-energized. Full pressure on the
in order to direct the oil to the end of the shift rail. The opposite end of the shift rail pushes the synchronizer in
oil will then flow to the tank. order to engage the gear to the shaft.
31200270 51
Systems Operation Section

Neutral Into First Gear (End of Shift)

(FORWARD)

Illustration 64 g01003735
(1) Machine electronic control module (ECM) (12) Reverse clutch solenoid (22) Transmission and Hydraulic oil
(2) Parking brake switch (13) Differential lock switch temperature
(3) Neutralizer switch (Gear selector lever) (14) Differential lock solenoid (23) Torque converter outlet (oil temperature)
(4) Transmission output speed (15) Synchronizer modulation solenoid (24) Transmission (Intermediate shaft
(5) Torque converter output speed (16) Return screen speed)
(6) Torque converter inlet relief valve (17) Pump (25) Pressure regulator
(7) Transmission lube (18) Differential lock actuator (26) Gear selector lever
(8) Synchronizer solenoids (19) Filter (27) Shift rail position sensor 1
(9) Torque converter (20) Forward clutch solenoid (28) Shift rail position sensor 2
(10) Oil cooler (21) Engine speed sensor (29) Shift rail position sensor 3
(11) Scavenge pump

The position sensor detects the position of the shift rail. When a gear change is made, all energized solenoids for
When the shift rail is in the ENGAGED Position, the the synchronizer are de-energized. Oil is then sent to
solenoid for the synchronizer that is on the opposite both ends of the shift rail and the shift rail is moved to
end of the same shift rail is energized. The oil that is on the NEUTRAL Position. There is a double piston
that end of the shaft is sent to the tank. The gear is kept arrangement on each end of each shift rail. The smaller
in the engaged position by the spring and ball detents piston is used to push the shift rail into gear and the
that are in the synchronizers. larger piston is used to shift that particular shift rail into
neutral.
52 31200270
Systems Operation Section

For example, the port for the small piston is blocked on

the "in gear end" of the shift rail and the oil acts on the
large piston. The oil on the other end of the shift rail is
acting on the small piston. This imbalance pushes the
shift rail to the Neutral Position. As the shift rail gets
closer to the NEUTRAL Position, less oil acts on the
large piston and more oil acts on the small piston.
When neutral for that particular shift rail is attained, oil
on both ends of the shaft acts on the small piston and
the shaft stops moving. The spring and ball detents
hold the shift rail in the NEUTRAL Position.
When the transmission control lever is placed into the
NEUTRAL Position, only the direction clutch is
disengaged and the synchronizers stay in gear.
31200270 53
Systems Operation Section

Configuration Parameters

Illustration 65 g00993238
This is a summary screen.

Some parameters need to be configured for the

machine to operate properly. The configuration screen
for the ECM can be accessed by using the Cat
Electronic Technician (ET). The configuration screen
for each ECM is accessed from the above ECM
summary screen by selecting "Configuration" from the
"Service" drop-down menu.

Reference: Refer to the service manual module

Testing and Adjusting, 31200279, "Electronic Control
Module (ECM) - Configure" for further instructions on
configuring the ECM for your machine.
54 31200270
Systems Operation Section
31200270 55
Testing and Adjusting Section

Testing and Adjusting Warming the Transmission Oil

Increase the transmission oil temperature to at least 35
Section °C (95 °F).
1. Apply the service brakes and start the engine.
Transmission Shift Rail - 2. Disengage the parking brake. Ensure that
Calibrate the switch that disables the transmission
neutralizer control is in the OFF position. Refer
This calibration procedure is for machines with the to the Operation and Maintenance Manual,
powersynchro transmission. The sensors detect the "Transmission Neutralizer Control".
position of the shift rails and the sensors indicate to the 3. Move the transmission control to the FOURTH
machine ECM if the transmission is neutralized. SPEED position with the drive in the NEUTRAL
position. Depress the accelerator pedal until the
Machine Preparation engine speed has reached high idle. The high idle
speed is 2350 ± 25 (rpm).
4. Move the transmission control to the FORWARD
position and stall the torque converter until the
transmission oil temperature gauge in the cab
Personal injury or death can result from sudden reads 3/4 of the way to the red line.
machine movement.
Note: To ensure that the transmission oil does not get
Sudden movement of the machine can cause injury to
too hot, do not keep the torque converter in a full stall
persons on or near the machine.
condition for more than 10 seconds.
Prevent possible injury by performing the procedure
that follows before working on the machine. 5. Move the transmission control to the NEUTRAL
position and continue to run the engine at high idle
1. Move the machine to a smooth, horizontal location until the needle of the transmission oil temperature
that is away from operating machines and away returns to the middle of the scale.
from personnel.
2. In order to prevent the drive wheel from turning Calibrate the Shift Rail
during the test, put the machine in position against
Table 6
a solid, stationary object such as a loading dock.
Engage the parking brake. Required Tools
3. Permit only one operator on the machine. Keep Part Number Description Quantity
all other personnel away from the machine or in
the operator's sight. Caterpillar Electronic
JEBD3003 1
Technician (ET)
4. Move the transmission control to the NEUTRAL
Communications
position. 171-4400 1
Adapter II
5. Lower the boom. If equipped, lower the work tool
207-6845 Adapter Cable As 1
to the ground and stop the engine.
160-0141 Adapter Cable As 1
6. If the machine is in a confined area, ensure that
exhaust gases are vented to the outside when the 9U-7400 Multitach Tool Group 1
engine is operated.
7. Make sure that all the oil pressure is released
before you perform any of the following
procedures:
•Loosen any fitting, any hose, or any component.
•Tighten any fitting, any hose, or any component.
•Remove any fitting, any hose, or any
component.
•Adjust any fitting, any hose, or any component.
56 31200270
Testing and Adjusting Section

The Caterpillar Electronic Technician service tool (ET) • A sensor is repositioned.

is used to access the calibration procedures. A • The transmission is removed or the transmission
message on the ET screen will give instructions that is replaced.
guide the user through the calibration procedure. Refer
to the Manual that is provided with the ET for more • An active error code
information about ET. Note: The following information is an example of the
calibration procedure. The actual calibration screens
may vary as new versions of the software are released.

Illustration 66 g00898916
This is the location of the service connector that contains the CAT data
link. The connector is located to the side and rear of the seat.

The machine ECM is located under the engine hood.

Illustration 67 g00947840
This is the location for the machine ECM.

The transmission shift rail calibration should be

performed if any of the following items occur:
• The shifting is harsh or slow.
• Seasonal transmission fluid changes.
• Replacement of a rail sensor
31200270 57
Testing and Adjusting Section

Illustration 68 g00931831

Note: Calibrate the position sensors for the

transmission shift rail first if the machine is equipped
with the powersynchro transmission.
To get to the calibration procedures for the
transmission, you click on the "Service" menu. Click on
"Calibration". Click on the "Transmission Shift Rail".
The "Transmission Shift Rail" is the last item on the list.
Next, the first calibration screen will appear.
58 31200270
Testing and Adjusting Section

Illustration 69 g00927353

There are up to 3 position sensors for the shift rail in

the automatic transmission. The shift rail position
sensor sends an input to the machine ECM if the
transmission is neutralized. 2 position sensors for the
shift rail are used in the automatic transmission with four
speeds. One rail sensor is for the one and two
synchronizers. The second rail sensor is used for
synchronizers three and four. The automatic
transmission with five speeds has a third shift rail
position sensor for the fifth speed.
After all of the conditions are met, click "Next" in order to
continue with the calibration procedure.
31200270 59
Testing and Adjusting Section

Illustration 70 g00931874

ET is calibrating the number one shift rail. If ET does not

calibrate the number one shift rail successfully, ET will
discontinue the calibration. A dialog box for the failure
will appear on the screen. A fault error code will be
displayed in the window. The error codes are listed in
table 7. If a failure occurs ET will not try to calibrate the
number two shift rail.
60 31200270
Testing and Adjusting Section

Illustration 71 g00931882

ET is now calibrating the number two shift rail. The shift

rails two and three are calibrated automatically after the
number one shift rail has been calibrated.
31200270 61
Testing and Adjusting Section

Illustration 72 g00931892

The calibration procedure was successful. A window Table 7

will appear if a failure occurs. Data in the window will
TRANSMISSION SHIFT RAIL CALIBRATION
include an error code for the failure. The error codes are
ERROR CODES
listed in table 7. After correcting the problem, the
calibration is repeated by pressing the "Restart" button. CODE Cause
You complete the process by clicking on the "Finish" 0002 Active diagnostic present
button.
0006 Aborted by user
Note: Turn off the ignition key, after the calibration
0009 Aborted by ECM
procedure is finished. Leave the key off for fifteen
seconds. The new parameters are then stored in the 1012 Engine RPM incorrect
ECM. 1018 Parking brake not engaged
101B Machine speed not zero
101F Direction lever not in NEUTRAL
1021 Transmission oil temperature too low
1022 Transmission oil temperature too high
108F Shift rail readings inconsistent

1090 Shift rail maximum position out of range

1091 Shift rail detent position out of range

1092 Shift rail NEUTRAL position out of range

62 31200270
Testing and Adjusting Section

Transmission Fill - Calibrate 2. Run the engine at Low Idle for 2 minutes. Then
run the engine at High Idle for 2 minutes.
This calibration procedure is for calibrating the fill time 3. Disengage the parking brake. Ensure that
for the forward clutch and the reverse clutch. This the switch that disables the transmission
calibration procedure is done on the Power Shuttle and neutralizer control is in the OFF position. Refer
the Powersynchro transmissions. to the Operation and Maintenance Manual,
"Transmission Neutralizer Control".
Machine Preparation 4. Move the transmission control to the FOURTH
SPEED position with the drive in the NEUTRAL
position. Depress the accelerator pedal until the
engine speed has reached high idle. The high idle
Personal injury or death can result from sudden speed is 2350 ± 25 (rpm).
machine movement. 5. Move the transmission control to the FORWARD
Sudden movement of the machine can cause injury to position and stall the torque converter until the
persons on or near the machine. transmission oil temperature gauge in the cab
Prevent possible injury by performing the procedure reads 3/4 of the way to the red line.
that follows before working on the machine. Note: To ensure that the transmission oil does not get
1. Move the machine to a smooth, horizontal location too hot, do not keep the torque converter in a full stall
that is away from operating machines and away condition for more than 10 seconds.
from personnel. 6. Move the transmission control to the NEUTRAL
2. In order to prevent the drive wheel from turning position and continue to run the engine at high idle
during the test, put the machine in position against until the needle of the transmission oil temperature
a solid, stationary object such as a loading dock. gauge returns to the middle of the scale.
Engage the parking brake.
Calibration Procedure
3. Permit only one operator on the machine. Keep
all other personnel away from the machine or in Table 8
the operator's sight.
Required Tools
4. Move the transmission control to the NEUTRAL
position. Part Number Description Quantity
5. Lower the boom. If equipped, lower the work tool Caterpillar Electronic
JEBD3003 1
to the ground and stop the engine. Technician (ET)
6. If the machine is in a confined area, ensure that Communications
171-4400 1
exhaust gases are vented to the outside when the Adapter II
engine is operated. 207-6845 Adapter Cable As 1
7. Make sure that all the oil pressure is released 160-0141 Adapter Cable As 1
before you perform any of the following
9U-7400 Multitach Tool Group 1
procedures:

•Loosen any fitting, any hose, or any component.

•Tighten any fitting, any hose, or any component.
•Remove any fitting, any hose, or any
component.
•Adjust any fitting, any hose, or any component.
8. Install the 9U-7400 Multitach Tool Group or ET on
the engine in order to enable an accurate
measurement of the engine speed (rpm). Refer to
Special Instruction, NEHS0605 for further
information on the use of this equipment.
Warming the Transmission Oil
Increase the transmission oil temperature to at least 60
°C (140 °F).
1. Apply the service brakes and start the engine.
31200270 63
Testing and Adjusting Section

The Caterpillar Electronic Technician service tool (ET) • Seasonal transmission fluid changes.
is used to access the calibration procedures. A • Replacement of a rail sensor
message on the ET screen will give instructions that
guide the user through the calibration procedure. Refer • A sensor is repositioned.
to the Manual that is provided with the ET for more • The transmission is removed or the transmission
information about ET. is replaced.
• An active error code
Note: The following information is an example of the
calibration procedure. The actual calibration screens
may vary as new versions of the software are released.

Illustration 73 g00898916
This is the location of the service connector that contains the CAT data
link. The connector is located to the side and rear of the seat.

The location for the machine ECM is under the engine

hood.

Illustration 74 g00947840
This is the location for the machine ECM.

The transmission fill calibration should be performed if

any of the following items occur:
• The shifting is harsh or slow.
64 31200270
Testing and Adjusting Section

Illustration 75 g00931831

Note: Calibrate the position sensors for the

transmission shift rail first if the machine is equipped
with the powersynchro transmission.

Reference: For additional information about

calibrating the position sensors for the transmission shift
rail, refer to the Service Manual module Testing and
Adjusting, "Transmission Shift Rail - Calibrate" for the
machine that is being serviced.

To get to the calibration procedures for the

transmission, you click on the "Service" menu. Click on
"Calibration". Click on the "Transmission Fill Calibrate".
The "Transmission Fill Calibrate" is the first item on the
list. Next, the first calibration screen will appear.
31200270 65
Testing and Adjusting Section

Illustration 76 g00932422

All requirements must be met in order to continue the

calibration. The screen illustrates that all conditions are
not met. In this particular case, the transmission oil
temperature is too low.

Note: Both calibration procedures involve heating the

transmission oil to a certain temperature and running
the engine at high idle.

Follow the instructions on the ET screens in order to

successfully complete the calibration procedure.
66 31200270
Testing and Adjusting Section

Illustration 77 g00932434
The number one clutch is the reverse clutch.
All the conditions have been met. ET is now
calibrating the number one clutch. If ET does not
calibrate the number one clutch successfully ET will
discontinue the calibration. A dialog box for the failure
will appear on the screen. A fault error code will be
displayed in the window. The error codes are listed in
table 9. If a failure occurs ET will not try to calibrate the
number two clutch.
31200270 67
Testing and Adjusting Section

Illustration 78 g00932439
The number two clutch is the forward clutch.

The second clutch is calibrated automatically after the

first clutch is calibrated.
68 31200270
Testing and Adjusting Section

Illustration 79 g00932443
Table 9

The calibration procedure was successful. A window TRANSMISSION FILL CALIBRATION ERROR CODES
will appear if a failure occurs. Data in the window will
CODE Cause
include an error code for the failure. The error codes are
listed in table 9. After correcting the problem, the 0002 Active diagnostic present
calibration is repeated by pressing the "Restart" button. 0006 Aborted by user
You complete the process by clicking on the "Finish"
button. 0009 Aborted by ECM
1012 Engine RPM incorrect

Note: Turn off the ignition key, after the calibration 1018 Parking brake not engaged
procedure is finished. Leave the key off for fifteen 101B Machine speed not zero
seconds. The new parameters are then stored in the
101F Direction lever not in NEUTRAL
ECM.
1021 Transmission oil temperature too low

i02120212
31200270 69
Testing and Adjusting Section

Torque Converter Stall - Test

Introduction When testing and adjusting the transmission and
power train, move the machine to an area clear of
The torque converter stall test is designed to test the obstructions, with safe exhaust ventilation for the
engine, the torque converter and the drive train. The exhausts. Sudden movement of the machine or release
engine speed indicates whether the engine and the of oil under pressure can cause injury to persons on or
transmission are operating correctly under full load. near the machine. To prevent possible injury, do the
procedure that follows before testing and adjusting the
If the engine performance is correct and the torque transmission and power train.
converter stall speed is not correct, the problem is in the
torque converter or in the transmission. To ensure that 1. Move the machine to a smooth, horizontal location
the engine performance is not responsible for the that is away from operating machines and away
wrong torque converter stall speed, check the engine from personnel.
by other methods after the first test. 2. In order to prevent the drive wheel from turning
during the test, put the machine in position against
a solid, stationary object such as a loading dock.
Note: Refer to Telehandlers Machine Systems Engage the parking brake.
Troubleshooting, 31200279 for problems that involve
the engine. 3. Permit only one operator on the machine. Keep
all other personnel away from the machine or in
The service brakes must be applied when tests are the operator's sight.
performed. Check the operation of the brakes before
you perform any tests. 4. Move the transmission control to the NEUTRAL
position.
5. Lower the boom. If equipped, lower the work tool
Reference: See Systems Operation/Testing and to the ground and stop the engine.
Adjusting, "Torque Converter" for more information on
the torque converter. 6. If the machine is in a confined area, ensure that
exhaust gases are vented to the outside when the
engine is operated.
Required Tools
7. Make sure that all the oil pressure is released
Table 10 provides a list of the tools that are required to before you perform any of the following
carry out the stall test for the torque converter. procedures:
Table 10
•Loosen any fitting, any hose, or any component.
Required Tools
•Tighten any fitting, any hose, or any component.
Qty Part Number Description
•Remove any fitting, any hose, or any
1 9U-7400 Multitach Tool Group component.
•Adjust any fitting, any hose, or any component.
Test Procedure 8. Install the 9U-7400 Multitach Tool Group or ET
NOTICE on the engine in order to enable an accurate
measurement of the engine speed (rpm). Refer
Care must be taken to ensure that fluids are contained
to Special Instruction, NEHS0605 for further
during performance of inspection, maintenance, testing,
information on the use of this equipment.
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any Warming the Transmission Oil
compartment or disassembling any component
In order to ensure that the transmission oil is at the
containing fluids.
normal operating temperature of 60° ± 10°C (140° ±
Refer to Special Publication, "Caterpillar Tools and Shop 18°F), complete the following procedure:
Products Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
1. Apply the service brakes and start the engine.
2. Run the engine for 2 minutes at Low Idle. Then,
run the engine for 2 minutes at High Idle.
70 31200270
Testing and Adjusting Section

3. Disengage the parking brake. Ensure that Table 11

the switch that disables the transmission
Direct Drive Transmission Arrangement
neutralizer control is in the OFF position. Refer
to the Operation and Maintenance Manual, Engine Power Rating Stall RPM
"Transmission Neutralizer Control". Tier I 74 kW (99 hp) 2037+/-102
4. Move the transmission control to the FOURTH Tier II 61 kW (82hp) 1850+/-105
SPEED position with the drive in the NEUTRAL
position. Depress the accelerator pedal until the Tier II 74 kW (99 hp) 2035 +/- 90
engine speed has reached high idle. The high idle Tier II 92kW (120hp) 2145+/-75
speed is 2350 ± 25 (rpm).
5. Move the transmission control to the FORWARD Note: The stall speeds are calculated by using number
position and stall the torque converter until the 2 diesel fuel.
transmission oil temperature gauge in the cab 5. If you must repeat the test, keep the transmission
reads 3/4 of the way to the red line. in neutral and wait for two minutes between tests.
Note: To ensure that the transmission oil does not get 6. After the test, operate the engine for five minutes
too hot, do not keep the torque converter in a full stall at low idle in order to allow the temperature of the
condition for more than 10 seconds. components to equalize.
6. Move the transmission control to the NEUTRAL
position and continue to run the engine at high idle Transmission Pressures - Test
until the needle of the transmission oil temperature
gauge returns to the middle of the scale.
and Adjust
7. Repeat Step 5 and Step 6. Then follow the
procedure for "Measurement of the Stall Speed"
that is shown below.

Measurement of the Stall Speed When testing and adjusting the transmission and
power train, move the machine to an area clear of
Test the torque converter stall according to the obstructions, with safe exhaust ventilation for the
following procedure: exhausts. Sudden movement of the machine or release
of oil under pressure can cause injury to persons on or
1. Apply the service brakes and start the engine. near the machine. To prevent possible injury, do the
2. Disengage the parking brake. Ensure that the procedure that follows before testing and adjusting the
transmission neutralizer switch on the instrument transmission and power train.
panel is in the OFF position. NOTICE
Note: To ensure that the transmission oil does not get Care must be taken to ensure that fluids are contained
too hot, do not keep the torque converter in a full stall during performance of inspection, maintenance, testing,
condition for more than 10 seconds. After the torque adjusting and repair of the product. Be prepared to collect
converter is stalled, move the transmission control to the fluid with suitable containers before opening any
the NEUTRAL position and run the engine at half compartment or disassembling any component
speed. containing fluids.
3. Move the transmission control to the FOURTH Refer to Special Publication, "Caterpillar Tools and Shop
SPEED position with the drive in the NEUTRAL Products Guide" for tools and supplies suitable to collect
position. Depress the accelerator pedal until the and contain fluids on Caterpillar products.
engine speed has reached high idle. The high idle
Dispose of all fluids according to local regulations and
speed is 2350 ± 25 (rpm). Check that the water
mandates.
temperature gauge and the oil temperature gauge
are showing the correct reading.
4. Move the transmission control to the FORWARD
position and record the torque converter stall
speed after 10 seconds. The torque converter
temperature during the stall test should be 80° ±
10°C (176 ° ± 18 °F). Refer to Table 11 for the
correct stall RPM of the various power ratings for
the available engines.
31200270 71
Testing and Adjusting Section

Table 12 Pressure Test Points for the

Required Tools Powersynchro Transmission
Qty Part Number Description
1 9U-7400 Multitach Tool Group
Pressure Gauge (0 to 4,000
1 8T-0855
kPa (0 to 580 psi))
1 5P-4675 Adapter
1 6V-3966 Fitting
1 6V-4143 Coupler
1 177-7861 Hose As
1 6V-4142 Fitting
1 6V-4144 Coupler
Illustration 80 g00888737
Problems with the transmission may be caused by (1) Pressure test point (forward clutch)
mechanical faults, electrical faults or hydraulic faults. (2) Pressure test point (reverse clutch)
The mechanical components and the electrical (3) Pressure test point (synchronizer for the fourth speed)
components must be in good condition and the (4) Pressure test point (synchronizer for the second speed)
components must operate properly. In addition, the (5) Pressure test point (synchronizer for the fifth speed)

correct operation of the transmission hydraulic system

is critical. The transmission oil circulates through the
system for operation, for lubrication, and for cooling.

To ensure the correct operation of the torque

converter, the clutches, and the synchronizers in the
transmission, the oil must be supplied in the correct
quantity. Also, the oil must be regulated at the required
temperature and the required pressures.

The operating temperatures and the operating

pressures can be checked in order to help you identify
Illustration 81 g00888738
problems when you are troubleshooting the system.
(6) Pressure test point (regulated pump)
(7) Pressure test point (torque converter inlet)
(8) Pressure test point (synchronizer for the third speed)
Note: If you have a power shuttle transmission, you
(9) Pressure test point (synchronizer for the first speed)
only need to do the test points that are common to the
manual transmission.
The test points for the synchronizers are for the
powersynchro transmission. The remaining test points
Test the transmission pressures according to the are able to be performed on both transmissions.
following procedures:
72 31200270
Testing and Adjusting Section

Pressure Test Points for the Power

Shuttle Transmission

Illustration 82 g00954898
(10) Pressure test point (forward clutch)
(11) Pressure test point (reverse clutch)

Illustration 83 g00955320
Drawing of the manual transmission

Oil Level Check Torque Converter Inlet Pressure

Pressure tests must be made with the oil in the Introduction
transmission at the correct level and at the normal
The pressure test for the torque converter inlet is
operating temperature. Use the following procedure to
designed to test the operation of the relief valve for the
check the oil level:
torque converter. If the pressure at the test point for the
1. Operate the machine until the oil in the torque converter inlet is within the given parameters
transmission is at 30° ± 5°C (86° ± 9°F). then it is likely that the relief valve for the torque
2. Operate the engine at low idle 950 rpm. converter is operating correctly. If the pressure at the
3. Check the level mark for the hydraulic oil system. test point is not within the given parameters refer to
Telehandler Machine Systems Troubleshooting,
4. If necessary, add oil. 31200279 manual.
31200270 73
Testing and Adjusting Section

Test Procedure Regulated Pump Pressure

Pressure gauges are used in the following test Required Tools
procedure.
1. Move the machine to a smooth, horizontal location Table 12 provides a list of the tools that are required to carry
that is away from operating machines and away out the test for the regulated pump pressure.
from personnel. Test Procedure
2. Permit only one operator on the machine. Keep Pressure gauges are used in the following test
all other personnel away from the machine or in procedure.
the operator's sight.
1. Move the machine to a smooth, horizontal location
3. Move the transmission control to the NEUTRAL that is away from operating machines and away
position. from personnel.
4. Lower the boom. If equipped, lower the work tool 2. Permit only one operator on the machine. Keep
to the ground. all other personnel away from the machine or in
5. Engage the parking brake and stop the engine. the operator's sight.
6. Place wheel blocks in front of the wheels and 3. Move the transmission control to the NEUTRAL
behind the wheels. position.
7. If the machine is in a confined area, ensure that 4. Lower the boom. If equipped, lower the work tool
exhaust gases are vented to the outside when the to the ground.
engine is operated. 5. Engage the parking brake and stop the engine.
8. Install the 9U-7400 Multitach Tool Group or 6. Place wheel blocks in front of the wheels and
the Caterpillar Electronic Technician (ET) on behind the wheels.
the engine in order to enable an accurate
measurement of the engine speed (rpm). 7. If the machine is in a confined area, ensure that
exhaust gases are vented to the outside when the
engine is operated.
8. Install the 9U-7400 Multitach Tool Group or ET
on the engine in order to enable an accurate
measurement of the engine speed (rpm).

Illustration 84 g00888741
Pressure Test Point for the Torque Converter Inlet
9. The torque converter inlet pressure can be tested
at test point (7). Remove the plug from the test
point. Use suitable fittings from Table 12 in order
to install the 8T-0855 Pressure Gauge (0 to
4,000 kPa (0 to 580 psi)). Illustration 85 g00888742
Pressure Test Point for the regulated pump pressure
10. Start the engine and operate the engine at HIGH
9. The regulated pump pressure can be tested at
IDLE 2350 rpm.
test point (6). Remove the plug from the test point.
11. The pressure should be 800 ± 100 kPa Use suitable fittings from Table 12 in order to
(116 ± 15 psi) when the engine is operating install the 8T-0855 Pressure Gauge (0 to 4,000
at 2350 rpm at a temperature of 25° ± 5°C kPa (0 to 580 psi)).
(77° ± 9°F).
10. Start the engine and operate the engine at 2350
Note: This pressure is dependent on the oil rpm +100 or- 50.
temperature. A temperature range from 120 °C (248
11. The pressure should be 1625 ± 75 kPa
°F) to -30 °C (-22 °F) will cause the inlet oil pressure to
(235 ± 11 psi) when the engine is operating at
be from 500 kPa (73 psi) to 1100 kPa (160 psi).
HIGH IDLE at a temperature of 80 °C (176°F).
12. Remove the fittings and install the plug that was
removed from the test point.
74 31200270
Testing and Adjusting Section

12. Remove the fittings and install the plug that was
removed from the test point.

Operating Pressures of Clutches and

Synchronizers
Introduction
The pressure tests for the clutches and synchronizers
are designed to test the operation of the solenoid
valves for the transmission. If the pressures at the test
points are within the given parameters then it is likely
that the solenoid valves for the transmission are
Illustration 87 g00888828
operating correctly. If the pressures at the test points
(8) Pressure test point (synchronizer for the third speed)
are not within the acceptable range refer to Telehandler
(9) Pressure test point (synchronizer for the first speed)
Machine Systems Troubleshooting, 31200279 manual.
Test Procedure
Pressure gauges are used in the following test
procedure.
1. Move the machine to a smooth, horizontal location
that is away from operating machines and away
from personnel.
2. Permit only one operator on the machine. Keep
all other personnel away from the machine or in
the operator's sight.
3. Move the transmission control to the NEUTRAL
position.
4. Lower the boom. If equipped, lower the work tool
to the ground.
5. Engage the parking brake and stop the engine.
6. Place wheel blocks in front of the wheels and
behind the wheels. Illustration 88 g01075880
(3) Pressure test point (synchronizer for the fourth speed)
7. If the machine is in a confined area, ensure that
(4) Pressure test point (synchronizer for the second speed)
exhaust gases are vented to the outside when the
(5) Pressure test point (synchronizer for the fifth speed)
engine is operated.
Note: The test point for the fifth speed is shown for the
8. Install the 9U-7400 Multitach Tool Group or the optional five speed powersynchro transmission.
ET on the engine in order to enable an accurate
9. The operating pressures of clutches and
measurement of the engine speed (rpm). synchronizers can be tested at the test points that
are shown in Illustration 86, Illustration 87 and
Illustration 88. Remove the plug from the desired
test point. Use suitable fittings from Table 12 in
order to install the 8T-0855 Pressure Gauge (0to
4,000 kPa (0 to 580 psi)).
10. Start the engine and operate the engine at LOW
IDLE 950 RPM.
11. Place the machine into forward gear in order
to test the forward clutch pressure. To test
the pressure for the reverse clutch, place the
transmission in reverse gear.
Illustration 86 g01075877 12. The correct oil pressures for each test point are
(1) Pressure test point (forward clutch) shown in Table 13 and table 14.
(2) Pressure test point (reverse clutch)
31200270 75
Testing and Adjusting Section

Table 13

Clutch Disengaged Engaged

Low Idle 950 RPM Low Idle 950 RPM
Forward Clutch 10 ± 10 kPa (1.5 ± 1.5 psi) 1350 ± 100 kPa(195± 15 psi)
Reverse Clutch 10 ± 10 kPa (1.5 ± 1.5 psi) 1350 ± 100 kPa(195± 15 psi)

Cycle through the first gear, the second gear, the third
Table 13 is for both the power shuttle transmission and gear, the fourth gear and fifth gears for this test on the
the powersynchro transmission. powersynchro transmission.

Table 14

Synchronizer Disengaged Engaged

Low Idle 950 RPM Low Idle 950 RPM
Synchronizer for the First Speed 1350 ± 100 kPa(195± 15 psi) 10 ± 10 kPa (1.5 ± 1.5 psi)
Synchronizer for the Second Speed 1350 ± 100 kPa(195± 15 psi) 10 ± 10 kPa (1.5 ± 1.5 psi)
Synchronizer for the Third Speed 1350 ± 100 kPa(195± 15 psi) 10 ± 10 kPa (1.5 ± 1.5 psi)
Synchronizer for the Fourth Speed 1350 ± 100 kPa(195± 15 psi) 10 ± 10 kPa (1.5 ± 1.5 psi)
Synchronizer for the Fifth Speed
10 ± 10 kPa (1.5 ± 1.5 psi) 1350 ± 100 kPa(195± 15 psi)
(if equipped)

Table 14 pertains to the powersyncro transmission. Reference: For additional information about
13. Remove the fittings and install the plug that was differential backlash, refer to the Systems Operation,
removed from the test point. Testing and Adjusting, "Differential Backlash and
Bearings - Adjust".

Required Tools
Differential Pinion Bearing -
Table 15 provides a list of the tools that are required to carry
Adjust out the adjustment of the differential pinion bearing.

Use the procedure that follows in order to adjust the

depth of the pinion gear. Use the same procedure for
both axles.

Introduction
The following procedures describe adjustments to the
pinion gear which are necessary when you are
assembling the bevel gear set.

NOTICE
The bevel gear and the pinion gear are a matched set. If
either part is worn or damaged, both parts must be
replaced with a matched set.
Note: If you are reinstalling the old bevel gear set into the
old axle, the thickness of the shim will not need to be
changed. The following procedure is necessary when
you are replacing the bevel gear set or when you are
replacing the center housing.
Reference: For further information regarding the
removal and the installation of the bevel gear and the
pinion gear, refer to Disassembly and Assembly, "Power
Train".
76 31200270
Testing and Adjusting Section

Table 15 1. Move the machine to a smooth, horizontal location

that is away from operating machines and away
Required Tools
from personnel.
Tooling Part Number Description Qty 2. Permit only one operator on the machine. Keep
all other personnel away from the machine or in
A 9U-5017 Torque Wrench 1 the operator's sight.
Pinion depth gauge 3. Move the transmission control to the NEUTRAL
208-5526 tool that includes the 1 position.
parts that follow
4. Lower the boom. If equipped, lower the work tool
B 203-4348 Pinion Depth Gauge 1 to the ground.
5. Engage the parking brake and stop the engine.
204-9319 Bar 1
6. If the machine is in a confined area, ensure that
6J-2819 Bolt 2
exhaust gases are vented to the outside when the
6V-6106 Dial Indicator Group 1 engine is operated.
7. Make sure that all the oil pressure is released
3P-1565 Collet Clamp 1 before you perform any of the following
5P-4156 Indicator Base 1 procedures:
C
Contact Point
5P-4162 1 •Loosen any fitting, any hose, or any component.
(Plunger) (98 mm)
Contact Point
•Tighten any fitting, any hose, or any component.
3S-3269 1
(Plunger) (20 mm) •Remove any fitting, any hose, or any
Optional Tooling component.
6V-2012 Micrometer (inch) 1 •Adjust any fitting, any hose, or any component.
D
6V-7030 Micrometer (mm) 1 Adjustment Procedure
Refer to Disassembly and Assembly, "Power Train" for
Procedure information regarding the removal of the bevel gear
and pinion gear.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.

Refer to Special Publication, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.

When testing and adjusting the transmission and power

train, move the machine to an area clear of obstructions,
with safe exhaust ventilation for the exhausts. Sudden
movement of the machine or release of oil under pressure
can cause injury to persons on or near the machine. To
prevent possible injury, do the procedure that follows
before testing and adjusting the transmission and power
train.
31200270 77
Testing and Adjusting Section

Illustration 89 g00798589 Illustration 90 g00798590

Pinion Gear (Front Axle) Pinion Gear (Rear Axle)
(1) Cone (bearing) (1) Cone (bearing)
(2) Cup (bearing) (2) Cup (bearing)
(3) Washer (3) Washer
(4) Sleeve (4) Sleeve
(5) Washer (5) Washer
(6) Cup (bearing) (6) Cup (bearing)
(7) Cone (bearing) (7) Cone (bearing)
(8) Shim (8) Shim
(9) Housing (9) Center housing
(10) O-ring seal (10) O-ring seal
(11) Pinion gear (11) Pinion gear
(12) Seal (12) Seal
(13) Washer (13) Washer
(14) Nut (14) Nut
(15) Yoke (15) Yoke
(16) Bolt
(17) Bracket for the caliper 1. Install cup (6) and install cup (2). Use an
appropriate driving tool to seat the cups.
2. Install shim (8) with the chamfer against the
rear face of the pinion gear. Use the following
procedure to determine the thickness of the shim.
a. If you are installing the old bevel gear set into a
new center housing use the original shim as a
starting point.
78 31200270
Testing and Adjusting Section

Table 16

Available Shims
Part Number Shim Thickness
199-0684 2.5 mm (0.098 inch)
199-0685 2.6 mm (0.102 inch)
199-0686 2.7 mm (0.106 inch)
199-0687 2.8 mm (0.110 inch)
199-0688 2.9 mm (0.114 inch)
199-0689 3.0 mm (0.118 inch)
Illustration 91 g00798772 199-0690 3.1 mm (0.122 inch)
Location of the number on the pinion gear
199-0691 3.2 mm (0.126 inch)
b. If you are installing a new bevel gear set into
the old center housing first record the number 199-0692 3.3 mm (0.129 inch)
that is etched on the old pinion gear. Then 199-0693 3.4 mm (0.1339 inch)
record the number that is etched on the new
pinion gear. Subtract the number on the old 3. Use a suitable driver to install cone (7) onto the
pinion gear from the number on the new pinion pinion gear and install the pinion gear into the
gear in order to determine the thickness of the center housing. Install washer (5), sleeve (4) and
shim. washer (3).
Example 1 Note: Always use a new sleeve (4).
• The number on the old pinion gear is 135.02. 4. Use a suitable driver to install cone (1). Use an
• The number on the new pinion gear is appropriate driver to install a new seal (12).
135.04. 5. If you are working on a pinion gear that is part of a
• Install a shim that is 0.02 mm (0.0008 inch) front axle, install bracket (17). Secure the bracket
thinner than the old shim. with six bolts (16). Torque the bolts to a torque
wrench setting of 85 Nm (63 lb ft).
Example 2
6. Install O-ring seal (10), yoke (15), washer (13)
• The number on the old pinion gear is 135.04. and a new nut (14). Tighten the nut until slight
• The number on the new pinion gear is resistance is felt.
135.01. Note: Nut (14) is a self-locking type. Always use a new
• Install a shim that is 0.03 mm (0.0012 inch) nut.
thicker than the old shim. 7. Seat the bearings by striking both ends of the
c. If you are replacing both the center housing pinion gear with a soft mallet while tightening the
and the bevel gear set, use a shim that is 3 mm nut until the rolling resistance begins to increase.
(0.118 inch) thick as a starting point.
31200270 79
Testing and Adjusting Section

Illustration 92 g00801648
8. Use tooling (A) to check the rolling resistance.
Tighten nut (14) until the torque that is required to
turn the assembly is between 4.9 Nm (43 lb in)
and 5.4 Nm (48 lb in).
Note: Seal (12) must be installed when you measure
Illustration 94 g00801651
the rolling resistance.
Tooling (C)
(20) Bar
(21) Dial Indicator group
(22) Collet clamp
(23) Indicator base
(24) Indicator contact point (plunger)
(25) Hole 98 mm (3.85 inch) (front axle)
(26) Hole 20 mm (0.78 inch) (rear axle)

11. Assemble tooling (C).

12. If you are setting the depth of the pinion gear for
a front axle, install the contact point (plunger) on
tool (C) into the 98 mm (3.86 inch) deep hole (25)
in tool (A). Zero the dial indicator reading. If you
are setting the depth of the pinion gear for a rear
Illustration 93 g00798591
axle, install the contact point (plunger) on tool (C)
Tooling (B)
(18) Bolt
into the 20 mm (0.78 inch) deep hole (26) in tool
(19) Pinion depth gauge
(A). Zero the dial indicator reading.
(20) Bar Note: Check that the hole (25) or the hole (26) is
clean. The dial indicator will not be set correctly if there
9. Use tooling (B) to measure the depth of the pinion
is dirt in the hole. Use a micrometer to check the depth
gear. Correct depth of the pinion gear is necessary
of hole (25) or hole (26).
in order to establish the correct tooth contact
pattern.
10. Assemble tooling (B). One end of pinion depth
gauge (19) is designed to fit over a left hand spiral.
The opposite end will fit over a right hand spiral.
The pinion gear that is used in the front axle has a
left hand spiral. The pinion gear that is used in the
rear axle has a right hand spiral. Spiral orientation
is marked on the tool.
80 31200270
Testing and Adjusting Section

Illustration 96 g00801647
Measuring pinion depth (rear axle)
(8) Shim
Tooling (B)
Tooling (C)
15. Assemble tooling (C) to tooling (B) and measure
Illustration 95 g00799993 dimension (Z) if you are setting the depth of
Measuring pinion depth (front axle) the pinion gear for a rear axle. Use the outer
(8) Shim hole in bar (20). Dimension (Z) must be 20 mm
Tooling (B) (0.79 inch).
Tooling (C)
16. If the measurement is incorrect, the pinion gear
13. Position tooling (B) on the pinion gear. The three must be removed and a shim of the correct
tangs (projections) on the tool must rest against thickness must be installed.
shim (8).
Example
14. Assemble tooling (C) to tooling (B) and measure
dimension (Y) if you are setting the depth of • Dimension (Y) is 99 mm (3.90 inch).
the pinion gear for a front axle. Use the inner • The required dimension is 98 mm (3.86 inch).
hole in bar (20). Dimension (Y) must be 98 mm
• Shim (8) must be 1 mm (0.04 inch) thinner.
(3.86 inch).
17. When the correct depth of the pinion gear has
been established, check the rolling resistance
again. The rolling resistance must be between
4.9 Nm (43 lb in) and 5.4 Nm (48 lb in).
31200270 81
Testing and Adjusting Section

Table 17

Required Tools
Part
Tooling Description Qty
Number
A 8T-5096 Dial Indicator Group 1
B 202-7965 Adjuster 1
C 9U-5017 Torque Wrench 1
207-0481 Socket 1
207-0485 Rod 1
D
207-0478 Socket Assembly 1
6V-2316 Screw 1

Procedure
NOTICE
Illustration 97 g00799994
Care must be taken to ensure that fluids are contained
Alternative measuring tool during performance of inspection, maintenance, testing,
(8) Shim adjusting and repair of the product. Be prepared to collect
(B) Tooling (B) the fluid with suitable containers before opening any
(D) Tooling (D) compartment or disassembling any component
Tooling (D) can be used as an alternative to tooling (C). containing fluids.
Use tooling (B) in conjunction with a micrometer in order Refer to Special Publication, "Caterpillar Tools and Shop
to measure dimension (Y) or dimension (Z). Products Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Differential Backlash and Dispose of all fluids according to local regulations and
mandates.
Bearings - Adjust
Front Axle Differential
Introduction When testing and adjusting the transmission and
power train, move the machine to an area clear of
The following procedure controls the differential obstructions, with safe exhaust ventilation for the
backlash and differential bearings preload settings for exhausts. Sudden movement of the machine or release
the front axle. Adjust the differential backlash and of oil under pressure can cause injury to persons on or
bearings for the front axle according to the following near the machine. To prevent possible injury, do the
procedure. procedure that follows before testing and adjusting the
transmission and power train.
Reference: For information regarding the removal and
installation of the differential, refer to the Power Train,
Disassembly and Assembly, "Differential and Bevel 1. Move the machine to a smooth, horizontal location
Gear - Remove" and the Power Train, Disassembly that is away from operating machines and away
and Assembly, "Differential and Bevel Gear - Install" for from personnel.
your machine. 2. Permit only one operator on the machine. Keep
Required Tools all other personnel away from the machine or in
the operator's sight.
Table 17 provides a list of the tools that are required to
carry out the adjustment of the differential backlash and 3. Move the transmission control to the NEUTRAL
the differential bearings for the front axle. position.
4. Lower the boom. If equipped, lower the work tool
to the ground.
5. Engage the parking brake and stop the engine.
6. If the machine is in a confined area, ensure that
exhaust gases are vented to the outside when the
engine is operated.
82 31200270
Testing and Adjusting Section

7. Make sure that all the oil pressure is released 1. Install cup (14) into brake cylinder (1). Apply a
before you perform any of the following coating of 1U - 8846 Gasket Sealant to the mating
procedures: surface of the brake cylinder. Install brake cylinder
(1) and secure in place using two bolts. Tighten
•Loosen any fitting, any hose, or any component. the bolts to a torque wrench setting of 79 Nm
•Tighten any fitting, any hose, or any component. (58 lb ft).
2. Install bevel gear (2) onto the assembled case
•Remove any fitting, any hose, or any
(11). Apply 9S-3263 Thread Lock Compound to
component.
the threads of bolts (9). Secure the bevel gear
••Adjust any fitting, any hose, or any component. to the case with bolts (9). Tighten the bolts to a
torque wrench setting of 180 Nm (133 lb ft). Install
cones (5) and (13) and check for full seating of the
Adjustment Procedure cones. Lubricate the cones with axle oil.

Illustration 99 g00797356
3. Support the differential on a bar in order to aid
assembly. Install the assembled differential into
brake cylinder (1). Install nut (12).
4. Install cup (4) into brake cylinder (3). Apply a
Illustration 98 g00797118 coating of 1U - 8846 Gasket Sealant to the mating
Differential and Bevel Gear (Front Axle) surface of the brake cylinder. Install brake cylinder
(1) Brake cylinder
(3) and secure in place using two bolts. Tighten
(2) Bevel gear
the bolts to a torque setting of 79 Nm (58 lb ft).
(3) Brake cylinder
(4) Cup (bearing)
Install nut (6).
(5) Cone (bearing)
(6) Nut
(7) Retainer
(8) Bolt
(9) Bolt
(10) Center housing
(11) Case (differential)
(12) Nut
(13) Cone (bearing)
(14) Cup (bearing)

Illustration 100 g00797516

5. Use tooling (B) to tighten each nut until slight
resistance is felt. Strike both sides of the assembly
with a soft mallet in order to seat the bearings.
Repeat this process until the rolling resistance
begins to increase.
31200270 83
Testing and Adjusting Section

Illustration 101 g00797368 Illustration 103 g00797361

Checking the Rolling Resistance
8. Install the assembled tooling (D) into the bore of
6. Use tooling (C) to measure the rolling resistance. the differential assembly. Install the tool on the
The rolling resistance must be between 5.2 Nm side closest to the bevel gear. Turn the Rod
(46 lb in) and 5.9 Nm (52 lb in). Adjust one of the clockwise until the tool is held firmly in the
nuts (6) or (12) in order to establish the correct bore of the differential assembly. Identify a line on
rolling resistance. Tighten the nut in order to the arm of the tool. This line corresponds to the
increase the rolling resistance. Back off the nut in outer radius of the bevel gear. The line is marked
order to reduce the rolling resistance. with the letter "A".
9. Install tooling (A) on the center housing. Position
the contact point (plunger) of the dial indicator on
the mark that corresponds to the outer radius of
the bevel gear. Zero the dial indicator.

Illustration 102 g00797358

Tooling (D)
(15) Rod
(16) Socket
(17) Socket assembly
Illustration 104 g00797364
10. Hold the pinion gear stationary while you rotate the
7. Partially screw Rod (15) into Socket (16). Install
tool back and forth in order to measure the bevel
Socket assembly (17) onto Socket (16). Secure
gear backlash. The bevel gear backlash is the total
socket assembly (17) to socket (16) with Screw.
deflection of the dial indicator. Take further
measurements at three equally spaced positions in
order to establish an average backlash. The
backlash should be between 0.18 mm (0.007 inch)
to 0.23 mm (0.009 inch).
11. If the measurement is not within the specification
adjust nuts (6) and (12). Back off nut (6) and
tighten nut (12) by the same amount in order to
increase the backlash. Back off nut (12) and
tighten nut (6) by the same amount in order to
decrease the backlash. Adjusting the nuts by the
same amount will maintain the correct rolling
resistance.
84 31200270
Testing and Adjusting Section

12. Use tooling (C) to remeasure the rolling 1. Move the machine to a smooth, horizontal location
resistance. The rolling resistance should be that is away from operating machines and away
between 5.2 Nm (46 lb in) and 5.9 Nm (52 lb in). from personnel.
13. When the backlash and the rolling resistance are 2. Permit only one operator on the machine. Keep
within the specification install retainers (7) and all other personnel away from the machine or in
bolts (8) in order to fix nuts (6) and (12) in place. the operator's sight.
3. Move the transmission control to the NEUTRAL
Rear Axle Differential position.

Introduction 4. Lower the boom. If equipped, lower the work tool

to the ground.
The following procedure controls the differential
5. Engage the parking brake and stop the engine.
backlash and differential bearings preload settings for
the rear axle. Adjust the differential backlash and 6. If the machine is in a confined area, ensure that
bearings for the rear axle according to the following exhaust gases are vented to the outside when the
procedure. engine is operated.
7. Make sure that all the oil pressure is released
Required Tools
before you perform any of the following
Table 18 provides a list of the tools that are required to procedures:
carry out the adjustment of the differential backlash and
the differential bearings for the front axle. •Loosen any fitting, any hose, or any component.
Table 18 •Tighten any fitting, any hose, or any component.
Required Tools •Remove any fitting, any hose, or any
Part
component.
Tool Description Qty
Number ••Adjust any fitting, any hose, or any component.
A 8T-5096 Dial Indicator Group 1
B 202-7965 Adjuster 1 Adjustment Procedure
C 9U-5017 Torque Wrench 1

Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Refer to Special Publication, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.

Illustration 105 g00907688

Differential and Bevel Gear (Rear Axle)
(1) Bevel gear (10) Cone (bearing)
When testing and adjusting the transmission and (2) Bolt (11) Cup (bearing)
power train, move the machine to an area clear of (3) Cup (bearing)
obstructions, with safe exhaust ventilation for the (4) Cone (bearing)
exhausts. Sudden movement of the machine or release (5) Nut
of oil under pressure can cause injury to persons on or (6) Bolt
near the machine. To prevent possible injury, do the (7) Retainer
procedure that follows before testing and adjusting the (8) Case
transmission and power train. (9) Nut
31200270 85
Testing and Adjusting Section

1. Install bevel gear (1) onto the assembled case resistance. Back off the nut in order to reduce the
(8). Apply Thread Lock Compound to rolling resistance. The rolling resistance must be
the threads of bolts (2). Secure the bevel gear between 5.2 Nm (46 lb in) and 5.9 Nm (52 lb in).
to the case with bolts (2). Tighten the bolts to a
torque wrench setting of 180 Nm (133 lb ft). Install
cones (4) and (10) and check for full seating of the
bearing cones. Lubricate the cones with axle oil.
2. Support the assembly in a fixture. Position the
assembly so that the pinion gear is pointing
vertically downward. Install cups (3) and (11).
Lower the differential assembly into position.

Illustration 108 g00797559

Measuring Pinion Backlash
6. Install tooling (A). Position the contact point
(plunger) at 90 degrees to one of the bevel gear
teeth. Adjust the dial indicator so that the contact
point (plunger) is just in contact with the tooth.
Zero the dial indicator. Hold the pinion gear
stationary and rotate the bevel gear back and forth
Illustration 106 g00797546 in order to measure the backlash. The bevel gear
Differential Assembly backlash is the total deflection of the dial indicator.
(12) Cap
Use tooling (B) to tighten nuts (5) and (9) by equal
(13) Bolt
amounts until the measured backlash is between
3. Install caps (12). Strike each cap with a soft mallet 0.18 mm (0.007 inch) and 0.23 mm (0.009 inch).
in order to seat the cap. Install bolts (13) and
tighten to a torque wrench setting of 413 Nm 7. If the measurement is not within the specification,
(305 lb ft). adjust nuts (5) and (9). Back off nut (5) and tighten
nut (9) by the same amount in order to increase
4. Install nuts (5) and (9). Use tooling (B) to tighten the backlash. Back off nut (9) and tighten nut (5)
each nut until slight resistance is felt. Strike both by the same amount in order to decrease the
sides of the assembly with a soft mallet in order backlash. Adjusting the nuts by the same amount
to seat the bearings. Repeat the process until the will maintain the correct rolling resistance.
rolling resistance increases.
8. When the backlash and the rolling resistance are
within the specification, install retainers (7) and
bolts (6) in order to fix nuts (5) and (9) in place.
9. Check the tooth contact pattern.

Tooth Contact Pattern

Introduction
It is important to have the correct tooth contact
between the pinion gear and the bevel gear in order to
prevent excessive wear of the gear teeth.
Procedure
Illustration 107 g00729325 Check the tooth contact pattern according to the
5. Reposition the carrier in the supporting fixture so following procedure:
that the pinion gear is horizontal. Use tooling (C) to
measure the rolling resistance. The rolling
resistance must be between 5.2 Nm (46 lb in) and
5.9 Nm (52 lb in). Adjust one of the nuts (5) or (9) in
order to establish the correct rolling resistance.
Tighten the nut in order to increase the rolling
86 31200270
Testing and Adjusting Section

Illustration 109 g00729328

Examples of Incorrect Tooth Contact Patterns
The illustration gives an indication of possible bevel gear or pinion gear movements in order to achieve correct tooth contact.
1. 1. Apply marking compound (prussian blue) to the
teeth of bevel gear (2). Rotate pinion gear (1)
clockwise and rotate the pinion gear
counterclockwise until all the teeth on the bevel
gear have made contact with the pinion gear in
both directions. Refer to Illustration 109 and check
the tooth contact pattern of the bevel gear and
pinion gear (bevel gear set).
2. 2. Adjust the position of the bevel gear or adjust the
position of the pinion gear in order to achieve
optimum tooth contact.
•In order to move bevel gear (2) toward pinion gear
(1), adjust the nuts that are used to establish
Illustration 110 g00797650
(1) Pinion Gear
correct backlash. Adjust the nuts by the same
(2) Bevel Gear
amount in order to maintain the correct backlash
and rolling resistance.
•In order to move bevel gear (2) away from
pinion gear (1), adjust the nuts that are used
to establish correct backlash. Adjust the nuts
by the same amount in order to maintain the
correct backlash and rolling resistance.
•In order to move pinion gear (1) toward bevel
gear (2), an adjustment must be made to the
31200270 87
Testing and Adjusting Section

thickness of the shim that is used to establish 1. Move the machine to a smooth, horizontal location
the correct depth of the pinion gear. Refer to that is away from operating machines and away
Systems Operation, Testing and Adjusting, from personnel.
"Differential Pinion Bearing - Adjust". 2. Permit only one operator on the machine. Keep
•In order to move pinion gear (1) away from all other personnel away from the machine or in
bevel gear (2), an adjustment must be made the operator's sight.
to the thickness of the shim that is used to 3. Move the transmission control to the NEUTRAL
establish the correct depth of the pinion gear. position.
Refer to Systems Operation, Testing and
Adjusting, "Differential Pinion Bearing -Adjust". 4. Lower the boom. If equipped, lower the work tool
to the ground.
3. Clean the marking compound from the bevel gear
5. Engage the parking brake and stop the engine.
and pinion gear. Recheckthe backlash and the
rolling resistance. 6. If the machine is in a confined area, ensure that
exhaust gases are vented to the outside when the
engine is operated.
Axle Housing and Bearing
7. Make sure that all the oil pressure is released
Preload - Adjust before you perform any of the following
procedures:
Introduction
•Loosen any fitting, any hose, or any component.
Use the procedure that follows in order to adjust the •Tighten any fitting, any hose, or any component.
axle housing and bearing preload. Use the same
procedure for both axles. •Remove any fitting, any hose, or any
component.

Reference: For information regarding the removal and •Adjust any fitting, any hose, or any component.
installation of the kingpins for the axle, refer to the
Power Train, Disassembly and Assembly, "Final Drive
and Wheel - Remove" and the Power Train,
Disassembly and Assembly, "Final Drive and Wheel -
Install" for your machine.

Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Refer to Special Publication, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.

When testing and adjusting the transmission and

power train, move the machine to an area clear of
obstructions, with safe exhaust ventilation for the
exhausts. Sudden movement of the machine or release
of oil under pressure can cause injury to persons on or
near the machine. To prevent possible injury, do the
procedure that follows before testing and adjusting the
transmission and power train.
88 31200270
Testing and Adjusting Section

Adjustment Procedure

Illustration 112 g00798200

(5) Bolt

4. Install a lever under the top lug of knuckle (11) and

lever up the knuckle. Tighten bolts (5) until there is
no vertical play in the knuckle. The knuckle must
still be free to rotate.
5. Use a feeler gauge to establish clearance (K) at
two opposite positions. Calculate the average
clearance from the two measurements. Subtract
0.5 ± 0.1 mm (0.02 ± 0.004 inch) from the average
measurement. The remaining dimension is the
thickness of the shims that are required.
Illustration 111 g00797733
Axle and Housing
(1) Bearing
(2) Seal
(3) Dust cap (seal)
(4) Kingpin
(5) Bolt
(6) Bearing
(7) Seal
(8) Dust cap (seal)
(9) Kingpin
(10) Bolt
(11) Knuckle
(K) Clearance dimension
Illustration 113 g00798201
(12) Shims
1. Install bearing (6), seal (7) and dust cap (8) onto 6. Install the shims. Raise the kingpin slightly in order
kingpin (9). Install the kingpin assembly. Secure to install the required shims. Install each pair of
the kingpin assembly with four bolts (10). Do not shims in an overlapping pattern. Tighten bolts (5)
torque bolts (10) fully at this stage. and bolts (10) to a torque wrench setting of 300
2. Install bearing (1), seal (2) and dust cap (3) onto Nm (221 lb ft).
kingpin (4). Install the kingpin assembly. Do not Note: Shims are available in the following
install shims at this stage. thicknesses: 0.15 mm (0.006 inch), 0.20 mm (0.008
3. Install four bolts (5). Tighten the bolts evenly until inch), and 0.50 mm (0.020 inch).
there is zero bearing end play.
31200270 89
Index Index

A Electronic Control Module............................................... 9

Axle Housing and Bearing Preload - Adjust ....................... 87 Engine Speed Sensor ..................................................... 8
Adjustment Procedure .................................................. 88 Modulating Valve for the Synchronizers ......................... 9
Introduction................................................................... 87 Parking Brake Switch...................................................... 7
Procedure ..................................................................... 87 Service Brake Pressure Switch ...................................... 7
Shift Rail Sensors ........................................................... 9
C Solenoid Valves ............................................................ 10
Configuration Parameters .................................................. 53 Torque Converter Output Sensor for the Temperature of
Cooler (Hydraulic Oil)......................................................... 38 the Oil ............................................................................. 8
Torque Converter Output Speed Sensor ........................ 8
D Transmission Direction Control Lever (Power Shuttle
Data Link ............................................................................ 22 Transmission) ................................................................. 8
CAN Data Link .............................................................. 22 Transmission Intermediate Speed Sensors .................... 9
CAT Data Link .............................................................. 22 Transmission Neutralizer Override Switch.................... 10
Differential Backlash and Bearings - Adjust ....................... 81 Transmission Neutralizer Switch .................................... 7
Front Axle Differential ................................................... 81 Transmission Oil Temperature Sensor ........................... 8
Rear Axle Differential.................................................... 84 Transmission Output Speed Sensor ............................... 9
Tooth Contact Pattern................................................... 85 Transmission Speed Selector (Powersynchro
Transmission) ................................................................. 8
Differential Lock Control (If Equipped) ............................... 44
Location of Hydraulic Components .................................... 10
Differential Pinion Bearing -Adjust ..................................... 75
Hydraulic Oil Cooler...................................................... 11
Introduction................................................................... 75
Torque Converter.......................................................... 11
Procedure ..................................................................... 76
Transmission Charge Pump ......................................... 11
Required Tools ............................................................. 75
M
E
Modulating Valve (Transmission) ....................................... 24
Electrical Input Components .............................................. 12
Sensors......................................................................... 12 S
Switches ....................................................................... 14 Solenoid Valves (Transmission)......................................... 24
Transmission Control.................................................... 15 Directional Solenoids .................................................... 24
Electrical Output Components ........................................... 20 Speed or Synchronized Solenoids................................ 25
Directional Solenoids .................................................... 21
Instrument Cluster ........................................................ 21 T
Synchronizer Solenoids ................................................ 21 Table of Contents................................................................. 1
Electrical Schematic........................................................... 22 Testing and Adjusting Section............................................ 55
Electronic Control Module .................................................. 16 Torque Converter ............................................................... 26
Input/Output.................................................................. 16 Torque Converter Stall - Test ............................................. 69
Inputs ............................................................................ 16 Introduction ................................................................... 69
Outputs ......................................................................... 16 Required Tools ............................................................. 69
Test Procedure ............................................................. 69
F
Transmission...................................................................... 28
Front Axle and Rear Axle ................................................... 46 Clutch Operation........................................................... 31
Final Drives................................................................... 46 Limits ............................................................................ 37
G Operation of the Synchronizers .................................... 32
Transmission Charge Pump............................................... 24
General Information ............................................................. 5
Transmission Control (Shift Lever)..................................... 38
Graphic Color Codes............................................................ 3
Power Shuttle Transmission ......................................... 39
H Powersynchro Transmission......................................... 39
Hydraulic Schematic (Power Train System)....................... 48 Transmission Fill - Calibrate............................................... 62
Neutral (Power Shuttle Transmission) .......................... 48 Machine Preparation..................................................... 62
Neutral (Powersynchro Transmission).......................... 49 Transmission Power Flow .................................................. 40
Neutral Into First Gear (End of Shift) (FORWARD) ...... 51 Examples of Power Flow Through the Transmission ... 42
Neutral into First Gear (Start of shift)............................ 50 Transmission Pressures - Test and Adjust ........................ 70
Oil Level Check............................................................. 72
I Operating Pressures of Clutches and Synchronizers ... 74
Important Safety Information.................................................ii Pressure Test Points for the Power Shuttle
Introduction .......................................................................... 4 Transmission ................................................................ 72
Pressure Test Points for the Powersynchro
L Transmission ................................................................ 71
Location of Electrical Components....................................... 6 Regulated Pump Pressure............................................ 73
Differential Lock Switch (if Equipped .............................. 8 Torque Converter Inlet Pressure Introduction............... 72
90 31200270
Index

Transmission Shift Rail -Calibrate...................................... 55

Machine Preparation..................................................... 55
Manufactured by JLG under license from Caterpillar
31200300
December 15, 2006

Disassembly and
Assembly

TH360B Telehandler Power Train

S/N TBH00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200300 1
Table of Contents
Table of
Table of Contents Assembly Procedure.......................... 96
Disassembly and Assembly Section Axle Housing and Flange Install ............ 98
Transmission Control (Select Lever) - Installation Procedure ........................ 98
Remove ................................................... 3 Axle Shaft - Remove and Install........... 101
Removal Procedure............................. 3 Removal Procedure ......................... 101
Transmission Control (Select Lever) - Installation Procedure ...................... 102
Install ....................................................... 5 Axle Housing (Service Brakes, Differential
Installation Procedure.......................... 5 and Bevel Gear) (Front) - Remove....... 103
Transmission - Remove........................... 6 Removal Procedure ......................... 103
Removal Procedure............................. 6 Axle Housing (Service Brakes, Differential
Transmission - Disassemble ................. 10 and Bevel Gear) (Front) - Disassemble104
Disassembly Procedure .................... 10 Disassembly Procedure................... 104
Transmission - Assemble ...................... 38 Axle Housing (Service Brakes, Differential
Assembly Procedure ......................... 38 and Bevel Gear) (Front) - Assemble .... 109
Transmission - Install............................. 66 Assembly Procedure........................ 109
Installation Procedure........................ 66 Axle Housing (Service Brakes, Differential
Drive Shaft (Front) - Remove and Install 68 and Bevel Gear) (Front) - Install .......... 119
Removal Procedure........................... 68 Installation Procedure ...................... 119
Installation Procedure........................ 69 Axle Housing (Differential and Bevel Gear)
Drive Shaft (Rear) - Remove and Install 69 (Rear) - Remove .................................. 120
Removal Procedure........................... 69 Removal Procedure ......................... 120
Installation Procedure........................ 70 Axle Housing (Differential and Bevel Gear)
Drive and Steering Axle (Front) - (Rear) -Disassemble ............................ 121
Remove ................................................. 70 Disassembly Procedure................... 121
Removal Procedure........................... 70 Axle Housing (Differential and Bevel Gear)
Drive and Steering Axle (Front) - Install 75 (Rear) - Assemble ................................ 124
Installation Procedure........................ 75 Assembly Procedure........................ 124
Drive and Steering Axle (Rear) - Axle Housing (Differential and Bevel Gear)
Remove ................................................. 79 (Rear) - Install ...................................... 130
Removal Procedure........................... 79 Installation Procedure ...................... 130
Drive and Steering Axle (Rear) - Install . 82 Parking Brake Control -Remove and
Tie Rod (Steering) - Remove and Install 86 Install.................................................... 130
Removal Procedure........................... 86 Removal Procedure ......................... 130
Installation procedure ........................ 86 Installation Procedure ...................... 131
Steering Cylinder - Remove and Install . 87 Parking Brake - Remove ...................... 132
Removal Procedure........................... 87 Removal Procedure ......................... 132
Installation Procedure........................ 88 Parking Brake - Disassemble............... 133
Final Drive Planetary - Remove............. 89 Disassembly Procedure................... 133
Removal Procedure........................... 89 Parking Brake - Assemble ................... 134
Final Drive Planetary Disassemble........ 90 Assembly Procedure........................ 134
Disassembly Procedure .................... 90 Parking Brake - Install .......................... 136
Final Drive Planetary Assemble ............ 90 Installation Procedure ...................... 136
Assembly Procedure ......................... 90 Brake Cylinder (Master) Remove and
Final Drive Planetary - Install................. 91 Install.................................................... 137
Installation Procedure........................ 91 Removal Procedure ......................... 137
Axle Housing and Flange Remove ........ 91 Installation Procedure ...................... 139
Removal Procedure........................... 91 Tire and Rim - Remove and Install....... 140
Axle Housing and Flange -Disassemble 94 Removal Procedure ......................... 140
Disassembly Procedure .................... 94 Installation Procedure ...................... 141
Axle Housing and Flange -Assemble .... 96
2 31200300
Table of Contents
31200300 3
Disassembly and Assembly Section

3. Carefully lower cover (1) and loosen the hose

Disassembly and clamp before disconnecting heater hose (2).
Loosen retaining nut (3) and remove key start
Assembly Section switch (4) from cover (1). Lay the key start switch
aside. Remove cover (1) from the machine.
Transmission Control (Select
Lever) - Remove
Removal Procedure
Start By:
a. Remove the steering wheel. Refer to Disassembly and
Assembly, "Steering Wheel - Remove and Install".
1. Put identification marks on all wires and on all
harnesses for installation purposes.

Illustration 4 g00934417
4. Remove the bolts that secure cover (5).

Illustration 1 g00934412
2. Remove the bolts that secure cover (1).

Illustration 5 g00934418
Right Side

Illustration 2 g00934415

Illustration 6 g00934419
Left Side
5. Carefully lift cover (5) in order to disconnect
electrical connectors (6) from switches (7).
Remove the cover.

Illustration 3 g00934416
4 31200300
Disassembly and Assembly Section

Illustration 7 g00934420 Illustration 10 g00934423

6. Remove the bolts that secure display module (8). 9. Remove the bolts that secure housing (13).
Carefully remove the housing and at the same time
feed harness (14) out of the housing.

Illustration 8 g00934421
7. Carefully lift display module (8) and loosen bolt (9)
in order to disconnect electrical connector (10). Illustration 11 g00934424
Remove the display module. 10. From the underside of transmission control (16),
disconnect electrical connector (15).

Illustration 9 g00934422
8. Disconnect electrical connector (11) from switch Illustration 12 g00934426
(12) for directional turn signal control. 11. Remove four screws (17) in order to remove
transmission control (16) from steering column (18).
31200300 5
Disassembly and Assembly Section

Transmission Control (Select

Lever) - Install
Installation Procedure

Illustration 16 g00934534
4. Connect electrical connector (11) to switch (12) for
the directional turn signal control.

Illustration 13 g00934520
1. Position transmission control (16) onto steering
column (18) and install four screws (17).

Illustration 17 g00934535
5. Position display module (8) in order to connect
electrical connector (10) before tightening bolt (9).

Illustration 14 g00934522
2. Connect electrical connector (15) to transmission
control (16).

Illustration 18 g00934536
6. Install the bolts in order to secure display module
(8).

Illustration 15 g00934532
3. Carefully feed harness (14) through housing (13)
before positioning the housing onto the steering
column. Install the bolts in order to secure the
housing.
6 31200300
Disassembly and Assembly Section

Illustration 19 g00934538 Illustration 23 g00934946

Right Side 9. Position cover (1) in order to install key start
switch (4) and retaining nut (3). Connect heater
hose (2) to cover (1) and tighten the hose clamp.

Illustration 20 g00934938
Left Side
7. Position cover (5) in order to connect connectors Illustration 24 g00934948
(6) to switches (7).
10. Carefully lift cover (1) and install the bolts in order to
secure the cover.
End By:
a. Install the steering Wheel. Refer to Disassembly and
Assembly, "Steering Wheel - Remove and Install".

Transmission - Remove
Removal Procedure
Table 1

Required Tools
Illustration 21 g00934942
8. Install the bolts to secure cover (5). Tool Part Number Part Description Qty

A 9U-6198 Crankshaft Turning Tool 1

Hydraulic Transmission
B 1U-9753 1
Jack

Start By:
a. Remove the hood. Refer to the appropriate service manual
for more information.
b. Remove the fan guard. Refer to the appropriate service
manual for more information.
c. Remove the radiator. Refer to the appropriate service
manual for more information.
Illustration 22 g00934945
31200300 7
Disassembly and Assembly Section

d. Remove the alternator. Refer to the appropriate service

manual for more information.
e. Remove the refrigerant compressor. Refer to the
appropriate service manual for more information.
f. Remove the hydraulic pump. Refer to the appropriate
service manual for more information.
g. Remove the drive shafts. Refer to the appropriate service
manual for more information.

Personal injury or death can result from improper

lifting or blocking. Illustration 25 g00979392

When a hoist or jack is used to lift any part or 2. Remove four bolts (1) and the washers in order to
component, stand clear of the area. Be sure the remove spider (2), spacer (3) and pulley (4) from
hoist or jack has the correct capacity to lift a transmission (5).
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
Illustration 26 g00979400
system after the engine has been stopped. Serious
3. Remove four bolts (6) and the washers that secure
injury can be caused if this pressure is not released
bracket (7) to transmission (5). Lift the bracket
before any service is done on the hydraulic system.
away from the transmission and use several cable
Make sure all of the attachments have been straps to secure the bracket to a suitable fixing.
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and Illustration 27 g00979401
mandates. 4. Loosen the retaining nut in order to disconnect
1. Put identification marks on all hoses, on all tubes hose (8) from transmission (5). Loosen the hose
and on all wires for installation purposes. Plug all clamp in order to disconnect hose (9).
hoses and all tubes. This helps prevent fluid loss
and this helps to keep contaminants from entering
the system.
8 31200300
Disassembly and Assembly Section

Illustration 28 g00984850 Illustration 31 g00984852

5. Disconnect electrical connector (10) from solenoid 8. Loosen the retaining nut in order to disconnect
valve (11). Remove three bolts (12) in order to hose (21) from solenoid valve (22). Remove bolt
remove the solenoid valve from transmission (5). (24), the washer and the hose clamp which secures
hose (25) to the chassis. Loosen the hose clamp in
order to disconnect hose (25) from tee (26).

Illustration 29 g00979402
6. Remove bolt (13) and hose clamp (14) from the
bottom of transmission (5). Loosen the hose Illustration 32 g00984853
clamps in order to disconnect hose (9) and hose 9. Use a suitable allen wrench to loosen screw (27) in
(16) from oil cooler (15). order to disconnect electrical connector (28) for the
chassis harness from electrical connector (29) for
the transmission harness.

Illustration 30 g00984851
7. Loosen the hose clamp in order to disconnect
hose (17) from the bottom of transmission (5). Illustration 33 g00984855
Remove four bolts (18) in order to remove adapter 10. Remove two plastic plugs (30) from the underside of
plate (19) and the O-ring seal (not shown). Loosen transmission (5).
the retaining nut in order to disconnect hose (20).
31200300 9
Disassembly and Assembly Section

Illustration 34 g00986275 Illustration 37 g00986311

13. Position Tooling (B) on the underside of
transmission (5). If necessary, install suitable
cribbing between the Tooling and the transmission.
This will ensure that the transmission is fully
seated on the base of the tooling. Raise the
Tooling in order to support the transmission. Install a
suitable strap in order to secure the transmission
onto the Tooling.

Illustration 35 g00986276
11. Install Tooling (A) onto crankshaft (31) on the
engine. Use Tooling (A) to rotate the engine in
order to align bolt (32) with the access hole.
Remove bolt (32) and the washer from the access
hole which is indicated by the white arrow.
12. Repeat step 11 until all eight bolts (32) and
washers are removed.
Illustration 38 g00986314
14. Remove bolts (33) and the washers that secure
transmission (5) to the engine.
Note: Note the location of the bolts that are removed in
this step. Some bolts may have already been removed
as part of the Start By procedures.
15. Use Tooling and move transmission (5) toward the
front of the machine in order to separate the
transmission from the engine. When the
Transmission is clear of the engine, use Tooling (B)
to carefully lower the transmission. The weight of
the transmission is approximately 330 kg (728 lb).
Illustration 36 g00986277
10 31200300
Disassembly and Assembly Section

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
Illustration 39 g00986316 shown. Clean all surfaces where parts are to be
16. Use Tooling (B) and remove transmission (5) from installed.
the left side of the machine.
NOTICE
Care must be taken to ensure that fluids are contained
Transmission - Disassemble during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
Disassembly Procedure the fluid with suitable containers before opening any
compartment or disassembling any component
Start By: containing fluids.
a. Remove the transmission. Refer to Disassembly
Dispose of all fluids according to local regulations and
and Assembly, "Transmission - Remove".
mandates.
b. Remove the torque converter. Refer to
Disassembly and Assembly, "Torque Converter - NOTICE
Disassemble". Keep all parts clean from contaminants.
Table 2
Contaminants may cause rapid wear and shortened
Required Tools component life.

Tool Part Number Part Description Qty

A 138-7575 Link Bracket 2

B 1U-7262 Telescoping Magnet 1
C 1U-8241 Lifting Sling 1
D 1P-2320 Combination Puller 1
E 138-7573 Link Bracket 3
F 1P-1857 Retaining Ring Pliers 1
G 156-7100 Slide Hammer Puller Gp 1
H 1P-0510 Driver Gp 1 Illustration 40 g00892840

I 1P-1856 Retaining Ring Pliers 1 1. Attach Tooling (A) and a suitable lifting device to
the transmission and position the transmission
J 1P-2321 Combination Puller 1
onto a suitable bench. The weight of the
K 4C-8359 Eyebolt (M12) 1 transmission is approximately 350 kg (772 lb).
L 1P-1860 Retaining Ring Pliers 1
8B-7550 Push-Puller Leg 1
M
8H-0663 Bearing Puller Gp 1
N 1P-0074 Slide Hammer Puller Gp 1
31200300 11
Disassembly and Assembly Section

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
b. Use a suitable allen wrench in order to remove cap (5).

Illustration 41 g00893165
2. Use a suitable allen wrench to remove allen head
screws (1) in order to remove sensors (2) for the
shift rails.
3. Machines that are equipped with five speeds have
additional components that need to be removed.

Illustration 44 g00895720

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Illustration 42 g00895246
Follow the recommended procedure and use all
recommended tooling to release the spring force.
c. Remove spring (6). Use Tooling (B) (not shown) in order
Personal injury can result from being struck by parts
to remove detent ball (7) from the transmission.
propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
a. Use a suitable allen wrench to remove two allen head
screws (3) in order to remove sensor (4) for the shift rail.

Illustration 45 g00895742
d. Remove bolts (8) that secure actuator (9) to transmission
cover (10). Remove the actuator from the transmission
cover and take care not to lose the two O-ring seals that
are between the actuator and the transmission cover.

Illustration 43 g00895262
12 31200300
Disassembly and Assembly Section

Illustration 46 g00892932 Illustration 49 g00892661

e. Remove allen head screw (11) that is shown in 6. Remove neutralizing piston (23), and actuator
Illustration 45. Remove locking plate (12) in piston (24) from actuator (20). Remove O-ring
order to remove solenoid (13) from actuator (9).
seals (25) and (26) from the pistons and inspect the
Remove O-ring seals (14) and (15) from the
spool and inspect the O-ring seals for damage. O-ring seals for damage. Replace the O-ring seals,
Replace the O-ring seals, if necessary. if necessary.
f. Remove actuator piston (16) from the actuator,
and remove O-ring seals (17) and (18). Inspect
the O-ring seals for damage and replace the
O-ring seals, if necessary.

Illustration 50 g00892881
7. Repeat Step 6 for neutralizing piston (27) and
actuator piston (28).
8. Remove allen head screw (29) and locking plate
Illustration 47 g00892825
(30) in order to remove solenoid (31) from actuator
4. Remove bolts (19) that secure actuator (20) to
(20).
transmission housing (21). Remove the actuator
from the transmission housing and take care not to
lose the four O-ring seals that are between the
actuator and the transmission housing.

Illustration 51 g00892889
9. Remove O-ring seals (32) and (33) from the spool
and inspect the O-ring seals for damage. Replace
the O-ring seals, if necessary.
Illustration 48 g00892853
5. Remove O-ring seals (22) from actuator (20) and 10. Repeat Step 8 and Step 9 for solenoid (34).
inspect the O-ring seals for damage. Replace the
O-ring seals, if necessary.
31200300 13
Disassembly and Assembly Section

Illustration 52 g00892810 Illustration 55 g00893166

11. Remove bolts (35) that secure actuator (36) to 14. Attach Tooling (C) around the middle of the
transmission cover (10). Remove the actuator transmission and take care not to stress any of the
from the transmission cover and take care not to solenoids. Use Tooling (C) and a suitable lifting
lose the four O-ring seals that are between the device in order to carefully lift the transmission. The
actuator and the transmission cover. weight of the transmission is approximately 350 kg
12. Repeat Step 5 to Step 10 for actuator (36). (772 lb).

Illustration 53 g00893163 Illustration 56 g00893167

15. Position suitable cribbing in order to support each
end of the transmission. Ensure that the cribbing
allows clearance between valve housing (43) and
the bench. Lower the transmission in the
orientation that is shown in Illustration 56.

Illustration 54 g00893164
13. Remove bolts (37) and (38) and washers (39) and
(40) in order to remove drive yokes (41) and (42)
from both ends of the output shaft.

Illustration 57 g00893168
16. Remove bolt (44) and washer (45) in order to
remove fan drive (46) from the fan drive shaft.
14 31200300
Disassembly and Assembly Section

Illustration 58 g00893171 Illustration 61 g00896588

17. Remove bolts (47) in order to remove access panel 21. Remove O-ring seal (56) from speed sensor (55)
(48) from transmission cover (10). and inspect the O-ring seal for damage. Replace
the O-ring seal, if necessary.

Illustration 59 g00893172
18. Remove bolt (49) and washer (50) from the pump Illustration 62 g00893174
drive shaft. Remove ring (51) from the top of roller 22. Remove bolts (57) that secure modulating valve
bearing (52). (58) to transmission cover (10). Remove the
modulating valve from the transmission cover and
take care not to lose the three O-ring seals that are
between the modulating valve and the
transmission cover.

Illustration 60 g00893173
19. Remove temperature sensor (53) from
transmission housing (21).
20. Remove bolt (54) in order to remove speed
Illustration 63 g00893176
sensor (55).
23. Remove O-ring seals (59) from modulating valve
(58) and inspect the O-ring seals for damage.
Replace the O-ring seals, if necessary. Remove nut
(60) and washer (61) in order to remove solenoid
(62).
31200300 15
Disassembly and Assembly Section

Illustration 64 g00893199 Illustration 67 g00893259

24. Remove spool (63) from modulating valve (58). 26. Use a suitable press in order to take the load off
Remove O-ring seals (64) and (65) from the valve snap ring (68) that secures bearing (69) and
spool and inspect the O-ring seals for damage. remove the snap ring.
Replace the O-ring seals, if necessary.

Illustration 68 g00893302
Illustration 65 g00893230 27. Use a suitable spring compressor in order to press
25. Remove allen head screws (66) in order to remove the bearing from mounting flange (70).
idler (67) for the fan drive.

Illustration 69 g00893317
Illustration 66 g00893246 28. Use Tooling (D) and a suitable bench vise in order to
remove bearing (69) from idler (67).
16 31200300
Disassembly and Assembly Section

Illustration 70 g00893374 Illustration 73 g00893599

31. Make sure that shift rail (76) and shift rail (77) are in
the NEUTRAL position. Use Tooling (B) in order to
remove four detent balls (78) from the cavity.

Illustration 71 g00893387

Illustration 74 g00893600
Personal injury can result from being struck by Note: Record the positions of three supports (71) for
parts propelled by a released spring force. the harness before removing 22 bolts (80).
Make sure to wear all necessary protective 32. Remove 22 bolts (80) that secure the transmission
equipment. cover to the transmission housing.
Follow the recommended procedure and use all 33. Attach Tooling (E) to the three 10 mm holes that
recommended tooling to release the spring force. are shown in Illustration 74.
29. Remove spring retainers (71), springs (72) and
detent balls (73). Use a Tooling (B) in order to
remove the two detent balls from the transmission
housing. Remove O-ring seals (74) from spring
retainers (71) and inspect the O-ring seals for
damage. Replace the O-ring seals, if necessary.

Illustration 75 g01040523
34. Use Tooling (E) and a suitable lifting device in order
to lift transmission cover (10). The weight of the
transmission cover is approximately 42 kg (93 lb).
Lift the transmission cover away from transmission
housing (21).
Illustration 72 g00893598 Note: Ensure that the transmission cover is lifted
30. Use a suitable M4 screw to remove cap (75). square in order to smoothly disengage the two
locating pins that are between the interface of the
transmission cover and the transmission housing.
31200300 17
Disassembly and Assembly Section

Illustration 76 g00893602 Illustration 79 g00895560

35. Remove O-ring seals (81) from transmission 37. Use Tooling (G) to remove four bearing sleeves (84),
housing (21) and inspect the O-ring seals for (85), (86) and (87). Remove any shims that are
damage. Replace the O-ring seals, if necessary. under the bearing sleeves.

Illustration 77 g01040762 Illustration 80 g00895562

36. Use Tooling (F) in order to remove circlip (82). 38. Use Tooling (G) in order to remove bearing sleeve
Remove bearing (83) for the pump drive shaft from (88) for the fan drive shaft from transmission cover
transmission cover (10). (10). Remove shims (89), and use Tooling (F) in
order to remove circlip (90).

Illustration 78 g00895559
Illustration 81 g00895563
18 31200300
Disassembly and Assembly Section

Illustration 82 g00895564 Illustration 85 g00895675

39. Use Tooling (H) in order to remove two seals (91) Cover of a Transmission with Four Speeds

and (92) from transmission cover (10). Inspect the a. Remove four allen head screws (96) in order to remove oil
two seals for damage and replace the seals, if tube (97).
necessary.

Illustration 86 g00895659
Cover of a Transmission with Five Speeds
Illustration 83 g00895566
b. Remove four allen head screws (98) in order to remove oil
40. Remove bearing carrier (93) for the input shaft and tube (99).
inspect the bearing carrier. Replace the bearing
carrier, if necessary. Note: There is an O-ring seal at both ends of the oil
tube. Inspect each seal and replace the seals, if
necessary.

Illustration 84 g00895658
41. Remove four allen head screws (94) in order to
Illustration 87 g00893603
remove oil tube (95).
43. Remove thrust bearing (100) and sleeve (101) for
Note: There is an O-ring seal at both ends of the oil
the thrust bearing from the end of input shaft (102).
tube. Inspect each seal and replace the seals, if
necessary.
42. Remove the other oil tube from the transmission
cover. The position of the oil tube in a transmission
with five speeds is different to the position of the
oil tube for a transmission with four speeds.
31200300 19
Disassembly and Assembly Section

Illustration 88 g00893604 Illustration 91 g00893607

44. Remove input shaft (102) from the transmission. 47. Use a suitable press in order to remove bearing
carrier (106) from input shaft (102).

Illustration 89 g00893605
45. Use Tooling (I) in order to remove circlip (103), and Illustration 92 g00893608
remove gear (104) from input shaft (102). 48. Remove roller bearing (107) for the input shaft from
transmission housing (21).

Illustration 90 g00893606
46. Remove split seal (105) from input shaft (102) and Illustration 93 g00893609
inspect the split seal for damage. Replace the split 49. Remove fan drive shaft (108) from the
seal, if necessary. transmission.
20 31200300
Disassembly and Assembly Section

Illustration 94 g00893611 Illustration 97 g00893951

50. Remove bearing cup (109) for the fan drive shaft from 53. Remove needle bearing (114) and thrust washer
transmission housing (21). (115) from fan drive shaft (108).

Illustration 95 g00893610 Illustration 98 g00893952

51. Remove split seal (110) from fan drive shaft (108) 54. Use Tooling (J) in order to remove drive gear (116)
and inspect the split seal for damage. Replace the and taper roller bearing (117) from the other end of
split seal, if necessary. fan drive shaft (108).

Illustration 96 g00893634 Illustration 99 g00893953

52. Use Tooling (J) in order to remove idler gear (111), 55. Remove pump drive shaft (118) from the
thrust washer (112) and taper roller bearing (113) transmission.
from fan drive shaft (108).
31200300 21
Disassembly and Assembly Section

Illustration 100 g00893954 Illustration 103 g00893957

56. Remove O-ring seal (119) from pump drive shaft 60. Use a suitable press in order to remove pump drive
(118) and check the O-ring seal for damage. gear (126) from pump drive shaft (118).
Replace the O-ring seal, if necessary. 61. Transmissions with five speeds are equipped with a
57. Use Tooling (J) in order to remove idler gear (120), shift rail and a fork for the fifth speed.
thrust washer (121) and bearing carrier (122) from
pump drive shaft (118).

Illustration 104 g00896791

a. Remove guide rail (127) and use a suitable drift and a
Illustration 101 g00893955 hammer in order to remove pin (128).
58. Remove needle bearings (123) and thrust washer
(124) from pump drive shaft (118).

Illustration 105 g00896792

b. Remove shift rail (129), fork (130), and O-ring seal (131).
Inspect the O-ring seal for damage and replace the O-ring
Illustration 102 g00893956
seal, if necessary.
59. Use Tooling (I) in order to remove circlip (125) from
pump drive shaft (118).
22 31200300
Disassembly and Assembly Section

66. Remove forward/reverse shaft (134) from the

transmission. The weight of the forward/reverse
shaft is approximately 20 kg (44.1 lb).

Illustration 106 g00893958

62. Install Tooling (K) on the end of output shaft (132).
Use a suitable lifting device in order to raise the
output shaft slightly. The weight of the output shaft is Illustration 109 g00893965
approximately 25.5 kg (56.2 lb). 67. Remove output shaft (132), selector forks (137)
63. Place a pinch bar under input drive gear (133) of and (138), and shift rails (139) and (140) from the
forward/reverse shaft (134). Use the pinch bar in transmission.
order to raise the forward/reverse shaft at the same 68. Remove selector forks (137) and (138) and shift
time as using a suitable lifting device to raise the rails (139) and (140) from output shaft (132).
output shaft.

Illustration 110 g00895978

Illustration 107 g00893963
69. Use a suitable hammer and a pin punch in order to
64. Raise forward/reverse shaft (134) and output shaft remove pin (141) before removing fork (138) from
(132) sufficiently in order to remove reverse idler shift rail (140) for the third speed and fourth speed.
shaft (135) from the transmission. The weight of the
reverse idler shaft is approximately 6 kg (13.2 lb).

Illustration 111 g00895979

70. Use a suitable hammer and a pin punch in order to
Illustration 108 g00893962
remove pin (142) before removing fork (137) from
65. Slide countershaft (136) into the former position shift rail (139) for the first speed and second speed.
of the reverse idler shaft, and lift the countershaft
from the transmission. The weight of the
countershaft is approximately 14 kg (30.9 lb).
31200300 23
Disassembly and Assembly Section

Illustration 112 g00893978 Illustration 115 g00894000

71. Use Tooling (J) in order to remove first gear (143), 74. Use a suitable screwdriver in order to lift
thrust washer (144) and taper roller bearing (145) synchronizer (148) for the first speed and second
from output shaft (132). speed from output shaft (132).
Note: Lift synchronizer (148) in one piece in order to
prevent losing internal parts.

Illustration 113 g00893984

72. Remove two needle bearings (146) from output
shaft (132). Illustration 116 g00894027
75. Remove plate (149) from the synchronizer.

Illustration 114 g00893989

73. Use Tooling (L) in order to remove circlip (147) that Illustration 117 g00894032
retains synchronizer (148) for the first speed and 76. Remove inner cone (150) from the synchronizer.
second speed.
24 31200300
Disassembly and Assembly Section

Illustration 118 g00894037 Illustration 121 g00894046

77. Remove friction ring (151) from the synchronizer. 80. Remove connecting blocks (153) from the
synchronizer.
81. Turn the synchronizer onto the other side and
repeat Steps 75 through 79.

Illustration 119 g00894591

Example of Damaged Inner Core (150) and Damaged Friction Ring (151)
78. Check the surfaces of inner cone (150) and friction
ring (151). Replace the inner cone or the friction ring Illustration 122 g00894593
with a new part if any of the following damage is
found:
• Scuffing
• Burn marks. Personal injury can result from being struck by
parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
82. Remove outer ring (154) from inner sprocket (155).
Note: Take care not to lose energizers (156), locating
pins (157), and springs (158) when the outer ring is
removed from the inner sprocket.

Illustration 120 g00894044

79. Remove outer cone (152) from the synchronizer.

Illustration 123 g00894595

31200300 25
Disassembly and Assembly Section

83. Remove second gear (159) from output shaft (132).

Illustration 127 g00895551

Output Shaft of a Transmission with Five Speeds
Illustration 124 g00894596
b. Lift tachometer drive (162) and fifth gear (164) off output
84. Remove needle bearings (160) from output shaft
shaft (132).
(132).

Illustration 128 g00894599

Illustration 125 g00894597
85. Use Tooling (M) in order to remove taper roller
bearing (161) from the other end of output shaft
(132).
86. Remove the tachometer drive from the output
shaft. The components on the output shaft of a
transmission with five speeds are different to the
components on the output shaft of a transmission
with four speeds.

Illustration 129 g00894600

87. Use a suitable press in order to take the load off
circlip (165). Use Tooling (L) in order to remove the
circlip.
Note: Take care not to lose washer (166) that is
located between spacer (163) and tachometer drive
(162).
Note: The spacer in Step 87 is replaced by a fifth gear
Illustration 126 g00894598
for transmissions that are equipped with five speeds.
Output Shaft of a Transmission with Four Speeds
a. Lift tachometer drive (162) and spacer (163) off output
shaft (132).
26 31200300
Disassembly and Assembly Section

91. Remove synchronizer (171) for the third speed and

fourth speed from output shaft (132).
Note: Lift the synchronizer in one piece in order to
prevent losing internal parts.

Illustration 130 g00894601

88. Remove fourth gear (167) from output shaft (132).

Illustration 134 g00894609

92. Remove plate (172) from the synchronizer.

Illustration 131 g00894602

89. Remove needle bearings (168) and spacer (169)
from output shaft (132).

Illustration 135 g00894610

93. Remove outer cone (173) from the synchronizer.
94. Turn the synchronizer onto the other side and
repeat Step 92 and Step 93.

Illustration 132 g00894603

90. Use Tooling (L) in order to remove circlip (170) that
secures synchronizer (171) to output shaft (132).

Illustration 136 g00894630

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
Illustration 133 g00894604 recommended tooling to release the spring force.
31200300 27
Disassembly and Assembly Section

95. Remove outer ring (173) that is shown in

Illustration 135 in order to remove energizers
(175), springs (176), and three steel balls (177).
Note: When outer ring (174) is removed, take care not
to lose energizers (175), springs (176), or steel balls
(177).

Illustration 140 g00894689

99. Remove thrust bearing (183) from the top of
forward primary gear (184).

Illustration 137 g00894637

96. Remove third gear (178) and needle bearings (179)
from output shaft (132).

Illustration 141 g00894697

100.Remove forward primary gear (184), needle
bearings (185), spacer (186), and thrust washer
(187).

Illustration 138 g00894664

97. Remove split seals (180) from forward/reverse shaft
(134). Check the split seals for damage and replace the
split seals, if necessary.

Illustration 142 g00894711

101.Use a suitable screwdriver in order to remove snap
ring (188).

Illustration 139 g00894682

98. Use Tooling (J) in order to remove input drive gear (133),
spacer (181) and taper roller bearing (182) from forward/
reverse shaft (134).
28 31200300
Disassembly and Assembly Section

Illustration 143 g00894719 Illustration 146 g00894935

102.Remove top plate (189) from the clutch assembly.

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
106.Remove piston spring (193), support (194) for the
piston spring, and spring retainer (195) from the
Illustration 144 g00894726
clutch assembly.
103.Remove friction plate (190) and clutch plate
(191).
104.Repeat Step 103 until the six friction plates and
the six clutch plates are removed.

Illustration 147 g00894936

107.Use a suitable air line in order to lift the piston.

Illustration 145 g00894934

Typical Example of Tooling (L)
105.Use a suitable press in order to take the load off
circlip (192) and remove the circlip with Tooling (L).

Illustration 148 g00894937

108.Remove piston (196) from the clutch assembly.
Note: Oil is located behind the piston. When the piston
is removed, drain the oil into a suitable container.
31200300 29
Disassembly and Assembly Section

Illustration 149 g00894939 Illustration 152 g00894955

109.Use Tooling (M) in order to remove taper roller 112.Remove needle bearings (201) and thrust
bearing (197) from forward/reverse shaft (134). washer (202) from forward/reverse shaft (134).
113.Turn the forward/reverse shaft onto the opposite
end and repeat Steps 101 through 108.

Illustration 150 g00894940

110.Remove thrust washer (198) and thrust bearing
(199) from forward/reverse shaft (134). Illustration 153 g00895005
114.Use Tooling (M) in order to remove taper roller
bearings (203) and (204) from the ends of reverse
idler shaft (135).

Illustration 151 g00894945

111.Remove reverse primary gear (200) from forward/
reverse shaft (134).
Illustration 154 g00896478
115.Use Tooling (M) in order to remove taper roller
bearing (205) from countershaft (136).
116.Remove the components from one end of the
countershaft. The components on the countershaft
of a transmission with five speeds are different
from the components on the countershaft of a
transmission with four speeds.
30 31200300
Disassembly and Assembly Section

Illustration 155 g00895231 Illustration 158 g00895239

Countershaft of Transmission with Four Speeds Countershaft of Transmission with Five Speeds
b. Use Tooling (J) in order to remove fifth gear (208),
synchronizer (209) for the fifth speed, and taper roller
bearing (210). Then remove needle bearings (211).
c. Repeat Step 92 and Step 93 for the synchronizer for the
fifth speed.

Illustration 156 g00895232

Countershaft of Transmission with Four Speeds
a. Use Tooling (M) in order to remove taper roller bearing
(206) from countershaft (136). Then remove spacer (207)
from the countershaft.
Illustration 159 g00894629
d. Turn the synchronizer onto the other side and remove
circlip (212).
e. Repeat Step 95 for the synchronizer for the fifth speed.

Illustration 157 g00895237

Countershaft of Transmission with Five Speeds

Illustration 160 g00895981

117.Use a suitable allen wrench in order to remove four
allen head screws (213) that secure oil tube (214)
to the inside of transmission housing (21).
31200300 31
Disassembly and Assembly Section

Illustration 161 g00895983 Illustration 164 g00895986

118. Remove oil tube (214) and two O-ring seals (215), and 122.Remove suction pipe (224) from scavenge pump
inspect the O-ring seals for damage. Replace the O-ring (223).
seals, if necessary.

Illustration 165 g00895987

Illustration 162 g00895984
123.Remove scavenge pump (223) from transmission
119.Use a suitable allen wrench in order to remove allen housing (21).
head screw (217) and washer (218). Remove bolt
(219) and washer (220).

Illustration 166 g00895989

124.Use a suitable allen wrench in order to remove
Illustration 163 g00895985
allen head screw (224).
120.Remove baffle plate (221) from transmission
housing (21).
121.Remove bolts (222) that secure scavenge pump
(223) to transmission housing (21).
32 31200300
Disassembly and Assembly Section

Illustration 167 g00895990 Illustration 170 g01040558

125.Remove back plate (225) of the scavenge pump. 129.Attach Tooling (A) and Tooling (E) onto
transmission housing (21). Use Tooling (A),
Tooling (E), and a suitable lifting device in order to
turn the transmission housing onto the side. The
weight of the transmission housing is
approximately 135 kg (298 lb).

Illustration 168 g00895991

126.Remove annulus (226) of the scavenge pump.

Illustration 171 g00895994

130.Remove bolts (228) that secure charge pump (229)
to transmission housing (21).

Illustration 169 g00895992

127.Remove rotor (227) of the scavenge pump.
128.Check the components of the scavenge
pump for wear and for damage. Replace any
components that are worn or damaged.

Illustration 172 g00895995

131.Remove charge pump (229) from transmission housing
(21) and remove O-ring seal (230). Check the O-ring seal
for damage and replace the O-ring seal, if necessary.
31200300 33
Disassembly and Assembly Section

Illustration 173 g00896087 Illustration 176 g00896136

132.Remove O-ring seal (231) and check the O-ring seal for 135.Use a suitable press in order to remove pump
damage. Replace the O-ring seal, if necessary. Use a coupling (238) and the bearing from the cover
suitable allen wrench in order to remove allen head screw plate (233).
(232).

Illustration 177 g00896137

Illustration 174 g00896134
136.Use Tooling (I) in order to remove circlip (239) that
133.Turn the charge pump onto the other side, and secures bearing (237) to pump coupling (238).
remove cover plate (233), annulus (234) and rotor
(235). Check the annulus and the rotor for wear,
and replace the annulus or the rotor, if necessary.

Illustration 178 g00896138

137.Install bolt (49) and washer (50) from the end of the
fan drive shaft onto the end of pump coupling (238)
Illustration 175 g00896135
in order to allow the use of Tooling (D). Use Tooling
134.Use Tooling (G) in order to remove circlip (236) that (D) in order to remove bearing (237) from the pump
secures bearing (237) in cover plate (233). coupling.
34 31200300
Disassembly and Assembly Section

Illustration 179 g00896463 Illustration 182 g00896466

141.Remove thrust bearing (243) from the rear of cover
(242).

Illustration 180 g00896464

138.Use Tooling (H) and a suitable mallet in order to remove
needle bearing (240) for the pump drive shaft. Illustration 183 g00896467
142.Check seal (244) for damage and replace the seal,
if necessary.

Illustration 181 g00896465

139.Remove bolts (241) that secure cover (242) for
the pump drive gear.
Illustration 184 g00896468
140.Install three of bolts (241) into the three tapped 143.Remove pump drive gear (245).
holes in cover (242). Use these bolts in order to
release the cover.

Illustration 185 g00896469

31200300 35
Disassembly and Assembly Section

144.Remove O-ring seal (246) from pump drive gear (245),

and inspect the O-ring seal for damage. Replace the O-
ring seal, if necessary.

Illustration 189 g00896473

148.Remove thrust washer (250) from support (249).

Illustration 186 g00896470

145.Check bush (247) for damage and replace the bush, if
necessary.

Illustration 190 g00896474

149.Remove bolts (251) that secure valve housing (43)
to transmission housing (21).
Illustration 187 g00896471
146.Use a suitable allen wrench in order to remove
allen head screws (248) that secure support (249).

Illustration 191 g00896475

150.Valve housing (43) is seated on locating dowels.
Use a suitable screwdriver in order to separate the
valve housing from transmission housing (21). Do
Illustration 188 g00896472
not lose the three O-ring seals that are behind the
147.Use a mallet and a suitable drift in order to punch valve housing.
the support from transmission housing (21).
36 31200300
Disassembly and Assembly Section

Illustration 192 g00896476 Illustration 195 g00896535

151.Remove O-ring seals (252) from valve housing (43), 156.Cover (263) is seated on locating dowels. Use a
and inspect the O-ring seals for damage. Replace suitable screwdriver in order to separate the cover
the O-ring seals, if necessary. Remove any shims from transmission housing (21).
from the valve housing.

Illustration 196 g00896537

Illustration 193 g00896477 157.Use Tooling (H) in order to remove seal (264) that is
152.Use a suitable allen wrench in order to remove shown in Illustration 195 from cover (263).
allen head screw (253) and locking plate (254).
Remove solenoid (255) and refer to Step 9 for
details of removing the O-ring seals.
153.Remove nuts (256) and washers (257) in order
to remove solenoids (258) and (259). Refer to
Step 24 for details of removing the spools and the
O-ring seals.

Illustration 197 g00896539

158.Use Tooling (N) in order to remove bearing cups
(265) and (266) from transmission housing (21).

Illustration 194 g00896533

154.Use Tooling (N) in order to remove bearing cups
(260) and (261) from transmission housing (21).
155.Remove bolts (262) that secure cover (263)
for the output shaft and the countershaft to
transmission housing (21).
31200300 37
Disassembly and Assembly Section

Illustration 198 g00896540 Illustration 201 g00896635

159.Use a suitable allen wrench in order to remove 162.Remove O-ring seals (274) and (275) from torque
allen head bolts (267) that secure speed sensors converter relief valve (273). Inspect the O-ring
(268) and (269) to transmission housing (21). seals for damage and replace the O-ring seals, if
Remove bolt (270) that secures speed sensor necessary.
(271) and remove the three sensors (not shown)
from the transmission housing.

Illustration 202 g00896637

163.Remove pressure regulator valve (276) from
Illustration 199 g00896542 transmission housing (21).
160.Remove O-ring seals (272) from speed sensors
(268), (269) and (271). Inspect the O-ring seals for
damage and replace the O-ring seals, if necessary.

Illustration 203 g00896638

164.Remove O-ring seals (277) and (278) from
pressure regulator valve (276). Inspect the O-ring
Illustration 200 g00896634 seals for damage and replace the O-ring seals, if
161.Remove torque converter relief valve (273) from necessary.
transmission housing (21).
38 31200300
Disassembly and Assembly Section

Transmission - Assemble NOTICE

Keep all parts clean from contaminants.
Assembly Procedure Contaminants may cause rapid wear and shortened
component life.
Table 3

Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
B 1U-7262 Telescoping Magnet 1
C 1U-8241 Lifting Sling 1
D 1P-2320 Combination Puller 1
E 138-7573 Link Bracket 3
F 1P-1857 Retaining Ring Pliers 1
G 156-7100 Slide Hammer Puller Gp 1
H 1P-0510 Driver Gp 1 Illustration 204 g00900310
1. Install O-ring seals (277) and (278) onto pressure
I 1P-1856 Retaining Ring Pliers 1
regulator valve (276).
J 1P-2321 Combination Puller 1
K 4C-8359 Eyebolt(M12) 1
L 1P-1860 Retaining Ring Pliers 1
M 8B-7550 Push-Puller Leg 1
8H-0663 Bearing Puller Gp 1
N 1P-0074 Slide Hammer Puller Gp 1

Personal injury or death can result from improper

lifting or blocking. Illustration 205 g00899489
When a hoist or jack is used to lift any part or 2. Install pressure regulator valve (276) into
component, stand clear of the area. Be sure the transmission housing (21).
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component Illustration 206 g00900314
containing fluids. 3. Install O-ring seals (274) and (275) onto torque
Dispose of all fluids according to local regulations and converter relief valve (273).
mandates.
31200300 39
Disassembly and Assembly Section

Illustration 207 g00899490 Illustration 210 g00901654

4. Install torque converter relief valve (273) into 7. Install O-ring seals (64) and (65) onto valve spool
transmission housing (21). (63). Install the spool into modulating valve (58).

Illustration 208 g00903008 Illustration 211 g00901655

5. Use a suitable drift in order to remove core plug 8. Install solenoid (62), washer (61), and nut (60).
(279) from transmission housing (21). Install O-ring seals (59) onto modulating valve (58).
Note: It is necessary to remove the core plug in order to
shim the forward/reverse shaft.

Illustration 212 g00901649

9. Install O-ring seals (32) and (33) onto the valve
Illustration 209 g00899492 spool of solenoid (31).
6. Use Tooling (H) in order to install seal (264) that is
shown in Illustration 217 into cover (263).
40 31200300
Disassembly and Assembly Section

Illustration 213 g00901651 Illustration 216 g00899524

10. Install solenoid (31), locking plate (30), and allen 16. Refer to Step 7 for details of installing the O-ring
head screw (29) onto actuator (20). seals on the spools of solenoids (258) and (259).
11. Repeat Step 9 and Step 10 in order to install 17. Install the two spools and solenoids (258) and
solenoid (34) onto actuator (20). (259) into valve housing (43). Install nuts (256)
and washers (257) in orderto secure the solenoids
to the spools.
18. Refer to Step 9 for details of installing the O-ring
seals on the spool of solenoid (255).
19. Install solenoid (255), locking plate (254), and
allen head screw (253) onto valve housing (43).
20. Install O-ring seals (252) into valve housing (43).

Illustration 214 g00901652

12. Install O-ring seals (25) and (26) onto neutralizing
piston (23) and actuator piston (24). Then install
the two pistons into actuator (20).

Illustration 217 g00899601

21. Install cover (263) and bolts (262) onto
transmission housing (21).
22. Install valve housing (43) and bolts (251) onto
transmission housing (21).

Illustration 215 g00901653

13. Repeat Step 12 in orderto install neutralizing
piston (27) and actuator piston (28).
14. Install O-ring seals (22) onto actuator (20).
15. Repeat Steps 9 through 14 in orderto assemble
the actuator for the second and fourth speeds.

Illustration 218 g01040680

31200300 41
Disassembly and Assembly Section

23. Install Tooling (E) onto transmission housing (21).

Use Tooling (E) and a suitable lifting device in order
to turn the transmission housing so that the bell
housing is facing downward. Lower the
transmission housing onto suitable cribbing. The
weight of the transmission housing is
approximately 135 kg (298 lb).

Illustration 222 g00900218

26. Install annulus (227) for scavenge pump (223).
Ensure that the chamfered edge of the annulus is
facing downward.

Illustration 219 g00899635

24. Install bearing cups (260), (261), (264), and (265)
into transmission housing (21).

Illustration 223 g00900355

27. Install rotor (226) of the scavenge pump. Ensure
that the chamfered edge of the rotor is facing
downward.

Illustration 220 g00899636

Illustration 224 g00900366

28. Install back plate (225) of the scavenge pump.
Ensure that the bolt holes are correctly aligned.
Illustration 221 g00899638
25. Use Tooling (H) and a suitable mallet in order to
install needle bearing (240) for the pump drive
shaft. The needle bearing must be installed 5 mm
(0.197 inch) below the edge of transmission
housing (21).
42 31200300
Disassembly and Assembly Section

Illustration 225 g00900382 Illustration 228 g00900415

29. Use a suitable allen wrench in order to install allen 34. Use a suitable allen wrench in order to install allen
head screw (224) that secures the back plate to the head screw (217) and washer (218). Install bolt
scavenge pump. (219) and washer (220).

Illustration 226 g00900399 Illustration 229 g00900417

30. Invert scavenge pump (223). Install the scavenge 35. Install O-ring seals (215) and oil tube (214).
pump onto transmission housing (21) in the
orientation that is shown in Illustration 226.
31. Install suction pipe (224) onto scavenge pump
(223).

Illustration 230 g00900418

36. Use a suitable allen wrench in order to install four
allen head screws (213) that secure oil tube (214) to
the inside of transmission housing (21).
Illustration 227 g00900406
32. Install bolts (222) in order to secure suction pipe
(224) and scavenge pump (223) to transmission
housing (21).
Note: The two bolts that secure the suction pipe are
longer than the other two bolts.
33. Install baffle plate (221) into transmission housing
(21).
31200300 43
Disassembly and Assembly Section

39. Install outer cone (173) so that the three lugs

on the outer cone are aligned with the three
energizers.

Illustration 231 g00900445

37. Install needle bearings (179) and third gear (178)
onto output shaft (132).
Illustration 234 g00900531
40. Install plate (172) for the synchronizer.
41. Turn the synchronizer onto the other side and
repeat Step 39 and Step 40.

Illustration 232 g00900447

Illustration 235 g00900532

42. Install synchronizer (171) for the third speed and
fourth speed onto output shaft (132).

Illustration 233 g00900449

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established Illustration 236 g00900533
assembly procedure and wear protective
43. Use Tooling (L) in order to install circlip (170) that
equipment.
secures synchronizer (171) to output shaft (132).
38. Install springs (176), steel balls (177), and
energizers (175) around the edge of the inner
sprocket for the synchronizer for the third speed
and fourth speed. At the same time install outer
ring (174) around the inner sprocket.
44 31200300
Disassembly and Assembly Section

46. Install washer (166) between spacer (163) and

tachometer drive (162). Use a suitable press and
Tooling (L) in order to install circlip (165).
Note: The spacer in Step 46 is replaced by a fifth gear
for transmissions that are equipped with five speeds.
47. Install the tachometer drive onto the output
shaft. The components on the output shaft of a
transmission with five speeds are different to the
components on the output shaft of a transmission
with four speeds.

Illustration 237 g00900534

44. Install spacer (169) and needle bearings (168) onto
output shaft (132).

Illustration 241 g00900538

Output Shaft of a Transmission with Four Speeds
a. Install tachometer drive (162) and spacer (163) onto output
shaft (132).

Illustration 238 g00900535

45. Install fourth gear (167) onto output shaft (132).

Illustration 242 g00900539

Output Shaft of a Transmission with Five Speeds
b. Install tachometer drive (162) and fifth gear (164) onto
output shaft (132).
Illustration 239 g009005356

Illustration 243 g00900540

Illustration 240 g00900537
31200300 45
Disassembly and Assembly Section

48. Use a suitable press in order to install taper roller the edge of inner sprocket (155). Install outer ring
bearing (161) onto output shaft (132). (154) over the inner sprocket at the same time as
holding the locating pins, springs and energizers in
position.

Illustration 244 g00900541

49. Install needle bearings onto the other end of output
shaft (132). Illustration 247 g00900546
52. Install ring (152) so that the three lugs on the outer
cone are aligned with the three energizers.

Illustration 245 g00900542

50. Install second gear (159) onto output shaft (132).
Illustration 248 g00900554
Example of Damaged Inner Cone (150) and Damaged Friction Ring (151).
53. Check the surfaces of inner cone (150) and friction
ring (151). Replace the inner cone of the friction ring
with a new part if any of the following damage is
found:
• Scuffing
• Burn marks.

Illustration 246 g00900543

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment. Illustration 249 g00900589
51. Begin the assembly of the synchronizer for the first 54. Install friction ring (151) for the synchronizer.
speed and second speed by positioning springs
(157), springs (158), and energizers (156) around
46 31200300
Disassembly and Assembly Section

Illustration 250 g00900595 Illustration 253 g00900603

55. Install inner cone (150) for the synchronizer. 59. Install synchronizer (148) for the first speed and
second speed onto output shaft (132).

Illustration 251 g00900596

56. Install plate (149) for the synchronizer. Illustration 254 g00900853
60. Use Tooling (L) in order to install circlip (147) that
retains synchronizer (148) for the first speed and
second speed.

Illustration 252 g00900544

57. Turn the synchronizer onto the other side and
install connecting blocks (153).
Illustration 255 g00900854
58. Repeat Steps 52 through 56 for the second side
of the synchronizer. 61. Install needle bearings (146) onto output shaft
(132).
31200300 47
Disassembly and Assembly Section

Illustration 256 g00900856 Illustration 259 g00991739

62. Install first gear (143) and thrust washer (144) onto a. Install spacer (207) onto countershaft (136). Then use a
output shaft (132) and then use a suitable press in suitable press in order to install taper roller bearing (206)
onto the countershaft.
order to install taper roller bearing (145) onto the
output shaft.

Illustration 260 g00900857

Countershaft of a Transmission with Five Speeds
Illustration 257 g00991732
b. Install needle bearings (211) and fifth gear
63. Use a suitable press in order to install taper
roller bearing (205) onto the first gear end of c. Repeat Step 38 and Step 40 for the synchronizer for the
fifth speed.
countershaft (136).
64. Install the components onto the other end of the
countershaft. The components on the countershaft
of a transmission with five speeds are different
from the components on the countershaft of a
transmission with four speeds.

Illustration 261 g00900858

d. Turn the synchronizer onto the other side and install circlip
(212).

Illustration 258 g00900432

Countershaft of a Transmission with Four Speeds
48 31200300
Disassembly and Assembly Section

Illustration 262 g00900859 Illustration 265 g00900861

e. Install synchronizer (209) for the fifth speed and then use
a suitable press in order to install taper roller bearing
(210).

Illustration 266 g00900862

Illustration 263 g00991740

65. Use a suitable press in order to install taper roller Improper assembly of parts that are spring loaded
bearings (203) onto reverse idler shaft (135). Invert can cause bodily injury.
the shaft and install taper bearing (204) (not shown).
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
67. Install piston spring (193), support (194) for the
piston spring, and spring retainer (195) into the
clutch assembly. Use a suitable press in order to
compress the spring. Then use Tooling (L) in order
to install circlip (192).

Illustration 264 g00900860

66. Install piston (196) into the forward clutch assembly.

Illustration 267 g00900863

68. Install clutch plate (191) and friction plate (191).
31200300 49
Disassembly and Assembly Section

Illustration 268 g00902087 Illustration 271 g00900866

69. Use forward primary gear (184) in order to align 73. Install thrust washer (187), needle bearings (185),
the clutch plate and the friction plate. spacer (186), and forward primary gear (184).
70. Repeat Step 68 and Step 69 until the six clutch
plates and six friction plates are installed.

Illustration 272 g00900867

74. Install thrust bearing (183) onto the top of forward
Illustration 269 g00900864 primary gear (184).
71. Install top plate (189) into the clutch assembly.

Illustration 273 g00900868

Illustration 270 g00900865 75. Install input drive gear (133) and spacer (181)
72. Use a suitable screwdriver in order to install snap onto forward/reverse shaft (134). Ensure that the
ring (188). boss of the input drive gear is facing downward.
76. Use a suitable press in order to install taper roller
bearing (182) onto forward/reverse shaft (134).
77. Turn the forward/reverse shaft onto the opposite
end and repeat Steps 66 through 72 for the
reverse clutch assembly.
50 31200300
Disassembly and Assembly Section

Illustration 274 g00900869 Illustration 277 g00991741

78. Install thrust washer (202) and needle bearings 81. Heat taper roller bearing (197) to a maximum of
(201) onto forward/reverse shaft (134). 135 °C (275 °F). Install the bearing onto forward/
reverse shaft (134). Reset the bearing with a
suitable driver after the mating parts have reached a
uniform temperature.

Illustration 275 g00900870

79. Install reverse primary gear (200) onto forward/
reverse shaft (134).
Illustration 278 g00900872
82. Install split seals (180) onto forward/reverse shaft
(134).

Illustration 276 g00900871

80. Install thrust bearing (199) and thrust washer (198)
onto forward/reverse shaft (134).
Illustration 279 g00900907
83. Use a suitable hammer to install pin (142) in order to
install fork (137) onto shift rail (139) for the first
speed and second speed.
31200300 51
Disassembly and Assembly Section

88. Install countershaft (136) into the position for the

reverse idler shaft. The weight of the countershaft
is approximately 14 kg (31 lb).

Illustration 280 g00900908

84. Use a suitable hammer to install pin (141) in order to
install fork (138) onto shift rail (140) for the third
speed and fourth speed. Illustration 283 g00900953
89. Place a pinch bar under input drive gear (133) of
forward/reverse shaft (134). Use the pinch bar in
order to raise the forward/reverse shaft slightly.
Keep the forward/reverse shaft and output shaft
(132) raised and move countershaft (136) into the
position that is shown in Illustration 283.
90. Maintain forward/reverse shaft (134) and output
shaft (132) in a slightly raised position and install
reverse idler shaft (135). Ensure that the threaded
end of the reverse idler shaft is facing downward.

Illustration 281 g00900922

85. Install selector forks (137) and (138) and shift rails
(139) and (140) onto output shaft (132).

Illustration 284 g00900958

91. Lower output shaft (132) and forward/reverse
shaft into the bearing cups. Then remove the pinch
bar and Tooling (K). Ensure that the bearings on
the bottoms of the following shafts are properly
seated in the bearing cups:
Illustration 282 g00900938
86. Install Tooling (K) on the end of output shaft • Output shaft (132)
(132) and use a suitable lifting device to lift the • Countershaft (136)
output shaft, shift rails and selector forks into
• Reverse idler shaft (135)
transmission housing (21). The weight of the
output shaft is approximately 28 kg (62 lb). Move • Forward/reverse shaft (134)
the output shaft into position but do not lower the
92. Ensure that the ends of shift rails (139) and (140)
output shaft fully into the bearing sleeve.
are properly located in transmission housing (21).
87. Install forward/reverse shaft (134) into
93. Transmissions with five speeds are equipped with
transmission housing (21). The weight of the
a shift rail and a fork for the fifth speed.
forward/reverse shaft is approximately 20 kg
(44 lb).
52 31200300
Disassembly and Assembly Section

Illustration 285 g00900974 Illustration 288 g00900995

a. Install O-ring seal (131) onto shift rail (129), 95. Use Tooling (I) in order to install circlip (125) onto
and slide selector fork (130) onto the shift rail. pump drive shaft (118).
b. Install shift rail (129) into the hole in
transmission housing (21). At the same time
engage selector fork (130) with synchronizer
(209) for the fifth speed.

Illustration 289 g00900998

96. Install thrust washer (124) and needle bearings
(123) onto pump drive shaft (118).
Illustration 286 g00900979 97. Install O-ring seal (119) onto pump drive shaft
c. Install guide rail (127) into transmission housing (21) and (118).
use a suitable hammer in order to install pin (128).

Illustration 290 g00901004

Illustration 287 g00900993 98. Install idler gear (120) and thrust washer (121) onto
94. Use a suitable press in order to install drive gear pump drive shaft (118). Use a suitable press in
(126) onto pump drive shaft (118). order to install bearing carrier (122) onto the pump
drive shaft.
31200300 53
Disassembly and Assembly Section

Illustration 291 g00901011 Illustration 294 g00901259

99. Install pump drive shaft (118) into the 102.Install needle bearing (114) onto fan drive shaft
transmission. Ensure that the tangs on the rotor of (108).
scavenge pump (223) are aligned with the slots on
the pump drive shaft.
Note: The gear on the end of the pump drive shaft may
be at a slightly lower level than the gears that are on
the ends of the other shafts. This difference in levels will
be automatically corrected when the transmission
cover is installed.

Illustration 295 g00901258

103.Install idler gear (111) and thrust washer (112) and
then use a suitable press in order to install taper
roller bearing (113).

Illustration 292 g00901257

100.Use a suitable press in order to install drive gear
(116) and taper roller bearing (117) onto fan drive
shaft (108).
Note: Ensure that the boss of drive gear (116) faces the
middle of fan drive shaft (108).

Illustration 296 g00901260

104.Install split seal (110) onto fan drive shaft (108).

Illustration 293 g00901824

101.Install thrust washer (115) onto fan drive shaft
(108). Ensure that the pin on the fan drive shaft
engages with the slot in the thrust washer.
54 31200300
Disassembly and Assembly Section

Illustration 297 g00901261 Illustration 300 g00901264

105.Install bearing cup (109) for the fan drive shaft into 108.Use a suitable press in order to install bearing
transmission housing (21). carrier (106) onto input shaft (102).

Illustration 298 g00901262 Illustration 301 g00901265

106.Install fan drive shaft (108) into transmission 109.Install split seal (105) onto input shaft (102).
housing (21).

Illustration 302 g00901266

Illustration 299 g00901263 110.Install gear (104) onto input shaft (102), and use
107.Install roller bearing (107) for the input shaft into Tooling (I) in order to install circlip (103).
transmission housing (21). Note: Ensure that the boss of gear (104) is at the same
side as circlip (103).
31200300 55
Disassembly and Assembly Section

113.Use Tooling (H) in order to install seals (91) and

(92) into transmission cover (10).
Note: Install the seals from the top side of the cover.
114.Turn the transmission cover onto the other side
and install the oil tube into the transmission cover.
The position of the oil tube in a transmission with
five speeds is different to the position of the oil
tube in a transmission with four speeds.

Illustration 303 g00996881

111.Install input shaft (102) into transmission housing
(21).

Illustration 307 g00901269

Cover of a Transmission with Four Speeds
a. Install an O-ring seal at both ends of oil tube (97). Install
the oil tube and four allen head screws (96) onto the
transmission cover.

Illustration 304 g00901268

112.Install thrust washer (101) and thrust bearing (100)
onto the end of input shaft (102).

Illustration 308 g00901270

Cover of a Transmission with Five Speeds
b. Install an O-ring seal at both ends of oil tube (99). Install
the oil tube and four allen head screws (98) onto the
transmission cover.

Illustration 305 g00902088

Illustration 309 g00901271

Illustration 306 g00902089

56 31200300
Disassembly and Assembly Section

115.Install an O-ring seal at both ends of oil tube (95).

Install the oil tube and four allen head screws (94)
onto the transmission cover.

Illustration 313 g00901299

119.Install O-ring seals (81) onto transmission housing
(21).
Illustration 310 g00901273
116.Install bearing carrier (93) for the input shaft into the
transmission cover.

Illustration 314 g01040681

120.Install Tooling (E) to the three 10 mm holes in
transmission cover (10). Use a suitable lifting
Illustration 311 g00901289 device and Tooling (E) in order to lift the
117.Use Tooling (F) in order to install circlip (90) and transmission cover. The weight of the transmission
then install bearing sleeve (88). cover is approximately 42 kg (93 lb).

Illustration 312 g00901298 Illustration 315 g01040683

118.Install bearing sleeves (84), (85), (86), and (87) into 121.Use Tooling (E) and the suitable lifting device
the transmission cover. in order to lower transmission cover (10) onto
transmission housing (21). On transmissions with
four speeds, shift rails (139) and (140) will engage
with the transmission cover first. On transmissions
with five speeds, the shift rail for the fifth speed
will engage with the transmission cover first.
31200300 57
Disassembly and Assembly Section

122.Use the suitable lifting device to fully lower float is not within these parameters you must
transmission cover (10) onto transmission housing complete the following procedure:
(21). Ensure that the two locating pins that are a. Remove the components that were installed in Step 124
between the interface of the transmission cover and Step 123. Then Refer to Step 121 in order to remove
and the transmission housing are engaged. the transmission cover from the transmission housing.

Illustration 316 g00901337 Illustration 319 g00902508

123.Install supports (79) for the harness and 22 bolts b. Turn over transmission cover (10) and remove
(80) in order to secure the transmission cover to bearing sleeve (88). Install the required
thickness of shims against circlip (90) and then
the transmission housing. install the bearing sleeve on top of the shims.
c. Repeat Steps 121 through 125.

Illustration 317 g00901648

124.Install fan drive (46), O-ring seal (45b), washer Illustration 320 g00901340
(45a), and bolt (44) on the end of fan drive shaft
126.Make sure that shift rail (76) and shift rail (77) are
(108).
in the neutral position, and install detent balls (78)
into the cavity.

Illustration 318 g00902415

125.Install Tooling (P) and place a suitable screwdriver Illustration 321 g00901343
between fan drive (46) and transmission cover
127.Install cap (75) into transmission cover (10).
(10) in order to check the float on the fan drive
shaft. The float must be between 0.0254 mm
(0.001 inch) and 0.0762 mm (0.003 inch). If the
58 31200300
Disassembly and Assembly Section

Illustration 322 g00901353 Illustration 325 g00901784

130.Use a suitable press in order to install bearing (69)
onto idler (67). Then use the press in order to install
mounting flange (70) on the bearing. Install snap
ring (68) that secures the bearing inside the
mounting flange.

Illustration 323 g00901355

Improper assembly of parts that are spring loaded

can cause bodily injury. Illustration 326 g00901795
To prevent possible injury, follow the established 131.Install allen head screws (66) through mounting
assembly procedure and wear protective flange (70) in order to install idler (67) for the fan
equipment. drive.
128.Install O-ring seals (74) onto spring retainers (71).
Install detent balls (73), springs (72), and spring
retainers (71) into transmission cover (10).

Illustration 327 g00901657

132.Install O-ring seal (56) onto speed sensor (55).

Illustration 324 g00901656

129.Position modulating valve (58) and install bolts (57)
onto transmission cover (10).
31200300 59
Disassembly and Assembly Section

Illustration 328 g00901658 Illustration 331 g00901661

133.Install bolt (54) and speed sensor (55). 137.Install bolts (47) and access panel (48) onto
134.Install temperature sensor (53) into transmission transmission cover (10).
housing (21).

Illustration 332 g00902784

Illustration 329 g00901659 138.Install Tooling (A) and use a suitable lifting device
135.Install roller bearing (52) onto the end of pump drive in order to lift the transmission. The weight of the
shaft (118) and use Tooling (F) in order to install transmission is approximately 350 kg (772 lb).
circlip (82). Rotate the transmission to the orientation that is
shown in Illustration 333 and then lower the
transmission.

Illustration 330 g00901660

136.Install spacer (51), washer (50), and bolt (49) onto
Illustration 333 g00902785
the end of pump drive shaft (118).
139.Install Tooling (C) and a suitable lifting device in
order to lift the transmission. The weight of the
transmission is approximately 350 kg (772 lb).
Rotate the transmission so that the bell housing
is facing upward. Position a piece of cribbing
that measures at least 10 cm (3.9 inch) by 5 cm
(2 inch) under each end of the transmission and
then lower the transmission onto the cribbing.
140.Remove the plug from valve housing (43).
60 31200300
Disassembly and Assembly Section

on the forward/reverse shaft. The float must be

between 0.0254 mm (0.001 inch) and 0.0762 mm
(0.003 inch).
145.If the float on the reverse idler shaft or on the
forward/reverse shaft is not between 0.0254 mm
(0.001 inch) and 0.0762 mm (0.003 inch),
complete the following procedure:

Illustration 334 g00902807

141.Install an M12 bolt that is at least 80 mm long into
the end of the reverse idler shaft. Use the bolt in
order to rotate all of the shafts for several
revolutions. This rotation will ensure that the
bearings are seated before the floats on the shafts
are checked.
Illustration 337 g00902832
a. Remove bolts (251) in order to remove valve housing (43)
from transmission housing (21).

Illustration 335 g00902808

142.Install Tooling (P) and place a suitable pinch
bar between the bolt head and valve housing
(43) in order to check the float on the reverse Illustration 338 g00902848
idler shaft. The float must be between 0.0254 mm b. Install shims or spacers for reverse idler shaft
(0.001 inch) and 0.0762 mm (0.003 inch). (135) and forward/reverse shaft (134), as
143.Install a hose fitting onto the lube port of valve required.
housing (43). Insert a 60 mm long M12 bolt into c. Add sealant to the mating surface of
the end of the fitting. transmission housing (21).
d. Refer to Illustration 337 in order to install bolts
(251) and valve housing (43) onto transmission
housing (21).

Illustration 336 g00902826

144.Install Tooling (P) and pass a suitable
screwdriver through the hole for the core plug. Illustration 339 g00902915
Use the screwdriver as a lever and check the float
31200300 61
Disassembly and Assembly Section

146. Install an 80 mm long M12 bolt through cover

(263) onto the end of the countershaft. Install
Tooling (P) and pass a suitable screwdriver
through the hole for the transmission speed
sensor. Use the screwdriver as a lever and check
the float on the countershaft. The float must be
between 0.0254 mm (0.001 inch) and 0.0762 mm
(0.003 inch).

Illustration 342 g00902930

b. Install shims or spacers for countershaft (136)
and output shaft (132), as required.
c. Add sealant to the mating surface of
transmission housing (21).
d. Refer to Illustration 341 in order to install
bolts (262) and cover (263) onto transmission
housing (21).

Illustration 340 g00902920

147.Install Tooling (P) and place a suitable pinch bar
between the bottom of output shaft (132) and the
bench in order to check the float on the output
shaft. The float must be between 0.0254 mm
(0.001 inch) and 0.0762 mm (0.003 inch).
148.If the float on the countershaft or on the output
shaft is not between 0.0254 mm (0.001 inch) and
0.0762 mm (0.003 inch), complete the following
procedure:

Illustration 343 g00901702

149.Use a suitable press in order to install bearing
(237) onto pump coupling (238). Then use Tooling
(I) in order to install circlip (239) that secures the
bearing to the pump coupling.

Illustration 341 g00902925

a. Remove bolts (262) in order to remove cover (263) from
transmission housing (21).

Illustration 344 g00901706

150.Use a suitable press in order to install bearing
(237) and pump coupling (238) into cover plate
(233). Then use Tooling (G) in order to install
circlip (236) that secures the bearing to the cover
plate.
62 31200300
Disassembly and Assembly Section

Illustration 345 g00901713 Illustration 348 g00901735

151.Install rotor (234) and annulus (235) into the 154.Use bolts (228) in order to install charge pump
housing of charge pump (229). Ensure that the (229) onto transmission housing (21). Tighten bolts
chamfered edge of the rotor and the chamfered (228) diagonally.
edge of the annulus are facing downward. Then fit Note: Ensure that the bolt holes in the charge pump are
cover plate (233) onto the housing of the charge aligned with the bolt holes in the transmission housing.
pump.
Note: Ensure that the bolt holes of the cover plate and
the bolt holes of the housing are aligned.

Illustration 349 g00900213

155.Install thrust washer (250) onto support (249).
Ensure that the rough side of the thrust washer is
Illustration 346 g00901719 facing outward, and ensure that the small pin on
152.Turn the charge pump onto the other side, and the support is engaged with the hole in the thrust
install allen head screw (232) in order to secure washer.
cover plate (233) to the housing of the charge
pump. Install O-ring seal (231).

Illustration 350 g00902090

156.Install support (249) into transmission housing (21).
Illustration 347 g00901730 Ensure that the oil galleries on the support are
153.Install O-ring seal (230) in the groove on aligned with the holes in the transmission housing.
transmission housing (21).
31200300 63
Disassembly and Assembly Section

Illustration 351 g00900214 Illustration 354 g00900216

157.Install support (249) onto transmission housing (21) 160.Install thrust bearing (243) onto the rear of cover
with five allen head screws (248). (242) for the pump drive gear. Ensure that the two
small pins on the cover engage with the holes in
the thrust bearing.

Illustration 352 g00900350

158. Install O-ring seal (246) onto pump drive gear
(245). Illustration 355 g00900217
161.Install cover (242) for the pump drive gear onto
transmission housing (21) with bolts (241). Tighten
the bolts (241) in a diagonal pattern.

Illustration 353 g00900215

159.Install pump drive gear (245) onto support (249).

Illustration 356 g00901662

64 31200300
Disassembly and Assembly Section

Illustration 357 g00901663 Illustration 360 g00901666

162.Install drive yokes (41) and (42), washers (39) and a. Install O-rings (17) on actuator (9) and install
(40), and bolts (37) and (38) onto both ends of the O-ring seal (18) on piston (16). Then install the
piston into the actuator.
output shaft.
b. Install O-ring seals (14) and (15) onto the valve
Note: Ensure that drive yokes (41) and (42) are spool of solenoid (13).
installed with the same phase angle.

Illustration 361 g00901667

Illustration 358 g00901664
c. Install solenoid (13), locking plate (12) and allen head
163.Install actuator (36) and bolts (35) onto screw (11) onto actuator (9). Position actuator (9) onto
transmission cover (10). transmission cover (10) and install bolts (8).

Illustration 359 g00901665 Illustration 362 g00901668

164.Install actuator (20) and bolts (19) onto

transmission cover (21).
165.Transmissions with five speeds have additional
components that need to be assembled and Improper assembly of parts that are spring loaded
installed. can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
d. Install detent ball (7) and spring (6) into the cavity of
transmission cover (10).
31200300 65
Disassembly and Assembly Section

Illustration 363 g00901669 Illustration 366 g00900315

e. Use a suitable allen wrench in order to install cap (5) onto 167.Install O-ring seals (272) onto speed sensors (268),
transmission cover (10). (269) and (271).

Illustration 364 g00901670 Illustration 367 g00899491

f. Install sensor (4) for the shift rail and allen head screws (3) 168.Install speed sensors (268), (269), and (271) into
onto transmission cover (10).
transmission housing (21). Install allen head bolts
(267) and bolt (270) in order to secure speed
sensors (268), (269), and (271) to the transmission
housing.
Note: The speed sensors differ from each other, and
each one must be installed in the correct location that is
shown in Illustration 367.

Illustration 365 g00903009

166.Use a suitable drift in order to install core plug (279)
into transmission housing (21).

Illustration 368 g00901672

169.Use allen head screws (1) in order to install
position sensors (2) onto transmission housing (21).
End By:
a. Install the torque converter. Refer to Disassembly
and Assembly, "Torque Converter - Assemble".
b. Install the transmission. Refer to Disassembly and
Assembly, "Transmission - Install".
66 31200300
Disassembly and Assembly Section

Transmission - Install
Installation Procedure
Table 4

Required Tools
Tool Part Number Part Description Qty
Crankshaft Turning
A 9U-6198 1
Tool
Hydraulic
B 1U-9753 1
Transmission Jack
Illustration 370 g00986311
4. Use Tooling (B) to carefully raise the transmission.
When the transmission is aligned with the
mounting plate on the engine use Tooling (B) to
Personal injury or death can result from improper move the transmission into position.
lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement. Illustration 371 g00986314
5. Install bolts (33) and the washers that secure
transmission (5) to the engine.
Note: Not all bolts and washers are installed at this
time. Refer to Disassembly and Assembly,
"Transmission - Remove " for the location of the bolts
which are installed at this time.

Illustration 369 g00988454

2. Place transmission (5) onto Tooling (B). If
necessary, install suitable cribbing between the
Tooling and the transmission. This will ensure that
the transmission is fully seated on the base of the
tooling. Install a suitable strap in order to secure
the transmission onto the Tooling. The weight of the Illustration 372 g00986275
transmission is approximately 330 kg (728 lb).
3. Use Tooling (A) to move transmission (5) into
position under the left side of the machine.
31200300 67
Disassembly and Assembly Section

Illustration 373 g00986276 Illustration 376 g00984852

6. Install Tooling (A) onto crankshaft (31) on the 10. Connect hose (25) to tee (26) and tighten the hose
engine. Use Tooling (A) to rotate the engine in clamp. Install bolt (24), the washer and the hose
order to align threaded hole in the engine flywheel clamp in order to secure hose (25) to the chassis.
with the bolt hole in the drive coupling before Connect hose (21) to solenoid valve (22) and
installing bolt (32) and the washers through the tighten the retaining nut.
access hole.
7. Repeat step 6 until all eight bolts (32) and washers
are installed.

Illustration 377 g00984851

11. Connect hose (20) to transmission (5) and tighten
the retaining nut. Install adapter plate (19), the O-
Illustration 374 g00984855 ring seal (not shown) and four bolts (18). Connect
8. Install two plastic plugs (30) from the underside of hose (17) to the bottom of transmission and tighten
transmission (5). the hose clamp.

Illustration 375 g00984853 Illustration 378 g00979402

9. Use a suitable allen wrench to tighten screw (27) in 12. Connect hose (9) and hose (16) to oil cooler (15)
order to connect electrical connector (28) for the and tighten the hose clamps. Install bolt (13) and
chassis harness to electrical connector (29) for the hose clamp (14) to the bottom of transmission (5) in
transmission harness. order to secure hose (9).
68 31200300
Disassembly and Assembly Section

Illustration 379 g00984850 Illustration 382 g00979392

13. Position solenoid valve (11) onto transmission (5) 16. Position spider (3), spacer (3) and pulley (4) onto
and install three bolts (12). Connect electrical transmission (5) before installing four bolts (1) and
connector (10) for the solenoid valve. the washers.
End By:
a. Install the drive shafts. Refer to Disassembly and
Assembly, "Drive Shaft - Remove and Install".
b. Install the hydraulic pump. Refer to the appropriate
service manual for more information.
c. Install the refrigerant compressor. Refer to the
appropriate service manual for more information.
d. Install the alternator. Refer to the appropriate
service manual for more information.
e. Install the radiator. Refer to the appropriate service
manual for more information.
f. Install the fan guard. Refer to the appropriate
service manual for more information.
Illustration
380 g. Install the hood. Refer to the appropriate service
g00979401 manual for more information.
14. Connect hose (9) to transmission (5) and tighten
the hose clamp. Connect hose (8) to the Drive Shaft (Front) - Remove
transmission and tighten the retaining nut.
and Install
Removal Procedure
Table 5

Required Tools

Part
Tool Part Description Qty
Number

A 155-3597 Wheel Chock 1

1. Install Tooling (A) against the front tires in order to

Illustration 381 g00979400 prevent machine movement after the removal of the
15. Move bracket (7) into position and install four bolts drive shaft.
(6) and the washers in order to secure the bracket
to transmission (5).
31200300 69
Disassembly and Assembly Section

Illustration 383 g01030817 Illustration 385 g01030818

2. Remove bolts (1). Remove strap (2). 2. Install drive shaft (5) into position. Install strap (4).
Secure strap (4) with bolts (3).

Illustration 384 g01030818

3. Remove bolts (3). Remove strap (4) from the Illustration 386 g01030817
opposite end of drive shaft (5). 3. Install strap (2). Secure strap (2) with bolts (1) on
Note: Support the drive shaft in order to prevent the the opposite end of drive shaft (5).
drive shaft from dropping as the straps are removed. 4. Remove Tooling (A).
4. Remove drive shaft (5).
Drive Shaft (Rear) - Remove and
Installation Procedure Install
Table 6

Required Tools Removal Procedure

Part Table 7
Tool Part Description Qty
Number
Required Tools
A 155-3597 Wheel Chock 2 Part
Tool Part Description Qty
Number
1. Align the drive shaft universal joint with the drive
shaft yoke. A 155-3597 Wheel Chock 2

1. Install Tooling (A) against the front tires in order to

prevent machine movement after the removal of the
drive shaft.
70 31200300
Disassembly and Assembly Section

Illustration 389 g01030857

Illustration 387 g01030856
2. Remove bolts (1). Remove strap (2). 2. Install drive shaft (5) into position. Install strap (4).
Secure strap (4) with bolts (3).

Illustration 388 g01030857

3. Remove bolts (3). Remove strap (4) from the Illustration 390 g01030856

opposite end of the drive shaft. 3. Install drive shaft (5) on the opposite end. Install
Note: Support the drive shaft in order to prevent the strap (2). Secure strap (2) with bolts (1).
drive shaft from dropping as the straps are removed. 4. Remove Tooling (A).
4. Remove drive shaft (5).
Drive and Steering Axle (Front) -
Installation Procedure Remove
Table 8

Required Tools
Removal Procedure
Table 9
Part
Tool Part Description Qty
Number Required Tools

A 155-3597 Wheel Chock 2 Tool Part Number Part Description Qty

8S-7620 Base 1
1. Align the drive shaft universal joint with the drive
shaft yoke. 8S-7615 Pin 1

A 8S-7650 Cylinder 1

3S-6224 Electric Hydraulic Pump 1

4C-6486 Stand 1
8S-7621 Tube 1
B
8S-7615 Pin 1
4C-6486 Stand 1

C 8S-7611 Tube 1
8S-7615 Pin 1
31200300 71
Disassembly and Assembly Section

4C-6486 Stand 1 NOTICE

8S-7621 Tube 1 Care must be taken to ensure that fluids are contained
D(1) during performance of inspection, maintenance, testing,
8S-8048 Saddle 1 adjusting and repair of the product. Be prepared to collect
8S-7615 Pin 1 the fluid with suitable containers before opening any
compartment or disassembling any component
4C-6486 Stand 1
containing fluids.
8S-7621 Tube 1
E Dispose of all fluids according to local regulations and
8S-8048 Saddle 1 mandates.
8S-7615 Pin 1 1. Put identification marks on all hoses, and on all
6V-6146 Load Leveling Beam 1 tubes for installation purposes. Plug all lines, all
F hoses, and all tubes. This will prevent fluid loss and
6V-3144 Chain 2 contamination.
(1) The Tooling was installed during the removal of the stabilizer. Refer
to the appropriate service manual for more information.
Start By:
a. Park the machine on level ground. Place wheel
blocks in front of the rear wheels and behind the
rear wheels. Disengage the parking brake. Refer
to Operation and Maintenance Manual, "Parking
and Seconardy Brake Control".
b. Remove the fenders from the axle. Refer to the
appropriate service manual for more information.
c. Remove the stabilizer from the machine. Refer to the
appropriate service manual for more information.
d. Remove the drive shaft from the axle. Refer to the
appropriate service manual for more information. Illustration 391 g00987151
2. Before removing the axle, install suitable cribbing
on both sides of the machine between the chassis
and the rear axle.
Personal injury or death can result from improper
lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
Illustration 392 g00987115
3. Remove clip (1) and pin (2) in order to disconnect
cable (3) from lever (4). Remove two bolts (5) and
the washers in order to remove bracket (6) from
Personal injury can result from hydraulic oil parking brake (7).
pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to
the ground, and the oil is cool before removing any
components or lines. Remove the oil filler cap only
when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
72 31200300
Disassembly and Assembly Section

Illustration 393 g00987155 Illustration 396 g00987158

4. Disconnect hose (8) from the service brake. 7. Disconnect hoses (12) from the steering cylinder.
Disconnect hose (9) from the differential lock.

Illustration 397 g00987153

Illustration 394 g00987156 8. Remove bolt (15), the washer and the spacer that
5. Disconnect electrical connector (10) for the sensor secures pin (13) to bracket (16). Remove the pin
on the differential lock. out of the bracket and the cylinder (14). Move the
cylinder to one side.

Illustration 395 g00987157

6. Disconnect electrical connector (11) for the sensor Illustration 398 g00987116
on the steering cylinder. Cut the cable strap that 9. Loosen wheel nuts (17) but do not remove the
secures the electrical connector in position. Make a wheel nuts.
note of the position of the cable strap for the 10. Repeat the Step 9 on the wheel nuts on the other
purpose of installation. end of the axle.
31200300 73
Disassembly and Assembly Section

Illustration 399 g00987117 Illustration 402 g00989529

Illustration 400 g00989527 Illustration 403 g00989580

13. Replace Tooling (D) that was installed under the
boom during the removal of the stabilizer with
Tooling (E). Refer to the appropriate service
manual for more information.

Illustration 401 g00989528

11. Use Tooling (A) to raise the machine. Raise the
machine so that the wheels are off the ground.
12. Position Tooling (B) under the chassis and Tooling
(C) under the engine. Use Tooling (A) to lower Illustration 404 g00987118
the machine onto Tooling (B) and Tooling (C). Typical Example
Ensure that the wheels are off the ground before 14. Attach a suitable nylon lifting sling around the wheel
removing Tooling (A) from the machine. Otherwise (18). Attach the nylon lifting sling to a suitable
return to Step 11. hoist in order to support the wheel. The weight of
the wheel without ballast is approximately 190 kg
(420 lb).
74 31200300
Disassembly and Assembly Section

Note: Liquid ballast is installed in the tires of certain 17. Attach Tooling (C) to a suitable hoist. Attach two
machines. Liquid ballast will greatly increase the suitable nylon lifting slings between the Tooling and
weight of a wheel. You must be sure that the weight of the axle. Ensure that the lifting equipment is of
the wheel will not exceed the lifting capacity of your sufficient length in order to lower the axle to the
lifting equipment. Refer to Operation and Maintenance ground. Use the lifting equipment to support the
Manual, "Tire Inflation Information" for additional weight of the axle. The weight of the axle is
information about the recommended weight of installed approximately 550 kg (1212 lb).
liquid ballast.

Illustration 408 g00989836

Illustration 405 g00987119 18. Position a suitable pallet fork with suitable cribbing
15. Remove wheel nuts (17) and the spring washers. under the axle.
Use the attached lifting equipment to remove
wheel (18) from the machine.
16. Repeat Step 14 to Step 15 for the wheel on the
other end of the axle.

Illustration 409 g00987120

19. Remove bolt (19) and the washer that secures pin
(20) in position.

Illustration 406 g00989836

Illustration 410 g00989594

Typical example
Illustration 407 g00989837 20. Use a suitable driver and a suitable mallet in order
Typical example that shows a suitable attachment of lifting slings to carefully remove pin (20).
31200300 75
Disassembly and Assembly Section

21. Use the attached lifting equipment to carefully

lower the axle onto the pallet fork. Remove all
the washers that are between the axle and the
chassis. Make a note of the positions of all the
washers for the purpose of installation. Personal injury or death can result from improper
lifting or blocking.
22. Remove the lifting equipment from the axle before
using the pallet fork to remove the axle from the When a hoist or jack is used to lift any part or
machine. component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
Drive and Steering Axle (Front) - performance of any work under a heavy
Install component.
Approximate weights of the components are
Installation Procedure shown. Clean all surfaces where parts are to be
installed.
Table 10
1. Clean all parts and inspect all parts. If any parts
Required Tools are worn or damaged, use new Caterpillar parts
for replacement.
Tool Part Number Part Description Qty
2. Use Tooling (F) and two suitable nylon lifting slings
8S-7620 Base 1 in order to place the axle on a suitable pallet fork
with suitable cribbing. The weight of the axle is
8S-7615 Pin 1
approximately 550 kg (1212 lb).
A 8S-7650 Cylinder 1

3S-6224 Electric Hydraulic Pump 1

4C-6486 Stand 1
8S-7621 Tube 1
B
8S-7615 Pin 1
4C-6486 Stand 1
8S-7611 Tube 1
C
8S-7615 Pin 1
4C-6486 Stand 1
Illustration 411 g00989836
8S-7621 Tube 1
D(1)
8S-8048 Saddle 1
8S-7615 Pin 1
4C-6486 Stand 1
8S-7621 Tube 1
E
8S-8048 Saddle 1
8S-7615 Pin 1
6V-6146 Load Leveling Beam 1
F
6V-3144 Chain 2

(1) The Tooling was installed during the removal of the stabilizer. Refer
Illustration 412 g00989842
to the appropriate service manual for more information.
Typical Example
3. Detach the nylon lifting slings from Tooling (F)
before using the pallet fork to position the axle
under the machine. Reattach the nylon lifting slings
to the Tooling.
76 31200300
Disassembly and Assembly Section

8. Remove Tooling (F) and the attached lifting

equipment from the axle.

Illustration 413 g00989837

Typical example that shows the position of the axle to the machine
4. Use the attached lifting equipment in order to
Illustration 416 g00987121
raise the axle to the chassis. Install the washers Typical example
that were removed during the removal procedure
9. Attach a suitable nylon lifting sling around wheel
before raising the axle in position to the machine.
(18). Attach the nylon lifting sling to a suitable hoist
Refer to the note that was made during the
in order to support the wheel. The weight of the
removal procedure for the position of all the
wheel without ballast is approximately 190 kg (420
washers.
lb).
5. Remove the pallet fork with the cribbing from the
Note: Liquid ballast is installed in the tires of certain
machine.
machines. Liquid ballast will greatly increase the
weight of a wheel. You must be sure that the weight of
the wheel will not exceed the lifting capacity of your
lifting equipment. Refer to Operation and Maintenance
Manual, "Tire Inflation Information" for additional
information about the recommended weight of installed
liquid ballast.

Illustration 414 g00989841

6. Align the bores in the chassis with the bore in the
axle. Lubricate pin (20) with 5P-0960 Molybdenum
Grease before using a suitable mallet in order to
install the pin.

Illustration 417 g00987119

10. Position wheel (18) to the machine before
installing wheel nuts (17) and the spring washers.
Do not tighten the nuts at this step.
11. Remove the nylon lifting sling and the hoist from
the machine.
12. Repeat Step 9 to Step 11 for the wheel on the
other end of the axle.

Illustration 415 g00987120

7. Install bolt (19) and the washer in order to secure
pin (20) in position.
31200300 77
Disassembly and Assembly Section

Illustration 418 g00987117 Illustration 422 g00989529

14. Replace Tooling (E) with Tooling (D). Tooling (D)
was initially used during the removal of the
stabilizer. Refer to the appropriate service manual
for more information.

Illustration 419 g00989527

Illustration 423 g00989844

15. Use Tooling (A) to lower the machine onto wheels
and tires. At the same time, adjust the position of
Tooling (D) and the height of the Tooling that is
under the boom.
16. Remove Tooling (A) from the machine.

Illustration 420 g00989528

13. Use Tooling (A) to raise the machine. Remove
Tooling (B) and Tooling (C) from the machine.

Illustration 424 g00987116

Typical example
17. Tighten wheel nuts (17) in a cross pattern to a
torque of 240 ± 40 Nm (177 ± 30 lb ft) and then
turn an additional 60 degrees ± 5 degrees.
Note: Check the wheel nut torque on new wheels and
Illustration 421 g00989580 on repaired wheels after every ten service hours until
the specified torque is maintained. Refer to Operation
and Maintenance Manual, "Wheel Nut Torque - Check".
78 31200300
Disassembly and Assembly Section

18. Repeat the Step 17 on the wheel nuts on the

other end of the axle.

Illustration 428 g00987156

23. Connect electrical connector (10) to the sensor on
Illustration 425 g00987153 the differential lock.
19. Position the rod end of cylinder (14) to bracket
(16). Align the bore in the cylinder with bores in
the bracket and install pin (13).
20. Secure pin (13) in place with bolt (15), the spacer
and the washer.

Illustration 429 g00987155

24. Connect hose (9) to the differential lock. Connect
hose (8) to the service brake.

Illustration 426 g00987158

21. Connect hoses (12) to the steering cylinder.

Illustration 430 g00987115

25. Position bracket (6) onto parking brake (7) and
secure the bracket in place with two bolts (5) with
the washers. Align cable (3) with lever (4) and
install pin (2) and clip (1).
Illustration 427 g00987157
22. Connect electrical connector (11) to the sensor on
the steering cylinder. Install a new cable strap in
order to secure the electrical connector in position.
Refer to the note that was made during the removal
procedure for the position of the cable strap.
31200300 79
Disassembly and Assembly Section

a. Park the machine on level ground. Engage the parking

brake. Refer to Operation and Maintenance Manual,
"Parking and Secondary Brake Control".
b. Remove the fenders from the axle. Refer to the
appropriate service manual for more information.

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
Illustration 431 g00987151 hoist or jack has the correct capacity to lift a
26. Remove the cribbing that was placed between the component. Install blocks or stands before
chassis and the rear axle during the removal performance of any work under a heavy
procedure. component.
End By: Approximate weights of the components are
a. Install the drive shaft to the axle. Refer to Disassembly and shown. Clean all surfaces where parts are to be
Assembly Manual, "Drive Shaft - Remove and Install". installed.
b. Install the stabilizer to the machine. Refer to the
appropriate service manual for more information.
c. Check the parking brake. Refer to Operation and
Maintenance Manual, "Parking Brake - Check.".
Personal injury can result from hydraulic oil
d. Purge the air from the braking system. Refer to the pressure and hot oil.
appropriate service manual for more information.
e. Engage the parking brake before removing any blocks that
Hydraulic oil pressure can remain in the hydraulic
were installed in front of the rear wheels and behind the system after the engine has been stopped. Serious
rear wheels during the removal procedure. Refer to injury can be caused if this pressure is not released
Operation and Maintenance Manual, "Parking and before any service is done on the hydraulic system.
Secondary Brake Control".
Make sure all of the work tools have been lowered to
the ground, and the oil is cool before removing any
Drive and Steering Axle (Rear) - components or lines. Remove the oil filler cap only
Remove when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.

Removal Procedure NOTICE

Care must be taken to ensure that fluids are contained
Table 11 during performance of inspection, maintenance, testing,
Required Tools adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
Tool Part Number Part Description Qty compartment or disassembling any component
containing fluids.
8S-7620 Base 2
Dispose of all fluids according to local regulations and
8S-7615 Pin 2
mandates.
8S-7650 Cylinder 2
A 1. Put identification marks on all hoses, and on all
tubes for installation purposes. Plug all lines, all
3S-6224 Electric Hydraulic Pump 1
hoses, and all tubes. This will prevent fluid loss and
8S-7645 Hose 1 contamination of the hydraulic oil system.
4C-6486 Stand 1
8S-7621 Tube 1
B
8S-7615 Pin 1
6V-6146 Load Leveling Beam 1
C
6V-3144 Chain 2

Start By:
80 31200300
Disassembly and Assembly Section

Illustration 432 g00987257 Illustration 435 g00987259

2. Before removing the axle, install suitable cribbing 5. Remove bolt (6), the washer and the spacer that
on both sides of the machine between the chassis secures pin (5) to bracket (7). Remove the pin out of
and the axle. the bracket and the cylinder (4). Move the rod eye
of the cylinder to one side.

Illustration 433 g00987479

3. Disconnect electrical connector (1) for the level Illustration 436 g00987107
sensor on the axle. 6. Loosen wheel nuts (8) but do not remove the
wheel nuts.
7. Repeat the Step 6 on the wheel nuts on the other
end of the axle.

Illustration 434 g00987478

4. Disconnect electrical connector (2) for the sensor
on the steering cylinder. Disconnect hoses (3) from
the steering cylinder. Illustration 437 g00987108
8. Install Tooling (A) under the rear of the machine.
Use the Tooling to raise the machine. Raise the
machine so that the wheels are off the ground.
31200300 81
Disassembly and Assembly Section

Note: Liquid ballast is installed in the tires of certain

machines. Liquid ballast will greatly increase the
weight of a wheel. You must be sure that the weight of
the wheel will not exceed the lifting capacity of your
lifting equipment. Refer to Operation and Maintenance
Manual, "Tire Inflation Information" for additional
information about the recommended weight of installed
liquid ballast.

Illustration 438 g00989518

Left side of the machine

Illustration 441 g00987111

11. Remove wheel nuts (8) and the spring washers.
Use the attached lifting equipment to remove
wheel (9) from the machine.
12. Repeat Step 10 to Step 11 on the wheel on the
other end of the axle.
Illustration 439 g00987112
Right side of the machine
9. Position Tooling (B) in a suitable place under the
axle. Use Tooling (A) to lower the machine onto
Tooling (B). Ensure that the wheels are still off the
ground before removing Tooling (A) from the
machine, otherwise return to the previous Step 8
and try again.

Illustration 442 g00989865

13. Attach Tooling (C) to a suitable hoist. Attach two
Illustration 440 g00987109
suitable nylon lifting slings between the Tooling and
10. Attach a suitable nylon lifting sling around wheel the axle. Use the lifting equipment to support the
(9). Attach the nylon lifting sling to a suitable hoist in weight of the axle. Ensure that the lifting
order to support the wheel. The weight of the wheel equipment is of sufficient length in order to lower
without ballast is approximately 190 kg (420 lb). the axle to the ground. The weight of the axle is
approximately 550 kg (1212 lb).
82 31200300
Disassembly and Assembly Section

Illustration 443 g00987257 Illustration 446 g00989869

Typical example 17. Position a suitable pallet fork with suitable
14. Remove the cribbing that was installed during cribbing under the axle.
Step 2. 18. Use the attached lifting equipment to carefully
lower the axle onto the pallet fork. Remove all
the washers that are between the axle and the
chassis. Make a note of the positions of all the
washers for the purpose of installation.
19. Remove the lifting equipment from the axle before
using the pallet fork to remove the axle from the
machine.

Drive and Steering Axle (Rear) -

Install
Illustration 444 g00989871 Installation Procedure
15. Remove bolt (11) and the washer that secures pin
Table 12
(10) in place.
Required Tools

Tool Part Number Part Description Qty

8S-7620 Base 2
8S-7615 Pin 2
8S-7650 Cylinder 2
A
3S-6224 Electric Hydraulic Pump 1

8S-7645 Hose 1
4C-6486 Stand 1

B 8S-7621 Tube 1
Illustration 445 g00989873
16. Use suitable tooling to remove pin (10). 8S-7615 Pin 1
6V-6146 Load Leveling Beam 1
C
6V-3144 Chain 2
31200300 83
Disassembly and Assembly Section

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be Illustration 448 g00989869
installed. 5. Remove the pallet fork with the cribbing from the
1. Clean all parts and inspect all parts. If any parts machine.
are worn or damaged, use new Caterpillar parts
for replacement.
2. Use Tooling (C) and two suitable nylon lifting
slings to place the axle on a suitable pallet fork
with suitable cribbing. The weight of the axle is
approximately 550 kg (1212 lb).
3. Detach the two nylon lifting slings from Tooling
(C) before using the pallet fork to position the axle
under the machine.

Illustration 449 g00989811

6. Align the bores of the chassis with the bore of the
axle. Lubricate pin (10) with 5P-0960 Molybdenum
Grease before using a suitable mallet to install the
pin.

Illustration 447 g00990250

4. Reattach the two nylon lifting slings to Tooling (C).
Use the attached lifting equipment to raise the axle Illustration 450 g00989871
to the chassis. Install the washers that were 7. Install bolt (11) and the washer in order to secure
removed during the removal procedure before pin (10) in position.
raising the axle in position to the machine. Refer to
the note that was made during the removal
procedure for the position of all the washers.
84 31200300
Disassembly and Assembly Section

the wheel will not exceed the lifting capacity of your

lifting equipment. Refer to Operation and Maintenance
Manual, "Tire Inflation Information" for additional
information about the recommended weight of installed
liquid ballast.

Illustration 451 g00987257

Typical example
8. Install suitable cribbing on both sides of the
machine between the chassis and the axle.

Illustration 454 g00987111

11. Position wheel (9) to the machine before installing
wheel nuts (8) and the spring washers. Do not
tighten the nuts at this step.
12. Remove the nylon lifting sling and the hoist from
wheel (9).
13. Repeat Step 10 to Step 12 for the wheel on the
other end of the axle.

Illustration 452 g00989865

9. Remove Tooling (C) and the attached lifting
equipment from the axle.

Illustration 455 g00989518

Left side of the machine

Illustration 453 g00987114

10. Attach a suitable nylon lifting sling around wheel
(9). Attach the nylon lifting sling to a suitable hoist in
order to support the wheel. The weight of the wheel Illustration 456 g00987112
without ballast is approximately 190 kg (420 lb). Right side of the machine

Note: Liquid ballast is installed in the tires of certain 14. Position Tooling (A) under the machine and use
machines. Liquid ballast will greatly increase the the Tooling to raise the machine off Tooling (B).
weight of a wheel. You must be sure that the weight of 15. Remove Tooling (B) from the machine.
31200300 85
Disassembly and Assembly Section

Illustration 457 g00987108 Illustration 460 g00987478

16. Use Tooling (A) to lower the machine onto the 20. Connect electrical connector (2) for the sensor on
ground before removing the Tooling from the the steering cylinder. Connect hoses (3) to the
machine. steering cylinder.

Illustration 458 g00987107 Illustration 461 g00987479

17. Tighten wheel nuts (8) in a cross pattern to a torque 21. Connect electrical connector (1) for the level sensor
of 240 ± 40 Nm (177 ± 30 lb ft) and then turn an on the axle.
additional 60 degrees ± 5 degrees.
Note: Check the wheel nut torque on new wheels and
on repaired wheels after every ten service hours until
the specified torque is maintained. Refer to Operation
and Maintenance Manual, "Wheel Nut Torque - Check".
18. Repeat the Step 17 on the wheel nuts on the other
end of the axle.

Illustration 462 g00987257

22. Remove the cribbing that was installed between the
chassis and the axle in Step 8.
End By:
a. Install the fenders to the axle. Refer to the appropriate
service manual for more information.

Illustration 459 g00987259

19. Position the rod eye of cylinder (4) to bracket (7)
before installing pin (5). Install bolt (6), the washer
and the spacer that secures the pin to the bracket.
86 31200300
Disassembly and Assembly Section

Tie Rod (Steering) - Remove

and Install
Removal Procedure
Table 13

Required Tools

Part
Tool Part Description Qty
Number

Illustration 465 g01031050

A 1P-2320 Puller Group 1 4. Loosen jam nut (4).

Illustration 466 g01031051

Illustration 463 g01031039
1. Loosen locknut (1). Do not remove the locknut at 5. Remove tie rod (5).
this time.
Installation procedure

Illustration 464 g01033288

2. Install Tooling (A). Remove ball joint (2) from Illustration 467 g01031051
steering knuckle (3).
3. Remove locknut (1) and the tie rod after the tie rod
has been loosened with Tooling (A).
31200300 87
Disassembly and Assembly Section

Steering Cylinder - Remove and

Install
Removal Procedure
Table 14

Required Tools

Part
Tool Part Description Qty
Number

6V-9508 Tapered Cap/Plug 2

Illustration 468 g01031053
1. Install tie rod (5) into position. Do not tighten at this 6V-9829 Tapered Cap/Plug 2
ZZ
time.
2. Adjust tie rod (5) to Dimension (X). Dimension (X) is 6U-7073 Tapered Cap/Plug 1
443 ± 2.0 mm (17.0 ± 0.07 inch).
6U-7077 Tapered Cap/Plug 1
Note: Dimension (X) is measured from the center to the
center. Start By:
a. Remove the tie rods. Refer to Disassembly and Assembly,
"Tie Rods - Remove and Install".
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Illustration 469 g01031050 Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE
3. After the proper adjustment is made, tighten jam IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL
nut (4) to a torque of 250 Nm (184 lb ft). OR THE INSTALLATION. THIS TOOLING IS SHOWN
IN ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
1. Put identification marks on all lines, on all hoses
and on all wires for installation purposes. Plug all
lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.

Illustration 470 g01031139

4. Install ball joint (2) into steering knuckle (3).
5. Install locknut (1). Tighten locknut (1) to a torque
of250Nm (184 lb ft).

Illustration 471 g01032671

2. Disconnect hose assembly (1). Remove fitting (2).
88 31200300
Disassembly and Assembly Section

Illustration 472 g01032673 Illustration 475 g01049817

3. Disconnect harness assembly (3). Disconnect hose 6. Remove ball joints (9) from steering cylinder
assembly (4). assembly (8.).

Installation Procedure

Illustration 473 g01032674

4. Loosen clamps (5). Remove sensor (6).
Illustration 476 g01049817
1. Install ball joints (9) onto the ends of steering
cylinder assembly (8). Tighten ball joints (9) to a
torque of 190 Nm (140 lb ft).

Illustration 474 g01032677

5. Remove bolts (7). Remove steering cylinder
assembly (8). The weight of steering cylinder
assembly (8) is approximately 20 kg (45 lb).
31200300 89
Disassembly and Assembly Section

Illustration 480 g01032673

4. Connect hose assembly (4). Connect harness
assembly (3).

Illustration 477 g01032772

Illustration 481 g01032671

5. Install fitting (2). Connect hose assembly (1).
End By:
a. Install the tie rods. Refer to Disassembly and Assembly,
"Tie Rods - Remove and Install".

Final Drive Planetary - Remove

Illustration 478 g01032677 Removal Procedure
2. Install steering cylinder assembly (8) into the axle
housing. The weight of steering cylinder assembly Start By:
(8) is approximately 20 kg (45 lb). Install bolts (7). a. Remove the tire and rim. Refer to Disassembly and
Assembly, "Tire and Rim - Remove and Install".
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the oil from the final drive planetary. Refer to
Operation and Maintenance Manual, "Final Drive
Illustration 479 g01032674
Oil - Change".
3. Install sensor (6). Secure sensor (6) with clamps
(5).
90 31200300
Disassembly and Assembly Section

Illustration 482 g01022865 Illustration 483 g01023047

2. Remove screws (3) and remove planetary carrier 1. Use Tooling (A) and remove retaining ring (1).
assembly (4) from wheel flange (1). Remove O- Remove washer (2), needle bearings (3) and
ring seal (2) from wheel flange (1). planetary gear (4).
2. Repeat Step 1 for the remaining planetary gear
assemblies.
Final Drive Planetary
Disassemble Final Drive Planetary Assemble

Disassembly Procedure Assembly Procedure

Table 16
Table 15
Required Tools
Required Tools
Tool Part Number Part Description Qty
Tool Part Number Part Description Qty
A 1P-1863 Retaining Ring Pliers 1
A 1P-1863 Retaining Ring Pliers 1

Start By:
a. Remove the final drive planetary. Refer to Disassembly
and Assembly, "Final Drive Planetary - Remove".

Illustration 484 g1023047

31200300 91
Disassembly and Assembly Section

1. Apply a thin layer of suitable grease onto needle Axle Housing and Flange
bearings (3). This will help to hold needle bearings
(3) in position. Install half of needle bearings (3) Remove
into planetary gear (4). Install planetary gear (4).
Install the remaining half of needle bearings (3) Removal Procedure
into planetary gear (4). Install washer (2). Use
Tooling (A) and install retaining ring (1). Table 17
2. Repeat Step 1 for the remaining planetary gear Required Tools
assemblies.
End By: Tool Part Number Part Description Qty
a. Install the final drive planetary. Refer to Disassembly and A 1P-2320 Combination Puller 1
Assembly, "Final Drive Planetary - Install".
B 230-7923 Spanner Wrench 1

Final Drive Planetary - Install C 246-5254 Spanner Wrench 1

D 2P-8312 Retaining Ring Pliers 1

Installation Procedure
Start By:
a. Remove the final drive planetary. Refer to Disassembly
and Assembly, "Final Drive Planetary - Remove".

Illustration 485 g01022865

Note: Check the O-ring seal for damage or for wear. If
necessary, replace the O-ring seal.
1. Install O-ring seal (2) onto wheel flange (1). Illustration 486 g01047618
Position planetary carrier assembly (4) onto wheel 1. Loosen nut (2). Do not remove nut (2) at this time.
flange (1). Install screws (3). Tighten screws (3) Install Tooling (A). Remove tie rod end (1) from the
to a torque of 25 Nm (18 lb ft). taper of the knuckle. Remove nut (2) and remove tie
2. Fill the final drive planetary with oil. Refer to rod end (1).
Operation and Maintenance Manual, "Capacities Note: Follow Step 2 or Step 3 for the correct
(Refill)" and refer to Operation and Maintenance procedure for the axle that is being serviced.
Manual, "Final Drive Oil - Change".
End By:
a. Install the tire and rim. Refer to Disassembly and
Assembly, "Tire and Rim - Remove and Install".
92 31200300
Disassembly and Assembly Section

Illustration 487 g01047569 Illustration 489 g01023074

2. Remove bolts (5) and remove locking plate (4).
Use Tooling (B) in order to remove spanner nut (3).

Illustration 490 g01023075

4. Use a suitable pry bar and push the double U-joint
Illustration 488 g01040507 toward the wheel flange. This will make the
3. Remove retaining ring (4). Remove dowel pin (5). removal of retaining ring (8) easier. Use Tooling (D)
Use Tooling (C) in order to remove spanner nut (3). and remove retaining ring (8). Remove thrust
washer (7) and washer (6).
31200300 93
Disassembly and Assembly Section

Illustration 491 g01023088

5. Remove ring gear (9).

Illustration 493 g01023130

7. Remove bolts (12). Remove pin assembly (13) and
shims (14). Remove bolts (16) and pin assembly
(15).

Illustration 492 g01023126

6. Remove wheel flange (10).
Note: Bearing cone (11) will fall out of wheel flange (10)
when wheel flange (10) is removed.
94 31200300
Disassembly and Assembly Section

Illustration 494 g01023136

8. The weight of knuckle (17) is approximately 50 kg
(110 lb). Use two people and remove knuckle (17).

Axle Housing and Flange -

Disassemble
Disassembly Procedure
Table 18

Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Gp 1
B 1P-0520 Driver Gp 1

Start By:
a. Remove the axle housing and the wheel flange. Refer to
Disassembly and Assembly, "Axle Housing and Flange -
Remove".
31200300 95
Disassembly and Assembly Section

Illustration 495 g01023873

1. Remove retaining ring (1) and ring gear hub (2)
from ring gear (3).

Illustration 497 g01023875

3. Remove bearing cone (9) and seal (10) from pin
assembly (11). Repeat forthe other pin assembly.

Illustration 496 g01023874

2. Remove seal (4) from wheel flange (7). Use
Tooling (B) and a suitable hammer in order to
remove bearing cup (5). Remove spacer (6). Use
Tooling (B) and a suitable hammer in order to
remove bearing cup (8).

Illustration 498 g01023881

4. Remove seal (12) from knuckle (13).
96 31200300
Disassembly and Assembly Section

Illustration 499 g01038749 Illustration 501 g01038749

5. Remove bearing cone (14) from knuckle (13). 1. Install bearing cone (14) onto knuckle (13).

Illustration 500 g01023876

6. Use Tooling (A) and a suitable hammer in order to
remove the bushing from knuckle (13).

Axle Housing and Flange -

Assemble Illustration 502 g01026726
2. Use Tooling (A) and a suitable hammer and install
Assembly Procedure the bushing into knuckle (13).

Table 19

Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Gp 1
B 1P-0520 Driver Gp 1
31200300 97
Disassembly and Assembly Section

Illustration 505 g01023874

5. Use Tooling (B) and a suitable hammer and install
bearing cup (8) into wheel flange (7). Install spacer
(6). Use Tooling (B) and a suitable hammer and
install bearing cup (5) into wheel flange (7). Install
bearing cup (5). Install seal (4).
Illustration 503 g01029981
3. Use Tooling (A) and install seal (12) into knuckle
(13).

Illustration 504 g01023875

4. Install seal (10) onto pin assembly (11). Raise the
temperature of bearing cone (9). Install bearing
cone (9) onto pin assembly (11). Repeat for the
other pin assembly.
98 31200300
Disassembly and Assembly Section

Illustration 506 g01023873

6. Install ring gear hub (2) into ring gear (3). Install retaining
ring (1).
End By:
a. Install the axle housing and the wheel flange. Refer to
Disassembly and Assembly, "Axle Housing and Flange -
Install".

Axle Housing and Flange Install

Installation Procedure
Table 20

Required Tools

Tool Part Number Part Description Qty

B 230-7923 Spanner Wrench 1

C 246-5254 Spanner Wrench 1

D 2P-8312 Retaining Ring Pliers 1

31200300 99
Disassembly and Assembly Section

Illustration 507 g01023136

1. The weight of knuckle (17) is approximately 50 kg 2. Do not install shims (14) at this time. Install pin
(110 lb). Use two people and install knuckle (17). assembly (13). Install bolts (12). Do not tighten bolts
(12) at this time. Install pin assembly (15) and bolts
(16). Tighten bolts (16) to a torque of 300 Nm
(221 lb ft).

Illustration 509 g01023126

3. Install wheel flange (10) and bearing cone (11).

Illustration 508 g01023130

100 31200300
Disassembly and Assembly Section

Illustration 510 g01023088 Illustration 512 g01047569

4. Install ring gear (9). 6. Use Tooling (B) and install spanner nut (3).
Tighten spanner nut (3) to a torque of 1000 Nm
Note: Follow Step 5 or Step 6 for the correct (738 lb ft). Install locking plate (4) and bolts (5).
procedure for the axle that is being serviced. Tighten bolts (5) to a torque of 70 Nm (52 lb ft).
Note: If the tab on locking plate (4) does not line up with
the slot in spanner nut (3), tighten spanner nut (3) until
the slot and the tab are aligned.

Illustration 511 g01040507

5. Use Tooling (C) and install spanner nut (3). Tighten
spanner nut (3) to a torque of 1000 Nm (738 lb ft).
Install dowel pin (5). Install retaining ring (4).
Illustration 513 g01023074
Note: If dowel pin (5) does not line up with the hole in
spanner nut (3), tighten spanner nut (3) until dowel pin
(5) and the hole are aligned.
31200300 101
Disassembly and Assembly Section

Illustration 514 g01023075 Illustration 516 g01032913

7. Use a suitable pry bar and push the double U-joint 9. Install tie rod end (1) into the axle housing. Install
toward the wheel flange. This will make the nut (2). Tighten nut (2) to a torque of 250 Nm
installation of retaining ring (8) easier. Install (184 lb ft).
washer (6) and thrust washer (7). Use Tooling (D) End By:
and install retaining ring (8).
a. Install the final drive planetary. Refer to Disassembly and
Assembly, "Final Drive Planetary - Install".

Axle Shaft - Remove and Install

Removal Procedure
Start By:
a. Remove the axle housing and the wheel flange. Refer to
Disassembly and Assembly, "Axle Housing and Flange -
Remove".
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Illustration 515 g01029956
Dispose of all fluids according to local regulations and
8. Insert a suitable pry bar and move the knuckle up mandates.
and down while you tighten bolts (12). Tighten bolts
(12) until there is no end play. Use a suitable feeler
gauge and measure the clearance between pin
assembly (13) and the knuckle. Measure the
clearance at several points and average the
measurement. Use shims (14) that equal the
measurement. Install correct shims (14) and
tighten bolts (12) to a torque of 300 Nm (221 lb ft).
102 31200300
Disassembly and Assembly Section

1. Drain the oil from the axle. Refer to Operation and 4. If necessary, remove the upper and lower bearing
Maintenance Manual, "Differential Oil - Change". cups (5).

Installation Procedure
Table 21

Required Tools
Part Part
Tool Qty
Number Description
A 1P-0510 Driver Gp 1

NOTICE
Care must be taken to ensure that fluids are contained
Illustration 517 g01023934 during performance of inspection, maintenance, testing,
2. Remove axle shaft (1) from axle housing (2). adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Illustration 518 g01026864

3. Remove seal (3). If necessary, remove bushing (4)
from axle housing (2).

Illustration 520 g01029778

1. Lower the temperature of bearing cups (5) and use
Tooling (A) in order to install bearing cups (5) into
axle housing (2).

Illustration 519 g01026866

31200300 103
Disassembly and Assembly Section

and Operation and Maintenance Manual,

"Capacities (Refill)".
End By:
a. Install the axle housing and the wheel flange. Refer to
Disassembly and Assembly, "Axle Housing and Flange -
Install".

Axle Housing (Service Brakes,

Differential and Bevel Gear)
(Front) - Remove
Removal Procedure
Start By:
a. Remove the drive and steering axle from the machine.
Refer to Disassembly and Assembly, "Drive and Steering
Axle (Front) - Remove".
Illustration 521 g01026864
2. Use Tooling (A) and install bushing (4) and seal (3)
NOTICE
into axle housing (2).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the oil from the axle. Refer to Operation and
Maintenance Manual, "Differential Oil - Change".

Illustration 522 g01023934

3. Install axle shaft (1) into axle housing (2).
4. Fill the axle with oil. Refer to Operation and
Maintenance Manual, "Differential Oil - Change"

Illustration 523 g01024181

104 31200300
Disassembly and Assembly Section

Note: Put location marks on the axle housing, brake a. Remove the axle housing. Refer to Disassembly and
Assembly, "Axle Housing (Service Brakes, Differential
cylinder assemblies, and the center housing for
and Bevel Gear) (Front) - Remove".
assembly purposes.
2. Position wood blocks under the drive and steering
axle in order to support the sections during
removal. Attach a suitable lifting device onto the
axle housing. The weight of the axle housing is
approximately 170 kg (375 lb). Remove bolts (1).

Illustration 525 g01024401

1. Remove plates (1), brake discs (2), and coupling
(3) from brake cylinder assembly (4).

Illustration 524 g01024184

3. Remove axle housing (2) from brake cylinder
assembly (3).
4. Repeat Steps 2 through 3 for the other side.

Axle Housing (Service Brakes,

Differential and Bevel Gear)
(Front) - Disassemble
Disassembly Procedure
Table 22
Illustration 526 g01024444
Required Tools

Tool Part Number Part Description Qty

A 235-2797 Spanner Socket 1

Personal injury can result from being struck by
parts propelled by a released spring force.
B 1P-2321 Combination Puller 1
Make sure to wear all necessary protective
C 1P-1859 Retaining Ring Pliers 1 equipment.
D 235-5784 Pinion Wrench 1 Follow the recommended procedure and use all
E 8H-0663 Bearing Puller Gp 1 recommended tooling to release the spring force.
2. Remove bolts (7). Remove bolts and springs (8).
Start By: Use a suitable pry bar and remove brake piston (6)
from brake cylinder assembly (4). Remove O-ring
seals (5) from brake piston (6).
31200300 105
Disassembly and Assembly Section

Illustration 527 g01024510 Illustration 529 g01026257

3. Remove bolts (9) from brake cylinder assembly (4). 5. Remove bolt (11) and retainer (10). Use Tooling (A)
and remove spanner nut (12). If necessary, remove
bearing cup (13) from brake cylinder assembly (4).

Illustration 528 g01024677

4. Remove brake cylinder assembly (4). Remove the
differential and bevel gear assembly from the right
side of the center housing.

Illustration 530 g01024629

6. Use Tooling (B) and remove bearing cone (14).
106 31200300
Disassembly and Assembly Section

Illustration 533 g01026263

9. Lock the differential in a vise. Remove bolts (20)
and remove bevel gear (21) from the differential.

Illustration 531 g01024627

7. Use Tooling (B) and remove bearing cone (15).

Illustration 534 g01026293

10. Remove cover (22). Remove thrust washer (23) and
side gear (24). Use a suitable punch and a
hammer and drive out locking pins (25). Remove
planetary shafts (26).
Illustration 532 g01026258
8. Push collar (17) inward. Use Tooling (C) and
remove retaining ring (19). Remove plate (18) and
remove collar (17). Remove pins (16).
31200300 107
Disassembly and Assembly Section

Illustration 535 g01026297 Illustration 537 g01047687

11. Remove thrust washers (27), gears (28) and spider 13. Use Tooling (D) in order to hold the pinion flange
(29). Remove side gear (31) and thrust washer and remove nut (32).
(30).

Illustration 538 g01047690

14. Remove washer (35) and O-ring seal (34). Remove
Illustration 536 g01026410
brake disc (33).
12. Straighten nut (32) out of the locking tab.
108 31200300
Disassembly and Assembly Section

Illustration 539 g01026575 Illustration 541 g01026580

15. Remove lip seal (36) from the center housing.
17. Remove bearing cone (40), washers (38), and
collapsible spacer (39) from pinion shaft (37).

Illustration 540 g01026577

16. Tap the end of pinion shaft (37) with a soft hammer
Illustration 542 g01047692
in order to remove pinion shaft (37) from the center
housing. 18. Use Tooling (E) and a suitable press in order to remove
bearing cone (41) from pinion shaft (37). Remove the
shim that is positioned under bearing cone (41). Check the
shim for wear. If necessary, replace the shim.
31200300 109
Disassembly and Assembly Section

Illustration 544 g01026617

20. Use a suitable hammer and a punch and remove
bearing cups (58) from the center housing.

Axle Housing (Service Brakes,

Illustration 543 g01026603 Differential and Bevel Gear)
(Front) - Assemble
Personal injury can result from being struck by Assembly Procedure
parts propelled by a released spring force.
Table 23
Make sure to wear all necessary protective
equipment. Required Tools
Follow the recommended procedure and use all Tool Part Number Part Description Qty
recommended tooling to release the spring force.
19. Remove bolts (42), cover (43), O-ring seal (44), A 235-2797 Spanner Socket 1
spring (45), washer (46), and retaining ring (47) C 1P-1859 Retaining Ring Pliers 1
from the center housing. Remove bolts (57), cover
(56), O-ring (55), piston (54), O-ring seals (53), D 235-5784 Pinion Wrench 1
retaining ring (52), bushing (51), spring (50), and F 1P-0520 Driver Gp 1
shaft (49) from the center housing. Remove fork
G 235-2788 False Pinion 1
(48) from the center housing.
H 235-2793 False Differential 1
J 6V-2012 Depth Micrometer 1
K Loctite 270 1
L 069-4707 Sealant 1
M 8T-5096 Dial Indicator Gp 1
110 31200300
Disassembly and Assembly Section

Illustration 545 g01047698 Illustration 547 g01024510

3. Align the location marks that were made during the
1. Use Tooling (F) and install bearing cups (58) into
removal procedure. Position brake cylinder (4) and
the center housing.
temporarily install bolts (9). Repeat for the other
side.

Illustration 546 g01047700

2. Install bearing cones (40) and (41). Install Tooling Illustration 548 g01047702
(G). 4. Install Tooling (H) into the center housing. Make
sure that Tooling (H) is inserted into both brake
cylinders.
31200300 111
Disassembly and Assembly Section

Illustration 551 g01047712

6. Measurement (V) is stamped on the head of

pinion shaft (37). Use the following formula in
order to calculate Measurement (S): X mm -V
Illustration 549 g01047703 mm = S mm.
7. Among the available list of shims, choose the shim
with the thickness of Measurement (S).

Illustration 550 g01047705

5. Use Tooling (J) in order to measure Distance (A).

Distance (B) equals 145 mm (5.7 inch). Distance Illustration 552 g01047713
(C) equals 50 mm (2.0 inch). Use the following 8. Remove Tooling (H). Remove brake cylinders (4).
formula in order to calculate Measurement (X): A Remove the nut and the washer from Tooling (G)
mm + C mm - B mm = X mm. Record and remove Tooling (G). Remove bearing cones
Measurement (X). (40) and (41).
112 31200300
Disassembly and Assembly Section

Illustration 555 g1027394

11. Install pinion shaft (37) into the center housing.
Raise the temperature of bearing cone (40) and
install bearing cone (40) onto pinion shaft (37).

Illustration 553 g01027392

9. Install the suitable shim onto pinion shaft (37).
Install the shim with the chamfer against the gear.
Raise the temperature of bearing cone (41) and
install bearing cone (41) onto pinion shaft (37).

Illustration 556 g01026575

12. Install seal (36) into the center housing.

Illustration 554 g01033145

10. Install washers (38) and collapsible spacer (39)
onto pinion shaft (37).
31200300 113
Disassembly and Assembly Section

Illustration 557 g01026413

.Illustration 559 g01026410
Note: Check the O-ring seal for wear or for damage. If 15. Use a suitable hammer and a punch and stake nut
necessary, replace the O-ring seal. (32).
13. Install brake disc (33), O-ring seal (34), washer
(35), and nut (32).

Illustration 560 g01026258

16. Install pins (16). Install collar (17), and plate (18).
Illustration 558 g01047714
Use Tooling (C) and install retaining ring (19).
14. Use Tooling (D) with a dial type torque wrench in
order to set the rotating torque. Tighten nut (32) in
order to achieve a rotating torque of 1.80 to 2.60
Nm (16.0 to 23.0 lb in).
114 31200300
Disassembly and Assembly Section

Illustration 561 g01038163

Illustration 563 g01029527
17. Install thrust washer (30) and side gear (31). Install 19. Raise the temperature of bearing cones (14) and
spider (29), gears (28), and thrust washers (27). (15). install bearing cones (14) and (15).

Illustration 562 g01038164 Illustration 564 g01026263

18. Install planetary shafts (26). Install locking pins 20. Install bevel gear (21) onto the differential. Apply
(25). Install side gear (24) and thrust washer (23). Tooling (K) to the threads of bolts (20). Install bolts
Install cover (22). (20) and tighten bolts (20) to a torque of 70 Nm
(52 lb ft).
31200300 115
Disassembly and Assembly Section

Illustration 565 g01028682

Note: Check the O-ring seals for wear or for damage. If

necessary, replace the O-ring seals.
21. Apply a thin coat of grease onto O-ring seals (5).
Install O-ring seals (5) onto brake piston (6).
Illustration 567 g01047720

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
23. Install springs and bolts (8). Install bolts (7).
Tighten bolts (7) to a torque of 10 Nm (7 lb ft).
Tighten springs and bolts (8) to a torque of 10 Nm
(7 lb ft).

Illustration 566 g01028683

22. Install brake piston (6) into brake cylinder (4). Make
sure that the holes on brake piston (6) align with the Illustration 568 g01028752
holes in brake cylinder (4).
116 31200300
Disassembly and Assembly Section

24. Position brake cylinder (4) on a flat surface. Use

Tooling (F) and install bearing cup (13).

Illustration 568 g01028800

25. Use Tooling (A) and install spanner nut (12) into
brake cylinder (4).
Illustration 571 g01026603

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
Note: Check the O-ring seals for wear or for damage. If
necessary, replace the O-ring seals.
27. Position fork (48) into the center housing. Install
shaft (49), spring (50), bushing (51), retaining ring
(52), O-ring seals (53), piston (54), O-ring (55), and
cover (56). Apply Tooling (K) to the threads of bolts
(57) and install bolts (57). Install retaining ring (47),
washer (46), spring (45), O-ring seal (44), and
cover (43). Apply Tooling (K) to the threads of bolts
Illustration 570 g01028802 (42) and install bolts (42). Tighten bolts (42) and
26. Apply Tooling (L) to the mating surfaces of the (57) to a torque of 23 Nm (17 lb ft).
center housing and the left brake cylinder (4). Align
the location marks that were made during the
removal procedure. Position brake cylinder (4) onto
the center housing and install bolts (9). Tighten bolts
(9) to a torque of 79 Nm (58 lb ft).
31200300 117
Disassembly and Assembly Section

Illustration 572 g01029529 Illustration 574 g01029534

28. Install the differential into the right side of the center 30. Oscillate the pinion shaft and use Tooling (A) to
housing. advance the spanner nuts until there is slight
backlash with no end play.

Illustration 573 g01029530

Illustration 575 g01038165
29. Apply Tooling (L) to the mating surfaces of the 31. Install a dial type torque wrench onto the pinion
center housing and the right brake cylinder (4). shaft. Measure the total rotating torque. Use the
Align the location marks that were made during the following formula in order to calculate the total
removal procedure. Position brake cylinder (4) onto rotating torque (TRT): P equals the rotating torque
the center housing and install bolts (9). Tighten bolts that was measured in Step 14. TRT = P + 0.280
(9) to a torque of 79 Nm (58 lb ft). Use Tooling (A) Nm (2.48 lb in) to P + 0.467 Nm (4.13 lb in)
and install spanner nut (12).
32. If the total rotating torque (TRT) is less than
the specified amount tighten both spanner nuts
equally. If the total rotating torque (TRT) is greater
than the specified amount, loosen both spanner
nuts equally. Be sure to always maintain slight
backlash.
118 31200300
Disassembly and Assembly Section

Illustration 578 g01029578

35. Install retainer (10) and bolt (11) into both brake
cylinders (4). Tighten bolts (11) to a torque of
1 3 N m ( 1 0 lb ft).

Illustration 576 g01047722

33. Mount Tooling (M) onto the center housing, as
shown. Measure the backlash between the pinion
and the bevel gear. The proper backlash setting is
0.180 to 0.230 mm (0.0071 to 0.0091 inch).

Illustration 579 g01033162

36. Install coupling (3) with brake discs (2) and plates
(1) into brake cylinder (4).
End By:
a. Install the axle housing. Refer to Disassembly and
Assembly, "Axle Housing (Service Brakes, Differential
and Bevel Gear) (Front) - Install".

Illustration 577 g01029595

34. If the backlash is not within the specification, retract
one spanner nut and advance the opposite spanner
nut equally. This will maintain the bearing preload. If
the backlash is less than the specified amount,
move the bevel gear in Direction (A). If the
backlash is greater than the specified amount,
move the bevel gear in Direction (B).
31200300 119
Disassembly and Assembly Section

Axle Housing (Service Brakes,

Differential and Bevel Gear)
(Front) - Install
Installation Procedure
Table 24

Required Tools

Tool Part Number Part Description Qty

A Loctite 270 1

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Illustration 580 g01024184

Note: Align the location marks that were made during

the removal procedure.
1. Attach a suitable lifting device onto axle housing
(2). The weight of axle housing (2) is approximately
170 kg (375 lb). Position axle housing (2) onto
brake cylinder assembly (3).
120 31200300
Disassembly and Assembly Section

Illustration 581 g01024181

2. Apply Tooling (A) on the threads of bolts (1). Install
bolts (1). Tighten bolts (1) to a torque of 190 Nm
(140 lb ft).
3. Repeat Steps 1 and 2 for the other side.
4. Fill the axle with oil. Refer to Operation and
Maintenance Manual, "Differential Oil - Change"
and Operation and Maintenance Manual,
"Capacities (Refill)".134
End By:
a. Install the drive and steering axle onto the machine.
Refer to Disassembly and Assembly, "Drive and Steering
Axle (Front) - Install".

Axle Housing (Differential and

Bevel Gear) (Rear) - Remove
Removal Procedure
Illustration 582 g01032925
Start By: 1. Attach a suitable lifting device onto the housing for
a. Remove the drive and steering axle from the the differential and bevel gear. The weight of
machine. Refer to Disassembly and Assembly, differential and bevel gear housing (1) is
"Drive and Steering Axle (Rear) - Remove". approximately 100 kg (220 lb). Remove bolts (2)
b. Remove the axle shafts. Refer to Disassembly and remove the differential and bevel gear housing
and Assembly, "Axle Shaft - Remove and Install". (1) from the axle housing.
31200300 121
Disassembly and Assembly Section

Axle Housing (Differential and

Bevel Gear) (Rear) -
Disassemble
Disassembly Procedure
Table 25

Required Tools

Tool Part Number Part Description Qty

A 235-2797 Spanner Socket 1

B 1P-2321 Combination Puller 1
C 235-2784 Pinion Wrench 1
D 8H-0663 Bearing Puller Gp 1

Start By: Illustration 585 g01032080

a. Remove the rear axle differential and bevel gear from the 3. Use Tooling (A) and remove spanner nuts (3).
axle housing. Refer to Disassembly and Assembly, "Axle
Housing (Differential and Bevel Gear) (Rear) - Remove".

Illustration 583 g01032160

1. Make reference marks on the caps and the
housing for installation purposes.

Illustration 586 g01032081

4. Remove bolts (4) and caps (5).

Illustration 584 g01032077

2. Remove bolts (1) and retainers (2).
122 31200300
Disassembly and Assembly Section

Illustration 587 g01032317

5. Remove the differential from the differential
housing. Remove bearing cups (6) and (7).

Illustration 589 g01032334

7. Use Tooling (B) and remove bearing cone (9).

Illustration 588 g01032333

6. Use Tooling (B) and remove bearing cone (8).

Illustration 590 g01032336

8. Remove bolts (10) and remove bevel gear (11).
31200300 123
Disassembly and Assembly Section

Illustration 593 g01032416

11. Straighten nut (22) out of the locking tab.

Illustration 591 g01032576

9. Remove cover (12). Remove thrust washer (13)
and side gear (14). Use a suitable punch and a
hammer and drive out locking pins (15). Remove
planetary shafts (16).

Illustration 594 g01032578

12. Use Tooling (C) in order to hold pinion flange (23)
and remove nut (22).

Illustration 592 g01032369

10. Remove thrust washers (17), gears (18), and spider
(19). Remove side gear (21) and thrust washer (20).

Illustration 595 g01032419

124 31200300
Disassembly and Assembly Section

13. Remove washer (24) and O-ring seal (25). Remove

pinion flange (23).

Illustration 596 g01032628

14. Remove lip seal (26) from the differential housing.

Illustration 599 g01032636

17. Use Tooling (D) and a suitable press in order to
remove bearing cone (33) from pinion shaft (30).
Remove the shim that is positioned under bearing
cone (33). Check the shim for wear. If necessary,
replace the shim.

Axle Housing (Differential and

Bevel Gear) (Rear) - Assemble
Assembly Procedure
Table 26

Required Tools

Tool Part Number Part Description Qty

A 235-2797 Spanner Socket 1

Illustration 597 g01032609
15. Tap the end of pinion shaft (30) with a soft hammer C 235-2784 Pinion Wrench 1
in order to remove pinion shaft (30) from the E 1P-0520 Driver Gp 1
differential housing. Remove bearing cone (29),
F 235-2789 False Pinion 1
washers (27), and collapsible spacer (28).
G 235-2795 Disc 2
H 238-0287 Shaft 1
J 6V-2012 Depth Micrometer 1
K Loctite 270 1
L 8T-5096 Dial Indicator Gp 1

Illustration 598 g01032612

16. Use a suitable hammer and a punch and remove
bearing cups (31) and (32).
31200300 125
Disassembly and Assembly Section

Illustration 600 g01032612

1. Use Tooling (E) and install bearing cups (31) and
(32).

Illustration 602 g01034156

3. Install Tooling (G) and (H). Install caps (5) and
bolts (4). Install Tooling (J).
4. Use Tooling (G), (H), and (J) to measure the
distance to the pinion.
5. Measure the depth from Tooling (H) to the
bottom of the hole in Tooling (F). Record the
measurement as Measurement (X).

Illustration 601 g01034151

2. Install bearing cone (33) onto Tooling (F). Install
Tooling (F). Install bearing cone (29), washer (24),
and nut (22). Tighten nut (22) until there is no
backlash.

Illustration 603 g01048231

6. Measurement (V) is stamped on the head of
pinion shaft (30). Use the following formula in
order to calculate Measurement (S): X mm -V
mm = S mm.
7. Among the available list of shims, choose the shim
with the thickness of Measurement (S).
126 31200300
Disassembly and Assembly Section

Illustration 604 g01034182

8. Remove bolts (4), caps (5), Tooling (G), and

Tooling (H). Remove nut (22), washer (24), and
bearing cone (33). Remove Tooling (F) and
bearing cone (29).

Illustration 606 g01032609

10. Install pinion shaft (30), washers (27), collapsible
spacer (28), and bearing cone (29).

Illustration 605 g01034186

9. Install the suitable shim onto pinion shaft (30).
Install the shim with the chamfer against the gear.
Raise the temperature of bearing cone (33) and
install bearing cone (33) onto pinion shaft (30).
Illustration 607 g01032628
11. Install lip seal (26).
31200300 127
Disassembly and Assembly Section

Illustration 610 g01032416

14. Use a suitable hammer and a punch and stake nut
(22).

Illustration 608 g01034256

Note: Check the O-ring seal for wear or for damage. If
necessary, replace the O-ring seal.
12. Install pinion flange (23). Install O-ring seal (25),
washer (24), and nut (22).

Illustration 611 g01032369

15. Install thrust washer (20) and side gear (21). Install
spider (19), gears (18), and thrust washers (17).

Illustration 609 g01034429

13. Use Tooling (C) with a dial type torque wrench in
order to set the rotating torque. Tighten nut (22) in
order to achieve a rotating torque of 1.81 to
2.60 Nm (16.0 to 23.0 lb in).

Illustration 612 g01032576

128 31200300
Disassembly and Assembly Section

16. Install planetary shafts (16). Install locking pins

(15). Install side gear (14) and thrust washer (13).
Install cover (12).

Illustration 615 g01032317

19. Install bearing cups (6) and (7) and install the
differential into the axle housing.
Illustration 613 g01034446
17. Raise the temperature of bearing cones (8) and (9).
Install bearing cones (8) and (9).

Illustration 616 g01032081

20. Install caps (5) and install bolts (4). Slightly tighten
bolts (4). Do not torque bolts (4) at this time.
Illustration 614 g01034447
18. Install bevel gear (11) onto the differential. Apply
Tooling (K) to the threads of bolts (10). Install bolts
(10) and tighten bolts (10) to a torque of 70 Nm
(52 lb ft).
31200300 129
Disassembly and Assembly Section

Illustration 617 g01034579 Illustration 619 g01034591

21. Use Tooling (A) and install spanner nuts (3). 25. Mount Tooling (L) onto the differential housing, as
22. Oscillate the pinion shaft and use Tooling (A) shown. Measure the backlash between the pinion
to advance spanner nuts (3) until there is slight and the bevel gear. The proper backlash setting is
backlash and no end play on the bearings. 0.180 to 0.230 mm (0.0071 to 0.0091 inch).

Illustration 618 g01032416

23. Use a dial type torque wrench and measure the
total rotating torque. Use the following formula in
order to calculate the total rotating torque (TRT):
P equals the rotating torque that was measured in
Step 13. TRT = P + 0.280 Nm (2.48 lb in) to P +
0.467 Nm (4.13 lb in) Illustration 620 g01029595

24. If the total rotating torque (TRT) is less than the 26. If the backlash is not within the specification, retract
specified amount, tighten the spanner nuts. If one spanner nut and advance the opposite spanner
the total rotating torque (TRT) is greater than the nut equally. This will maintain the bearing preload. If
specified amount, loosen the spanner nuts. Be the backlash is less than the specified amount,
sure to always maintain a slight backlash. move the bevel gear in Direction (A). If the
backlash is greater than the specified amount,
move the bevel gear in Direction (B).
130 31200300
Disassembly and Assembly Section

Illustration 621 g01032077

27. Install retainers (2) and bolts (1). Tighten bolts (1) to
a torque of 13 Nm (10 lb ft).

Illustration 623 g01032925

1. Attach a suitable lifting device onto the differential
and bevel gear housing (1). The weight of
differential and bevel gear housing (1) is
approximately 100 kg (220 lb). Install the
differential and bevel gear housing (1) into the rear
axle housing. Apply Tooling (A) to the threads of
bolts (2). Install bolts (2). Tighten bolts (2) to a
torque of 169 N-m (125 lb ft).
End By:
a. Install the axle shafts. Refer to Disassembly and Assembly,
"Axle Shaft - Remove and Install".
b. Install the drive and steering axle onto the machine. Refer
to Disassembly and Assembly, "Drive and Steering Axle
(Rear) - Install".
Illustration 622 g01034820
28. Tighten bolts (4) to a torque of 266 Nm (196 lb ft). Parking Brake Control -Remove
End By: and Install
a. Install the rear axle differential and bevel gear into the
axle housing. Refer to Disassembly and Assembly, "Axle
Housing (Differential and Bevel Gear) (Rear) - Install". Removal Procedure
1. 1. Park the machine on level ground. Place blocks
Axle Housing (Differential and in front of the rear wheel and behind the rear wheels.
Bevel Gear) (Rear) - Install
Installation Procedure
Table 27

Required Tools
Part
Tool Part Description Qty
Number
A 4C-9507 Retaining Compound 1

Illustration 624 g00931612

31200300 131
Disassembly and Assembly Section

Illustration 625 g00931615 Illustration 628 g00934439

2. Turn grip (1) in a counterclockwise direction in
order to fully release the tension on the parking
brake cable. Remove bolts (2) and slide cover (3)
off the hand control. Move the cover until you are
able to disconnect electrical connector (4) before
removing the cover from the machine.

Illustration 629 g00931645

5. Remove cotter pin (12), pin (13) and two washers
(14) in order to disconnect brake cable (15) from
hand control (10). Compress the fingers on spring
clip (16) and remove brake cable (15) from hand
control (10).
Illustration 626 g00931616
3. Remove screws (5) in order to remove limit switch Installation Procedure
(6). Lay the limit switch aside.

Illustration 630 g00931645

Illustration 627 g00931643
1. Install brake cable (15) into hand control (10).
4. Remove two nuts (7), the washers, two bolts (8)
Make sure that the fingers on spring clip (16) have
and two spacers (9) in order to remove hand
locked the brake cable into the hand control.
control (10) from mounting bracket (11).
132 31200300
Disassembly and Assembly Section

Illustration 631 g00934439 Illustration 634 g00931615

2. Align the holes in hand control (10) with the holes
in brake cable (15) and install pin (13), two washers
(14)and cotter pin (12).

Illustration 635 g00931612

5. Connect electrical connector (4) before sliding
cover (3) over hand control into position. Install two
Illustration 632 g00931643
bolts (2). Rotate grip (1) in a clockwise direction in
3. Position hand control (10) onto mounting bracket order to adjust the tension on the parking brake
(11) and install two bolts (8), two spacers (9), two cable. Refer to the appropriate service manual for
nuts (7) and the washers. more information.

Parking Brake - Remove

Removal Procedure
1. Park the machine on level ground. Place wheel
blocks in front of the rear wheels and behind the
rear wheels. Disengage the parking brake. Refer to
Operation and Maintenance Manual, "Parking
Brake - Check".

Illustration 633 g00931616

4. Position limit switch (6) and install two screws (5).
31200300 133
Disassembly and Assembly Section

Illustration 636 g00948295

2. Remove clip (1) and pin (2) in order to disconnect
cable (3) from lever (4). Remove two bolts (5) and
the washers in order to remove bracket (6) from
parking brake (7).

Illustration 639 g00950993

2. Turn the parking brake onto the opposite side and
remove two brake lining's (2).

Illustration 637 g00948296

3. Loosen two bolts (8). Unscrew the bolts until the
bolts are clear of the axle housing. Carefully lift
parking brake (7) off brake disc (9) and away from
the machine.

Parking Brake - Disassemble

Disassembly Procedure
Start By: Illustration 640 g00951047
a. Remove the parking brake. Refer to Disassembly and 3. Slide two bolts (3) out of torque plate (4) and
Assembly, "Parking Brake - Remove". torque plate (5). Remove nut (6) and sleeve (7)
from bolts (3). Remove two seals (8) that are
installed between the torque plates.

Illustration 638 g00950992

1. Remove retaining spring (1) from the parking
brake. Illustration 641 g00951050
4. Clamp torque plate (5) (not shown) in a suitable
soft jawed vise. Remove nut (9), nut (10), washer
(11), washer (12), thrust (13) and lever (14).
134 31200300
Disassembly and Assembly Section

Illustration 642 g00951224

Illustration 645 g00951227
5. Slide cam assembly (15) off bolt (16) and torque 8. Slide torque plate (4) off bolt (16).
plate (4).

Illustration 646 g00951228

Illustration 643 g00951225
9. Remove bolt (16) from torque plate (5).
6. Remove boot (17) and boot (18) from cam
assembly (15).
Parking Brake - Assemble
Assembly Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 644 g00951226

7. Remove cam ring (19), ball bearing and retainer
(20) from cam ring (21).

Illustration 647 g00951228

2. Install bolt (16) into torque plate (5). Make sure
that the bolt head is correctly located in the locking
tabs on the torque plate.
31200300 135
Disassembly and Assembly Section

Illustration 648 g00951229

Illustration 651 g00951230
3. Clamp torque plate (5) in a suitable soft jawed 6. Slide cam assembly (15) over bolt (16) and onto
vise. Install torque plate (4) onto bolt (16). torque plate (4). Make sure that you align the
dowels on the cam assembly with the dowel holes
in the torque plate.

Illustration 649 g00951226

4. Apply a thin coat of 1P-0808 Multipurpose
Grease to the ball bearings and retainer (20).
Install the ball bearings and the retainer onto the Illustration 652 g00951050
paths in cam ring (21). Install cam ring (19) onto the
ball bearings and the retainer.

Illustration 653 g00951253

Illustration 650 g00951225 7. Align the dowel holes in lever (14) with the dowels
5. Install boot (18) and boot (17) onto cam assembly on the cam assembly. Install the lever into position.
(15). Refer to illustration 653 for the correct position.
Install thrust (13), washer (12), washer (11), nut
(10) and nut (11).
Note: Nut (10) and nut (11) can only be adjusted when
the parking brake is installed on the machine. Refer to
Disassembly and Assembly, "Parking Brake - Install" for
the correct adjustment procedure.
136 31200300
Disassembly and Assembly Section

Parking Brake - Install

Installation Procedure

Illustration 654 g00951047

8. Install two seals (8) between torque plate (4) and
torque plate (5). Install sleeve (7) and nut (6)
onto two bolts (3). Apply a thin coat of 1P- 0808
Multipurpose Grease onto the sleeves before Illustration 657 g00948296
sliding the bolts and sleeves into the torque plates. 1. Slide parking brake (7) onto brake disc (9) and
9. Nut (6) can only be adjusted when the parking install two bolts (8). Do not tighten the bolts at this
brake is installed on the machine. Refer to time.
Disassembly and Assembly, "Parking Brake - 2. Use the following procedure to adjust the parking
Install" for the correct adjustment procedure. brake:

Illustration 655 g00950993 Illustration 658 g00948297

10. Install two brake lining's (2) into the parking brake.

Illustration 659 g00948298

a. Use a suitable feeler gauge to measure the distance
Illustration 656 g00950992 between locknuts (11) and sleeves (10). If necessary,
11. Turn the parking brake onto the opposite side and adjust the locknuts in order to set the gap to 0.6350 ±
install retaining spring (1). 0.3810 mm (0.025 ± 0.015 inch) before tightening two
bolts (8) to a torque of 150 Nm (110 lb ft).
End By:
a. Install the parking brake. Refer to Disassembly and
Assembly, "Parking Brake - Install".
31200300 137
Disassembly and Assembly Section

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
Illustration 660 g00951541 shown. Clean all surfaces where parts are to be
b. Loosen nut (13). Turn nut (12) in a clockwise installed.
direction. This action will apply the parking
brake. Tighten the nut to a torque of 11 ±2 Nm
NOTICE
(100 ±20 lb in). Care must be taken to ensure that fluids are contained
c. When the correct torque is achieved, turn nut during performance of inspection, maintenance, testing,
(12) in a counterclockwise direction by 300 adjusting and repair of the product. Be prepared to collect
degrees ± 60 degrees. This action will release the fluid with suitable containers before opening any
the parking brake and the parking brake lever
will be set correctly.
compartment or disassembling any component
containing fluids.
d. Tighten nut (13) against nut (12). Tighten the
nut to a torque of 68 ±6 Nm (50 ±5 lb ft). Dispose of all fluids according to local regulations and
mandates.

Illustration 661 g00948295

3. Position bracket (6) onto parking brake (7) and Illustration 662 g00940864
install two bolts (5) with the washers. Align cable (3) 1. Remove cover (1).
with lever (4) and install pin (2) and clip (1).
End By:
a. Adjust the parking brake. Refer to the appropriate
service manual for more information.

Brake Cylinder (Master)

Remove and Install
Removal Procedure
Table 28

Required Tools Illustration 663 g00940865

2. Disconnect hose assemblies (2) from brake
Part
Tool
Number
Part Description Qty cylinder (3). Loosen the hose clamp and
disconnect hose (4).
A 1P-1855 Retaining Ring Pliers 1
138 31200300
Disassembly and Assembly Section

Illustration 664 g00940866 Illustration 667 g00940869

3. Remove the bolts that secure cover (5). 5. Use Tooling (A) in order to remove retaining ring
(9) from pin assembly (10). Remove the pin
assembly out of linkage (11) and lever (12).

Illustration 665 g00940867

Illustration 668 g00940870

Illustration 666 g01050119

4. Carefully lower cover (5) and loosen the hose
clamp before disconnecting heater hose (6). Illustration 669 g00940871

Loosen retaining nut (8) and remove key start 6. With the aid of a second person, support brake
switch (7) from cover (5). Move the key start cylinder (3). at the same time remove two locknuts
switch aside. Remove cover (5) from the machine. (13) and the washers. Carefully remove the brake
cylinder from the machine.
Note: The second person is necessary in order to
prevent damage to the master cylinder when the
locknuts are removed.
31200300 139
Disassembly and Assembly Section

Installation Procedure
Table 29

Required Tools

Part
Tool Part Description Qty
Number

A 1P-1855 Retaining Ring Pliers 1

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Illustration 672 g00940878
component life. 2. Align the holes in linkage (11) with the hole in
lever (12) before installing pin (10). Use Tooling (A)
in order to install retaining ring (9) onto pin
assembly (10).
Note: If necessary, adjust the brake pedal. Refer to
Systems Operation, Testing and Adjusting," Service
Brake Control (pedal) - Adjust".

Illustration 670 g00940876

Illustration 673 g01050119

Illustration 671 g00940877

1. With the aid of a second person, position brake
cylinder (3) on the machine and install locknuts (13)
with the washers.

Illustration 674 g00940880

3. Position cover (5) in order to install key start switch
(7) and retaining nut (8). Tighten the retaining nut
to a torque of 13.6 ±4 Nm (120 ±35 lb in).
Connect heater hose (6) and tighten the hose
clamp.
140 31200300
Disassembly and Assembly Section

Tire and Rim - Remove and

Install
Removal Procedure
Table 30

Required Tools

Tool Part Number Part Description Qty

8S-7610 Base 1

A 8S-7650 Cylinder 1

Illustration 675 g00940881 3S-6224 Electric Hydraulic Pump 1

4. Carefully lift cover (5) and install the bolts that
B 1U-9760 Jack Stand Gp 1
secure the cover.

Start By:
a. Remove the fender from the wheel that requires removing.
Refer to the appropriate service manual for more
information.

Servicing and changing tires and rims can be

dangerous and should be done only by trained
personnel using proper tools and procedures.

Illustration 676 g00940882

5. Connect hose (4) to brake cylinder (3) and tighten
the hose clamp. Connect hose assemblies (2).
Personal injury or death can result from improper
lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
Note: The following procedure is performed on the rear
Illustration 677 g00940883 axle. The procedure of the front axle is identical. Park
6. Install cover (1). the machine on firm level ground. Apply the parking
brake and block all the wheels except the wheel that
7. Purge the air from the brake system. Refer to
requires removing.
Systems Operation, Testing and Adjusting,
"Service Brake Air - Purge" for the proper
procedure.
31200300 141
Disassembly and Assembly Section

and Maintenance Manual, "Tire Inflation Information" for

additional information about the recommended weight
of installed liquid ballast.

Illustration 678 g00951912

1. Loosen wheel nuts (1) but do not remove the
wheel nuts.
Illustration 681 g00951915
4. Remove wheel nuts (1) and the spring washers.
Use the attached lifting equipment to remove the
wheel and tire from the machine.

Installation Procedure
Table 31

Required Tools

Tool Part Number Part Description Qty

Illustration 679 g00951913

8S-7620 Base 1
2. Use Tooling (A) to raise the machine. Position Tool A 8S-7650 Cylinder 1
(B) in a suitable place under the axle. Use Tooling
(A) to lower the machine onto Tool (B). 3S-6224 Electric Hydraulic Pump 1
Note: If both wheels are being removed at the same B 1U-9760 Jack Stand Gp 1
time, repeat Steps 1 and 2 at the other end of the axle.
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 680 g00951914

3. Attach a suitable nylon lifting sling around the
wheel and tire. Attach the nylon lifting sling to a
suitable hoist in order to support the wheel and tire. Illustration 682 g00952212

The weight of the wheel and tire without ballast is 2. Attach a suitable nylon lifting sling around the
approximately 190 kg (420 lb). wheel and tire. Attach the nylon lifting sling to a
suitable hoist in order to support the wheel and
Note: Liquid ballast is installed in the tires of certain
tire. Use the attached lifting equipment to position
machines. Liquid ballast will greatly increase the
the tire and rim to the axle. The weight of the
weight of a wheel and tire. You must be sure that the
wheel and tire without ballast should be no greater
weight of the wheel and tire will not exceed the lifting
than 190 kg (420 lb).
capacity of your lifting equipment. Refer to Operation
142 31200300
Disassembly and Assembly Section

Note: Liquid ballast is installed in the tires of certain

machines. Liquid ballast will greatly increase the
weight of a wheel and tire. You must be sure that the
weight of the wheel and tire will not exceed the lifting
capacity of your lifting equipment. Refer to Operation
and Maintenance Manual, "Tire Inflation Information" for
additional information about the recommended weight
of installed liquid ballast.

Illustration 685 g00951912

6. Tighten wheel nuts (1) in a cross pattern to a
torque of 240 ± 40 Nm (177 ± 30 lb ft) and then
turn an additional 60 degrees ± 5 degrees.
Note: Check the wheel nut torque on new wheels and
on repaired wheels after every ten service hours until
the specified torque is maintained. Refer to Operation
and Maintenance Manual, "Wheel Nut Torque - Check".
Illustration 683 g00951915 End By:
3. Install wheel nuts (1). Do not tighten the nuts at a. Install the fender. Refer to the appropriate service
this step. manual for more information.
4. Remove the nylon lifting sling and the hoist from
the machine.

Illustration 684 g00951913

5. Use Tooling (A) to raise the machine in order to
remove Tool (B). Use Tooling (A) to lower the wheel
to the ground before removing the Tooling from the
machine.
Note: If both wheels are being installed at the same
time, repeat Step 2 through 5 at the other end of the
axle.
31200300 143
Index Index

A Drive and Steering Axle (Rear) - Install

Axle Housing (Differential and Bevel Gear) (Rear) - Assemble Installation Procedure ................................................... 82
Assembly Procedure................................................... 124 Drive and Steering Axle (Rear) - Install.............................. 82
Axle Housing (Differential and Bevel Gear) (Rear) - Drive and Steering Axle (Rear) - Remove
Assemble ......................................................................... 124 Removal Procedure ...................................................... 79
Axle Housing (Differential and Bevel Gear) (Rear) - Install Drive and Steering Axle (Rear) - Remove.......................... 79
Installation Procedure................................................. 130 Drive Shaft (Front) - Remove and Install
Axle Housing (Differential and Bevel Gear) (Rear) - Install130 Installation Procedure ................................................... 69
Axle Housing (Differential and Bevel Gear) (Rear) - Remove Removal Procedure ...................................................... 68
Removal Procedure.................................................... 120 Drive Shaft (Front) - Remove and Install............................ 68
Axle Housing (Differential and Bevel Gear) (Rear) - Drive Shaft (Rear) - Remove and Install
Remove............................................................................ 120 Installation Procedure ................................................... 70
Axle Housing (Differential and Bevel Gear) (Rear) - Removal Procedure ...................................................... 69
Disassemble
Drive Shaft (Rear) - Remove and Install ............................ 69
Disassembly Procedure.............................................. 121
Axle Housing (Differential and Bevel Gear) (Rear) - F
Disassemble..................................................................... 121
Final Drive Planetary - Install
Axle Housing (Service Brakes, Differential and Bevel Gear)
(Front) - Assemble Installation Procedure ................................................... 91
Assembly Procedure................................................... 109 Final Drive Planetary - Install ............................................. 91
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary - Remove
(Front) - Assemble ........................................................... 109 Removal Procedure ...................................................... 89
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary - Remove ......................................... 89
(Front) - Disassemble....................................................... 104 Final Drive Planetary Assemble
Disassembly Procedure.............................................. 104 Assembly Procedure..................................................... 90
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary Assemble ......................................... 90
(Front) - Install.................................................................. 119
Final Drive Planetary Disassemble .................................... 90
Installation Procedure................................................. 119
Disassembly Procedure................................................ 90
Axle Housing (Service Brakes, Differential and Bevel Gear)
(Front) - Remove I
Removal Procedure.................................................... 103
Important Safety Information.................................................ii
Axle Housing (Service Brakes, Differential and Bevel Gear)
(Front) - Remove.............................................................. 103 P
Axle Housing and Flange -Assemble ................................. 96
Parking Brake - Assemble
Assembly Procedure..................................................... 96
Assembly Procedure................................................... 134
Axle Housing and Flange -Disassemble
Parking Brake - Assemble................................................ 134
Disassembly Procedure................................................ 94
Parking Brake - Disassemble
Axle Housing and Flange -Disassemble ............................ 94
Disassembly Procedure.............................................. 133
Axle Housing and Flange Install
Parking Brake - Disassemble ........................................... 133
Installation Procedure................................................... 98
Parking Brake - Install
Axle Housing and Flange Install......................................... 98
Installation Procedure ................................................. 136
Axle Housing and Flange Remove..................................... 91
Parking Brake - Install ...................................................... 136
Removal Procedure...................................................... 91
Parking Brake - Remove
Axle Shaft - Remove and Install
Removal Procedure .................................................... 132
Installation Procedure................................................. 102
Parking Brake - Remove .................................................. 132
Removal Procedure.................................................... 101
Parking Brake Control -Remove and Install
Axle Shaft - Remove and Install....................................... 101
Installation Procedure ................................................. 131
B Removal Procedure .................................................... 130
Brake Cylinder (Master) Remove and Install Parking Brake Control -Remove and Install ..................... 130
Installation Procedure................................................. 139 S
Removal Procedure.................................................... 137
Steering Cylinder - Remove and Install
Brake Cylinder (Master) Remove and Install ................... 137
Installation Procedure ................................................... 88
D Removal Procedure ...................................................... 87
Disassembly and Assembly Section .................................... 3 Steering Cylinder - Remove and Install.............................. 87
Drive and Steering Axle (Front) - Install
Installation Procedure................................................... 75
Drive and Steering Axle (Front) - Install ............................. 75
Drive and Steering Axle (Front) - Remove
Removal Procedure...................................................... 70
Drive and Steering Axle (Front) - Remove ......................... 70
144 31200300
Index

T
Table of Contents................................................................. 1
Tie Rod (Steering) - Remove and Install
Installation procedure ................................................... 86
Removal Procedure ...................................................... 86
Tie Rod (Steering) - Remove and Install............................ 86
Tire and Rim - Remove and Install
Installation Procedure ................................................. 141
Removal Procedure .................................................... 140
Tire and Rim - Remove and Install................................... 140
Transmission - Assemble
Assembly Procedure..................................................... 38
Transmission - Assemble................................................... 38
Transmission - Disassemble
Disassembly Procedure................................................ 10
Transmission - Disassemble .............................................. 10
Transmission - Install
Installation Procedure ................................................... 66
Transmission - Install ......................................................... 66
Transmission - Remove
Removal Procedure ........................................................ 6
Transmission - Remove ....................................................... 6
Transmission Control (Select Lever) - Install
Installation Procedure ..................................................... 5
Transmission Control (Select Lever) - Install ....................... 5
Transmission Control (Select Lever) - Remove
Removal Procedure ........................................................ 3
Transmission Control (Select Lever) - Remove ................... 3
Manufactured by JLG under license from Caterpillar
Component Locations 31200304 FLUID POWER SYMBOLS
Description
Part Machine Schematic December 15, 2006 BASIC COMPONENT SYMBOLS
Number Location Location
Cooler & Mtg Gp - (12kW) 206-5502
1 A-6
Hydraulic Oil (Xmsn) (Option) (20kW) 194-0952 MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
Cylinder Gp - (FIXED)
Boom (Raise) (360) 253-3933
2 G-4
(560) 253-4258
11 20 37 VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
COMPENSATION
Cylinder Gp - Brake (Master) 295-3424 3 A-1 (ADJUSTABLE) (VARIABLE) ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

Cylinder Gp - Coupler 295-3419 4 H-5, H-7 VALVES

VALVE ENVELOPES VALVE PORTS
Cylinder Gp - (360) 203-7756
Tilt 5 F-5 16 27 8 31 14 15 7 9 32
(560) 211-1322
Cylinder Gp - (360) ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY
6 I-4
Frame Leveling (560) 211-1327
CONTROL VALVES CHECK VALVES
Cylinder Gp - (360) 203-7847
Hydraulic (Compensating) (560) 7 F-5 AB AB
207-5070
Cylinder Gp - (360) 259-8723
8 H-1, H-2
Stabilizer (560) 263-9955 P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
Cylinder Gp - Telescoping SYMBOL LOADED CONTROLLED
9 G-7
(560) 241-3160
MEASUREMENT ROTATING SHAFTS
Filter Gp - Oil (Power Train) 191-1060 10 B-5
Pump Gp -
Lower (Dead Engine Lower) (560) 264-0616 11 H-10
(Emergency Lower)
PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
Pump Gp - (360) 233-6072
Metering 12 F-9 FLUID STORAGE RESERVOIRS
(Steering - HMU) (560) 237-4154
Pump Gp -
Piston (Main)
(360) 295-3457
13 B-9 TH360B and TH560B
Telehandler
(560) 295-3462 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

Strainer - (Tank Filter) 202-5350 14 A-8

(360) 248-4000
18 21 23 24 25 COMBINATION CONTROLS
Tank As - Hydraulic

Hydraulic System
15 A-8
(560) 219-0538
5 17 4 22 8 31 39 6 30 2 29 3 12 38 1 40 19 13 36 10 26 28 33 34 35
Valve & Mtg Gp - Diverter (Dual Auxiliary) 222-4662 16 H-7
Valve As - (Tilt Cylinder Lock) (Cartridge) 295-3372 17 F-6 SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT
11 20 37
TH360B:
Valve Gp - Bank 4 (Implement) 295-3450 18 B-7 or MANUAL and PILOT PILOT or MANUAL

Valve Gp - Check (Xmsn) 257-4830 19 B-6

MANUAL CONTROL SYMBOLS
Valve Gp -
(560) 270-4157 20 H-9 7
S/N TBH00100 & After
Check (Emergency Lower)
Valve Gp - Check (Back Pressure) 225-1912 21 B-9 TH560B:
Valve Gp - PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
Check (Coupler Cylinder Check)
236-4441 22 H-5, H-6
S/N TBP00100 & After
Valve Gp - Control (Aux) 227-1207 23 D-6 PILOT CONTROL SYMBOLS
RELEASED PRESSURE REMOTE SUPPLY PRESSURE
Valve Gp - 227-1206 24 D-7
Control (Boom Extend, Retract)
Valve Gp - Control (Boom Raise, Lower) 227-1209 25 D-5
Valve Gp - Control (Quick Coupler Tilt) 227-1208 26 D-5 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
SUPPLY PRESSURE
Valve Gp - Diverter (Single Auxiliary) 295-3437 27 H-7, I-5
Valve Gp - Electronic Pilot 247-7829 28 B-4 ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS
Valve Gp -
295-3370 29 G-4
Load Control (Boom Raise Lock)
SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING
Valve Gp - Load Control (Frame Level) 265-0884 30 H-4
Valve Gp -
Load Control (360/560) 204-6924 31 G-1, G-2 HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS
(Stabilizer Cylinder Lock)
FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT THREE TWO
Valve Gp - Load Control (Tele Cylinder) 252-5652 32 F-7 INFINITE
DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION
Valve Gp - Manifold (Inlet) 227-1203 33 D-8 9 18 21 23 24 25
Valve Gp - Manifold (Outlet) 227-1205 34 D-4
4 22 16 27 8 31 14 15 UNIDIRECTIONAL UNIDIRECTIONAL

Valve Gp - Pilot (Anti Kick) 223-4153 35 G-5 26 28 32 33 34 35

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN
Valve Gp - Solenoid BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION

Machine Component Locations

295-3459 36 C-9
(Frame Level Arctic) (Option)
Valve Gp - Last Modified: 05/10/2004
Solenoid (Sequence) (360/560) 270-3593 37 I-10
(Emergency Lower)
© 2006 Caterpillar Printed in U.S.A.
Valve Gp - Solendoid (Steer Mode Select) 210-7217 38 E-10
Valve Gp -
All Rights Reserved
(360/560) 265-0881 39 F-1
Stabilizer Control
XMSN Gp - (4spPsy) 206-4387
40 A-6
(Option) (4spPsh) 206-4388

Electrical Symbols Table

Hydraulic Symbols (Electrical)
Tap Locations Outlet
Manifold
Pressure, Sampling, and Sensor Inlet

M
Tap Schematic Manifold
Number
Description
Location
Auxiliary Diverter Sol.
G
AA Main Pump Pressure C-9
BB Load Sensor Pressure C-9
BB Transducer Transducer Generator Electric Motor
CC Implement Pilot Pressure C-3 (Fluid) (Gas / Air)
DD SOS Oil Sample Port B-5

A
16 Pressure Switch Temperature Switch Electrical Wire
Pressure Switch
(Adjustable)

31200304
AA Electrical Symbols (Electrical)
27 Inlet
VIEW OF AREA A
Manifold Tele

24 Page
T
Quick Coulper Sol. Auxiliary
Pressure Temperature Level Flow
Tilt Symbol Symbol
Symbol Symbol
Boom
BB
Outlet
Manifold
Wire Number Identification Codes
Valve & Mtg Gp - Diverter (Dual Auxiliary) Electrical Schematic Example Hydraulic Schematic Example
18
Current Standard Current Standard
The load control valves are attached to the casings
of the stabilizer cylinders. Harness identification code
This example indicates
CC wire 135 in harness "AG". Wire
The load control valves lock oil into both sides Quick Coulper Sol. Circuit Number Wire Color
of the cylinders in order to hold the cylinders in Identification
position when the cylinders are stationary. The valves 325-AG135 PK-14
also prevent the stabilizer legs from collapsing if a
hydraulic hose bursts.
27 B Circuit Identification
325-PK
Wire Color Wire Gauge
Number

Valve Gp - Load Control 28

Location of
Previous Standard

(Stabilizer Cylinders) (Lock) Implement Disable Sol. Wire

Wire Color

Valve Gp - Implement Asy 4-Bank (15), 325-PK-14

Main Pump Pressure Port (AA),
Load Sensor Pressure Port (BB, B A
B Implement Pilot Pressure Port (CC) Circuit Number Wire Gauge
VIEW B-B Identification (EXAMPLE VALVE)

Valve Gp - Diverter (Single Auxiliary) Valve Gp - Bank 4 (Implement) Last Modified: 10/15/2003

Stabilizers are used to increase the stability of the

machine during stationary lifting operations. The (1) Flow control valve (stabilizer)
stabilizers are used when the machine is lifting heavy (2) Control valve (left stabilizer)
loads or when an access platform is installed on the (3) Control valve (right stabilizer)
machine.
The valve group (stabilizer) is installed in the center
Independent operation of the stabilizers allows the
The frame leveling cylinder is located at the front of of the stabilizer frame at the front of the machine.
machine to be leveled when the machine is operating The stabilizer cylinders are located on the stabilizers
the machine on the right side. The head end of the on uneven ground. at the front of the machine. The head end of the
cylinder is attached to the machine frame, and the The valve group (stabilizer) consists of the flow
cylinder is attached to the stabilizer frame and the
rod end is attached to the front axle. control valve (stabilizer) (1), the control valve (left
Stabilizers are installed as optional equipment on rod end is attached to the stabilizer leg.
stabilizer) (2) and the control valve (right stabilizer)
TH360 and TH560 machines only.
The frame leveling cylinder allows the machine frame (3).
The cylinders extend in order to lower the stabilizers
to be levelled in order to improve the stability of the
and the cylinders retract in order to raise the
machine during operation. The flow control valve (1) controls the flow of oil
Valve Group (Stabilizer) stabilizers.
into the stabilizer cylinders and out of the stabilizer
(1) Flow control valve (stabilizer) cylinders.
(2) Control valve (left stabilizer)
(3) Control valve (right stabilizer)
Stabilizers are used in order to improve the stability
of the machine.
The valve group (stabilizer) is located in the center of
the stabilizer frame at the front of the machine.

Cylinder Gp - Frame Leveling Stabilizer System Stabilizer Cylinders Valve Gp - Stabilizer Control
31200302
December 15, 2006

System Operation
Testing and
Adjusting
TH360B and TH560B Telehandlers
Hydraulic System
S/N TBH00100 & After
S/N TBP00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200302 1
Table of Contents
Table of
Table of Contents Solenoids (Frame Level).................... 21
Systems Operation Section Solenoid (Diverter Valve)................... 21
Graphic Color Codes ............................... 5 Relay (Frame Level) .......................... 21
Introduction.............................................. 6 Relays (Diverter Valve)...................... 22
General Information................................. 7 Relays (Quick Coupler)...................... 22
Main Control Valve Group (Implement)7 Location of Hydraulic Components ........ 22
Electronic Pilot Valve Group Hydraulic Tank................................... 22
(Implement) ......................................... 8 Piston Pump (Implement and
Stabilizer Control Valve Gp Steering) ............................................ 23
(If Equipped)........................................ 9 Compensator Valve ........................... 23
Machine ECM.................................... 10 Main Control Valve (Implement) ........ 23
Electronic Joystick............................. 12 Inlet Manifold ..................................... 24
Operator Switches............................. 13 Outlet Manifold................................... 25
Piston Pump (Implement and Boom Cylinder ................................... 25
Steering)............................................ 13 Load Control Valve (Boom Cylinder)
Hydraulic Oil Tank ............................. 13 (Lock)................................................. 25
Hydraulic Oil Filter ............................. 13 Telescoping Cylinder ......................... 25
System Operation.............................. 13 Load Control Valve (Telescoping
Load Independent Flow Division Cylinder) (Lock) ................................. 26
(LIFD) ................................................ 15 Tilt Cylinder........................................ 26
Location of Electrical Components ........ 15 Load Control Valve (Tilt Cylinder)
Switch (Lockout Control) ................... 15 (Lock)................................................. 26
Joystick Control ................................. 16 Compensating Cylinders.................... 26
Sensor (Boom Raise/Lower) ............. 17 Diverter Valve .................................... 27
Sensor for Boom Extend and Boom Quick Coupler Cylinder...................... 27
Retract or Boom Tilt Forward and Tilt Frame Leveling Cylinder.................... 27
Rackback........................................... 17 Lock Valve (Frame Leveling Cylinder)28
Switch for Boom Extend and Boom Control Valve Gp (Stabilizer) ............. 28
Retract or Boom Tilt Forward and Tilt Stabilizer Cylinders ............................ 28
Rackback........................................... 17 Load Control Valve (Stabilizer Cylinders)
Switch (Auxiliary Actuator in the + (Lock)................................................. 29
Direction) for Joystick (Type 1).......... 17 Lowering Control Pump (Manual) ...... 29
Switch (Auxiliary Actuator in the - Switches ............................................ 30
Direction) for Joystick (Type 1).......... 17 Joystick Control ................................ 31
Switch (Auxiliary Actuator) for Joystick Auxiliary Switches.............................. 31
(Type 2) ............................................. 17 Thumb Slider ..................................... 31
Switch (Auxiliary 1 or 2)..................... 17 Stabilizer Switches............................. 31
Switch (Continuous Auxiliary Flow) ... 17 Boom Critical Angle Switch................ 31
Switch (Quick Coupler)...................... 18 Boom Retracted Switch ..................... 31
Switch (Right Stabilizer) .................... 18 Stabilizer Pressure Switches ............. 32
Switch (Left Stabilizer)....................... 18 Quick Coupler Switch ........................ 32
Switch (Frame Level) ........................ 18 Continuous Flow SwitchImplement.... 32
Pressure Switches (Stabilizer) .......... 19 Lockout Switch................................... 32
Switch (Fully Lowered Boom)............ 19 Boom Lowered Switch ....................... 32
Switch (Critical Angle) ....................... 19 Electronic Control Module ...................... 33
Switch (Fully Retracted Boom).......... 19 Inputs ................................................. 33
Machine (ECM) ................................. 20 Outputs .............................................. 33
Main Control Valve (Implement)........ 20 Data Links.......................................... 33
Stabilizer Control Valve Gp Input/Output ....................................... 33
(If Equipped)...................................... 20 Electrical Output Components ............... 37
2 31200302
Table of Contents

Relays ................................................38 Valve for the Cylinder in the EXTEND

Solenoids ...........................................38 Position.............................................. 67
Electrical Function Requirements...........39 Valve for the Cylinder in the RETRACT
Transmission Neutralizer ...................39 Position.............................................. 68
Solenoid Outputs ...............................39 Load Control Valves .......................... 69
System Voltage ..................................39 Lowering Control Valve (If Equipped) 70
Shuttle Shift for the Power Shuttle Boom RAISE ..................................... 71
Transmission......................................39 Boom LOWER ................................... 72
Shift Lever (Cat Data Link) for Telescoping System .............................. 73
Powersynchro Transmission ..............39 Valve for the Telescoping Cylinder in the
Rear Axle Lock (if equipped)..............39 HOLD Position................................... 73
Machine Security System ..................40 Valve for the Telescoping Cylinder in the
Parking Brake ....................................40 EXTEND Position .............................. 75
Service Brake Pressure Switch for the Valve for the Telescoping Cylinder in the
Transmission Neutralizer ...................40 RETRACT Position............................ 77
More Electrical Function Auxiliary Hydraulic System .................... 79
Requirements.....................................40 Introduction........................................ 79
Steering..............................................40 Auxiliary Control (Combined Circuit) . 80
The Neutral Start Is Disabled .............40 Auxiliary Circuit 1............................... 82
Stabilizer Raise/Lower (if equipped) is Auxiliary Circuit 2............................... 83
Disabled .............................................41 Continuous Flow (Auxiliary
Boom Raise/Lower Is Disabled ..........41 Hydraulics)......................................... 84
The Boom Extend/Retract Is Disabled41 Quick Coupler.................................... 84
Disable The Rackback And Dump .....41 Quick Coupler Circuit DISENGAGED 85
The Frame Level (if equipped) is Quick Coupler Pins ENGAGED......... 86
Disabled .............................................42 Relief Valves and Makeup Valves ..... 87
Disable the Quick Coupler .................42 Compensating System........................... 87
Miscellaneous ....................................42 Boom Lower ...................................... 88
Electrical Schematic...........................43 Boom Raise ....................................... 89
Piston Pump (Implement and Steering) .45 Pressure Relief and Makeup Valves . 90
Piston Pump.......................................45 Frame Leveling System ......................... 91
Compensator Valve ...........................46 Locked Axle (HOLD).......................... 92
Low Pressure Standby .......................47 Frame that is Angled to the Left ........ 93
Upstroke.............................................48 Stabilizer System ................................... 94
Constant Flow ....................................49 Stabilizer Cylinders (HOLD) .............. 96
Destroke.............................................50 Stabilizer Cylinders (RAISE).............. 97
High Pressure Stall ............................52 Stabilizer Cylinders (LOWER) ........... 98
Main Control Valve (Implement).............53 Hydraulic System Schematic ................. 99
Check and Relief Valves ........................56 All Implements In HOLD .................... 99
Manifold Valve (Outlet)...........................58 Configuration Parameters................ 102
Pilot Hydraulic System ...........................59 Testing and Adjusting Section
Lowering Control Pump (Electric)...........60 Testing and Adjusting .......................... 103
Electric Lowering Control Pump (If Joystick Control - Calibrate.............. 103
Equipped)...........................................60 Main Control Valve (Implement) -
Lowering Control Pump (Manual) ......63 Calibrate .............................................. 123
Boom Hydraulic System .........................65 Programmable Hydraulic System (PHS)
Control valve (implement) ..................65 Valve Calibrations............................ 123
Valve for the Cylinder in the HOLD Manual Adjustment After Calibrating
Position ..............................................66 The Valves ...................................... 132
Hydraulic System Pressure -Release .. 132
31200302 3
Table of Contents

Relieving Pressure in the Hydraulic

System ............................................ 133
Lock Valve Locations ...................... 133
Location of the Shutoff Valve for the Axle
Lock................................................. 134
Relieving Pressure from the Lock
Valves.............................................. 134
Verifying the Correct Setting of the Load
Control Valves ................................. 138
Relieving Pressure from the Shutoff
Valve on the Axle Lock.................... 138
Hydraulic System Pressures -Test and
Adjust................................................... 138
Test and Adjustment Procedures .... 138
Pilot Pressure (Pressure Reducing Valve) -
Test and Adjust.................................... 139
Pilot Pressure Test .......................... 139
Warming the Transmission Oil ........ 139
Test Procedure................................ 139
Pressure Reducing Valve
Adjustment ...................................... 140
Relief Valve (Implement) - Test and
Adjust................................................... 141
Auxiliary Pressure Test (Port A and
Portable ........................................... 141
Warming the Transmission Oil ........ 141
Test Procedure................................ 142
Auxiliary Relief Valve Adjustments.. 142
Pressure Adjustment for Disengaging
the Quick Coupler............................ 142
Pressure Adjustment for Engaging the
Quick Coupler.................................. 143
Hydraulic Oil Contamination -Test ....... 143
Hydraulic Oil Contamination............ 143
Flushing the Sampling Valve........... 143
In order to obtain a representative oil
sample, it is first necessary to flush the
sampling valve................................. 143
Obtaining the Sample...................... 144
Maximum Contamination Levels ..... 144
Boom Chain - Clean/Inspect/ Lubricate144
Boom Chains................................... 144
Check Condition .............................. 144
Cleaning and Inspection.................. 144
General Information Table ................... 145
4 31200302
Table of Contents
31200302 5
Systems Operation Section

Systems Operation (A) Red.......................................................... High pressure oil

(B)Red Stripes and White Stripes ... First pressure reduction
Section (C) Red Crosshatch ..................... Second pressure reduction
(D) Pink .............................................. Third pressure reduction
Graphic Color Codes (E) Orange...........................Pilot, signal or torque converter oil
(F) Orange Stripes and White Stripes...........................Reduced
pilot, signal or torque converter oil
(G) Blue ................................................................. Trapped oil
(H) Green ............................................ Tank, sump or return oil
(I) Brown ............................................................. Lubricating oil
(J) Orange Crosshatch ........................... Second reduction in
pilot, signal or torque converter oil
(K) Yellow............................ Moving or activated components
(L) Purple ............................................... Pneumatic pressure
(M) Light Gray..................................................... Surface color
Note: The information that is covered in this manual
may not require all of the colors in Illustration 1.

Illustration 1 g01023555
6 31200302
Systems Operation Section

Introduction

Illustration 3 g00902881

This module discusses the features and operation of • Closed center spools in the control valves for the
the implement hydraulic system. In addition, the major boom extend/retract, boom raise/lower and coupler
electrical components and hydraulic components are tilt
also discussed. The following Telehandler B-Series • Open center spools from cylinder to tank in the
Machines are covered in this module: control valves for the auxiliary system, stabilizers
• TH360B and frame level
• TH560B • Load sensing
Hydraulic System • Pressure and flow compensation
The hydraulic system supplies oil flow to the following • Load independent flow division (LIFD)
systems:
When the flow demand of the implements exceeds the
• Steering output of the hydraulic pump, the system will reduce
• Braking flow to each of the active circuits. The flow from each
circuit will be reduced by the same percentage of the
• Power Train
flow that is commanded.
• Implements (Including the Boom, Work Tools,
Stabilizers and Frame Level)
Note: The steering system is described in Steering
System, Specifications, Systems Operation, Testing and
Adjusting.
Note: The braking system is described in Braking
System, Specifications, Systems Operation, Testing and
Adjusting.
Note: The power train system is described in Power
Train System, Specifications, Systems Operation,
Testing and Adjusting.
The implement hydraulic system includes the
following features:
31200302 7
Systems Operation Section

General Information Main Control Valve Group

(Implement)
The hydraulic system includes the following main
components:
• "Main control valve (implement)"
• "Stabilizer Control Valve Gp (if equipped)"
• "Machine ECM"
• "Electronic joystick"
• "Operator Switches"
• "Piston Pump (Implement and Steering)"
• "Hydraulic oil tank"
• "Hydraulic oil filter"

Illustration 12 g01009691
(1) Control Valve (Auxiliary)
(2) Control Valve (Coupler Tilt)
(3) Control Valve (BOOM EXTEND/RETRACT)
(4) Boom Control Valve (RAISE/LOWER)
(5) Outlet Manifold
(6) Inlet Manifold
(7) Electronic Pilot Valve
(8) Pilot Shutoff Solenoid
(9) Pilot Valve ECM 1
(10) Pilot Valve ECM 2
8 31200302
Systems Operation Section

The main control valve (implement) contains an outlet Electronic Pilot Valve Group (Implement) (7) contains
manifold (5), an inlet manifold (6) and an Electronic two Control Manifold Group (Pilot ECMs) and eight
Pilot Valve Group (implement) (7). The inlet manifold proportional pilot solenoids. The electronic pilot valve
contains the following items, the Valve As (Steering (implement) uses the eight proportional pilot solenoids
priority), the Relief Valve (Load sensing oil), and the in order to control 4 functions. Two functions are
Flow Control Valve Group (Dump valve for the load controlled by each ECM. Each function requires 2
sensing oil). The outlet manifold contains the Relief proportional solenoids.
Valve (Pressure reducing valve) and the Solenoid
• Control Manifold Group (Pilot ECM1) (10) controls
Valve Group (shutoff for Pilot oil) (8). The Main Control
the boom RAISE/LOWER and the coupler tilt
Valve Group (Implement) also includes hydraulic control
FORWARD and the coupler tilt BACKWARD. Pilot
valve sections for the following functions:
ECM1 is located on the Electronic Pilot Valve
• Auxiliary circuits (1) Group (Implement).
• Coupler Tilt (2) • Control Manifold Group (Pilot ECM2) (9)
• Boom EXTEND/RETRACT (3) controls the auxiliary functions and the boom
EXTEND/RETRACT. Pilot ECM2 is located on the
• Boom RAISE/LOWER (4) Electronic Pilot Valve Group (Implement).
The electronic pilot valve electronically controls the
Electronic Pilot Valve Group (Implement) amount of pilot pressure that is sent to the control
valve sections in order to obtain movement of the
functions. The electronic pilot valve is controlled by the
machine ECM. The machine ECM controls the pilot
pressure by sending a signal to the Pilot ECM. The
Pilot ECM sends a signal to the proportional pilot
solenoid for that function.
The Pilot ECM is powered by 10 VDC that is supplied by
the machine ECM. The Pilot ECM supplies 12 VDC
from the battery to the pilot solenoids in order to
operate the pilot solenoids. If the 10 VDC is
interrupted, the Pilot ECM cannot communicate with
the machine ECM and a diagnostic code will be
generated. If the current of the 12 VDC that is
delivered to the pilot solenoid by the Pilot ECM is not
correct, a diagnostic code will be generated.
The Electronic Pilot Valve Group (Implement) is
calibrated in ET in order to ensure the proper
operation of the control valves.

Illustration 13 g01009705
(7) Electronic Pilot Valve (Implement)

(9) Pilot Valve ECM 2

(10) Pilot Valve ECM 1

31200302 9
Systems Operation Section

Stabilizer Control Valve Gp (If

Equipped)

Illustration 14 g01186621
Stabilizer Control Valve Gp
(11) Flow control valve (stabilizer)
(12) Control valve (left stabilizer)
(13) Control valve (right stabilizer)

The optional control valve Gp (stabilizer) contains a

flow control valve (stabilizer) (11), a left stabilizer
control valve (12) and a right stabilizer control valve
(13). The solenoids for the right stabilizer valve and
the solenoids for the left stabilizer valve are controlled
by the right stabilizer switch and the left stabilizer
switch. Flow control valve (11) is controlled by the
machine (ECM).
10 31200302
Systems Operation Section

Machine ECM

Illustration 15 g01184966

The machine ECM (46) makes decisions based on the The machine ECM communicates to the other
operator inputs, the machine conditions and the components on the machine via the CAN data link (40),
parameters that are programmed into the machine the CAT data link (39) and a CAN/ADDRESS data link
ECM in order to provide proper control of the hydraulic (38) that is dedicated for the electronic control modules
system. that are on the electronic pilot valves.
31200302 11
Systems Operation Section

CAN data link (40) is used in order to Interlocks

communicate with the following components:
The machine ECM monitors the switches of the
• Machine ECM Machine condition in order to control the hydraulic
• Engine ECM (if equipped) system correctly. Switches for machine condition would
include the following components:
• Instrument Cluster
• Switch for Critical angle (24)
CAT data link (39) is used in order to communicate
with the following components: • Parking brake switch (25)
• Machine ECM • Stabilizer pressure switches (22 and 23)
• The Diagnostic Connector • Engine speed sensors (26)
• Machine Security System ECM (if equipped) • Transmission speed sensors (27)
• Product Link ECM (if equipped) The machine ECM also receives information regarding
the machine condition from other electronic control
• Engine ECM (if equipped)
modules that are equipped on the machine.
CAN/ADDRESS data link (38) is used in order to If the machine is in a condition that could create a
communicate with the following components: dangerous situation, the machine ECM will limit the
• The electronic control modules that are on the movement of the hydraulic implements.
electronic pilot valves
Interlock for the Machine Security System
The machine ECM stores the diagnostic codes and the When the interlock for the machine security system is
event codes that are generated from the hydraulic active, the following functions may be disabled:
system.
• Boom (raise/lower)
Inputs to the Machine ECM • Boom extend/retract
Inputs to the machine ECM include the following • Stabilizers
components:
• Frame leveling
• The joystick (16)
• Transmission
• The operator switches (17, 18, 19, 20, and 21)
Interlock for the Longitudinal Stability Indicator
• The switches for machine condition (22, 23, 24
System
and 25)
When the interlock for the longitudinal stability
• Engine and transmission speed sensors (26 and indicator system is active, the following functions may
27) be limited:
• Engine ECM (43) (if equipped) • Frame leveling
• Machine Security System ECM (45) (if equipped) • Stabilizers
• Product Link ECM (44) (if equipped)

Outputs from the Machine ECM

Outputs from the machine ECM include the following
components:
• Pilot valve ECM 1 (8)
• Pilot valve ECM 2 (7)
• Instrument cluster (41)
• Relays for the quick coupler (35), the diverter valve
(33) for the auxiliary functions (if equipped) and the
frame leveling system (28)
• Solenoid for the flow control valve (stabilizer) (31)
• Engine ECM (43) (if equipped)
• Machine Security System ECM (45) (if equipped)
• Product Link ECM (44) (if equipped)
• Pilot shutoff solenoid (37)
12 31200302
Systems Operation Section

Electronic Joystick

Illustration l17 g01052178

Joystick (Type 2)
Illustration 16 g01052104 (16) Joystick
Joystick (Type 1) (47) Auxiliary Thumb Slider
(48) Trigger Switch
(16) Joystick
(49) Thumb Slider
(47) Auxiliary Buttons
(48) Trigger Switch
(49) Thumb Slider The joystick is calibrated in ET in order to ensure the
proper input from the joystick to the machine ECM.
The joystick (16) is located on the right side of the The joystick has two modes of operation. Table 2
operator seat. The joystick (Type 1) contains two shows the configurations and the functions that are
auxiliary buttons (47), one trigger switch (48) and one controlled by the joystick. The configuration of the
thumb switch (49). The joystick (Type 2) contains two joystick is selected in ET.
thumb switch (47) and (49) and one trigger switch (48). Table 2
The lateral movement of the joystick and the Configuration of the Joystick
longitudinal movement of the joystick is monitored by
two sensors that are mounted in the base of the Construction Bucket
joystick. These sensors send signals to the machine Joystick forward
Boom raise/lower Boom raise/ lower
ECM (46) in order to operate the selected functions. and backward
The signals that are sent to the machine ECM are Coupler Tilt
proportional to the distance of the joystick movement. Joystick left and Boom extend/
forward and Tilt
right retract
Thumb switch (49) also sends a proportional signal to backward
the machine ECM for the function that is assigned to the Coupler Tilt
Boom extend/
thumb switch. Thumb switch forward and Tilt
retract
backward
On the joystick (Type 1), The two auxiliary buttons
control the auxiliary functions. The trigger switch
is used in order to select the auxiliary circuit, if
more than one auxiliary circuit is installed.
On the joystick (Type 2), The thumb switch (47)
controls the auxiliary functions. The trigger switch (48)
is used in order to select the auxiliary circuit, if more
than one auxiliary circuit is installed.
31200302 13
Systems Operation Section

Operator Switches Hydraulic Oil Filter

The following switches are located in the cab. These The filter for the hydraulic system is located in the
switches provide direct input to the machine ECM in transmission section. Oil from the hydraulic oil tank
order to control some of the functions of the hydraulic passes through the hydraulic oil filter before entering
system: the transmission. The oil is then returned to the
• Lockout switch (19) hydraulic oil tank.

• Continuous flow switch (18)

System Operation
• Quick coupler switch (17)
Hydraulic pump (51) draws oil from the hydraulic oil
• Left stabilizer switch (20) tank (50). The pump is a variable displacement piston
• Right stabilizer switch (21) pump with permanent drive. The output of the pump is
controlled by the highest signal pressure that is
• Differential lock switch (47)
present in the hydraulic system.
The switch for the frame level (29) is also located in the
Pump supply oil flows into the inlet manifold of the main
cab but the switch for the frame level does not provide
control valve (implement). The pump supply oil flows to
direct input to the machine ECM. The switch for the
the steering priority valve and the pilot pressure
frame level directly controls the solenoids on the frame
reducing valve. The pilot pressure reducing valve
leveling valve (30). The frame leveling system is
supplies oil to the pilot system and the braking system.
enabled by the machine ECM through the relay for the
interlock of the frame (28). The steering priority valve gives flow priority to the
steering system over the rest of the hydraulic system.
When the demands of the steering system have been
met, excess oil is then diverted by the priority valve to
Piston Pump (Implement and the implement control valve, the stabilizer control valve
Steering) (if equipped) and the frame leveling valve (if equipped).

The hydraulic pump is capable of producing a

maximum flow of 106 L/min (28 US gpm). The
hydraulic pump is a variable displacement axial piston
pump. Also, the pump has flow and pressure
compensation.
The hydraulic pump supplies pressurized oil for the
braking system, the steering system and the implement
system.
Pump output only takes place when an implement
demands flow. When the demand is low, the pump
destrokes and the pump output is reduced. This
conserves power that can be used on other systems
and increases fuel efficiency.

Hydraulic Oil Tank

The hydraulic oil tank supplies oil for two hydraulic
circuits that operate independently.
The hydraulic system
The transmission system
The hydraulic system contains the implement system,
the stabilizer system, the braking system, the frame
leveling system and the steering system.
The transmission system includes the hydraulic oil
cooler, the torque converter, and the hydraulic oil filter.
14 31200302
Systems Operation Section

Illustration 18 g01185792

Hydraulic pump (51) draws oil from the hydraulic oil When the operator selects a function that is controlled by
tank (50). The pump is a variable displacement piston ECM (8) or by ECM (7), a signal is sent to the machine
pump with permanent drive. The output of the pump is ECM (46) by the joystick. The signal is in the form of a
controlled by the highest load sensing oil pressure that pulse width modulation (PWM). The machine ECM
is present in the hydraulic system. makes decisions based on operator input, machine
Pump supply oil flows into the inlet manifold of the Main conditions and the programmed parameters in the
Control Valve Group (implement). The pump supply oil machine ECM. The machine ECM then sends a signal
flows to the steering priority valve and the pressure to the proper Pilot ECM. The ECM for the pilot valve
reducing valve. The pressure reducing valve supplies sends a proportional signal to the pilot solenoid valve of
oil to the pilot system and the braking system. that function. When the solenoid opens, oil moves past
the open spool in order to operate the function. Oil is
The steering priority valve gives flow priority to the returned to the tank through the control valve.
steering system over the rest of the hydraulic system.
When the demands of the steering system have been A load sensing oil relief valve is located in the load
met, excess oil is then diverted by the priority valve to sensing oil line. This load sensing oil relief valve limits
the Main Control Valve Group (implement) . The oil the pressure of the load sensing oil to the hydraulic
flows into the control valve for the stabilizer (if pump in order to limit the maximum system pressure.
equipped).
31200302 15
Systems Operation Section

Load Independent Flow Division • Solenoids (Frame Level)

(LIFD) • Solenoid (Diverter Valve)
• Relay (Frame Level)
The control valve (implement) on these machines
utilizes Load Independent Flow Division (LIFD). The • Relays (Diverter Valve)
(LIFD) system operates in one of two modes. Oil flow • Relays (Quick Coupler)
that is demanded from the attached implement
determines the mode of operation for the (LIFD)
system. The (LIFD) system is similar to the proportional
Switch (Lockout Control)
priority pressure compensated system (PPPC). The
(PPPC) system is available on other Caterpillar
products.

Condition One
The flow that is demanded by the main control
valve (implement) is less than the maximum output
of the pump.
In this condition, the flow demand for each implement
control valve will be met.

Condition Two
The flow that is demanded by the main control valve Illustration 45 g00902787
(implement) is more than the maximum output of the Switch (lockout control)
pump.
In this condition, the pressure compensator in each The switch is located at the right side of the seat.
individual valve will restrict the flow proportionally to the
flow that is commanded by each valve. This will bring The switch signals the ECM that the operator wants to
the flow demand in line with the pump output. disable the following functions:
• Fork control
• Boom raise/lower
Location of Electrical • Boom extend/retract

Components • Quick coupler pins

• Auxiliary actuators
• Frame level (if equipped)
The electronic system for the implement
hydraulics consists of the following components: • Stabilizers (if equipped)
• Switch (Lockout Control)
• Joystick Control
• Switch (Continuous Auxiliary Flow)
• Switch (Quick Coupler)
• Switch (Right Stabilizer)
• Switch (Left Stabilizer)
• Switch (Frame Level)
• Pressure Switches (Stabilizers)
• Switch (Fully Lowered Boom)
• Switch (Critical Angle)
• Switch (Fully Retracted Boom)
• Machine ECM
• Main Control Valve (Implement)
• Control Valve Gp (Stabilizer)
16 31200302
Systems Operation Section

Joystick Control

Illustration 48 g00942111
Joystick control (Type 1)
Illustration 46 g00902788 (1) Sensors for boom raise/lower
Joystick Control (Type 1) (2) Sensors for boom extend/retract or quick coupler tilt
(3) Switch for boom extend/retract or quick coupler tilt
(4) Switch for auxiliary actuator + direction
(5) Switch for auxiliary actuator - direction

Illustration 47 g01052237
Joystick Control (Type 2)
Illustration 49 g01052246
Joystick control (Type 2)
The joystick is located at the right side of the seat. The
(1) Sensors for boom raise/lower
joystick controls the following operations:
(2) Sensors for boom extend/retract or quick coupler tilt
• Boom raise/lower (3) Switch for boom extend/retract or quick coupler tilt
(4) Switch for auxiliary actuator + or - direction
• Boom extend/retract
• Tilt forward and rackback
• Auxiliary actuator + and - directions
• Auxiliary 1 and 2

Illustration 50 g00942119
(6) Toggle switch for auxiliary 1 or 2

The joystick control can be configured for the following

two different operating arrangements.
31200302 17
Systems Operation Section

First Arrangement - Sensor (2) controls the function Switch (Auxiliary Actuator in the -
for the coupler tilt. Switch (3) controls the function for
the boom extend/retract.
Direction) for Joystick (Type 1)
Second Arrangement - Sensor (2) controls the Switch (5) is located on the top of the joystick control.
function for the boom extend/retract. Switch (3) The switch signals the ECM to operate the function for
controls the function for the coupler tilt. the auxiliary actuator in the - direction.
Both Arrangements - Sensor (1) controls the Reference: See Systems Operation/Testing and
function for the boom raise/lower. Switch (4) controls Adjusting, "Electrical Input Components" for more
the auxiliary actuator in the + direction. Switch (5) information.
controls the auxiliary actuator in the - direction. Switch
(6) selects either the auxiliary services 1 or 2 function.
Switch (Auxiliary Actuator) for Joystick
Sensor (Boom Raise/Lower) (Type 2)
Sensor (1) is located in the base of the joystick control. Switch (4) is located on the top right of the joystick
control.
The sensor signals the ECM to operate the function for
the boom raise or the boom lower. The switch signals the ECM to operate the function for
the auxiliary actuator in the + or the - direction. Move
Reference: See Systems Operation/Testing and the switch forward for + direction. Move the switch
Adjusting, "General Information" for more information. backward for- direction.
Reference: See Systems Operation/Testing and
Sensor for Boom Extend and Boom Adjusting, "Electrical Input Components" for more
Retract or Boom Tilt Forward and Tilt information.
Rackback.
Switch (Auxiliary 1 or 2)
Sensor (2) is located in the base of the joystick control.
The sensor signals the ECM to operate the function for Switch (6) is located on the front of the joystick control.
the boom extend/retract or the sensor signals the ECM The switch allows the operator to toggle between
to operate the function for tilt forward and for the tilt auxiliary 1 and auxiliary 2.
rackback. Reference: See Systems Operation/Testing and
Reference: See Systems Operation/Testing and Adjusting, "Electrical Input Components" for more
Adjusting, "General Information" for more information. information.

Switch for Boom Extend and Boom Switch (Continuous Auxiliary Flow)
Retract or Boom Tilt Forward and Tilt
Rackback.
Switch (3) is located on the top of the joystick control.
The switch signals the ECM to operate the function for
the boom extend/retract or the quick coupler tilt.
Reference: See Systems Operation/Testing and
Adjusting, "Electrical Input Components" for more
information.

Switch (Auxiliary Actuator in the +

Direction) for Joystick (Type 1)
Illustration 51 g01006706
Switch (4) is located on the top of the joystick control.
Switch (continuous auxiliary flow)

The switch signals the ECM to operate the function for the
auxiliary actuator in the + direction. The switch is located on the right side of the
Reference: See Systems Operation/Testing and instrument cluster.
Adjusting, "Electrical Input Components" for more The switch signals the ECM that a continuous flow of
information. hydraulic oil is required for the auxiliary services. The
continuous flow switch will allow a maximum of 60 L/
18 31200302
Systems Operation Section

min (16 US gpm). 90 L/min (24 US gpm) is possible by Note: Holding the switch can determine the speed of
pressing the switch for four or five seconds. the stabilizer.
Reference: See Systems Operation/Testing and Reference: See Systems Operation/Testing and
Adjusting, "Electronic Input Components" for more Adjusting, "Electronic Input Components" for more
information. information.

Switch (Quick Coupler) Switch (Left Stabilizer)

Illustration 52 g01006691 Illustration 54 g00902793

Switch (quick coupler) Switch for the left stabilizer (if equipped)

The switch is located on the left side of the instrument The switch is located on the left side of the instrument
cluster. cluster.
The switch signals the ECM that the operator wants to The switch signals the ECM that the operator wants to
actuate the locking pins for the quick coupler. actuate the left side stabilizer. Then, the ECM
Reference: See Systems Operation/Testing and energizes the flow control valve. The flow control valve
Adjusting, "Electronic Input Components" for more opens. This allows hydraulic fluid to pass through the
information. stabilizer control valve and to the stabilizer cylinder.
Note: Holding the switch can determine the speed of
Switch (Right Stabilizer) the stabilizer.
Reference: See Systems Operation/Testing and
Adjusting, "Electronic Input Components" for more
information.

Switch (Frame Level)

Illustration 53 g00902792
Switch for the right stabilizer (if equipped)

The switch is located on the right side of the

instrument cluster.
The switch signals the ECM that the operator wants to
actuate the right side stabilizer. Then, the machine ECM Illustration 55 g00902794
will energize the solenoid for the flow control valve. The Switch for the frame level
flow control valve opens. This allows hydraulic fluid to
pass through the stabilizer control valve and to the
stabilizer cylinder.
31200302 19
Systems Operation Section

The switch is located on the right side of the instrument Switch (Critical Angle)
cluster. The switch controls the solenoids in the frame
leveling valve.

Pressure Switches (Stabilizer)

Illustration 58 g00902789
Switch (critical angle)

The switch that detects the critical angle is located

Illustration 56 g01186851
inside the main frame at the rear of the boom.
Pressure switch for the stabilizer (if equipped) The switch signals the ECM when the angle of the
boom is above 40 degrees. The ECM then sends a
The pressure switches are located in the lock valves for signal in order to activate the following:
the stabilizers.
• Rear axle lock (if equipped)
The pressure switches signal the ECM about the
• Disable the frame leveling.
stabilizer cylinders. The ECM then determines if
stabilizer cylinder is under a load. • The transmission is neutralized.
Reference: See Systems Operation/Testing and
Switch (Fully Lowered Boom) Adjusting, "Rear Axle Lock" for further information.

Switch (Fully Retracted Boom)

Illustration 57 g00941761
Switch (fully lowered boom)

Illustration 59 g00941765
The switch is located inside the main frame at the rear Switch (fully retracted boom)
of the boom on the right side.
The switch signals the machine ECM that the boom is in The switch is located on the front left side of the fixed
the stored position or the position for travelling the boom section.
machine. The switch signals the ECM to lock out the following
functions when the boom is extended:
• Stabilizer (raise)
• Frame leveling
20 31200302
Systems Operation Section

Reference: See Systems Operation/Testing and Electronic Pilot Valve (Implement)

Adjusting, "Electronic Input Components" for more
information. Electronic pilot valve (implement) (7) is attached to the
bank valve 4 (implement). The main control valve is
located inside the main frame at the rear of the
Machine (ECM) machine.
Pilot valve (7) includes four pairs of pilot solenoids.
Each pair of solenoids control one of the spools in the
bank valve 4 (implement) that control the machine
functions. The solenoids control the spools in the bank
valve 4 (implement) in response to electronic signals
from the pilot valve ECM's (8).
Reference: See Systems Operation/Testing and
Adjusting, "General Information" for more information.

Valve ECM (Implement)

The ECM's (8) for the pilot valve are connected to pilot
valves (7).
The ECM's for the pilot valve send a signal to the pilot
solenoids in pilot valve (7), in order to control the pilot
pressure to the pilot solenoids. The ECM for the pilot
valve receives information from the machine ECM via
the CAN (PHS) data link. The valve ECM also
transmits diagnostic information back to the machine
Illustration 60 g00987318
ECM.
Location of Machine ECM Reference: See Systems Operation/Testing and
Adjusting, "General Information" for more information.
The machine ECM is located on the inside of the
engine enclosure. Stabilizer Control Valve Gp (If
The machine ECM receives information from switches, Equipped)
sensors and other electronic controls on the machine
via the following electronic links.
• CAT data link
• CAN PHS data link
• CAN data link (Machine)
The ECM then processes all of the information in order
to activate the various outputs.

Main Control Valve (Implement)

Illustration 62 g01186621
Stabilizer Control Valve Gp
(11) Flow control valve (stabilizer)
(12) Control valve (left stabilizer)
(13) Control valve (right stabilizer)
Illustration 61 g00902798
(7) Electronic Pilot Valve (Implement)
(8) Valve ECM (Implement)
31200302 21
Systems Operation Section

Solenoids (Frame Level) Solenoid (Diverter Valve for Auxiliary 2)

Illustration 63 g00902804 Illustration 65 g00902806

Solenoids for the frame level Solenoid (auxiliary diverter valve for auxiliary 2)

The solenoids are located on the lock valve for the A second diverter valve is installed as an option to
frame leveling cylinder. The lock valve is attached to the direct oil to a second auxiliary.
frame leveling cylinder. The machine ECM energizes the relay for the
The machine ECM controls the state of the relays for solenoid on the diverter valve. The relay then
the frame leveling valve. The solenoids are then energizes the solenoid on the diverter valve. The
energized or de-energized by the relays. The solenoids solenoid moves the spool in the diverter valve. The
shift the spool in the control valve which sends pump oil spool controls the flow of oil to an actuator for the
to the frame leveling cylinder. auxiliary 2.

Relay (Frame Level)

Solenoid (Diverter Valve)
Solenoid (Diverter Valve for Auxiliary 1)

Illustration 66 g00941811
Relay (frame level)

Illustration 64 g00941838
Solenoid (diverter valve for auxiliary 1)
The relay is located in the fuse panel. The fuse panel is
located behind an access cover in the left side of the
The solenoid is located in the diverter valve. The cab arrangement.
diverter valve is installed on the left side of the boom The machine ECM energizes the relay for the solenoid
head. On standard machines, a single diverter valve is in the frame leveling valve. The relay then energizes
installed. the solenoid on the lock valve for the frame leveling
The machine ECM energizes the relays for the valve when the switch for the frame level on the
solenoid on the diverter valve. The relays then instrument cluster is operated.
energize the solenoid on the diverter valve. The
solenoid moves the spool in the diverter valve. The
spool controls the flow of oil to either the auxiliary 1, or
to the hydraulic actuator for the quick coupler pins.
22 31200302
Systems Operation Section

Relays (Diverter Valve) Location of Hydraulic

Components

The system for the implement hydraulics consists of

the following components:
• Hydraulic Tank
• Piston Pump (Implement and Steering)
• Main Control Valve (Implement)
• Boom Cylinder
• Load Control Valve (Boom Cylinder) (Lock)
• Telescoping Cylinder
Illustration 67 g00941817
Relays (diverter valve)
• Load Control Valve (Telescoping Cylinder) (Lock)
• Tilt Cylinder (Quick Coupler)
The relays are located in the fuse panel. The fuse panel
is located behind an access cover in the left side of the • Load Control Valve (Tilt Cylinder) (Lock)
cab arrangement. • Compensating Cylinders
The machine ECM energizes the relays for the • Diverter Valve
solenoid on the diverter valve. The relay then
energizes the solenoid on the diverter valve. • Quick Coupler Cylinder
The relay on the left is for the ground function. The • Frame Leveling Cylinder
relay on the right is for the power function. • Load Control Valve (Frame Leveling Cylinder)
(Lock)
Relays (Quick Coupler) • Control Valve Gp (Stabilizer)
• Stabilizer Cylinders
• Load Control Valve (Stabilizer Cylinders) (Lock)
• Pump for Manual Lowering

Hydraulic Tank

Illustration 68 g00941818
Relays (quick coupler)

The relays are located in the fuse panel. The fuse panel
is located behind an access cover in the left side of the
cab arrangement.
The machine ECM energizes the relays for the
solenoid on the quick coupler valve. The relay then
energizes the solenoid on the quick coupler valve.
Illustration 93 g01006699
The relay on the left is for the ground function. The Hydraulic tank
relay on the right is for the power function.
The hydraulic tank is located at the rear of the operator
compartment.
31200302 23
Systems Operation Section

The tank supplies oil to the following machine Compensator Valve

systems:
• Steering
• Braking
• Transmission
• Implements (including the boom, work tools,
stabilizers, frame level and rear axle lock)

Piston Pump (Implement and

Steering)

Illustration 95 g00902949
Compensator valve (piston pump)

The compensator valve is bolted to the piston pump.

The compensator regulates the pump output flow in
response to the following signals:
• Signal pressure (Load sensing oil pressure)
• Supply pressure from the pump outlet
Note: Load sensing oil pressure is sometimes referred
to as signal oil. The two terms have the same meaning
Illustration 94 g00902945
throughout this story.
Piston Pump (implement and steering)
The compensator valve also serves as a backup for
The pump is mounted on the transmission case. limiting the maximum system pressure.
The pump has permanent drive. Pump output is
controlled by steering pressure or implement pressure
and flow. Main Control Valve (Implement)
The pump delivers oil to the following systems:
• Steering
• Implements (including the boom, work tools,
stabilizers, frame level and rear axle lock)
• Braking
Reference: See Systems Operation/Testing and
Adjusting, "Piston Pump (Implement and Steering)" for
more information.

Illustration 96 g00902950
Main control valve (implement)

The Main Control Valve Group (Implement) is located at

the rear of the machine. The Main Control Valve Group
(Implement) consists of the Electronic Pilot Valve
Group (Implement) and the bank of 4 Control Valves.
The valves are directional control valves.
The Control Valves control the flow of oil to the
machine implements and from the machine
implements.
24 31200302
Systems Operation Section

Reference: See Systems Operation/Testing and Relief Valve (Load Sensing Oil)
Adjusting, "Main Control Valve Group (Implement)" for
more information.
The bank of 4 Control Valves includes the
following four implement sections:
• Control Valve (Boom EXTEND/RETRACT)
• Control Valve (Auxiliary)
• Control Valve (Tilt)
• Control Valve (Boom RAISE/LOWER)
The Main Control Valve Group (Implement) also
includes the following sections.
• Inlet Manifold
• Outlet Manifold Illustration 98 g00902952
Relief Valve (Load sensing oil)

Inlet Manifold
The load sensing relief valve is located in the inlet
Valve Assembly (Steering Priority) section for the control valve.
The Relief Valve (load sensing oil) is used to limit the
maximum system pressure. The relief valve is
adjustable.
Note: Relief Valve (load sensing oil) is sometimes
referred to as the signal limiter valve. The two terms
have the same meaning throughout this story.
Reference: See Systems Operation/Testing and
Adjusting, "Main Control Valve Group (Implement)" for
more information.

Flow Control Valve Group (Dump Valve

for Load Sensing Oil)

Illustration 97 g00902951
Valve Assembly (Steering priority)

The Valve Assembly (Steering priority) is located in the

inlet manifold for the main control valve.
The steering priority valve divides the flow of oil from
the piston pump between the demands from the
steering system and the demands from the implement
system.

Illustration 99 g00902953
Flow Control Valve Group (dump valve for load sensing oil)

The Flow Control Valve Group (dump valve for load

sensing oil) is located in the inlet manifold for the
control valve.
The flow control valve provides a drain back to the
hydraulic tank for the load sensing oil after the load has
gone.
Reference: See Systems Operation/Testing and
Adjusting, "Main Control Valve Group (Implement)" for
more information.
31200302 25
Systems Operation Section

Note: Load sensing oil pressure is sometimes referred

to as signal oil. The two terms have the same meaning
throughout this story.

Outlet Manifold
Relief Valve (Pressure Reducing Valve)

Illustration 102 g00902957

Load Control valve (Boom Cylinder) (Lock)

The load control valve is attached to the lower end of

the boom cylinder.
The load control valve locks oil into the head end of the
cylinder in order to hold the cylinder in position when
Illustration 100 g00902954 the cylinder is stationary.
Relief Valve (pressure reducing valve) The load control valve prevents the boom cylinder
from lowering in the event of a loss of hydraulic power.
The pressure reducing valve is located in the outlet The load control valve also prevents the boom cylinder
manifold of the control valve. from collapsing if a hydraulic hose bursts.
The pressure reducing valve provides a supply of oil to Reference: See Systems Operation/Testing and
the pilot system and the brake system at a reduced Adjusting, "Load Control Valves (Lock Valves)" for more
pump supply pressure. information.

Boom Cylinder Telescoping Cylinder

Illustration 101 g00902955 Illustration 103 g00902958

Boom cylinder Telescoping cylinder

The cylinder is located under the boom. The cylinder The cylinder is located inside the boom. The cylinder is
end is attached to the machine frame and the rod end attached to the rear of the second section of the boom
is attached to the boom. by a trunnion. The rod end is attached to the rear of the
The cylinder is a double acting cylinder. The cylinder is first section. The front of the cylinder is supported by a
used to raise the boom. The cylinder is also used to pad and slides inside the head section of the boom.
lower the boom. The cylinder is a double acting cylinder. The cylinder is
used to extend the boom. The cylinder is also used to
retract the boom.
Load Control Valve (Boom Cylinder)
(Lock)
26 31200302
Systems Operation Section

Load Control Valve (Telescoping Reference: See Systems Operation/Testing and

Adjusting, "Compensating System" for more
Cylinder) (Lock) information.

Load Control Valve (Tilt Cylinder)

(Lock)

Illustration 104 g00902959

Load Control Valve (Telescoping Cylinder) (Lock)

The load control valve is attached to the rear of the

telescoping cylinder.
Illustration 106 g00902964
The load control valve locks oil into the head end of the
Load Control Valve (Tilt Cylinder) (Lock)
cylinder in order to hold the cylinder in position when
the cylinder is stationary.
The load control valve is attached to the top of the tilt
The load control valve prevents the telescoping cylinder.
cylinder from retracting in the event of a loss of
hydraulic power. The load control valve also prevents The load control valve locks oil into the head end of the
the telescoping cylinder from collapsing if a hydraulic cylinder in order to hold the cylinder in position when
hose bursts. the cylinder is stationary.

Reference: See Systems Operation/Testing and The load control valve also prevents the tilt cylinder
Adjusting, "Load Control Valves (Lock Valves)" for more from collapsing if a hydraulic hose bursts.
information. Reference: See Systems Operation/Testing and
Adjusting, "Load Control Valves (Lock Valves)" for more
Tilt Cylinder information.

Compensating Cylinders

Illustration 105 g00902960

Tilt cylinder
Illustration 107 g00902961
The tilt cylinder is mounted inside the boom head. The Compensating Cylinders
cylinder end is attached to the boom head and the rod
end is attached to the linkage for the quick coupler. The cylinders are located at both sides of the boom at
The cylinder is a double acting cylinder that is used to the rear of the machine. The head ends of the
tilt the carriage forward and backward. cylinders are attached to the machine frame and the rod
ends are attached to the first section of the boom.
31200302 27
Systems Operation Section

The cylinder is a double acting cylinder. The Quick Coupler Cylinder

compensating cylinder works with the tilt cylinder in
order to maintain the selected angle of the carriage
when the boom is raised and lowered. The
compensating cylinder and the tilt cylinder utilize the
same oil lines and the same control valve.
Reference: See Systems Operation/Testing and
Adjusting, "Compensating System" for more
information.

Diverter Valve

Illustration 109 g00902967

Quick Coupler Installation

The quick coupler cylinder is located in the

hydraulically operated quick coupler.
The hydraulic quick coupler allows the operator to
change the work tools on the quick coupler without
leaving the cab.
The rods of the quick coupler cylinder serve as pins.
The rods extend out of the cylinder in order to engage
Illustration 108 g00902965
the work tool that is attached to the quick coupler and
Diverter valve
the rods retract into the cylinder in order to disengage
The diverter valve is installed on the left side of the the work tool that is attached to the quick coupler.
boom head. Reference: See Systems Operation/Testing and
On standard machines, a single diverter valve is Adjusting, "Auxiliary Control (Combined Circuit)" for
installed. A dual diverter valve is installed as an option. more information.
The single valve diverts the oil flow from the auxiliary
section of the implement control valve to either the Frame Leveling Cylinder
quick coupler cylinder or through push-on couplers to a
work tool cylinder. The dual diverter valve provides an
oil flow to an additional auxiliary service.
Reference: See Systems Operation/Testing and
Adjusting, "Auxiliary Control (Combined Circuit)" for
more information.

Illustration 110 g00902970

Frame Leveling Cylinder

The frame leveling cylinder is located at the front of the

machine on the right side. The head end of the cylinder
is attached to the machine frame, and the rod end is
attached to the front axle.
The frame leveling cylinder allows the machine frame to
be levelled in order to improve the stability of the
machine during operation.
28 31200302
Systems Operation Section

Reference: See Systems Operation/Testing and Control Valve Gp (Stabilizer)

Adjusting, "Frame Leveling System" for more
information.
The lock valve is attached to the casing of the frame
leveling cylinder.
The valve controls the flow of oil into the cylinder and
out of the cylinder. The valve also locks oil into both
sides of the cylinder in order to hold the cylinder in
position when the frame leveling system is in HOLD.

Lock Valve (Frame Leveling

Cylinder)

Illustration 112 g01184585

Valve Group (stabilizer)
(1) Flow control valve (stabilizer)
(2) Control valve (left stabilizer)
(3) Control valve (right stabilizer)

The valve group (stabilizer) is installed in the center of

Illustration 111 g00902971 the stabilizer frame at the front of the machine.
The valve group (stabilizer) consists of the flow control
The lock valve is attached to the casing of the frame valve (stabilizer) (1), the control valve (left stabilizer)
leveling cylinder. (2) and the control valve (right stabilizer) (3).
The valve controls the flow of oil into the cylinder and The flow control valve (1) controls the flow of oil into
out of the cylinder. The valve also locks oil into both the stabilizer cylinders and out of the stabilizer cylinders.
sides of the cylinder in order to hold the cylinder in
Stabilizers are used in order to improve the stability of
position when the frame leveling system is in HOLD.
the machine.

Stabilizer Cylinders

Illustration 113
g00902992
Stabilizer cylinders
The stabilizer cylinders are located on the stabilizers at
the front of the machine. The head end of the cylinder
is attached to the stabilizer frame and the rod end is
attached to the stabilizer leg.
31200302 29
Systems Operation Section

The cylinders extend in order to lower the stabilizers

and the cylinders retract in order to raise the
stabilizers.
Reference: See Systems Operation/Testing and
Adjusting, "Stabilizer System" for more information.

Load Control Valve (Stabilizer

Cylinders) (Lock)

Illustration 114 g01187180

Load Control Valve (stabilizer cylinders) (Lock)

The load control valves are attached to the casings of

the stabilizer cylinders.
The load control valves lock oil into both sides of the
cylinders in order to hold the cylinders in position when
the cylinders are stationary. The valves also prevent the
stabilizer legs from collapsing if a hydraulic hose bursts.

Lowering Control Pump (Manual)

The pump is located at the rear of the machine on the
right hand side.
The pump is used to manually retract the boom when
there is a loss of hydraulic power.
The pumping action of the pump circulates the oil in the
lines between the pump and the telescoping cylinder in
order to retract the boom.
30 31200302
Systems Operation Section

Electrical Input Components

Illustration 115 g01007819

Switches
Switches provide information to the ECM (19).
Switches are two state devices. The switches are
either open or the switches are closed. This is true for
each of the terminals on the switch. The terminals are
inverse of each other when a switch has two terminals
that are connected. The implement disable switch is an
example of this type of switch.
Closed - The switch closes the circuit to ground or the
switch closes the circuit to the battery.
Open - The switch opens a circuit to the ECM input.
31200302 31
Systems Operation Section

Joystick Control Stabilizer Switches

Illustration 117 g00901130

The left stabilizer switch (3) and right stabilizer switch (6)
are three-position rocker switches, which are spring
centered. The signal from the machine ECM to the
control valve ECM increases as the switch is held
closed. The increase causes the valve to be shifted.

Boom Critical Angle Switch

If equipped, the boom critical angle switch (4) will signal
the ECM when the angle of the boom is above the
Illustration 116 g00900916 critical angle of 40 degrees. The signal from the boom
critical angle switch is required in order to actuate the
The three auxiliary switches and the thumb slider are rear axle lock.
located in the joystick control. Note: If the critical angle switch fails, a diagnostic
code will be generated and the rear axle will be locked.
Auxiliary Switches When this situation occurs, the function for the boom
raise is still operational provided that the parking brake
The auxiliary select switch (11) allows the operator to is applied. The transmission will also be in the disabled
choose the auxiliary one circuit or the auxiliary two mode.
circuit. The auxiliary plus switch (2) controls the circuit
in a positive direction and uses port A flow. The
auxiliary negative switch (5) controls the circuit in a Boom Retracted Switch
negative direction and port B for flow. This switch (7) signals the machine ECM when the
boom is retracted. This signal must be received by the
Thumb Slider ECM before the machine can be roaded.
The thumb slider (8) can be configured in one of two The switch is also used as a lockout function for the
modes. stabilizer raise and as a lockout function for the frame
leveling. This prevents the stabilizers from being raised
The thumb slider sensor is configured in the North and the frame leveling from being operated while the
American Construction configuration. Then, the thumb boom is extending. This function is available only if the
slider sensor is configured for the coupler tilt. The machine ECM is equipped with a feature to inhibit
telescope in and the telescope out is configured for the lateral stability.
side-to-side movement of the joystick.
The thumb slider sensor is configured in the Bucket
mode configuration. The thumb slider sensor is
configured for the telescope in and the telescope out.
Then, the side to side motion of the joystick is for the
coupler tilt.
32 31200302
Systems Operation Section

Stabilizer Pressure Switches Continuous Flow SwitchImplement

Illustration 118 g00901522

Illustration 120 g00903130

The left stabilizer pressure switch (10) and the right

stabilizer pressure switch (13) signal the ECM when The continuous flow switch (18) signals the ECM that a
the stabilizer cylinders are supporting a predefined continuous flow of hydraulic oil is required for the
weight. This indicates that the stabilizers are lowered. actuators of the work tools. This is done on the auxiliary
circuit only.
Quick Coupler Switch
Lockout Switch

Illustration 119 g00900999 Illustration 121 g00903419

The quick coupler switch (17) allows the operator to The implement lockout switch (20) disables the PHS
operate the pins of the coupler in order to change the functions. The switch signals to the machine ECM. The
work tools that are attached to the coupler. This machine ECM de-energizes the pilot shutoff solenoid
operation is performed remotely by the operator and the ET implement status screen will indicate if the
without the need to exit the machine. implement lockout switch has locked out the
functionality of the hydraulic system.

Boom Lowered Switch

Table 3

Boom Lowered Switch

Pin Description
1 Power
2 Normally Open
3 Normally Closed
4 Ground
31200302 33
Systems Operation Section

The boom lowered switch (14) signals the machine The electronic control module is located on the inside of
ECM that the boom is in the store or the travel the engine enclosure.
position. The electronic control module (ECM) makes decisions
that are based on input information and memory
Electronic Control Module information. After the ECM receives the input
information, the ECM sends a corresponding response
to the outputs. The inputs and outputs of the ECM are
connected to the machine harness by two 70 contact
connectors (J1 and J2). The ECM sends the
information to the Caterpillar Electronic Technician on
the CAT data link.
Note: The ECM is not serviceable. The ECM must be
replaced if the ECM is damaged. Replace the ECM if a
failure of the ECM is diagnosed.

Inputs
The inputs describe the status of the machine
systems. Two types of inputs exist. The inputs can be
either a switch type or a sensor type. Switches provide
an open, a ground, or a + battery signal to the inputs of
the controller. Sensors (frequency, pulse width
modulation or voltage) provide a changing signal to the
sensor inputs of the controller. The inputs to the ECM
are listed in table 6 and table 7.
Illustration 124 g00785019
Electronics Control Module (ECM)
Outputs
The ECM responds to decisions by sending electrical
signals to the outputs. The outputs can create an
action or the outputs can provide information to the
operator or the service technician. The outputs of the
machine ECM are listed in table 6 and table 7.

Data Links
The machine ECM supports three data links.
• Cat Data Link
• J1939 CAN Data Link
• PHS CAN Data Link
The three data links are the main structure for the
communications between the machine ECM and any
other ECM on the machine.

Input/Output
Illustration 125 g00987330
Location of Electronic Control Module (ECM) The CAT Electronic Technician (ET) is used in order to
provide a connection for the service tool for
troubleshooting, testing, and calibrations. The data link
is bidirectional. The data link allows the ECM to receive
information. The data link allows the ECM to send
information.
34 31200302
Systems Operation Section

Table 6 (Table 6, contd)

The Contact Description for the Machine ECM The Contact Description for the Machine ECM
(Connector "J1")(1) (Connector "J1")(1)
No. Function Type No. Function Type
Key Switch Switch to
1 Key Switch ON 42 Switch (Left Stabilizer Lower)
ON Ground
Speed Sensor (Transmission Output Switch to
2 Frequency 43 Switch (Boom Retracted)
+) Ground
Speed Sensor (Transmission Output 44 8 Volt Sensor Power Power
3 Frequency
-)
45 8 Volt Sensor Return Return
Speed Sensor (Transmission
6 Frequency 47 Unswitched Battery + Battery
Intermediate #1 +)
Solenoid (Transmission Speed
Speed Sensor (Transmission 48 PWM driver
7 Frequency Clutch 1)
Intermediate #1 -)
Solenoid (Transmission Speed
10 CAN Data Link + Input/Output 49 PWM driver
Clutch 2)
12 Relay (Backup Alarm) On/Off Driver 50 Transmission Solenoid 1-5 Return Return
Solenoid (Transmission Speed
13 Ground Battery - 51 PWM driver
Clutch 3)
14 Frame Level Activate SWB Temperature Sensor (Transmission
53 Analog
+)
Oil)
15 Speed sensor (Converter Output Frequency
Solenoid (Transmission Speed
52 PWM driver
16 Speed sensor (Converter Output -) Frequency Clutch 4)
20 CAN Data Link - Input/Output 54 FWD/REV Clutch Return Return

21 5 Volt Sensor Return Return 55 PWM Driver Return Return

Temperature Sensor (Torque 57 Machine Ground -Battery
22 Analog
Converter) Solenoid (Transmission Speed
58 PWM driver
Switch to Clutch 5)
24 Switch (Shuttle Reverse Duality)
Battery Solenoid Valve (Transmission
59 PWM driver
Switch to Synchronizer Modulation)
25 Switch (Shuttle Forward Duality)
Battery
60 PWM Driver Return Return
Switch to
26 Boom Lower Parity 61 P-LS Load Sense Solenoid PWM Driver
Ground
Switch to
Switch to 63 Switch (Implement Disable) -Enable
27 Switch (Auto/Manual) - Manual Ground
Ground
Switch to
Switch to 64 Switch (Implement Disable) -Disable
28 Switch (Auto/Manual) - VSC Ground
Ground
65 Solenoid (Flow Control Valve) PWM Driver
29 Sensor (Engine Coolant) Analog
66 Solenoid (Auxiliary Diverter Valve) PWM Driver
30 Sensor (Fuel Level) Analog
Solenoid Valve (Transmission
Switch (Transmission Neutralizer Switch to 67 PWM Driver
33 Forward Clutch)
Disable) Ground
Solenoid Valve (Transmission
Switch to 68 PWM Driver
34 Boom Retract Parity Reverse Clutch)
Ground
Switch (Transmission Oil Filter Switch to 69 10 Volt Power Supply (PHS Control) Power
35
Bypass) Ground
70 Machine Ground -Battery
38 Unswitched Battery + Battery
39 Unswitched Battery + Battery (1) "J1" is a 70 pin connector.

Switch to
40 Switch (Left Stabilizer Raise)
Ground

(continued)
31200302 35
Systems Operation Section

Table 7 (Table 7, contd)

Contact Description for the Machine ECM (Connector Contact Description for the Machine ECM (Connector
"J2")(1) "J2")(1)
No. Function Type No. Function Type
1 Switch (Key Start) Key Start 33 Joystick Thumb Slider Command Input
2 Solenoid (Implement Disable) On/Off Driver Switch to
36 Switch (Quick Coupler) - Engaged
Ground
3 Relay (Quick Coupler) On/Off Driver
Switch (Quick Coupler) - Switch to
4 Implement Disable Return Return 37
=Disengaged Ground
5 Relay (Circle Steer) On/Off Driver Switch (Quick Coupler) -Engaged/ Switch to
38
6 Relay (Crab Steer) On/Off Driver Disengaged Parity Ground

7 Relay (Start) On/Off Driver 39 Unused

8 Relays (Load Return 2-5) Return 40 Joystick Lateral Command

9 Lamp (Continuous Flow) Driver 42 Switch (Service Brake Pressure)

10 Relay (Frame Level Disable) Driver 43 Switch (Engine Oil Pressure)

11 Relay (Stabilizer Isolation 1) Driver Switch (Right Stabilizer Down Switch to

44
Pressure) Ground
12 Relay (Stabilizer Isolation 2) Driver
Switch (Left Stabilizer Down Switch to
45
13 PHS Address Out Driver Pressure) Ground
14 Alternator R Terminal R-Terminal Switch to
46 Switch (Trigger Parity)
Ground
Switch to
15 Switch (Continuous Flow) Switch to
Ground 47 Switch (Boom Angle) - 40 degrees
Ground
Sensor (Load Stability Indicator -
16 PWM Input
LSI) 48 Aux Parity/Aux Proportional
Switch to 49 Switch (Shift Rail 1)
17 Switch (Inlet Air Filter Restriction)
Ground
50 Switch (Shift Rail 2)
20 Lamp Driver (MSS Hold) Driver
51 Switch (Shift Rail 3)
21 Lamp Driver (MSS Hold) Driver
Switch to
52 Switch (Park Brake Engaged)
Switch to Ground
23 Switch (AUX Select 2)
Ground
Switch to
53 Switch (Park rake Disengaged)
Switch to Ground
24 Switch (Rear Axle Align)
Ground
Switch to
54 Switch (Boom Lowered)
Switch to Ground
25 Switch (Steer Mode Front)
Ground
Switch to
55 PHS Control - Address In
Switch to Ground
26 Switch (Steer Mode - Circle)
Ground
Switch to
58 Switch (Transmission Neutralizer)
Switch to Ground
27 Switch (Steer Mode - Crab)
Ground
Switch to
59 Shuttle Control - Forward
Switch to Ground
28 Switch (Front Axle Align)
Ground
Switch to
60 Shuttle Control - Reverse
Switch to Ground
29 Switch (Right Stabilizer Raise)
Ground
Switch to
61 Switch (Boom 40 degree) - Parity
Switch to Ground
31 Switch (Right Stabilizer Lower)
Ground
64 CAN B+ Input/Output
32 Joystick Longitudal Command Input
(continued)
(continued)
36 31200302
Systems Operation Section

(Table 7, contd)

Contact Description for the Machine ECM (Connector

"J2")(1)
No. Function Type
65 CAN B- Input/Output
67 CAN A+ Input/Output
68 CAN A- Input/Output

(1) "J2" is a 70 pin connector.

31200302 37
Systems Operation Section

Electrical Output Components

Illustration 131 g01187410

38 31200302
Systems Operation Section

Relays ECM 1

Illustration 132 g00904067

There are six relays in the programmable hydraulic

valve system.
• The interlock relay (2) for the frame level.
• One relay for the quick coupler (10) is for the power Illustration 133 g00913924
and the other relay is for the ground.
Implement control valve
• One relay for the auxiliary diverter valve (13) is for
the power and the other relay is for the ground.
The relays are activated directly by the machine ECM
(11).

Solenoids
Solenoids For Frame Level
Solenoids for the frame leveling system follow:
• Left hand frame level (1)
• Right hand frame level (4)
The frame leveling system enables the operator to
level the machine on uneven ground in order to
improve the stability of the machine during stationary
operation.

Solenoid For The Diverter Valve

The diverter valve solenoid (12) operates the diverter Illustration 134 g00913862
valve. The diverter valve diverts the oil flow from the
auxiliary section of the implement control valve to either ECM 1 (23) controls the solenoids for the following
the quick coupler cylinder or through push on couplers implements:
to a work tool cylinder. An optional dual diverter valve • Boom lower and boom raise
provides an oil flow to an additional auxiliary service.
• Coupler tilt forward and coupler tilt backward
ECM 2
ECM 2 (24) controls the solenoids for the following
implements:
• Auxiliary port (21) and auxiliary port (22).
• Boom retract and boom extend
31200302 39
Systems Operation Section

Solenoid For The Flow Control Valve Solenoid Outputs

(Stabilizer) Directional Solenoid and Modulation Valve for the
Synchronizer
• Any active short to ground or open circuit fault
• The command to the solenoid is off and there is a
fault for a short to the battery.
Solenoids for the Synchronizers for the
Powersynchro Transmission
• The command to the solenoid is off. There is a
fault for a short to the ground or there is a fault for
a open circuit.
• Any active short to the battery fault

Illustration 135 g01187438

System Voltage
Stabilizer Control Valve Gp
Overvoltage Condition
(18) Flow control valve (stabilizer)
The control shuts off all the solenoids when the voltage
When one of the stabilizer switches is held down the in the system is 16 DCV. The transmission will be
switch sends a signal to the ECM. Also, the switch placed into neutral. Normal operation can take place
energizes the solenoid for the control valve (stabilizer). after the voltage drops below 15.5 DCV and the shift
Simultaneously, the machine ECM energizes the lever is placed in neutral.
solenoid for the flow control valve (stabilizer) (18). The Undervoltage Condition
flow control valve opens and hydraulic fluid flows The control will maintain any solenoid which is
through the control valve and to the stabilizer cylinder. currently on when the voltage is below 10 DCV for
This action causes the stabilizer cylinder to move. The more than 30 seconds. All the solenoids will be turned
speed of the stabilizer movement ramps upward as the off if a new solenoid is engaged. The loss of the
switch is held down. solenoids will cause the transmission to be placed in
Other Outputs neutral.

The machine ECM (11) also sends information to the Shuttle Shift for the Power Shuttle
dash panel cluster (19) and the service connector (20)
via the CAT data link (16). Transmission
• Any active faults

Electrical Function Shift Lever (Cat Data Link) for

Requirements Powersynchro Transmission
Note: This machine must be serviced by a technician. • A loss of communications for more than 1 second
The technician must be familiar with Caterpillar • An invalid gear and direction input
Electronic Technician (ET). A number of parameters
can be installed and modified through the configuration Rear Axle Lock (if equipped)
screen. The following is an example: You have the
ability to change the maximum forward and the • The machine is in "Locked Axle Mode".
maximum reverse gear for the transmission. The
configuration of the machine may appear as an
interlock. See APPROPRIATE SERVICE MANUAL,
"ELECTRONIC CONTROL MODULE (ECM) -
CONFIGURE" for information concerning the machine
configuration.

Transmission Neutralizer
The following subject titles will cause the transmission to
be neutralized.
40 31200302
Systems Operation Section

Machine Security System • The machine is in two-wheel steer mode and there
is a diagnostic code for a short to ground or a open
• An incorrect key is being used. circuit on the relay for either the circle steer or crab
steer.
Parking Brake • The last valid steering mode is not known.
If the parking brake is on or if there is a failure the • There is a diagnostic code for both relays for the
transmission is neutralized. If a failure is noticed on the steering for a short to the battery.
inputs for the parking brake, the ECM will use the last
• The feature for the auto alignment is installed. the
valid communications for 2.5 seconds as the signal is
machine is in the two-wheel steering mode, and
returning to an initial state. Once the time has elapsed
both sensors for the alignment are not detecting
the system will default. The parking brake will be
the centered position.
enabled electrically and the transmission will be
neutralized. Once the parking brake failure is resolved The machine will default to circle steer mode under the
the technician needs to cycle the parking brake from the following conditions.
applied position to the released position in order to • The machine is in circle steer mode and there is a
return the machine to normal operation. The shift lever diagnostic code for a short to ground or an open
needs to be moved from neutral to a valid direction in circuit on the relay for the crab steer.
order to engage the transmission.
• Circle steer is the last valid steering mode and
there is an active diagnostic on the selector switch
Service Brake Pressure Switch for the for the steering mode.
Transmission Neutralizer • The relay for the circle steer mode has a diagnostic
The transmission neutralizer pressure switch is used to code for a short to the battery.
neutralize the transmission when the service brakes • The auto sensors for the alignment do not detect
are applied. This feature will help reduce the wear of the the centered position.
service brakes.
The machine will default to crab steer mode under the
The transmission is neutralized when any of the following conditions.
following conditions are true for the brake.
• The machine is in crab steer mode and there is a
• If you release the service brake within three diagnostic for an active short to ground or an open
minutes the machine will go into gear. If you circuit on the relay for the circle steer.
depress the brake longer than three minutes in
order to move in gear the shuttle lever is placed • Crab steer is the last valid steering mode and there
into neutral and then back into gear. is an active diagnostic on the selector switch for
the steering mode.
• The neutralizer switch for the brake has been
grounded and the service brake pedal is • The relay for the crab steer has a diagnostic code
for a short to the battery.
depressed.
• The feature for the auto alignment is installed and
More Electrical Function the machine is in the crab steer mode. Neither of
the two sensors for alignment are detecting the
Requirements centered position.
Additional electrical function requirements are included
in the following topics. The Neutral Start Is Disabled
The ECM monitors the system for shorts to the battery
for the key start switch. There is a limitation to the length
Steering of time for cranking the starter. Input that lasts longer
than one minute from the switch to the battery is a short
The machine will default to two-wheel steer mode to ground. When a failure exists for the key start switch
under the following conditions. the system will be unable to start.
• The machine is in circle steer mode and there is a The shift lever sends a signal to the ECM via the CAT
diagnostic for a active short to ground or a open Data Link. The signal tells the ECM the desired direction
circuit on the relay for the circle steer. of travel for the machine. If any position but the neutral
• The machine is in crab steer mode and there is a is communicated the ECM will prevent the start relay
diagnostic for a short to ground or a open circuit on coil from being energized.
the relay for crab steer. The shuttle lever will signal on all four inputs when the
lever is in the neutral position without using the data
31200302 41
Systems Operation Section

link. If any of the outputs from the shuttles provide a • An active diagnostic code exists for the solenoid
switch to battery signal or if any of the switch to ground for the boom raise.
signal to the ECM, the ECM will prevent the start relay • The boom exceeds the critical angle.
coil from being energized.
• The machine is in the Free Axle Mode or the
The following conditions will allow the neutral start to
machine is in the Limited Free Axle Mode.
become disabled:
• A start relay has a failure. • An invalid entry is made into the machine security
system.
• The transmission is NOT in the neutral position.
• An active diagnostic code exists for the solenoid that
• The engine speed is NOT zero rpm. raises the stabilizer.
• An invalid key was entered for the machine security
system (MSS). The Boom Extend/Retract Is
Disabled
Stabilizer Raise/Lower (if equipped) is
The boom extend or the boom retract will be disabled
Disabled when any of the following conditions are true.
The stabilizer raise or stabilizer lower will be disabled • Both the stabilizers are not extended.
when any of the following conditions are true.
• The limit for the extension of the boom is active.
• The status for the initialization screen for the
Programmable Hydraulic System (PHS) is not • The status for the initialization screen for the PHS
equal to "Complete". is not equal to "Complete".
• The implement lockout switch is enabled or an
• The implement lockout switch is enabled or an
active failure exists for the switch.
active failure exists for the switch.
• The machine is not placed into the neutral position
• The machine is not placed into the neutral position
during the system power up or after the system
during the system power up or after the system
powerup.
powerup.
• An active diagnostic code exists for the inputs on • An active diagnostic code exists for the boom
the stabilizer control. extend solenoid.
• An active diagnostic code exists for the boom
• An active diagnostic code exists for the solenoid
retract solenoid.
on the stabilizer lower.
• An invalid entry is made into the machine security
• The feature for locking the rear axle is in the
system.
""Locked Axle Mode"".
• An invalid key was entered for the machine security Disable The Rackback And Dump
system (MSS).
• The "Lateral Stability Adjustment Inhibit" feature The rack or the dump will be disabled when any of the
is installed and the boom is not retracted. The conditions are true.
"Lateral Stability Adjustment Inhibit" feature is for • The status for the initialization screen for the PHS
the "French" market. is not equal to "Complete".
• The implement lockout switch is enabled or an
Boom Raise/Lower Is Disabled active failure exists for the switch.
The boom raise or the boom lower will be disabled • The machine is not placed into the neutral position
when any of the following conditions are true. during the system power up after system powerup.
• The status for the initialization screen for the PHS • An active diagnostic code exists for the control.
is not equal to "Complete".
• An active diagnostic code exists for the rack
• The implement lockout switch is enabled or an actuator solenoid.
active failure exists for the switch. • An active diagnostic code exists for the dump
• The machine is not placed into the neutral position solenoid.
during power up or after powerup.
• A failure exists for the inputs to the control for the
boom raise or the boom lower.
• An active diagnostic code exists for the solenoid
that is used for lowering the boom.
42 31200302
Systems Operation Section

The Frame Level (if equipped) is

Disabled
The feature for the frame level will be disabled when
any of the following conditions are true.
• The feature for the rear axle lock is in the ""Locked
Axle Mode"".
• The "Lateral Stability Adjustment Inhibit" feature
is installed and the boom is not retracted. The
"Lateral Stability Adjustment Inhibit" feature is for
the "French" market.

Disable the Quick Coupler

The circuit of the quick coupler switch will be disabled if
an invalid switch input is detected. The quick coupler
will be disabled until the failure is corrected and the
input is cycled through the neutral state.
If the ECM receives mismatching information from a
proportional input device and the quick coupler switch,
the system will turn off the auxiliary valve as well as
the solenoid for the quick coupler. The components are
disabled until both inputs return to the neutral state and
a valid input is provided.

Miscellaneous
The following list consists of miscellaneous interlocks.
• The machine security system may disable the
machine by controlling the electronic devices that
are used to power critical machine systems.
This is a simplified schematic of the Programmable
Hydraulic System (PHS) that is electrically correct. This
schematic does not show all possible harness
connectors. Always see the Electrical System
Schematic in the Service Manual for the machine for an
accurate schematic of a particular machine.
31200302 43
Systems Operation Section

Electrical Schematic

Illustration 138 g01174585

“J1” Connector
44 31200302
Systems Operation Section

Illustration 139 g01174588

“J2” Connector
31200302 45
Systems Operation Section

Piston Pump (Implement and

Steering)
Piston Pump

Illustration 140 g01022614

Steering and Implement Pump (Engine Off)
(1) Piston Pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line To the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

Piston pump (1) has the following characteristics: Note: Load sensing oil pressure is sometimes referred
• variable displacement to as signal oil. The two terms have the same meaning
throughout this story.
• load sensing
The piston pump has the following components:
• compensation for pressure
Piston and barrel assembly (3) - The cylinder barrel
• compensation for flow contains nine pistons. The cylinder barrel assembly
This piston type pump has variable flow and pressure. rotates whenever the engine is running. The pistons
The flow and pressure are dependent on the system move oil into the barrel and out of the barrel.
demands that are sensed by pressure and flow Shaft (4) - The rotation of the pump is
compensator valve (2). counterclockwise when the pump is viewed from the
drive end. The piston and barrel assembly is splined to
the drive shaft.
Bias spring (5) - If there is no pressure on the right
side of the actuator piston, the bias spring will hold the
swashplate at the maximum angle.
46 31200302
Systems Operation Section

Swashplate (6) - The displacement of the pump is Note: The maximum system pressure is controlled by
controlled by the angle of the swashplate. The angle of the load sensing oil relief valve and the margin
the swashplate causes the pistons to move in and out of pressure. The load sensing oil relief valve is set at
the rotating barrel. 22800 kPa (3300 psi) and the margin pressure is set at
Actuator piston (7) - When oil pressure increases 2200 kPa (320 psi). The maximum system pressure is
behind the actuator piston, the piston will overcome the 25000 ± 500 kPa (3625 ± 75 psi).
force of the bias spring. This causes the angle of the Pressure compensator spool (14) is used as a backup
swashplate to be reduced. to limit the maximum system pressure to 26000 ± 500
Pressure and flow compensator valve (2) - The kPa (3770 ± 73 psi) if the load sensing oil relief valve
fails.
pressure and flow compensator valve controls the
delivery of oil and the return of oil to the actuator Pressure and flow compensator valve (2) has orifice
piston. (15) in the load sensing oil passage to actuator piston
(16). Orifice (15) is used in order to regulate the
When the engine is OFF, pressure and flow response rate of the actuator piston by creating a
compensator valve (2) does not receive load sensing oil consistent leak path.
pressure (8) or supply pressure from pump outlet (9).
Margin spring (10) pushes flow compensator spool Note: If the load sensing oil relief valve is operating
(11) completely downward. Any pressure that is on the correctly the load sensing oil relief valve controls the
right side of actuator piston (7) is vented to the case maximum system pressure. Maximum system
drain across flow compensator spool (11). pressure should be the pressure of the load sensing oil
relief valve plus the margin pressure. If the load
When there is no pressure behind actuator piston (7), sensing oil relief valve is not adjusted correctly the
bias spring (5) is able to hold swashplate (6) at the pressure compensator acts as a backup.
maximum angle.
When the engine is started, shaft (4) starts to rotate. Oil
flows into the piston bore from pump inlet (12). Oil is
forced out of pump outlet (9) and into the system as the
piston and barrel assembly (3) rotates.

Compensator Valve
Pressure and flow compensator valve (2) is bolted to
the top of the piston pump. Pressure and flow
compensator valve (2) compensates for pressure
variations and flow variations in the implement
hydraulic system in order to meet the system
demands.
Flow compensator spool (11) regulates the pump
output flow in response to the following oil
pressures:
• Load sensing oil pressure (8)
• Supply pressure from pump outlet (9)
The load sensing oil is received through the load
sensing oil control network for the pump.
The flow that is supplied by the hydraulic pump is the
amount that is required in order to keep the supply
pressure 2200 ± 100 kPa (320 ± 15 psi) above the
load sensing oil pressure (8). The difference between
load sensing oil pressure (8) from the main hydraulic
control valve and the supply pressure from pump outlet
(9) is called the margin pressure. Flow compensator
spool (11) controls the margin pressure.
Margin pressure is equal to the spring force value of
margin spring (10).
The margin pressure is adjusted by turning adjusting
screw (13) on flow compensator spool (11).
31200302 47
Systems Operation Section

Low Pressure Standby

Illustration 141 g01022627

Steering and Implement Pump (Low pressure Standby)
(1) Piston Pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line To the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

When piston pump (1) produces flow, the system Even when no implements are being used, the steering
pressure begins to increase because the oil flow from system maintains a load sensing oil to the pump.
pump outlet (9) is blocked at the closed center The pressure at pump outlet (9) must overcome the
implement control valves. force of margin spring (10) and the dynamic bleed
The supply pressure from pump outlet (9) is felt at the signal. Pressure at pump outlet (9) is called "low
bottom end of flow compensator spool (11). The supply pressure standby". Low pressure standby is
pressure from pump outlet (9) is greater than the approximately 4500 kPa (650 psi).
combined pressure of load sensing oil pressure (8) and The low pressure standby is higher than the margin
margin spring (10). The flow compensator spool moves pressure. The higher pressure is needed to maintain the
upward against the margin spring. This permits system pilot pressure.
oil to flow to actuator piston (7).
When piston pump (1) is at low pressure standby, the
When the pressure on actuator piston (7) increases, the supply pressure from pump outlet (9) raises flow
force of bias spring (5) is overcome and swashplate compensator spool (11) higher. This will further
(6) is moved to a slight angle. compress margin spring (10). An increased amount of
Piston pump (1) produces enough flow in order to supply oil from pump outlet (9) will flow to actuator
compensate for normal system leakage when piston (7). This will slightly destroke the hydraulic
swashplate (6) is at a slight angle. Also, the piston pump.
pump has sufficient pressure in order to provide The low pressure standby can be adjusted by
instantaneous response when an implement is changing the setting of the margin spring.
activated.
48 31200302
Systems Operation Section

Upstroke

Illustration 142 g01022648

Steering and Implement Pump (Upstroke)
(1) Piston Pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line To the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

When an implement hydraulic circuit requires flow, the • The hydraulic pump will upstroke when the flow
pressure from pump outlet (9) is reduced. The force of demand increases from changing the position of
margin spring (10) and load sensing oil pressure (8) is the main control spool in a hydraulic control valve.
greater than supply pressure from pump outlet (9). The
• If another implement hydraulic circuit is engaged,
overall force is on the top end of flow compensator
there is a need for increased pump flow.
spool (11).
• If the flow demand on the implement hydraulic
The spool moves down. The spool blocks the flow of oil
system remains constant or the flow demand
to actuator piston (7). Oil that is in the chamber for
increases, the hydraulic pump will upstroke when
actuator piston (7) is vented to the case drain across
the engine speed decreases.
flow compensator spool (11). This allows bias spring (5)
to move swashplate (6) to a greater angle. Note: The load sensing oil pressure does not need to
increase in order to upstroke the hydraulic pump.
The pump now produces more flow. This condition is
known as "upstroking". For example, if one implement hydraulic circuit is
activated at an operating pressure of 13800 kPa (2000
The following conditions can result in upstroking
psi), the system pressure is 16000 kPa (2320 psi). The
the pump:
pressure of 16000 kPa (2320 psi) is a combination of the
margin pressure and the pressure of the load sensing
• If an implement hydraulic circuit is initially activated oil.
from low pressure standby, the load sensing load If another implement hydraulic circuit is activated at an
sensing oil increases the pump output flow. This initial operating pressure of 6900 kPa (1000 psi), the
increased pump output flow is routed to the position maximum pressure of the load sensing oil will still be
of a main control spool of a hydraulic control valve
that demands the oil.
31200302 49
Systems Operation Section

13800 kPa (2000 psi). The supply oil pressure will

decrease momentarily.
The combined force of the load sensing oil pressure (8)
and margin spring (10) is now higher than the supply
pressure from pump outlet (9) at the bottom end of the
spool. Flow compensator spool (11) is pushed to the
bottom. This allows oil that is behind actuator piston (7)
to be vented to the case drain. The angle of swashplate
(6) now increases and the hydraulic pump provides
more flow in order to meet the flow demands of both
circuits.

Constant Flow

Illustration 143 g01022658

Steering and Implement Pump (Constant Flow)
(1) Piston Pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line To the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

As the pump increases flow or decreases flow in order The following pressure will act on the bottom end of
to match the change in the flow requirements, the flow compensator spool (11):
forces above the flow compensator spool and below • Supply pressure from pump outlet (9)
the flow compensator spool will equalize.
Once the pressures become equal on each end of the
The following pressures will act on the top end of spool, flow compensator spool (11) will meter oil to
flow compensator spool (11): actuator piston (7). Bias spring (5) will be compressed
• Margin spring (10) and the system will stabilize.
• Load sensing oil pressure (8) Swashplate (6) is held at a relative constant angle in
order to maintain the required flow.
50 31200302
Systems Operation Section

Destroke

Illustration 144 g01022669

Steering and Implement Pump (Destroke)
(1) Piston Pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line To the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

When less flow is required, piston pump (1) destrokes. • If the main control spool for a hydraulic control
The piston pump destrokes when the supply pressure valve is moved to a position that requires less flow,
from pump outlet (9) becomes greater than the the hydraulic pump will destroke.
combined pressure of load sensing oil pressure (8) and • If multiple hydraulic control valves are being used,
margin spring (10). the hydraulic pump will destroke when there is
Flow compensator spool (11) is raised. This allows
• a reduction in flow demand from any one of the
more oil flow to actuator piston (7). Pressure on
hydraulic control valves.
actuator piston (7) is now increased.
The increased pressure overcomes the force of bias • If the engine speed increases, the piston pump
spring (5) which moves swashplate (6) to a reduced destrokes.
angle. When the supply pressure at pump outlet (9) When the piston pump destrokes, supply oil pressure
matches the combined pressure of load sensing oil from pump outlet (9) decreases on the bottom side of
pressure (8) and margin spring (10), the flow flow compensator spool (11).
compensator spool returns to a metering position. The force on the top of flow compensator spool (11)
Piston pump (1) will return to a constant flow. is the sum of the following pressures:
The following conditions result in destroking the • Margin spring (10)
pump:
• Load sensing oil pressure (8)
• When a main control spool for a hydraulic control
valve is moved to the HOLD position the hydraulic The following force acts on the bottom of flow
pump will destroke. compensator spool (11):
• • Supply pressure at pump outlet (9)
31200302 51
Systems Operation Section

Once the forces become equal on each end of the

spool, flow compensator spool (11) will meter oil to
actuator piston (7) and the system will stabilize. The
system will provide a constant flow until the flow
requirements change.
Note: Load sensing oil pressure (8) does not need to
decrease in order to destroke the hydraulic pump.
For example, if two implement hydraulic circuits are
activated at operating pressures of 13800 kPa (2000
psi) and 6900 kPa (1000 psi), the system pressure is
16000 kPa (2320 psi).
If the implement hydraulic circuit which is activated at
6900 kPa (1000 psi) is returned to the HOLD position, the
maximum load sensing oil pressure (8) will still be 13800
kPa (2000 psi). However, the supply pressure at pump
outlet (9) is momentarily increased due to the reduced
oil flow that is required in the implement hydraulic
circuits.
Supply pressure at pump outlet (9) raises flow
compensator spool (11). This allows more oil flow
behind actuator piston (7). The angle of swashplate (6)
now decreases and the hydraulic pump provides less
flow.
52 31200302
Systems Operation Section

High Pressure Stall

Illustration 145 g01022710

Steering and Implement Pump (Maximum System Pressure)
(1) Piston Pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line To the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

Note: Relief Valve (Load sensing oil) is sometimes If the load sensing oil relief valve (20) is not adjusted
referred to as the signal limiter valve. The two terms correctly, pressure compensator spool (14) serves as a
have the same meaning throughout this story. backup relief in order to protect the hydraulic system.
Note: This condition will only occur when the load At high pressure stall, the piston pump is at minimum
sensing oil relief valve is set below the valve of the flow and the supply oil at pump outlet (9) is at
pressure compensator. maximum pressure. These conditions are maintained for
If piston pump (1) is at a high pressure stall or a single implement in a stall condition.
maximum system pressure, the combined pressure of If multiple implement hydraulic circuits are activated and
load sensing oil pressure (8) and margin spring (10) is one circuit is at a stall, the piston pump (1) will
equal to the supply pressure at pump outlet (9). upstroke in order to meet the increased flow demands.
Load sensing oil relief valve (20) limits the maximum This flow meets the needs of the other circuits that are
system pressure at any pump displacement. Load operating at a lower work port pressure.
sensing oil relief valve (20) is set at 22800 kPa (3300
psi).
A margin pressure of 2200 ± 100 kPa (320 ± 15 psi)
above the load sensing oil is still maintained while
piston pump (1) is at a high pressure stall.
If the piston pump is at a high pressure stall, the
maximum system pressure will be 25000 ± 500 kPa
(3625 ± 75 psi).
31200302 53
Systems Operation Section

Main Control Valve (Implement)

Illustration 146 g00999457

Main Control Valve (Implement)
(1) Electronic Pilot Valve (Implement) (8) Solenoid Valve (shutoff for the Pilot Oil) (14) Valve Assembly (Steering priority)
(2) Control Valve (Implement) (9) Manifold Valve (Inlet) (15) Relief Valve (Load sensing signal)
(3) Control Valve (boom raise/lower) (10) Manifold Valve (Outlet) (16) Flow Control Valve (Dump valve
(4) Control Valve (tilt) (11) Relief Valve (Pressure reducing valve) for the load sensing signal)
(5) Control Valve (auxiliary) (12) Screw (17) Check Valve (Return oil back pressure)
(6) Control Valve (boom extend/retract) (13) Relief Valve (line relief valve and check valve
(7) Control Manifold (Pilot ECM)

The Main Control Valve (Implement) is located at the • (5) Control Valve (auxiliary)
rear of the machine. The main control valve is pilot • (4) Control Valve (tilt)
operated. The Electronic Pilot Valve (implement) (1) is
directly mounted to the side of the Control Valve • (3) Control Valve (boom raise/lower)
(implement) (2). Pilot valve (1) consists of two Control • (10) Manifold Valve (outlet)
Manifolds (Pilot ECM) (7), eight proportional solenoids
and eight pressure reducing valves. The machine ECM The manifold valve (inlet) includes the following
sends commands that are activated by the operatorto components:
the correct pilot ECM (7). Pilot ECM (7) controls the • (14) Valve Assembly (Steering priority)
proportional solenoids. The proportional solenoids • (15) Relief Valve (Load sensing signal)
control the pilot reducing valves. Pilot valve (1) contains
four pair of proportional pilot solenoid valves. Each pair • (16) Flow Control Valve Group (Dump valve for the
of proportional pilot solenoid valves are used to actuate load sensing signal)
an individual spool within the Control Valve (implement) • (17) Check Valve (Return oil back pressure)
(2). Relief Valve (pressure reducing valve) (11) supplies
pilot pressure to the ends of the spools in proportion to • Orifice Check valve
the current that is supplied to the solenoid. • Screens (75 and 100 micron)
Control Valve (implement) (2) includes the following Note: Relief Valve (Load sensing signal) is sometimes
sections: referred to as the signal limiter valve. The two terms
• (9) Manifold Valve (inlet) have the same meaning throughout this story.
• (6) Control Valve (boom extend/retract)
54 31200302
Systems Operation Section

Reference: See Systems Operation/Testing and tank. The telescoping cylinder and the boom cylinders
Adjusting, "Manifold Valve (Inlet)" for more information. can then be lowered or retracted.
The valve sections for the telescoping cylinder, Note: Refer to the Operation and Maintenance Manual,
auxiliary services, coupler tilt and the boom "Boom Retacting and Boom Lowering without Hydraulic
cylinder include the following components: Power" for more information.
• Pressure compensator valve Each implement valve section contains a pressure
compensating valve. All pressure compensating valves
• Load check valve
are interconnected. The pressure compensating
• Main control valve spool valves allow the oil flow to be proportionally divided
• (13) Relief Valve (Line relief valve and check valve) between each of the operating circuits when the flow
demands of the system exceed the total flow that is
Note: The Relief Valves (Line relief valve and check available from the pump. All of the hydraulic actuators will
valve) are only installed in the sections for the continue to function. However, the actuators will operate
auxiliary circuits and the coupler tilt. at a reduced speed.
The control valves control the delivery and the return of Also, the pressure compensating valves can determine
hydraulic oil to the machine implements. the function that has the highest demand in all of the
valves. Then, the load sensing signal pressure for the
highest demand is sent to the pump.The pump uses the
load sensing signal pressure in order to determine the
amount of flow that is required.
Note: Load sensing signal pressure is sometimes
referred to as signal oil. The two terms have the same
meaning throughout this story.
The pressure compensating valves maintain cylinder
speeds which are proportional to the position of the
joystick control. The cylinder speed will not increase if
the engine speed is increased in order to engage an
additional system. These characteristics aid smooth
machine operation when more than one system is in
operation.
Each implement control valve section includes the
following positions:
The positions for the boom extend/retract
(telescoping) function:
Illustration 147 g01133581
• Extend.
The spools for the Control Valve are shown in the HOLD position. • Hold
(T) Passage to hydraulic tank.
• Retract.
The control valve spools for the boom extend/retract
(telescoping), coupler tilt, and boom raise/lower for the The positions for the auxiliary circuits function:
Control Valve (implement) are closed to the hydraulic • Open
tank (T) when the joystick control is in the HOLD
• Hold
position. The main spool in the section for the auxiliary
circuits is open to the hydraulic tank (T) when the • Close
joystick control is in the HOLD position. The positions for the tilt cylinder function:
In the event of a loss of hydraulic power, oil locked into • Tilt forward.
the telescoping cylinder and the boom cylinder will
prevent the boom from lowering. The cylinders can not • Hold
be lowered or retracted until the lock valves on the • Tilt rearward.
cylinders are overridden. The implement control valve
The positions for the boom raise/lower cylinder
for the telescoping cylinder and the implement control
function:
valve for the boom cylinder are equipped with screws
for manually moving the main spools. • Raise.
After the lock valves on the cylinders are overridden, • Hold
the main spools are moved into the position that allows • Lower.
the blocked oil in the cylinders to return to the hydraulic
31200302 55
Systems Operation Section

Reference: See Systems Operation/Testing and

Adjusting, "Compensating System" for more
information.
The manifold valve (outlet) includes the following
components:
• (8) Solenoid Valve (Shutoff for the Pilot oil)
• (11) Relief Valve (Pressure reducing valve)
Reference: See Systems Operation/Testing and
Adjusting, "Manifold Valve (Outlet)" for more
information.

Manifold Valve (Inlet)

Illustration 148 g01023297

The Steering Priority Valve in Operation
(1) Check Valve (7) Screen (12) Relief Valve (Load sensing signal)
(2) Line to implement system (8) Load sensing signal from steering (13) Line to implement system
(3) Valve Assembly (Steering priority) (9) Pump Supply (14) Check Valve (Return oil back pressure)
(4) Spring (10) Load sensing signal from implements (15) Line to tank
(5) Return oil from implement system (11) Load sensing signal from implement (16) Flow Control Valve (Dump valve for the
(6) Line to metering pump system load sensing signal)

The manifold valve (inlet) is attached to the main • (1) Check valve
control valve. The main control valve is located at the • (3) Valve Assembly (Steering priority)
rear of the machine.
• (7) Screens (75 and 100 micron)
The manifold valve (implement) includes the
following components: • (12) Relief Valve (Load sensing signal)
56 31200302
Systems Operation Section

• (14) Check Valve (Return oil back pressure) Relief Valve (Load sensing signal)
• (16) Flow Control Valve Group (Dump valve for the Note: Relief Valve (Load sensing signal) is sometimes
load sensing signal) referred to as the signal limiter valve. The two terms
have the same meaning throughout this story.
Valve Assembly (Steering Priority)
Relief Valve (Load sensing signal) (12) limits the load
Valve Assembly (steering priority) (3) divides the flow of
sensing signal to the pressure and flow compensator
oil from the hydraulic piston pump between the
valve on the piston pump. The pressure and flow
demands from the steering system and the demands
compensator valve controls the pump output pressure.
from the implement system.
The pump output pressure is proportional to the load
Oil from the hydraulic piston pump enters the manifold sensing signal pressure. The relief valve has a
valve (inlet) and flows to the steering priority valve. The maximum pressure setting of 22800 kPa (3300 psi).
oil then flows through the open spool of the steering
Check Valve (Return oil back pressure)
priority valve and flows to the metering pump through
line (6). Check Valve (Return oil back pressure) (14) is located in
the return oil circuit for the main implements. The back
When the steering wheel is stationary, the spool in the
pressure valve maintains a minimum pressure in the
steering metering unit is spring centered and the oil is
return oil system. The back pressure valve has a
blocked at the spool. The pressure then builds up in
pressure setting of 3.5 ± .5 kPa (0.50 ± 0.1 psi).
the line (6). The increased pressure acts upon the top
of the priority valve spool. The spool proportionally Flow Control Valve Group (Dump valve for the load
moves down against the force of spring (4). The mid- sensing signal)
position of the spool allows oil flow to the steering system Note: Load sensing signal pressure is sometimes
and to the implement control system. Further movement referred to as signal oil. The two terms have the same
of the spool in the steering priority valve closes off the meaning throughout this story.
supply of oil to the steering system. All oil flow through
Flow Control Valve Group (Dump valve for the load
the priority valve is then supplied to the implement
sensing signal) (16) is installed in order to provide a
system through line (2).
drain back to the hydraulic tank for the load sensing
The steering priority valve ensures that the steering signal once the load has been reduced on the
system has oil flow priority. When the steering wheel is machine requirements. The drain valve is pressure
turned, load sensing signal pressure is transmitted compensated.
through line (8) to a chamber at the bottom of the
steering priority valve. The pressure in load sensing
signal line (8) combines with the force of spring (4) in
Check and Relief Valves
order to move the spool. When the steering wheel is
turned faster, the load sensing signal pressure
increases in the load sensing line. The pressure
determines the amount of proportional movement of the
priority valve spool.
Note: Load sensing signal pressure is sometimes
referred to as the signal oil. The two terms have the
same meaning throughout this story.
Check Valve
Check valve (1) is a spring-loaded valve. The check
valve only allows oil flow in one direction.
When the spool in the steering priority valve moves up,
Illustration 149 g01009888
pressure from the top side of the spool is exhausted
Schematic of Check and Relief Valves
through check valve (1) into line (6).
(1) Relief Valve
Screens (2) Line to implement control valve
(3) Line to implement control valve
The manifold valve (inlet) of the implement control valve
(4) Relief valve
contains three screens (7). The screens are dedicated (5) Check Valve
to the following circuits: (6) Check valve
• The system for the pilot supply (75 micron) (7) Return to tank passage

• Load sensing signal system for the priority valve

Combined relief and check valves are installed in the
(100 micron)
implement control valves for the auxiliary circuits and the
• Drain for the load sensing signal for the implement coupler tilt. The valves serve a dual purpose. The
system (100 micron) valves limit the maximum oil pressure in the circuit. The
31200302 57
Systems Operation Section

valves also provide makeup oil in order to prevent

cavitation.
Note: Check valves that provide makeup oil are also
called makeup valves or anticavitation valves.
The valves will open if the pressure in lines (2) or (3)
rises above the preset pressure. The relieved pressure
will then flow through the open relief valve into tank
passage (7).
The check valves act as anticavitation valves. When
the pressure in the supply side of the system falls
below the pressure in the hydraulic tank, the check
valve in that line opens. Oil at tank pressure then flows
from tank passage (7) into the passage in order to
prevent cavitation.
For example, the operator moves the control lever in
the cab to the TILT FORWARD position. When the
forks are moving at a speed that is greater than the oil
pressure in line (2) then line (2) will cavitate. The
pressure of the oil in line (2) becomes less than the
pressure of the oil in return to tank passage (7). Since
the pressure of the oil in line (7) is greater than the
pressure of the oil in line (2), check valve (5) opens.
When the check valve opens, oil in the return to tank
line flows into line (2). This oil prevents line (2) from
cavitating.
Reference: See Systems Operation/Testing and Adjusting,
"Compensating System" for more information about the check
and relief valves.
58 31200302
Systems Operation Section

Manifold Valve (Outlet)

The manifold valve (outlet) is attached to the main
control valve. The main control valve is located at the
rear of the machine.

Illustration 150 g01023323

Manifold Valve (outlet)
(1) Return to tank passage (5) Pump supply passage (11) Supply oil to the trailer and towing hitch
(2) Return oil from trailer and towing hitch (6) Manifold valve (outlet) hydraulic system (if equiped)
hydraulic system (if equiped) (7) Pressure reducing valve (12) Return oil from Electronic Pilot Valve
(3) Load sensing signal passage (8) Pilot oil passage (implement)
(4) Load sensing signal from trailer and (9) Shutoff valve for the pilot oil (13) Return oil from brake circuit
towing hitch hydraulic system (if (10) Supply oil from the passage of the (14) Return to tank oil line
equiped) steering priority valve (15) Supply oil to brake circuit

The manifold valve (outlet) includes the following reduced pressure oil flows from valve (7) through
components: internal passages and through line (15) to the master
• (7) Pressure reducing valve cylinder for the brake system. The rest of the reduced
pressure oil flows from valve (7) through internal
• (9) Shutoff valve for the pilot oil passages to shutoff valve (9).
Pressure Reducing Valve Shutoff Valve for the Pilot Oil
Pump supply oil flows through a 100 micron filter that is Shutoff valve (9) provides a means of cutting off pilot oil
located in the manifold valve (inlet), and through line pressure to the main control valve. During normal
(5) into pressure reducing valve (7). Valve (7) reduces operation, the pilot oil flows through the shutoff valve
pump supply oil from the hydraulic piston pump to 3450 into passage (8). The oil then flows through passage (8)
± 145 kPa (500 ± 20 psi). to the electronic pilot valves.
This oil is used as pilot oil for the implement system If an actuator for an implement malfunctions, or if a
and supply oil for the braking system. Part of the fault occurs in the electronic system for the
31200302 59
Systems Operation Section

implements, then the machine ECM will send a signal to

the solenoid on the shutoff valve. The solenoid causes
the spool in the shutoff valve to shift. When the spool
shifts the flow of oil from pressure reducing valve (7) to
the main control valve is blocked.
When the spool in the shutoff valve blocks the flow of oil
from the pressure reducing valve to the main control
valve, the spool routes the oil into internal passage (4).
Passage (4) intersects with internal passage (12). The
oil in passage (12) flows into the return to tank line (13)
for the brake system . Line (13) routes the oil back to
the hydraulic tank.

Pilot Hydraulic System

Illustration 151 g01052621

Main Control Valve Group (Implement)
(1) Inlet Manifold (5) Relief Valve (Pressure reducing valve) (9) Proportional piot reducing valves
(2) Valve Assembly (6) Solenoid Valve Group (Pilot oil shutoff) (10) Return oil line
(3) Proportional pilot reducing valves (7) Pump supply (11) Supply oil to brake circuit
(4) Outlet Manifold (8) Pilot oil passage

Oil from the piston pump flows into pump supply Reference: See Systems Operation/Testing and
passage (7) that is located in inlet manifold (1). The oil Adjusting, "Outlet Manifold" for more information.
flows to Valve Assembly (Steering priority) (2) that is The Relief Valve (Pressure reducing valve) reduces
also located in the inlet manifold. the high pressure of the pump supply to 3450 ±150
Reference: See Systems Operation/Testing and kPa (500 ± 20 psi). The reduced pressure oil is used as
Adjusting, "Inlet Manifold" for more information. pilot oil in the implement hydraulic system and as
Part of the oil flows through the steering priority valve brake oil in the brake hydraulic system. Part of this oil
and part of the oil flows through the main body of the flows through an internal passage into supply oil to
main control valve group. This oil flows into outlet brake circuit (11). The rest of the reduced pressure oil
manifold (4). The oil then flows to Relief Valve flows through Solenoid Valve Group (Pilot oil shutoff) (6)
(Pressure reducing valve) (5) that is located in the into pilot oil passage (8).
outlet manifold.
60 31200302
Systems Operation Section

The excess oil from pump supply (7) flows out of • Allow a means of retracting the boom when the
Relief Valve (Pressure reducing valve) (5) and into boom will not retract under gravity.
return oil line (10). The pump includes four check valves. The check
The main control valve is pilot operated. The valves open and the check valves close in response to
Electronic Pilot Valve Group (implement) is directly the action of the pump in order to provide the correct
mounted to the side of the Main Control Valve Group characteristics for the operation of the pump.
(implement). The pilot valve consists of two Control
Retracting the Telescoping Cylinder
Manifold Group (Pilot ECM), and eight pressure
reducing valves. Each pressure reducing valve has a
proportional solenoid.
Pilot oil passage (8) is a common passage in the
Electronic Pilot Valve Group (implement). The oil in
pilot oil passage (8) flows to proportional pilot reducing
valves (3) and proportional pilot reducing valves (9). If
there is no demand for the use of the implements the
proportional pilot reducing valves block the oil. When
there is demand for the use of the implements, the
proportional pilot reducing valves route the pilot oil to
the main control valve spools in metered amounts in
order to control the work tool.
Reference: See Systems Operation/Testing and
Adjusting, "Operation of the Implement Control Valve"
for more information.

Lowering Control Pump

(Electric)
S/N: SLE4500-Up
S/N: SLG1300-Up

Electric Lowering Control Pump (If

Equipped)
When there is a loss of hydraulic power, the load
control valve on the telescoping cylinder locks oil in the
cylinder in order to prevent the boom from retracting.
Refer to Systems Operation, Testing and Adjusting,
"Load Control Valves (Lock)" for information on the
operation of the load control valve. When this happens
the boom can be retracted by manually opening the
lock valve on the telescoping cylinder and by manually
opening the implement control valve for the
telescoping cylinder. The oil is then free to flow from
the head end of the cylinder and the cylinder will retract
under the weight of the load. Refer to Operation and
Maintenance Manual for more information.
When the angle of the boom is below approximately 20
degrees, the deflection of the second stage of the boom
may prevent the boom from fully retracting. In this
situation, the boom can be retracted provided that the
machine is equipped with an electric lowering control
pump.
The electric motor and the pump are directly
connected by steel lines to the telescoping cylinder
and to the load control valve for the telescoping
cylinder. The pump provides the following functionality:
31200302 61
Systems Operation Section

Illustration 152 g01188365

Hydraulic Schematic for the Lowering of the Telescoping Cylinder

Switch (13) activates motor (14). The motor turns

pump (15). The oil passes from pump (15) through line
(11) past check valve (10A). If the solenoid for
sequence valve (9) is not energized, the oil from the
pump continues through the sequence valve and past
check valve (6). The pump pressure opens lock valve
(1). The increased oil pressure enters the rod end of
the telescopic cylinder (2). The oil in the head end of the
telescopic cylinder is then forced backward through lock
valve (1). The oil continues through line (19) to the
telescopic control valve. The oil is then blocked at the
control. Pilot oil pressure from line (11) to check valve
(10B) holds the check valve open. Oil from line (17)
passes through check valve (10B) and the oil returns to
tank (18).
Retracting the Boom
62 31200302
Systems Operation Section

Illustration 153 g01188373

Hydraulic Schematic for the Lowering of the Boom Cylinder

Retracting the boom is similar to the telescoping check valve open. Oil from line (21) passes through
cylinder. check valve (10C). Then, the oil flows through line (17)
past check valve (10B) and returns to tank (18).
Press switch (8) for the boom lower. The switch for the
boom lower activates the solenoid for the sequence
valve (9). The oil is directed to the boom circuit.
Switch (13) activates motor (14). The motor turns
pump (15). The oil passes from pump (15) through line
(11) past check valve (10A). The solenoid for
sequence valve (9) is energized. The oil from the
pump continues through the sequence valve. The
pump pressure opens lock valve (7). The increased oil
pressure enters the rod end of the boom cylinder (4).
The oil in the head end of the boom cylinder is forced
backward through lock valve (7). The oil continues
through line (22) to the boom cylinder control valve.
The oil is then blocked at the control valve. Pilot oil
pressure from line (11) to check valve (10B) holds the
31200302 63
Systems Operation Section

Lowering Control Pump The pump is located at the rear of the machine on the
right hand side of the main frame. The pump is directly
(Manual) connected by steel lines to the telescoping cylinder and
to the load control valve for the telescoping cylinder.
When there is a loss of hydraulic power, the load The pump is equipped with a short operating handle. A
control valve on the telescoping cylinder locks oil in the separate longer handle is provided in order to provide
cylinder in order to prevent the boom from retracting. the necessary leverage for operating the pump. The
Refer to Systems Operation, Testing and Adjusting, long handle slides over the short handle. The long
"Load Control Valves (Lock)" for information on the handle is stowed in the engine compartment. The
operation of the load control valve. When this happens pump provides the following functionality:
the boom can be retracted by manually opening the
lock valve on the telescoping cylinder and by manually • Allow a means of retracting the boom when the
opening the implement control valve for the boom will not retract under gravity.
telescoping cylinder. The oil is then free to flow from The pump includes four check valves. The check
the head end of the cylinder and the cylinder will retract valves open and the check valves close in response to
under the weight of the load. the action of the pump in order to provide the correct
When the angle of the boom is below approximately 20 characteristics for the operation of the pump.
degrees, the deflection of the second stage of the boom Retracting the Boom with the Lowering Control
may prevent the boom from fully retracting. In this Pump
situation, the boom can be retracted provided that the
machine is equipped with a lowering control pump.

Illustration 154 g01023265

Hydraulic Schematic for the Lowering Control Pump (Intake Stroke)

When pump (1) is on the intake stroke, oil in line (14)

opens check valve (14). All other check valves remain
closed. The oil flows into the pump and the oil fills the
pump.
64 31200302
Systems Operation Section

Illustration 155 g01053124

Hydraulic Schematic for the Lowering Control Pump (Pumping Stroke)
(1) Lowering control pump (6) Line (13) Line
(2) Handle (7) Check valve (14) Check valve
(3) Load control valve (8) Line (15) Blocked oil at implement control valve
(4) Telescoping cylinder (11) Check Valve (telescoping)
(5) Check valve (12) Line (16) Flow Control Orifice

When pump (1) is on the pumping stroke, oil in line (12) Due to the surface area of the cylinder piston, the
opens check valves (5) and (7). Check valve (11) is also volume of oil that leaves the head end of the cylinder is
opened by the oil in line (12). Oil in line (8) from the head greater than the volume of oil that enters the rod end of
end of the cylinder flows past check valve (9) into line the cylinder. The additional volume of oil from the
(6). The oil then flows into the rod end of telescoping cylinder flows through check valve (11) to tank return
cylinder (4) in order to retract the boom. line (13). Check valve (14) prevents pilot oil from
Oil from the head end of the telescoping cylinder flows flowing into the tank return line. Check valve (5)
through lock valve (3). The oil enters lowering control prevents the main oil flow from flowing back to the
pump (1) through line (8). The majority of the oil from pump when the pump is on the upstroke.
line (8) flows through check valve (11) and flows to the
rod end of the cylinder in order to continue the retract
cycle.
31200302 65
Systems Operation Section

Boom Hydraulic System

Illustration 156 g01187247

Boom Hydraulic System
(1) Boom Cylinder (5) Lowering Control Valve (if equiped) (B) Line from the controkl valve for LOWER
(3) Load control valves (A) Line from the control valve for RAISE (C) Return line to tank

The boom hydraulic system consists of the Operating the joystick in the longitudinal direction will
following main components: shift the spool in the boom section of the control valve.
• Boom cylinder (1)
• Load control valve (3)
• Lowering control valve (5)
The boom hydraulic system controls the following
functions of the boom:
• RAISE
• LOWER
Oil is supplied to the boom hydraulic system by the
piston pump. For more information, refer to Systems
Operation, "Piston Pump (Implement and Steering)". Control valve (implement)
The flow of oil to the boom hydraulic system is
controlled by the control valve. The control valve is The following text describes the operation of the
sometimes referred to as the bank valve. The spool in implement control valve. The operation of the
the boom section of the control valve is operated by implement control valve sections for the boom cylinder,
solenoids. The solenoids are activated by electronic the telescoping cylinder, and the tilt cylinder is the same
signals that are sent from the joystick to the ECM. operation.
66 31200302
Systems Operation Section

Valve for the Cylinder in the HOLD Solenoids (6) or (23) and proportional pilot
reducingvalves (7) or (21) are part of Electronic Pilot
Position Valve (implement) (4). When the joystick control is in
the HOLD position, neither of the solenoids (6) or (23)
on proportional pilot reducing valves (7) or (21) are
energized. Pilot oil in pilot oil passage (26) is blocked at
the proportional reducing valves. Therefore, no pilot oil
is present on the downstream side of the proportional
pilot reducing valves. If pilot oil is not acting on control
valve spool (13), springs (11) and (17) will keep the
control valve spool in the center HOLD position.
Supply oil from the hydraulic pump enters the
hydraulic control valve and flows through pump supply
passage (20). Pump supply passage (20) is a common
passage through all the sections of the Control Valve
(implement). When the joystick control is in the HOLD
position, and the main control valve spool is centered,
supply oil in passage (20) is blocked by control valve
spool (13).
Load check valve (14) is seated. The load check valve
prevents implement drift until the supply pressure
builds enough pressure in order to move the load. Load
check valve (14) and control valve spool (13) blocks
the flow of oil in passages (2) and (3) from the cylinder.
When the flow of oil from the cylinder in passage (2)
and in passage (3) is blocked at control valve spool
(13), the implements are held in the HOLD position.
Control valve spool (13) also blocks the flow of oil to
pressure compensating valve (19). When there is no oil
pressure against the pressure compensating valve the
valve remains in the down position.
Each implement section contains pressure
Illustration 157 g01009187 compensating valve (19). All pressure compensating
(1) Pilot oil passage valves are interconnected. The pressure
(2) Passage to cylinder head end
compensating valves allow the oil flow to be
(3) Passage to cylinder rod end
proportionally divided between each of the operating
(4) Electronic Pilot Valve (implement)
(5) Tank return passage
circuits when the flow demands of the system exceed
(6) Solenoid
the total flow that is available from the pump. All of the
(7) Proportional pilot reducing valve hydraulic actuators will continue to function. However,
(8) Chamber the actuators will operate at a reduced speed.
(9) Tank return passage
Also, the pressure compensating valves can
(10) Load sensing signal passage
determine the function that has the highest demand in
(11) Spring
all of the valve sections. Load sensing signal pressure
(12) Passage
(13) Control valve spool
reacts to the highest demand and flows through load
(14) Load check valve
sensing passage (10) to the pump controller. The
(15) Passage pump controller adjusts the pump output in order to
(16) Oil passage maintain the required demand. Load sensing passage
(17) Spring (10) is a common passage through all the sections of
(18) Chamber the Control Valve (implement). The pump uses the load
(19) Pressure compensator sensing signal in order to determine the amount of flow
(20) Pump supply passage that is required.
(21) Proportional pilot reducing valve
(22) Chamber
Note: Load sensing signal pressure is sometimes
(23) Solenoid referred to as signal oil. The two terms have the same
(24) Screen meaning throughout this story.
(25) Pilot oil passage
31200302 67
Systems Operation Section

The pressure compensating valves maintain cylinder (13) Control valve spool

speeds which are proportional to the position of the (14) Load check valve
(15) Passage
joystick control. The cylinder speed will not increase if
(16) Oil passage
the engine speed is increased in order to engage an
(17) Spring
additional system. These characteristics aid smooth (18) Chamber
machine operation when more than one system is in (19) Pressure compensator
operation. (20) Pump supply passage
The oil in passage (12) will drain to the hydraulic tank (21) Proportional pilot reducing valve

through tank return passage (9). Passage (9) is a (22) Chamber

(23) Solenoid
common passage through all the sections of the
(24) Screen
Control Valve (implement).
(25) Pilot oil passage

Valve for the Cylinder in the EXTEND When the valve ECM receives a signal from the
Position machine ECM, the signal is sent to boom extend
solenoid (6). The boom extend solenoid is part of
Electronic Pilot Valve (implement) (4). The solenoid is
energized and proportional pilot reducing valve (7) is
shifted to the right.
This allows pilot oil from the pressure reducing valve to
flow through the proportional pilot reducing valve (7).
The pressure reducing valve is located in the outlet
manifold of the Control Valve (implement). The pilot oil
flows from the pressure reducing valve into Electronic
Pilot Valve (implement) (4) through pilot oil passage
(25). Pilot oil passage (25) is a common passage
through the Electronic Pilot Valve.
The pilot oil flows through screen (24) into pilot oil
passage (1). The pilot oil then flows into chamber (8) in
order to move the spool in the control valve downward.
The amount of current that is applied to solenoid (6)
determines the amount of movement of the spool. As
the proportional pilot reducing valve spool moves to the
right the pressure in pilot chamber (8) increases. The
spool moves downward as the pressure in pilot
chamber (8) increases. The pressure in chamber (8)
determines the movement of control valve spool (13).
Because boom retract solenoid (23) does not receive a
signal from the machine ECM, proportional pilot
reducing valve (21) does not move. A spring causes
proportional pilot reducing valve (21) to remain shifted
to the left. When proportional pilot reducing valve (21)
is in this position any pilot oil in chamber (22) flows
through the proportional pilot reducing valve into the
return to tank passage (5). The return to tank passage
(5) is a common passage through the Electronic Pilot
Valve.
Illustration 158 g01009197
(1) Pilot oil passage Supply oil from the hydraulic pump flows into the valve
(2) Passage to cylinder head end section for the cylinder through pump supply passage
(3) Passage to cylinder rod end (20). Supply passage (20) is a common passage
(4) Electronic Pilot Valve (implement) through the Control Valve (implement).
(5) Tank return passage
(6) Solenoid
The force of the pilot oil in chamber (8) overcomes the
(7) Proportional pilot reducing valve tension of spring (17). This action causes control valve
(8) Chamber spool (13) to move downward. This allows supply oil
(9) Tank return passage from the hydraulic pump to flow past control valve spool
(10) Load sensing signal passage (13) into chamber (18). The pressure in chamber (18)
(11) Spring causes the spool in pressure compensator (19) to
(12) Passage move up.
68 31200302
Systems Operation Section

A portion of the pump supply oil flows through Valve for the Cylinder in the RETRACT
pressure compensator (19) into oil passage (16). The
oil flows through passage (16) into load sensing oil Position
passage (10). Load sensing oil passage (10) is a
common passage through the Control Valve
(implement). The load sensing oil is routed to the
compensator valve that is mounted on the hydraulic
pump. This causes the pump to upstroke.

Note: Load sensing signal pressure is sometimes

referred to as signal oil. The two terms have the same
meaning throughout this story.

Reference: See Systems Operation/Testing and

Adjusting, "Piston Pump (Implement and Steering)" for
more information about the load sensing signal circuit.
The majority of the oil that flows through pressure
compensator (19) flows into oil passage (15). The oil
then flows to load check valve (14). The increasing
pressure opens load check valve (14). This allows the oil
to flow past open control valve spool (13). The oil then
flows through passage (2) and into the head end of the
cylinder. The oil pressure that is acting against the head
end of the cylinder forces the cylinder rod to move out of
the cylinder. As the rod moves out of the cylinder, the
rod causes the boom to extend.
The oil that is displaced from the rod end of the
cylinder flows out of the cylinder into passage (3). The
oil flows through passage (3) past open control valve
spool (13). The oil then flows into passage (12) and into
the return to tank passage (9). The return to tank
passage (9) is a common passage through the Control
Valve (implement). The oil then returns to the hydraulic Illustration 159 g01009220
tank. (1) Pilot oil passage
(2) Passage to cylinder head end
(3) Passage to cylinder rod end
(4) Electronic Pilot Valve (implement)
(5) Tank return passage
(6) Solenoid
(7) Proportional pilot reducing valve
(8) Chamber
(9) Tank return passage
(10) Load sensing signal passage
(11) Spring
(12) Passage
(13) Control valve spool
(14) Load check valve
(15) Passage
(16) Oil passage
(17) Spring
(18) Chamber
(19) Pressure compensator
(20) Pump supply passage
(21) Proportional pilot reducing valve
(22) Chamber
(23) Solenoid
(24) Screen
(25) Pilot oil passage
31200302 69
Systems Operation Section

When the valve ECM receives a signal from the Reference: See Systems Operation/Testing and
machine ECM, the signal is sent to boom retract Adjusting, "Piston Pump (Implement and Steering)" for
solenoid (23). The boom retract solenoid is part of more information about the load sensing signal system.
Electronic Pilot Valve (implement) (4). The solenoid is The majority of the oil that flows through pressure
energized and proportional pilot reducing valve compensator (19) flows into oil passage (15). The oil
(21)is shifted to the right. then flows to load check valve (14). The increasing
This allows pilot oil from the pressure reducing valve to pressure opens load check valve (14). The oil then
flow through the proportional pilot reducing valve (21). flows through passage (3) and into the rod end of the
The pressure reducing valve is located in the outlet cylinder. The oil pressure that is acting against the rod
manifold of the Control Valve (implement). The pilot oil end of the cylinder forces the cylinder rod to move into
flows from the pressure reducing valve into Electronic the cylinder. As the rod moves into the cylinder, the rod
Pilot Valve (implement) (4) through pilot oil passage causes the boom to retract.
(25). Pilot oil passage (25) is a common passage The oil that is displaced from the head end of the
through the Electronic Pilot Valve. cylinder flows out of the cylinder into passage (2). The
The pilot oil flows through screen (24) into pilot oil oil flows through passage (2) past open control valve
passage (1). The pilot oil flows into chamber (22) in spool (13). The oil then flows into passage (12) into the
order to move the spool in the control valve upward. return to tank passage (9). The return to tank passage
The amount of current that is applied to solenoid (23) (9) is a common passage through the Control Valve
determines the amount of movement of the spool. As (implement). The oil then returns to the hydraulic tank.
the proportional pilot reducing valve spool moves to the
right the pressure in pilot chamber (22) increases. The Load Control Valves
spool moves downward as the pressure in pilot
chamber (22) increases. The pressure in chamber
(22)determines the movement of control valve spool
(13).
Because boom extend solenoid (6) does not receive a
signal from the machine ECM, proportional pilot
reducing valve (7) does not move. A spring causes
proportional pilot reducing valve (7) to remain shifted to
the left. When proportional pilot reducing valve (7) is in
this position any pilot oil in chamber (8) flows through
the proportional pilot reducing valve into the return to
tank passage (5). The return to tank passage (5) is a
common passage through the Electronic Pilot Valve.
Supply oil from the hydraulic pump flows through pump
supply passage (20) and into the valve section for the
cylinder. Supply passage (20) is a common passage
through the Control Valve (implement).
The force of the pilot oil in chamber (22) overcomes the
tension of spring (11). This action causes control valve Illustration 160 g01167245
spool (13) to move upward. This allows supply oil from Load control valve in Lower position
the hydraulic pump to flow past control valve spool (6) Check valve
(13) into chamber (18). The pressure in chamber (18) (7) Lock Valve
causes the spool in pressure compensator (19) to (A) Line from the control valve for RAISE
move up. (B) Line from the control valve for LOWER
(D) Pilot line from the boom dampening system
A portion of the pump supply oil flows through
When the engine is OFF, the load control valves
pressure compensator (19) into oil passage (16). The
prevent the boom from lowering. Oil in the head end of
oil flows through passage (16) into load sensing oil
the boom cylinder is trapped by the check valve (6) and
passage (10). Load sensing signal passage (10) is a
the lock valve (7).
common passage through the Control Valve
(implement). The load sensing oil is routed to the
compensator valve that is mounted on the hydraulic
pump. This causes the pump to upstroke.
Note: Load sensing signal pressure is sometimes
referred to as signal oil. The two terms have the same
meaning throughout this story.
70 31200302
Systems Operation Section

Lowering Control Valve (If

Equipped)

Illustration 161 g01187283

(5) Lowering control valve (A) Line from the control valve for RAISE (C) Return line to tank
(7) Lock valve (B) Line from the control valve for LOWER

The lock valve (7) can be manually shifted and the

boom control valve can be manually shifted in order to
open the head end of the boom cylinders and the rod
end of the boom cylinders to tank. The weight of the
boom should cause the boom to lower. The lowering
control valve (5) provides a means of lowering the
boom when the boom will not lower under gravity. For
more information, refer to Operation and Maintenance
Manual, "Equipment Lowering with Loss of Hydraulic
Power".
31200302 71
Systems Operation Section

Boom RAISE

Illustration 162 g01187288

(1) Boom cylinder (A) Line from the control valve for RAISE (C) Return line to tank
(6) Check valve (B) Line from the control valve for LOWER

When the boom control valve is in the RAISE position,

high pressure oil is directed to line (A). The high
pressure oil flows through check valve (6) to the head
end of the boom cylinder (1). Return oil in the rod end
of the boom cylinders flows to line (B). Line (B) is open
to the tank.
72 31200302
Systems Operation Section

Boom LOWER

Illustration 163 g01187290

(1) Boom cylinder (A) Line from the control valve for RAISE (C) Return line to tank
(7) Lock valve (B) Line from the control valve for LOWER

When the boom control valve is in the LOWER

position, high pressure oil is directed to line (B). The
high pressure oil flows to the rod end of the boom
cylinder (1). Pilot oil from the boom dampening system
shifts the lock valves. Return oil flows from the head
end of the boom cylinders through the lock valve (7) and
to line (A). Line (A) is open to the tank.
31200302 73
Systems Operation Section

Telescoping System
Valve for the Telescoping Cylinder in
the HOLD Position

Illustration 164 g01188138

Telescoping Hydraulics
(A) Telescoping Cylinder
(B) Load Control Valve (Lock)
(C) Lowering Control Pump
(D) Blocked oil at the implement control valve (telescoping)

The following text describes the operation of the

implement control valve section for the telescoping
cylinder. The operation of the implement control valve
sections for the boom cylinder and the tilt cylinder is the
same operation as the telescoping cylinder.
74 31200302
Systems Operation Section

Solenoids (6) or (23) and proportional pilot reducing

valves (7) or (21) are part of Electronic Pilot Valve
(implement) (4). When the joystick control is in the
HOLD position, neither of the solenoids (6) or (23) on
proportional pilot reducing valves (7) or (21) are
energized. Pilot oil in pilot oil passage (26) is blocked at
the proportional reducing valves. Therefore, no pilot oil
is present on the downstream side of the proportional
pilot reducing valves. If pilot oil is not acting on control
valve spool (13), springs (11) and (17) will keep the
control valve spool in the center HOLD position.
Supply oil from the hydraulic pump enters the
hydraulic control valve and flows through pump supply
passage (20). Pump supply passage (20) is a common
passage through all the sections of the Control Valve
(implement). When the joystick control is in the HOLD
position, and the main control valve spool is centered,
supply oil in passage (20) is blocked by control valve
spool (13).
Load check valve (14) is seated. The load check valve
prevents implement drift until the supply pressure
builds enough pressure in order to move the load. Load
check valve (14) and control valve spool (13) blocks
the flow of oil in passages (2) and (3) from the
telescoping cylinder.
When the flow of oil from the telescoping cylinder in
passage (2) and in passage (3) is blocked at control
valve spool (13), the implements are held in the HOLD
position. Control valve spool (13) also blocks the flow of
oil to pressure compensating valve (19). When there is
Illustration 165 g01009187
no oil pressure against the pressure compensating
(1) Pilot oil passage valve the valve remains in the down position.
(2) Passage to cylinder head end Each implement section contains pressure
(3) Passage to cylinder rod end compensating valve (19). All pressure compensating
(4) Electronic Pilot Valve (implement)
valves are interconnected. The pressure
(5) Tank return passage
compensating valves allow the oil flow to be
(6) Solenoid
proportionally divided between each of the operating
(7) Proportional pilot reducing valve
(8) Chamber
circuits when the flow demands of the system exceed
(9) Tank return passage the total flow that is available from the pump. All of the
(10) Load sensing signal passage hydraulic actuators will continue to function. However,
(11) Spring the actuators will operate at a reduced speed.
(12) Passage
Also, the pressure compensating valves can
(13) Control valve spool
determine the function that has the highest demand in
(14) Load check valve
(15) Passage
all of the valve sections. Load sensing signal pressure
(16) Oil passage
reacts to the highest demand and flows through load
(17) Spring sensing passage (10) to the pump controller. The
(18) Chamber pump controller adjusts the pump output in order to
(19) Pressure compensator maintain the required demand. Load sensing passage
(20) Pump supply passage (10) is a common passage through all the sections of
(21) Proportional pilot reducing valve the Control Valve (implement). The pump uses the load
(22) Chamber sensing signal in order to determine the amount of flow
(23) Solenoid that is required.
(24) Screen
(25) Pilot oil passage
31200302 75
Systems Operation Section

Note: Load sensing signal pressure is sometimes Valve for the Telescoping Cylinder in
referred to as signal oil. The two terms have the same
meaning throughout this story. the EXTEND Position
The pressure compensating valves maintain cylinder
speeds which are proportional to the position of the
joystick control. The cylinder speed will not increase if
the engine speed is increased in order to engage an
additional system. These characteristics aid smooth
machine operation when more than one system is in
operation.
The oil in passage (12) will drain to the hydraulic tank
through tank return passage (9). Passage (9) is a
common passage through all the sections of the
Control Valve (implement).

Illustration 166 g01009197

(1) Pilot oil passage
(2) Passage to cylinder head end
(3) Passage to cylinder rod end
(4) Electronic Pilot Valve (implement)
(5) Return to tank passage
(6) Solenoid
(7) Proportional pilot reducing valve
(8) Chamber
(9) Return to tank passage
(10) Load sensing signal passage
(11) Spring
(12) Passage
(13) Control valve spool
(14) Load check valve
(15) Passage
(16) Oil passage
(17) Spring
(18) Chamber
(19) Pressure compensator
(20) Pump supply passage
(21) Proportional pilot reducing valve
(22) Chamber
(23) Solenoid
(24) Screen
(25) Pilot oil passage
76 31200302
Systems Operation Section

When the valve ECM receives a signal from the Reference: See Systems Operation/Testing and
machine ECM, the signal is sent to boom extend Adjusting, "Piston Pump (Implement and Steering)" for
solenoid (6). The boom extend solenoid is part of more information about the load sensing signal circuit.
Electronic Pilot Valve (implement) (4). The solenoid is The majority of the oil that flows through pressure
energized and proportional pilot reducing valve (7) is compensator (19) flows into oil passage (15). The oil
shifted to the right. then flows to load check valve (14). The increasing
This allows pilot oil from the pressure reducing valve to pressure opens load check valve (14). This allows the
flow through the proportional pilot reducing valve (7). oil to flow past open control valve spool (13). The oil
The pressure reducing valve is located in the outlet then flows through passage (2) and into the head end of
manifold of the Control Valve (implement). The pilot oil the telescoping cylinder. The oil pressure that is acting
flows from the pressure reducing valve into Electronic against the head end of the cylinder forces the cylinder
Pilot Valve (implement) (4) through pilot oil passage rod to move out of the cylinder. As the rod moves out
(25). Pilot oil passage (25) is a common passage of the cylinder, the rod causes the boom to extend.
through the Electronic Pilot Valve. The oil that is displaced from the rod end of the
The pilot oil flows through screen (24) into pilot oil cylinder flows out of the cylinder into passage (3). The
passage (1). The pilot oil then flows into chamber (8) in oil flows through passage (3) past open control valve
order to move the spool in the control valve downward. spool (13). The oil then flows into passage (12) and into
The amount of current that is applied to solenoid (6) the return to tank passage (9). The return to tank
determines the amount of movement of the spool. As passage (9) is a common passage through the Control
the proportional pilot reducing valve spool moves to the Valve (implement). The oil then returns to the hydraulic
right the pressure in pilot chamber (8) increases. The tank.
spool moves downward as the pressure in pilot
chamber (8) increases. The pressure in chamber (8)
determines the movement of control valve spool (13).
Because boom retract solenoid (23) does not receive a
signal from the machine ECM, proportional pilot
reducing valve (21) does not move. A spring causes
proportional pilot reducing valve (21) to remain shifted
to the left. When proportional pilot reducing valve (21)
is in this position any pilot oil in chamber (22) flows
through the proportional pilot reducing valve into the
return to tank passage (5). The return to tank passage
(5) is a common passage through the Electronic Pilot
Valve.
Supply oil from the hydraulic pump flows into the valve
section for the telescoping cylinder through pump
supply passage (20). Supply passage (20) is a common
passage through the Control Valve (implement).
The force of the pilot oil in chamber (8) overcomes the
tension of spring (17). This action causes control valve
spool (13) to move downward. This allows supply oil
from the hydraulic pump to flow past control valve spool
(13) into chamber (18). The pressure in chamber (18)
causes the spool in pressure compensator (19) to
move up.
A portion of the pump supply oil flows through
pressure compensator (19) into oil passage (16). The
oil flows through passage (16) into load sensing oil
passage (10). Load sensing oil passage (10) is a
common passage through the Control Valve
(implement). The load sensing oil is routed to the
compensator valve that is mounted on the hydraulic
pump. This causes the pump to upstroke.
Note: Load sensing signal pressure is sometimes
referred to as signal oil. The two terms have the same
meaning throughout this story.
31200302 77
Systems Operation Section

Valve for the Telescoping Cylinder in When the valve ECM receives a signal from the
machine ECM, the signal is sent to boom retract
the RETRACT Position solenoid (23). The boom retract solenoid is part of
Electronic Pilot Valve (implement) (4). The solenoid is
energized and proportional pilot reducing valve
(21)is shifted to the right.
This allows pilot oil from the pressure reducing valve to
flow through the proportional pilot reducing valve (21).
The pressure reducing valve is located in the outlet
manifold of the Control Valve (implement). The pilot oil
flows from the pressure reducing valve into Electronic
Pilot Valve (implement) (4) through pilot oil passage
(25). Pilot oil passage (25) is a common passage
through the Electronic Pilot Valve.
The pilot oil flows through screen (24) into pilot oil
passage (1). The pilot oil flows into chamber (22) in
order to move the spool in the control valve upward.
The amount of current that is applied to solenoid (23)
determines the amount of movement of the spool. As
the proportional pilot reducing valve spool moves to the
right the pressure in pilot chamber (22) increases. The
spool moves downward as the pressure in pilot
chamber (22) increases. The pressure in chamber
(22)determines the movement of control valve spool
(13).
Because boom extend solenoid (6) does not receive a
signal from the machine ECM, proportional pilot
reducing valve (7) does not move. A spring causes
proportional pilot reducing valve (7) to remain shifted to
the left. When proportional pilot reducing valve (7) is in
this position any pilot oil in chamber (8) flows through
the proportional pilot reducing valve into the return to
Illustration 167 g01009220
tank passage (5). The return to tank passage (5) is a
(1) Pilot oil passage
(2) Passage to cylinder head end
common passage through the Electronic Pilot Valve.
(3) Passage to cylinder rod end Supply oil from the hydraulic pump flows through pump
(4) Electronic Pilot Valve (implement) supply passage (20) and into the valve section for the
(5) Return to tank passage telescoping cylinder. Supply passage (20) is a common
(6) Solenoid passage through the Control Valve (implement).
(7) Proportional pilot reducing valve
(8) Chamber The force of the pilot oil in chamber (22) overcomes the
(9) Return to tank passage tension of spring (11). This action causes control valve
(10) Load sensing signal passage spool (13) to move upward. This allows supply oil from
(11) Spring the hydraulic pump to flow past control valve spool
(12) Passage (13) into chamber (18). The pressure in chamber (18)
(13) Control valve spool causes the spool in pressure compensator (19) to
(14) Load check valve move up.
(15) Passage
(16) Oil passage A portion of the pump supply oil flows through
(17) Spring pressure compensator (19) into oil passage (16). The
(18) Chamber oil flows through passage (16) into load sensing oil
(19) Pressure compensator passage (10). Load sensing signal passage (10) is a
(20) Pump supply passage common passage through the Control Valve
(21) Proportional pilot reducing valve (implement). The load sensing oil is routed to the
(22) Chamber compensator valve that is mounted on the hydraulic
(23) Solenoid
pump. This causes the pump to upstroke.
(24) Screen
(25) Pilot oil passage
78 31200302
Systems Operation Section

Note: Load sensing signal pressure is sometimes

referred to as signal oil. The two terms have the same
meaning throughout this story.
Reference: See Systems Operation/Testing and
Adjusting, "Piston Pump (Implement and Steering)" for
more information about the load sensing signal system.
The majority of the oil that flows through pressure
compensator (19) flows into oil passage (15). The oil
then flows to load check valve (14). The increasing
pressure opens load check valve (14). The oil then
flows through passage (3) and into the rod end of the
telescoping cylinder. The oil pressure that is acting
against the rod end of the cylinder forces the cylinder
rod to move into the cylinder. As the rod moves into the
cylinder, the rod causes the boom to retract.
The oil that is displaced from the head end of the
cylinder flows out of the cylinder into passage (2). The
oil flows through passage (2) past open control valve
spool (13). The oil then flows into passage (12) into the
return to tank passage (9). The return to tank passage
(9) is a common passage through the Control Valve
(implement). The oil then returns to the hydraulic tank.
31200302 79
Systems Operation Section

Auxiliary Hydraulic System

Introduction

Illustration 168 g01022066

Auxiliary Hydraulic System in the HOLD Position
(1) Quick disconnect (auxiliary circuit) for (5) Proportional pilot reducing valve
Port B (6) Pump supply passage
(2) Quick disconnect (auxiliary circuit) for (7) Relief Valve (Pressure reducing valve)
Port A (8) Solenoid Valve Group (Pilot oil shutoff)
(3) Relief Valve (Line and anticavitation (9) Main Control valve spool
valve) (10) Proportional pilot reducing valve
(4) Relief Valve (Line and anticavitation (11) Pressure compensator
valve) (12) Pilot oil passage

Illustration 169 g00999160

Illustration 170 g00902965
Diverter Valve (auxiliary single)
Control Valve (dual auxiliary)
80 31200302
Systems Operation Section

coupler in the ENGAGE position the pins extend. The

pins are extended in order to attach the work tool onto
the quick coupler. When the operator places the control
for the quick coupler in the DISENGAGE position the
pins retract. The pins are retracted in order to remove
the work tool onto the quick coupler.
On some machines, a Diverter Valve (auxiliary single) is
installed. The diverter valve allows the operator to
alternate between the hydraulic quick coupler function
and the auxiliary circuit 1 function. The function for
auxiliary circuit 1 allows the operator to control the flow
of oil to a work tool that is attached to the quick coupler.
The Diverter Valve (auxiliary single) is optional.
Illustration 171 g00902967 A Control Valve (dual auxiliary) is installed as an
Quick Coupler
option. The Control Valve (dual auxiliary) provides oil
flow to an additional auxiliary circuit 2.
The auxiliary hydraulic system provides a supply of
oil to a diverter valve that is located on the boom Note: The auxiliary circuits cannot be used
head for the operation of the following functions: simultaneously. Only one auxiliary circuit may be
selected at any one time.
• Quick coupler (hydraulically actuated pins)
• Auxiliary 1 circuit Auxiliary Control (Combined Circuit)
• Auxiliary 2 circuit (option)
Auxiliary Circuit 1 and 2
The auxiliary hydraulic control system consists of
the following main components:
• The spool of the main control valve (9), pressure
compensator (11), and Relief Valves (Line and
anticavitation valve) (3) and (4) that are located in
the Main Control Valve Group (implement)
• Proportional pilot reducing valves (5) and (10) that
are located in the Control Manifold Group (Pilot
ECM)
• Diverter Valve (auxiliary single)
• Control Valve (dual auxiliary) that is optional
• Quick coupler cylinder
• Optional work tools Illustration 172 g01010702
(1) Toggle Switch
The auxiliary hydraulic system provides the (2) Control switch for port “A”
following arrangements: (3) Control switch for port “B”
• Auxiliary 1 (ON/OFF)
• Auxiliary 1 (ON/OFF with continuous flow)
• Auxiliary 1 (ON/OFF with continuous flow and
quick coupler)
• Auxiliary 1 and 2 (ON/OFF)
• Auxiliary 1 and 2 (ON/OFF with continuous flow)
• Auxiliary 1 and 2 (ON/OFF with continuous flow
and quick coupler)
The auxiliary hydraulic system provides the operator
with a method of controlling a work tool and the
hydraulically operated quick coupler pins that are used
to attach various optional work tools to the machine.
The quick coupler pins are hydraulically actuated.
When the operator places the control for the quick
31200302 81
Systems Operation Section

Illustration 173 g01052948

(1) Trigger switch
(2) Control switch for port “A” and port “B”

Selection between the auxiliary circuit 1 and the

auxiliary circuit 2 is achieved by trigger switch (1). The
switch is located on the front of the joystick control.

Illustration 174 g01010703

(4) Lamp

When the operator depresses switch (1), auxiliary

circuit 2 is selected. When auxiliary circuit 2 is
selected, lamp (4) on the dash panel is illuminated.
When the machine is started, the system will default to
the auxiliary 1 circuit.
The spool in the auxiliary section of the Main Control
Valve Group (implement) is operated by solenoids. The
solenoids are activated by electronic signals that are
sent from switches on the joystick control to the ECM.
Switch (2) controls the flow of oil from the auxiliary
section to port "A" of the diverter valve. Switch (3)
controls the flow of oil from the auxiliary section to port
"B" of the diverter valve.
Switches (2) and (3) are single pole ON/OFF switch
types. The switches are not proportional. The machine
ECM will ramp up the command to the ECM of the
auxiliary valve when switch (2) or (3) is pressed.
82 31200302
Systems Operation Section

Auxiliary Circuit 1

Illustration 175 g01010705

Auxiliary Circuit 1 Activated and the Quick Coupler ENGAGED
(5) Port A from the auxiliary control valve (8) Quick disconnects (Auxiliary circuit 2) (11) Quick coupler cylinder
(6) Port B from the auxiliary control valve (9) Diverter valve (Auxiliary circuit 1)
(7) Diverter valve (Auxiliary circuit 2) (10) Quick disconnects (Auxiliary circuit 1)

The schematic shows a system for a machine that is The proportional pilot reducing valves route metered
equipped with a Control Valve (dual auxiliary) and a pilot oil to one side of the spool in the auxiliary valve
hydraulic quick coupler. Switch (1) is a momentary section of the Main Control Valve Group (implement).
switch. Toggle the switch in order to activate between The movement of the spool allows pressurized pump oil
the auxiliary circuit 1 and the auxiliary circuit 2. Refer to to flow past the spool and flow into port "A" (5). The oil
Illustration 172 for the location of the switch. flows through diverter valves (7) and (9) before flowing
The schematic shows both of the diverter valves with into the auxiliary circuit 1. Return oil flows back to the
solenoids that are de-energized. Because switch (1) hydraulic tank through the two diverter valves, port "B"
has not been activated, oil flow to auxiliary circuit 2 is (6) and the auxiliary section of the Main Control Valve
blocked. Oil flow is also blocked to the hydraulic quick Group (implement).
coupler cylinder. Control of the spool in the auxiliary valve section from
The solenoid on diverter valve (9) is de-energized while the joystick control is not proportional. The machine
the machine is operating in auxiliary circuit 1. The spool ECM will ramp up the command to the ECM of the
for diverter valve (9) is positioned by a spring . Oil flow auxiliary valve section when either switch (2) or (3) is
is then diverted to quick disconnects (10) for the pressed.
auxiliary circuit 1.
When switch (2) is activated an electrical signal is sent
to the ECM. Refer to Illustration 172 for the location of
the switches. The ECM sends a signal to the
proportional pilot reducing valves. The proportional
pilot reducing valves are located in the Control Manifold
Group (Pilot ECM) which is a part of the Main Control
Valve Group (implement). Refer to Illustration 168 for
additional information.
31200302 83
Systems Operation Section

Auxiliary Circuit 2

Illustration 176 g01010706

Auxiliary Circuit 2 Activated and the Quick Coupler ENGAGED
(5) Port A from the auxiliary control valve (8) Quick disconnects (Auxiliary circuit 2) (11) Quick coupler cylinder
(6) Port B from the auxiliary control valve (9) Diverter valve (Auxiliary circuit 1)
(7) Diverter valve (Auxiliary circuit 2) (10) Quick disconnects (Auxiliary circuit 1)

The schematic shows a system for a machine that is section of the Main Control Valve Group (implement).
equipped with a Control Valve (dual auxiliary) and a The movement of the spool allows pressurized pump oil
hydraulic quick coupler. The schematic shows an to flow past the spool and flow into port "B" (6). The oil
energized solenoid on diverter valve (7) and a de- flows through the diverter valve for auxiliary circuit 2 (7)
energized solenoid on diverter valve (5). Oil flow to the and on to the auxiliary circuit 2 system. Return oil flows
auxiliary circuit 1 and the hydraulic quick coupler back to the hydraulic tank through the diverter valve,
cylinder is blocked at the auxiliary circuit 2 diverter through port "A" (5) and through the auxiliary section of
valve. the Main Control Valve Group (implement).
When switch (1) activates the auxiliary circuit 2, the Control of the spool in the auxiliary valve section from
solenoid on diverter valve (7) is energized. Switch (1) is the joystick control is not proportional. The machine
a momentary switch. The solenoid moves the spool in ECM will ramp up the command to the ECM of the
diverter valve (7) to the right which opens a path for the auxiliary valve section when either switch (2) or (3) is
oil to flow to quick disconnects (8) for the auxiliary pressed.
circuit 2. Refer to Illustration 172 for the location of the
switch.
When switch (3) is activated an electrical signal is sent
to the ECM. Refer to Illustration 172 for the location of
the switches. The ECM sends a signal to the
proportional pilot reducing valves. The proportional pilot
reducing valves are located in the Control Manifold
Group (Pilot ECM) which is part of the Main Control
Valve Group (implement). Refer to Illustration 168 for
additional information.
The proportional pilot reducing valves route metered
pilot oil to one side of the spool in the auxiliary valve
84 31200302
Systems Operation Section

Continuous Flow (Auxiliary Hydraulics) the OFF position. To engage the pins, press and hold
the bottom of the switch. Release the switch when the
quick coupler pins are fully engaged into the work tool.
In order to disengage the quick coupler pins, move
sliding red locking device (13) downward and press the
top of the switch. Hold the switch until the coupler pins
are fully disengaged. Refer to Illustration 177 for the
location of switches.
Note: When quick coupler switch (14) is selected, the
solenoid on diverter valve (9) is de-energized.

Illustration 177 g01010707

(12) Continuous flow switch
(13) Lock for quick coupler switch
(14) Quick coupler switch

Switch (12) for the continuous flow (auxiliary

hydraulics) is located on the right side of the dash panel.
The continuous flow function operates with the
auxiliary controls. The function allows the operator to
select a constant flow rate and flow direction. The flow
rate and flow direction is also maintained without
continued use of the switches on the joystick controls.
When the rate of flow and the direction of flow have
been selected using buttons (1), (2) and (3), pressing
and releasing switch (12) will maintain the rate of flow
and the direction of flow. Refer to Illustration 172 for
the location of switches (1), (2) and (3). This
maintained operation will continue until any of the
following devices are actuated:
• Continuous flow switch (12).
• Switches (2) and (3) for auxiliary circuit.
• Switch (1) for auxiliary circuit 1 and 2.
• Quick coupler switch (14).
• Lock for quick coupler switch (13).

Quick Coupler
The hydraulic quick coupler function allows the
operator to operate the pins of the coupler in order to
change the work tools that are attached to the coupler.
This operation is performed remotely by the operator
without the need to exit the machine.
Note: The quick coupler function cannot be activated if
an auxiliary function is already selected. The controls
must be returned to the neutral state before a different
function can be requested.
Operation of the pins is controlled by three-position
switch (14). The switch is located on the left side of the
instrument cluster. The switch includes locking device
(13) in order to prevent accidental disengagement of
the quick coupler pins. The switch is spring centered to
31200302 85
Systems Operation Section

Quick Coupler Circuit DISENGAGED

Illustration 178 g01010709

Quick Coupler Circuit DISENGAGED.
(5) Port A (return oil to the auxiliary control (7) Diverter valve (Auxiliary circuit 2) (11) Quick coupler cylinder
valve) (8) Quick disconnects (Auxiliary circuit 2)
(6) Port B (supply oil from the auxiliary control (9) Diverter valve (Auxiliary circuit 1)
valve) (10) Quick disconnects (Auxiliary circuit 1)

When the top of switch (14) is pressed, the machine

ECM sends a predetermined command to the ECM of
the proportional pilot reducing valves. Refer to
Illustration 177 for the location of switches. The ECM of
the proportional pilot reducing valves sends a signal to
the solenoid of diverter valve for auxiliary circuit 1 (9)
which causes the valve to shift to the right. Oil flow is
now diverted from the auxiliary circuit to the circuit for
the quick coupler.
The proportional pilot reducing valves route metered
pilot oil to one side of the spool in the auxiliary valve
section of the Main Control Valve Group (implement).
The movement of the spool allows pressurized pump oil
to flow past the spool and flow into port "B" (6). The oil
flows through the diverter valve for auxiliary circuit 2
(7), through the diverter valve for auxiliary circuit 1 (9)
and into the rod ends of quick coupler cylinder (11).
Oil enters the rod ends of coupler cylinder (11) in order
to disengage the pins. Return oil from the head end of
the cylinder is returned to the hydraulic tank through
the two diverter valves, port "A" (5) and the auxiliary
section of the Main Control Valve Group (implement).
86 31200302
Systems Operation Section

Quick Coupler Pins ENGAGED

Illustration 179 g01010710

Quick Coupler Circuit ENGAGED.
(5) Port A (supply oil to the auxiliary control (7) Diverter valve (Auxiliary circuit 2) (11) Quick coupler cylinder
valve) (8) Quick disconnects (Auxiliary circuit 2)
(6) Port B (return oil from the auxiliary control (9) Diverter valve (Auxiliary circuit 1)
valve) (10) Quick disconnects (Auxiliary circuit 1)

When the bottom of switch (14) is pressed, the

machine ECM sends a predetermined command to the
ECM of the proportional pilot reducing valves. Refer to
Illustration 177 for the location of switches. The ECM of
the proportional pilot reducing valves sends a signal to
the solenoid of the diverter valve for auxiliary circuit 1 (9)
which causes the valve to shift to the right. Oil flow is
now diverted from the auxiliary circuit to the circuit for
the quick coupler.
The proportional pilot reducing valves route metered
pilot oil to the opposite side of the spool in the
auxiliary valve section of the Main Control Valve Group
(implement). The movement of the spool in this
direction allows pressurized pump oil to flow past the
spool and flow into port "A" (5). The oil flows through
the diverter valve for auxiliary circuit 2 (7) and through
the diverter valve for auxiliary circuit 1 (9). The oil
pressure opens the check valve and the oil enters the
head end of quick coupler cylinder (11) in order to
engage the pins.
Return oil from the rod ends of the cylinder is returned to
the hydraulic tank through the two diverter valves, port
"B" (6) and the auxiliary section of the Main Control
Valve Group (implement).
31200302 87
Systems Operation Section

Relief Valves and Makeup Valves attached to the machine frame. The piston rod of the
compensating cylinders extend when the boom is
raised. The piston rod of the compensating cylinders
retract when the boom is being lowered.
When the quick coupler is not operating, the spool in the
implement control valve for the coupler tilt is in the
HOLD position. Oil is locked into the lines between the
tilt cylinder and the compensating cylinders in order to
create a closed hydraulic circuit.
The volume of oil in the head end of the tilt cylinder is
matched to the total volume in the head ends of the
compensating cylinders. The rod end of the tilt cylinder
and the rod ends of the compensating cylinders are
similarly matched. Therefore, movement of the tilt
cylinder will be in proportion to the movement of the
Illustration 180 g01010711
compensating cylinders.
(1) Relief valve
(2) Oil line from auxiliary circuit
(3) Oil line from auxiliary circuit
(4) Relief valve
(5) Makeup valve
(6) Oil line from the Main Control Valve Group (implement)
(7) Oil line from the Main Control Valve Group (implement)
(8) Makeup valve
(9) Tank passage

Combined relief valves (1) and (4), and makeup valves

(5) and (8) are installed in the auxiliary section of the
Main Control Valve Group (implement). The relief
valves serve a dual purpose. The valves will open if the
pressure in lines (2) or (3) rises above the preset
pressure. The relieved pressure will then flow through
the open relief valve into tank passage (9).
The valves are also makeup valves. For example,
when the pressure in supply oil line (2) falls below the
pressure in the hydraulic tank, makeup valve (5)
opens. Oil at tank pressure then flows from tank
passage (9) into line (2) in order to prevent cavitation.
Reference: See Systems Operation/Testing and
Adjusting, "Compensating System" for more
information about the relief valves and makeup valves.

Compensating System
The compensating system includes the following
main components:
• Tilt cylinder
• Compensating cylinders
• Load control valve
• Relief valves
The compensating system automatically maintains the
selected angle of the quick coupler in relation to the
ground, when the boom is being raised or when the
boom is being lowered.
The piston rod ends of the compensating cylinders are
attached to the boom and the cylinder ends are
88 31200302
Systems Operation Section

Boom Lower

Illustration 181 g01022461

Boom Lower
(1) Load Control Valve (7) Check Valve (14) Block at tilt control valve
(2) Tilt Cylinder (10) Spring (15) Check Valve
(3) Compensating Cylinders (12) Makeup Valve (16) Lock Valve
(6) Lock Valve

When the boom is being lowered, compensating

cylinders (3) are retracting due to the movement of the
boom. Oil is displaced from the head end of the
compensating cylinders and opens check valve (15).
The displaced oil then flows into load control valve (1).
Check valve (7) is unseated. Oil then flows into the
head end of tilt cylinder (2). The oil flow extends the tilt
cylinder, which tilts the quick coupler backward in order
to maintain the selected angle of the coupler relative to
the ground. Oil is displaced from the rod end of the tilt
cylinder and flows to the rod ends of the compensating
cylinders.
31200302 89
Systems Operation Section

Boom Raise

Illustration 182 g01022501

(1) Load Control Valve (7) Check Valve (14) Block at tilt control valve
(2) Tilt Cylinder (10) Spring (15) Check Valve
(3) Compensating Cylinders (12) Makeup Valve (16) Lock Valve
(6) Lock Valve (13) Block at tilt control valve (17) Load Control Valve

When the boom is being raised, compensating

cylinders (3) are extending due to the movement of the
boom and the oil which is displaced from the rod end of
the compensating cylinders flows into the rod end of tilt
cylinder (2). The oil opens lock valve (17) in load
control valve (16). Also, the pressure that is developed
in the rod end of the tilt cylinder opens lock valve (6) in
load control valve (1). The piston rod of the tilt cylinder
retracts and the quick coupler is tilted forward in order
to maintain the selected angle of the coupler relative to
the ground. Lock valve (6) in load control valve (1)
opens in proportion to the pressure that is applied. This
controls the flow of oil from the head end of the tilt
cylinder to the head end of the compensating cylinder.
90 31200302
Systems Operation Section

Pressure Relief and Makeup Valves

Illustration 183 g01022526

Pressure Relief and Makeup Valves
(1) Load Control Valve (5) Relief Valve (9) Line
(2) Tilt Cylinder (6) Lock Valve (10) Spring
(3) Compensating Cylinders (7) Check Valve (11) Tank Gallery
(4) Relief Valve (8) Line (12) Makeup Valve

Pressure Relief When the oil pressure returns to a level below the
If the quick coupler is tilted fully forward or if the quick pressure setting, spring (10) closes the valve.
coupler is tilted fully backward and the boom is still Makeup
moving the compensating cylinder would continue to Relief valve (4) and relief valve (5) also have
move with the boom. In this event, the pressure in the anticavitation features which allow makeup oil to flow
lines between the compensating cylinder and the tilt into the compensating system from the return gallery of
cylinder would rise sharply. In order to limit the the implement control valve, if the pressure in the
pressure in the system, relief valves (4) and (5) are compensating system falls below the return oil
installed in the implement section of the control valve for pressure.
the coupler tilt. Relief valve (5) will operate when the
boom is being raised. Relief valve (4) will operate when If the pressure in line (8) or (9) falls below the pressure
the boom is being lowered. in tank gallery (11), then oil at tank pressure will unseat
makeup valve (12) against the force of a spring. Oil
A sharp pressure rise in line (8) or line (9) acts on relief then enters line (8) or (9) from tank gallery (11). The
valve (4) or (5). As the pressure rises above the setting increase in the pressure in line (8) or (9) will prevent
of the relief valve, the valve unseats against the force cavitation in the supply lines to the implements.
of spring (10). The pressure oil is then relieved to the
When the oil pressure between line (8) or (9) and tank gallery
tank through gallery (11).
(11) has been equalized, the makeup valve (12) is reseated by
the spring.
31200302 91
Systems Operation Section

Frame Leveling System switch is released the switch is spring centered to the
HOLD position.
The frame leveling system enables the operator to The frame leveling system consists of three
level the machine on uneven ground in order to functional modes:
improve the stability of the machine during stationary
• . Locked axle (HOLD)
operation.
The frame leveling system includes the following • Frame that is angled to the left
main components: • Frame that is angled to the right
• Machine ECM
• Switch (frame leveling)
• Relay (frame Leveling)
• Load control valve for the frame leveling cylinder
• Cylinder (Frame leveling)
The frame leveling control valve includes the
following components:
• Directional control valve
• Check valves
• Lock valves
The frame leveling cylinder is installed on the right of
the machine. The cylinder is located between the
machine frame and the front axle. The cylinder is
attached to the machine frame, and the piston rod is
attached to the front axle. The cylinder is extended in
order to angle the frame to the left and the cylinder is
retracted in order to angle the frame to the right.
The frame leveling cylinder is equipped with a load
control valve that controls the flow of oil into the
cylinder and out of the cylinder. The load control valve
is attached to the cylinder.

Illustration 184 g00833767

The frame leveling cylinder is operated by switch (1).
The machine ECM energizes the relay for the frame
leveling. The relay then sends power to switch (1) for
the frame leveling. The switch operates the solenoids
that are installed on the load control valve for the frame
leveling. The solenoids control the spool in the load
control valve for the frame leveling. Press and hold the
left side of the switch in order to angle the machine to
the left. Press and hold the right side of the switch in
order to angle the machine to the right. When the
92 31200302
Systems Operation Section

Locked Axle (HOLD)

Illustration 185 g01096408

Hydraulic Schematic for the frame level in HOLD
(1) Frame leveling switch (7) Resolver (14) lock Valve
(2) Machine ECM (9) Solenoid (angle left) (15) Directional control valve spool
(3) Interlock relay for the frame leveling (10) Solenoid (angle right) (16) Check Valve
(4) Check Valve (11) Frame leveling cylinder (17) Load signal network
(5) Lock Valve (12) return oil to tank (18) Load signal network
(6) Load Control Valve (13) Pump supply oil (19) Check Valve

The machine ECM (2) energizes the interlock relay (3)

for the frame leveling. The relay then sends power to
switch (1) for the frame leveling. When the switch for
the frame level is in the HOLD position, spool (15) in
load control valve (3) is spring centered and the flow of
oil to lock valves (5) and (14) is blocked at the spool.
This causes valves (5) and (14) to close. Oil in the rod
end and the head end of the frame leveling cylinder is
now blocked and the axle is locked. If the supply of oil
to the frame leveling cylinder fails for any reason during
operation, lock valves (5) and (14) will close. Oil will be
blocked in both sides of the frame leveling cylinder and
the cylinder will be prevented from lowering.
31200302 93
Systems Operation Section

Frame that is Angled to the Left

Illustration 186 g01096514

Hydraulic schematic for the frame level in TILT LEFT mode
(1) Machine ECM (8) Line (14) lock Valve
(2) Interlock relay for the frame leveling (9) Solenoid (angle left) (15) Directional control valve spool
(3) Frame leveling switch (10) Solenoid (angle right) (16) Check Valve
(4) Check Valve (11) Cylinder (frame leveling) (17) Line
(5) Lock Valve (12) Return oil to tank (18) Load signal network
(6) Load Control Valve (13) Pump supply oil (19) Lock Valve
(7) Resolver

The machine ECM (2) energizes the interlock relay (3) As the cylinder extends, oil flows from the rod end of
for the frame leveling. The relay then sends power to the cylinder to lock valve (14). Initially, the oil passes
switch (1) for the frame leveling. When the left side of slowly through the partially open lock valve. Increased
the switch for the frame level is pressed, solenoid (9) is pressure in the line from the rod end of the cylinder
energized. The solenoid moves spool (15) to the angle causes the lock valve to fully open. Oil then passes
left position. Pump oil then flows past the open spool in through the lock valve and returns to the hydraulic
order to unseat check valve (4). The oil then passes into tank.
the head end of the frame leveling cylinder and the Frame that is Angled to the Right
pump upstrokes. As the pressure and the volume of oil
in the head end of the cylinder increases, the piston See illustration 186 for item numbers that are referred to
begins to move and the cylinder is extended in order to in the following text.
angle the machine to the left. Also, pump flow The machine ECM (2) energizes the interlock relay (3)
increases and the pressure opens lock valve (14). for the frame leveling. The relay then sends power to
The pressure increase in line (8) causes resolver valve switch (1) for the frame leveling. When the right side of
(7) to unseat. Pressurized oil then flows past check the switch for the frame level is pressed, solenoid (14) is
valve (19) into the load signal network. energized. The solenoid moves spool (15) to the angle
right position. Pump oil then flows past the open spool
94 31200302
Systems Operation Section

in order to unseat check valve (16). The oil then The valve group (stabilizer) includes the following
passes into the rod end of the frame leveling cylinder components:
and the pump upstrokes. As the oil in the rod end of • Flow control valve (1)
the cylinder increases, the piston begins to move and
the cylinder is retracted in order to angle the machine to • Left stabilizer Control valve (2)
the right. Also, pump flow increases and the pressure • Right stabilizer control valve (3)
opens lock valve (5).
Reference: See Systems Operation Section, "General
The pressure increase in the line (17) causes resolver Information" for more information.
valve (7) to unseat and supply pressurized oil to the
The stabilizer system includes the following
load signal network through check valve (19).
components:
As the cylinder retracts, oil flows from the head end of
the cylinder to lock valve (5). Initially, the oil passes • Switch (LH stabilizer)
slowly through the partially open lock valve. Increased • Switch (RH stabilizer)
pressure in the line from the head end of the cylinder
• Pressure switches (stabilizer cylinders)
causes the lock valve to fully open. Oil then passes
through check valve (19) and returns to the hydraulic • Switch (fully retracted boom)
tank. • Control valve Gp (stabilizer)
• Lock valve
Stabilizer System
• Cylinders
S/N: SLE4500-Up
The lock valve includes the following components:
S/N: SLG1300-Up
• Dual overcenter valves
Stabilizers are used to increase the stability of the
• Check valves
machine during stationary lifting operations. The
stabilizers are used when the machine is lifting heavy The stabilizers are installed on each side of the
loads. stabilizer frame at the front of the machine. A lock
valve is attached by hydraulic pipes to each stabilizer
Independent operation of the stabilizers allows the
cylinder.
machine to be leveled when the machine is operating on
uneven ground. The stabilizers are operated by stabilizer cylinders. The
stabilizer cylinders are controlled by a valve group
(stabilizer) and a lock valve. The lock valve is mounted
on the stabilizer cylinder.

Illustration 196 g01182961

(5) left stabilizer switch
(6) Right stabilizer switch
Both of the sections for the stabilizer control valve are
Illustration 195 g01184585 operated by solenoids that are controlled by switches
Valve Group (Stabilizer) (5) and (6). The switches are mounted on the dash
(1) Flow control valve (stabilizer)
panel. The switches are three-position rocker switches,
(2) Control valve (left stabilizer)
which are spring centered.
(3) Control valve (right stabilizer)
When one of the switches is held down the machine
The valve group (stabilizer) is located in the center of ECM turns on the flow control valve. The flow control
the stabilizer frame at the front of the machine. valve sends proportional pressure to the control valve.
31200302 95
Systems Operation Section

The speed of the stabilizer movement ramps upward

as the switch is held down.
The stabilizer cylinders are equipped with lock valves.
The lock valves lock oil into both sides of the cylinders
when switches (5) and (6) are in the HOLD position.
The lock valves provide the following functionality:
• Maintain the desired position of the stabilizer legs
within the limits of drift that are defined by the
specification of the valve.
• Prevent overrun of the stabilizer legs while the legs
are being lowered.
• Prevent the stabilizer legs from collapsing in the
event of a burst hose. Illustration 199 g01183439
(9) Switch (fully retracted boom)

Switch (9) for the boom retract is installed on the front

left side of the fixed boom section. The switch sends a
signal to the machine ECM in order to inhibit the
function for raising the stabilizer when the boom is
extended. This function is available only if the machine
ECM is equipped with a feature to inhibit lateral
stability.
The following text describes the procedure to
operate the right stabilizer. The procedure for
operating the left stabilizer is the same procedure as
operating the right stabilizer.

Illustration 197 g01183121

(7) Pressure Switch

Illustration 198 g01183231

(8) Indicator for the stabilizer

Pressure switches (7) are installed in the stabilizer

cylinders. When the cylinders are extended and the
stabilizers are supporting a predefined weight, the
contacts in the pressure switches will close and
indicator (8) on the dash panel will illuminate.
96 31200302
Systems Operation Section

Stabilizer Cylinders (HOLD)

Illustration 200 g01183515

Hydraulic Schematic for the stabilizers (HOLD)
(11) Check Valve (16) Check Valve (21) Flow control valve
(12) Lock Valve (17) Load control valve gp (22) Pump pressure
(13) Right stabilizer cylinder (18) Load control valve for the left stabilizer (23) Return to tank
(14) pressure switch for the right stabilizer (19) Load control valve for the right stabilizer
(15) Lock Valve (20) Valve group (stabilizer control)

Until the dash panel switch is depressed, the solenoid in Spool (19) is spring centered to the HOLD position. In
flow control valve (21) is de-energized. The spring in HOLD position, supply oil from the pump is blocked by
flow control valve (21) causes the spool in flow control the closed center of the spool. Check valve (11) and
valve (21) to move to the left. The supply of pilot oil is check valve (16) in load control valve (17) is seated.
now blocked. This blocks oil in the head end and the rod end of
stabilizer cylinder (12). Oil is also blocked in the rod
end of the stabilizer cylinder by the valve stem in lock
valve (12). The spring in the lock valve (12) overcomes
the pressure of the blocked oil from the rod end of the
cylinder. The spool shifts to the left and the oil is
blocked at the lock valve.
The pressure sensor (14) for stabilizer (13) signals the
ECM when the stabilizer is under load.
31200302 97
Systems Operation Section

Stabilizer Cylinders (RAISE)

Illustration 201 g01184186

Hydraulic Schematic for the right stabilizer (RAISE)
(11) Check Valve (16) Check Valve (21) Flow control valve
(12) Lock Valve (17) Load control valve gp (22) Pump pressure
(13) Right stabilizer cylinder (18) Load control valve for the left stabilizer (23) Return to tank
(14) Pressure switch for the right stabilizer (19) Load control valve for the right stabilizer
(15) Lock Valve (20) Valve group (stabilizer control)

Note: When the right stabilizer is raised the right side of The machine ECM will ramp up the command to the
the machine will be lowered to the ground and the stabilizer when switch (6) is pressed. The ramp up
stabilizer cylinder will retract. time is approximately two seconds. The scale of the
To raise the right stabilizer cylinder, press right ramp up is adjustable in ET.
stabilizer switch (6) on the dash panel to the left. The Oil from the control valve flows into load control valve
switch energizes the solenoid for the load control valve (17). The oil flow causes check valve (11) to open. The
for the right stabilizer (19). At the same time, the oil passes through the check valve and into the rod end
machine electronic control module proportionally of right stabilizer (13). As the oil in the rod end of the
energizes the flow control valve (21). Oil flows past the stabilizer cylinder increases, the piston begins to move
open spool of the flow control valve and through load and the stabilizer cylinder is retracted.
control valve (19).
Simultaneously, pressurized oil acts against the spring
in lock valve (15) to open the lock valve. As stabilizer
98 31200302
Systems Operation Section

cylinder (13) retracts, the oil flows from the head end of
the cylinder to the open lock valve (15). Oil flows from
the lock valve back to the hydraulic tank through the
valve group (stabilizer control) (20).

Stabilizer Cylinders (LOWER)

Illustration202 g01184399
Hydraulic Schematic for the Right Stabilizers (LOWER)
(11) Check Valve (16) Check Valve (21) Flow control valve
(12) Lock Valve (17) Load control valve gp (22) Pump pressure
(13) Right stabilizer cylinder (18) Load control valve for the left stabilizer (23) Return to tank
(14) pressure switch for the right stabilizer (19) Load control valve for the right stabilizer
(15) Lock Valve (20) Valve group (stabilizer control)

Note: When the right stabilizer is lowered the right side proportionally energizes the flow control valve (21). Oil
of the machine will be raised from the ground and the flows past the open spool of the flow control valve and
stabilizer cylinder will extend. through load control valve (19).
Lower the right stabilizer cylinder by pressing right The machine ECM will ramp up the command to the
stabilizer switch (6), on the dash panel to the right. The stabilizer when switch (6) is pressed. The ramp up
switch energizes the load control valve for the right time is approximately two seconds. The scale of the
stabilizer (19). The spool shifts to the right. At the same ramp up is adjustable in ET.
time, the machine electronic control module
31200302 99
Systems Operation Section

Oil from the stabilizer control valve flows into load Hydraulic System Schematic
control valve (17). The oil flow causes check valve (16)
to open. The oil passes through the check valve and S/N: SLE4500-Up
into the head end of right stabilizer (13). As the oil in the S/N: SLG1300-Up
head end of the stabilizer cylinder increases, the piston
begins to move and the stabilizer cylinder is extended.
All Implements In HOLD
Simultaneously, pressurized oil acts against the spring
in lock valve (12) to open the lock valve. As stabilizer The schematic shows all of the implement control
cylinder (13) extends, the oil flows from the rod end of valves in the HOLD position.
the cylinder to the open lock valve (12). The Oil flows
from the lock valve and returns to the hydraulic tank
through the valve group (stabilizer control) (20).
100 31200302
Systems Operation Section

Illustration 204 g01183103

All implements in HOLD position
31200302 101
Systems Operation Section

(1) Return pilot oil from stabilizer circuit (13) Control valve (boom raise) (25) Load control valve (telescoping cylinder)
(2) Return oil from stabilizer circuit (14) Load Control valves (26) Manual pump for lowering
(3) Load signal from stabilizer circuit (15) control valve (coupler tilt) (27) Inlet Section
(4) Pressure reducing valve (pilot) (16) Quick disconnects (auxiliary services) (28) Priority valve
(5) Pilot shutoff valve (17) Line relief valve (29) Supply to steering
(6) Supply oil to stabilizer circuit (18) Control valve (auxiliary) (30) Pump supply (Steering priority signal)
(7) Pilot oil to stabilizer circuit (19) Main control valve (Implement) (31) Pump supply
(8) Return oil from brake circuit (20) Control valve (boom extend) (32) Load signal to pump
(9) Supply oil to breaking circuit (21) 100 micron filter (33) Relief valve (load signal)
(10) Boom cylinder (22) Proportional pilot reducing valve (34) Return to tank
(11) Load control valve (boom cylinder) (23) Telescoping cylinder
(12) Compensating cylinders (24) Flow Control Valve (Drain)

The illustration shows the standard implement valve Note: The passages are shown for the control valve in
that is used in all the B - Series Telehandlers. HOLD.
The centering spring that centers the spool is located on
the right side of the valve. In HOLD, the centering
spring will center the spool in the valve body. The
valve may feature a combination of the line relief valve
and of the makeup valve.
Part of the control valves are equipped with a manual
lowering screw. As an example, this screw is used to
assist in lowering the boom when the engine is not
running. Load check valves prevent implement drift
whenever the supply pressure is less than the load
pressure or the work port pressure.
The pressure compensator maintains a controlled
pressure differential across the spool in order to
control flow to the circuit. If more than one circuit is
used at a time, the circuit with the highest port
pressure is used to regulate the flow through each
control valve.
The hydraulics of the main control valves are similar to
the former machines. The valves are similar to PPPC
hydraulic system that is used in other Caterpillar
machines. The system that is shown incorporates the
flow control and the resolver into one component called
a pressure compensator valve. This is different from
other hydraulic systems that had resolvers. The
pressure compensator acts as a resolver to compare
the different port pressures. The pressure compensator
sends signal pressure that is equal to the highest circuit
pressure back to the pump. As shown, another circuit
has been activated. The load sensing oil flows to the
compensator valve. The oil then causes the
compensator valve to move down. The compensator
valve sends part of the supply oil through the signal
passage. The oil then becomes signal oil. The signal
network consists of all of the pressure compensator,
internal passages and signal lines. This signal is sent to
the pump control and to all of the other pressure
compensator valves. Also, passages in the valve drain
will allow oil to flow back to the tank. The passages
prevent pressure from building up. High pressure
leakage around the spool may cause an increase in the
pressures in the ports.
102 31200302
Systems Operation Section

Configuration Parameters

Illustration 205 g00993238

This is a summary screen.

Some parameters need to be configured for the

machine to operate properly. The configuration screen
for the ECM can be accessed by using the Cat
Electronic Technician (ET). The configuration screen
for each ECM is accessed from the above ECM
summary screen by selecting "Configuration" from the
"Service" drop-down menu.
Reference: Refer to the service manual module
Testing and Adjusting, "Electronic Control Module
(ECM) - Configure" for further instructions on
configuring the ECM for your machine.
31200302 103
Testing and Adjusting Section

Testing and Adjusting

Section
Testing and Adjusting
Joystick Control - Calibrate

Personal injury or death can result from sudden

machine movement.
Sudden movement of the machine can cause
injury to persons on or near the machine.
Prevent possible injury by performing the
procedure that follows before working on the
Illustration 206 g00898916
machine.
This is the location of the service connector that contains the CAT Data Link.
Table 8 The connector is located to the side of the seat.

Required Tools

Part Number Description Quantity

Caterpillar Electronic
JEBD3003 1
Technician (ET)
Communications Adapter
171-4400 1
II
207-6845 Adapter Cable As 1
160-0141 Adapter Cable As 1

The Caterpillar Electronic Technician service tool (ET)

is used to access the calibration procedures. A
message on the ET screen will give instructions that
guide the user through the calibration procedure. Refer
to the Manual that is provided with the ET for more
information about ET.

Illustration 207 g00987571

The machine electronic control module (ECM)
The calibration of the Joystick Control Gp (Joystick)
should be performed if any of the following items occur:
• The cycle speed is slow.
• When the machine is first started there is no
movement.
• Drift of the implements.
• The joystick is remounted.
• The joystick is replaced.
• The machine ECM is replaced.
Note: The following information is an example of the
calibration procedure. The actual calibration screens
may vary as new versions of the software are released.
104 31200302
Testing and Adjusting Section

Illustration 208 g00931831

To get to the calibration procedures for the joystick, you

click on the Service menu. Click on Calibration. Click
on the PHS Lever Calibrations. The PHS Lever
Calibrations is the second item on the list. Next, the first
calibration screen will appear.
31200302 105
Testing and Adjusting Section

Illustration 209 g00940468

Set up conditions have not been met. The parking brake

has not been set. After the parking brake is set, press
the "Next" button.
106 31200302
Testing and Adjusting Section

Illustration 210 g00940459

This screen shows that the set up conditions have

been met. The check in the check box is a completed
indicator for that line. The next instructions are located
in the next line. The box for this line is not checked and
the line is highlighted.
Move the lever to the full FORWARD position. Then
press the "Next" button.
31200302 107
Testing and Adjusting Section

Illustration 211 g00940415

The ECM now knows the signal input when the lever is
moved full FORWARD position.
Move the lever to the full REARWARD position and
press the "Next" button.
108 31200302
Testing and Adjusting Section

Illustration 212 g00940440

The ECM now knows the signal input when the lever is
moved full REWARD position.
Move the lever to the full LEFT position and press the
"Next" button.
31200302 109
Testing and Adjusting Section

Illustration 213 g00940437

The ECM now knows the signal input when the lever is
moved full LEFT position.
Move the lever to the full RIGHT position and press the
"Next" button.
110 31200302
Testing and Adjusting Section

Illustration 214 g00940456

The ECM now knows the signal input when the lever is
moved full RIGHT position.
Release the lever and press the "Next" button.
31200302 111
Testing and Adjusting Section

Illustration 215 g00940488

The right hand lever calibration is successful. The next

calibration is for the right hand left thumb wheel.
Press the "Continue" button. The first calibration screen
for the thumb wheel will appear.
112 31200302
Testing and Adjusting Section

Illustration 216 g00940480

This screen shows that the set up conditions have been

met.
Press the "Next" button in order to continue with the
calibration procedure.
31200302 113
Testing and Adjusting Section

Illustration 217 g00941092

This screen shows that the set up conditions have

been met. The check in the check box is a completed
indicator for that line. The next instructions are located
in the next line. The box for this line is not checked and
the line is highlighted.
Move the right hand left thumb wheel to the UP
position. Then press the "Next" button.
114 31200302
Testing and Adjusting Section

Illustration 218 g00940482

The ECM now knows the signal input when the thumb
wheel is moved into the Up position.
Move the thumb wheel to the DOWN position and press
the "Next" button.
31200302 115
Testing and Adjusting Section

Illustration 219 g00940476

The ECM now knows the signal input when the thumb
wheel is moved into the Down position.
Release the thumb wheel and press the "Next" button.
116 31200302
Testing and Adjusting Section

Illustration 220 g00940471

The calibration procedure for the thumb wheel was pressing the "Restart" button. Complete the process by
successful. A window will appear if a failure occurs. clicking on the "Finish" button.
Data in the window will include an error code for the
Note: Turn off the ignition key, after the calibration
failure. The error code is provided in order to explain the
procedure is finished. Leave the key off for fifteen
failure. The error codes are listed in table 9. After
seconds. The new parameters are then stored in the
correcting the problem, the calibration is repeated by
ECM.
31200302 117
Testing and Adjusting Section

Table 9

Joystick Control Calibration Error Codes

Error Code Description Cause Corrective Action

A diagnostic fault in the system is

related to the inputs used for the
0002 Active diagnostic calibration. Such as the joystick Troubleshoot and clear the fault.
sensor inputs, the parking brake
inputs, and the engine speed input.

The user clicked the "Cancel"

0006 Aborted by user button during the calibration Restart the calibration.
process.
The duty cycle from the joystick is
less than 5% or greater than 30% at
Ensure the joystick is moved to the
the bottom end of the PWM range.
position indicated by the instructions in the
The duty cycle from the joystick is
Calibration value/s out of calibration procedure. If the movement is
0103 less than 70% or greater than 95% at
range correct, check the PWM output on the
the top end of the PWM range. The
joystick sensor in order to verify the duty
duty cycle from the joystick is less
cycle percentages are correct.
than 40% or greater than 60% at the
center of the PWM range.
118 31200302
Testing and Adjusting Section

Illustration 221 g01088761

This screen shows that the set up conditions have been

met.
Press the "Next" button in order to continue with the
calibration procedure.
31200302 119
Testing and Adjusting Section

Illustration 222 g01088767

This screen shows that the set up conditions have

been met. The check in the check box is a completed
indicator for that line. The next instructions are located
in the next line. The box for this line is not checked and
the line is highlighted.
Move the right hand right thumb wheel to the UP
position. Then press the "Next" button.
120 31200302
Testing and Adjusting Section

Illustration 223 g01088775

The ECM now knows the signal input when the thumb
wheel is moved into the Up position.
Move the thumb wheel to the DOWN position and press
the "Next" button.
31200302 121
Testing and Adjusting Section

Illustration 224 g01088780

The ECM now knows the signal input when the thumb
wheel is moved into the Down position.
Release the thumb wheel and press the "Next" button.
122 31200302
Testing and Adjusting Section

Illustration 225 g01088782

The calibration procedure for the thumb wheel was

successful. A window will appear if a failure occurs.
Data in the window will include an error code for the
failure. The error code is provided in order to explain
the failure. The error codes are listed in table 10. After
correcting the problem, the calibration is repeated by
pressing the "Restart" button. Complete the process by
clicking on the "Finish" button.
Note: Turn off the ignition key, after the calibration
procedure is finished. Leave the key off for fifteen
seconds. The new parameters are then stored in the
ECM.
31200302 123
Testing and Adjusting Section

Table 10

Joystick Control Calibration Error Codes

Error Code Description Cause Corrective Action

A diagnostic fault in the system is related to

the inputs used for the calibration. Such
0002 Active diagnostic Troubleshoot and clear the fault.
as the joystick sensor inputs, the parking
brake inputs, and the engine speed input.

The user clicked the "Cancel" button

0006 Aborted by user during the calibration process. Restart the calibration.

Ensure the joystick is moved to the

position indicated by the instructions
The duty cycle from the joystick is less in the calibration procedure. If the
Calibration value/s
0103 out of range than 40% or greater than 60% at the movement is correct, check the
center of the PWM range. PWM output on the joystick sensor in
order to verify the duty cycle
percentages are correct.

Main Control Valve (Implement) -

Calibrate
Programmable Hydraulic System
(PHS) Valve Calibrations
Table 11

Required Tools
Part Number Description Quantity
Caterpillar Electronic
JEBD3003 1
Technician (ET)
Communications
171-4401 1
Adapter II
207-6845 Adapter Cable As 1
160-0141 Adapter Cable As 1

The Caterpillar Electronic Technician service tool (ET) Illustration 226 g00898916
is used to access the calibration procedures. A This is the location of the service connector that contains the CAT data link.

message on the ET screen will give instructions that

guide the user through the calibration procedure. Refer
to the Manual that is provided with the ET for more
information about ET.
124 31200302
Testing and Adjusting Section

Illustration 227 g00933825

The calibration of the Joystick Control Gp (Joystick), the

Main Control Valve (Implement) and/or Control Valve
(Stabilizer) need to be performed if any of the following
items occur:
• Replacement of the Control Valve (Stabilizer) (1)
• Replacement of the Main Control Valve
(Implement) (2)
Reference: Refer to the Service Manual module
Testing and Adjusting, "JOYSTICK CONTROL -
CALIBRATE" for instructions on calibrating the joystick.
The stabilizer control valve controls the oil to the
stabilizer cylinders. This control enables the cylinders to
hydraulically operate.
The main control valve controls the following
components:
• Boom raise and boom lower
• Boom extend and boom retract
• The bucket/fork rack and the bucket/fork dump
• Auxiliary extend and auxiliary retract
The result of a calibration will be the programming or
changing of a characteristic parameter or parameters
within a control.
Note: The following information is an example of the
calibration procedure. The actual calibration screens
may vary as new versions of the software are released.
31200302 125
Testing and Adjusting Section

Illustration 228 g00931831

To get to the calibration procedures for the main

control valve and the stabilizer control valve, you click
on the "Service" menu. Click on "Calibration". Click on
the "PHS Valve Calibrations".
126 31200302
Testing and Adjusting Section

Illustration 229 g00933552

Click on the "Next" button after the conditions for the

setup are met.
31200302 127
Testing and Adjusting Section

Illustration 230 g00933561

This is the screen that appears if you click the "Next"

button and all the conditions for the setup are not met.
128 31200302
Testing and Adjusting Section

Illustration 231 g00933568

Release all of the implement controls and click on the “Next”

button in order to continue with the calibration.
31200302 129
Testing and Adjusting Section

Illustration 232 g00933569

ET is now calibrating. Move and hold the control for the

boom in the RAISED position. Click on the "Next" button
when the boom starts to move.
130 31200302
Testing and Adjusting Section

Illustration 233 g00933574

The boom raise was calibrated successfully.

Click on the "Continue" button in order for the next
pending function to be calibrated.
Click on the "Cancel" button in order to cancel the
remaining calibrations. The confirmation message in
illustration 235 appears.
31200302 131
Testing and Adjusting Section

Illustration 234 g00933575

The calibration for the boom raise valve has failed.

Data in the window will include an error code for the
failure. The error code is provided in order to explain the
failure. The error codes are listed in table 12.
Click on "Continue" in order to calibrate the next
pending function.

Illustration 235 g00933577

132 31200302
Testing and Adjusting Section

If all the calibrations are not completed, and the

"Cancel" button is clicked this screen appears. Click on
"Yes" button in order to cancel the remaining
calibrations. Click on the "No" button in order to
resume calibrating.
Note: Turn off the ignition key, after the calibration
procedure is finished. Leave the key off for fifteen
seconds. The new parameters are then stored in the
ECM.
Table 12

PHS Valve Calibration Error Codes

Error Code Description Cause Corrective Action
A diagnostic fault in the system is
related to the inputs used for the
0002 Active diagnostic calibration. Such as the joystick sensor Troubleshoot and clear the fault.
inputs, the parking brake inputs, and the
engine speed input.
The user clicked the "Cancel" button
0006 Aborted by user Restart the calibration.
during the calibration process.
Calibration value out of This is not possible to obtain because of
0100 N/A
range low the telehandler design.
If motion occurred on the last
calibration then repeat the calibration.
Click the "Next" button when the
The "Next" button was not pressed
Calibration value out of linkage starts to move. If no motion
0100 before the current command in the
range high was observed then begin
calibration reached 1.100 amps.
troubleshooting the system. Check for
an obstruction that is keeping the
cylinder from moving.
Restart the calibration. Check for
Calibration value was not Valve ECM or CAN data link failure. This
0101 system functionality, active faults, and
saved is a rare fault.
event codes if the error occurs again.

Manual Adjustment After Calibrating Hydraulic System Pressure -

The Valves Release
After the valves have been calibrated and there is a Required Tools
problem with the joystick deadband or a problem with
the cycle time then manual adjustments can be Use the following tool when you remove the lock valve
performed. Use ET in order to make the adjustments for for the tilt cylinder.
the configuration of the maximum electrical current Table 13
flow to the coils.
Required Tools
Reference: Refer to the appropriate service manual,
Part Number Description Qty
"Electronic Control Module (ECM) - Configure" for
information concerning the machine configuration. 242-0779
36 mm Deep
1
Socket
1U-7565 Hex Wrench 1
31200302 133
Testing and Adjusting Section

6. Relieve the system pressure from the shutoff

valve on the axle lock.

Personal injury can result from hydraulic oil Lock Valve Locations
pressure and hot oil.
Care must be taken when you are removing lock valves
Hydraulic oil pressure can remain in the hydraulic
from the load control valve.
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released Lock valves are installed in the load control valves on
before any service is done on the hydraulic system. the following cylinders:
Make sure all of the attachments have been • Telescoping Cylinder
lowered, oil is cool before removing any • Boom Cylinder (Boom Raise/Lower)
components or lines. Remove the oil filler cap only
when the engine is stopped, and the filler cap is cool • Tilt cylinder
enough to touch with your bare hand. • Frame Leveling Cylinder
• Stabilizer Cylinder

Cylinders equipped with load control valves can

remain pressurized, even with hoses removed.
Failure to relieve pressure before removing a load
control valve or disassembling a cylinder can result
in personal injury or death.
Ensure all pressure is relieved before removing a
load control valve or disassembling a cylinder.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, Illustration 236 g01030220
adjusting and repair of the product. Be prepared to collect Lock Valve for the Telescoping Cylinder
the fluid with suitable containers before opening any The lock valve is on the front side of the control valve.
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Relieving Pressure in the Hydraulic

System
Before you remove any hydraulic components from the
machine make sure that all hydraulic pressure in the
hydraulic system is relieved.
Before you start any maintenance on the boom,
support the boom on a suitable stand. Refer to the
"Tools and Shop Products Guide" for information on Illustration 237 g01030224
stands that are available. Lock Valve for the Boom Cylinder (Boom Raise/Lower)

1. Lower the work tool to the ground.

2. Shut off the engine.
3. In order to release any pressure from the hydraulic
tank, you must loosen the hydraulic tank filler cap
slowly.
4. Tighten the filler cap.
5. Relieve the system pressure from the lock valves
and cylinders.
134 31200302
Testing and Adjusting Section

Location of the Shutoff Valve for the

Axle Lock

Illustration 238 g01030232

This is the lock valve for the tilt cylinder

Illustration 241 g01030236

The lock valve for the tilt cylinder is a cartridge type
Shutoff valve on the cylinder for the axle lock
valve. The lock valve is located in the cartridge which is
screwed directly into the cylinder.
Care must be taken when you are removing the make
up check valves from the shutoff valve.
The check valves are installed in the shutoff valve on
the cylinder for the axle lock.

Relieving Pressure from the Lock

Valves
The procedures in this section may be used in the
following operations:
• Boom lowering without hydraulic power
• Boom retract without hydraulic power
Illustration 239 g01030230 • Maintenance on load control valves
Lock Valve for the Frame Leveling Cylinder
• Maintenance on hydraulic cylinders

Note: For information regarding machine operation

without hydraulic power, refer to Operation and
Maintenance Manual, "Boom Retracting and Boom
Lowering without Hydraulic Power".
The following procedure should be used for the
adjustable lock valves.

Illustration 240 g01030227

Lock Valve for the Stabilizer Cylinder

Illustration 242 g00747777

Typical Lock Valve
(1) Lock Valve
(2) Locknut
(3) Adjustment screw
31200302 135
Testing and Adjusting Section

1. Hold adjusting screw (3) in place with a 5/16 inch 6. Loosen the lock valve slowly in order to release
allen wrench while you use a 9/16 inch spanner any pressure that remains in the lock valve.
wrench with an open end to remove locknut (2). Ensure that all the hydraulic pressure is released
Keep the locknut for reassembly later. from the lock valve before you remove the lock
valve from the load control valve. Remove the lock
2. Turn the adjustment screw (3) as far as possible valve from the load control valve.
in a clockwise direction. Record the number of
turns in order to reset the adjustment screw later. The following procedure should be used for the
The adjustment screw should move into the body boom cylinder (boom raise/lower).
of lock valve (1). The pressure in the lock valve
will now be relieved.
3. Reset the lock valve after all the pressure has
been relieved.
4. Loosen the lock valve slowly in order to release
any pressure that remains in the lock valve.
Ensure that all the hydraulic pressure is released
from the lock valve before you remove the lock
valve from the load control valve. Remove the lock
valve from the load control valve.
The following procedure should be used for the
telescoping cylinder.

Illustration 244 g01100221

Lock Valve for the Boom Cylinder
(7) Lock Valve
(8) Locknut
(9) Screw
1. The lock valve is mounted to the underside of
the cylinder, and toward the rear of the cylinder.
The valve can be accessed from the underside of
the machine.
2. Measure the distance from the head of adjusting
screw (9) to the body of lock valve (7). Record this
measurement. This measurement will be required
later when adjusting screw (9) is reset.
Illustration 243 g01100212
Load Control Valve for the Telescoping Cylinder 3. Fully loosen locknut (8). Turn adjusting screw (9)
(4) Lock Valve as far as possible in a clockwise direction by hand.
(5) Locknut 4. Attach a wrench to adjusting screw (9) and turn
(6) Adjustment screw adjusting screw (9) for an additional two full turns
1. Measure the distance from the head of adjusting in a clockwise direction. The pressure in the lock
screw (6) to the body of lock valve (4). Record this valve will now be relieved.
measurement. This measurement will be required 5. Reset the lock valve after all the pressure has been
later when the adjustment screw (6) is reset. relieved. Refer to Operation and Maintenance
Manual, "Boom Retracting and Boom
2. Fully loosen locknut (5). Turn adjusting screw (6)
Lowering without Hydraulic Power" for information
as far as possible in a clockwise direction by hand.
on resetting the lock valve.
3.
6. Loosen the lock valve slowly in order to release
4. Attach a wrench to adjusting screw (6) and turn any pressure that remains in the lock valve.
adjusting screw (6) for an additional two full turns Ensure that all the hydraulic pressure is released
in a clockwise direction. The pressure in the lock from the lock valve before you remove the lock
valve will now be relieved. valve from the load control valve. Remove the lock
5. Reset the lock valve after all the pressure has been valve from the load control valve.
relieved. Refer to Operation and Maintenance
Manual, "Boom Retracting and Boom
Lowering without Hydraulic Power" for information
on resetting the lock valve.
136 31200302
Testing and Adjusting Section

The following procedure should be used for the tilt

cylinder.

Illustration 245 g00795016

Lock Valve for the Tilt Cylinder

(10) Cap (11) Adjustment screw

The following procedure is for the machine with a

two-section boom.
1. Place the front coupler in a horizontal position and
support the front coupler on the ground in order to
ensure no movement of the function, when the
lock valve is removed.
2. Remove cap (10).
3. Use the hex tool 1U-7565 Wrench and turn
adjusting screw (11) in a counterclockwise
direction in order to relieve the pressure.
Record the number of turns in order to reset the
counterbalance valve later. The adjustment screw
should move out of the body of the lock valve. The
pressure in the lock valve will now be relieved.
4. Reset the counterbalance valve after all the
pressure has been relieved.
5. The remaining residual pressure that is sustained
within the spool will release in two to five minutes.
Use the tool 242-0779 36 mm Deep Socket and
loosen the lock valve slowly in order to release any
pressure that remains in the lock valve. Ensure
that all the hydraulic pressure is released from
the counterbalance valve before you remove the
counterbalance valve from the lock valve. Remove
the counterbalance valve from the lock valve.
6. On installation, torque the lock valve to
1 5 0 ±8 N m ( 11 0 ±6 l b f t ) .
31200302 137
Testing and Adjusting Section

The following procedure is for the machine with a

three-section boom.
1. 1.Place the front coupler in a vertical position. The
lower edge of the coupler should just clear the
ground and hanging in the lowest position. This
will take the load off the head end of the cylinder
and the pressure should be relieved.
2. Remove cap (10).
3. Use the hex tool 1U-7565 Wrench and turn
adjusting screw (11) counterclockwise in order to
relieve the pressure. Record the number of turns
in order to reset the counterbalance valve later.
The adjustment screw should move out of the
body of the lock valve. The pressure in the lock Illustration 247 g01097067
valve will now be relieved. 1. Turn the wheels to a full RIGHT position. This will
4. Reset the counterbalance valve after all the allow access to the frame leveling valve.
pressure has been relieved. 2. Place a jack under the front axle. Raise the front
5. Remaining residual pressure that is sustained wheels of the machine from the ground.
within the spool will be released in two to five 3. Place two stands under either end of the front
minutes. Use the tool 242-0779 36 mm Deep plate of the chassis. Lower the chassis onto the
Socket and loosen the lock valve slowly in order stands. This will prevent the machine from tipping.
to release any pressure that remains in the lock
valve. Ensure that all the hydraulic pressure is 4. Support the wheel on the side of the axle with the
released from the counterbalance valve before frame leveling by placing a block under the wheel.
you remove the counterbalance valve from the This will help prevent any oil pressure that would
lock valve. Remove the counterbalance valve be caused by the weight of the wheel. See figure
from the lock valve. 247.

6. On installation, torque the lock valve to 5. Put identification marks on all hoses. Before you
150 ±8 Nm (110 ±6 lb ft). remove the hoses locate three plugs that will be
used for plugging the hoses. Remove the three
Use this procedure to remove the pressure from the hoses that are connected to the valve (12). Plug
frame leveling valve and the cylinder. the hose ends.
6. Disconnect the two solenoid connections. Mark
the connections and the solenoids in order to make the
correct connections during the installation of the valve.
7. Ensure that any oil that may leak is collected
properly. Do not remove the four bolts. Carefully
loosen the four bolts (13) that hold the valve
down. This will relieve the pressure from the frame
leveling cylinder and the lock valves.
8. Continue to remove the four bolts and the valve.
9. Clean all parts and inspect all parts for damage.
10. Install a new valve or reinstall the old valve in
reverse order. Install two new 240-5121 O-Ring
Seals during reinstallation.
Illustration 246 g01030599
11. Reconnect the hoses and the solenoid
connections.
Lock valves for the frame leveling are not adjustable. Use this procedure to remove the pressure from the
stabilizer valve and the cylinder.
138 31200302
Testing and Adjusting Section

Verifying the Correct Setting of the

Load Control Valves
The procedure for verifying the correct setting of the
load control valves can be found in the following
reference Operation and Maintenance Manual,
"Equipment Lowering with Loss of Hydraulic Power".

Relieving Pressure from the Shutoff

Valve on the Axle Lock
The following procedure should be used for
relieving the pressure from the shutoff valve on the
Illustration 248 g00922982 axle lock:

Illustration 249 g01030227

Illustration 250 g01030601
Lock valves for the stabilizer cylinders are not Shutoff Valve and Make up Check Valves in the cylinder for the Axle Lock
adjustable. (14) Cap
(15) Adjustment screw
1. Start the engine. Lower the stabilizer to the ground
but do not lift the machine. Turn off the engine and
relieve the system hydraulic pressure. 1. Remove cap (14).
2. Put identification marks on all hoses. Before you 2. Turn adjusting screw (15) in a counterclockwise
remove the hoses locate three plugs that will be direction in order to relieve the pressure. Record
used for plugging the hoses. Remove the three the number of turns in order to reset the lock valve
hoses that are connected to the valve. Plug the later. The adjustment screw should move into the
hose ends. body of the lock valve. The pressure in the shutoff
valve will now be relieved.
3. Disconnect the two solenoid connections. Mark
the connections and the solenoids in order 3. Reset the lock valve after all the pressure has
been relieved.
4. to make the correct connections during the installation of
the valve. 4. Loosen the lock valve slowly in order to release
any pressure that remains in the shutoff valve.
5. Ensure that any oil that may leak is collected Ensure that all the hydraulic pressure is released
properly. Do not remove the bolts. Carefully loosen from the lock valve before you remove the lock
the four bolts that hold the valve down. This will valve from the shutoff valve. Remove the lock
relieve the pressure from the stabilizer cylinder valve from the shutoff valve.
and the lock valves.
6. Continue to remove the four bolts and the valve.
7. Clean all parts and inspect all parts for damage.
Hydraulic System Pressures -
8. Install a new valve or reinstall the old valve in Test and Adjust
reverse order. Install two new 240-5121 O-Ring
Seals during reinstallation.
Test and Adjustment Procedures
9. Reconnect the hoses and the solenoid
connections. For information on pump pressure settings and the
following procedures, refer to theappropriate service
manual.
• Steering Pressure Test
31200302 139
Testing and Adjusting Section

• Steering Pressure Adjustment • Appropriate pressure gauges

• Margin Pressure Table 1 provides a list of the tools that are required in
order to perform the following test procedure.
• Margin Pressure Adjustment
Table 14
• Test for the Implement Relief Valve (Load Sensing
Oil or Signal Oil) Required Tools
• Adjustment for the Implement Relief Valve (Load Part
Tool Part Description Qty
Sensing Oil or Signal Oil) Number

• Test for Pressure Compensator A 6V-7830 Pressure Gauge 1

• Pressure Compensator Adjustment

• Low Pressure Standby Test
• Low Pressure Standby Adjustment Warming the Transmission Oil
In order to ensure that the transmission oil is at the
Pilot Pressure (Pressure normal operating temperature of 60° ± 10°C (140° ±
Reducing Valve) - Test and 18°F), complete the following procedure:
1. Apply the service brakes and start the engine.
Adjust
2. Run the engine for 2 minutes at Low Idle. Then,
run the engine for 2 minutes at High Idle.
3. Disengage the parking brake. Ensure that
the switch that disables the transmission
neutralizer control is in the OFF position. Refer
to the Operation and Maintenance Manual,
"Transmission Neutralizer Control".
4. Move the transmission control to the FOURTH
SPEED position with the drive in the NEUTRAL
position. Depress the accelerator pedal until the
engine speed has reached high idle. The high idle
speed is 2350 ± 25 (rpm).
5. Move the transmission control to the FORWARD
position and stall the torque converter until the
transmission oil temperature gauge in the cab
Illustration 251 g00945669 reads 3/4 of the way to the red line.
Location of the Pressure Reducing Valve in the Main Control Valve (Implement)
(1) Outlet section
Note: To ensure that the transmission oil does not get
(2) Pressure reducing valve too hot, do not keep the torque converter in a full stall
condition for more than 10 seconds.
The pilot pressure for the main control valve 6. Move the transmission control to the NEUTRAL
(implement) is controlled by pilot reducing valve (2) in position and continue to run the engine at high idle
outlet section (1) of the main control valve (implement). until the needle of the transmission oil temperature
gauge returns to the middle of the scale.
Pilot Pressure Test 7. Repeat Step 5 and Step 6 until the proper
hydraulic oil temperature is obtained.
Introduction
The test indicates if the pressure reducing valve in the
Test Procedure
supply line to the main control valve (implement) is set
correctly. The pressure reducing valve supplies oil at
reduced pressure in order to activate the pilot valves in
the main control valve (implement), and the control
Personal injury can result from removing hoses or
valve Gp (stabilizer), if equipped.
fittings in a system under pressure.
Reference: See Systems Operation/Testing and
Failure to relieve pressure can cause personal
Adjusting, "Outlet Manifold" for more information.
injury.
Required Tools Do not remove or disconnect hoses or fittings until
Use the following test equipment in order to all pressure in the hydraulic system has been
perform the following procedure: relieved.
140 31200302
Testing and Adjusting Section

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Ensure the use of 6V-7830 Pressure Gauge.
During engine start-up, a 17250 kPa (2500 psi)
pressure spike is possible.
1. Ensure that the hydraulic oil is at the correct Illustration 253 g00945864

temperature.
1. Turn off the engine.
2. Retract the boom and lower the boom. Ensure
that the frame is level. 2. To increase the pressure setting on the pressure
3. Stop the engine. Move the steering wheel from reducing valve, loosen locknut (4) and use an
left to right. This procedure helps purge pressure allen wrench to turn adjusting screw (5) clockwise.
from the hydraulic system. To decrease the pressure setting, loosen locknut
(4) and turn adjusting screw (5) counterclockwise.
One turn equals approximately 700 kPa (100 psi).
3. While you hold adjusting screw (5) from turning,
tighten locknut (4).
4. Recheck the pressure settings.

Illustration 252 g00945668

4. 3. Connect Tooling (A) to test fitting (3).
Note: Ensure the use of 6V-7830 Pressure Gauge.
During engine start-up, a 17250 kPa (2500 psi)
pressure spike is possible.
5. Start the engine and operate the engine at low
idle.
6. The pressure gauge should read 3450 ± 150 kPa
(500 ± 20 psi). If the pressure is not within the
specification, adjust the pressure reducing valve. Refer
to Testing and Adjusting, "Pressure Reducing Valve
Adjustment" for your machine.
7. If the pressure is within the specification, stop the
engine and remove the tooling.

Pressure Reducing Valve

Adjustment
Introduction
Use the following procedure to adjust the setting for the
pressure reducing valve.
Adjustment Procedure
31200302 141
Testing and Adjusting Section

Relief Valve (Implement) - Test Required Tools

and Adjust Use the following test equipment in order to
perform the following procedure:
• Appropriate pressure gauges
Table 1 provides a list of the tools that are required in
order to perform the following test procedure.
Table 15

Required Tools
Part
Tool Part Description Toy
Number
8T-0860 Pressure Gauge 1
6V-3989 Test fitting 1
A
177-7861 Hose 1
6V-4143 Coupler 2

Warming the Transmission Oil

In order to ensure that the transmission oil is at the
normal operating temperature of 60° ± 10°C (140° ±
18°F), complete the following procedure:
1. Apply the service brakes and start the engine.
2. Run the engine for 2 minutes at Low Idle. Then,
run the engine for 2 minutes at High Idle.
Illustration 254 g01003786
3. Disengage the parking brake. Ensure that
Location of line relief valves in the auxiliary section of the main control
the switch that disables the transmission
valve
neutralizer control is in the OFF position. Refer
(1) Control valve (boom raise/lower)
to the Operation and Maintenance Manual,
(2) Control valve (tilt)
“Transmission Neutralizer Control”.
(3) Relief valve
(4) Control valve (auxiliary) 4. Move the transmission control to the FOURTH
(5) Control valve (boom extend/retract) SPEED position with the drive in the NEUTRAL
(6) Relief valve position. Depress the accelerator pedal until the
(A) Work port engine speed has reached high idle. The high idle
(B) Work port speed is 2350 ± 25 (wpm.
The pressure for the auxiliary services is controlled by 5. Move the transmission control to the FORWARD
line relief valves (3) and (6) in the implement section. A position and stall the torque converter until the
relief valve is installed for each work port. transmission oil temperature gauge in the cab
reads 3/4 of the way to the red line.
Note: Refer to the Operation and Maintenance Manual
Note: To ensure that the transmission oil does not get
for more information on the operation of the control
too hot, do not keep the torque converter in a full stall
switches that are used in this procedure.
condition for more than 10 seconds.
6. Move the transmission control to the NEUTRAL
Auxiliary Pressure Test (Port A and position and continue to run the engine at high idle
Portable until the needle of the transmission oil temperature
gauge returns to the middle of the scale.
Introduction 7. Repeat Step 5 and Step 6 until the proper
The test indicates if the pressure relief valves in work hydraulic oil temperature is obtained.
ports (A) and (B) of the auxiliary implement control
valves are set correctly. The relief valve limits the
pressure in work ports (A) and (B). Refer to Table 16 for
the pressure.
Note: The following test is performed with a quick
coupler that is hydraulically actuated. The test can be
performed with any work tool that is operated by a
hydraulic actuator.
142 31200302
Testing and Adjusting Section

Test Procedure position until the auxiliary control valve is stalled.

Refer to Table 16 for the pressure. Release the
switch.
8. Press and hold the bottom of the quick coupler
switch in order to engage the quick coupler pins.
Personal injury can result from removing hoses or Hold the switch in this position until the auxiliary
control valve is stalled. Refer to Table 16 for the
fittings in a system under pressure.
pressure.
Failure to relieve pressure can cause personal
injury.
Do not remove or disconnect hoses or fittings until Table 16
all pressure in the hydraulic system has been
relieved. Hydraulic Specifications

Pressures
NOTICE
Care must be taken to ensure that fluids are contained Model
during performance of inspection, maintenance, testing, Description
adjusting and repair of the product. Be prepared to collect TH360B TH560B
the fluid with suitable containers before opening any (S/N: SLE1-1349)
compartment or disassembling any component Auxiliary Pressure 17500 ± 500 kPa
containing fluids. (S/N: SLG1-Up)
(2538 ± 73 psi)
Dispose of all fluids according to local regulations and 21000 ± 500 kPa
(S/N: SLE1350-Up)
mandates. (3045 ± 73 psi)
Auxiliary Pressure 21000 ± 500 kPa
(3045 ± 73 psi)

9. Stop the engine and remove the test equipment.

Auxiliary Relief Valve Adjustments

Introduction
Use the following procedures to adjust the setting for
the auxiliary relief valves.

Pressure Adjustment for Disengaging

the Quick Coupler
Illustration 255 g01003812

1. Ensure that the hydraulic oil is at the correct

temperature.
2. Retract the boom and lower the boom. Ensure that the
frame is level.
3. Stop the engine. Move the steering wheel from left to
right. This procedure helps purge pressure from the
hydraulic system.
4. Connect tooling (A) to test fitting (7).
5. Ensure that the switch on the front of the joystick
control is toggled to the auxiliary services 1
position. Illustration 256 g01024114

Reference: Refer to Systems Operation, "Auxiliary 1. Turn off the engine.

Control (Combined Circuit)" for further information. 2. To increase the pressure setting on the relief
6. Start the engine and operate the engine at low valve, loosen locknut (9) and use an allen wrench
idle. to turn adjusting screw (8) clockwise. To decrease
the pressure setting, loosen locknut (9) and turn
7. Move the sliding red portion of the quick coupler
adjusting screw (8) counterclockwise.
switch downward and press the top of the switch.
Press and hold the switch in order to disengage 3. While you hold adjusting screw (8) from turning,
the quick coupler pins. Hold the switch in this tighten locknut (9).
31200302 143
Testing and Adjusting Section

4. Start the engine. NOTICE

5. Recheck the pressure settings. Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting
and repair of the product. Be prepared to collect the fluid with
Pressure Adjustment for Engaging the suitable containers before opening any compartment or
Quick Coupler disassembling any component containing fluids.

Dispose of all fluids according to local regulations and

mandates.

In order to obtain a representative oil sample, it is first

necessary to flush the sampling valve.

Required Tools
Use the following equipment in order to Flush the
Sampling Valve:
Table 17

Required Tools
Illustration 257 g01024132
Part
1. Turn off the engine. Tool Part Description Qty
Number
2. To increase the pressure setting on the relief valve, 8T-9208 Probe Assembly 1
loosen locknut (9) and use an allen wrench to A
turn adjusting screw (10) clockwise. To decrease 6K-0713 Hose 1
the pressure setting, loosen locknut (11) and turn
adjusting screw (10) counterclockwise. 1. Shift the transmission to NEUTRAL and engage
3. While you hold adjusting screw (10) from turning, the parking brake.
tighten locknut (11). 2. Start the engine.
4. Start the engine. 3. Extend the boom and retract the boom several
5. Recheck the pressure settings. times in order to warm the hydraulic oil.
4. Operate each implement several times in order to
circulate the warm oil. Rotate the steering wheel
Hydraulic Oil Contamination - from stop to stop several times.
Test 5. Allow the engine to run on low idle.
6. Open the engine enclosure.
Hydraulic Oil Contamination
Introduction
The steering system and the transmission system use
hydraulic oil from the hydraulic tank. Caterpillar
recommends the use of the SOS oil analysis program
in order to monitor the condition of your equipment.
If the oil becomes contaminated, premature
component failure could result. Contaminated oil can
also contribute to overheating. Use the following
procedure to sample the oil in the system.
Reference: See Operation and Maintenance Manual,
"SOS Fluid Analysis" for further information about this
Illustration 258 g00867454
SOS oil analysis program.
7. Locate the sampling valve that is positioned at the
top of the hydraulic oil filter. Remove the rubber
Flushing the Sampling Valve cap from the sampling valve.
8. Attach the 8T-9208 Probe Assembly to the
6K-0713 Hose.
9. Direct the hose into a container for fluid waste.
Hot oil and components can cause personal injury. Remove approximately 30 mL (1 fl oz) of fluid
from the sampling valve.
Do not allow hot oil or components to contact
skin.
144 31200302
Testing and Adjusting Section

Obtaining the Sample Boom Chain - Clean/Inspect/

Lubricate
NOTICE
Hot oil and components can cause personal injury. Care must be taken to ensure that fluids are contained
Do not allow hot oil or components to contact during performance of inspection, maintenance, testing,
skin. adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
NOTICE compartment or disassembling any component
containing fluids.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, Dispose of all fluids according to local regulations and
adjusting and repair of the product. Be prepared to collect mandates.
the fluid with suitable containers before opening any Table 20
compartment or disassembling any component
containing fluids. Required Tools

Dispose of all fluids according to local regulations and Part Number Description Quantity
mandates. 6V-0028 Wear Gauge 1
Once the sampling valve has been flushed, carry out
the following procedure in order to obtain an oil sample:
Boom Chains
Required Tools
The chain extends the boom and the chain that
Use the following equipment in order to obtain the retracts the boom must be cleaned and inspected. Also,
Sample: the chains must be measured for wear. The chains
Table 18 must be lubricated after two years or every 3000 hours.
In severe operating conditions, this service interval
Required Tools must be reduced.
Part Disassemble the chains from the boom. For
Tool Part Description Qty
Number
disassembly and assembly procedures for the chains,
Fluid Sampling Cap and refer to appropriate service manual.
177-9343 1
B Probe Gp
169-7373 Bottle 1 Check Condition
1. Attach the probe from the 177-9343 Fluid 1. Park the machine on level ground. Fully retract
Sampling Cap and Probe Gp to a 169-7373 the boom and lower the boom.
Bottle. 2. Remove the cover from the rear of the chassis.
2. Draw a 50 mL (1.7 fl oz) oil sample from the 3. A limited inspection of the chains can be made
sampling valve. through the rear of the boom. The boom extension
chain can be inspected by fully extending the
Maximum Contamination Levels boom and looking on top of the intermediate
section. If the chains are corroded, the chains
The level of contaminants that is found in the hydraulic must be removed from the boom for cleaning and
system must meet the ISO 18/15 cleanliness level. a full inspection. If the chains require lubricant,
the chain must be removed from the boom for
The following table contains the maximum cleaning and a full inspection.
acceptable contamination levels:
Table 19 Cleaning and Inspection
Hydraulic Oil Contamination Use a suitable de greaser to thoroughly clean the
Maximum Number of chains. Remove all traces of dirt and grease and lay the
Particle Size (Microns) Particles in a 50 mL (1.7 fl chains on a clean bench for inspection.
oz) Sample
Carefully inspect the full length of the chains for
10 to 20 48000 damage, and in particular check for the following
21 to 50 2580 possible damage:
51 to 100 150 • Cracked link plate or missing link plates

100 or more 20 • Elongated holes in link plate

31200302 145
Testing and Adjusting Section

• Pins that are loose Lubrication

• Pins with damaged heads Spray the full length of each chain on both sides with
• Rust or corrosion on link plates 1U-8266 Chain and Cable Lubricant. Ensure that the
lubricant penetrates the working surfaces between the
Mark the most noticeable worn section of each chain. links and pins by articulating the chain as the spray is
This will usually be near the center of the chain. applied.
Check and Adjust the Chain Tension When the chains are assembled into the boom,
Refer to the Operation and Maintenance, "Boom Chain lubricate the pins at the anchor points.
Tension - Check/Adjust" for the correct procedure. Ensure that the proper precautions are taken when you
Measuring Chain Wear use pressurized containers and solvents. Also, use the
proper protective equipment and clothing when you use
Nominal pitch of the link pins equals 25.4 mm (1 pressurized containers and solvents.
inch).

Nominal height of the plate equals 24.1 mm (0.95 General Information Table
inch).
Table 21
1. Fully retract the boom. Position the boom
horizontally. Hydraulic Specifications
2. Extend the boom by 2 m (6 ft 7 inch) or extend the Pressures
boom to the section of chain that most frequently
Description Model
passes over the boom extension chain pulley.
TH360B TH560B

Do not retract the boom sections before you begin to Maximum Pump 25000 ± 500 kPa 25000 ± 500 kPa
measure the chains.assembly and Assembly, Pressure (3626 ± 73 psi) (3626 ± 73 psi)

Pilot Pressure 3450 ± 150 kPa 3450 ± 150 kPa

(500 ± 22 psi) (500 ± 22 psi)
(S/N: SLE1-1349)
Auxiliary Pressure 17500 ± 500 kPa
(2538 ± 73 psi) (S/N: SLG1-Up)
21000 ± 500 kPa
(S/N: SLE1350- (3045 ± 73 psi)
Up) 21000 ± 500
Auxiliary Pressure
kPa (3045 ± 73
psi)
Flow Rate
Auxiliary Flow Rate
(Joystick) 90 ± 5 L/min (24.0 ± 1.5 US gpm)
Continuous 60 ± 5 L/min (16 ± 1 US gpm)
Illustration 259 g00747739 Auxiliary Flow Rate

3. Use a caliper in order to measure the height of

inner plate (A) and the height of outer plate (A)
over 15 pitches of the selected worn section of
chain. If any plate for the chain shows a reduction
in height of more that 5% wear, all chains must
be replaced. Also, if the measurement is less
than 22.89 mm (0.901 inch), all chains must be
replaced.
4. Use a 6V-0028 Wear Gauge in order to measure
the chain between the 16 pin centers of the
selected worn section (B). The nominal length of 16 pin
centers is 381 mm (15 inch). If the measurement shows
an elongation of more that 2%, all chains must be
replaced. Also, if the measurement is greater than 388.6
mm (15.30 inch), all chains must be replaced.
146 31200302
Testing and Adjusting Section

Table 22

Cycle Times for Implement Functions (Seconds)

Engine at high idle and the hydraulic oil temperature
above 45 °C (113 °F)
Model
Function
TH360B TH560B
Boom Raise 14 - 17 15 - 18
Boom Lower 8 - 11 10 - 14
Boom Extend 16 -18 11 - 13
Boom Retract 13 - 16 11 - 14
Coupler Tilt
2-3 3-4
Backward
Coupler Tilt
2-3 3-4
Forward
Frame Level (Left
10 - 18 18 - 23
to Right)
Frame Level (Right
10 - 19 16 - 23
to Left)
Single Stabilizer
5 -7 6-8
Down
Single Stabilizer
5-7 5-7
Up
LH Stabilizer and
6 - 10 9 - 12
RH Stabilizer Down
LH Stabilizer and
6 - 10 8 - 11
RH Stabilizer Up
31200302 147
Index Index

A The Neutral Start Is Disabled........................................ 40

Auxiliary Hydraulic System Transmission Neutralizer .............................................. 39
Auxiliary Circuit 1 .......................................................... 82 Electrical Input Components .............................................. 30
Auxiliary Circuit 2 .......................................................... 83 Auxiliary Switches......................................................... 31
Auxiliary Control (Combined Circuit)............................. 80 Boom Critical Angle Switch........................................... 31
Continuous Flow (Auxiliary Hydraulics) ........................ 84 Boom Lowered Switch .................................................. 32
Introduction................................................................... 79 Boom Retracted Switch ................................................ 31
Quick Coupler ............................................................... 84 Continuous Flow Switch Implement.............................. 32
Quick Coupler Circuit DISENGAGED........................... 85 Joystick Control ............................................................ 31
Quick Coupler Pins ENGAGED .................................... 86 Lockout Switch.............................................................. 32
Relief Valves and Makeup Valves ................................ 87 Quick Coupler Switch ................................................... 32
Auxiliary Hydraulic System................................................. 79 Stabilizer Pressure Switches ........................................ 32
Stabilizer Switches........................................................ 31
B Thumb Slider ................................................................ 31
Boom Chain - Clean/Inspect/ Lubricate ........................... 144 Electrical Output Components
Boom Chains .............................................................. 144 Relays........................................................................... 38
Check and Adjust the Chain Tension ......................... 145 Solenoids ...................................................................... 38
Check Condition ......................................................... 144 Electrical Output Components ........................................... 37
Cleaning and Inspection ............................................. 144 Electrical Schematic........................................................... 43
Lubrication .................................................................. 145 Electronic Control Module .................................................. 33
Measuring Chain Wear ............................................... 145 Data Links..................................................................... 33
Boom Hydraulic System Input/Output .................................................................. 33
Boom LOWER .............................................................. 72 Inputs ............................................................................ 33
Boom RAISE................................................................. 71 Outputs ......................................................................... 33
Control valve (implement)............................................. 65
F
Load Control Valves ..................................................... 69
Lowering Control Valve (If Equipped) ........................... 70 Frame Leveling System
Valve for the Cylinder in the EXTEND Position ............ 67 Frame that is Angled to the Left.................................... 93
Valve for the Cylinder in the RETRACT Position.......... 68 Locked Axle (HOLD) ..................................................... 92
Boom Hydraulic System..................................................... 65 Frame Leveling System ..................................................... 91

C G
Check and Relief Valves .................................................... 56 General Information ............................................................. 7
Compensating System ....................................................... 87 Electronic Joystick ........................................................ 12
Boom Lower.................................................................. 88 Electronic Pilot Valve Group (Implement ........................ 8
Boom Raise .................................................................. 89 Hydraulic Oil Filter ........................................................ 13
Pressure Relief and Makeup Valves............................. 90 Hydraulic Oil Tank ........................................................ 13
Configuration Parameters ................................................ 102 Load Independent Flow Division (LIFD) ....................... 15
Machine ECM ............................................................... 10
E Main Control Valve Group (Implement) .......................... 7
Electrical Function Requirements ...................................... 39 Operator Switches ........................................................ 13
Boom Raise/Lower Is Disabled..................................... 41 Piston Pump (Implement and Steering) ........................ 13
Disable the Quick Coupler ............................................ 42 Stabilizer Control Valve Gp (If Equipped) ....................... 9
Disable The Rackback And Dump................................ 41 System Operation ......................................................... 13
Machine Security System ............................................. 40 General Information Table ............................................... 145
Miscellaneous............................................................... 42 Graphic Color Codes............................................................ 5
More Electrical Function Requirements........................ 40
H
Parking Brake ............................................................... 40
Rear Axle Lock (if equipped) ........................................ 39 Hydraulic Oil Contamination -Test ................................... 143
Service Brake Pressure Switch for the Transmission Flushing the Sampling Valve ...................................... 143
Neutralizer .................................................................... 40 Hydraulic Oil Contamination ....................................... 143
Shift Lever (Cat Data Link) for Powersynchro Transmission Maximum Contamination Levels................................. 144
39 Obtaining the Sample ................................................. 144
Shuttle Shift for the Power Shuttle Transmission ......... 39 Hydraulic System Pressure -Release
Solenoid Outputs .......................................................... 39 Location of the Shutoff Valve for the Axle Lock .......... 134
Stabilizer Raise/Lower (if equipped) is Disabled .......... 41 Lock Valve Locations.................................................. 133
Steering ........................................................................ 40 Relieving Pressure from the Lock Valves ................... 134
System Voltage............................................................. 39 Relieving Pressure from the Shutoff Valve
The Boom Extend/Retract Is Disabled.......................... 41 on the Axle Lock ......................................................... 138
The Frame Level (if equipped) is Disabled ................... 42 Relieving Pressure in the Hydraulic System ............... 133
148 31200302
Index

Verifying the Correct Setting of the Piston Pump (Implement and Steering)........................ 23
Load Control Valves ................................................... 138 Quick Coupler Cylinder................................................. 27
Hydraulic System Pressure -Release .............................. 132 Relief Valve (Load Sensing Oil).................................... 24
Hydraulic System Pressures -Test and Adjust Stabilizer Cylinders ....................................................... 28
Test and Adjustment Procedures ............................... 138 Telescoping Cylinder .................................................... 25
Hydraulic System Pressures -Test and Adjust................. 138 Tilt Cylinder................................................................... 26
Hydraulic System Schematic ............................................. 99 Lowering Control Pump (Electric)
All Implements In HOLD ............................................... 99 Electric Lowering Control Pump (If Equipped).............. 60
I Lowering Control Pump (Electric) ...................................... 60
Lowering Control Pump (Manual) ...................................... 63
Important Safety Information................................................. ii
Introduction .......................................................................... 6 M
L Main Control Valve (Implement)......................................... 53
Main Control Valve (Implement) - Calibrate
Location of Electrical Components..................................... 15
Manual Adjustment After Calibrating The Valves ....... 132
Joystick Control ............................................................ 16
Programmable Hydraulic System (PHS) Valve
Machine (ECM)............................................................. 20 Calibrations................................................................. 123
Main Control Valve (Implement) ................................... 20 Main Control Valve (Implement) - Calibrate ..................... 123
Pressure Switches (Stabilizer)...................................... 19 Main Control Valve Group (Implement)................................ 7
Relay (Frame Level) ..................................................... 21 Manifold Valve (Inlet) ......................................................... 55
Relays (Quick Coupler)................................................. 22 Manifold Valve (Outlet)....................................................... 58
Sensor (Boom Raise/Lower)......................................... 17
Sensor for Boom Extend and Boom Retract or Boom P
Tilt Forward and Tilt Rackback. .................................... 17 Pilot Hydraulic System ....................................................... 59
Solenoid (Diverter Valve).............................................. 21 Pilot Pressure (Pressure Reducing Valve) - Test and Adjust
Solenoids (Frame Level)............................................... 21 Adjustment Procedure ................................................ 140
Stabilizer Control Valve Gp (If Equipped) ..................... 20 Pilot Pressure Test ..................................................... 139
Switch (Auxiliary 1 or 2) ................................................ 17 Pressure Reducing Valve Adjustment ........................ 140
Switch (Auxiliary Actuator in the + Direction) for Joystick Test Procedure ........................................................... 139
(Type 1) ........................................................................ 17
Warming the Transmission Oil.................................... 139
Switch (Auxiliary Actuator in the -Direction) for Joystick
(Type 1) ........................................................................ 17 Pilot Pressure (Pressure Reducing Valve) -
Test and Adjust ................................................................ 139
Switch (Auxiliary Actuator) for Joystick (Type 2) .......... 17
Piston Pump (Implement and Steering)
Switch (Continuous Auxiliary Flow) .............................. 17
Compensator Valve ...................................................... 46
Switch (Critical Angle)................................................... 19
Constant Flow............................................................... 49
Switch (Frame Level).................................................... 18
Destroke ....................................................................... 50
Switch (Fully Lowered Boom) ....................................... 19
High Pressure Stall ....................................................... 52
Switch (Fully Retracted Boom) ..................................... 19
Low Pressure Standby.................................................. 47
Switch (Left Stabilizer) .................................................. 18
Piston Pump ................................................................. 45
Switch (Lockout Control)............................................... 15
Upstroke ....................................................................... 48
Switch (Quick Coupler) ................................................. 18
Piston Pump (Implement and Steering) ............................. 45
Switch (Right Stabilizer)................................................ 18
Switch for Boom Extend and Boom Retract or Boom R
Tilt Forward and Tilt Rackback. .................................... 17
Relief Valve (Implement) - Test and Adjust...................... 141
Location of Hydraulic Components .................................... 22
Auxiliary Pressure Test (Port A and Portable ............. 141
Boom Cylinder .............................................................. 25
Auxiliary Relief Valve Adjustments ............................. 142
Compensating Cylinders............................................... 26
Pressure Adjustment for Disengaging the
Compensator Valve ...................................................... 23 Quick Coupler ............................................................. 142
Control Valve Gp (Stabilizer) ........................................ 28 Pressure Adjustment for Engaging the Quick Coupler 143
Diverter Valve ............................................................... 27 Required Tools ........................................................... 141
Frame Leveling Cylinder............................................... 27 Test Procedure ........................................................... 142
Hydraulic Tank.............................................................. 22 Warming the Transmission Oil.................................... 141
Inlet Manifold ................................................................ 24
Load Control Valve (Boom Cylinder) (Lock) ................. 25 S
Load Control Valve (Stabilizer Cylinders) (Lock) .......... 29 Stabilizer System
Load Control Valve (Telescoping Cylinder) (Lock) ....... 26 Stabilizer Cylinders (HOLD).......................................... 96
Load Control Valve (Tilt Cylinder) (Lock)...................... 26 Stabilizer Cylinders (LOWER) ...................................... 98
Lock Valve (Frame Leveling Cylinder).......................... 28 Stabilizer Cylinders (RAISE)......................................... 97
Lowering Control Pump (Manual) ................................. 29 Stabilizer System ............................................................... 94
Main Control Valve (Implement) ................................... 23 Systems Operation Section.................................................. 5
Outlet Manifold ............................................................. 25
31200302 149
Index

T
Table of Contents................................................................. 1
Telescoping System........................................................... 73
Valve for the Telescoping Cylinder in the
EXTEND Position ......................................................... 75
Valve for the Telescoping Cylinder in the
HOLD Position .............................................................. 73
Valve for the Telescoping Cylinder in the
RETRACT Position ....................................................... 77
Testing and Adjusting
Joystick Control - Calibrate......................................... 103
Testing and Adjusting Section.......................................... 103
Testing and Adjusting....................................................... 103
150 31200302
Index
Manufactured by JLG under license from Caterpillar
31200273
December 15, 2006

Systems Operation
Testing and
Adjusting
TH220B, TH330B, TH360B, TH560B and
TH580B Telehandlers Steering System
S/N TBF00100 & After
S/N TBG00100 & After
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200273 1
Table of Contents
Table of
Table of Contents Right Turn in Two-Wheel Steer Mode22
Systems Operation Section Left Turn in Circle Steer Mode........... 24
Graphic Color Codes ............................... 3 Left Turn in Crab Steer Mode ............ 26
General Information................................. 4 Hydraulic Schematic (Steering System). 28
Steering Arrangement ......................... 4 Piston Pump (Implement and Steering) . 29
Introduction.............................................. 6 Piston Pump ...................................... 29
Location of Electrical Components .......... 7 Compensator Valve ........................... 30
Selector Switch for the Steering Mode 7 Low Pressure Standby....................... 31
Position Sensors ................................. 7 Upstroke ............................................ 32
Electronic Control Module ................... 8 Constant Flow.................................... 33
Solenoid for Crab Steer....................... 8 Destroke ............................................ 34
Solenoid for Circle Steer ..................... 8 High Pressure Stall ............................ 36
Relay (Crab Steer) .............................. 8 Solenoid Valve (Steering Mode
Relay (Circle Steer) ............................. 9 Selector)................................................. 37
Location of Hydraulic Components.......... 9 Solenoid Valve................................... 37
Steering Wheel.................................... 9 Metering Pump (Steering) ...................... 37
Metering Pump .................................. 10 Hold ................................................... 39
Piston Pump ...................................... 10 Right Turn .......................................... 40
Line for the Signal Limiter Valve for the Position Sensor (Steering) ..................... 42
Steering ............................................. 10 Configuration Parameters ...................... 43
Priority Valve ..................................... 10 Testing and Adjusting Section
Control Valve (Steering) .................... 11 Hydraulic Oil Contamination -Test ......... 45
Steering Cylinders ............................. 11 Hydraulic Oil Contamination .............. 45
Hydraulic Tank .................................. 11 Flushing the Sampling Valve ............. 45
Hydraulic Tank Breather.................... 11 Obtaining the Sample ........................ 45
Hydraulic Oil Level Indicator.............. 12 Pump Flow - Test ................................... 46
Hydraulic Oil Drain Plugs .................. 12 Pump Flow......................................... 46
Electrical Input Components.................. 12 Test On The Machine ........................ 46
Steering Mode Switch ....................... 12 Test On The Bench............................ 47
Position Sensor ................................. 13 Steering System Pressures -Test and
Electronic Control Module ..................... 13 Adjust ..................................................... 47
Electrical Output Components............... 14 Steering System Pressure Tests and
Relays ............................................... 14 Adjustments ....................................... 47
Instrument Cluster ............................. 14 Steering Pressure Test ...................... 48
Data Link ............................................... 14 Steering Pressure Adjustment ........... 48
CAT Data Link ................................... 14 Margin Pressure Test ........................ 49
CAN Data Link................................... 15 Margin Pressure Adjustment ............. 50
Electrical Schematic .............................. 15 Test for the Relief Valve (Load Sensing
Inlet Manifold ......................................... 15 Oil) ..................................................... 50
Steering Priority Valve....................... 16 Adjustment of the Relief Valve (Load
Screens (75 and 100 Micron) ............ 16 Sensing Oil) ....................................... 51
Flow Control Valve (Dump valve for the Test for Pressure Compensator......... 51
load sensing oil) ................................ 16 Pressure Compensator Adjustment... 52
Relief Valve (Load sensing oil).......... 16 Low Pressure Standby Test............... 52
Check Valve ...................................... 16 Low Pressure Standby Adjustment.... 53
Steering Not Activated....................... 17 Steering System - Purge ........................ 54
Steering Activated ............................. 18 Purging the Steering System ............. 54
Steering System .................................... 19 Solenoid Valve (Steering Mode Selector) -
Steering Control System ................... 19 Test ........................................................ 54
Steering in Neutral............................. 20
2 31200273
Table of Contents

The Solenoid's for the Steering

Modes ................................................54
Position Sensor (Steering) -Adjust .........55
Position Sensor ..................................55
Wheel Alignment - Check and Adjust.....57
Checking the Wheel Alignment With
Wheels In Place .................................58
Adjusting the Wheel Alignment ..........58
Adjusting the Steering Angle..............59
General Information Table......................60
31200273 3
Systems Operation Section

Systems Operation (A) Red.......................................................... High pressure oil

(B) Red Stripes and White Stripes ... First pressure reduction
Section (C) Red Crosshatch ..................... Second pressure reduction
(D) Pink .............................................. Third pressure reduction
Graphic Color Codes (E) Orange...........................Pilot, signal or torque converter oil
(F) Orange Stripes and White Stripes ..................Reduced pilot,
signal or torque converter oil
(G) Blue.................................................................. Trapped oil

(H) Green ............................................ Tank, sump or return oil

(I) Brown ............................................................. Lubricating oil

(J) Orange Crosshatch ........................... Second reduction in
pilot, signal or torque converter oil
(K) Yellow............................ Moving or activated components
(L) Purple ............................................... Pneumatic pressure
(M) Light Gray..................................................... Surface color
Note: The information that is covered in this manual
may not require all of the colors in Illustration 1.

Illustration 1 g01023555
4 31200273
Systems Operation Section

General Information action allows the wheels to turn in the desired

direction.
Note: The steering mode and the direction of the
Steering Arrangement rotation of the steering wheel will determine the
direction of movement of the wheels.
The machine may be operated in the following three
steering modes:
• Two-wheel steer
• Circle steer
• Crab steer
Two-wheel Steer
When the machine is operated in two-wheel steer, the
front wheels are the only active steering wheels. The
rear wheels must be in a straight ahead position for
proper operation of two-wheel steer. This mode is the
only acceptable mode for roading the machine.
Circle Steer
All wheels are steered in this mode. The rear wheels
are steered in the opposite direction to the front
wheels. This mode provides a shorter turning radius for
turns in tight areas.
Crab Steer
All wheels are steered in this mode. The rear wheels
are steered in the same direction as the front wheels.
This mode enables the machine to move in a sideways
manner for maneuverability in confined areas.
There are two different arrangements for the
steering modes.
• Manually aligned rear wheels
• Self-aligning steering
Some machines are equipped with a self-aligning
feature for the front wheels and the rear wheels. This
feature helps to align the wheels in a straight ahead
position. The alignment of the wheels is necessary in
order to properly operate the machine in two-wheel
Illustration 2 g00737628 steer. In addition, the wheels must be aligned when you
(1) Front axle switch modes from crab steer to circle steer and from
(2) Front steering cylinder
circle steer to crab steer. On machines that do not have
(3) Tie rod
the self-aligning feature, the wheels must be manually
(4) Steering case
(5) Pivot pin
aligned by using the various steering modes.
(6) Rear steering cylinder Reference: See the Operation and Maintenance
(7) Rear axle Manual, "Steering Mode Control" for additional
Front axle (1) and rear axle (7) have similar steering information on the operation of the switches.
arrangements. Front steering cylinder (2) and rear
steering cylinder (6) are an integral part of each axle
housing. Each cylinder is equipped with two tie rods
(3). Each tie rod is mounted to steering case (4) at
each wheel. When the steering wheel is being turned,
hydraulic oil forces steering cylinders to move tie rods
(3). The tie rods act on steering cases (4). The steering
cases rotate on pivot pins (5) at each wheel. This
31200273 5
Systems Operation Section

Manually Aligned Rear Wheels When the bottom of the switch is depressed, the
contacts for circle steer close. A signal is sent to the
machine ECM. The machine ECM sends power to the
solenoid for circle steer which is mounted on the control
valve for the steering mode. The energized solenoid
shifts the spool in order to allow oil flow to the rear steer
cylinder for circle steer. Indicator light (9) for circle steer
will illuminate when this mode is selected.
Machines With Self-Aligning Steering
The machine may be equipped with self-aligning
steering. The self-aligning feature ensures that the front
wheels and the rear wheels are aligned before the
steering mode is changed.
Illustration 3 g01006730 When steering mode switch (8) is pressed by the
(8) Mode select switch operator, the machine will not change to the desired
steering mode unless the front wheels and the rear
wheels are in the straight ahead position.
If steering mode switch (8) is pressed by the operator
Mode select switch (8) - This switch is a three- and the wheels of the machine are not aligned, the
position switch that controls the steering mode. The current steering mode will remain selected. The
mode select switch allows the machine to travel in two- indicator for the current steering mode on the display
wheel steer, in crab steer, or in circle steer. panel will remain ON, and the desired mode indicator
Note: Always move the front wheels and the rear will flash. When the front wheels and the rear wheels
wheels to the straight ahead position before you are moved to the straight ahead position by the
change the steering mode. operator, the steering mode will then change to the
desired mode.

Illustration 4 g00866446
(9) Indicator for circle steer
(10) Indicator for crab steer
(11) Indicator for two-wheel steer
When the top of mode select switch (8) is depressed,
the contacts for crab steer close. A signal is sent to the
machine electronic control module (ECM). The
machine ECM sends power to the solenoid for crab
steer which is mounted on the control valve for the
steering mode. The energized solenoid shifts the spool
in order to allow oil flow to the rear steering cylinder for
crab steer. Indicator light (10) for crab steer will
illuminate when this mode is selected.
When the switch is in the center position, the contacts
are open and the solenoids on the control valve for the
steering mode will not be energized. This will allow the
machine to operate in two-wheel steer. Indicator (11)
will illuminate when this mode is selected.
6 31200273
Systems Operation Section

Introduction

Illustration 5 g00902881

This module discusses the features and operation of

the steering system. The following Telehandlers are
covered in this module:
• TH220B
• TH330B
• TH360B
• TH560B
• TH580B
The steering system on these machines has the
following modes of operation:
• Two-wheel steer
• Circle steer
• Crab steer
Some machines are equipped with a self-aligning
feature for the front wheels and the rear wheels.
31200273 7
Systems Operation Section

Location of Electrical Selector Switch for the Steering

Components Mode
The steering system consists of the following
electronic components:
• Selector switch for the steering mode
• Position sensor
• Electronic control module (ECM)
• Solenoid for crab steer
• Solenoid for circle steer
• Relay for crab steer
• Relay for circle steer

Illustration 7 g01023564
Steering selector switch (1) is located to the left of the
instrument panel inside the cab. The selector switch for
the steering mode is an input to the Electronic Control
Module that controls the steering mode.

Position Sensors

Illustration 8 g00866458
Front Position Sensor

Illustration 6 g00878479
(1) Selector switch for the steering mode
(2) Position sensors
(3) Electronic control module
(4) Solenoid for crab steer
(5) Solenoid for circle steer
(6) Relay for crab steer
(7) Relay for circle steer

Illustration 9 g00903910
Rear Position Sensor
Machines with self-aligning steering are equipped with
two steering position sensors (2). One position sensor
is attached to the front steering cylinder. The sensor
sends a signal to the ECM when the front wheels are
in the centered position. The other position sensor is
8 31200273
Systems Operation Section

attached to the rear steering cylinder. The sensor sends Reference: See Systems Operation/Testing and
a signal to the ECM when the rear wheels are in the Adjusting, "Control Valve (Steering Mode)" for more
centered position. information.
Reference: See Systems Operation/Testing and
Adjusting, "Position Sensor (Steering)" for more Solenoid for Circle Steer
information.

Electronic Control Module

Illustration 12 g00903921
On/Off solenoid (5) for circle steer is located at the front
of the cab. Remove the cover from the front of the cab
in order to gain access to the solenoid for circle steer.
The solenoid for circle steer is attached to the control
valve for the steering mode. The solenoid for circle
steer shifts the control valve for the steering mode.
Reference: See Systems Operation/Testing and
Adjusting, "Control Valve (Steering Mode)" for more
Illustration 10 g00986607 information.
Electronic Control Module (ECM) (3) is mounted to the
inner fender under the engine hood. The ECM controls Relay (Crab Steer)
most of the functions of the machine.
Reference: See Systems Operation/Testing and
Adjusting, "Electronic Control Module" for more
information.

Solenoid for Crab Steer

Illustration 13 g00943694
Relay (6) for the crab steer is located in the fuse panel.
The fuse panel is located behind an access cover in the
left side of the cab arrangement. The relay for crab
steer enables the solenoid for crab steer to be
energized.
Illustration 11 g00903915 Reference: See Systems Operation/Testing and
On/Off solenoid (4) for crab steer is located at the front Adjusting, "Electrical Output Components" for more
information.
of the cab. Remove the cover from the front of the cab
in order to gain access to the solenoid for circle steer.
The solenoid for crab steer is attached to the control
valve for the steering mode. The solenoid for crab steer
shifts the control valve for the steering mode.
31200273 9
Systems Operation Section

Relay (Circle Steer)

Illustration 14 g00943695
Relay (7) for the circle steer is located in the fuse
panel. The fuse panel is located behind an access
cover in the left side of the cab arrangement. The relay
for circle steer enables the solenoid for circle steer to be
energized.
Reference: See Systems Operation/Testing and
Adjusting, "Electrical Output Components" for more
information.

Location of Hydraulic Illustration 15 g00878481

Components (1) Steering wheel

(2) Metering pump
The steering system consists of the following hydraulic (3) Piston pump

components: (5) Priority valve on the main control valve (implement)

(6) Control valve for the steering mode
• Steering wheel (7) Steering cylinders

• Metering pump (8) Hydraulic tank

(9) Hydraulic tank breather
• Piston pump (10) Hydraulic oil level indicator

• Line for the Signal Limiter Valve for the Steering

Steering Wheel
• Priority valve
• Control valve for the steering mode
• Steering cylinders
• Hydraulic tank
• Hydraulic tank breather
• Hydraulic oil level indicator
• Hydraulic oil drain plugs

Illustration 16 g00866825
Steering wheel (1) is located in the center of the main
operator console. The steering wheel provides input to
the metering pump in order to control the direction of the
machine.
10 31200273
Systems Operation Section

Metering Pump Line for the Signal Limiter Valve for

the Steering

Illustration 17 g00903734
Metering pump (2) is located at the front of the cab at
Illustration 19 g00874759
the end of the steering rod. Remove the cover from the
front of the cab in order to gain access to the metering The line for the signal limiter valve (4) is located at the
pump. The metering pump directs oil flow to the front of the cab on the left side of the metering pump.
steering cylinders. Remove the cover from the front of the cab in order to
gain access to the line for the signal limiter valve.
Reference: See Systems Operation/Testing and
Adjusting, "Metering Pump (Steering)" for more
information. Priority Valve

Piston Pump

Illustration 20 g00866827
Priority valve (5) is located on the inlet manifold on the
main control valve. Remove the cover from left side of
Illustration 18 g00866455 the machine in order to gain access to the priority
Piston pump (3) is located underneath the valve. The priority valve gives priority to the steering
transmission in the engine enclosure. The piston pump system over the implement system regarding hydraulic
provides hydraulic oil flow to the steering and implement oil flow. The priority valve directs hydraulic oil flow to the
systems. steering system when the steering system requires oil
Reference: See Systems Operation/Testing and flow.
Adjusting, "Piston Pump (Implement and Steering)" for Reference: See Systems Operation/Testing and
more information. Adjusting, "Inlet Manifold" for more information.
31200273 11
Systems Operation Section

Control Valve (Steering) Hydraulic Tank

Illustration 23 g00870517
Illustration 21 g00903903 Hydraulic tank (8) is located on the left side of the
Control valve (6) for the steering mode is located at the machine behind the cab. The hydraulic tank provides a
front of the cab, next to the metering pump. Remove reservoir for the hydraulic oil.
the cover from the front of the cab in order to gain
access to the control valve for the steering mode. The Hydraulic Tank Breather
control valve for the steering mode directs oil flow for the
various modes of steering operation.
Reference: See Systems Operation/Testing and
Adjusting, "Control Valve (Steering)" for more
information.

Steering Cylinders

Illustration 24 g00870519
Breather (9) for the hydraulic tank is located on top of
the hydraulic tank under the windshield washer
reservoir. The hydraulic tank breather vents the tank to
the atmosphere.

Illustration 22 g00870515

Steering cylinders (7) are attached to the front axle

housing and the rear axle housing. The steering
cylinders are used in order to turn the tires.
12 31200273
Systems Operation Section

Hydraulic Oil Level Indicator Electrical Input Components

Illustration 25 g00870523

Hydraulic oil level indicator (10) is located on the left

side of the machine behind a protection cover. The
hydraulic oil level indicator allows the level of the
hydraulic oil tank to be observed.
Illustration 28 g00943697

Hydraulic Oil Drain Plugs

Steering Mode Switch
There are two drain plugs for the hydraulic oil system.
The drain plugs allow the hydraulic oil to be drained.

Illustration 26 g00870527
Hydraulic tank drain plug (11) is located on the bottom
of the hydraulic tank.

Illustration 29 g00926215
The steering mode switch is a three-position switch.
The three steering modes crab steer mode, front steer
mode, and circle steer mode.
A faulty switch can be detected due to the signal
pattern of the switch. The CID fault code is number 750
and the FMI code is number 02.

Illustration 27 g00870538
Transmission drain plug (12) is located on the bottom of
the transmission housing. The transmission drain plug
allows the transmission oil to be drained.
31200273 13
Systems Operation Section

Position Sensor right side of the machine inside the engine

compartment. The ECM sends the information to the
Caterpillar Electronic Technician on the CAT data link.
Note: The ECM is not serviceable. The ECM must be
replaced if the ECM is damaged. Replace the ECM if a
failure is diagnosed.
Inputs
The inputs describe the status of the machine
systems. Two types of inputs exist. The inputs can be
either a switch type or a sensor type. Switches provide
an open, a ground, or a + battery signal to the inputs of
the controller. Sensors (frequency, PWM or voltage)
provide a changing signal to the sensor inputs of the
controller. The inputs to the machine ECM are listed in
table 1.
Outputs
The ECM responds to decisions by sending electrical
signals to the outputs. The outputs can create an
Illustration 30 g00926252
action or the outputs can provide information to the
The position sensors are a requirement of the auto operator or the service technician. The outputs of the
align function. There are two steering position sensors. machine ECM are listed in table 1.
One is located on the front axle and the other sensor is Input/Output
located on the rear axle. The sensors are magnetic
position sensors that send a signal to the ECM when The CAT data link is used in order to provide a
the sensors are in the centered position. connection for the service tool for troubleshooting,
testing, and calibrations. The data link is bidirectional.
The data link allows the ECM to receive information.
Electronic Control Module The data link allows the ECM to send information.
Table 1

Contact Description J2(1)

No.( Function Type
5 Relay (Circle Steer) On/Off
6 Relay (Crab Steer) On/Off
Switch (Rear Axle
24 Switch to Ground
Align)
Switch (Steer Mode
25 Switch to Ground
Select - Front)
Switch (Steer Mode
26 Switch to Ground
Select - Circle)
Switch (Steer Mode
27 Switch to Ground
Select - Crab)
Switch (Front Axle
28 Switch to Ground
Align)

(1) The ECM responds to an active input only when all the
Illustration 31 g00785019
necessary conditions are satisfied.
Electronic Control Module (ECM)
(2) The connector contacts that are not listed are not used.
The electronic control module (ECM) makes decisions
that are based on input information and memory
information. After the ECM receives the input
information, the ECM sends a corresponding response
to the outputs. The inputs and outputs of the ECM are
connected to the machine harness by two 70 contact
connectors (J1 and J2). The ECM is located on the
14 31200273
Systems Operation Section

Electrical Output Components Data Link

Illustration 32 g00900637

Relays

Illustration 34 g00991545

CAT Data Link

The data link is an input and an output of the ECM. The
data link is designed to communicate with other
electronic control modules through the machine
harness. The data link is not a visible component. The
data link consists of internal ECM circuits and the
connecting harness wiring. The data link is
bidirectional. The data link allows the ECM to receive
Illustration 33 g00900769 information and the data link allows the ECM to send
information.
Relay (Circle Steer) and Relay (Crab Steer) Caterpillar Electronic Technician (ET) also
communicates with other ECM modules through the
These relays will energize the solenoids that will direct
data link. The ET will list the other ECM modules and
the pressure to the appropriate control valve for the
the available diagnostic information.
desired steering mode. The relay connects to the ECM
through contact J2-5, contact J2-6, and contact J2-8. Note: All electronic control modules (ECM) that use the
data link have a module identifier (MID). The MID is
Instrument Cluster listed for each module:
Machine ECM ................................................................... 039
The indicators for the steering system are located
Shift Lever.......................................................................................................117
within the Instrument Cluster (IC). The machine ECM
communicates to the IC over the CAN data link. See
the appropriate Service Manual for additional
information.
31200273 15
Systems Operation Section

CAN Data Link

The CAN Data Link is used in order to aid the machine
ECM with the control of the transmission. The CAN data
link is used for communication with the display module.

Electrical Schematic
This is a simplified schematic of the steering system for
the machine ECM. This schematic does not show all
possible harness connectors. See the appropriate
Electrical Schematic, for an accurate schematic of the
machine.

Illustration 35 g00900807

Inlet Manifold
Reference: See Systems Operation/Testing and
Adjusting, "Location of Hydraulic Components" for the
location of the inlet manifold on the implement control
valve.
The inlet manifold includes the following
components:
• Valve Assembly (Steering priority)
• Screens (75 and 100 micron)
• Relief Valve (load sensing oil)
• Flow Control Valve (Dump valve for the load
sensing oil)
Illustration 36 g00904260 • Check valves
The inlet manifold is part of the main control valve
(implement).
16 31200273
Systems Operation Section

Steering Priority Valve

The flow of oil from the hydraulic piston pump is
prioritized by the steering priority valve. The priority
valve satisfies the demands from the steering system
before the demands from the implement system.

Screens (75 and 100 Micron)

The inlet section of the main control valve (implement)
contains three screens. The screens are dedicated to
the following circuits:
• The system for the pilot supply (75 micron)
• Load sensing oil system for the priority valve (100
micron)
• Drain for the load sensing oil for the implement
system (100 micron)

Flow Control Valve (Dump valve for

the load sensing oil)
The Flow Control Valve is installed in order to provide a
drain back to the hydraulic tank for the load sensing
signal once the load has been reduced on the machine
requirements. The signal drain valve is pressure
compensated.

Relief Valve (Load sensing oil)

The Relief valve (Load sensing oil) is the main
implement pressure relief valve for the hydraulic
system. The signal limiter valve limits the maximum
pressure in the load signal system. The relief valve has
a pressure setting of 22800 kPa (3300 psi).

Check Valve
When the spool in the steering priority valve moves up,
pressure from the top side of the spool is exhausted
through the check valve. Systems Operation Section
31200273 17
Systems Operation Section

Steering Not Activated

Illustration 37 g01023649
This schematic shows the steering priority valve in operation.
(1) Check valve (8) Screen (15) Line to implement system
(2) Line to implement system (9) Orifice (16) Tank
(3) Valve As (Steering Priority) (10) Line to metering pump (17) Check valve (Return oil back pressure)
(4) Return oil from implement system (11) Pump supply (18) Flow Control Valve GP (Dump valve for the load sensing oil)
(5) Spring (12) Load sensing oil from implements
(6) Orifice (13) Load sensing oil from implement system
(7) Line to metering pump (14) Relief valve (Load sensing oil)

When the steering wheel is stationary, there is no supply passage to the metering pump. Some of the oil
demand from the metering pump for oil. The spool in the through orifice (9) acts with spring (5) in order to work
steering metering unit is spring centered and the oil is against the pressure above priority valve (3). When
blocked at the spool. This causes an increase in steering is activated there is instant response from the
pressure in supply line (10) to the metering pump. The metering pump.
increased pressure acts upon the top of the priority Some oil in Passage (7) opens check valve (19) and the
valve spool. The spool proportionally moves down oil enters the load sensing line (20). The oil in the load
against the force of spring (5). The mid-position of the sensing oil pressure line (20) flows to the pump
spool allows oil flow to the steering system and to the compensator and the oil causes the pump to upstroke
implement control system. Further movement of the slightly. The upstroke of the pump will increase the low
spool in the steering priority valve closes off the majority pressure standby. The higher low pressure standby
of the supply of oil to the steering system. Most of the pressure maintains the pilot supply pressure for the
oil flow through the priority valve is then supplied to the valves of the pilot hydraulic system.
implement system through line (15).
Orifice (6) and orifice (9) allow a small leakage from
supply line (10) back to the hydraulic tank. This
leakage prevents Priority Valve (3) from closing off the
18 31200273
Systems Operation Section

Steering Activated

Illustration 38 g01016788
This schematic shows the steering priority valve in operation.
(1) Check valve (8) Screen (15) Line to implement system
(2) Line to implement system (9) Orifice (16) Tank
(3) Valve As (Steering Priority) (10) Line to metering pump (17) Check valve (Return oil back pressure)
(4) Return oil from implement system (11) Pump supply (18) Flow Control Valve GP (Dump valve for the load sensing oil)
(5) Spring (12) Load sensing oil from implements
(6) Orifice (13) Load sensing oil from implement system
(7) Line to metering pump (14) Relief valve (Load sensing oil)

When the steering wheel is turned, there is a pressure meet the demand for steering flow. This causes the
drop in passage (7). Due to the leakage oil past orifice hydraulic flow to the metering pump to increase.
(9) and the force of spring (5), the priority valve (3) The oil from the piston pump is directed to the
moves up rapidly in order to direct supply oil in passage metering unit through line (7). When the steering wheel
(11) to the metering pump (7). is turned faster, the pressure increases in load signal
The flow of oil in line (7) is also blocked at the line (7). The pressure determines the amount of
metering pump. This causes a buildup of pressure in proportional movement of the priority valve spool.
line (7). The pressure in the form of a load sensing If the steering system and another implement are used
signal is transmitted through line (7) to a chamber at the at the same time, the priority valve can supply oil to
bottom of steering priority valve (3). Also, oil flows both the metering unit and the main control valve
through Check Valve (9) into signal line (19) in order to
signal the pump. The pump increases flow in order to
31200273 19
Systems Operation Section

(implement) once the requirements of the steering flow

are met.

Steering System
Steering Control System
The hydraulic pump for the steering system is a
variable displacement axial piston type. The pump
output is matched to system requirements by a priority
valve in the inlet manifold on the main control valve.
The priority valve in the inlet manifold is connected by
a line to the metering pump.
The control valve for the steering mode is a three-
position solenoid operated valve which controls the
steering modes.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Hydraulic Components" for the
location of the hydraulic components in the steering
system.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Electrical Components" for the
location of the electrical components in the steering
system.
Reference: See Systems Operation/Testing and
Adjusting, "Piston Pump (Implement and Steering)" for
operating information.
Reference: See Systems Operation/Testing and
Adjusting, "Steering Valve (Steering Mode Selector)" for
operating information.
Reference: See Operation and Maintenance Manual,
"Steering Mode" for the operating information of the
modes.
The four schematics show the Steering System in
the following modes of operation:
• Steering in neutral
• Right Turn in Two-Wheel Steer Mode
• Left Turn in Circle Steer Mode
• Left Turn in Crab Steer Mode
20 31200273
Systems Operation Section

Steering in Neutral

Illustration 39 g01023657
(1) Front steering cylinder (10) Oil flow to pilot valve (19) Front axle
(2) Rear steering cylinder (11) Oil flow from implement valve (20) Rear axle
(3) Inlet manifold (12) Signal from implement valve (21) Signal limiter valve (steering)
(4) Priority valve (13) Oil flow from control valve (22) Orifice
(5) Main control valve (implement) (14) Signal drain valve (23) Signal line
(6) Signal limiter valve (implement) (15) Return to tank (24) Check Valve
(7) Steering selector valve (16) Load signal to pump (25) Orifice
(8) Gerotor pump (17) Supply from pump
(9) Metering pump (18) Return to tank
31200273 21
Systems Operation Section

When the steering wheel is stationary the main supply of

oil from priority valve (4) is blocked at the spool in the
metering pump and there is no flow to the steering
cylinders. When the steering is not in operation, a
small amount of supply oil flows through orifice (22)
and orifice (25). The orifices allow a constant flow of
hydraulic oil to flow through signal line (23) to the
metering pump and to the tank when the steering
wheel is stationary. This leakage prevents the priority
valve from closing off the supply passage to the
metering pump. When steering is activated there is an
instant response from the metering pump.
Some oil in Passage (8) opens check valve (24) and the
oil enters signal line (2). The oil in signal line (2) flows to
the pump compensator and the oil causes the pump to
upstroke slightly. The upstroke of the pump will
increase the low pressure standby. The higher low
pressure standby pressure maintains the pilot supply
pressure for the valves of the pilot hydraulic system.
22 31200273
Systems Operation Section

Right Turn in Two-Wheel Steer Mode

Illustration 40 g01023692
(1) Front steering cylinder (10) Oil flow to pilot valve (19) Front axle
(2) Rear steering cylinder (11) Oil flow from implement valve (20) Rear axle
(3) Inlet manifold (12) Signal from implement valve (21) Signal limiter valve (steering)
(4) Priority valve (13) Oil flow from control valve (22) Orifice
(5) Main control valve (implement) (14) Signal drain valve (23) Signal line
(6) Signal limiter valve (implement) (15) Return to tank (24) Check Valve
(7) Steering selector valve (16) Load signal to pump (25) Orifice
(8) Gerotor pump (17) Supply from pump
(9) Metering pump (18) Return to tank
31200273 23
Systems Operation Section

When the mode select switch is in the center position,

the solenoids on steering selector valve (7) for the
steering mode are de-energized. The valve spool is
then centered by spring force, and the ports that
connect rear steering cylinder (2) are blocked. Oil that
is locked into the cylinder by the valve spool holds the
rear wheels in the straight ahead position and the rear
axle operates as a rigid axle.
When the steering wheel is turned, the priority valve (4)
moves in order to allow oil to flow into metering pump
(9). Also, oil flows through Check Valve (24) into signal
line (2) in order to signal the pump. The pump
increases flow in order to meet the demand for steering
flow. This causes the hydraulic flow to the metering
pump to increase. The oil from the piston pump is
directed to the metering pump.
When a right turn is made in two-wheel steer mode, oil
flows through gerotor pump (8), through steering
selector valve (7) for the steering mode, and to the right
side of front steering cylinder (1). Oil that enters the
cylinder causes the tie rods to move to the left. This
causes the wheels to move to the right. Oil in the left
side of the steering cylinder flows to the tank through
the metering pump.
If the steering cylinder reaches the end of the stroke
and the operator continues to turn the steering wheel,
pressure in the steering system will increase. The
increase in pressure causes signal limiter valve (21) in
metering pump (9) to open. The excess signal oil is
directed to the tank in order to relieve the pressure.
When the steering wheel is turned to the left the flow of
oil is reversed. Oil flows directly to the left side of the
steering cylinder and return oil is routed through the
control valve for the steering mode and back to the
tank.
Note: If the engine stops and the machine is in motion,
the machine can still be steered. When the steering
wheel is turned in this situation, the metering section of
hand metering pump (9) acts as a pump.
24 31200273
Systems Operation Section

Left Turn in Circle Steer Mode

Illustration 41 g01023711
(1) Front steering cylinder (10) Oil flow to pilot valve (19) Front axle
(2) Rear steering cylinder (11) Oil flow from implement valve (20) Rear axle
(3) Inlet manifold (12) Signal from implement valve (21) Signal limiter valve (steering)
(4) Priority valve (13) Oil flow from control valve (22) Orifice
(5) Main control valve (implement) (14) Signal drain valve (23) Signal line
(6) Signal limiter valve (implement) (15) Return to tank (24) Check Valve
(7) Steering selector valve (16) Load signal to pump (25) Orifice
(8) Gerotor pump (17) Supply from pump
(9) Metering pump (18) Return to tank
31200273 25
Systems Operation Section

When the bottom of the mode select switch is

depressed, and the circle steer mode is selected,
solenoid (A) on steering selector valve (7) for the
steering mode is energized. The valve spool is offset to
the circle steer position.
When the steering wheel is turned, the priority valve (4)
moves in order to allow oil to flow into metering pump
(9). Also, oil flows through Check Valve (24) into signal
line (2) in order to signal the pump. The pump
increases flow in order to meet the demand for steering
flow. This causes the hydraulic flow to the metering
pump to increase. The oil from the piston pump is
directed to the metering pump.
When a left turn is made in circle steer mode, oil flows
directly from gerotor pump (8) to the left side of front
steering cylinder (1). Oil that is displaced from the right
side of the front steering cylinder flows through steering
selector valve (7) for the steering mode to the left side
of rear steering cylinder (2).
Oil that is displaced from the right side of the rear
steering cylinder flows through steering selector valve
(7) for the steering mode, and metering pump (9) to the
tank. The front cylinder rods move to the right. This
causes the front wheels to pivot to the left. The rear
cylinder rods move to the right. This causes the rear
wheels to pivot to the right.
26 31200273
Systems Operation Section

Left Turn in Crab Steer Mode

Illustration 42 g01023720
(1) Front steering cylinder (10) Oil flow to pilot valve (19) Front axle
(2) Rear steering cylinder (11) Oil flow from implement valve (20) Rear axle
(3) Inlet manifold (12) Signal from implement valve (21) Signal limiter valve (steering)
(4) Priority valve (13) Oil flow from control valve (22) Orifice
(5) Main control valve (implement) (14) Signal drain valve (23) Signal line
(6) Signal limiter valve (implement) (15) Return to tank (24) Check Valve
(7) Steering selector valve (16) Load signal to pump (25) Orifice
(8) Gerotor pump (17) Supply from pump
(9) Metering pump (18) Return to tank
31200273 27
Systems Operation Section

Note: In crab steer, the front wheels and the rear

wheels turn in the same direction. Crab steer allows the
machine to move in a sideways manner for
maneuverability in confined areas.
When the top of the mode select switch is depressed,
and the crab steer mode is selected, solenoid (B) on
steering selector valve (7) for the steering mode is
energized. The valve spool is offset to the crab steer
position.
When the steering wheel is turned, the priority valve (4)
moves in order to allow oil to flow into metering pump
(9). Also, oil flows through Check Valve (24) into signal
line (2) in order to signal the pump. The pump
increases flow in order to meet the demand for steering
flow. This causes the hydraulic flow to the metering
pump to increase. The oil from the piston pump is
directed to the metering pump.
When the steering wheel is turned counterclockwise in
crab steer mode, oil flows directly from gerotor pump
(8) to the left side of front steering cylinder (1). Oil that is
displaced from the right side of the front steering
cylinder flows through the control valve for the steering
mode to the right side of rear steering cylinder (2).
Return oil from the left side of the rear cylinder flows to
the tank through steering selector valve (7) for the
steering mode and metering pump (9). The front steer
cylinder rods move to the right, and the rear cylinder
rods move to the left. This causes the front wheels and
the rear wheels to pivot to the left. All the wheels are
now turned in the same direction and all wheels are
steered.
28 31200273
Systems Operation Section

Hydraulic Schematic (Steering

System)

Illustration 43 g01023580
Steering system in neutral
(1) Steering line relief valves (11) Priority valve
(2) Front axle (12) Oil flow to pilot valve
(3) HAND metering unit (13) Oil flow from implement valve
(4) Front steering cylinder (14) Steering selector valve
(5) Rear steering cylinder (15) Signal from implement valve
(6) Rear axle (16) Signal limiter valve (implement)
(7) Gerotor pump (17) Signal drain valve
(8) Inlet Manifold (18) Oil flow to main control valve
(9) Main hydraulic control valve (24) Check Valve
(10) Signal limiter valve (steering) (25) Orifice
31200273 29
Systems Operation Section

Piston Pump (Implement and

Steering)
Piston Pump

Illustration 44 g01022614
Steering and Implement Pump (Engine Off)
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line to the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

Piston pump (1) has the following characteristics: Shaft (4) - The rotation of the pump is
• variable displacement counterclockwise when the pump is viewed from the
drive end. The piston and barrel assembly is splined to
• load sensing the drive shaft.
• compensation for pressure Bias spring (5) - If there is no pressure on the right
• compensation for flow side of the actuator piston, the bias spring will hold the
swashplate at the maximum angle.
This piston type pump has variable flow and pressure.
The flow and pressure are dependent on the system Swashplate (6) - The displacement of the pump is
demands that are sensed by pressure and flow controlled by the angle of the swashplate. The angle of
compensator valve (2). the swashplate causes the pistons to move in and out of
the rotating barrel.
Note: Load sensing oil pressure is sometimes referred
to as signal oil. The two terms have the same meaning Actuator piston (7) - When oil pressure increases
throughout this story. behind the actuator piston, the piston will overcome the
force of the bias spring. This causes the angle of the
The piston pump has the following components: swashplate to be reduced.
Piston and barrel assembly (3) - The cylinder barrel Pressure and flow compensator valve (2) - The
contains nine pistons. The cylinder barrel assembly
rotates whenever the engine is running. The pistons
move oil into the barrel and out of the barrel.
30 31200273
Systems Operation Section

pressure and flow compensator valve controls the 27500 ± 500 kPa (3988 ± 73 psi) if the load sensing oil
delivery of oil and the return of oil to the actuator relief valve fails.
piston. Pressure and flow compensator valve (2) has orifice
When the engine is OFF, pressure and flow (15) in the load sensing oil passage to actuator piston
compensator valve (2) does not receive load sensing oil (16). Orifice (15) is used in order to regulate the
pressure (8) or supply pressure from pump outlet (9). response rate of the actuator piston by creating a
Margin spring (10) pushes flow compensator spool consistent leak path.
(11) completely downward. Any pressure that is on the The load sensing oil relief valve in the TH330B is set at
right side of actuator piston (7) is vented to the case 22800 kPa (3300 psi) and the margin pressure is set at
drain across flow compensator spool (11). 2200 kPa (320 psi). The maximum system pressure is
When there is no pressure behind actuator piston (7), 25000 ± 500 kPa (3625 ± 75 psi).
bias spring (5) is able to hold swashplate (6) at the Pressure compensator spool (14) is used as a backup
maximum angle. to limit the maximum system pressure to
When the engine is started, shaft (4) starts to rotate. Oil 27500 ± 500 kPa (3988 ± 73 psi) on the TH220B and
flows into the piston bore from pump inlet (12). Oil is 26000 ± 500 kPa (3770 ± 73 psi) on the TH330B if the
forced out of pump outlet (9) and into the system as the load sensing oil relief valve fails.
piston and barrel assembly (3) rotates. Note: If the load sensing oil relief valve is operating
correctly the load sensing oil relief valve controls the
Compensator Valve maximum system pressure. Maximum system
pressure should be the pressure of the load sensing oil
Pressure and flow compensator valve (2) is bolted to relief valve plus the margin pressure. If the load
the top of the piston pump. Pressure and flow sensing oil relief valve is not adjusted correctly the
compensator valve (2) compensates for pressure pressure compensator acts as a backup.
variations and flow variations in the implement
hydraulic system in order to meet the system
demands.
Flow compensator spool (11) regulates the pump
output flow in response to the following oil
pressures:
• Load sensing oil pressure (8)
• Supply pressure from pump outlet (9)
The load sensing oil is received through the load
sensing oil control network for the pump.
The flow that is supplied by the hydraulic pump is the
amount that is required in order to keep the supply
pressure 2200 ± 100 kPa (320 ± 15 psi) above the
load sensing oil pressure (8). The difference between
load sensing oil pressure (8) from the main hydraulic
control valve and the supply pressure from pump outlet
(9) is called the margin pressure. Flow compensator
spool (11) controls the margin pressure.
Margin pressure is equal to the spring force value of
margin spring (10).
The margin pressure is adjusted by turning adjusting
screw (13) on flow compensator spool (11).
Note: The maximum system pressure is controlled by
the load sensing oil relief valve and the margin
pressure. The load sensing oil relief valve in the
TH220B is set at 24300 kPa (3524 psi) and the margin
pressure is set at 2200 kPa (320 psi). The maximum
system pressure is 26500 ± 500 kPa (3843 ± 75 psi).

Pressure compensator spool (14) is used as a backup

to limit the maximum system pressure to
31200273 31
Systems Operation Section

Low Pressure Standby

Illustration 45 g01022627
Steering and Implement Pump (Low pressure Standby)
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line to the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

When piston pump (1) produces flow, the system Even when no implements are being used, the steering
pressure begins to increase because the oil flow from system maintains a load sensing oil to the pump.
pump outlet (9) is blocked at the closed center The pressure at pump outlet (9) must overcome the
implement control valves. force of margin spring (10) and the dynamic bleed
The supply pressure from pump outlet (9) is felt at the signal. Pressure at pump outlet (9) is called "low
bottom end of flow compensator spool (11). The supply pressure standby". Low pressure standby is
pressure from pump outlet (9) is greater than the approximately 4500 kPa (650 psi).
combined pressure of load sensing oil pressure (8) and The low pressure standby is higher than the margin
margin spring (10). The flow compensator spool moves pressure. The higher pressure is needed to maintain the
upward against the margin spring. This permits system pilot pressure.
oil to flow to actuator piston (7).
When piston pump (1) is at low pressure standby, the
When the pressure on actuator piston (7) increases, the supply pressure from pump outlet (9) raises flow
force of bias spring (5) is overcome and swashplate compensator spool (11) higher. This will further
(6) is moved to a slight angle. compress margin spring (10). An increased amount of
Piston pump (1) produces enough flow in order to supply oil from pump outlet (9) will flow to actuator
compensate for normal system leakage when piston (7). This will slightly destroke the hydraulic
swashplate (6) is at a slight angle. Also, the piston pump.
pump has sufficient pressure in order to provide The low pressure standby can be adjusted by
instantaneous response when an implement is changing the setting of the margin spring.
activated.
32 31200273
Systems Operation Section

Upstroke

Illustration 46 g01022648
Steering and Implement Pump (Upstroke)
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line to the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

When an implement hydraulic circuit requires flow, the • The hydraulic pump will upstroke when the flow
pressure from pump outlet (9) is reduced. The force of demand increases from changing the position of
margin spring (10) and load sensing oil pressure (8) is the main control spool in a hydraulic control valve.
greater than supply pressure from pump outlet (9). The • If another implement hydraulic circuit is engaged,
overall force is on the top end of flow compensator there is a need for increased pump flow.
spool (11).
• If the flow demand on the implement hydraulic
The spool moves down. The spool blocks the flow of oil
system remains constant or the flow demand
to actuator piston (7). Oil that is in the chamber for
increases, the hydraulic pump will upstroke when
actuator piston (7) is vented to the case drain across
the engine speed decreases.
flow compensator spool (11). This allows bias spring (5)
to move swashplate (6) to a greater angle. Note: The load sensing oil pressure does not need to
increase in order to upstroke the hydraulic pump.
The pump now produces more flow. This condition is
known as "upstroking". For example, if one implement hydraulic circuit is
activated at an operating pressure of 13800 kPa (2000
The following conditions can result in upstroking
psi), the system pressure is 16000 kPa (2320 psi). The
the pump:
pressure of 16000 kPa (2320 psi) is a combination of the
• If an implement hydraulic circuit is initially activated margin pressure and the pressure of the load sensing
from low pressure standby, the load sensing load oil.
sensing oil increases the pump output flow. This
increased pump output flow is routed to the position If another implement hydraulic circuit is activated at an
of a main control spool of a hydraulic control valve initial operating pressure of 6900 kPa (1000 psi), the
that demands the oil. maximum pressure of the load sensing oil will still be
31200273 33
Systems Operation Section

13800 kPa (2000 psi). The supply oil pressure will

decrease momentarily.
The combined force of the load sensing oil pressure (8)
and margin spring (10) is now higher than the supply
pressure from pump outlet (9) at the bottom end of the
spool. Flow compensator spool (11) is pushed to the
bottom. This allows oil that is behind actuator piston (7)
to be vented to the case drain. The angle of swashplate
(6) now increases and the hydraulic pump provides
more flow in order to meet the flow demands of both
circuits.

Constant Flow

Illustration 47 g01022658
Steering and Implement Pump (Constant Flow)
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line to the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

As the pump increases flow or decreases flow in order • Supply pressure from pump outlet (9)
to match the change in the flow requirements, the Once the pressures become equal on each end of the
forces above the flow compensator spool and below spool, flow compensator spool (11) will meter oil to
the flow compensator spool will equalize. actuator piston (7). Bias spring (5) will be compressed
The following pressures will act on the top end of and the system will stabilize.
flow compensator spool (11):
Swashplate (6) is held at a relative constant angle in
• Margin spring (10) order to maintain the required flow.
• Load sensing oil pressure (8)
The following pressure will act on the bottom end of
flow compensator spool (11):
34 31200273
Systems Operation Section

Destroke

Illustration 48 g01022669
Steering and Implement Pump (Destroke)
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line to the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

When less flow is required, piston pump (1) destrokes. • If the main control spool for a hydraulic control
The piston pump destrokes when the supply pressure valve is moved to a position that requires less flow,
from pump outlet (9) becomes greater than the the hydraulic pump will destroke.
combined pressure of load sensing oil pressure (8) and
• If multiple hydraulic control valves are being used,
margin spring (10).
the hydraulic pump will destroke when there is
Flow compensator spool (11) is raised. This allows
• a reduction in flow demand from any one of the
more oil flow to actuator piston (7). Pressure on
hydraulic control valves.
actuator piston (7) is now increased.
• •If the engine speed increases, the piston pump
The increased pressure overcomes the force of bias
destrokes.
spring (5) which moves swashplate (6) to a reduced
angle. When the supply pressure at pump outlet (9) When the piston pump destrokes, supply oil pressure
matches the combined pressure of load sensing oil from pump outlet (9) decreases on the bottom side of
pressure (8) and margin spring (10), the flow flow compensator spool (11).
compensator spool returns to a metering position. The force on the top of flow compensator spool (11)
Piston pump (1) will return to a constant flow. is the sum of the following pressures:
The following conditions result in destroking the • Margin spring (10)
pump:
• Load sensing oil pressure (8)
• When a main control spool for a hydraulic control
valve is moved to the HOLD position the hydraulic The following force acts on the bottom of flow
pump will destroke. compensator spool (11):
• Supply pressure at pump outlet (9)
31200273 35
Systems Operation Section

Once the forces become equal on each end of the

spool, flow compensator spool (11) will meter oil to
actuator piston (7) and the system will stabilize. The
system will provide a constant flow until the flow
requirements change.
Note: Load sensing oil pressure (8) does not need to
decrease in order to destroke the hydraulic pump.
For example, if two implement hydraulic circuits are
activated at operating pressures of 13800 kPa (2000
psi) and 6900 kPa (1000 psi), the system pressure is
16000 kPa (2320 psi).
If the implement hydraulic circuit which is activated at
6900 kPa (1000 psi) is returned to the HOLD position, the
maximum load sensing oil pressure (8) will still be 13800
kPa (2000 psi). However, the supply pressure at pump
outlet (9) is momentarily increased due to the reduced
oil flow that is required in the implement hydraulic
circuits.
Supply pressure at pump outlet (9) raises flow
compensator spool (11). This allows more oil flow
behind actuator piston (7). The angle of swashplate (6)
now decreases and the hydraulic pump provides less
flow.
36 31200273
Systems Operation Section

High Pressure Stall

Illustration 49 g01022710
Steering and Implement Pump (Maximum System Pressure)
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
(2) Compensator Valve (9) Pump Outlet (16) Passage to Actuator Piston
(3) Piston and Barrel Assembly (10) Margin Spring (17) Line to the Control Valve Group
(4) Shaft (11) Margin Spool (18) Orifice
(5) Bias Spring (12) Pump Inlet (19) Passage
(6) Swashplate (13) Adjusting Screw
(7) Actuator Piston (14) Pressure Cutoff Spool

Note: Relief Valve (Load sensing oil) is sometimes If the load sensing oil relief valve (20) is not adjusted
referred to as the signal limiter valve. The two terms correctly, pressure compensator spool (14) serves as a
have the same meaning throughout this story. backup relief in order to protect the hydraulic system.
Note: This condition will only occur when the load At high pressure stall, the piston pump is at minimum
sensing oil relief valve is set below the valve of the flow and the supply oil at pump outlet (9) is at
pressure compensator. maximum pressure. These conditions are maintained for
If piston pump (1) is at a high pressure stall or a single implement in a stall condition.
maximum system pressure, the combined pressure of If multiple implement hydraulic circuits are activated and
load sensing oil pressure (8) and margin spring (10) is one circuit is at a stall, the piston pump (1) will
equal to the supply pressure at pump outlet (9). upstroke in order to meet the increased flow demands.
Load sensing oil relief valve (20) limits the maximum This flow meets the needs of the other circuits that are
system pressure at any pump displacement. Load operating at a lower work port pressure.
sensing oil relief valve (20) is set at 22800 kPa (3300
psi).
A margin pressure of 2200 ± 100 kPa (320 ± 15 psi)
above the load sensing oil is still maintained while i02141790
piston pump (1) is at a high pressure stall.
If the piston pump is at a high pressure stall, the
maximum system pressure will be 26500 ± 500 kPa
(3843 ± 75 psi) for the TH220B and 25000 ± 500 kPa
(3625 ± 75 psi) for the TH330B.
31200273 37
Systems Operation Section

Solenoid Valve (Steering Mode

Selector)
Solenoid Valve
The solenoid valve controls oil flow to the rear steering
cylinder. The solenoids are controlled by the switch for
the steering mode that is located on the dash panel.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Hydraulic Components" for the
location of the control valve.
Reference: See Operation and Maintenance Manual,
"Steering Mode" for the operating information of the
steering modes.
Reference: See Systems Operation/Testing and
Adjusting, "Steering System" for further information on
the control valve for the steering modes.
The solenoid valve has the following
characteristics:
• Three-position
• Spring centered valve
• Solenoid operated valve

Metering Pump (Steering)

Illustration 50 g00740715
(A) Control section
(B) Metering section
(1) Spool
(2) Sleeve
(3) Outlet to the tank
(4) Makeup valve
(5) Inlet (pump supply from priority valve)
(6) Check valve
(7) Rotor
(8) Stator
(9) Centering springs
(10) Drive pin
(11) Left turn port
(12) Right turn port
(13) Body
(14) Drive shaft
(15) Signal port
38 31200273
Systems Operation Section

The steering metering pump consists of the

following two sections:
• Control section (A)
• Metering section (B)
Section (A) contains a closed center rotary control
valve. Metering section (B) is a gerotor pump.

Illustration 51 g00744660
Spool and sleeve of the steering metering pump
(1) Spool
(2) Sleeve
(16) Holes for the drive pin
(17) Slots for the drive pin
(18) Holes
(19) Grooves
(20) Slots for the centering springs
The metering pump controls the following actions:
• Direction of a turn
• Speed of a turn
As the steering wheel is turned faster, there is an
increase in the flow of oil to the steering cylinders. The
increased flow of oil to the steering cylinders causes
the steering cylinder rods to move faster. This causes
the machine to make a faster turn.
The main components of the metering pump are
connected in the following way:
The steering column is connected to spool (1) by a
splined drive shaft. Sleeve (2), spool (1), and drive
shaft (14) are connected by drive pin (10). Drive pin (10)
is installed through holes (16) in the sleeve and slots
(17) in the spool.
The three schematics show the steering system in
the following positions:
• Hold
• Right Turn
• Left Turn
31200273 39
Systems Operation Section

Hold

Illustration 52 g01023926
(1) Spool (22) Relief Valve (26) Oil flow to load signal network
(2) Sleeve (23) Signal limiter valve (27) Signal to priority valve
(4) Makeup valve (24) Oil flow to left side of front steering cylinder. (28) Return to tank
(6) Check valve (25) Pump supply from priority valve (29) Oil flow to steering control valve
(21) Check valve

When the steering wheel is stationary, centering

springs (9) position spool (1) so that the drive pin is in
the center of the slots. When the spool and sleeve (2)
are in this position, pump supply oil (25) from the priority
valve is blocked by the spool. This stops the oil flow
between control section (A) and metering section (B).
When the steering wheel is stationary, a small quantity
of oil is constantly supplied to the metering pump
through signal line (27). This creates a slight signal
pressure in the metering pump. This signal oil flows
through port (15) into the control section of the pump.
Oil flows through sleeve (2) and through spool (1). The
spool directs the oil to port (3) and oil flows back to the
tank. This constant flow allows the oil in the system to
warm up. As a result, when the steering wheel is
turned, a quicker steering response is achieved.
Refer to Illustrations 50, 51 and 52.
40 31200273
Systems Operation Section

Right Turn

Illustration 53 g01024003
(1) Spool (22) Relief Valve (26) Oil flow to load signal network
(2) Sleeve (23) Signal limiter valve (27) Signal to priority valve
(4) Makeup valve (24) Oil flow to left side of front steering cylinder. (28) Return to tank
(6) Check valve (25) Pump supply from priority valve (29) Oil flow to steering control valve
(21) Check valve

components to the tank: left turn port (11), spool (1),

When the steering wheel is turned to the right, the sleeve (2), and outlet port (3).
spool turns. This compresses the centering springs
until the drive pin contacts the ends of the slots in the Refer to Illustration 50, 51 and 53.
spool, and the sleeve starts to turn. When the spool
and the sleeve are in this position, passages are
opened through grooves (19) in the spool and holes
(18) in the sleeve. This connects control section (A) to
metering section (B).
Oil is allowed to flow past check valve (6) in inlet port (5)
to rotor (7) and stator (8) in gerotor pump (21).
When the steering is turned further, drive pin (10) turns
drive shaft (14) and the rotor turns inside the stator.
This pumps a metered flow of oil back through the spool
and sleeve in the control section of the pump. Oil flows
through right turn port (12) and the control valve
(steering mode) to the steering cylinder. Return oil from
the left side of the front steering cylinder flows into the
steering metering pump through the following
31200273 41
Systems Operation Section

Left Turn

Illustration 54 g01024021
(1) Spool (22) Relief Valve (26) Oil flow to load signal network
(2) Sleeve (23) Signal limiter valve (27) Signal to priority valve
(4) Makeup valve (24) Oil flow to left side of front steering cylinder. (28) Return to tank
(6) Check valve (25) Pump supply from priority valve (29) Oil flow to steering control valve
(21) Check valve

When a left turn is made, oil flows past check valve (6) Relief valves (22) are installed in the metering unit in
in inlet port (5) of the metering valve to gerotor pump order to reduce the effect of shocks that are
(21). The oil is then directed through left turn port (11) to transmitted from the road wheels.
the left side of the front steering cylinder. Return oil from Note: If a pressure spike occurs in the system due to an
the control valve (steering mode) flows into the outside factor, check valve (6) protects the system from
steering metering pump through the following damage.
components to the tank: right turn port (12), spool (1),
sleeve (2), and outlet port (3). Refer to Illustrations 50, 51 and 54.

If there is a hydraulic pump failure, the metering pump

can be manually operated. The metering pump can be
manually operated if the engine stops and the engine
can not be started again. Makeup valve (4) and check
valve (6) allow steering with an inoperable engine. The
makeup valve opens in order to allow return oil to flow
between the metering pump and steering cylinder.
Check valve (6) prevents the oil from returning to the
implement and steering pump.
42 31200273
Systems Operation Section

Position Sensor (Steering) pressure to the appropriate control valve for the
desired steering mode. The ECM then sends an input
through a CAN data link to the dash panel. A light on
the dash panel will illuminate when steering mode is
selected.
When two-wheel steer is selected the steering position
sensor is energized. If the rear wheels are in the
straight ahead position, lamp (3) on steering position
sensor (2) will be illuminated. The contacts inside the
sensor are open and power to the electrical relay for the
selector valve is disconnected. Both of the solenoids
for the valve are now de-energized regardless of the
position of the steering mode select switch.
If the rear wheels are not in the straight ahead
Illustration 55 g00866458
position, the lamp on the steering position sensor will
Front Position Sensor
not be illuminated. The contacts in the steering position
sensor will be closed and power is still connected to
the electrical relay for the selector valve. The
appropriate solenoid on the selector valve remains
energized.
When the steering wheel is turned, the rear wheels will
move in the selected mode until the wheels are in the
straight ahead position. The contacts in the steering
position sensor are open and the selector valve is de-
energized. The spool in the selector valve is then
centered by spring force, and the rear wheels remain in
the straight ahead position.

Illustration 56 g00793912
When the master steering select switch is moved to the
(1) Rear axle center position, power is disconnected from the
(2) Steering position sensor electrical circuit for the steering. This position is
intended for operation of the machine in two-wheel steer
mode.
Refer to Systems Operation/Testing and Adjusting,
"Position Sensor (Steering) - Adjust" for information on
adjusting the sensor.
Refer to the Operation and Maintenance Manual,
"Steering Alignment" for additional information on
adjusting the steering position sensor.
Refer to the Systems Operation/Testing and Adjusting,
"Location of Electrical Components" for the location of
the steering position sensors.

Illustration 57 g00908667
(2) Steering position sensor
(3) Lamp
Machines with self-aligning steering are equipped with
two steering position sensors (2). One position sensor
is attached to the front steering cylinder. One sensor is
mounted on the rear axle. The steering position sensor
is activated when the wheels are in the centered
position. The switches are magnetic position sensors
that will supply a ground to the ECM when the sensors
are in the centered position.
The ECM reads the input from the steering position
sensor. The ECM will energize the appropriate relay in
order to control the solenoid and direct hydraulic
31200273 43
Systems Operation Section

Configuration Parameters

Illustration 58 g00993238
This is a summary screen
Some parameters need to be configured for the
machine to operate properly. The configuration screen
for the ECM can be accessed by using the Cat
Electronic Technician (ET). The configuration screen
for each ECM is accessed from the above ECM
summary screen by selecting "Configuration" from the
"Service" drop-down menu.
Reference: Refer to the appropriate service manual
for further instructions on configuring the ECM for your
machine.
44 31200273
Systems Operation Section
31200273 45
Testing and Adjusting Section

1. Shift the transmission to NEUTRAL and engage

Testing and Adjusting the parking brake.
2. Start the engine.
Section 3. Extend the boom and retract the boom several
times in order to warm the hydraulic oil.
Hydraulic Oil Contamination - 4. Operate each implement several times in order to
circulate the warm oil. Rotate the steering wheel
Test from stop to stop several times.
5. Allow the engine to run on low idle.
Hydraulic Oil Contamination
6. Open the engine enclosure.
Introduction
The steering system and the transmission system use
hydraulic oil from the hydraulic tank. Caterpillar
recommends the use of the SOS oil analysis program
in order to monitor the condition of your equipment.
If the oil becomes contaminated, premature
component failure could result. Contaminated oil can
also contribute to overheating. Use the following
procedure to sample the oil in the system.
Reference: See Operation and Maintenance Manual,
"SOS Fluid Analysis" for further information about this
SOS oil analysis program.
Illustration 59 g00867454
Flushing the Sampling Valve The Hydraulic Oil Sampling Valve is Located in the Engine Compartment.
7. Locate the sampling valve that is positioned at the
top of the hydraulic oil filter. Remove the rubber
cap from the sampling valve.
8. Attach the 8T-9208 Probe Assembly to the
Hot oil and components can cause personal injury. 6K-0713 Hose.
Do not allow hot oil or components to contact 9. Direct the hose into a container for fluid waste.
skin. Remove approximately 30 mL (1 fl oz) of fluid
NOTICE from the sampling valve.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, Obtaining the Sample
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Hot oil and components can cause personal injury.
Dispose of all fluids according to local regulations and
mandates. Do not allow hot oil or components to contact
skin.
In order to obtain a representative oil sample, it is first
necessary to flush the sampling valve. NOTICE
Required Tools Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
Use the following equipment in order to Flush the adjusting and repair of the product. Be prepared to collect
Sampling Valve: the fluid with suitable containers before opening any
Table 2 compartment or disassembling any component
containing fluids.
Required Tools
Dispose of all fluids according to local regulations and
Part
Tool Part Description Qty mandates.
Number
Once the sampling valve has been flushed, carry out
8T-9208 Probe Assembly 1
A
the following procedure in order to obtain an oil sample:
6K-0713 Hose 1
46 31200273
Testing and Adjusting Section

Required Tools Table 5

Use the following equipment in order to obtain the

Pump flow at 690 kPa (100 psi)
Sample:
Table 3
- Pump flow at 6900 kPa (1000 psi)
Required Tools
Part = Flow loss
Tool Part Description Qty
Number
Fluid Sampling Cap and Example of determining flow loss
177-9343 1
B Probe Gp Table 6
169-7373 Bottle 1
217.6 L/min (57.5 US gpm)
1. Attach the probe from the 177-9343 Fluid
Sampling Cap and Probe Gp to a 169-7373 - 196.8 L/min (52.0 US gpm)
Bottle.
2. Draw a 50 mL (1.7 fl oz) oil sample from the = 20.8 L/min (5.5 US gpm)
sampling valve.
Maximum Contamination Levels Flow loss is used as a measure of pump performance.
The level of contaminants that is found in the hydraulic Flow loss is expressed as a percentage of pump flow.
system must meet the ISO 18/15 cleanliness level. Method of determining percent of flow loss
The following table contains the maximum Table 7
acceptable contamination levels:
Table 4 Flow loss (L/min or US gpm)
x 100 = Percent of
Hydraulic Oil Contamination flow loss
Pump flow at 690 kPa (100 psi)
Maximum Number of
Particle Size (Microns) Particles in a 50 mL (1.7 fl Example of determining percent of flow loss
oz) Sample
Table 8
10 to 20 48000
21 to 50 2580 20.8 L (5.5 US gal)
51 to 100 150 x 100 = 9.5%
100 or more 20 217.6 L/min (57.5 US gpm)

If the percent of flow loss is more than 10%, the pump

Pump Flow - Test performance is inadequate.
Note: The values in the examples are not set values for
Pump Flow any specific pump or for any specific pump condition.

Introduction
This test is designed to check a pump for operation
within the design parameters.
For any pump test, the pump flow at 690 kPa (100 psi)
will be larger than the pump flow at 6900 kPa (1000
psi) if the pump is operating at the same rpm. The
pump flow is measured in L/min (US gpm). Test On The Machine
The difference between the pump flow of the two
operating pressures is the flow loss.
Reference: See the appropriate service manual for
specifications of the pump on your machine.
Hot oil and components can cause personal injury.
Method for determining flow loss
Do not allow hot oil or components to contact
skin.
31200273 47
Testing and Adjusting Section

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Required Tools
Use the following equipment in order to test the
pump flow: Illustration 60 g00903590
View on the left side of the machine
Table 9
(1) Test fitting for the load signal
Required Tools
Part
Tool Part Description Qty
Number
A 5P-3600 Hydraulic Flow Meter 1

Install tool (A). Run the engine at high idle. Measure the
pump flow at 690 kPa (100 psi), and at 6900 kPa (1000
psi). Use these values in the formula that is shown in
(Table 8).

Test On The Bench

If the test bench can be run at 6900 kPa (1000 psi) and
at 2000 rpm, determine the percent of flow loss by using Illustration 61 g00903592
the following formula (Table 10). View on the right side of the machine
(2) Test fitting for the pump supply
If the test bench can not be run at 6900 kPa (1000 psi)
When you check the pressures for the piston pump,
and at 2000 rpm, run the pump shaft at 1000 rpm.
several factors must be considered. Outlet pressure for
Measure the pump flow at 690 kPa (100 psi) and at
the piston pump should remain approximately 2200 ±
6900 kPa (1000 psi). Use these values in the top
100 kPa (320 ± 20 psi) higher than the maximum
portion of the following formula (Table 9). For the
implement signal pressure. This difference in pressure
bottom part of the formula, run the pump shaft at 2000
is called the margin pressure.
rpm. Measure the pump flow at 690 kPa (100 psi).
Note: Load sensing oil pressure is sometimes referred
Table 10
to as signal oil. The two terms have the same meaning
throughout this story.
Pump flow at 690 kPa (100 psi)
A low pressure setting on the pressure compensator
x 100 = Percent of valve will also cause a low high pressure stall. The
Pump flow at 6900 kPa (1000 psi)
flow loss pressure compensator only functions as a backup to
Pump flow at 690 kPa (100 psi) and the relief valve (load sensing oil) and to the flow
at 2000 rpm compensator. The pressure compensator should not be
set to a lower pressure than the sum of the relief valve
(load sensing oil) and the flow compensator. The
Steering System Pressures - setting for the relief valve (load sensing oil) must be
Test and Adjust checked after you adjust the high pressure stall.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Hydraulic Components" for the
Steering System Pressure Tests and location of the hydraulic components on the machine.
Adjustments Reference: See the steering Machine Systems
Introduction Specifications for your machine.

The test fittings are located on the control valve at the

rear of the machine.
48 31200273
Testing and Adjusting Section

Steering Pressure Test 4. Divide Tooling (B) into two separate gauge
assemblies. Install a pressure gauge on test fitting
Introduction (1) and install a pressure gauge on test fitting (2).
Refer to Illustrations 60 and 61.
The steering system pressure and the margin pressure
can be checked at the same time. 5. Connect Tooling (B) to test fitting (1). Refer to
Illustration 60.
Required Tools 6. Start the engine and operate the engine at low
Use the following test equipment in order to idle. Raise the boom until the work tool is off of
perform the following procedure: the ground. Rotate the steering wheel for the full
• Appropriate pressure gauges distance of travel. Continue to rotate the steering
wheel in order to check the steering pressure. The
Table 11 provides a list of required tools if pressure pressure reading will not be constant. Record the
gauges will be used to perform the following test high side of the measured value. If the pressure
procedure. is not within the specification, adjust the steering
Table 11 relief valve. Refer to Testing and Adjusting,
"Steering Pressure Adjustment".
Required Tools
Table 12
Part
Tool Part Description Qty Steering Pressure
Number
Pressure Gauge (0 to 40000 Model Pressure
8T-0860 2
kPa (5800 psi))
16250 ± 1000 kPa (2350.0
TH220B, TH330B, TH360B
6V-3989 Test fitting 2 ± 145.0 psi)
B
177-7861 Hose 2 TH560B with axles 231-
17750 ± 1000 kPa (2575.0
6V-4143 Coupler 4 0707or231-0708 231-
± 145.0 psi)
0709or231-0710
Test Procedure 17750 ± 1000 kPa (2600.0
TH580
± 145.0 psi)

7. Straighten the steering wheel and lower the work

tool to the ground.
Personal injury can result from removing hoses or
8. If the pressure is within the specification, stop the
fittings in a system under pressure.
engine, and proceed to the Testing and Adjusting,
Failure to relieve pressure can cause personal Margin Pressure Test.
injury.
Do not remove or disconnect hoses or fittings until Steering Pressure Adjustment
all pressure in the hydraulic system has been
relieved. Introduction
NOTICE The steering pressure can be adjusted at the metering
Care must be taken to ensure that fluids are contained pump (steering).
during performance of inspection, maintenance, testing, Reference: See Systems Operation/Testing and
adjusting and repair of the product. Be prepared to collect Adjusting, "Location of Hydraulic Components" for the
the fluid with suitable containers before opening any location of the metering pump.
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Ensure that the hydraulic oil is warm. Refer to
the appropriate service manual for further
information.
2. Retract the boom and lower the boom. Ensure
that the machine is on level ground.
3. Stop the engine. Turn the steering wheel in both
directions. This procedure helps purge pressure
from the hydraulic system.
31200273 49
Testing and Adjusting Section

Adjustment Procedure Margin Pressure Test

Introduction
The test indicates the difference's between the pump
output pressure and the pressure for the load signal.
This difference in pressure is called margin pressure.
Required Tools
Use the following test equipment in order to
perform the following procedure:
• Appropriate pressure gauges
Table 11 provides a list of required tools if pressure
gauges will be used to perform the following test
procedure.
Test Procedure

Personal injury can result from removing hoses or

Illustration 62 g01001790
fittings in a system under pressure.
relief valve (load sensing oil or signal oil) (Steering)
(3) Plug Failure to relieve pressure can cause personal
(4) Adjustment screw injury.
1. Remove plug (3). Do not remove or disconnect hoses or fittings until
2. Use an appropriate sized hex key wrench to turn all pressure in the hydraulic system has been
adjusting screw (4). Turn the screw clockwise in relieved.
order to increase the pressure setting. Turn the NOTICE
screw counterclockwise in order to lower the
Care must be taken to ensure that fluids are contained
pressure setting.
during performance of inspection, maintenance, testing,
Note: Do not turn the adjustment screw more than a adjusting and repair of the product. Be prepared to collect
half turn at a time. A half turn equals approximately the fluid with suitable containers before opening any
2480 kPa (360 psi). compartment or disassembling any component
3. Recheck the pressure setting. Refer to Testing containing fluids.
and Adjusting, "Steering Pressure Test". Dispose of all fluids according to local regulations and
4. Install plug (3). Torque the plug to 62.5 ± 2.5 Nm mandates.
(46.0 ± 2.0 lb ft). 1. Ensure that the hydraulic oil is still warm. Refer to
to the appropriate service manual for further
information.
2. Retract the boom and lower the boom. Ensure
that the machine is level.
3. Divide Tooling (B) into two separate gauge
assemblies. Install a pressure gauge on test fitting
(1) and install a pressure gauge on test fitting (2).
Refer to Illustrations 60 and 61.
4. Start the engine and operate the engine at low idle.
Rotate the steering wheel for the full distance of
travel. Subtract the pressure at test fitting (1) from
the pressure at test fitting (2). The difference in
pressure should be 2200 ± 100 kPa (320 ± 20 psi).
This is the margin pressure. If the pressure is
not within the specification, refer to Testing and
Adjusting, "Margin Pressure Adjustment".
50 31200273
Testing and Adjusting Section

Margin Pressure Adjustment Test Procedure

Margin pressure should be within the specifications
when the steering pressure is within the specification. If
the margin pressure is not within the specification, then
adjust the low pressure standby on the pump. Personal injury can result from removing hoses or
fittings in a system under pressure.
Refer to Testing and adjusting, "Low Pressure Standby
Adjustment" for the proper procedure. Failure to relieve pressure can cause personal
injury.
Test for the Relief Valve (Load Do not remove or disconnect hoses or fittings until
all pressure in the hydraulic system has been
Sensing Oil) relieved.
Introduction NOTICE
The pressure and flow compensator valve and the Care must be taken to ensure that fluids are contained
relief valve (load sensing oil) will determine the pump during performance of inspection, maintenance, testing,
output pressure against the load. If the relief valve (load adjusting and repair of the product. Be prepared to collect
sensing oil) is set below specifications, the high pressure the fluid with suitable containers before opening any
stall will be low. compartment or disassembling any component
containing fluids.
Note: The Relief Valve (Load sensing oil) is
sometimes referred to as the signal limiter valve. The Dispose of all fluids according to local regulations and
two terms have the same meaning throughout this mandates.
story. Note: Low pressure standby should be within
Reference: See Systems Operation/Testing and specifications before this test is performed.
Adjusting, "Location of Hydraulic Components" for the Note: The test for the relief valve (load sensing oil) and
location of the hydraulic components on the machine. the high pressure stall test can be done at the same
Required Tools time.
1. Ensure that the hydraulic oil is warm. Refer to
Use the following test equipment in order to
the appropriate service manual for further
perform the following procedure:
information.
• Appropriate pressure gauges
2. Retract the boom and lower the boom. Ensure
Table 13 provides a list of required tools if pressure that the machine is level.
gauges will be used to perform the following test 3. Stop the engine. Turn the steering wheel in both
procedure. directions. This procedure helps purge pressure
Table 13 from the hydraulic system.
4. Connect Tooling (B) to test fitting (1). Refer to
Required Tools Illustration 60.
Part 5. Start the engine and operate the engine at
Tool Part Description Qty
Number low idle. Operate the control for the boom
retract until the piston pump reaches a stall
Pressure Gauge (0 to 40000
8T-0860 1 condition. The pressure at test fitting (1) should
kPa (5800 psi))
be 22800 ± 500 kPa (3300 ± 70 psi). This is
6V-3989 Test fitting 1 the pressure for the load signal. If the relief
B valve (load sensing oil or signal oil) is not within
177-7861 Hose 1
the specification, adjust the valve before you
6V-4143 Coupler 2 proceed with any other tests. Refer to Testing
and Adjusting, "Relief Valve (Load Sensing Oil or
Signal Oil) Adjustment".
6. If the pressure is within the specification, stop the
engine and remove Tooling (B).
31200273 51
Testing and Adjusting Section

Adjustment of the Relief Valve (Load Test for Pressure Compensator

Sensing Oil) Introduction
Introduction The pressure compensator functions as a backup for
Use the following procedure to adjust the setting for the controlling the high pressure stall. Ensure that all other
relief valve (load sensing oil or signal oil). The relief pressures are within the specifications. A procedure for
valve controls the hydraulic system testing and adjusting the pressure compensator is
pressure. available. Refer to Testing and Adjusting, "Adjustment
for the Pressure Compensator Relief Setting".
There is not a simple adjustment for the high pressure
stall on this hydraulic system. This is due to the fact
that the flow compensator and the relief valve (load
sensing oil) control high pressure standby. On this
hydraulic system, the pressure compensator serves as
a backup.
Test Procedure

Personal injury can result from removing hoses or

fittings in a system under pressure.
Failure to relieve pressure can cause personal
injury.
Do not remove or disconnect hoses or fittings until
all pressure in the hydraulic system has been
Illustration 63 g01001360 relieved.
Relief valve (load sensing oil or signal oil)
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Perform Step 1 through Step 4 in Testing and
Adjusting, "Margin Pressure Test".
2. Operate the control for the boom retract until the
Illustration 64 g01001794 pump reaches a stall condition. If the margin
(5) Locknut pressure is correct the pressure at test fitting (1)
(6) Adjustment screw should be 22800 ± 500 kPa (3300 ± 70 psi).
1. Loosen locknut (5). Turn adjusting screw (6) a. If the pressure for the relief valve (load sensing
clockwise in order to increase the pressure setting oil) is incorrect at test fitting (1) and the margin
or turn counterclockwise in order to decrease the pressure is correct, the relief valve (load
pressure setting. sensing oil or signal oil) needs to be adjusted.
Note: Do not turn the adjustment screw more than a Refer to Testing and Adjusting, "Relief Valve
(Load Sensing Oil) Adjustment".
half turn at a time.
b. If the margin pressure was correct and the pressure
2. Hold adjusting screw (6) in place while you tighten for the relief valve (load sensing oil) was correct,
locknut (5). check the pressure at test fitting (2). The pressure
3. Recheck the pressure setting. Refer to Testing should be
and Adjusting, "Test for the Relief Valve (Load 26500 ± 500 kPa (3843 ± 70 psi) 25000 ± 500 kPa
Sensing Oil)". (3630 ± 70 psi) for the TH330B. This is the high
pressure stall reading. If the pressure at test fitting
Note: If the signal does not change the pressure at the (2) was identical to the signal pressure at test
compensator on the pump needs to be adjusted.
52 31200273
Testing and Adjusting Section

fitting (1) then the pressure compensator needs to 4. Turn adjusting screw (8) counterclockwise in order
be adjusted. Refer to Testing and Adjusting, to reduce the setting of the pressure compensator.
"Pressure Compensator Adjustment". Refer to Turn the screw until the margin pressure begins
Illustrations 60 and 61 for the location of the test fittings. to drop.
c. If the high pressure stall reading is low, the pressure 5. When the margin pressure begins to drop, turn
compensator needs to be adjusted. Refer to Testing adjusting screw (8) clockwise by a 1/4 turn. This
and Adjusting, "Pressure Compensator
ensures that the pressure compensator is set
Adjustment".
above the adjustment for the relief valve (load
sensing oil).
Pressure Compensator Adjustment
6. Tighten locknut (9) while you hold screw (8) in
Adjustment Procedure place.
7. Install seal (10) and cap nut (7).
8. Stop the engine and remove Tooling (B) from the
machine.

Low Pressure Standby Test

Introduction
When the machine is not being steered and all
implement controls are in HOLD, the piston pump
should operate in low pressure standby. The pump
output pressure is at a minimum in low pressure
standby.
Illustration 65 g00903590 Reference: See Systems Operation/Testing and
View on the left side of the machine Adjusting, "Location of Hydraulic Components" for the
(1) Test fitting for the load signal location of the hydraulic components on the machine.
Required Tools
Use the following test equipment in order to
perform the following procedure:
• Appropriate pressure gauges
Table 14 provides a list of required tools if pressure
gauges will be used to perform the following test
procedure.
Table 14

Required Tools
Part
Tool Part Description Qty
Number
A 6V-7830 Pressure Gauge 1

Note: Ensure the use of 6V-7830 Pressure Gauge.

During engine start-up, a 17250 kPa (2500 psi)
pressure spike is possible.
Illustration 66 g01001801
(7) Cap nut
(8) Adjustment screw
(9) Locknut
(10) Seal
Note: Make this adjustment only after trying to make
the adjustment of the load sensing valve first.
1. Do not remove Tooling (B). Operate the engine at
low idle.
2. Remove cap nut (7) and seal (10).
3. Loosen locknut (9).
31200273 53
Testing and Adjusting Section

Test Procedure Low Pressure Standby Adjustment

Introduction
Low pressure standby is controlled by the setting of the
Personal injury can result from removing hoses or flow compensator spool.
fittings in a system under pressure. Adjustment Procedure
Failure to relieve pressure can cause personal
injury.
Do not remove or disconnect hoses or fittings until
all pressure in the hydraulic system has been
relieved.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Ensure that the hydraulic oil is warm. Refer to
the appropriate service manual for further
information.
2. Retract the boom and lower the boom. Ensure
that the frame is level. Illustration 67
(11) Locknut
3. Stop the engine. Turn the steering wheel in both
(12) Seal
directions. This procedure helps purge pressure (13) Adjustment screw
from the hydraulic system. (14) Cap nut
4. Connect Tooling (A) to test fitting (2). Refer to
Illustration 61. 1. Turn off the engine.
Note: Ensure the use of 6V-7830 Pressure Gauge. 2. Remove cap nut (14) and seal (12). Loosen
During engine start-up, a 17250 kPa (2500 psi) locknut (11). Turn adjusting screw (13) clockwise in
pressure spike is possible. order to increase the low pressure standby setting.
Turn the adjustment screw counterclockwise in
5. 5.Start the engine and operate the engine at low
order to decrease the low pressure standby setting.
idle. Do not turn the steering wheel and do not
operate the implement controls. The output Note: Do not turn the adjustment screw more than a
pressure for the piston pump at test fitting (2) half turn at a time. A half turn equals approximately
should be approximately 4500 ± 1000 kPa 8000 kPa (116 psi).
(650 ± 150 psi). This is the standby pressure for 3. Hold adjusting screw (13) in place while you
the piston pump. If the pressure is not within the tighten locknut (11).
specification, adjust the standby pressure. Refer 4. Install seal (12) and cap nut (14).
to Testing and adjusting, "Low Pressure Standby
5. Recheck the pressure setting. Refer to Testing
Adjustment" for the proper procedure.
and Adjusting, "Low Pressure Standby Test".
6. 6. If the pressure is within the specification, stop
the engine and remove Tooling (A).
54 31200273
Testing and Adjusting Section

Steering System - Purge Reference: See the Operation and Maintenance

Manual, "Operator Controls" for the location of the
service tool connector.
Purging the Steering System 2. Turn on the ignition.
Introduction 3. Use Caterpillar Electronic Technician (ET) to
disable the auto function for the wheel alignment.
If the steering system has been disassembled or the
axles have been removed from the machine the Reference: See the appropriate service manual for
steering system should be purged before the machine more information.
is returned to service. 4. Turn off the ignition. Allow a fifteen second period
of time in order for the system to power down.
Required Tools
5. Start the engine. Ensure that all the wheels are
Use the following equipment in order to perform the aligned with the frame in order to center the
following procedure: wheels into the straight ahead position.
• Caterpillar Electronic Technician service tool (ET) 6. Select circle steer mode on the switch for the
The Caterpillar Electronic Technician service tool (ET) steering mode. Turn the wheels fully to the right.
is used to access the configuration screen. A message 7. Select two-wheel steer mode on the switch for the
on the ET screen will give instructions that guide the steering mode. Turn the wheels fully to the left.
user through the procedure. Refer to the Manual that is
8. Select crab steer mode on the switch for the
provided with the ET software for more information
steering mode. Turn the wheels fully to the right.
about ET.
9. Repeat steps 6 through 8 five more times.
Table 15
10. Select circle steer mode on the switch for the
Required Tools steering mode. Align all the wheels with the frame.
Part Number Description Quantity 11. Stop the engine.
Caterpillar Electronic 12. Turn on the ignition.
JEBD3003 1
Technician (ET) 13. Use Caterpillar Electronic Technician (ET) in order
Communications Adapter to enable the auto function for wheel alignment.
171-4401 1
II Reference: See the appropriate service manual for
207-6845 Adapter Cable As 1 more information.
160-0141 Adapter Cable As 1 14. Turn off the ignition. Allow a fifteen second period
of time in order for the system to power down.
15. Start the engine. Check that all the steering
modes are operating correctly.
16. 16.Disconnect the communications adapter and
the computer from the diagnostic service tool
connector.

Solenoid Valve (Steering Mode

Selector) - Test
The Solenoid's for the Steering
Modes
Introduction
The solenoids on the steering selector valve operate on
12 volts that is supplied from the fuse for the steering
system.
Illustration 68 g00898916 Reference: See Systems Operation/Testing and
Location of the diagnostic service tool connector Adjusting, "Location of Electrical Components" for the
Purging Procedure location of the electrical components on the machine.

1. Connect the communications adapter and the

computer to the diagnostic service tool connector.
31200273 55
Testing and Adjusting Section

Required Tools Procedure for Checking the Solenoid

Use the following test equipment in order to Resistance
perform the following procedure: 1. Disconnect the electrical connector at the solenoid
• Voltage Tester that is not functioning properly.

• Digital multimeter 2. Use Tooling (B) to check the resistance of the

solenoid. Place a lead of the multimeter on each
Table 16 provides a list of tools that are required to terminal on the solenoid. The resistance should
perform the following procedures. be approximately 4.8 ohms at 20 °C (68 °F).
Table 16

Required Tools Position Sensor (Steering) -

Tool
Part
Part Description Qty
Adjust
Number
A 5P-7277 Voltage Tester 1 Position Sensor
B 6V-7070 Digital Multimeter 1
Introduction
The Procedure for testing the Circuit The position sensor (steering) is installed on
Two people are needed to perform this test. machines that are equipped with self-aligning rear
steering. The sensor is attached to the rear steering
Note: Ensure that the battery is fully charged for this cylinder. Use the following procedure to adjust the
check. sensor.
1. Turn the start switch ON, but do not start the Reference: See Systems Operation, "General
engine. Information".
2. Use the steering switch on the instrument panel Reference: See Testing and Adjusting, "Wheel
to activate the solenoid circuits. Refer to Systems Alignment - Check and Adjust" for the proper
Operation, "General Information" for operating procedure.
information on the switch. If a click is heard or if a
vibration is felt, the solenoid is being energized. Reference: See Operation and Maintenance Manual,
Ensure that both solenoids are checked. If the "Steering Mode Control".
solenoid did not energize, proceed with the test. Adjustment Procedure
3. Disconnect the electrical connector at the solenoid
that is not functioning properly.
4. Use the steering switches on the dash panel in
order to activate the disconnected solenoid circuit.
Personal injury or death can result from machine
5. Use Tooling (A) to check for voltage on the movement.
electrical connector from the steering circuit. Place
a lead from the voltage tester on the terminal Place blocks in front of and behind the wheels to make
with the black wire. This is the ground side of the sure the machine does not move while the parking brakes
circuit. Place the probe of the voltage tester on the are disengaged.
remaining terminal in the connector. This is the
battery side of the circuit. The light on the voltage
tester should be at full brilliance.
6. If the light on the voltage tester does not illuminate,
check the fuse for the steering circuit. If the fuse
is not damaged, check the circuit for an open. If
the light on the voltage tester is dim, check the
circuit for a bad connection. Refer to the Electrical
Schematic for your machine.

Illustration 69 g00744667
56 31200273
Testing and Adjusting Section

Illustration 70 g00744669 Illustration 72 g00793646

1. In following the above warning, place blocks in (3) Rear axle
front of the wheels and behind the wheels. (4) Position sensor

2. Attach string (1) to steering stop (2) at the front of

the front axle. Attach the string to the steering stop
at the rear of the rear axle, as shown.

Illustration 73 g00793916
(4) Position sensor
(5) Clamp
6. Slacken two clamps (5) that secure position sensor
(4).

Illustration 71 g00744670
3. Ensure that the wheels are aligned straight
ahead. The string should be touching the outer
circumference of each wheel in two places. If
necessary, move the wheels to a straight ahead
position. If the wheels do not touch the string in
two places, adjust the wheel alignment.
4. Turn the engine start switch key to the ON
position, but do not start the engine.
5. Move the master steering select switch to position Illustration 74 g00793939
2. Refer to Operation and Maintenance Manual
for additional information on the operation of the
switches.
31200273 57
Testing and Adjusting Section

7. Move the sensor to the right until the lamp on

the sensor is extinguished. Make a mark on the
steering cylinder corresponding to the right hand
edge of the sensor. Move the sensor to the left
until the lamp on the sensor is extinguished. Make
a mark on the steering cylinder corresponding to
the right hand edge of the sensor. Move the sensor
so that the right hand edge of the sensor is
positioned midway between the two marks. This is
the optimum position for the sensor. Secure the
sensor in place with the existing clamps (5).
8. Turn the engine start switch to the OFF position.
9. Remove the blocks from the wheels.

Wheel Alignment - Check and

Adjust
Introduction
Correct steering alignment minimizes tire wear. There
should be no toe on either axle.
Reference: See the Systems Operation, "General
Information".
Reference: See the Operation and Maintenance
Manual, "Steering Mode".
Reference: See the Operation and Maintenance
Manual, "Steering Mode Control".
Reference: See the Specifications Manual, "Drive and
Steering Axles".
58 31200273
Testing and Adjusting Section

Checking the Wheel Alignment With

Wheels In Place

Illustration 75 g00795375
Steering geometry adjustment
(1) Cord lines (3) Guide rod (5) Bolt
(2) Locknut (4) Knuckle (6) Locknut

1. Park the machine on level ground and align the Adjusting the Wheel Alignment
wheels straight ahead. Move the transmission
control to the NEUTRAL position and engage the 1. Loosen locknuts (2). Place an open end wrench
parking brake. on the flats of each guide rod (3). Rotate each
guide rod clockwise by an equal amount until the
Note: Ensure that the rear wheels are straight ahead.
wheels are parallel. Alternatively, rotate each
If the steering is not synchronized, the rear wheels
guide rod counterclockwise by an equal amount
may be at an angle when the front wheels are straight.
until the wheels are parallel. The amount of
Refer to the Operation and Maintenance Manual,
chrome rod that is visible on each side of the
"Steering Mode Control".
steering cylinder must remain equal. Refer to
2. Lower the boom and retract the boom. Stop the distance (A) in Illustration 75. Tighten the locknuts
engine and attach a "DO NOT OPERATE" warning after the adjustments for the tie rods are complete.
tag or similar warning tag to the controls. Tighten locknuts (2) to the proper torque. See the
3. Place a cord line (1) on each side of the machine. Specifications Manual, "Drive and Steering Axles"
The lines should be parallel with the centerline of for your machine in order to determine proper
the machine. Each cord should be approximately torque values.
100 mm (4 inch) from the tires and at a height 2. Remove the cord lines.
that corresponds to the centerline of the wheels.
Measure the distance between the outer face of
the tire and the adjacent cord in order to check that
the wheels are parallel. Record the measurement
at the front of each wheel and at the back of each
wheel.
4. If the wheels are not parallel it will be necessary to
adjust the wheel alignment.
31200273 59
Testing and Adjusting Section

Adjusting the Steering Angle 5. Loosen locknuts (6) on all four stop bolts (5). Turn
all four bolts (5) clockwise until the bolts bottom
out.
6. Hold a long straight bar (8) against the housing
for the steering cylinder.

Illustration 76 g00894957
(4) Knuckle
(5) Bolt
(6) Locknut
After the wheels have been correctly aligned the Illustration 78 g00950064
maximum steering angle must be adjusted. Each wheel Typical Example
is equipped with a knuckle (4). The knuckle is equipped 7. Rotate the left side final drive until the angle that is
with two bolts (5) that act as steering stops. Each bolt is formed by the two bars measures the correct
secured in place with a locknut (6). angle. See table 17.
Park the machine on level ground. Move the Table 17
transmission control to the NEUTRAL position. Lower
Steering Angles
the boom and retract the boom. Engage the parking
brake. Model Front Rear
1. Raise the front of the machine in order to lift the TH220B & TH330B 48° 50°
front wheels off the ground. Place the jack in a TH360B 46° 48°
location that will sustain the weight of the machine
such as the axle pads. The axle pad should be TH560B 46° 48°
parallel to the ground. The head of the jack should
8. Apply 154-9731 Thread Lock Compound to the
be against a flat surface. Use a jack which will
four stop bolts (5). Apply the compound to the
support the weight of the machine.
threads in the knuckle and apply the compound in
2. Remove both of the front wheels. the locknuts (6). See Illustration 76.
9. Turn stop bolt (5) on the left side knuckle
counterclockwise until the head of the screw
contacts the steering stop. Secure the screw in
place with locknut (6). Tighten locknuts (6) to a
torque of 150 N-m (111 lb ft). See Illustration 75.
Note: Use a piece of paper as a go/no-go gauge in
order to check that the stop bolts touch the casting. If
the paper slides between the bolt and the casting, reset
the bolt in order to contact the casting.
10. Repeat step 9 for the stop screw on the right side
knuckle that is diagonally opposite.
Note: The steering stop on the right side knuckle and
Illustration 77 g00950065 the steering stop that is directly opposite must make
Typical Example contact with the castings at the same time when the
3. 3. Place bar (7) against the outer flange of the final steering is at the maximum angle.
drive on the left side. Secure the bar in place with 11. Rotate the final drive on the right side until the
two existing wheel nuts. Repeat the procedure for angle that is formed by the two bars measures the
the final drive on the right side. correct angle. See table 17.
4. Clean the four stop bolts (5) and locknuts (6). 12. Turn stop bolt (5) on the right side knuckle
counterclockwise until the head of the bolt
60 31200273
Testing and Adjusting Section

contacts the steering stop. Secure the screw in

place with locknut (6). Tighten locknuts (6) to a
torque of 150 Nm (111 lb ft). See Illustration 75.
Note: Use a piece of paper as a go/no-go gauge in
order to check that the stop bolts touch the casting. If
the paper slides between the bolt and the casting, reset
the bolt in order to contact the casting.
13. 13.Repeat step 12 for the stop screw on the left side
knuckle that is diagonally opposite.
Note: The steering stop on the left side knuckle and the
steering stop that is directly opposite must make contact
with the castings at the same time when the steering is
at the maximum angle.
14. Remove measuring bars (7) and (8).
15. Replace both wheels and lower the machine to
the ground.
16. Repeat the procedure for the rear axle.

General Information Table

Table 18

Specifications
Low Idle (Engine) 950 ± 25 rpm
High Idle (Engine) 2350 ± 25 rpm

Torque Stall 1985 ± 25 rpm

High Pressure Stall - TH220B 26500 ± 500 kPa (3843 ± 70 psi)

High Pressure Stall - TH330B 25000 ± 500 kPa (3630 ± 70 psi)
Signal Relief Pressure 22800 ± 500 kPa (3300 ± 70 psi)
Low Pressure Standby 4500 kPa (650 psi)
Margin Pressure 2200 ± 100 kPa(320±20 psi)

Steering Pressure 220B, 330B, and 360B 16250 ± 750 kPa (2400 ± 100 psi)

Steering Pressure 560B and 580B 17750 ± 750 kPa (2575 ± 100 psi)

Table 19

Pressure of the Fan Pump and Speed of the Fan Motor 220B
and 330B Machines (Fan Reversing)
Engine Speed Pressure Fan Speed
Low Idle 4000 ± 200 kPa (580 ± 30 psi) 1230 ± 50 RPM
High Idle 15000 ± 200 kPa (2175 ± 30 psi) 2400 ± 50 RPM
Fan Motor in Reverse or Counterclockwise Direction
Low Idle 4000 ± 200 kPa (580 ± 30 psi) 1230 ± 50 RPM
High Idle 14500 ± 200 kPa (2100 ± 30 psi) 2840 ± 50 RPM

Note: Refer to the appropriate Operation & Safety

Manual for the proper operation of the reverse switch.
31200273 61
Index Index

A L
Adjustment of the Relief Valve (Load Sensing Oil) Location of Electrical Components
Low Pressure Standby Adjustment............................... 53 Electronic Control Module............................................... 8
Low Pressure Standby Test.......................................... 52 Position Sensors............................................................. 7
Pressure Compensator Adjustment.............................. 52 Relay (Circle Steer) ........................................................ 9
Test for Pressure Compensator.................................... 51 Relay (Crab Steer) .......................................................... 8
Adjustment of the Relief Valve (Load Sensing Oil) ............ 51 Selector Switch for the Steering Mode ........................... 7
Solenoid for Circle Steer ................................................. 8
C
Solenoid for Crab Steer .................................................. 8
Configuration Parameters .................................................. 43 Location of Electrical Components....................................... 7
E Location of Hydraulic Components
Control Valve (Steering) ............................................... 11
Electrical Input Components
Hydraulic Oil Drain Plugs.............................................. 12
Position Sensor............................................................. 13
Hydraulic Oil Level Indicator ......................................... 12
Steering Mode Switch................................................... 12
Hydraulic Tank.............................................................. 11
Electrical Input Components .............................................. 12
Hydraulic Tank Breather ............................................... 11
Electrical Output Components
Line for the Signal Limiter Valve for the Steering ......... 10
CAN Data Link.............................................................. 15
Metering Pump ............................................................. 10
CAT Data Link .............................................................. 14
Piston Pump ................................................................. 10
Data Link....................................................................... 14
Priority Valve................................................................. 10
Instrument Cluster ........................................................ 14
Steering Cylinders ........................................................ 11
Relays........................................................................... 14
Steering Wheel ............................................................... 9
Electrical Output Components ........................................... 14
Location of Hydraulic Components ...................................... 9
Electrical Schematic........................................................... 15
Electronic Control Module .................................................. 13 M
G Metering Pump (Steering)
Hold .............................................................................. 39
General Information ............................................................. 4
Left Turn ....................................................................... 41
Circle Steer..................................................................... 4
Right Turn ..................................................................... 40
Crab Steer ...................................................................... 4
Metering Pump (Steering) .................................................. 37
Machines With Self-Aligning Steering............................. 5
Manually Aligned Rear Wheels....................................... 5 P
Steering Arrangement..................................................... 4 Piston Pump (Implement and Steering)
Two-wheel Steer............................................................. 4 Compensator Valve ...................................................... 30
General Information Table ................................................. 60 Constant Flow ............................................................... 33
Graphic Color Codes............................................................ 3 Destroke ....................................................................... 34
H High Pressure Stall ....................................................... 36
Low Pressure Standby.................................................. 31
Hydraulic Oil Contamination -Test
Piston Pump ................................................................. 29
Flushing the Sampling Valve ........................................ 45
Upstroke ....................................................................... 32
Hydraulic Oil Contamination ......................................... 45
Piston Pump (Implement and Steering) ............................. 29
Obtaining the Sample ................................................... 45
Position Sensor (Steering) ................................................. 42
Hydraulic Oil Contamination -Test ..................................... 45
Position Sensor (Steering) -Adjust
Hydraulic Schematic (Steering System)............................. 28
Position Sensor............................................................. 55
I Position Sensor (Steering) -Adjust ..................................... 55
Important Safety Information.................................................ii Pump Flow - Test
Inlet Manifold Pump Flow .................................................................... 46
Check Valve.................................................................. 16 Test On The Machine ................................................... 46
Flow Control Valve Pump Flow - Test ............................................................... 46
(Dump valve for the load sensing oil) ........................... 16
S
Relief Valve (Load sensing oil) ..................................... 16
Screens (75 and 100 Micron) ....................................... 16 Solenoid Valve (Steering Mode Selector)
Steering Activated......................................................... 18 Solenoid Valve.............................................................. 37
Steering Not Activated.................................................. 17 Solenoid Valve (Steering Mode Selector) - Test
Steering Priority Valve .................................................. 15 The Solenoid’s for the Steering Modes......................... 54
Inlet Manifold...................................................................... 15 Solenoid Valve (Steering Mode Selector) - Test ................ 54
Introduction .......................................................................... 6 Solenoid Valve (Steering Mode Selector) .......................... 37
62 31200273
Index

Steering System
Left Turn in Circle Steer Mode...................................... 24
Left Turn in Crab Steer Mode ....................................... 26
Right Turn in Two-Wheel Steer Mode .......................... 22
Steering Control System............................................... 19
Steering in Neutral ........................................................ 20
Steering System - Purge
Purging the Steering System ........................................ 54
Steering System - Purge .................................................... 54
Steering System Pressures -Test and Adjust .................... 47
Margin Pressure Adjustment ........................................ 50
Margin Pressure Test ................................................... 49
Steering Pressure Adjustment ...................................... 48
Steering Pressure Test ................................................. 48
Steering System Pressure Tests and Adjustments ...... 47
Test for the Relief Valve (Load Sensing Oil)................. 50
Steering System................................................................. 19
Systems Operation Section.................................................. 3

T
Table of Contents................................................................. 1
Testing and Adjusting Section............................................ 45

W
Wheel Alignment - Check and Adjust
Adjusting the Steering Angle ........................................ 59
Adjusting the Wheel Alignment..................................... 58
Checking the Wheel Alignment With Wheels In Place . 58
Wheel Alignment - Check and Adjust................................. 57
Manufactured by JLG under license from Caterpillar
31200274
December 15, 2006

Systems Operation
Testing and
Adjusting
TH220B, TH330B, TH360B, TH560B and
TH580B Telehandlers Braking System
S/N TBF00100 & After
S/N TBG00100 & After
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200274 1
Table of Contents
Table of
Table of Contents The Neutral Start Is Disabled............. 22
Systems Operation Section Stabilizer Raise/Lower (if equipped) is
Graphic Color Codes ............................... 3 Disabled............................................. 23
Introduction.............................................. 4 Boom Raise/Lower Is Disabled.......... 23
General Information................................. 5 The Boom Extend/Retract Is Disabled23
Brake Packs ........................................ 5 Disable The Rackback And Dump..... 23
Brake Pedal......................................... 5 The Frame Level (if equipped) is
Brake Cylinder..................................... 5 Disabled............................................. 24
Service Brake Pressure Switch ........... 6 Disable the Quick Coupler ................. 24
Parking Brake Lever............................ 6 Miscellaneous .................................... 24
Location of Electrical Components .......... 6 Testing and Adjusting Section
Parking Brake Switch .......................... 6 Testing and Adjusting Service Brake -
Service Brake Pressure Switch ........... 6 Test ........................................................ 25
Stoplight Switch................................... 6 Holding Ability Test for the Service
Location of Components (Braking) .......... 7 Brakes................................................ 25
Parking Brake Lever............................ 7 Stopping Performance Test for the
Parking Brake Actuator ....................... 7 Service Brakes................................... 25
Service Brake Pedal............................ 7 Service Brake Control -
Brake Cylinder..................................... 8 Check and Adjust ................................... 25
Service Brake Discs ............................ 8 Adjusting the Brake Pedal Linkage.... 25
Service Brake .......................................... 8 Service Brake Discs - Check.................. 27
Service Brake ...................................... 8 Checking the Wear on the Service Brake
The Service Brake System with the Discs .................................................. 27
Brakes Disengaged ........................... 10 Procedure for Checking the Wear ..... 27
The Service Brake System with the Service Brake Air - Purge ...................... 28
Brakes Engaged................................ 11 Purging Air from the Braking System. 28
Parking Brake ........................................ 12 Parking Brake - Test .............................. 29
Engaging the Parking Brake.............. 12 Holding Ability Test for the Parking
Disengaging the Parking Brake......... 13 Brake ................................................. 29
Brake Cylinder (Master)......................... 14 Parking Brake Control -
Brake Cylinder with the Brakes Check and Adjust ................................... 30
Disengaged ....................................... 15 Adjusting the Parking Brake Control
Brake Cylinder with the Brakes Engaged Cable ................................................. 30
.......................................................... 17
Hydraulic Schematic (Braking System) . 19
Configuration Parameters...................... 20
Electrical Function Requirements .......... 21
Transmission Neutralizer................... 21
System Voltage ................................. 21
Shuttle Shift for the Power Shuttle
Transmission ..................................... 21
Shift Lever (Cat Data Link) for
Powersynchro Transmission ............. 21
Rear Axle Lock (if equipped) ............. 21
Machine Security System.................. 21
Parking Brake.................................... 21
Service Brake Pressure Switch for the
Transmission Neutralizer................... 22
More Electrical Function Requirements. 22
Steering ............................................. 22
2 31200274
Table of Contents
31200274 3
Systems Operation Section

Systems Operation (A) Red.......................................................... High pressure oil

(B) Red Stripes and White
Section Stripes .............................................. First pressure reduction
(C) Red Crosshatch ..................... Second pressure reduction

Graphic Color Codes (D) Pink.............................................. Third pressure reduction

(E) Orange..........................Pilot, signal or torque converter oil
(F) Orange Stripes and White Stripes ................Reduced pilot,
signal or torque converter oil
(G) Blue.................................................................... Trapped oil
(H) Green............................................. Tank, sump or return oil
( I ) Brown ........................................................... Lubricating oil
(J) Orange Crosshatch ................. Second reduction in pilot,
signal or torque converter oil
(K) Light Gray...................................................... Surface color
(L) Purple ............................................... Pneumatic pressure
(M) Light Gray ..................................................... Surface color
The information that is covered in this manual may not
require all of the colors in Illustration 1.

Illustration 1 g01023555
4 31200274
Systems Operation Section

Introduction

Illustration 2 g00902881

This module discusses the features and operation of

the braking system. In addition, the major electrical
components and hydraulic components that are
contained in the braking system are discussed.
The following Telehandlers are covered in this
module:
• TH220B
• TH330B
• TH360B
• TH560B
• TH580B
The braking system on these machines has the
following features:
• The brake reservoir on the previous Telehandlers
is no longer used.
• The braking system is fed through the main
hydraulic system.
• Brakes are only located on the front axle.
• The brake cylinder is a direct acting brake booster.
31200274 5
Systems Operation Section

General Information

Illustration 3 g01003761
Steering and Implement Pump (Engine Off)
(1) Parking brake (6) Brake pedal
(2) Brake pack (7) Service brake pressure switch
(3) Front axle (8) Rear axle
(4) Hydraulic tank (9) Brake cylinder
(5) Supply oil from the pressure reducing (10) Parking brake switch
valve which is located in the Main control (11) Parking brake lever
valve (implement) (12) Parking brake cable

The braking system has the following main Brake Cylinder

components:
The operation of brake cylinder (9) is assisted by boost
• Brake pack
pressure from the implement system. The boost
• Brake pedal pressure comes from the pressure reducing valve. The
• Brake cylinder pressure reducing valve is located in the main control
valve group (implement). Any excessive oil from the
• Service brake pressure switch brake cylinder is returned back to tank (4).
• Parking brake lever

Brake Packs
Oil immersed multiple brake discs are located in brake
packs (2) at each side of the differential on front axle
(3).

Brake Pedal
Brake pedal (6) is connected to a mechanical linkage in
order to operate brake cylinder (9). When the brake
pedal is pressed, the brake cylinder creates high oil
pressure that is transmitted through the brake lines in
order to engage the brake discs in the brake packs on
front axle (3).
6 31200274
Systems Operation Section

Service Brake Pressure Switch Service Brake Pressure Switch

Service brake pressure switch (7) is used in
conjunction with the transmission neutralizer control
(switch) on the dash panel to disengage the
transmission when force is applied to the brake pedal.
When brake pedal (6) is released, the transmission is
engaged at the speed which was previously selected.

Parking Brake Lever

Parking brake lever (11) is connected to parking brake
cable (12) in order to operate parking brake (1) on the
front axle. Parking brake switch (10) signals the
machine ECM that the parking brake is engaged. Then,
the machine ECM sends a signal in order to neutralize Illustration 5 g00874756
Service brake pressure switch
the transmission when the lever for the parking brake is
pulled slightly upward.
The service brake pressure switch is located on the left
side of the master cylinder at the front of the cab.
Location of Electrical The switch detects the pressure in the braking system.
Components The switch then sends a signal to the ECM.
The switch signals the ECM that the brakes are fully
The electrical components of the brake system
engaged for the neutralizer function for the
consists of the following components:
transmission.
• Parking brake switch
• Service brake pressure switch Stoplight Switch
• Stoplight switch

Parking Brake Switch

Illustration 6 g00904596

The stoplight switch is located in the operator's

compartment below steering wheel.
The stoplight switch causes the stop lights to
Illustration 4 g00905344
illuminate when the service brake pedal has been
Parking brake switch
pressed.
The parking brake switch is located to the left side of the
operator seat under the parking brake lever.
The switch signals the ECM that the parking brake is
disengaged or engaged.
31200274 7
Systems Operation Section

Location of Components Parking Brake Actuator

(Braking)
The braking system consists of the following
components:
• Parking brake lever
• Parking brake actuator
• Service brake pedal
• Brake cylinder
• Service brake discs
Reference: See Systems Operation/Testing and
Adjusting, "General Information" for more information
on the components. Illustration 8 g00867822
Parking brake actuator

Parking Brake Lever

The parking brake actuator is located on the rear of the
front axle housing.

Service Brake Pedal

Illustration 7 g00867822
Parking brake lever

The parking brake lever is located to the left side of the

operator seat.
Illustration 9 g00867880
Service brake pedal

The service brake pedal is located to the left of the

accelerator control in operator's compartment.
8 31200274
Systems Operation Section

Brake Cylinder Service Brake

Service Brake

Illustration 10 g00867782
Brake cylinder
The brake cylinder is located in the operator's
compartment below the steering wheel at the left side of
the steering column.

Service Brake Discs

Illustration 12 g01091844
Typical service brake for a Telehandler
(1) Center housing
(2) Brake housing
(3) Piston
(4) Plate
(5) Brake disc
(6) Pin
(7) Brake hub
(8) Clip
(9) Shaft assembly
(10) Housing
Brake packs are located in brake housing (2) between
center housing (1) and housing (10) on the right side
Illustration 11 g00869987
Service brake discs
and on the left side of the front axle.

The service brake discs are located inside the front axle. Table 1

Number of Number of Number of

Sales Model brake discs per plates per
packs brake pack brake pack
TH220B 2 4 5
TH330B 2 4 5
TH360B 2 4 5
TH560B 2 3 4
TH580B 2 3 4
31200274 9
Systems Operation Section

The service brakes have the following features: Grooves on each side of brake discs (5) allow the oil
• The service brakes are hydraulically applied. from the differential to flow through the brake disc
packs for cooling purposes. Plates (4) are smooth on
• The service brakes are released by springs. each side.
• The service brakes are oil immersed. When force is applied to the service brake pedal,
The service brakes have the following hydraulic pressure is forced against piston (3). Piston (3)
components: forces the plates (4) and brake discs (5) together in
order to prevent shaft assembly (9) from rotating.
• Brake Housing(2)
When force on the service brake pedal is released,
• Piston (3) spring force will move piston (3) away from the brake
• Plate (4) pack in order to allow the shaft assembly to rotate
freely.
• Brake Disc (5)
• Pin (6)
• Brake Hub (7)
• Clip (8)
• Shaft Assembly (9)

Illustration 13 g01015066

Lugs around the outside circumference of plates (4) are

located on three pins (6) in brake housing (2) in order
to prevent plates (4) from rotating. Splines on the inside
diameter of brake disc (5) are located in splines on the
outside diameter of brake hub (7). Brake hub (7) is
splined onto shaft assembly (9) in order to allow the
brake discs to rotate with the shaft assembly (9).
10 31200274
Systems Operation Section

The Service Brake System with the

Brakes Disengaged

Illustration 14 g01003826
(1) Front axle (5) Service brake pressure switch (11) Shaft assembly
(2) Hydraulic tank (6) Rear axle (12) Brake disc
(3) Supply oil from the pressure reducing (7) Brake cylinder (13) Plate
valve which is located in the main control (8) Parking brake switch (14) Parking brake
valve (implement). (9) Parking brake lever (15) Piston
(4) Brake pedal (10) Parking brake cable (16) Brake pack

When brake pedal (4) is fully released, the supply oil is

blocked by the piston inside the brake cylinder. The
retraction springs disengage piston (15) from brake
pack (16).
Note: The piston is not shown.
Service brake pressure switch (5) for the transmission
neutralizer is opened.
At front axle (1), pressure is relieved from pistons (15).
The force against the brake disc packs is relieved and
brake discs (12) which are splined to the brake hub are
free to rotate with shaft assemblies (11).
31200274 11
Systems Operation Section

The Service Brake System with the

Brakes Engaged

Illustration 15 g01003833
(1) Front axle (5) Service brake pressure switch (11) Shaft assembly
(2) Hydraulic tank (6) Rear axle (12) Brake disc
(3) Supply oil from the pressure reducing (7) Brake cylinder (13) Plate
valve which is located in the main control (8) Parking brake switch (14) Parking brake
valve (implement). (9) Parking brake lever (15) Piston
(4) Brake pedal (10) Parking brake cable (16) Brake pack

When brake pedal (4) is pressed, supply oil (3) is direction clutch in the transmission and the
transmitted from the pressure reducing valve (located transmission will be placed in neutral. If the
main control valve) to the inlet port of brake cylinder transmission neutralizer control (switch) on the dash
(7). The pedal moves the plunger and the plunger panel is in the OFF position, the increasing pressure in
moves the piston in the brake cylinder. The piston the brake line will have no effect on the position of the
pressurizes the oil in the brake cylinder and the brake service brake pressure switch (5). The transmission will
lines. As the piston moves, a passage in the brake stay in the selected gear.
cylinder opens. The oil flows above the piston and
through the passage in order to provide a boost for
assistance in applying the brakes.
At front axle (1), high pressure oil in the brake lines
forces plates (13) against brake discs (12). This action
prevents the shaft assemblies (11) from rotating.
If the transmission neutralizer control (switch) on the
dash panel is in the ON position, the increasing
pressure in the brake line will close the service brake
switch (5). The switch will signal the machine ECM.
The ECM will signal the transmission to release the
12 31200274
Systems Operation Section

Parking Brake Engaging the Parking Brake

The parking brake consists of a caliper brake which is
located on the rear of the front axle housing. The brake
is operated by a hand lever which is located in the
operator compartment.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Components (Braking)" for
more information on the location of the components.
NOTICE
Do not engage the parking brake while the machine is
moving unless the primary service brake fails. The use
of the parking brake as a service brake in regular
operation will cause severe damage to the brake
system.
The parking brake has the following features:
• The parking brake lever has an over-the-center
action.
• The parking brake is engaged and disengaged by
a cable.
The parking brake has the following components:
• Parking Brake Lever
• Release Lever
• Hook
Illustration 16 g00887654
• Outer Cable Parking Brake Engaged
(1) Parking brake lever
• Inner Cable (2) Release lever
• Lever (3) Hook
(4) Outer housing
• Brake Linings (5) Inner cable
• Brake Disc (6) Lever
(7) Brake linings
(8) Brake disc

When parking brake lever (1) is pulled fully upward, the

lever is locked in position by hook (3) and roller (4).
As the lever is pulled upward, inner cable (6) is pulled
through outer housing (5). The clevis that is attached to
the end of outer housing (5) moves lever (7) on the
caliper brake.
Lever (7) moves the brake linings (8) into contact with
brake disc (9) which prevents brake disc (9) from
rotating.
31200274 13
Systems Operation Section

Disengaging the Parking Brake

Illustration 17 g00887655
Parking Brake Disengaged
(1) Parking brake lever
(2) Release lever
(3) Hook
(4) Outer housing
(5) Inner cable
(6) Lever
(7) Brake linings
(8) Brake disc

The parking brake is disengaged when parking brake

lever (1) is pushed downward. Before the lever can be
pushed downward, release lever (2) is pulled upward
in order to lift hook (3) away from roller (4).
At the front axle, inner cable (6) moves lever (7) in
order to allow brake linings (8) to move away from
brake disc (9). The brake disc (9) is then free to rotate.
14 31200274
Systems Operation Section

Brake Cylinder (Master)

Illustration 18 g01015410
(1) Body (6) Port to brake actuators
(2) Piston (7) Spring
(3) Plunger (8) Spring
(4) Supply oil from the pressure reducing (9) Port
valve which is located in the main control (10) Port
valve (implement). (11) Check valve
(5) Return tank (12) Operator input from brake pedal

The brake system consists of a direct acting brake The piston has four similarly positioned axially
cylinder that is mounted in the cab. The direct acting spaced holes:
brake cylinder is connected to the service brakes that • Four holes at the rear end
are immersed in the oil in the front axle.
• Four holes at the forward end
The brake cylinder has four main elements:
The four holes at the back of the piston supply oil to the
• Body (1)
booster.
• Piston (2)
The four forward holes allow the oil to return to the tank.
• Plunger (3)
• Springs (7) and (8)
The piston acts as the piston for the brake cylinder and
as a closed center booster main boost piston. The
plunger is located in the center within the piston. The
plunger extends backward into a closed spigot that is
located outside of the main body.
31200274 15
Systems Operation Section

Brake Cylinder with the Brakes

Disengaged

Illustration 19 g01015837
The hydraulic schematic for Brakes disengaged.
(4) Supply oil from the pressure reducing (12) Input from brake pedal
valve which is located in the main control (13) Master cylinder
valve (implement). (14) Brake booster
(5) Return to tank (15) Brake actuators
16 31200274
Systems Operation Section

Illustration 20 g01003858
Brakes disengaged.
(1) Body (6) Port to brake actuators
(2) Piston (7) Spring
(3) Plunger (8) Spring
(4) Supply oil from the pressure reducing (9) Port
valve which is located in the main control (10) Port
valve (implement). (11) Check valve
(5) Return tank (12) Operator input from brake pedal

When you release the brake pedal, springs (7) and (8)
force piston (2) and plunger (3) to the right. The plunger
closes ports (9) in piston (2) and plunger (3) opens port
(10) in piston (2). The oil to the right of piston (2) and
inside plunger (3) is then open to the tank through port
(10). Check valve (11) allows the tank oil to flow into the
left side of the brake cylinder in order to maintain full oil
supply to brakes (6).
Note: Because the brake cylinder is located below the
level of oil in the hydraulic tank, the return line back to
the tank acts as a reservoir for the brake system.
31200274 17
Systems Operation Section

Brake Cylinder with the Brakes

Engaged

Illustration 21 g01015848
The hydraulic schematic for Brakes engaged.
(4) Supply oil from the pressure reducing (12) Input from brake pedal
valve which is located in the main control (13) Master cylinder
valve (implement). (14) Brake booster
(5) Return to tank (15) Brake actuators
18 31200274
Systems Operation Section

Illustration 22 g01015390
Brakes disengaged.
(1) Body (6) Port to brake actuators
(2) Piston (7) Spring
(3) Plunger (8) Spring
(4) Supply oil from the pressure reducing (9) Port
valve which is located in the main control (10) Port
valve (implement). (11) Check valve
(5) Return tank (12) Operator input from brake pedal

When the brake pedal is pressed, plunger (3) moves to

the left. The plunger comes into contact with piston (2).
This causes the piston to be pushed to the left against
the force of springs (7) and (8). As the piston (2) moves
left, the supply port (9) opens and supply oil flows to the
right end of the piston (2). Also, port (10) is closed.
Due to oil flow from the supply, the pressure increases
on the right of piston (2) and the pressure assists
plunger (3) in moving piston (2) left against springs (7)
and (8) and against the oil in the left end of the brake
cylinder.
As piston (2) moves left, the check valve closes and
the check valve traps oil in the left end of the brake
cylinder. The vent port to the return to tank line (5)
closes. Oil is forced out port (6) to the brake actuators.
At the brake actuators, pressure increases and the
pressure shifts the actuators in order to engage the
brakes.
The brake pressure will vary with the amount of pedal
travel.
31200274 19
Systems Operation Section

Hydraulic Schematic (Braking

System)

Illustration 23 g01016398
Brakes disengaged.
(1) Master cylinder (4) Brake booster (6) Return to tank
(2) Input from brake actuators (5) Supply from main control valve
(3) Brake actuators (implement)
20 31200274
Systems Operation Section

Configuration Parameters

Illustration 24 g00993238
This is a summary screen.

Some parameters need to be configured for the

machine to operate properly. The configuration screen
for the ECM can be accessed by using the Cat
Electronic Technician (ET). The configuration screen
for each ECM is accessed from the above ECM
summary screen by selecting "Configuration" from the
"Service" drop-down menu.
Reference: Refer to the service manual module
Testing and Adjusting, "Electronic Control Module
(ECM) - Configure" for further instructions on
configuring the ECM for your machine.
31200274 21
Systems Operation Section

Electrical Function System Voltage

Requirements Overvoltage Condition

S/N TBF00100 & After (TH220B) The control shuts off all the solenoids when the voltage
in the system is 16 DCV. The transmission will be
S/N TBG00100 & After (TH330B) placed into neutral. Normal operation can take place
after the voltage drops below 15.5 DCV and the shift
S/N TBH00100 & After (TH360B) lever is placed in neutral.
Undervoltage Condition
S/N TBP00100 & After (TH560B) The control will maintain any solenoid which is
currently on when the voltage is below 10 DCV for
Note: This machine must be serviced by a technician. more than 30 seconds. All the solenoids will be turned
The technician must be familiar with Caterpillar off if a new solenoid is engaged. The loss of the
Electronic Technician (ET). A number of parameters solenoids will cause the transmission to be placed in
can be installed and modified through the configuration neutral.
screen. The following is an example: You have the
ability to change the maximum forward and the Shuttle Shift for the Power Shuttle
maximum reverse gear for the transmission. The
configuration of the machine may appear as an Transmission
interlock. See TESTING AND ADJUSTING,
• Any active faults
"ELECTRONIC CONTROL MODULE (ECM) -
CONFIGURE" for information concerning the machine
configuration. Shift Lever (Cat Data Link) for
Powersynchro Transmission
Transmission Neutralizer • A loss of communications for more than 1 second
The following subject titles will cause the transmission to • An invalid gear and direction input
be neutralized.
Solenoid Outputs Rear Axle Lock (if equipped)
Directional Solenoid and Modulation Valve for the • An incorrect key is being used.
Synchronizer
• Any active short to ground or open circuit fault Machine Security System
• The command to the solenoid is off and there is a
• An incorrect key is being used.
fault for a short to the battery.
Solenoids for the Synchronizers for the Parking Brake
Powersynchro Transmission
If the parking brake is on or if there is a failure the
• The command to the solenoid is off. There is a
transmission is neutralized. If a failure is noticed on the
fault for a short to the ground or there is a fault for
inputs for the parking brake, the ECM will use the last
a open circuit.
valid communications for 2.5 seconds as the signal is
• Any active short to the battery fault returning to an initial state. Once the time has elapsed
the system will default. The parking brake will be
enabled electrically and the transmission will be
neutralized. Once the parking brake failure is resolved
the technician needs to cycle the parking brake from the
applied position to the released position in order to
return the machine to normal operation. The shift lever
needs to be moved from neutral to a valid direction in
order to engage the transmission.
22 31200274
Systems Operation Section

Service Brake Pressure Switch for the • The relay for the circle steer mode has a diagnostic
code for a short to the battery.
Transmission Neutralizer
• The auto sensors for the alignment do not detect
The transmission neutralizer pressure switch is used to the centered position.
neutralize the transmission when the service brakes
• The machine will default to crab steer mode under
are applied. This feature will help reduce the wear of the
the following conditions.
service brakes.
The transmission is neutralized when any of the • The machine is in crab steer mode and there is a
following conditions are true for the brake. diagnostic for an active short to ground or an open
circuit on the relay for the circle steer.
• If you release the service brake within three
minutes the machine will go into gear. If you • Crab steer is the last valid steering mode and there
depress the brake longer than three minutes in is an active diagnostic on the selector switch for
order to move in gear the shuttle lever is placed the steering mode.
into neutral and then back into gear. • The relay for the crab steer has a diagnostic code
• The neutralizer switch for the brake has been for a short to the battery.
grounded and the service brake pedal is • The feature for the auto alignment is installed and
depressed. the machine is in the crab steer mode. Neither of
the two sensors for alignment are detecting the
More Electrical Function centered position.

Requirements The Neutral Start Is Disabled

Additional electrical function requirements are included
The ECM monitors the system for shorts to the battery
in the following topics.
for the key start switch. There is a limitation to the length
of time for cranking the starter. Input that lasts longer
Steering than one minute from the switch to the battery is a short
The machine will default to two-wheel steer mode to ground. When a failure exists for the key start switch
under the following conditions. the system will be unable to start.
The shift lever sends a signal to the ECM via the CAT
• The machine is in circle steer mode and there is a
Data Link. The signal tells the ECM the desired direction
diagnostic for a active short to ground or a open
of travel for the machine. If any position but the neutral
circuit on the relay for the circle steer.
is communicated the ECM will prevent the start relay
• The machine is in crab steer mode and there is a coil from being energized.
diagnostic for a short to ground or a open circuit on
The shuttle lever will signal on all four inputs when the
the relay for crab steer.
lever is in the neutral position without using the data
• The machine is in two-wheel steer mode and there link. If any of the outputs from the shuttles provide a
is a diagnostic code for a short to ground or a open switch to battery signal or if any of the switch to ground
circuit on the relay for either the circle steer or crab signal to the ECM, the ECM will prevent the start relay
steer. coil from being energized.
• The last valid steering mode is not known.
• There is a diagnostic code for both relays for the
steering for a short to the battery.
• •The feature for the auto alignment is installed. the
machine is in the two-wheel steering mode, and
both sensors for the alignment are not detecting
the centered position.
The machine will default to circle steer mode under the
following conditions.
• The machine is in circle steer mode and there is a
diagnostic code for a short to ground or an open
circuit on the relay for the crab steer.
• Circle steer is the last valid steering mode and
there is an active diagnostic on the selector switch
for the steering mode.
31200274 23
Systems Operation Section

The following conditions will allow the neutral start to • An active diagnostic code exists for the solenoid
become disabled: for the boom raise.
• A start relay has a failure. • The boom exceeds the critical angle.
• The transmission is NOT in the neutral position. • The machine is in the Free Axle Mode or the
• The engine speed is NOT zero rpm. machine is in the Limited Free Axle Mode.

• An invalid key was entered for the machine security • An invalid entry is made into the machine security
system (MSS). system.

Stabilizer Raise/Lower (if equipped) is The Boom Extend/Retract Is

Disabled Disabled
The stabilizer raise or stabilizer lower will be disabled The boom extend or the boom retract will be disabled
when any of the following conditions are true. when any of the following conditions are true.

• The status for the initialization screen for the • Both the stabilizers are not extended.
Programmable Hydraulic System (PHS) is not • The limit for the extension of the boom is active.
equal to "Complete".
• The status for the initialization screen for the PHS
• The implement lockout switch is enabled or an is not equal to "Complete".
active failure exists for the switch.
• The implement lockout switch is enabled or an
• The machine is not placed into the neutral position active failure exists for the switch.
during the system powerup or after the system
• The machine is not placed into the neutral position
powerup.
during the system powerup or after the system
• An active diagnostic code exists for the inputs on powerup.
the stabilizer control.
• An active diagnostic code exists for the boom
• An active diagnostic code exists for the solenoid extend solenoid.
that raises the stabilizer.
• An active diagnostic code exists for the boom
• An active diagnostic code exists for the solenoid retract solenoid.
on the stabilizer lower.
• An invalid entry is made into the machine security
• The feature for locking the rear axle is in the system.
"Locked Axle Mode".
• An invalid key was entered for the machine security Disable The Rackback And Dump
system (MSS).
The rack or the dump will be disabled when any of the
• The "Lateral Stability Adjustment Inhibit" feature conditions are true.
is installed and the boom is not retracted. The
• The status for the initialization screen for the PHS
"Lateral Stability Adjustment Inhibit" feature is for
is not equal to "Complete".
the "French" market.
• The implement lockout switch is enabled or an
Boom Raise/Lower Is Disabled active failure exists for the switch.
• The machine is not placed into the neutral position
The boom raise or the boom lower will be disabled
during the system powerup after system powerup.
when any of the following conditions are true.
• An active diagnostic code exists for the control.

• The status for the initialization screen for the PHS • An active diagnostic code exists for the rack
is not equal to "Complete". actuator solenoid.

• The implement lockout switch is enabled or an • An active diagnostic code exists for the dump
active failure exists for the switch. solenoid.

• The machine is not placed into the neutral position

during powerup or after powerup.
• A failure exists for the inputs to the control for the
boom raise or the boom lower.
• An active diagnostic code exists for the solenoid
that is used for lowering the boom.
24 31200274
Systems Operation Section

The Frame Level (if equipped) is

Disabled
The feature for the frame level will be disabled when
any of the following conditions are true.
• The feature for the rear axle lock is in the "Locked
Axle Mode".
• The "Lateral Stability Adjustment Inhibit" feature
is installed and the boom is not retracted. The
"Lateral Stability Adjustment Inhibit" feature is for
the "French" market.

Disable the Quick Coupler

The circuit of the quick coupler switch will be disabled if
an invalid switch input is detected. The quick coupler
will be disabled until the failure is corrected and the
input is cycled through the neutral state.
If the ECM receives mismatching information from a
proportional input device and the quick coupler switch,
the system will turn off the auxiliary valve as well as
the solenoid for the quick coupler. The components are
disabled until both inputs return to the neutral state and
a valid input is provided.

Miscellaneous
The following list consists of miscellaneous interlocks.
• The machine security system may disable the
machine by controlling the electronic devices that are
used to power critical machine systems.
31200274 25
Testing and Adjusting Section

Testing and Adjusting Stopping Performance Test for the

Service Brakes
Section
Introduction
Testing and Adjusting If the service brake system has been disassembled or
adjusted, the performance of the service brake system
Service Brake - Test should be checked. The performance should also be
checked if the effectiveness of the brakes is in doubt.
Holding Ability Test for the Service Test Procedure
Brakes 1. Remove the work tool and park the machine in
the travel position.
Introduction
2. Start the engine and disengage the parking brake.
If the service brake system has been disassembled or Place the transmission in fourth gear forward.
adjusted, the performance of the service brake system Accelerate the machine until the machine reaches
should be checked. The performance of the service a constant speed.
brakes should be checked if the effectiveness of the
3. Disengage the transmission by placing the
brakes is in doubt.
transmission in neutral. Rapidly apply the brakes.
Test Procedure 4. The machine should be able to come to a stop
1. Remove the work tool and park the machine in within 10 m (33 ft) of travel from the point of
the travel position. service brake application.
2. Start the engine and disengage the parking brake. 5. Switch off the engine and engage the parking
Place the transmission in first gear forward. brake.
3. Apply the service brake pedal and increase the
engine speed by fully pressing the accelerator
pedal.
4. The machine should remain stationary during this If the machine stopping distance is greater than
test. 10m (33ft), contact your Caterpillar dealer.

5. Switch off the engine and engage the parking Have the dealer inspect and if necessary repair the
brake. service brakes before returning the machine to
operation. Failure to have the service brakes
inspected and repaired can result in injury or death.

Service Brake Control - Check

If the machine moved while testing the service
brakes, contact your Caterpillar dealer. and Adjust
Have the dealer inspect, and if necessary repair the
service brakes before returning the machine to Adjusting the Brake Pedal Linkage
operation. Failure to have the service brakes
inspected and repaired can cause injury or death. Introduction
It will be necessary to take up any free play in the
brake pedal linkage in order to maintain the
performance of the service brake.

Test Procedure

Personal injury or death can result from machine

movement.
Place blocks in front of and behind the wheels to
make sure the machine does not move while the
parking brakes are disengaged.
26 31200274
Testing and Adjusting Section

1. Park the machine on level ground and stop the

engine.
2. Block the wheels and engage the parking brake.
3. Remove the trim panel from the cab in order to
gain access to the brake pedal linkage. Disconnect
the heater hose.

Illustration 25 g00887280
Brake cylinder
(1) Pushrod

4. Carefully attempt to move the pushrod (1) forward

and backward. A small amount of end play should Illustration 27 g00871487
be detected. Brake pedal linkage
5. Slowly press the brake pedal. The end play at (3) Locknut

the pushrod should be taken up when the brake (4) Adjustment bolt
(5) Locknut
pedal has travelled approximately 5 ± 1 mm
(6) Adjustment bolt
(0.19 ± 0.03 inch).
(7) Dust cover
6. If there is no end play at the pushrod, the brake
linkage must be adjusted. If there is more than
5 ± 1 mm (0.19 ± 0.03 inch) of pedal travel, the 2. Loosen locknuts (3) and (5) on adjustment bolts
brake linkage must be also adjusted in order to (4) and (6). Turn adjusting bolts (4) and (6) in a
eliminate any excessive free play. counterclockwise direction. The adjusting bolts
must not contact the brake pedal linkage during
adjustment of the pushrod.
Procedure for Adjusting the Free Play in
3. Remove dust cover (7) on the brake cylinder
the Brake Linkage in order to allow access to the plunger. Rotate
pushrod (1) clockwise until the pushrod bottoms
out in the plunger. There should be 0.9 ± 0.3 mm
(0.03 ± 0.01 inch) of axial play between the
pushrod and the plunger. Tighten locknut (2).
4. Turn adjustment bolt (6) clockwise until the bolt
makes contact with the pedal linkage. Turn the
adjustment bolt clockwise by half a turn. Secure
the adjustment bolt with locknut (5).

Illustration 26 g00872948
Brake cylinder
(1) Pushrod
(2) Locknut

1. Loosen locknut (2) on pushrod (1).

31200274 27
Testing and Adjusting Section

5. Apply force to the brake pedal until the plunger in Procedure for Checking the Wear
the brake cylinder is fully displaced. If the pedal
makes contact with the floor of the cab then adjust
the height of the pedal with adjustment bolt (4).
Do not raise the pedal more than 5 mm (0.2 inch)
off the floor of the cab. Use locknut (3) to secure Personal injury or death can result from machine
the adjustment bolt (4) in place. If the pedal does movement.
not contact the floor, secure the adjustment bolt
(4) with locknut (3) in position. Ensure that the Place blocks in front of and behind the wheels to
adjustment bolt does not interfere with the pedal make sure the machine does not move while the
linkage. parking brakes are disengaged.
6. When the adjustment is complete, check that the 1. Park the machine on level ground and ensure that
plunger in the brake cylinder is flush with the body the parking brake is engaged.
of the brake cylinder and that the required axial 2. Stop the engine. Prepare the machine for
play is available. servicing. Refer to the Operation and Maintenance
7. Install the dust cover onto the brake cylinder and manual for your machine.
reconnect the heater hose. Install the trim in the 3. Place wheel blocks in front of the rear wheels and
cab. behind the rear wheels.
8. Remove the wheel blocks. 4. Use a tool (A) in order to measure the brake discs
9. Prepare the machine for operation. for minimum thickness.

Service Brake Discs - Check

Checking the Wear on the Service
Brake Discs
Introduction
It is necessary to check the service brake discs for
wear in order to maintain the performance of the
service brake.
Required Tools
Illustration 28 g00787712
Use the following test equipment in order to check
Top view of the Front Axle
for wear on the service brake discs:
Table 2 5. Remove oil filler plug (1).
Required Tools 6. Compress and hold the brake pack by applying
force to the service brake pedal.
Tool Part Number Description Qty
Note: Apply sufficient force to the pedal in order to
Brake Wear ensure that the brake pack is fully compressed.
A 242-0992 Gauge 1
28 31200274
Testing and Adjusting Section

Service Brake Air - Purge

Purging Air from the Braking System
Introduction
If the brake system has been disassembled or the oil
has been drained the brake system should be refilled
and purged of air.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Components (Braking)" for
more information on the location of the components.
Required Tools
Use the following test equipment in order to purge
air from the braking system:
Table 3

Required Tools
Part
Tool Description Qty
Number
A 148-7109 Tube 2 m(6.5 ft.)

Illustration 29 g00787713
Manual Purge Procedure for Purging Air
7. Measure the thickness of a brake disc (2) by from the Brake Lines
inserting tool (A) through the oil filler plug hole (3)
and between the plates of the compressed brake
pack. Refer to Illustration 29.
The minimum allowable thickness (S) is 3.350 mm Personal injury or death can result from machine
(0.1319 inch). movement.
8. Disengage the brakes. Place blocks in front of and behind the wheels to
9. Reinstall the oil filler plug. make sure the machine does not move while the
10. Repeat Steps 5 through 9 in order to check the parking brakes are disengaged.
thickness of the brake discs at the opposite side
of the differential for the front axle.
Note: Repeat this procedure as often as needed in order
to maintain the correct thickness of the brake discs.
11. Remove the wheel blocks.
12. Prepare the machine for operation.
31200274 29
Testing and Adjusting Section

NOTICE Note: Purge a minimum of 0.5 L (0.5 qt) of oil on the left
Care must be taken to ensure that fluids are contained side purge screw in order to remove any trapped air in
during performance of inspection, maintenance, testing, the booster and in the adapters.
adjusting and repair of the product. Be prepared to collect 10. When the air bubbles are no longer visible, repeat
the fluid with suitable containers before opening any the procedure 5 times more in order to ensure that
compartment or disassembling any component the braking system is fully purged.
containing fluids. 11. Tighten the purge screw and remove the tube.
Refer to Special Publication, "Caterpillar Tools and Shop Install the cap on the purge screw.
Products Guide" for tools and supplies suitable to collect 12. Loosen the other purge screw.
and contain fluids on Caterpillar products.
13. Repeat Step 8 through Step 11.
Dispose of all fluids according to local regulations and
mandates. 14. Repeat the purging procedure if the brakes
appear soft.
1. Start the engine.
After you have performed the above procedure and the
2. Park the machine on level ground and lower the brakes are still poor it may be necessary to allow the
boom. Engage the parking brake. vehicle to sit for a short time. This allows any aerated
3. Place wheel blocks in front of the wheels and oil to settle. Once the vehicle has sat for 60 minutes
behind the wheels. repeat the above procedures.
4. Disengage the parking brake and stop the engine. The Brake Pedal Degrades
If the brake pedal degrades within 24 hours of purging
the brakes there may be a leak in the brake system. It is
possible that a leak is present between two mating
components. You should check that all connections are
tight. An oil leak may not always be observed, unless
the suspect connection is carefully examined under
pressure. The oil may flow slowly and the oil may be
observed at this point.

Parking Brake - Test

Illustration 30 g00922892
Holding Ability Test for the Parking
Top View of the Front Axle Brake
(1) Purge screw on the left side of the front axle
(2) Purge screw on the right side of the front axle Introduction
5. Remove the two caps from purge screws (1) and If the parking brake system has been disassembled or
(2) on the top of the front axle. Attach a 1 m (3 ft) adjusted, the performance of the parking brake should
length of 148-7109 Tube to each of the purge be checked. The performance of the parking brake
screws. Place the other ends of the tubes into a should also be checked if the effectiveness of the
suitable container. The container should contain parking brake is in doubt.
approximately 2.5 L (.5 Imp gal) of clean hydraulic
oil.
Note: Before you attach the tube to the purge screw Test Procedure
ensure that the purge screw is free of dirt. 1. Remove the work tool from the quick coupler. Park
6. Start the engine. the machine in the travel position.
7. Loosen the purge screw on left side of the axle. 2. Engage the parking brake.
8. With the engine at low idle, begin to depress the 3. Position the transmission speed selector to
brake pedal. This will cause the piston for the Second Gear.
brake cylinder to stroke thus forcing oil from the 4. In order to engage the Second Gear Forward,
brake cylinder to the axle. Release the brake move the transmission speed selector from the
pedal. neutral position to the Forward position. Repeat
9. Continue to depress the brake pedal and release the action twice in a quick manner in order to
the brake pedal until the flow from the axle override the neutralizer function of the parking
appears free of air bubbles. brake.
30 31200274
Testing and Adjusting Section

5. Increase the engine speed from LOW Idle to HI Adjustment Procedure

Idle.
6. If the machine moved during the test disengage
the parking brake. Turn the adjustment knob on
the hand lever clockwise in order to tension the
brake cable. Personal injury or death can result from machine
7. Repeat steps 3 through 6 until the machine movement.
remains stationary during the test. Place blocks in front of and behind the wheels to
8. Engage the parking brake and switch off the make sure the machine does not move while the
engine. parking brakes are disengaged.
1. Park the machine on level ground. Stop the
engine.
2. Place wheel blocks in front of the rear wheels and
behind the rear wheels.
If the machine moved while testing the parking
brake, contact your Caterpillar dealer.
Have the dealer inspect, and if necessary repair the
parking brake before returning the machine to
operation. Failure to have the parking brakes
inspected and repaired can result in injury or death.

Parking Brake Control - Check

and Adjust
Adjusting the Parking Brake Control Illustration 31 g00905098
(1) Parking brake lever
Cable (2) Lever

Introduction 3. Place the parking brake in the DISENGAGED

The parking brake control cable can be adjusted at the position. Depress the release lever (2) and push the
parking brake control lever which is located in the cab of parking brake lever (1) downward.
the machine. The parking brake control cable can also
be adjusted at the brake caliper which is located on the
rear of the front axle.
Reference: See Systems Operation/Testing and
Adjusting, "Location of Components (Braking)" for the
location of the parking brake control lever and the
brake caliper.
31200274 31
Testing and Adjusting Section

9. When the hand lever for the parking brake is in

the DISENGAGED position, the brake caliper
that is located on the front axle should be fully
released. The switch (parking brake) should
also be disengaged when the hand lever for the
parking brake is in the DISENGAGED position.
10. When the hand lever for the parking brake is in
the DISENGAGED position, turn the switch for
the ignition circuit to the ON position. The ignition
circuit should remain off.

Illustration 34 g00905111
Illustration 32 g01084522
(6) Adjusting knob

4. Adjust dimension (A) to 120 ± 4 mm (4.7244

±0.1575 inch). 11. You can adjust the cable by the adjusting knob
(6) on the hand lever. Check the operation of the
parking brake. As you view the parking brake
adjuster knob from the operator seat, turn the
knob counterclockwise for one quarter of a turn.
12. Place the hand lever for the parking brake in the
DISENGAGED position. Turn the adjusting knob
(6) on the hand lever clockwise in increments of
two turns in order to increase the brake force.
Turn the adjusting knob on the hand lever
counterclockwise in order to decrease the brake
force.
13. When the parking brake adjustment is correct,
engage the parking brake and remove the wheel
blocks from all the wheels.
Illustration 33 g00795400
(3) Nut 14. Check the area around the machine. Make sure
(4) Nut that the machine is clear of personnel and clear
(5) Brake disc of obstacles.
5. Loosen nuts (3) and (4) on the brake caliper on 15. Refer to Service Manual, "Testing and Adjusting",
the front axle. "Parking Brake - Test" in order to
test the parking brake.
6. Tighten nut (3) to 14.0 ± 0.6 Nm (120 ± 5 lb in).
7. Turn nut (3) counterclockwise for three quarters of
a turn. Verify that brake disc (5) rotates freely.
8. Tighten nut (4) against nut (3). Tighten nut (4) to a
torque of 68 ± 7 Nm (50 ± 6 lb ft).
32 31200274
Testing and Adjusting Section
31200274 33
Index Index

B P
Brake Cylinder (Master) ..................................................... 14 Parking Brake..................................................................... 12
Brake Cylinder with the Brakes Disengaged ................ 15 Disengaging the Parking Brake .................................... 13
Brake Cylinder with the Brakes Engaged ..................... 17 Engaging the Parking Brake ......................................... 12
Parking Brake - Test
C
Holding Ability Test for the Parking Brake .................... 29
Configuration Parameters .................................................. 20 Parking Brake - Test .......................................................... 29
E Parking Brake Control - Check and Adjust......................... 30
Adjusting the Parking Brake Control Cable .................. 30
Electrical Function Requirements
Machine Security System ............................................. 21 S
Parking Brake ............................................................... 21 Service Brake....................................................................... 8
Rear Axle Lock (if equipped) ........................................ 21 Service Brake ................................................................. 8
Shift Lever (Cat Data Link) for Powersynchro The Service Brake System with the Brakes
Transmission ................................................................ 21 Disengaged................................................................... 10
Shuttle Shift for the Power Shuttle Transmission ......... 21 The Service Brake System with the Brakes Engaged .. 11
System Voltage............................................................. 21 Service Brake Air - Purge
Transmission Neutralizer .............................................. 21 Purging Air from the Braking System............................ 28
Electrical Function Requirements ...................................... 21 Service Brake Air - Purge................................................... 28
G Service Brake Control - Check and Adjust
Adjusting the Brake Pedal Linkage............................... 25
General Information
Service Brake Control - Check and Adjust ......................... 25
Brake Cylinder ................................................................ 5
Service Brake Discs - Check
Brake Packs.................................................................... 5
Checking the Wear on the Service Brake Discs ........... 27
Parking Brake Lever ....................................................... 6
Service Brake Discs - Check.............................................. 27
Service Brake Pressure Switch ...................................... 6
Systems Operation Section.................................................. 3
General Information ............................................................. 5
Systems Operation Section.................................................. 3
Graphic Color Codes............................................................ 3
Graphic Color Codes............................................................ 3 T
H Table of Contents................................................................. 1
Testing and Adjusting Section............................................ 25
Hydraulic Schematic (Braking System).............................. 19
Testing and Adjusting Service Brake - Test
I Holding Ability Test for the Service Brakes................... 25
Important Safety Information.................................................ii Stopping Performance Test for the Service Brakes...... 25
Introduction .......................................................................... 4 Testing and Adjusting Service Brake - Test ....................... 25

L Z
Location of Components (Braking) Location of Components (Braking)....................................... 7
Brake Cylinder ................................................................ 8
Parking Brake Actuator................................................... 7
Parking Brake Lever ....................................................... 7
Service Brake Discs........................................................ 8
Service Brake Pedal ....................................................... 7
Location of Electrical Components....................................... 6
Parking Brake Switch...................................................... 6
Service Brake Pressure Switch ...................................... 6
Stoplight Switch .............................................................. 6

M
More Electrical Function Requirements
Boom Raise/Lower Is Disabled..................................... 23
Disable the Quick Coupler ............................................ 24
Disable The Rackback And Dump................................ 23
Miscellaneous ............................................................... 24
Stabilizer Raise/Lower (if equipped) is Disabled .......... 23
Steering ........................................................................ 22
The Boom Extend/Retract Is Disabled.......................... 23
The Frame Level (if equipped) is Disabled ................... 24
The Neutral Start Is Disabled........................................ 22
More Electrical Function Requirements ............................. 22
34 31200274
Index
Manufactured by JLG under license from Caterpillar
31200306
December 15, 2006

Specifications
TH360B and TH560B Telehandlers
Machine Systems
S/N TBH00100 & After
S/N TBP00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200306 1
Table of Contents
Table of
Table of Contents Transmission.......................................... 43
Specifications Section Position Sensor (Transmission) ............. 45
Hydraulic Tank......................................... 3 Oil Filter.................................................. 46
Hydraulic Tank......................................... 5 Hydraulic Oil Cooler ............................... 48
Hydraulic Tank......................................... 6 Drive Shaft ............................................. 49
Piston Pump (Implement and Steering)... 7 Drive and Steering Axle (Front) ............. 50
Solenoid Valve (Pilot Selector) ................ 8 271 -6425 Drive and Steering
Main Control Valve (Implement) .............. 9 Axle Gp .............................................. 50
Frame .................................................... 11 271 -6426 Drive and Steering
Boom ..................................................... 12 Axle Gp .............................................. 52
Boom ..................................................... 13 Drive and Steering Axle (Front) ............. 54
Boom Cylinder ....................................... 14 271 -6427 Drive and Steering Axle Gp,
Boom Cylinder ....................................... 15 with Steering Sensor.......................... 54
Boom Cylinder ....................................... 16 Drive and Steering Axle (Rear) .............. 56
Load Control Valve (Boom Cylinder) 189-5717 Drive and Steering Axle Gp,
(Lock)..................................................... 17 with Steering Sensor.......................... 56
Compensating Cylinder ......................... 18 168-7443 Drive and Steering Axle Gp,
Compensating Cylinder ......................... 19 with Steering Sensor.......................... 57
Telescoping Cylinder ............................. 20 Drive and Steering Axle (Rear) .............. 58
Load Control Valve (Telescoping Cylinder) 231 -0710 Drive and Steering Axle Gp,
(Lock)..................................................... 21 without Steering Sensor..................... 58
Tilt Cylinder............................................ 22 231 -0709 Drive and Steering Axle Gp,
Tilt Cylinder............................................ 23 with Steering Sensor.......................... 59
Load Control Valve (Tilt Cylinder) (Lock)24 Differential and Bevel Gear Group ......... 60
Diverter Valve ........................................ 24 Differential and Bevel Gear Group ......... 61
Diverter Valve ........................................ 25 Axle Housing and Flange Group ............ 62
Towing Hitch .......................................... 26 Axle Housing and Flange Group ............ 62
Towing Hitch .......................................... 26 Final Drive Planetary Group................... 63
Towing Hitch .......................................... 27 Final Drive Planetary Group................... 64
Towing Hitch .......................................... 27 Axle Housing Group (Differential and Brake
Towing Hitch .......................................... 28 Cylinder)................................................. 65
Towing Hitch .......................................... 28 174-4642 Axle Housing Gp with a
Frame Leveling Cylinder........................ 29 Locking Differential ............................ 65
Frame Leveling Cylinder........................ 30 219-8780 Axle Housing Gp................ 67
Load Control Valve (Frame Leveling 219-8831 Axle Housing Gp with a
Cylinder) (Lock) ..................................... 31 Locking Differential ............................ 69
Control Valve (Stabilizer) ....................... 32 219-8842 Axle Housing Gp without a
Stabilizer Cylinder.................................. 33 Locking Differential ............................ 71
Stabilizer Cylinder.................................. 34 Axle Housing Group (Differential and Brake
Stabilizer Cylinder.................................. 35 Cylinder)................................................. 73
Load Control Valve (Stabilizer Cylinder) 253-4990 Axle Housing Gp with a
(Lock)..................................................... 36 Locking Differential ............................ 73
Axle Lock Cylinder ................................. 37 253-4985 Axle Housing Gp without a
Metering Pump (Steering) ..................... 38 Locking Differential ............................ 75
Solenoid Valve (Steering Mode Brake Cylinder (Master) ......................... 76
Selector) ................................................ 38 Parking Brake Control ............................ 77
Position Sensor (Steering)..................... 39 Parking Brake ........................................ 78
Position Sensor (Steering)..................... 39 Fender.................................................... 79
Flexible Coupling Drive.......................... 40 Wheel (Tire and Rim) ............................. 80
Transmission ......................................... 41 Fuel Tank ............................................... 81
2 31200306
Table of Contents

Fuel Tank ...............................................82

Engine Enclosure ...................................83
Engine and Transmission Mounting .......85
Air Cleaner .............................................86
Engine Oil Drain .....................................88
Muffler ....................................................89
Suction Fan ............................................90
Battery ....................................................91
Alternator................................................92
Coolant Lines Group ..............................93
Coolant Recovery Group........................94
Cab.........................................................96
Latch Adjustment ...............................96
Cab Mounting .........................................97
Cab Door ................................................98
Access Door .........................................100
Joystick Control ....................................101
Steering Wheel and Column ................102
Window Wiper and Wiper Motor...........103
Window Washer Tank ..........................104
Rear View Mirror ..................................105
Carriage Cylinder (Rotate) ...................105
Carriage Cylinder (Sideshift) ................106
Hydraulic Cylinder (Multipurpose
Bucket) .................................................107
Grapple Cylinder ..................................108
31200306 3
Specifications Section

Specifications Section
Hydraulic Tank

Illustration 1 g01076453

(1) Hydraulic filler cap

(2) The torque for the bolts for the oil level
indicator ...................................... 10 ± 1 Nm (88 ± 9 lb in)
Note: Remove nuts before assembly. The nuts are not
required.
(3) The torque for the bolt ............................. 2.25 ± 0.25 Nm
(20 ± 2 lb in)
(4) The torque for the drain plug .......................... 35 ± 5 Nm
(25 ± 3 lb ft)
(5) The torque for the bolts ........................... 2.25 ± 0.25 Nm
(20 ± 2 lb in)
4 31200306
Specifications Section

Illustration 2 g01076465

(6) The torque for the bolts for the hydraulic

tank.............................................. 30 ± 5 Nm (22 ± 3 lb ft)
(7) The torque for the bolts for the hydraulic
tank.............................................. 30 ± 5 Nm (22 ± 3 lb ft)
31200306 5
Specifications Section

Hydraulic Tank

Illustration 3 g01055813
203-1995 Fuel Tank Gp
(1) Hydraulic filler cap
(2) The torque for the bolts for the tube
assemblies .......................... 2.25 ± 0.25 Nm (20 ± 2 lb in)
(3) The torque for the drain plug ......................... 14 ± 1 Nm
(124 ±9 lb in)
6 31200306
Specifications Section

Hydraulic Tank

Illustration 5 g00862098
232-7695 Hydraulic Tank Gp
(1) Hydraulic filler cap
(2) The torque for the bolts for the oil level
indicator ...................................... 10 ± 1 Nm (88 ± 9 lb in)
(3) The torque for the bolts for the hydraulic
tank.............................................. 30 ± 5 Nm (22 ± 3 lb ft)
(4) The torque for the bolts for the tube
assemblies .......................... 2.25 ± 0.25 Nm (20 ± 2 lb in)
(5) The torque for the drain plug .......................... 35 ± 5 Nm
(25 ± 3 lb ft)
31200306 7
Specifications Section

Piston Pump (Implement and

Steering)

Illustration 6 g00937820

Pump type ......................................................... variable piston

The rotation of the shaft is counterclockwise when the rotation
of the shaft is viewed from the drive end.
Displacement of the pump.................... 45 cc/rev (2.75 in3/rev)
Pressure setting...................................... 31500 kPa (4570 psi)
Cut off pressure ...................................... 26000 kPa (3770 psi)
Margin pressure at full speed..................... 2200 kPa (320 psi)
Maximum case drain flow at port (T) ........................... 5 L/min
(1.32 US gpm)
The pump speed
LOW engine idle.....................................................1013 rpm
HIGH engine idle .................................................. 2515 rpm
(1) Torque setting for plug.......................... 190 Nm (140 lb ft)
(2) 223-8910 Valve As
(A) Pressure port
(S) Suction port
(X) LS pressure port
(T) Case Drain port
8 31200306
Specifications Section

Solenoid Valve (Pilot Selector)

Illustration 7 g00849505

Technical data
Maximum pressure ........................... 32000 kPa (4640 psi)
Oil flow at maximum pressure ............................ 25 L/min
(6.6 US gpm)
Voltage ....................................... 10.5 volts to 14 volts DC
Rated resistance...................................................................7.7Q
(1) Torque for fasteners . . . . . . . . . . . . . 4 ± 1 Nm (35 ± 9 lb in)
31200306 9
Specifications Section

Main Control Valve (Implement)

Illustration 8 g01134146
10 31200306
Specifications Section

Illustration 9 g01134171

(1) Load Signal port for Steering

(2) Control Valve for the Telescoping Cylinder
(3) Control Valve for the Auxiliary Function
(4) Control Valve for the Fork Cylinder
(5) Boom Cylinder Control Valve
(6) Torque for the locknut ....................20 ± 2 Nm (15 ± 1 lb ft)
(7) Torque for the valve....................... 55 ± 5 Nm (40 ± 5 lb ft)
(8) Torque for four nuts ................................. 35 Nm (25 lb ft)
(9) Oil Supply Port for Steering
(10) Relief Valve (Load sensing signal)
Pressure setting................................ 22800 kPa (3300 psi)
Torque for the relief valve........................ 45.0 ±4.5 Nm
(33.2 ± 3.3 lb ft)
(11) Torque for valve cap.................... 20 ± 2 Nm (15 ± 1 lb ft)
(12) Drain Port
(13) Torque for eight bolts ................. 3 ±0.3 Nm (27 ±3 lb in)
(14) Torque for eight bolts ................. 3 ±0.5 Nm (27 ±4 lb in)
31200306 11
Specifications Section

Frame

Illustration 10 g00998905

(1) Thickness of shim .....................................2 mm (0.08 inch)

(2) Thickness of shim ................................ 1.5 mm (0.06 inch)
(3) Thickness of shim ................................... 1 mm (0.04 inch)
(4) Thickness of shim ................................... 3 mm (0.12 inch)
Note: Use the shims in order to obtain a maximum gap of 1
mm (0.04 inch).
12 31200306
Specifications Section

Boom

Illustration 11 g01055968

(1) Use 4C-4030 Thread Lock Compound on

threads.
(2) Thickness of shims .............................. 1.5 mm (0.06 inch)
(3) Torque for the nuts on the chain .....................105 ± 5 Nm
(77 ± 4 lb ft)
(4) Torque for the nuts on the chain.......................70 ± 5 Nm
(52 ± 5 lb ft)
31200306 13
Specifications Section

Boom

Illustration 12 g01055968

(1) Use 4C-4030 Thread Lock Compound on

threads.
(2) Thickness of shims .............................. 1.5 mm (0.06 inch)
(3) Torque for the nuts on the chain..................... 130 ± 5 Nm
(95.88 ± 3.69 lb ft)
(4) Torque for the nuts on the chain ...................... 85 ± 5 Nm
(62.69 ± 3.69 lb ft)
14 31200306
Specifications Section

Boom Cylinder
Part No.: 253-3933

Illustration 16 g01170423

Cylinder stroke ..................................... 1951 mm (76.81 inch)

(1) Torque setting for self-locking
nut................................ 6500 ± 500 Nm (4795 ± 370 lb ft)
Lubricate the threads of the self-locking nut with clean grease.
(2) Diameter of piston ................................. 132.85 ± 0.03 mm
(5.2303 ±0.0012 inch)
(3) Bore of cylinder ..................................... 133.35 ± 0.08 mm
(5.250 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 101.55 ± 0.038 mm
(3.998 ±0.0015 inch)
(5) Bore of head .......................................... 101.93 ± 0.03 mm
(4.013 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7308 Sleeve Bearing
outside diameter................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter .................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
(9) 207-1738 Bearing
outside diameter............................. 104.993 ± 0.0075 mm
(4.1336 ±0.0003 inch)
Inside diameter ................................ 69.9930 ± 0.0075 mm
(2.7556 ± 0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 15
Specifications Section

Boom Cylinder
Part No.: 253-3964

Illustration 17 g01170423

Cylinder stroke ................................. 1832 mm (72.1258 inch)

(1) Torque setting for self-locking
nut ................................6500 ± 500 Nm (4795 ± 370 lb ft)
Lubricate the threads of the self-locking nut with clean grease.
(2) Diameter of piston ................................. 132.85 ± 0.03 mm
(5.230 ± 0.001 inch)
(3) Bore of cylinder ..................................... 133.35 ± 0.08 mm
(5.250 ± 0.003 inch)
(4) Diameter of piston rod ........................ 101.55 ± 0.038 mm
(3.998 ± 0.002 inch)
(5) Bore of head .......................................... 101.93 ± 0.03 mm
(4.013 ±0.001 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7308 Sleeve Bearing
outside diameter................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter.................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
(9) 207-1738 Bearing
outside diameter............................. 104.993 ± 0.0075 mm
(4.1336 ±0.0003 inch)
Inside diameter................................ 69.9930 ± 0.0075 mm
(2.7556 ± 0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
16 31200306
Specifications Section

Boom Cylinder
Part No.: 253-4258

Illustration 21 g01170707

Cylinder stroke ..................................... 1972 mm (77.64 inch)

(1) Torque setting for self-locking
nut................................ 6500 ± 500 Nm (4795 ± 370 lb ft)
Lubricate the threads of the self-locking nut with clean grease.
(2) Diameter of piston ................................... 154.5 ±0.03 mm
(6.083 ± 0.001 inch)
(3) Bore of cylinder .......................................... 155 ±0.08 mm
(6.102 ±0.003 inch)
(4) Diameter of piston rod ........................ 107.95 ± 0.038 mm
(4.248 ± 0.002 inch)
(5) Bore of head .......................................... 108.28 ± 0.03 mm
(4.263 ± 0.001 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 210-8897 Sleeve Bearing
outside diameter................................. 85.845 ± 0.025 mm
(3.3797 ±0.0010 inch)
Inside diameter................................... 70.315 ± 0.025 mm
(2.7683 ±0.0010 inch)
(9) 210-8374 Bearing
outside diameter............................. 119.9925 ± 0.0075 mm
(4.7241 ± 0.0003 inch)
Inside diameter............................... 79.9925 ± 0.0075 mm
(3.1493 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 17
Specifications Section

Load Control Valve (Boom

Cylinder) (Lock)

Illustration 22 g01170870
Load Control Valve (Boom Cylinder)

(1) Damper screw

The recommended torque for the mounting bolts is 23 ± 1 Nm
(204 ± 9 lb in).
18 31200306
Specifications Section

Compensating Cylinder
Part No.: 203-7847

Illustration 23 g01121416

Cylinder stroke ......................................... 344 mm (13.5 inch)

(1)Torque setting for bolt....................................850 ± 25 Nm
(625 ± 20 lb ft)
Lubricate the threads of the bolt with clean grease.
(2) Diameter of piston ..................................... 74.5 ± 0.03 mm
(2.9331 ±0.0012 inch)
(3) Bore of cylinder ............................................ 75 ± 0.08 mm
(2.9527 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 44.950 ± 0.038 mm
(1.7697 ±0.0015 inch)
(5) Bore of head ............................................ 45.33 ± 0.03 mm
(1.7846 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 193-3857 Bearing
Diameter......................................... 61.9935 ± 0.0065 mm
(2.4407 ± 0.0003 inch)
Bore .................................................... 39.994 ± 0.006 mm
(1.5746 ±0.0002 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 19
Specifications Section

Compensating Cylinder
Part No.: 207-5070

Illustration 24 g01121416

Cylinder stroke ......................................... 352 mm (13.9 inch)

(1) Torque setting for bolt .................................. 850 ± 25 Nm
(625 ± 20 lb ft)
Lubricate the threads of the bolt with clean grease.
(2) Diameter of piston ..................................... 74.5 ± 0.03 mm
(2.9331 ±0.0012 inch)
(3) Bore of cylinder ....................................... 90.00 ± 0.08 mm
(3.5433 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 44.950 ± 0.038 mm
(1.7697 ±0.0015 inch)
(5) Bore of head ............................................ 45.33 ± 0.03 mm
(1.7846 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7311 Bearing
Outside diameter ............................... 74.9935 ± 0.0065 mm
(2.9525 ± 0.0003inch)
Inside diameter ...................................... 49.994 ± .006 mm
(1.9683 ±0.0002 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
20 31200306
Specifications Section

Telescoping Cylinder
Part No.: 241-3160
Part No.: 241-3160

Illustration 26 g00842439

Cylinder stroke ..................................... 3570 mm (140.6 inch)

(1) Diameter of piston ................................. 99.55 ± 0.03 mm
(3.9193 ±0.0012 inch)
Torque setting for piston (1)........................... 1000 ± 100 Nm
(735 ± 75 lb ft)
Lubricate the threads of the piston with clean grease.
Apply sealant to the threads of the set screw (2).
(3) Bore of cylinder .......................................... 100 ±0.08 mm
(3.9370 ± 0.0031 inch)
(4) Diameter of piston rod ............................. 69.8 ± 0.038 mm
(2.7480 ±0.0015 inch)
(5) Bore of head ............................................ 70.13 ±0.03 mm
(2.7610 ±0.0012 inch)
(6) Torque setting of head . . . . . . . . . . . . . . . . . . . . . . . 6 0 0 ±1 3 0 N m
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to the wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
31200306 21
Specifications Section

Load Control Valve

(Telescoping Cylinder) (Lock)

Illustration 27 g01077337

(1) Damper screw

(2) Torque for four bolts.......................23 ± 1 N m ( 1 7 ±1 lb ft)
Pressure setting for the load control
valve ...................................................... 26000 kPa (3770 psi)
22 31200306
Specifications Section

Tilt Cylinder
Part No.: 203-7756

Illustration 28 g01171377

Cylinder stroke ................................... 327 mm (12.8740 inch)

(1) Torque setting for nut ...............................6500 ± 100 Nm
(4795 ± 75 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................... 124.5 ±0.03 mm
(4.9016 ±0.0012 inch)
(3) Bore of cylinder ....................................... 125.0 ±0.08 mm
(4.9213 ±0.0031 inch)
(4) Diameter of piston rod .......................... 74.95 ± 0.038 mm
(2.9508 ±0.0015 inch)
(5) Bore of head ............................................ 75.33 ± 0.03 mm
(2.9657 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 100 Nm
(445 ± 75 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 256-0181 Sleeve Bearing
Outside diameter................................ 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter .................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
(9) 193-3865 Bearing
Diameter......................................... 89.9925 ± 0.0075 mm
(3.5430 ± 0.0003 inch)
Bore ................................................ 59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 23
Specifications Section

Tilt Cylinder
Part No.: 211-1322

Illustration 30 g01171377

Cylinder stroke ......................................... 327 mm (12.9 inch)

(1) Torque setting for self-locking
nut ..................................6500 ± 100 Nm (4800 ± 75 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................... 149.5 ±0.03 mm
(5.89 ± 0.001 inch)
(3) Bore of cylinder ..................................... 150.00 ± 0.08 mm
(5.906 ± 0.003 inch)
(4) Diameter of piston rod .......................... 74.95 ± 0.038 mm
(2.950 ±0.0015 inch)
(5) Bore of head ............................................ 75.33 ± 0.03 mm
(2.966 ± 0.001 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 240-9962 Sleeve Bearing
Diameter............................................. 93.605 ± 0.025 mm
(3.6852 ±0.0010 inch)
Bore.................................................... 80.275 ± 0.025 mm
(3.1604 ±0.0010 inch)
(9) 210-8374 Bearing
Diameter ......................................... 119.9925 ± 0.0075 mm
(4.7241 ± 0.0003 inch)
Bore................................................ 79.9925 ±0.0075 mm
(3.1493 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
24 31200306
Specifications Section

Load Control Valve (Tilt Diverter Valve

Cylinder) (Lock)

Illustration 32 g00850222
Single Diverter Valve

Illustration 31 g00936419

(1) Installation torque .....................150 ± 8 Nm (110 ±6 lb ft)

Set pressure .......................................... 33000 kPa (4800 psi)
Pilot ratio......................................................................................... 4.2:1

Illustration 33 g00939703
Dual Diverter Valve
Technical Data
Maximum operating pressure.............................21000 kPa
(3045 psi)
Maximum flow ..................................90 L/min (25 US gpm)
(1) Torque for fastener......................... 8 ± 1 Nm (70 ± 9 lb in)
(2) Torque for cartridge ..................... 26 ± 1 Nm (20 ±1 lb ft)
(3) Torque for mounting bolts ................................ 14 ± 1 Nm
(10 ± 1 lb ft)
31200306 25
Specifications Section

Diverter Valve

Illustration 34 g01080341
Conversion kit for the diverter valve
(1) 226-6494 Diverter Valve (3) Components from original assembly
(2) 179-1867 Diverter Valve (4) Bolts from original assembly

Technical data
Maximum operating pressure ............................ 21000 kPa
(3045 psi)
Maximum flow ................................. 90 L/min (25 US gpm)
(3) Relocate the fittings. Torque for
fittings ..........................................80 ± 8 Nm (59 ± 6 lb ft)
(4) Relocate the bolts. Torque for bolts.....................13 ± 1 Nm
(115 ±9 lbin)
26 31200306
Specifications Section

Towing Hitch Towing Hitch

Part No.: 211-8359 Part No.: 211-8358

Illustration 35 g00943200 Illustration 36 g00943198

(1) 200-2141 Hitch Gp (1) 200-2142 Hitch Group

(2) Torque for Six Nuts ............................... 530±70Nm (2) Torque for Six Nuts ..................................... 530±70N-m
(390 ± 50 lb ft) (390 ± 50 lb ft)
31200306 27
Specifications Section

Towing Hitch Towing Hitch

Part No.: 211-8357 Part No.: 211-8356

Illustration 37 g00943195 Illustration 38 g00943109

(1) 200-2140 Hitch Group (1) Torque for Six Nuts .................................... 530±70N-m
(390 ± 50 lb ft)
(2) Torque for Six Nuts .............................. 530±70Nm
(390 ± 50 lb ft)
28 31200306
Specifications Section

Towing Hitch Towing Hitch

Part No.: 211-2381 Part No.: 211-9463

Illustration 39 g00941379 Illustration 40 g00943017

(1) Torque for Two Nuts .. ... ... .... ... ... ... ... ... .. 530±70Nm (1) Torque for Three Nuts .......................... 530±70Nm
(390 ± 50 lb ft) (390 ± 50 lb ft)
31200306 29
Specifications Section

Frame Leveling Cylinder

Part No.: 204-7813

Illustration 41 g01121213

Cylinder stroke ........................................... 168 mm (6.6 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................... 99.55 ± 0.03 mm
(3.9193 ±0.0012 inch)
(3) Bore of cylinder .......................................... 100 ±0.08 mm
(3.9370 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 50.750 ± 0.038 mm
(1.9980 ±0.0015 inch)
(5) Bore of head ............................................ 51.13 ±0.03 mm
(2.0130 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7311 Bearing
Outside diameter............................ 74.9935 ± 0.0065 mm
(2.9525 ± 0.0003 inch)
Inside diameter.................................... 49.988 ± 0.012 mm
(1.9680 ±0.0005 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
(9) 204-7310 Sleeve Bearing
Outside diameter................................. 60.195 ± 0.025 mm
(2.3699 ±0.0010 inch)
30 31200306
Specifications Section

Frame Leveling Cylinder

Part No.: 211-1327

Illustration 42 g01121139

Cylinder stroke ........................................... 168 mm (6.6 inch)

(1) Torque setting for self-locking
nut.................................... 1200 ± 120 Nm (885 ± 85 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................. 109.50 ± 0.03 mm
(4.3110 ±0.0012 inch)
(3) Bore of cylinder ...........................................110 ±0.08 mm
(4.3307 ± 0.0031 inch)
(4) Diameter of piston rod ............................. 44.4 ± 0.038 mm
(1.7480 ±0.0015 inch)
(5) Bore of head ............................................ 44.78 ± 0.03 mm
(1.7630 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 193-3865 Bearing
Diameter......................................... 89.9925 ± 0.0075 mm
(3.5430 ± 0.0003 inch)
Bore ................................................ 59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
(9) 204-7308 Sleeve Bearing
Outside diameter................................ 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter .................................... .60.305 ±0.025 mm
(2.3742 ±0.0010 inch)
31200306 31
Specifications Section

Load Control Valve (Frame

Leveling Cylinder) (Lock)

Illustration 44 g00849768

(1) Pressure setting of valve .................. 35000 kPa (5075 psi)

(2) Torque for four mounting bolts.........................23 ± 1 Nm
(17 ± 1 lb ft)
(3) Pressure setting of valve .................. 35000 kPa (5075 psi)
(4) Installation torque for cartridge ........................45 ± 6 Nm
(33 ± 5 lb ft)
(5) Installation torque for fastener . . . . . . . . . . . . . . . . 5 ± 1 Nm
(44 ± 9 lb in)

i
32 31200306
Specifications Section

Control Valve (Stabilizer)

Illustration 46 g01164853

Maximum Operating pressure ................................. 23800 kPa

(3450 psi)
Temperature range ..................................... 43 °C to - 40 °C
(109 °Fto-32°F)
(1) Torque for the eight bolts.................................. 8 ± 1 Nm
(71 ± 9 lb in)
(2) Installation torque ........................ 50 ± 1 Nm (37 ± 1 lb ft)
(3) Installation torque .......................... 7 ± 1 Nm (62 ± 9 lb in)
(4) Four coils
Voltage ......................................................................... 12 VDC
Resistance .........................................................................5.2 Q
Wattage ................................................................... 27 W
(5) Coil
Voltage.......................................................................... 10 VDC
Resistance..............................................................................................................5 Q.
Wattage ....................................................................19.9 W
31200306 33
Specifications Section

Stabilizer Cylinder
Part No.: 207-2068

Illustration 47 g01171677

Cylinder stroke......................................... 450 mm (17.72 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston ................................... 124.5 ±0.03 mm
(4.9016 ±0.0012 inch)
(3) Bore of cylinder ..................................... 125.00 ± 0.08 mm
(4.9213 ±0.0031 inch)
(4) Diameter of piston rod ........................ 54.930 ± 0.038 mm
(2.1626 ±0.0015 inch)
(5) Bore of the head ...................................... 55.28 ± 0.03 mm
(2.1764 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8) 193-3865 Bearing
Diameter .............................................. 89.9925 ± 0.0075 mm
(3.5430 ± 0.0003 inch)
Bore...................................................... 59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
(9) 204-7308 Sleeve Bearing
Diameter............................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore ................................................... 60.305 ±0.025 mm
(2.3742 ±0.0010 inch)
34 31200306
Specifications Section

Stabilizer Cylinder
Part No.: 259-8723

Illustration 48 g01171746

Cylinder stroke......................................... 450 mm (17.72 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston .................................... 114.50 ± 0.03 mm
(4.508 ± 0.001 inch)
(3) Bore of cylinder ......................................115.00 ±0.08 mm
(4.528 ± 0.003 inch)
(4) Diameter of piston rod ........................ 54.930 ± 0.038 mm
(2.1626 ±0.0015 inch)
(5) Bore of the head ...................................... 55.28 ± 0.03 mm
(2.1764 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8), (9) 204-7308 Sleeve Bearing
Diameter............................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore .................................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
31200306 35
Specifications Section

Stabilizer Cylinder
Part No.: 263-9955 S/N: SLG1300-Up

Illustration 50 g01165330

Cylinder stroke......................................... 450 mm (17.72 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston ................................... 139.5 ±0.03 mm
(5.4921 ±0.0012 inch)
(3) Bore of cylinder .......................................... 140 ±0.08 mm
(5.5118 ±0.0031 inch)
(4) Diameter of piston rod .......................... 64.95 ± 0.038 mm
(2.5571 ±0.0015 inch)
(5) Bore of the head ...................................... 65.28 ± 0.03 mm
(2.5701 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 300 Nm
(440 ± 220 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply 4C-4032 Bearing Mount Compound to seal groove (7)
prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8) 210-8895 Bearing
Outside diameter.................................... 85.85 ± 0.01 mm
(3.380 ± 0.0004 inch)
Inside diameter................................... 70.315 ± 0.025 mm
(2.7683 ±0.0010 inch)
(9) 204-7308 Sleeve Bearing
Diameter............................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore .................................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
36 31200306
Specifications Section

Load Control Valve (Stabilizer

Cylinder) (Lock)
Part No.: 204-6924
Part No.: 204-6924

Illustration 51 g00849802

(1) Pressure setting for the rod end of the

cylinder............................................ 10000 kPa (1450 psi)
(2) Pressure setting for the head end of the
cylinder ............................................. 35000 kPa (5075 psi)
Torque for four mounting bolts .............................. 23 ± 1 Nm
(17 ± 1 lb ft)
Maximum flow.....................................60 L/min (15.9 US gpm)
Maximum operating pressure................................... 35000 kPa
(5075 psi)
31200306 37
Specifications Section

Axle Lock Cylinder

Illustration 52 g01121364

Cylinder stroke............................................. 208 mm (8.2 inch)

(1) Torque setting for self-locking
nut ....................................1200 ± 120 Nm (885 ± 85 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston ................................... 99.55 ± 0.03 mm
(3.9193 ±0.0012 inch)
(3) Bore of cylinder ...........................................110 ±0.08 mm
(4.3307 ± 0.0031 inch)
(4) Diameter of piston rod ......................... 44.400 ± 0.038 mm
(1.7480 ±0.0015 inch)
(5) Bore of the head ...................................... 44.78 ± 0.03 mm
(1.7630 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8) 193-3865 Bearing
Diameter. ........................................... 89.9925 ±0.0075 mm
(3.5430 ± 0.0003 inch)
Bore ..................................................59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
38 31200306
Specifications Section

Metering Pump (Steering) Solenoid Valve (Steering Mode

Part No.: 233-6072 Selector)
Part No.: 237-4154

Illustration 56 g00930154
Illustration 53 g00927267
(1) Torque for the fastener ...................4 ± 1 Nm (35 ± 9 lb in)
Capacity per revolution................................ 250 cc (15.26 in3)
(2) Current at 12 VDC ..........................................................1.56A
(2) Resistance at 20 °C (68 °F) .............................................. 7.7Q
Maximum pressure ................................32000 kPa (4640 psi)

Illustration 54 g01094328

(1) Adjustment for the Relief pressure of the Steering Pressure

31200306 39
Specifications Section

Position Sensor (Steering) Position Sensor (Steering)

Part No.: 229-5075 Part No.: 198-7807 S/N: SLG1-Up

Illustration 57 g00926252 Illustration 58 g00926252

The switch is a magnetic position sensor. The switch is a magnetic position sensor.
Table 1 Table 2

Pin Circuit Color Pin Circuit Color

A (+) Bat Brown A Signal Black

B (-) Bat Blue B (+) Bat Brown

C Signal Black C (-) Bat Blue

Specifications for the position sensor Specifications for the position sensor
Maximum operating range of the sensor................. 7 mm Maximum operating range of the sensor................. 7 mm
(0.28 inch) (0.28 inch)
Nominal current draw ............................................. 800 mA Nominal current draw .............................................. 800 mA
Length of the cable................................ 250 mm (9.8 inch) Length of the cable ................................ 250 mm (9.8 inch)
40 31200306
Specifications Section

Flexible Coupling Drive

Illustration 59 g00998062

(1) Torque for the six bolts ..................55 ± 5 Nm (41 ± 4 lb ft)

(2) Apply 4C-5598 High Temperature Anti-Seize to
the pilot of the torque converter.
31200306 41
Specifications Section

Transmission
Part No.: 216-2273

Illustration 60 g01000938
42 31200306
Specifications Section

(1) Torque for the plug ..................... 24 ± 3.5 Nm (17 ± 3 lb ft)

(2) Torque for the 2 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(3) Torque for the bolt....................... 78 ± 10 Nm (57 ± 7 lb ft)
(4) Torque for the plugs .....................24 ± 3.5 Nm (17 ± 3 lb ft)
(5) Torque for the torque converter inlet relief
valve ........................................ 27 ± 3.5 Nm (20 ± 3 lb ft)
(6) Torque for the pressure regulator ................... 55 ± 9.5 Nm
(40 ± 7 lb ft)
(7) Torque for the sensor .................... 47 ± 7 Nm (35 ± 5 lb ft)
(8) Torque for the 4 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(9) Torque for the 7 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(10) Torque for the 6 bolts .................................. 55 ± 9.5 Nm
(40 ± 7 lb ft)
(11) Torque for the 2 bolts .................25 ±6 Nm (19 ±4 lb ft)
(12) Torque for the bolts ....................55 ± 9.5 Nm (40 ± 7 lb ft)
(13) Torque for the 3 bolts ................................. 25 ± 6.5 Nm
(18 ± 5 lb ft)
(14) Torque for the 2 bolts.................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(15) Torque for the sensor .................. 47 ±7 Nm (35 ± 5 lb ft)
(16) Torque for the 3 bolts ................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(17) Torque for the 2 bolts.................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(18) Torque for the bolt.................... 55 ± 9.5 Nm (40 ± 7 lb ft)
(19) Torque for the 2 bolts..................78 ± 10 Nm (58 ±7 lb ft)
(20) Torque for the plug....................24 ± 3.5 Nm (17 ± 3 lb ft)
(21) Torque for the 2 bolts ................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(22) Torque for the plug ................... 44 ± 10 Nm (32 ± 7 lb ft)
(23) Torque for the bolts ....................25 ± 6.5 Nm (18 ± 5 lb ft)
(24) Torque for the bolts.......................9± 1.5 N-m (6 ± 1 lb ft)
(25) Torque for the 3 modulating valves.............. .. 50 ± 5 Nm
(37 ± 4 lb ft)
31200306 43
Specifications Section

Transmission
Part No.: 216-2274

Illustration 61 g01007384
44 31200306
Specifications Section

(I) Torque for the plug.......................24 ± 3.5 Nm (17 ± 3 lb ft)

(2A) Torque for the valve ................. 50 ± 5.5 Nm (37 ± 4 lb ft)
(2B) Torque for the nuts ................................. 12.5 ± 1.5 Nm
(110 ± 13 lbin)
(3) Torque for the bolt....................... 78 ± 10 Nm (57 ± 7 lb ft)
(4) Torque fort he plug ..................... 24 ± 3.5 Nm (17 ± 3 lb ft)
(5) Torque for the torque converter inlet relief
valve ......................................... 27 ± 3.5 Nm (20 ± 3 lb ft)
(6) Torque for the pressure regulator ................... 55 ± 9.5 Nm
(40 ± 7 lb ft)
(7) Torque for the sensor ................... 47 ± 7 Nm (35 ± 5 lb ft)
(8) Torque for the 4 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(9) Torque for the 5 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(10) Torque for the bolt ....................24 ± 3.5 Nm (17 ± 3 lb ft)
(II) Torque for the 4 bolts.................. 25 ±6 Nm (19 ±4 lb ft)
(12) Torque for the bolts ....................55 ± 9.5 Nm (40 ± 7 lb ft)
(13) Torque for the 3 bolts................................. 25 ± 6.5 Nm
(18 ± 45 lb ft)
(14) Torque for the 2 bolts ................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(15) Torque for the sensor....................47 ±7 Nm (35 ± 5 lb ft)
(16) Torque for the 9 bolts ..................................25 ± 6.5 Nm
(18 ± 5 lb ft)
(17) Torque for the bolt....................55 ± 9.5 Nm (40 ± 7 lb ft)
(18) Torque for the bolt....................55 ± 9.5 Nm (40 ± 7 lb ft)
(19) Torque for the bolt ................. 105 ±20 Nm (77 ± 15 lb ft)
(20) Torque for the plug ..................... 24 ± 3.5 Nm (17 ± 3 lb ft)
(21) Torque for the 4 bolts .................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(22) Torque for the plug....................44 ± 10 Nm (32 ± 7 lb ft)
(23) Torque for the bolt.....................78 ± 10 Nm (58 ± 7 lb ft)
(24) Torque for the bolts .....................8.5 ±1.5 Nm (6 ± 1 lb ft)
(25) Torque for the 2 bolts................................. 25 ± 6.5 Nm
(18 ± 45 lb ft)
(26) Torque for the 2 bolts................................... 25 ± 6.5 Nm
(18 ±5 lb ft)
(27) Torque for the bolt .....................25± 6.5 Nm (18 ± 5 lb ft)
31200306 45
Specifications Section

Position Sensor (Transmission)

Illustration 62 g00926041

The position sensor is a pulse width modulated sensor

(PWM).
Table 3

Pin Circuit Color

1 (+) Bat Red
2 (-) Bat Blue
3 PWM Yellow
4 Reserved White

Specifications for the position sensor

Operating range of the sensor ............................... 12 mm
(0.47 inch)
Operating range of the duty cycle .................... 10% to 90%
Sensors need to be spaced................... 100 mm (4.0 inch)
Minimum operating temperature ........................... -40 °C
(-40 °F)
Maximum operating temperature............................ 120 °C
(248 °F)
Torque for the two mounting bolts .................... 8 ± 1 Nm
(70 ± 9 lb in)
Regulated supply voltage .................................. 8 ± .4 VDC
Nominal current draw ............................... 7 mA at 8 VDC
46 31200306
Specifications Section

Oil Filter

Illustration 63 g00883006

(1) Torque for switch ........................ 5 ± 1 Nm (45 ± 10 lb in)

Pressure setting for the differential pressure switch
(1) ................................................................... 276 kPa (40 psi)
The differential pressure switch (1) is a normally open switch.
(2) 8C-3446 Fluid Sampling Valve
Bypass pressure setting for the filter 345 ± 34 kPa (50 ± 5 psi)
31200306 47
Specifications Section

Illustration 64 g01077798

(3) Torque for the bolts.......................30 ± 7 Nm (22 ± 5 lb ft)

48 31200306
Specifications Section

Hydraulic Oil Cooler

Illustration 65 g01165467

Pressure test the oil cooler:

• Pressurize the oil cooler assembly to a minimum of
586 kPa (85 psi).
• The oil cooler assembly is rejected if there is a
pressure drop of 1.4 kPa (0.2 psi) in three minutes.
Note: A mixture of a soap solution and a rust preventive can
aid in finding slow leaks in the castings, joints, and welds.
(1) Torque for the connector ................................30 ± 5 Nm
(22 ± 4 lb ft)
(A) Place the assembly so that the flat surface of the
first baffle is this position.
(B) The depth of the 205-3658 Baffle at each of the
ends................................. 5.5 ± 0.5 mm (0.22 ± 0.02 inch)
(C) The depth of the 205-3658 Baffle at each of the
ends................................. 1.5 ± 0.8 mm (0.06 ± 0.03 inch)
31200306 49
Specifications Section

Drive Shaft

Illustration 67 g00927112

(1) Replacement 117-9887 Spider and Bearing Kit

(A) Front drive shaft.................. 946 ± 36 mm (37.2 ± 1.4 inch)
(A) Rear drive shaft ......................................... 1097 ±36 mm
(43.2 ± 1.4 inch)
50 31200306
Specifications Section

Drive and Steering Axle (Front)

271 -6425 Drive and Steering Axle
Gp

Illustration 70 g01172126
31200306 51
Specifications Section

(1) Torque for four bolts ............................. 300 Nm (220 lb ft)

(2) Torque of the locknut for the steering
stop .................................................. 150 Nm (110 lb ft)
(2A) Torque of the locknut for the steering stop (not
shown)...................................................150 Nm (110 lb ft)
(3) Torque for three bolts .............................190 Nm (140 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(4) Torque of the purging screw for the
brake........................................................ 50 Nm (37 lb ft)
(4A) Torque of the purging screw for the brake (not
shown)..................................................... 50 Nm (37 lb ft)
(5) Torque for the plug.................................... 50 Nm (35 lb ft)
(5A) Torque for the plug (not shown) ........................ 50 Nm
(35 lb ft)
(6) Torque for tie rod nut ........................... 250 Nm (184 lb ft)
(7) Torque for four kingpin bolts .. 300 Nm (220 lb ft)
(8) Torque for locknut................................. 250 Nm (184 lb ft)
(9) Torque for the ball joint......................... 300 Nm (220 lb ft)
(10) Torque for breather .................................10 Nm (90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(11) Torque for thirteen axle housing bolts....................310 Nm
(230 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(13) Torque for two bolts ............................ 450 Nm (332 lb ft)
(14) Torque for two plugs (each carrier
assembly) ............................................... 25 Nm (20 lb ft)
(15) Torque for plug (each carrier
assembly) ............................................... 60 Nm (45 lb ft)
(16) 217-2895 Brake Disc for the 271-6425 Drive
and Steering Axle Gp
Thickness of disc....................................... 4.80 ± 0.05 mm
(0.189 ±0.002 inch)
Minimum allowable thickness .............................. 3.95 mm
(0.156 inch)
(16) 238-5291 Brake Disc for the 271-6426 Drive and
Steering Axle Gp
Thickness of disc...................................... 4.00 ± 0.05 mm
(0.158 ±0.002 inch)
Minimum allowable thickness .............................. 3.27 mm
(0.129 inch)
52 31200306
Specifications Section

271 -6426 Drive and Steering Axle

Gp

Illustration 71 g01173621
31200306 53
Specifications Section

(1) Torque for four bolts ............................. 300 Nm (220 lb ft)

(2) Torque of the locknut for the steering
stop .................................................. 150 Nm (110 lb ft)
(2A) Torque of the locknut for the steering stop (not
shown)...................................................150 Nm (110 lb ft)
(3) Torque for three bolts ............................ 300 Nm (220 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(4) Torque of the purging screw for the
brake.......................................................... 12 Nm (9 lb ft)
(4A) Torque of the purging screw for the brake (not
shown)....................................................... 12 N-m (9 lb ft)
(5) Torque for the plug.................................... 50 Nm (35 lb ft)
(5A) Torque for the plug (not shown) ........................ 50 Nm
(35 lb ft)
(6) Torque for tie rod nut............................ 280 Nm (206 lb ft)
(7) Torque for four kingpin bolts ...................300 Nm (220 lb ft)
(8) Torque for locknut................................. 350 Nm (260 lb ft)
(9) Torque for the ball joint......................... 550 Nm (405 lb ft)
(10) Torque for breather .................................10 Nm (90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(11) Torque for thirteen axle housing bolts....................310 Nm
(230 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(13) Torque for two bolts ........................... 450 Nm (332 lb ft)
(14) Torque for two plugs (each carrier
assembly) ............................................... 25 N-m (20 lb ft)
(15) Torque for plug (each carrier
assembly) ............................................... 60 N-m (45 lb ft)
(16) 238-5291 Brake Disc for the 271-6426 Drive
and Steering Axle Gp
Thickness of disc....................................... 4.00 ± 0.05 mm
(0.158 ±0.002 inch)
Minimum allowable thickness .............................. 3.27 mm
(0.129 inch)
54 31200306
Specifications Section

Drive and Steering Axle (Front)

271 -6427 Drive and Steering Axle
Gp, with Steering Sensor

Illustration 76 g01083281
31200306 55
Specifications Section

(1) Torque for four bolts ............................. 300 Nm (220 lb ft)

(2) Torque of the locknut for the steering
stop .................................................. 150 Nm (110 lb ft)
(2A) Torque of the locknut for the steering stop (not
shown)...................................................150 Nm (110 lb ft)
(3) Torque for breather and the vent ........................... 10 Nm
(90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(4) Torque for three bolts............................ 300 Nm (220 lb ft)
(5) Torque of the purging screw for the
brake .................................................... 12 Nm (105 lb in)
(5A) Torque of the purging screw for the brake (not
shown) ................................................. 12 Nm (105 lb in)
(6) Torque for the plug.................................... 50 Nm (35 lb ft)
(6A) Torque for the plug (not shown) ........................ 50 Nm
(35 lb ft)
(7) Torque for tie rod nut ........................... 280 Nm (205 lb ft)
(8) Torque for four kingpin bolts ............... .. 300 Nm (220 lb ft)
(9) Torque for locknut................................. 350 Nm (260 lb ft)
(10) Torque for the ball joint....................... 550 Nm (405 lb ft)
(11) Torque for seventeen axle housing
bolts ..................................................... 310 Nm (230 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(12) Torque for the plug.................................. 30 Nm (22 lb ft)
(12A) Torque for the plug (not shown)....................... 30 Nm
(22 lb ft)
(13) Torque for two bolts ................................ 23 Nm (20 lb ft)
(14) Torque for two bolts ................................ 23 Nm (20 lb ft)
(16) Torque for two plugs (each carrier
assembly) .............................................. 25 Nm (20 lb ft)
(17) Torque for plug (each carrier
assembly) .............................................. 60 Nm (45 lb ft)
56 31200306
Specifications Section

Drive and Steering Axle (Rear)

189-5717 Drive and Steering Axle
Gp, with Steering Sensor

Illustration 81 g00944836

(1) Torque for four bolts.............................. 300 Nm (220 lb ft) (7) Torque for locknut................................. 250 Nm (185 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to (8) Torque for the ball joint......................... 300 Nm (220 lb ft)
installing the bolts. (9) Torque for the plug ................................... 60 Nm (45 lb ft)
(2) Torque of the locknut for the steering (10) Torque for the plug.................................. 60 Nm (45 lb ft)
stop .................................................. 150 Nm (110 lb ft) (11) Torque for 10 bolts ............................. 169 Nm (125 lb ft)
(2A) Torque of the locknut for the steering stop (not Note: Apply Loctite 243 sealant to the threads prior to
shown)...................................................150 Nm (110 lb ft) installation of the bolts.
(3) Torque for breather................................... 10 Nm (90 lb in) (12) Torque for plug (each carrier
Install the breather so that the slot in the breather is parallel assembly) ............................................... 60 Nm (45 lb ft)
with the axle half shaft.
Note: Apply Loctite 243 sealant to the threads prior to
Note: Apply Loctite 243 sealant to the threads prior to installing the plugs.
installing the breather.
(4) Torque for three bolts .............................190 Nm (140 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to
installing the bolts.
(5) Torque for tie rod nut............................ 250 Nm (185 lb ft)
(6) Torque for four kingpin bolts....................300 Nm (220 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to
installing the bolts.
31200306 57
Specifications Section

168-7443 Drive and Steering Axle

Gp, with Steering Sensor

Illustration 82 g00944837

(1) Torque for four bolts ............................. 300 Nm (220 lb ft) (7) Torque for locknut................................. 350 Nm (260 lb ft)
(2) Torque of the locknut for the steering (8) Torque for the ball joint......................... 550 Nm (405 lb ft)
stop .................................................. 150 Nm (110 lb ft) (9) Torque for the plug ................................... 60 Nm (45 lb ft)
(2A) Torque of the locknut for the steering stop (not Note: Apply Loctite 243 sealant to the threads prior to
shown)...................................................150 Nm (110 lb ft) installing the plugs.
(3) Torque for breather ...................................10 Nm (90 lb in) (10) Torque for thirteen axle housing bolts ..................169 Nm
Install the breather so that the slot in the breather is parallel (125 lb ft)
with the axle half shaft. Note: Apply Loctite 243 sealant to the threads prior to
Note: Apply Loctite 243 sealant to the threads prior to installing the bolts.
installing the breather. (11) Torque for plug (each carrier
(4) Torque for three bolts ............................ 300 Nm (220 lb ft) assembly) ............................................... 25 Nm (20 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to (12) Torque for plug (each carrier
installing the bolts. assembly) ............................................... 60 Nm (45 lb ft)
(5) Torque for tie rod nut ........................... 280 Nm (205 lb ft) Note: Apply Loctite 243 sealant to the threads prior to
Note: Apply Loctite 243 sealant to the threads prior to installing the plugs.
installing the nut.
(6) Torque for four kingpin bolts ....................300 Nm (220 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to
installing the bolts.
58 31200306
Specifications Section

Drive and Steering Axle (Rear)

231 -0710 Drive and Steering Axle
Gp, without Steering Sensor

Illustration 83 g00944835

(1) Torque of the locknut for the steering (10) Torque for two plugs (one plug in each carrier
stop .......................................................150 Nm (110 lb ft) assembly) ............................................... 60 Nm (45 lb ft)

(1A) Torque of the locknut for the steering stop (not

shown)...................................................150 Nm (110 lb ft)
(2) Torque for the breather and for the vent ..................10 Nm
(88 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(3) Torque for locknut................................. 350 Nm (260 lb ft)
(4) Torque for the ball joint......................... 550 Nm (405 lb ft)
(5) Torque for three bolts ........................... 300 Nm (220 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the plugs.
(6) Torque for the plug ................................... 60 Nm (45 lb ft)
(7) Torque for four plugs (two plugs in each carrier
assembly) ............................................... 25 N-m (20 lb ft)
(8) Torque for plug.......................................... 60 Nm (45 lb ft)
(9) Torque for 13 bolts................................ 260 Nm (190 lb ft)
31200306 59
Specifications Section

231 -0709 Drive and Steering Axle

Gp, with Steering Sensor

Illustration 84 g00944836

(1) Torque for four bolts .............................. 300 Nm (220 lb ft) (11) Torque for 13 bolts .............................. 260 Nm (190 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to (12) Torque for the 4 plugs (two plugs in each carrier
installing the bolts. assembly) ............................................... 25 N-m (18 lb ft)
(2) Torque of the locknut for the steering (13) Torque for two plugs (one plug in each carrier
stop .................................................. 150 Nm (110 lb ft) assembly) ............................................... 60 N-m (44 lb ft)

(2A) Torque of the locknut for the steering stop (not

shown)...................................................150 Nm (110 lb ft)
(3) Torque for breather and the vent ........................... 10 Nm
(90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(4) Torque for three bolts ............................ 300 Nm (220 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(5) Torque for tie rod nut ........................... 280 Nm (206 lb ft)
(6) Torque for four kingpin bolts ...................300 Nm (220 lb ft)
(7) Torque for locknut................................. 350 Nm (258 lb ft)
(8) Torque for the ball joint......................... 550 Nm (405 lb ft)
(9) Torque for the plug ................................... 60 N-m (45 lb ft)
(10) Torque for the plug ................................. 60 N-m (45 lb ft)
60 31200306
Specifications Section

Differential and Bevel Gear

Group
Part No,: 219-8765

Illustration 85 g01176266

(1) Backlash ................................................... 0.18 to 0.32 mm Note: Apply Loctite 638 4C-9507 Retaining Compound to
(0.0071 to 0.0126 inch) the mounting surface of the bevel gear.
(2) Torque for four bolts ............................. 266 Nm (196 lb ft) Note: Apply Loctite 271 155-0695 Thread Lock Compound
(3) Before assembly, apply anti-seize compound to to the bolts (6).
the seal. (7) Torque the screw for the bearing ........................... 13 Nm
(4) Shims for the pinion (115 lb in)

209-7473 Shim .............................. 2.5 mm (0.0984 inch)

219-8751 Shim .............................. 2.6 mm (0.1024 inch)
219-8752 Shim .............................. 2.7 mm (0.1063 inch)
219-8753 Shim ................................ 2.8 mm (0.1102 inch)
219-8754 Shim ................................ 2.9 mm (0.1142 inch)
219-8755 Shim ................................ 3.0 mm (0.1181 inch)
219-8756 Shim .............................. 3.1 mm (0.1220 inch)
219-8757 Shim .............................. 3.2 mm (0.1260 inch)
219-8758 Shim .............................. 3.3 mm (0.1299 inch)
219-8759 Shim .............................. 3.4 mm (0.1339 inch)
(5) Torque for magnetic plug .......................... 60 Nm (44 lb ft)
(6) Torque for the twelve bolts........................ 85 Nm (63 lb ft)
31200306 61
Specifications Section

Differential and Bevel Gear

Group
Part No.: 226-4348

Illustration 86 g00941671 199-0688 Shim ................................ 2.9 mm (0.1142 inch)

199-0689 Shim ................................ 3.0 mm (0.1181 inch)
(1) Backlash ................................................... 0.18 to 0.23 mm
(0.0071 to 0.0091 inch) 199-0690 Shim .............................. 3.1 mm (0.1220 inch)

(2) Torque for four bolts .............................. 413 Nm (305 lb ft) 199-0691 Shim .............................. 3.2 mm (0.1260 inch)

Note: If nut (3) is loosened, both 199-0678 Washers 199-0692 Shim .............................. 3.3 mm (0.1299 inch)

(4) must be replaced with new washers. 199-0693 Shim .............................. 3.4 mm (0.1339 inch)

(5) Torque for magnetic plug .......................... 60 Nm (44 lb ft)

(6) Torque for the twelve bolts........................ 85 Nm (63 lb ft)
Note: Apply Loctite 638 4C-9507 Retaining Compound to
the mounting surface of the bevel gear.
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts (6).
(7) Torque the screw for the bearing ........................... 13 Nm
(115 lbin)
Shims for the pinion
199-0684 Shim .............................. 2.5 mm (0.0984 inch)
199-0685 Shim .............................. 2.6 mm (0.1024 inch)
199-0686 Shim .............................. 2.7 mm (0.1063 inch)
199-0687 Shim .................................2.8 mm (0.1102 inch)
62 31200306
Specifications Section

Axle Housing and Flange Group Axle Housing and Flange Group
Part No.: 229-5086, 229-5087 Part No.: 253-4986, 253-4987

Illustration 87 g01177555 Illustration 88 g01084006

(1) Torque for spanner nut...................... 1000 Nm (740 lb ft) (1) Torque for the 3 locking bolts on the tab................... 70 Nm
(52 lb ft)
(2) Torque for the three lock bolts.................. 70 Nm (52 lb ft)
(2) Torque for spanner nut .........................1100 Nm (810 lb ft)
Note: After the spanner nut is torqued and the tab does not
fit, rotate the nut in the direction of tightening until the tab fits.
31200306 63
Specifications Section

Final Drive Planetary Group

Part No.: 210-5924

Illustration 89 g00949246

(1) Assemble the three bearings so that the radius is facing in

the direction of the arrow.
64 31200306
Specifications Section

Final Drive Planetary Group

Part No.: 253-4989

Illustration 90 g01084036

(1) Assemble the three bearings so that the radius is facing in

the direction of the arrow.
31200306 65
Specifications Section

Axle Housing Group

(Differential and Brake
Cylinder)
Part No.: 174-4642, 219-8780

174-4642 Axle Housing Gp with a

Locking Differential

Illustration 91 g00948248
66 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts....................70 Nm (50 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash ......................................... 0.20 to 0.32 mm
(0.008 to 0.0126 inch)
Note: Stake the pinion nut after the bearing preload is set.
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
209-7473 Shim ................................ 2.5 mm (0.098 inch)
219-8751 Shim ................................ 2.6 mm (0.102 inch)
219-8752 Shim ................................ 2.7 mm (0.106 inch)
219-8753 Shim .................................. 2.8 mm (0.110 inch)
219-8754 Shim .................................. 2.9 mm (0.114 inch)
219-8755 Shim .................................. 3.0 mm (0.118 inch)
219-8756 Shim ................................ 3.1 mm (0.122 inch)
219-8757 Shim ................................ 3.2 mm (0.126 inch)
219-8758 Shim .................................. 3.3 mm (0.13 inch)
219-8759 Shim .................................. 3.4 mm (0.14 inch)
31200306 67
Specifications Section

219-8780 Axle Housing Gp

Illustration 92 g00948248
68 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts....................70 Nm (50 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash ......................................... 0.20 to 0.32 mm
(0.008 to 0.0126 inch)
Note: Stake the pinion nut after the bearing preload is set.
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
209-7473 Shim ................................ 2.5 mm (0.098 inch)
219-8751 Shim ................................ 2.6 mm (0.102 inch)
219-8752 Shim ................................ 2.7 mm (0.106 inch)
219-8753 Shim .................................. 2.8 mm (0.110 inch)
219-8754 Shim .................................. 2.9 mm (0.114 inch)
219-8755 Shim .................................. 3.0 mm (0.118 inch)
219-8756 Shim ................................ 3.1 mm (0.122 inch)
219-8757 Shim ................................ 3.2 mm (0.126 inch)
219-8758 Shim .................................. 3.3 mm (0.13 inch)
219-8759 Shim .................................. 3.4 mm (0.14 inch)
31200306 69
Specifications Section

219-8831 Axle Housing Gp with a

Locking Differential

Illustration 93 g00948256
70 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts .............................. 180 Nm
(135 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash .......................................... 0.20 ± 0.02 mm
(0.008 ± 0.001 inch)
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
199-0684 Shim ................................ 2.5 mm (0.098 inch)
199-0685 Shim ................................ 2.6 mm (0.102 inch)
199-0686 Shim ................................ 2.7 mm (0.106 inch)
199-0687 Shim .................................. 2.8 mm (0.110 inch)
199-0688 Shim .................................. 2.9 mm (0.114 inch)
199-0689 Shim .................................. 3.0 mm (0.118 inch)
199-0690 Shim ................................ 3.1 mm (0.122 inch)
199-0691 Shim ................................ 3.2 mm (0.126 inch)
199-0692 Shim .................................. 3.3 mm (0.13 inch)
199-0693 Shim .................................. 3.4 mm (0.14 inch)
31200306 71
Specifications Section

219-8842 Axle Housing Gp without a

Locking Differential

Illustration 94 g00948264
72 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Torque for the ring gear bolts .............................. 180 Nm
(135 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(5) Gear backlash .......................................... 0.20 ± 0.02 mm
(0.008 ± 0.001 inch)
Note: Stake the pinion nut after the bearing preload is set.
(6) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(7) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
199-0684 Shim ................................ 2.5 mm (0.098 inch)
199-0685 Shim ................................ 2.6 mm (0.102 inch)
199-0686 Shim ................................ 2.7 mm (0.106 inch)
199-0687 Shim .................................. 2.8 mm (0.110 inch)
199-0688 Shim ................................. 2.9 mm (0.114 inch)
199-0689 Shim .................................. 3.0 mm (0.118 inch)
199-0690 Shim ................................ 3.1 mm (0.122 inch)
199-0691 Shim ................................ 3.2 mm (0.126 inch)
199-0692 Shim .................................. 3.3 mm (0.13 inch)
199-0693 Shim .................................. 3.4 mm (0.14 inch)
31200306 73
Specifications Section

Axle Housing Group

(Differential and Brake
Cylinder)
Part No.: 253-4985, 253-4990

253-4990 Axle Housing Gp with a

Locking Differential

Illustration 95 g00948248
74 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts .............................. 180 Nm
(132 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash ........................................... 0.20 ± 0.02 mm
(0.008 ± 0.001 inch)
Note: Stake the pinion nut after the bearing preload is set.
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
31200306 75
Specifications Section

253-4985 Axle Housing Gp without a

Locking Differential

Illustration 96 g00948264

(1) Bearing nut (5) Gear backlash .......................................... 0.20 ± 0.02 mm

(2) Brake cylinder assembly (0.008 ± 0.001 inch)

(3) Apply Loctite 638 4C-9507 Retaining Compound Note: Stake the pinion nut after the bearing preload is set.
to the dowel pin. Each brake cylinder assembly (6) Torque for the bolts of the brake cylinder .................79 Nm
contains two dowel pins. (60 lb ft)
(4) Torque for the ring gear bolts .............................. 180 Nm (7) Torque of the lock screw for the bearing nut
(132 lb ft) ...............................................................13 Nm (115 lb in)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
76 31200306
Specifications Section

Brake Cylinder (Master)

Illustration 97 g00866817

(1) Minimum operating temperature............................ -30 °C

(-22 °F)
(2) Maximum operating temperature ................................... 100°C
(212 °F)
(3) Maximum working pressure............................... 10500 kPa
(1523 psi)
(4) Minimum burst pressure .................................... 31500 kPa
(4569 psi)
(5) Maximum oil pressure.......................................... 3550 kPa
(515 psi)
(6) Minimum rate of flow............................................. 10 L/min
(2.64 US gpm)
Note: This assembly is suitable for use with approved fluid.
The use of the improper fluid may cause damage to the seal
which can result in system failure.
31200306 77
Specifications Section

Parking Brake Control

Illustration 98 g00926862

(1) Torque for the terminal screws .................0.43 ± 0.02 Nm

(3.805 ± 0.177 lb in)
(2) Mounting screw torque ........................... 0.32 ± 0.02 Nm
(2.832 ± 0.177 lb in)
Note: Use 6V-8373 Screws for mounting the switch. Apply
4C-4030 Thread Lock Compound to the threads.
(3) Minimum range for the actuator......................... 13.49 mm
(0.531 inch)
(3) Maximum range for the actuator ........................ 27.74 mm
(1.092 inch)
(A) Dimension ......................... 120 + 4.0 mm (4.7 + 0.2 inch)
78 31200306
Specifications Section

Parking Brake

Illustration 99 g01083721

Adjust mounting bolt (4) and jam nut (2) in order to leave a
gap of 0.51 mm (0.020 inch) to 1.52 mm (0.060 inch) (1)
between jam nut (2) and sleeve (3).
(2) Tighten the jam nut against the mounting
surface of the axle housing. Torque for the jam
nut.............................................. 109 ± 7 Nm (80 ± 5 lb ft)
Tighten nut (5) to the following torque 14 ± 0.6 Nm (120 ± 5 lb
in). Back off nut (5) 4 to 6 flats for a final adjustment
(6) After nut (5) is correctly adjusted you should
tighten nut (6) against nut (5). Torque for nut
(6) ............................................. 68 ± 6.7 Nm (50 ± 5 lb ft)
31200306 79
Specifications Section

Fender

Illustration 100 g00996996

(1) Torque for 16 nuts that fasten fender assemblies

to the machine .................... 300 ±20 Nm (221 ± 15 lb ft)
Note: Apply 154-9731 Thread Lock Compound to the
threads.
80 31200306
Specifications Section

Wheel (Tire and Rim)

Illustration 101 g00997061

Clean the hardware and dry the hardware. Apply one drop of
lubrication oil to the threads.
(1) Torque of the 32 nuts ............................ 460±60Nm
(339 ± 44 lb ft)
31200306 81
Specifications Section

Fuel Tank
Part No.: 224-4783

Illustration 102 g01078161

(1) Torque for the six bolts............................. 2.25 ± 0.25 Nm

(20 ± 2 lb in)
(2) Torque for the plug . . . . . . . . . . . . . . . . 1 0 ± 5 N m ( 7 ± 4 lb ft)
82 31200306
Specifications Section

Fuel Tank
Part No.: 203-1995

Illustration 103 g01011074

(1) Torque for the six bolts .............................2.25 ± 0.25 Nm

(20 ± 2 lb in)
(2) Torque for the plug.................... 35.0 ± 7.5 Nm (26 ± 5 lb ft)
31200306 83
Specifications Section

Engine Enclosure

Illustration 104 g00998630

(1) Torque for the 8 screws ............................... 2.3 ± 0.3 Nm

(20 ± 2.2 lb in)
(2) Torque for the 4 nuts . . . . . . . . . . . . . . 6 ± 3 N m ( 4 ± 2 lb ft)
(3) Torque for the 8 bolts..................... 14 ± 3 Nm (10 ± 2 lb ft)
(4) Torque for connecting the gas spring to the
hood ............................................ 10 ± 1 Nm (89 ± 9 lb in)
Note: Apply 154-9731 Thread Lock Compound to threads on
both ends of the gas spring.
84 31200306
Specifications Section

Illustration 105 g00998765

(5) Torque for the bolt.............................................. 20 ± 6 Nm

(15 ± 4 lb ft)
Note: Apply 4C-4030 Thread Lock Compound to the bolt.
(6) Torque for the 4 bolts ......................................... 14 ± 3 Nm
(10± 2 lb ft)
Note: Apply 4C-4030 Thread Lock Compound to the bolts.
31200306 85
Specifications Section

Engine and Transmission

Mounting

Illustration 106 g00997919

(1) Torque for the two bolts . . . . . . . . . . . . . . . . . . . . . 2 2 0 ±2 0 N m

(162 ± 15 lb ft)
(2) Torque for the bolt.........................................775 ± 20 Nm
(572 ± 15 lb ft)
86 31200306
Specifications Section

Air Cleaner

Illustration 107 g01078304

(1) Torque for the bolt........................ 20 ±2 Nm (15 ± 1 lb ft)

(2) Torque for the nut ......................... 20 ±2 N-m (15 ± 1 lb ft)
31200306 87
Specifications Section

Illustration 108 g01078352

(3) Torque for the clamp...................... 5 ± 1 Nm (44 ± 9 lb in)

Illustration 109 g01166232

(4) Torque for the bracket............................... 2 Nm (1.5 lb ft)

88 31200306
Specifications Section

Engine Oil Drain

Illustration 110 g00997117

(1) Torque for shutoff valve ................ 40 ±5 Nm (30 ±4 lb ft)

(2) Length of hose ....................... 130 ± 5 mm (5.1 ± 0.2 inch)
31200306 89
Specifications Section

Muffler

Illustration 111 g01057347

(1) Torque for the three nuts . . . . . . . . . . . . . . . . . . . . . . 3 0 ± 7 N m

(22 ± 5 lb ft)
(2) Torque for the clamp ................................... 45 ±10 Nm
(33±7 lb ft)
Note: Refer to Illustration 111 in order to position the clamp.
90 31200306
Specifications Section

Suction Fan

Illustration 112 g00997794

(1) Torque for the three bolts............................. 10 ±2 Nm

(7.5 ± 1.5 lb ft)
31200306 91
Specifications Section

Battery

Illustration 114 g01166295

(1) Torque for the battery terminals .................... 7.2 ± 1.6 Nm

(5.31 ± 1.18 lb ft)
(2) Torque for cable at the starter....................... 26 ± 3.5 Nm
(19 ± 3 lb ft)
(3) Torque for the cables ...........................................8 ± 2 Nm
(6 ± 1.5 lb ft)
(4) Torque for cable at the alternator ..................... 8 ± 1 Nm
(77 ± 9 lb in)
(5) Torque of the disc at the large stud . . . . . . . . . . . . . 2 3 ± 4 N m
(17 ± 3 lb ft)
(6) Torque for the two nuts . . . . . . . . . . . . . . . . . . . . . . . 6 . 8 ± 1 . 4 N m
(60 ± 12 lb in)
92 31200306
Specifications Section

Alternator

Illustration 115 g01078644

Nominal Voltage .................................................................... 14 V

Nominal current at 6000 RPM ............................................105 A
Direction of rotation ................................................... Clockwise
Polarity ................................................................Negative earth
(1) Tighten terminal nut "W" to the following
torque.................................. 2.25 ± 0.25 Nm (20 ± 2 lb in)
(2) Tighten terminal nut "D+" to the following
torque.................................. 2.25 ± 0.25 Nm (20 ± 2 lb in)
(3) Tighten terminal nut "B+" to the following
torque.................................... 3.6 ± 0.08 Nm (32 ± 1 lb in)
31200306 93
Specifications Section

Coolant Lines Group

Illustration 116 g00997961

(1) Torque for the bolt ......................... 30 ± 7 Nm (22 ± 5 lb ft)

(2) Length of trim .......................... 200 ± 5 mm (7.9 ± 0.2 inch)
94 31200306
Specifications Section

Coolant Recovery Group

Illustration 117 g01166550

(1) Torque for the two bolts . . . . . . . . . . . . . . . . . . . . . . . 1 0 ± 2 N m

(89 ± 18 lb in)
(2) Torque for the two bolts . . . . . . . . . . . . . . . . . . . . . . 1 0 ± 2 N m
(89 ± 18 lb in)
(3) Specifications of the Tank
Pressure relief for the cap ...................... 100 kPa (15 psi)
Working pressure of the Tank .................... 150 kPa (22 psi)
Burst pressure of the Tank.......................000 kPa (145 psi)
Working temperature of tank .................... 110 °C (230 °F)
31200306 95
Specifications Section

Illustration 118 g01167691

(B) 50° ± 15°
(4) Apply a 8T-0065 Silicone Sealant to the Elbow. Tighten a
minimum of two complete threads. Align the elbow. Refer
to Illustration 118.
96 31200306
Specifications Section

Cab

Illustration 120 g01173739

(1) Use a urethane adhesive for bonding the glass. 4. Adjust the position of the clevis on the rod end
Note: Equally space rubber spacers in order to maintain the 5 so that the release lever is perpendicular to the
adhesive gap for bonding. B post.

(2) Tighten the knob hand tight.

Note: Apply 4C-4030 Thread Lock Compound.

Latch Adjustment
The Test with the Door Closed
1. Close the door. Check for interference
2. Locate the striker on the cab. The striker should
be centered in the jaws of the latch. The striker
should engage the jaws smoothly. The striker
should not guide the door upward. The striker
should not guide the door downward.
3. Check the latch when the door is closed.

Hold Open Latch Check

1. Open the door.
2. Locate the hold open striker on the door (upper).
Ensure that the striker is centered in the jaws of
the latch. Check that the striker engages the jaws
smoothly. Check that the striker does not guide
the door upward. Check that the striker does not
guide the door downward.
3. In order to regulate the force of activation for the
hold open latch, adjust the bumper on the door
(upper). The maximum force is 50 N (11 lb).
31200306 97
Specifications Section

Cab Mounting

Illustration 121 g00999337

(1) Torque for the 4 bolts........................... 450 Nm (332 lb ft)

98 31200306
Specifications Section

Cab Door

Illustration 124 g01168043

(1) Torque for the bolts ........................4 ± 1 Nm (35 ± 9 lb in)

(2) Tighten hand tight. Use 4C-4030 Thread Lock
Compound
(3) Length of seal....................... 955 ± 5 mm (37.6 ± 0.2 inch)
(4) Length of seal ....................... 821 ± 5 mm (32.3 ± 0.2 inch)
Note: Use a urethane adhesive for bonding the glass.
(5) Equally space the rubber spacers in order to
maintain the 5 adhesive gap for bonding.
31200306 99
Specifications Section

Illustration 125 g01168116

(6) Torque for the nut ........................ 4 ± 1 Nm (35 ± 9 lb in)

Note: Use a urethane adhesive for bonding the glass.
100 31200306
Specifications Section

Access Door

Illustration 126 g00999902

(1) Torque for the 4 nuts ......................6 ± 1 Nm (53 ± 9 lb in)

(2) Torque for the 4 nuts................ 15±3N m(11 ± 2 lb ft)
31200306 101
Specifications Section

Joystick Control

Illustration 127 g01124256

(1) Torque for the screws ............................. 1.92 ± 0.20 Nm

(17.00 ± 1.78 lb in)
102 31200306
Specifications Section

Steering Wheel and Column

Illustration 128 g00999390

(1) Torque for the nut ....................... 48 ± 5 Nm (35 ±4 lb ft)

(2) Torque for the nut and the bolt.................. 22.5 ±2.5 Nm
(17 ±2 lb ft)
31200306 103
Specifications Section

Window Wiper and Wiper Motor

Illustration 129 g00997368

(1) Torque for the nut ............... 23 ± 1 N m ( 1 7 ± 1 lb ft) (4) Length of hose........................ 163 ± 3 mm (6.4 ± 0.1 inch)
(2) Torque for the nut of the wiper motor . . . . 9 ± 1 Nm (5) Length of hose........................ 112 ±3 mm (4.4 ±0.1 inch)
(80 ± 9 lb in) (6) Length of hose .................... 2351 ± 5 mm (92.6 ± 0.2 inch)
(3) Torque for the nut ....................8 ± 0.5 Nm (66 ±4.4 lb in)
104 31200306
Specifications Section

Window Washer Tank

Illustration 130 g00999432

(1) Torque for the fitting....................... 8 ± 1 Nm (71 ± 9 lb in)

31200306 105
Specifications Section

Rear View Mirror

Illustration 131 g01079722

(1) Torque for the two bolts .................28 ± 7 Nm (20 ± 5 lb ft)

Carriage Cylinder (Rotate)

Illustration 132 g00999602

106 31200306
Specifications Section

Length of the stroke ................................... 123 mm (4.8 inch)

(1) Diameter of the rod .................................. 45 mm (1.8 inch)
(2) Bore of the cylinder................................ 80 mm (3.2 inch)7

Carriage Cylinder (Sideshift)

Illustration 133 g00999632

Cylinder stroke ............................................ 300 mm (11.8 inch)

(1) Torque setting for bolt..................................850 ± 25 Nm
(625 ± 20 lb ft)
Lubricate the threads of the bolt with clean grease.
(2A) Diameter of piston ............................... 75.69 ± 0.03 mm
(2.9799 ±0.0012 inch)
(2B) Bore of piston.............................. 26.97 mm (1.062 inch)
(3) Bore of cylinder.............................. 76.20 mm (3.000 inch)
(4) Diameter of piston rod ................ ..38.05 mm (1.4980 inch)
(5) Bore of head ........................................... 38.38 ± 0.03 mm
(1.511 ±0.001 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 9T-4007 Bearing
Diameter............................................. .36.088 ±0.013 mm
(1.4208 ±0.0005 inch)
Bore.......................................................30.153 ±0.013 mm
(1.1871 ±0.0005 inch)
31200306 107
Specifications Section

Hydraulic Cylinder
(Multipurpose Bucket)

Illustration 134 g00999842

Cylinder stroke......................................... 260 mm (10.24 inch) Bore ................................................... 30.153 ±0.013 mm

(1) Torque setting for bolt ................................. 850 ± 25 Nm (1.1871 ±0.0005 inch)
(625 ± 20 lb ft)
Lubricate the threads of the nut with clean grease.
(2A) Diameter of piston................................ 75.69 ± 0.03 mm
(2.980 ± 0.001 inch)
(2B) Bore of piston.............................. 26.97 mm (1.062 inch)
(3) Bore of cylinder.................................. 76.2 mm (3.00 inch)
(4) Diameter of piston rod .................... 38.05 mm (1.498 inch)
(5) Bore of head ........................................... 38.38 ± 0.05 mm
(1.511 ±0.002 inch)
(6) Torque setting for the head ....................... 600 ± 130 Nm
(443 ± 96 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 9T-4007 Bearing
Diameter............................................. 36.088 ± 0.013 mm
(1.4208 ±0.0005 inch)
108 31200306
Specifications Section

Grapple Cylinder

Illustration 135 g01006744

(A) Open ................................................. 710 mm (28.0 inch)

(A) Closed................................................. 490 mm (19.3 inch)
(B) Diameter................................................. 85 mm (3.4 inch)
31200306 109
Index
Index
A E
Access Door..................................................................... 100 Engine and Transmission Mounting ................................... 85
Air Cleaner ......................................................................... 86 Engine Enclosure ............................................................... 83
Alternator............................................................................ 92 Engine Oil Drain ................................................................. 88
Axle Housing and Flange Group ........................................ 62
F
Axle Housing Group (Differential and Brake Cylinder)....... 65
174-4642 Axle Housing Gp with a Locking Differential. 65 Fender................................................................................ 79
219-8780 Axle Housing Gp........................................... 67 Final Drive Planetary Group............................................... 63
219-8831 Axle Housing Gp with a Locking Differential Final Drive Planetary Group............................................... 64
...................................................................................... 69 Flexible Coupling Drive ...................................................... 40
219-8842 Axle Housing Gp without a Locking Differential Frame................................................................................. 11
...................................................................................... 71 Frame Leveling Cylinder .............................................. 29, 30
253-4985 Axle Housing Gp without a Locking Differential Fuel Tank ........................................................................... 82
...................................................................................... 75
Fuel Tank ........................................................................... 81
253-4990 Axle Housing Gp with a Locking Differential
...................................................................................... 73 G
Axle Housing Group (Differential and Brake Cylinder)....... 73
Grapple Cylinder .............................................................. 108
Axle Lock Cylinder ............................................................. 37
H
B
Hydraulic Cylinder (Multipurpose Bucket) ........................ 107
Battery................................................................................ 91
Hydraulic Oil Cooler ........................................................... 48
Boom.................................................................................. 13
Hydraulic Tank ............................................................. 3, 5, 6
Boom Cylinder.............................................................. 15, 16
Boom Cylinder.................................................................... 14 I
Boom.................................................................................. 12 Important Safety Information.................................................ii
Brake Cylinder (Master) ..................................................... 76
J
C
Joystick Control................................................................ 101
Cab..................................................................................... 96
Latch Adjustment .......................................................... 96 L
Cab Door............................................................................ 98 Load Control Valve (Boom Cylinder) (Lock)....................... 17
Cab Mounting..................................................................... 97 Load Control Valve (Frame Leveling Cylinder) (Lock) ....... 31
Carriage Cylinder (Rotate) ............................................... 105 Load Control Valve (Stabilizer Cylinder) (Lock) ................. 36
Carriage Cylinder (Sideshift) ............................................ 106 Load Control Valve (Telescoping Cylinder) (Lock)............. 21
Compensating Cylinder...................................................... 18 Load Control Valve (Tilt Cylinder) (Lock) ........................... 24
Compensating Cylinder...................................................... 19
M
Control Valve (Stabilizer) ................................................... 32
Coolant Lines Group .......................................................... 93 Main Control Valve (Implement)........................................... 9
Coolant Recovery Group.................................................... 94 Metering Pump (Steering) .................................................. 38
Muffler ................................................................................ 89
D
O
Differential and Bevel Gear Group ............................... 60, 61
Diverter Valve..................................................................... 24 Oil Filter .............................................................................. 46
Diverter Valve..................................................................... 25 P
Drive and Steering Axle (Front).......................................... 50
Parking Brake..................................................................... 78
271 -6425 Drive and Steering Axle Gp ......................... 50
Parking Brake Control ........................................................ 77
271 -6426 Drive and Steering Axle Gp ......................... 52
Piston Pump (Implement and Steering) ............................... 7
271 -6427 Drive and Steering Axle Gp, with Steering
Sensor .......................................................................... 54 Position Sensor (Steering) ................................................. 39
Drive and Steering Axle (Front).......................................... 54 Position Sensor (Steering) ................................................. 39
Drive and Steering Axle (Rear) Position Sensor (Transmission) ......................................... 45
168-7443 Drive and Steering Axle Gp, with Steering R
Sensor .......................................................................... 57
189-5717 Drive and Steering Axle Gp, with Steering Rear View Mirror .............................................................. 105
Sensor .......................................................................... 56
S
231 -0709 Drive and Steering Axle Gp, with Steering
Sensor .......................................................................... 59 Solenoid Valve (Pilot Selector)............................................. 8
231 -0710 Drive and Steering Axle Gp, without Steering Solenoid Valve (Steering Mode Selector) .......................... 38
Sensor .......................................................................... 58 Specifications Section .......................................................... 3
Drive and Steering Axle (Rear) .................................... 56, 58 Stabilizer Cylinder .................................................. 33, 34, 35
Drive Shaft ......................................................................... 49 Steering Wheel and Column ............................................ 102
Suction Fan ........................................................................ 90
110 31200306
Index

T
Table of Contents................................................................. 1
Telescoping Cylinder.......................................................... 20
Tilt Cylinder .................................................................. 22, 23
Towing Hitch .......................................................... 26, 27, 28
Towing Hitch ................................................................ 27, 28
Transmission................................................................ 41, 43

W
Wheel (Tire and Rim) ......................................................... 80
Window Washer Tank ...................................................... 104
Window Wiper and Wiper Motor ...................................... 103
Manufactured by JLG under license from Caterpillar
31200308
December 15, 2006

Disassembly and
Assembly

TH360B Telehandler Machine Systems

S/N TBH00100 & After
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200308 1
Table of Contents
Table of
Table of Contents Install...................................................... 55
Disassembly and Assembly Section Installation Procedure ........................ 55
Hydraulic System Pressure -Release ...... 5 Solenoid Valve (Frame Leveling) - Remove
Release Procedure.............................. 5 and Install............................................... 56
Steering Wheel - Remove and Install ...... 5 Removal Procedure ........................... 56
Removal Procedure............................. 5 Installation Procedure ........................ 56
Installation Procedure.......................... 6 Diverter Valve (Boom Head) -Remove and
Metering Pump (Steering) -Remove ........ 6 Install...................................................... 57
Removal Procedure............................. 6 Removal Procedure ........................... 57
Metering Pump (Steering) -Install ............ 9 Installation Procedure ........................ 57
Installation Procedure.......................... 9 Control Valve (Stabilizer) -Remove........ 58
Steering Column - Remove ................... 11 Removal Procedure ........................... 58
Removal Procedure........................... 11 Electronic Pilot Valve (Stabilizer) - Remove
Steering Column - Install ....................... 14 and Install............................................... 59
Installation Procedure........................ 14 Removal Procedure ........................... 59
Main Control Valve (Implement) - Installation Procedure ........................ 60
Remove ................................................. 17 Bank Valve (Stabilizer) -Disassemble .... 60
Removal Procedure........................... 17 Disassembly Procedure..................... 60
Electronic Pilot Valve - Remove and Bank Valve (Stabilizer) -Assemble......... 63
Install ..................................................... 19 Assembly Procedure.......................... 63
Removal Procedure........................... 19 Control Valve (Stabilizer) -Install............ 65
Installation Procedure........................ 21 Installation Procedure ........................ 65
Bank Valve (Implement) -Disassemble . 22 Stabilizer Cylinder - Remove and Install 67
Disassembly Procedure .................... 22 Removal Procedure ........................... 67
Bank Valve (Implement) -Assemble ...... 28 Disassembly and Assembly
Assembly Procedure ......................... 28 Information......................................... 69
Main Control Valve (Implement) - Install 35 Installation Procedure ........................ 71
Installation Procedure........................ 35 Load Control Valve (Stabilizer Cylinder) -
Solenoid Valve (Steering Mode Selector) - Remove and Install ................................ 72
Remove and Install ................................ 37 Removal Procedure ........................... 72
Removal Procedure........................... 37 Installation Procedure ........................ 73
Installation Procedure........................ 38 Fuel Tank - Remove .............................. 73
Master Cylinder (Brake) -Remove ......... 39 Removal Procedure ........................... 73
Removal Procedure........................... 39 Fuel Tank - Install .................................. 75
Master Cylinder (Brake) - Install ............ 40 Installation Procedure ........................ 75
Installation Procedure........................ 40 Cab - Remove ........................................ 76
Hydraulic Tank - Remove ...................... 42 Removal Procedure ........................... 76
Removal Procedure........................... 42 Cab - Install ............................................ 80
Hydraulic Tank - Install .......................... 43 Installation Procedure ........................ 80
Installation Procedure........................ 43 Window Wiper and Wiper Motor (Front) -
Piston Pump (Implement and Steering) - Remove and Install ................................ 83
Remove ................................................. 44 Removal Procedure ........................... 83
Removal Procedure........................... 44 Installation Procedure ........................ 84
Piston Pump (Implement and Steering) - Window Wiper and Wiper Motor (Rear) -
Disassemble .......................................... 46 Remove and Install ................................ 85
Disassembly Procedure .................... 46 Removal Procedure ........................... 85
Piston Pump (Implement and Steering) - Installation Procedure ........................ 86
Assemble ............................................... 50 Window Wiper and Wiper Motor (Roof) -
Assembly Procedure ......................... 50 Remove and Install ................................ 87
Piston Pump (Implement and Steering) - Removal Procedure ........................... 87
2 31200308
Table of Contents

Installation procedure .............................88 Telescoping Cylinder - Remove and

Cab Heater - Remove ............................89 Install ................................................... 147
Removal Procedure ...........................89 Removal Procedure......................... 147
Cab Heater - Install ................................91 Disassembly and Assembly
Installation Procedure ........................91 Information ...................................... 152
Heater Coil - Remove and Install ...........93 Installation Procedure...................... 153
Removal Procedure ...........................93 Load Control Valve (Telescoping Cylinder) -
Installation Procedure ........................94 Remove and Install .............................. 158
Air Conditioner - Install ...........................94 Removal Procedure......................... 158
Installation Procedure ........................94 Installation Procedure...................... 159
Evaporator Coil - Remove and Install.....99 Boom Cylinder - Remove and Install ... 160
Removal Procedure ...........................99 Removal Procedure......................... 160
Installation procedure.......................100 Disassembly and Assembly
Joystick Control - Remove and Install ..101 Information ...................................... 162
Removal Procedure .........................101 Installation Procedure...................... 163
Installation Procedure ......................102 Load Control Valve (Boom Cylinder) -
Seat - Remove and Install ....................102 Remove and Install .............................. 165
Removal Procedure .........................102 Removal Procedure......................... 165
Installation Procedure ......................103 Installation Procedure...................... 166
Fender - Remove and Install ................103 Tilt Cylinder - Remove and Install........ 166
Removal Procedure .........................103 Removal Procedure......................... 166
Installation Procedure ......................103 Disassembly and Assembly
Sump Guard - Remove and Install .......104 Information ...................................... 168
Removal Procedure .........................104 Installation Procedure...................... 169
Installation Procedure ......................104 Load Control Valve (Tilt Cylinder) - Remove
Counterweight - Remove and Install ....104 and Install ............................................ 171
Removal Procedure .........................104 Removal Procedure......................... 171
Installation Procedure ......................106 Installation Procedure...................... 171
Quick Coupler - Remove ......................107 Frame Leveling Cylinder -Remove and
Removal Procedure .........................107 Install ................................................... 172
Quick Coupler - Disassemble...............109 Removal Procedure......................... 172
Disassembly Procedure ...................109 Disassembly and Assembly
Quick Coupler - Assemble....................111 Information ...................................... 174
Assembly Procedure ........................111 Installation Procedure...................... 175
Quick Coupler - Install ..........................112 Load Control Valve (Frame Leveling
Installation Procedure ......................112 Cylinder) - Remove and Install ............ 177
Boom - Remove ...................................114 Removal Procedure......................... 177
Removal Procedure .........................114 Installation Procedure...................... 178
Boom - Disassemble ............................116 Compensating Cylinder Remove and
Disassembly Procedure ...................116 Install ................................................... 178
Boom - Assemble .................................122 Removal Procedure......................... 178
Assembly Procedure ........................122 Disassembly and Assembly
Boom - Install .......................................131 Information ...................................... 180
Installation Procedure ......................131 Installation Procedure...................... 181
Hydraulic Oil Lines (Boom) -Remove ...133 Axle Lock Cylinder - Remove and
Removal Procedure .........................133 Install ................................................... 182
Tilt Cylinder Hoses (Boom) ..............134 Removal Procedure......................... 182
Auxiliary Hoses (Boom) ...................137 Disassembly and Assembly
Hydraulic Oil Lines (Boom) - Install ......140 Information ...................................... 185
Installation Procedure ......................140 Installation Procedure...................... 186
31200308 3
Table of Contents

Shutoff Valve (Axle Lock) -Remove and

Install ................................................... 188
Removal Procedure......................... 188
Installation Procedure...................... 188
Stabilizer - Remove ............................. 189
Removal Procedure......................... 189
Stabilizer - Install ................................. 192
Installation Procedure...................... 192
Stabilizer.......................................... 196
4 31200308
Table of Contents
31200308 5
Disassembly and Assembly Section

Disassembly and Note: Hydraulic cylinders and lock valves may contain
internal pressure. Refer to specific instructions for
Assembly Section each hydraulic component before performing any work
on each hydraulic component.

Hydraulic System Pressure -

Release Steering Wheel - Remove and
Install
Release Procedure
Removal Procedure
Table 1

Personal injury can result from hydraulic oil

pressure and hot oil. Required Tools
Hydraulic oil pressure can remain in the hydraulic
Tool Part Number Part Description Qty
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released 156-7100 Slide Hammer Puller Gp 1
before any service is done on the hydraulic system.
A
Make sure all of the attachments have been 7X-2534 Bolt 2
lowered to the ground, and the oil is cool before 9X-8256 Washer 2
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Lower the boom to the ground. Illustration 1 g00932369

2. Engage the parking brake. 1. Remove horn button (1) from the center of steering
wheel (2).
3. Stop the engine.
4. Turn the engine start switch to the ON position after
the engine stops.
5. If equipped, place the implement lockout switch in
the UNLOCKED position.
6. Move the control levers repeatedly through the
full range of travel. This will relieve any pressure
that may be present in the implement hydraulic
system.
7. Turn the engine start switch to the OFF position.
8. Depress the brake pedal repeatedly. This will
relieve any pressure that may be present in the Illustration 2 g00932370
brake system. 2. Disconnect wire (3) from horn button (1). Remove
9. Remove the hydraulic tank filler cap slowly in screw (4) in order to disconnect wire (5) from
order to relieve the tank pressure. steering wheel (2). Remove the horn button.
10. After all the pressure has been released, tighten
the filler cap on the hydraulic tank.
6 31200308

Illustration 3 g00932371
Illustration 6 g00932370
3. Loosen nut (6). Back off the nut by two full turns. 2. Position horn button (1). Connect wire (5) to the
Do not remove the nut at this time. center of steering wheel (2) with screw (4).
Connect wire (3) to horn button (1).

Illustration 4 g00932372
4. Install Tooling (A). Use the tooling to pull steering
Illustration 7 g00932369
wheel (2) off the splined tapered shaft on the
3. Install horn button (1) into the center of steering
steering column. When the steering wheel is
wheel (2).
loose, remove Tooling (A), nut (6) and then
steering wheel (2).
Metering Pump (Steering) -
Installation Procedure Remove
Removal Procedure

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
Illustration 5 g00932373
lowered to the ground, and the oil is cool before
1. Feed wire (3) through the center of steering wheel removing any components or lines. Remove the oil
(2) before installing the steering wheel onto the filler cap only when the engine is stopped, and the
splined tapered shaft on the steering column. filler cap is cool enough to touch with your bare
Install nut (6) and tighten the nut to a torque of 48 hand.
± 5 Nm (35 ± 4 lb ft).
31200308 7

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

1. Put identification marks on all lines, on all hoses

and on all wires for installation purposes. Plug all
Illustration 10 g00939899
lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering 4. Disconnect hose (5) from the bottom side of manifold
the system. (3). Disconnect hose (7) from metering pump (8)

Illustration 11 g00939900
Illustration 8 g00939894
2. Remove cover (1) 5. Disconnect two electrical connectors (9) from
solenoid valve (10).

Illustration 9 g00939896
3. Disconnect four hoses (2) from the top side of Illustration 12 g00939942
manifold (3). Loosen the hose clamp and 6. Remove the bolts that secure cover (11).
disconnect tube (4).
8 31200308

Illustration 13 g00939944 Illustration 16 g00939965

7. Carefully lower cover (11) and loosen the hose
clamp before disconnecting heater hose (12).

Illustration 17 g00939967
10. With the aid of a second person, support metering
Illustration 14 g00939945 pump (8) and at the same time remove four
8. Loosen retaining nut (13) and remove key start locknuts (18), four washers (19), four washers (20)
switch (14) from cover (11). Lay the key start and the four outer half's of mount (21). Carefully
switch aside. Remove cover (11) from the machine. remove the metering pump from the machine.

Illustration 15 g00939963
9. Remove bolt (15) and the locknut that secures Illustration 18 g00940110

universal joint (16) to shaft (17). 11. Remove two bolts (22) in order to remove manifold
(3) with solenoid valve (10) from metering pump (8).
31200308 9

Metering Pump (Steering) -

Install
Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 19 g00940113
12. Remove four O-ring seals (23) from manifold (3)

Illustration 22 g00940121
2. Align the splines on shaft (17) with splines in
metering pump (8) and install the shaft.

Illustration 20 g00940111
13. Remove four washers (24) and the four inner half's
of mounts (21) from plate (25). Remove seal (26).
Remove four bolts (27) in order to remove plate
(25).

Illustration 23 g00940128
3. Install plate (25) and four bolts (27). Install seal (26).
Install four inner half's of mounts (21) and four
washers (24).

Illustration 21 g00940112
14. Remove shaft (17) from metering pump (8).

Illustration 24 g00940131
10 31200308

4. Apply a thin coat of 1U-6396 O-Ring Assembly

Compound to four O-ring seals (23) before
installing the O-ring seals into manifold (3).

Illustration 28 g00940135
7. Align the groove in shaft (17) with the bolt holes in
universal joint (16) before installing bolt (15) and
Illustration 25 g00940132
the locknut. Tighten the bolt and the locknut to a
torque of 22.5 ± 2.5 Nm (17 ± 2 lb ft).
5. Position manifold (3) with solenoid valve (10) onto
metering pump (8) and install two bolts (22).

Illustration 29 g00940136

Illustration 26 g00940133

Illustration 30 g00940137
Illustration 27 g00940134
6. With the aid of a second person, position metering 8. Position cover (11) in order to install key start
pump (8) onto the machine. Make sure that you switch (14) and retaining nut (13). Tighten the
align shaft (17) with universal joint (16) before retaining nut to a torque of 13.6 ± 4 Nm (120 ± 35
installing four outer half's of mount (21), four lb in). Connect heater hose (12) and tighten the
washers (20), four washers (19) and four locknuts hose clamp.
(18).
31200308 11

Illustration 31 g00940138 Illustration 34 g00940141

9. Carefully lift cover (11) and install the bolts in order 12. Connect tube (4) and tighten the hose clamp.
to secure the cover. Connect four hoses (2) to the top side of manifold
(3).

Illustration 32 g00940139
Illustration 35 g00940142
10. Connect two electrical connectors (9) to solenoid
valve (10). 13. Install cover (1)

Steering Column - Remove

Removal Procedure
Start By:
a. Remove the steering wheel. Refer to Disassembly and
Assembly, "Steering Wheel - Remove and Install".
1. Put identification marks on all wires and on all
harnesses for installation purposes.

Illustration 33 g00940140
11. Connect hose (7) to metering pump (8). Connect
hose (5) to the bottom side of manifold (3).

Illustration 36 g00932541
2. Remove the bolts that secure cover (1).
12 31200308

Illustration 37 g00932540 Illustration 40 g00932544

Right Side

Illustration 38 g00932542
3. Carefully lower cover (1) and loosen the hose Illustration 41 g00932837
Left Side
clamp before disconnecting heater hose (2).
Loosen retaining nut (3) and remove key start 5. Carefully lift cover (5) in order to disconnect
switch (4) from cover (1). Lay the key start switch electrical connectors (6) from switches (7).
aside. Remove cover (1) from the machine. Remove the cover.

Illustration 39 g00932543
Illustration 42 g00932838
4. Remove the bolts that secure cover (5).
6. Remove the bolts that secure display module (8).
31200308 13

Illustration 43 g00932839 Illustration 46 g00932844

7. Carefully lift display module (8) and loosen bolt (9) 10. Carefully remove cover (15) and at the same time
in order to disconnect electrical connector (10). feed harness (14) and harness (16) out of the
Remove the display module. cover.

Illustration 44 g00932842 Illustration 47 g00932848

8. Disconnect electrical connector (11) from switch 11. Disconnect electrical connector (17) from
(12) for directional turn signal control. transmission control (18). Disconnect wire (19).

Illustration 45 g00932843
9. Remove the bolts that secure housing (13). Illustration 48 g00932849
Carefully remove the housing and at the same time 12. Remove bolts (20) and the locknut that secures
feed harness (14) out of the housing. universal joint (21) to shaft (22).
14 31200308

Illustration 52 g00932860
Illustration 49 g00932850
13. Remove bolts (23) that secure steering column (24) 2. Align universal joint (21) with shaft (22) before
to mounting plate (25). sliding the universal joint onto the shaft.

Illustration 53 g00932863
Illustration 50 g00932855
3. Install bolts (23) in order to secure steering column
14. Carefully lift steering column (24) out of the cab.
(24) to mounting plate (25).

Steering Column - Install

Installation Procedure

Illustration 54 g00932864
4. Align the groove in shaft (22) with the bolt holes in
universal joint (21) before installing bolts (20) and
the locknut. Tighten the bolt and the locknut to a
torque of 22.5 ± 2.5 Nm (17 ± 2 lb ft).
Illustration 51 g00932859
1. Carefully lift steering column (24) into position
inside the cab.
31200308 15

Illustration 55 g00932865 Illustration 58 g00932876

5. Connect electrical connector (17) to transmission 8. Connect electrical connector (11) to switch (12) for
control (18). Connect wire (19). the directional turn signal control.

Illustration 56 g00932866 Illustration 59 g00932877

6. Carefully feed harness (16) and harness (14) 9. Position display module (8) in order to connect
through cover (15) before positioning the cover electrical connector (10) before tightening bolt (9).
onto the steering column.

Illustration 57 g00932867 Illustration 60 g00932878

7. Carefully feed harness (14) through housing (13) 10. Install the bolts in order to secure display module (8).
before positioning the housing onto the steering
column. Install the bolts in order to secure the
housing.
16 31200308

Illustration 64 g00932884

Illustration 61 g00932880
Right Side Illustration 65 g00932885

13. Position cover (1) in order to install key start switch

(4) and retaining nut (3). Connect heater hose (2) to
cover (1) and tighten the hose clamp.

Illustration 62 g00932882
Left Side
11. Position cover (5) in order to connect connectors (6)
to switches (7).

Illustration 66 g00932887

14. Carefully lift cover (1) and install the bolts in order to
secure the cover.
End By:
a. Install the steering Wheel. Refer to Disassembly and
Assembly, "Steering Wheel - Remove and Install".

Illustration 63 g00932883
12. Install the bolts to secure cover (5).
31200308 17

Main Control Valve (Implement) -

Remove
Removal Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 229-1510 Lifting Bracket 1

Start By:
Illustration 67 g00920399
a. Release the hydraulic system pressure. Refer to 2. Remove bolts (1) and washers (2) that secure rear
Disassembly and Assembly, "Hydraulic System
Pressure - Release".
cover (3) to the frame. Remove the rear cover.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered, oil is cool before removing any
components or lines. Remove the oil filler cap only Illustration 68 g00920404
when the engine is stopped, and the filler cap is cool
3. Remove bolts (4) and washers (5) that secure cover
enough to touch with your bare hand.
(6) to the left side of the frame. Remove the cover.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all lines, on all hoses,
on all wires, and on all tubes for installation
purposes. Plug all lines, all hoses, and all tubes.
This helps to prevent fluid loss and this helps to Illustration 69 g00920406
keep contaminants from entering the system. 4. Remove bolts (7) and washers (8) that secure
Cleanliness is an important factor. Before the cover (9) to the right side of the frame. Remove the
removal procedure, the exterior of the component cover.
should be thoroughly cleaned. This will help to
prevent dirt from entering the internal components.
18 31200308

Illustration 70 g00920416 Illustration 73 g00921109

5. Disconnect wiring harnesses (10) from the 8. Loosen the retaining nuts (16) and disconnect the
solenoids. hoses and the tubes at the rear of the control valve.
Loosen the hose clamp at the rear of the control
valve and remove the hose (17) from the fitting. Lift
the tubes and the hoses away from the control
valve and secure the tubes and the hoses to a
suitable fixing.

Illustration71 g00920436
6. Remove clamp (11) that secures tubes (12) to the
frame.

Illustration 74 g00921127
9. Loosen the two retaining nuts (18) and disconnect
two tubes (19) from the tee pieces on the right side
of the machine. Remove the two tubes from the
machine.

Illustration 72 g00920447
7. Loosen eight retaining nuts (13) and disconnect
eight tubes (14) on the top of the control valve. Lift
the tubes away from the control valve. Secure the
steel tubes to a suitable fixing. Remove two fittings
(15) from the two rear ports on the top of the
control valve.
Illustration 75 g00921135
10. Loosen the two retaining nuts (20) and disconnect
two hoses (21) on the right side of the control
valve.
31200308 19

Illustration 76 g00921141 Illustration 79 g00921300

11. Loosen the retaining nuts (22) and disconnect 14. Install Tool (A) onto control valve (27). Attach a
tubes (23) on the end of the control valve. Remove suitable sling through Tool (A). Attach the sling to a
the fitting (24) from the port in the left side of the suitable lifting device and support the control valve.
control valve. The weight of the control valve is approximately 40
kg (88 lb).
Note: Care must be taken in order to ensure that no
damage to the electrical connectors is caused when
you are handling the control valve.

Illustration 77 g00921150

12. Remove bolts (25) and washers (26) that secure the
control valve to the frame.
Illustration 80 g00921314
15. Carefully remove control valve (27) through the
opening in the left side of the machine.

Electronic Pilot Valve - Remove

and Install
Removal Procedure
Table 3

Required Tools
Illustration 78 g00921225
Tool Part Number Part Description Qty
13. Lift the tubes and the hoses away from the control
valve (27). Slide the control valve sideways toward A 173-0960 Allen Wrench 1
the left side opening in the frame. Move the control
valve until the solenoids pass through the opening
in the frame.
20 31200308

1. Remove cover (1) from the leftside of the machine

and cover (2) from the right side of the machine.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
Illustration 83 g00935832
2. Disconnect two electrical connectors (3) from
NOTICE
electronic pilot valve (4).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Put identification marks on all wires and on all
harnesses for installation purposes.

Illustration 84 g00935896

Illustration 81 g00935830

Illustration 85 g00935900
3. Loosen three bolts (5). Rotate the bolts in a
counterclockwise direction by approximately five
full turns. Do not remove the bolts. Use a suitable
pry bar in order to lift control valve (6) upward by
approximately 3 mm (0.12 inch). At the same time
place a suitable small wedge between the chassis
and the control valve at the point which is indicated
with the white arrow. This will allow access to the
underside of the electronic pilot valve.
Illustration 82 g00935831
31200308 21

1. Apply a thin coat of 1U - 6396 O-Ring Assembly

Compound to four O-ring seals (9) and twelve O-
ring seals (8) before installing the O-ring seals into
electronic pilot valve (4). Make sure that the O-ring
seals are correctly seated.

Illustration 86 g00935903
4. Use Tooling (A) (not shown) and remove eight
bolts (7) in order to remove electronic pilot valve (4)
from control valve (6).

Illustration 89 g00935903
2. Position electronic pilot valve (4) onto control
valve (6). Use Tooling (A) (not shown) in order to
install eight bolts (7). Tighten the bolts to a torque
o f 3 ±0 . 3 N m ( 2 6 . 5 ±2 . 6 l b i n ) .

Illustration 87 g00935905
5. Remove twelve O-ring seals (8) and four O-ring
seals (9) from electronic pilot valve (4).

Installation Procedure
Table 4 Illustration 90 g00935896

Required Tools
Tool Part Number Part Description Qty
A 173-0960 Allen Wrench 1

Illustration 91 g00935900
3. Use a suitable pry bar in order to lift control valve (6)
upward. At the same time remove the small wedge
between the chassis and the control valve that was
placed during the removal procedure at the point
Illustration 88 g00935905 which is indicated with the white arrow. Tighten
three bolts (5).
22 31200308

Bank Valve (Implement) -

Disassemble
Disassembly Procedure
Start By:
a. Remove the main control valve. Refer to Disassembly
and Assembly, "Main Control Valve (Implement) -
Remove".
NOTICE
Care must be taken to ensure that fluids are contained
Illustration 92 g00935832 during performance of inspection, maintenance, testing,
4. Connect two electrical connectors (3) to electronic adjusting and repair of the product. Be prepared to collect
pilot valve (4). the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Cleanliness is an important factor. Before you
begin the disassembly procedure, the exterior of the
components should be thoroughly cleaned. This will
help to prevent dirt from entering the internal
components. Precision components can be damaged
by contaminants or dirt. Perform the disassembly
procedure on a clean work surface. Keep components
covered and protected at all times.

Illustration 93 g00935830

Illustration 95 g00949063
1. Remove eight bolts (1) in order to remove
Illustration 94 g00935831 electronic pilot valve (2) from bank valve (3). Refer
5. Install cover (2) to the right side of the machine and to Disassembly and Assembly, "Electronic Pilot
cover (1) to the left side of the machine. Valve - Remove and Install".
End By:
a. Check or reset the configuration of the electronic
pilot valve. Refer to appropriate Systems operation,
Testing and Adjusting Manual.
b. Calibrate the main control valve. Refer to appropriate
Systems operation, Testing and Adjusting Manual.
31200308 23

Illustration 96 g00949064 Illustration 99 g00949130

2. Position bank valve (3) on suitable cribbing so that 5. Remove four O-ring seals (10), O-ring seal (11) and
locknuts (4) are facing upward. Remove the four O-ring seal (12) from control valve (13).
locknut in order to remove manifold (5).

Illustration 100 g00949159

Illustration 97 g00949065 6. Slide control valve (13) off studs (14) and control
3. Place manifold (5) in a suitable soft jawed vise and valve (15).
remove pressure reducing valve (6).

Illustration 101 g00949193

Illustration 98 g00949066 7. Place control valve (13) in a suitable soft jawed

4. Remove two O-ring seals (7), two backup rings (8) vise. Remove plug (16) and O-ring seal (17) (not
and O-ring seal (9) from pressure reducing valve shown).
(6).
24 31200308

Illustration 102 g00949200 Illustration 105 g00949209

8. Remove compensator spool (18) from control valve 11. Remove four bolts (24) in order to remove cover
(13). (25) from the control valve (13).

Illustration 103 g00949203

Illustration 106 g00949211
9. Remove plug (19) from control valve (13). Remove 12. Remove O-ring seal (26) and O-ring seal (27) from
O-ring seal (20), backup ring (21) and O-ring seal cover (25). Remove adjusting screw (28) and
(22) from plug (19). Remove the plug from the sealing nut (29).
opposite side of the control valve.

Illustration 107 g00949212

Illustration 104 g00949207
13. Slide valve spool (30) out of the control valve (13)
10. Remove check valve (23) from control valve (13).
Remove the check valve from the opposite side of
the control valve.
31200308 25

Illustration 108 g00949213 Illustration 111 g00949395

14. Remove retainer (31), two collars (32) and spring 17. Place control valve (15) in a suitable soft jawed
(33) from valve spool (30). vise. Remove plug (38) and O-ring seal (39) (not
shown).

Illustration 109 g00949393

Illustration 112 g00949396
15. Remove four O-ring seals (34), O-ring seal (35)
18. Remove compensator spool (40) from control valve
and O-ring seal (36) from control valve (15).
(15).

Illustration110 g00949394
Illustration 113 g00949397
16. Slide control valve (15) off studs (14) and control
valve (37). 19. Remove relief valve (41) from control valve (15).
Remove the relief valve from the opposite side of
the control valve.
26 31200308

Illustration 114 g00949398 Illustration 117 g00949401

20. Remove O-ring seal (42), backup ring (43) and O- 23. Remove O-ring seal (48) and O-ring seal (49) from
ring seal (44) from relief valve (41). Repeat the cover (47).
procedure for the second relief valve.

Illustration 118 g00949402

Illustration 115 g00949399 24. Slide valve spool (50) out of the control valve (15).
21. Remove check valve (45) from control valve (15).
Remove the check valve from the opposite side of
the control valve.

Illustration 119 g00949403

25. Remove retainer (51), two collars (52) and spring
(53) from valve spool (50).
Illustration 116 g00949400
22. Remove four bolts (46) in order to remove cover
(47) from the control valve (15).
31200308 27

Illustration 120 goo949415 Illustration 123 g00949418

26. Remove four O-ring seals (54), O-ring seal (55)and 30. Slide control valve (57) off studs (14) and manifold
O-ring seal (56) from control valve (37). (61).
31. Refer to steps 7 through 14 for the procedure to
disassemble control valve (57).

Illustration 121 g00949416

27. Slide control valve (37) off studs (14) and control
Illustration 124 g00949709
valve (57).
32. Remove four O-ring seals (62), O-ring seal (63) and
28. Refer to steps 17 through 25 for the procedure to O-ring seal (64) from manifold (61).
disassemble control valve (37).

Illustration 125 g00949422

Illustration 122 g00949417 33. Clamp manifold (61) in a suitable soft jawed vise.
29. Remove four O-ring seals (58), O-ring seal (59) and Remove load signal relief valve (65) from the
O-ring seal (60) from control valve (57). manifold.
28 31200308

Illustration 126 g00949429

Illustration 129 g00949426
34. Remove O-ring seal (66), backup ring (67) and O- 37. Remove cap (73) for the steering priority valve from
ring seal (68) from load signal relief valve (65). manifold (61).

Illustration 130 g00949498

Illustration 127 g00949423
38. Remove O-ring seal (74) from cap (73). Remove
35. Remove flow control valve (69) from manifold (61). valve spool (75), spring (76), guide (77) and shims
(78) from the manifold.

Bank Valve (Implement) -

Assemble
Assembly Procedure
Note: Cleanliness is an important factor. Before
assembly, thoroughly clean all parts in cleaning fluid.
Allow the parts to air dry. Do not use wiping cloths or
rags to dry parts. Lint may be deposited on parts which
may cause trouble. Inspect all parts. if any parts are
Illustration 128 g00949424 worn or damaged, use new Caterpillar parts for
36. Remove O-ring seal (70), backup ring (71) and O- replacement. Dirt and other contaminants can damage
ring seal (72) from flow control valve (69). precision components. Perform assembly procedures
on a clean work surface. Keep components covered
and protected at all times.
31200308 29

Illustration 131 g00949426 Illustration 134 g00949423

3. Install flow control valve (69) into manifold (61).
Tighten the flow control valve to a torque of 20 ±2
N m ( 1 5 ± 1 lb ft).

Illustration 132 g00949498

1. Clamp manifold (61) in a suitable soft jawed vise.
Install valve spool (75), spring (76), guide (77) and Illustration 135 g00949429
shims (78) into manifold (61). Apply a thin coat of
4. Install O-ring seal (66), backup ring (67) and O-ring
1U-6396 O-Ring Assembly Compound to O-ring
seal (68) onto load signal relief valve (65). Lubricate
seal (74) before installing the O-ring into cap (73).
the O-ring seals and the backup ring with the
Install the cap into the manifold. Tighten the cap to a
lubricant that is being sealed.
torque of 100 ± 10 Nm (75 ± 7 lb ft).

Illustration136 g00949422
Illustration 133 g00949424
2. Install O-ring seal (70), backup ring (71) and O-ring 5. Install load signal relief valve (65) into the
seal (72) onto flow control valve (69). Lubricate the manifold. Tighten the signal relief valve to a torque
O-ring seals and the backup ring with the lubricant o f 4 5 ±4 . 5 N m ( 3 3 ±3 l b f t ) .
that is being sealed.
30 31200308

Illustration 137 g00949709 Illustration 140 g00949416

6. Position manifold (61) on suitable cribbing so that 10. Slide control valve (37) onto studs (14) and
studs are facing upward. Install four O-ring seals control valve (57).
(62), O-ring seal (63) and O-ring seal (64) into 11. Refer to steps 13 through 21 for the procedure to
manifold (61). assemble control valve (37).

Illustration 138 g00949418 Illustration 141 g00949415

7. Slide control valve (57) onto studs (14) and 12. Install four O-ring seals (54), O-ring seal (55) and O-
manifold (61). ring seal (56) into control valve (37).
8. Refer to steps 24 through 31 for the procedure to
assemble control valve (57).

Illustration 142 g00949403

13. Install retainer (51), two collars (52) and spring (53)
Illustration 139 g00949417 onto valve spool (50).
9. Install four O-ring seals (58), O-ring seal (59) and
O-ring seal (60) into control valve (57).
31200308 31

Illustration 143 g00949402 Illustration 146 g00949399

17. Install check valve (45) from control valve (15).
14. Place control valve (15) in a suitable soft jawed
Install the check valve into the opposite side of the
vise. Slide valve spool (50) into the control valve.
control valve.

Illustration 144 g00949401

15. Apply a thin coat of 1U-6396 O-Ring Assembly
Illustration 147 g00949398
Compound to O-ring seal (48) and O-ring seal (49)
18. Install O-ring seal (42), backup ring (43) and O-ring
before installing the O-ring seals into cover (47).
seal (44) onto relief valve (41). Lubricate the O-ring
seals and the backup ring with the lubricant that is
being sealed. Repeat the procedure for the second
relief valve.

Illustration 145 g00949400

16. Position cover (47) onto control valve (15) and
install four bolts (46).
Illustration 148 g00949397
19. Install relief valve (41) into control valve (15). Install
the relief valve into the opposite side of the control
valve.
32 31200308

Illustration 149 g00949396 Illustration 152 g00949393

20. Install compensator spool (40) into control valve 23. Install four O-ring seals (34), O-ring seal (35) and
(15). O-ring seal (36) into control valve (15).

Illustration 150 g00949395 Illustration 153 g00949213

21. Install O-ring seal (39) (not shown) onto plug (38) 24. Install retainer (31), two collars (32) and spring (33)
and install the plug into control valve (15). Remove onto valve spool (30).
control valve (15) from the soft jawed vise.

Illustration 154 g00949212

25. Place control valve (13) in a suitable soft jawed
Illustration 151 g00949394 vise. Slide valve spool (30) into the control valve.
22. Slide control valve (15) onto studs (14) and control
valve (37).
31200308 33

Illustration 155 g00949211 Illustration 158 g00949203

26. Apply a thin coat of 1U-6396 O-Ring Assembly 29. Install O-ring seal (20), backup ring (21) and O-ring
Compound to O-ring seal (26) and O-ring seal (27) seal (22) onto plug (19). Lubricate the O-ring seals
before installing the O-ring seals into cover (25). and the backup ring with the lubricant that is being
Install adjusting screw (28) and sealing nut (29). sealed. Install plug (19) into control valve (13).
Install the plug into the opposite side of the control
valve.

Illustration 156 g00949209

27. Position cover (25) onto control valve (13) and
install four bolts (24). Illustration 159 g00949200
30. Install compensator spool (18) into control valve
(13).

Illustration 157 g00949207

28. Install check valve (23) into control valve (13).
Install the check valve into the opposite side of the Illustration 160 g00949193
control valve. 31. Install O-ring seal (17) (not shown) onto plug (16)
and install the plug into control valve (13). Remove
control valve (13) from the soft jawed vise.
34 31200308

Illustration 161 g00949159 Illustration 164 g00949065

32. Slide control valve (13) onto studs (14) and control 35. Place manifold (5) in a suitable soft jawed vise and
valve (15). install pressure reducing valve (6). Tighten the
pressure reducing valve to a torque of 55 ± 5 Nm
(40 ± 4 lb ft).

Illustration 162 g00949130

33. Install four O-ring seals (10), O-ring seal (11) and O-
ring seal (12) into control valve (13). Illustration 165 g00949064
36. Install manifold (5) and four locknuts (4). Tighten the
locknuts to a torque of 35 Nm (26 lb ft).

Illustration 163 g00949066

34. Install two O-ring seals (7), two backup rings (8) and Illustration 166 g00949063

O-ring seal (9) onto pressure reducing valve (6). 37. Position electronic pilot valve (2) onto bank valve (3)
Lubricate the O-ring seals and the backup rings and install eight bolts (1). Refer to Disassembly and
with the lubricant that is being sealed. Assembly, "Electronic Pilot Valve - Install" for the
installation procedure.
End By:
a. Install the main control valve. Refer to Disassembly and
Assembly, "Main Control Valve (Implement) -Install".
31200308 35

Main Control Valve (Implement) -

Install
Installation Procedure
Table 5

Required Tools
Tool Part Number Part Description Qty
A 229-1510 Lifting Bracket 1

1. Inspect all parts and clean all parts. If any parts are
Illustration 169 g00921525
worn or damaged, use Caterpillar parts for
replacement. 4. Lift the tubes and the hoses away from the control
valve (27). Slide the control valve sideways toward
the mounting position on the frame.

Illustration 167 g00921523

2. Attach Tool (A) to the control valve. Attach a

Illustration170 g00921526
suitable sling through Tool (A). Attach the sling to a
5. Secure the control valve in position with bolts (25)
suitable lifting device and carefully lower control
and washers (26).
valve (27) into position next to the opening in the left
side of the frame. The weight of the control valve is
approximately 40 kg (88 lb).
Note: Care must be taken in order to ensure that no
damage to the electrical connectors is caused when
you are handling the control valve.

.
Illustration 171 g00921527
6. Install fitting (24) in the port on the left side of the
control valve. Connect tubes (23) and tighten
retaining nuts (22).

Illustration 168 g00921524

3. Slide control valve (27) through the opening in the
left side of the frame until the main body of the
control valve is resting on the frame. Remove Tool
(A) from the control valve.
36 31200308

Illustration 172 g00921539 Illustration 175 g00921545

7. Install fittings (15) in the two end ports on the top of 10. Release the supports for the tubes and the hoses.
the control valve. Release the supports for the Connect tubes (19) to the fittings at the rear of the
tubes. Connect tubes (14) to the fittings in the top of control valve. Connect the two hoses to the fittings
the control valve and tighten retaining nuts (13). at the rear of the control valve. Tighten retaining
nuts (16). Connect hose (17) to the fitting on the
rear of the control valve and tighten the hose
clamp.

Illustration 173 g00921540

8. Connect two hoses (21) on the right side of the
control valve and tighten retaining nuts (20). Illustration 176 g00921628
11. Connect the wiring harness (10) to the solenoids.

Illustration 174 g00921541

9. Connect two tubes (19) to the tee pieces on the
right side of the machine and tighten retaining nuts Illustration 177 g00921629

(18). 12. Install clamp (11) that secures tubes (12) to the
frame.
31200308 37

Solenoid Valve (Steering Mode

Selector) - Remove and Install
Removal Procedure

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
Illustration 178 g00921603 system after the engine has been stopped. Serious
13. Install cover (9) on the right side of the machine. injury can be caused if this pressure is not released
Secure the cover with bolts (7) and washers (8). before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Illustration 179 g00921604
14. Install cover (6) on the left side of the machine. Dispose of all fluids according to local regulations and
Secure the cover with bolts (5) and washers (4). mandates.
1. Put identification marks on all wires for installation
purposes.

Illustration 180 g00921606

15. Install rear cover (3) to the frame. Secure the cover
with bolts (1) and washers (2). Illustration 181 g00939793
38 31200308

2. Remove cover (1). Installation Procedure

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 182 g00939790

3. Disconnect two electrical connectors (2) from
solenoid valve (3).

Illustration 185 g00939792

2. Apply a thin coat of 1U-6396 O-Ring Assembly
Compound to four O-ring seals (8) before installing
the O-ring seals into solenoid valve (3). Install coils
(7) and fasteners (6). Tighten the fasteners to a
torque of 4 ± 1 Nm (35 ± 8.8 lb in).

Illustration 183 g00939791

4. Remove four bolts (4) in order to remove solenoid
valve (3) from manifold (5).

Illustration 186 g00939791

3. Position solenoid valve (3) onto manifold (5) and
install four bolts (4).

Illustration 184 g00939792

5. Remove fasteners (6) in order to remove coils (7)
from solenoid valve (3). Remove four O-ring seals
(8).

Illustration 187 g00939790

4. Connect two electrical connectors (2) to solenoid
valve (3).
31200308 39

Illustration 188 g00939793 Illustration 189 g00940864

5. Install cover (1). 1. Remove cover (1).

Master Cylinder (Brake) -

Remove
Removal Procedure
Table 6

Required Tools
Tool Part Number Part Description Qty
A 1P-1855 Retaining Ring Pliers 1

Illustration 190 g00940865

2. Disconnect two hoses (2) from master cylinder (3).
Loosen the hose clamp and disconnect tube (4).
Personal injury can result from hydraulic oil
pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect Illustration 191 g00940866
the fluid with suitable containers before opening any 3. Remove the bolts that secure cover (5).
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: Put identification marks on all hoses and on all
tube for installation purposes. Plug all hoses and all
tubes. This helps to prevent fluid loss and this helps to
keep contaminants from entering the system.
40 31200308

Illustration 192 g00940867 Illustration 195 g00940870

Illustration 193 g00940868

Illustration 196 g00940871
4. Carefully lower cover (5) and loosen the hose
6. With the aid of a second person, support master
clamp before disconnecting heater hose (6).
cylinder (3) and at the same time remove two
Loosen retaining nut (7) and remove key start
locknuts (13) and the washers. Carefully remove
switch (8) from cover (5). Lay the key start switch
the master cylinder from the machine.
aside. Remove cover (5) from the machine.

Master Cylinder (Brake) - Install

Installation Procedure
Table 7

Required Tools
Tool Part Number Part Description Qty
A 1P-1855 Retaining Ring Pliers 1

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
Illustration 194 g00940869 replacement.
5. Use Tool (A) in order to remove circlip (9) from pin
(10). Remove the pin out of linkage (11) and lever
(12).
31200308 41

Illustration 197 g00940876

Illustration 201 g00940880

Illustration 198 g00940877 4. Position cover (5) in orderto install key start switch
2. With the aid of a second person, position master (8) and retaining nut (7). Tighten the retaining nut
cylinder (3) on the machine and install two locknut to a torque of 13.6 ±4 Nm (120 ±35 lb in).
(13) with the washers. Connect heater hose (6) and tighten the hose
clamp.

Illustration 199 g00940878

3. Align the holes in linkage (11) with the hole in lever Illustration 202 g00940881
(12) before installing pin (10). Use Tool (A) in order 5. Carefully lift cover (5) and install the bolts that
to install circlip (9) onto pin (10). secure the cover.
Note: If necessary, adjust the brake pedal. Refer to
appropriate Systems Operation.

Illustration 203 g00940882

6. Connect tube (4) to master cylinder (3) and tighten
Illustration 200 g00940879 the hose clamp. Connect two hoses (2).
42 31200308

2. Put identification marks on all hoses, on all tube

and on all lines for installation purposes. Plug
all hoses, all tubes and all lines. This will help
to prevent fluid loss and this will help to prevent
contaminants from entering the system.

Illustration 204 g00940883

7. Install cover (1).
End By:
a. Purge the air from the braking system. Refer to
appropriate Systems operation, Testing and Adjusting
Manual. Illustration 205 g00945882
3. Remove two bolts (1) and the washers from
Hydraulic Tank - Remove window washer tank (2).

Removal Procedure
Start By:
a. Remove the fuel tank. Refer to Disassembly and
Assembly, "Fuel Tank - Remove".44

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious Illustration 206 g00945904
injury can be caused if this pressure is not released
4. Carefully lift window washer tank (2) and
before any service is done on the hydraulic system. disconnect tube (3).
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and Illustration207 g00945910
mandates. 5. Loosen the hose clamps in order to disconnect two
1. Drain the hydraulic tank into a suitable container hoses (4) from hydraulic tank (5).
for storage or disposal. The capacity of the
hydraulic tank is approximately 66 L (17.4 US gal).
Refer to appropriate Operation and Maintenance
Manual for the correct draining procedure.
31200308 43

Illustration 208 g00945883 Illustration 211 g00945911

6. From the underside of hydraulic tank (5), loosen 8. With the aid of a second person, support hydraulic
the hose clamps in order to disconnect three hoses tank (5) and at the same time remove two bolts (9),
(6). the washers and two spacers (10). Carefully
remove the hydraulic tank from the machine. The
weight of the hydraulic tank is approximately 16 kg
(35 lb).

Hydraulic Tank - Install

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 209 g00945884

7. Remove two bolts (7) and the washers which
secure hydraulic tank (5) to support bracket (8).

Illustration 212 g00945885

Illustration 210 g00945885

Illustration 213 g00945911

44 31200308

2. With the aid of a second person, lift hydraulic tank

(5) into position and install two spacers (10), two
bolts (9) and the washers. The weight of the
hydraulic tank is approximately 16 kg (35 lb).

Illustration 217 g00945904

Illustration 214 g00945884

3. Install two bolts (7) and the washers which secure
hydraulic tank (5) to support bracket (8).

Illustration 218 g00945882

6. Connect tube (3) to window washer tank (2).
Position the window washer tank and install two
bolts (1) and the washers.
7. Fill the hydraulic tank. The capacity of the
hydraulic tank is approximately 66 L (17.4 US gal).
Illustration 215 g00945883
4. Connect three hoses (6) and tighten the hose End By:
clamps. a. Install the fuel tank. Refer to Disassembly and Assembly,
"Fuel Tank - Install".

Piston Pump (Implement and

Steering) - Remove
Removal Procedure
Start By:
a. Release the pressure in the hydraulic system.
Refer to Disassembly and Assembly, "Hydraulic
System Pressure - Release".
b. Remove the guard for the sump. Refer to
Illustration 216 g00945910
Disassembly and Assembly, "Sump Guard -
Remove and Install".
5. At the top side of hydraulic tank (5), connect two
hoses (4) and tighten the hose clamps.
31200308 45

3. At the underside of the machine, disconnect tube

(1) and hose (2) from piston pump (3). Loosen the
clamp and disconnect tube (4) from the piston
Personal injury can result from hydraulic oil pump. Disconnect hose (5) from compensator
pressure and hot oil. valve (6).
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, Illustration 220 g00945564
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the hydraulic tank into a suitable container
for storage or disposal. The capacity of the
hydraulic tank is approximately 66 L (17.4 US gal).
Refer to appropriate Operation and Maintenance
Manual for the correct draining procedure.
2. Put identification marks on all hoses and on
all tubes. Plug all hoses and all tubes. This
will prevent fluid loss and this will prevent
contaminants from entering the system.

Illustration 221 g00945565

4. Remove two bolts (7) and the washers in order to
remove piston pump (3) from adapter plate (8) and
at the same time remove O-ring seal (9). The
weight of the piston pump is approximately 20 kg
(44 lb).

Illustration 219 g00945563

46 31200308

Piston Pump (Implement and

Steering) - Disassemble
Disassembly Procedure
Table 8

Required Tools

Tool Part Number Part Description Qty

A 1P-0510 Driver Gp 1
B 1P-1854 Retaining Ring Pliers 1
C 1P-1853 Retaining Ring Pliers 1

Start By:
a. Remove the implement and steering pump from the
machine. Refer to Disassembly and Assembly, "Piston
Pump (Implement and Steering) -Remove". Illustration 223 g00923928

Note: Cleanliness is an important factor. Before the 2. Remove plugs (4) and (5) from compensator valve
disassembly procedure, the exterior of the component (1). Remove fittings (6) from compensator valve (1).
should be thoroughly cleaned. This will help to prevent
dirt from entering the internal mechanism.

Illustration 224 g00923930

Illustration 222 g00923925

1. Remove the four allen head screws (2). Remove
the compensator valve (1) from housing (3).

Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
Illustration 225 g00923931
recommended tooling to release the spring force.
31200308 47

3. Remove O-ring seal (7) from plug (4). Remove

seat (8) from plug (4). Remove springs (9) and
(10). Remove spring retainer (11). Remove spool
(12) from body (19).
4. Remove O-ring seal (13) from plug (5). Remove
seat (14) from plug (5). Remove springs (15) and
(16). Remove spring retainer (17). Remove spool
(18) from body (19).

Illustration 228 g00923935

7. Remove bearing (26) from shaft (24). Remove O-
ring seals (25).

Illustration 226 g00923932

5. Remove allen head screws (20) and remove port
block (21) from housing (3). Illustration 229 g00923936
8. Remove the shim for the bearing preload (27) from
shaft (24).

Illustration 227 g00923933

6. Remove O-ring seal (22). Remove plate (23) from
port block (21). Illustration 230 g00923937
9. Remove rotating group (28) from housing (3).
Carefully retain the rotating assembly (28) in
housing (3). Turn the rotating assembly upside-
down. Slowly lift housing (3) off rotating group (28).
48 31200308

Illustration 231 g00923939 Illustration 234 g00923943

11. Use Tooling (A) and a press in order to compress
spring (34) until the snap ring (33) can be removed
from barrel (31) with Tooling (B). Slowly release the
pressure on the press because of the spring
pressure. Remove barrel (31) from the press.
Remove spring (34), retaining disc (35), and
pressure pins (36).

Illustration 232 g00923940

Note: Mark the location of pistons for assembly
purposes.
10. Remove plate (29) and pistons (30) from barrel
(31). Remove retaining ball (32).

Illustration 235 g00923944

Personal injury can result from being struck by 12. Remove plug (37) and the O-ring seal.
parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

Illustration 236 g00923990

13. Remove piston (38) from housing (3).

Illustration 233 g00923941

31200308 49

Illustration 237 g00923991 Illustration 240 g00923995

Note: The rod is engaged in the socket by the edges of 18. Lift shaft (24) out of the housing (3). If necessary,
the socket. Extreme care must be used in order to press bearing (44) off shaft (24).
disengage the rod from the socket. Remove the
actuator rod out of the smooth shaped socket.
14. Angle the swashplate (39) so rod (40) extends out
of the bore. Remove rod (40) from the socket in
swashplate (39).

Illustration 241 g00923996

19. Use Tooling (C) in order to remove snap ring (45)
from housing (3).

Illustration 238 g00923992

15. Remove swashplate (39) from housing (3). Check

the condition of socket (41).

Illustration 242 g00923998

20. Remove seal (46) from housing (3).

Illustration 239 g00923994

16. Remove two bearings (42).
17. Remove spring (43).
50 31200308

Piston Pump (Implement and 1. Use Tooling (A) in order to install seal (46) in
housing (3). Install the seal until the seal is just
Steering) - Assemble below the face of the housing. Do not seat the
seal at this time.
Assembly Procedure 2. Use Tooling (C) in order to install snap ring (45)
on top of seal (46).
Table 9
3. Use Tooling (A) in order to press snap ring (45) and
Required Tools seal (46) into housing (3). Press snap ring (45) and
Tool Part Number Part Description Qty seal (46) until snap ring (45) is installed in the
groove in housing (3).
A 1P-0510 Driver Gp 1

B 1P-1854 Retaining Ring Pliers 1

C 1P-1853 Retaining Ring Pliers 1

D 8T-5096 Dial Indicator Group 1

Note: Cleanliness is an important factor. Before the

disassembly procedure, the exterior of the component
should be thoroughly cleaned. This will help to prevent
dirt from entering the internal mechanism.
Note: Before you reassemble the pump, replace all
parts, assemblies, seals, and O-rings that are worn or Illustration 245 g00924208
damaged. Lubricate the seals and O-rings with 4. Install bearing (44) onto shaft (24). Make sure that
petroleum jelly in order to retain the seals and O-rings the bearing is seated properly. Install shaft (24) into
during reassembly. This will also provide lubrication to housing (3).
the dust seals and to the shaft seals.

Illustration 246 g00924209

5. Install bearings (42) and spring (43) into housing (3).
Illustration 243 g00924206

Illustration 247 g00885504

Illustration 244 g00924207
Note: Caution must be used when you install the plate.
Do not dislodge the spring or the bearings.
31200308 51

6. Install swashplate (39) in housing (3). Check the

condition of socket (41).

Illustration 251 g00885500

10. Install three pressure pins (36), retaining disc (35),
and spring (34) in barrel (31).
Illustration 248 g00885503
7. Install rod (40) in the bore and engage rod (40) in
socket (41).
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.

Illustration249 g00885502
8. Install piston (38) in the bore.

Illustration 252 g00885583

Illustration 250 g00885501

9. Install plug (37) and the O-ring seal. Tighten plug
(37) to 90 ± 15 Nm (66 ±11 lb ft).

Illustration253 g00885499
11. Install snap ring (33) on top of spring (34). Use
Tooling (A) and a press in order to compress
spring (34). Compress until snap ring (33) can be
installed in the groove in barrel (31) with Tooling
(B).
52 31200308

Illustration 254 g00885498

Illustration 257 g00924216

14. Install the port block (21) on housing (3). Install the
four allen head screws (20). Tighten to the torque
of 165 Nm (122 lb ft).

Illustration 255 g00885497

12. Install retaining ball (32) on barrel (31) and install
retaining plate (29) with pistons (30) in barrel (31).
Note: Set bearing preload before you install the
rotating group. The bearing preload should be
0.00 mm (0.000 inch) to 0.05 mm (0.002 inch).

Illustration 258 g00885594

Illustration 256 g00885593

13. Do not install shim (27). Install bearing (26) onto
shaft (24). Assemble the pump without shim (27) in
order to check the preload of bearing (26).

Illustration 259 g00885595

15. Install Tooling (D) onto the pump housing. Use

the dial indicator to determine the end play of shaft
(24). Be sure that you move shaft (24) completely
in both directions. Use appropriate tools to move
shaft (24).
31200308 53

16. The thickness of shim (27) should equal

the end play measurement plus 0.0508 mm
(0.00200 inch). For example, if the end play is
2.1590 mm (0.08500 inch) then the shim thickness
should be 2.2098 mm (0.08700 inch).
17. Record the measurement.
18. If necessary, grind the shim to the determined
measurement.

Illustration 262 g00885495

21. Install shim (27).

Illustration 260 g00924216

Illustration 263 g00885494
19. Remove bolts (20), port block (21), and the bearing.
22. Install bearing (26) on shaft (24). Install O-ring seals
(25).

Illustration 261 g00885693

Note: All parts must be in the proper position.
Illustration 264 g00885493
20. Wrap the nine pistons (30) with string but do not tie
23. Install O-ring seal (22) and plate (23) to the port
the string. Hold the string tight and carefully install
block (21).
rotating group (28) in housing (3). The splines on
shaft (24) must engage with splines in retaining ball
(32).
54 31200308

Improper assembly of parts that are spring loaded

can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
26. Install spool (18) to body (19). Install spring
retainer (17). Install springs (15) and (16). Install
seat (14) to plug (5). Install O-ring seal (13) to
plug (5).
27. Install spool (12) to body (19). Install spring
retainer (11). Install springs (9) and (10). Install
seat (8) to plug (4). Install O-ring seal (7) to plug
(4).

Illustration 265 g00924216

24. Install port block (21) on housing (3).
25. Install the four allen head screws (20). Tighten to the
torque of 165 Nm (122 lb ft).

Illustration 268 g0094218

28. Install fittings (6) to compensator valve (1). Install
plugs (4) and (5) to compensator valve (1).

Illustration 266 g00924217

Illustration 267 g00872434

31200308 55

Illustration 271 g00945564

2. Apply a thin cost of 1U-6396 O-Ring Assembly

Compound to O-ring seal (9) and install the O-ring
onto the flange of piston pump (3). Align the
spline's on the piston pump with the spline's on the
gear which is located behind mounting plate (8).
Illustration 269 g00924219
Install the piston pump onto the mounting plate
29. Position the compensator valve (1) on housing (3). and install two bolts (7) and the washers.
Install four allen head screws (2) and tighten to a
torque of 12 Nm (9 lb ft).
End By:
a. Install the implement and steering pump onto the machine.
Refer to Disassembly and Assembly, "Piston Pump
(Implement and Steering) - Install".

Piston Pump (Implement and

Steering) - Install
Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 272 g00945563

3. Connect hose (6) to compensator valve (5).
Connect tube (4) to piston pump (3) and tighten
the clamp. Connect hose (2) and tube (1) to the
piston pump.
4. Fill the hydraulic tank. The capacity of the
hydraulic tank is approximately 66 L (17.4 US gal).
Refer to appropriate Operation and Maintenance
Manual for the correct filling procedure.
End By:
a. Install the guard for the sump. Refer to Disassembly and
Assembly, "Sump Guard -Remove and Install".

Illustration 270 g00945565

56 31200308

Solenoid Valve (Frame

Leveling) - Remove and Install
Removal Procedure
Start By:
a. Remove the load control valve. Refer to
Disassembly and Assembly, "Load Control Valve (Frame
Leveling Cylinder) - Remove and Install".

Illustration 275 g00946517

2. Install two coils (10) and fastener (11) onto

solenoid valve (1). Tighten the fastener to a torque
o f 6 ± 1 Nm (4.4 ±0.7 lb ft).
3. Install O-ring seal (9), O-ring seal (8), two backup
rings (7), O-ring seal (6), two backup rings (5),
O-ring seal (4) and two backup rings (3) onto
solenoid valve (1).

Illustration 273 g00946516

1. Remove solenoid valve (1) from load control valve
(2).

Illustration 276 g00946516

4. Install solenoid valve (1) into load control valve (2).
Tighten the solenoid valve to a torque of
45 ± 6 Nm (33 ± 5 lb ft).
End By:
Illustration 274 g00946517 a. Install the load control valve. Refer to Disassembly and
2. Remove two backup rings (3), O-ring seal (4), Assembly, "Load Control Valve (Frame Leveling Cylinder)
two backup rings (5), O-ring seal (6), two backup - Remove and Install".
rings (7), O-ring seal (8) and O-ring seal (9) from
Solenoid valve (1).
3. Remove fastener (11) in order to remove two
coils (10).

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
31200308 57

Diverter Valve (Boom Head) - 3. Disconnect two electrical connectors (3) from
diverter valve (1).
Remove and Install 4. Disconnect two hoses (4) from diverter valve (1).

Removal Procedure

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
Illustration 278 g00930492
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the 5. Remove bolts (5) and the washers in order to
filler cap is cool enough to touch with your bare remove diverter valve (1) from the boom head.
hand.
NOTICE Installation Procedure
Care must be taken to ensure that fluids are contained 1. Clean all parts and inspect all parts. If any parts are
during performance of inspection, maintenance, testing, worn or damaged, use new Caterpillar parts for
adjusting and repair of the product. Be prepared to collect replacement.
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all hoses, on all tubes
and on all wires for installation purposes. Plug all
hoses and all tubes. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.

Illustration 279 g00930492

2. Position diverter valve (1) onto the boom head and
install bolts (5) and the washers.

Illustration 277 g00930491

2. Disconnect two hoses (2) from diverter valve (1).
58 31200308

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all hoses, on all tube
and on all wires for installation purposes. Plug all
hoses and all tubes. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.

Illustration 280 g00930491

3. Connect two hoses (4) to diverter valve (1).
4. Connect two electrical connectors (3) to diverter
valve (1).
5. Connect two hoses (2) to diverter valve (1).

Control Valve (Stabilizer) -

Remove
Illustration 281 g00923368
Removal Procedure 2. Start the engine and install Tooling (A) under hitch
Table 10
(1) in order to support the boom assembly. Make
sure that Tooling (A) is fully extended. Lower
Required Tools stabilizers (2) to the ground but do not lift the
Tool Part Number Part Description Qty machine. Shut off the engine. Remove cover (3).

4C-6486 Stand 1
8S-7621 Tube 1
A
8S-8048 Saddle 1
8S-7615 Pin 1

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
Illustration 282 g00923388
system after the engine has been stopped. Serious
3. Disconnect four hoses (4) from the front of control
injury can be caused if this pressure is not released
valve (5). Lay the hoses aside.
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
31200308 59

Illustration 283 g00923390 Illustration 286 g00923912

6. Remove bolts (9) and the washers that secure
4. Loosen the hose clamp in order to disconnect tube
control valve (5). Carefully remove the control
(6) from control valve (5). Disconnect four hoses
valve out of the stabilizer frame. The weight of the
(7) from the control valve.
control valve is approximately 20 kg (44 lb).

Electronic Pilot Valve

(Stabilizer) - Remove and Install
Removal Procedure
Start By:
a. Remove the stabilizer control valve. Refer to Disassembly
and Assembly, "Control Valve (Stabilizer) - Remove".
NOTICE
Care must be taken to ensure that fluids are contained
Illustration 284 g00923391 during performance of inspection, maintenance, testing,
5. Disconnect electrical connector (8) from control adjusting and repair of the product. Be prepared to collect
valve (5). the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Illustration 285 g00923911

Illustration 287 g00939481

1. Remove two bolts (1) and the washers from

electronic pilot valve (2).
60 31200308

Illustration 291 g00939482

Illustration 288 g00939482
2. Position electronic pilot valve (2) onto bank valve
2. Remove four bolts (3) in order to remove electronic
(4) and install four bolts (3). Tighten the bolts to a
pilot valve (2) from bank valve (4).
torque of 3 ± 0.5 Nm (27 ± 4.4 lb in).

Illustration 292 g00939481

Illustration 289 g00939483
3. Install two bolts (1) and the washers into electronic
3. Remove six O-ring seals (5) and two O-ring seals
pilot valve (2).
(6) from electronic pilot valve (2).
End By:
Installation Procedure a. Install the stabilizer control valve. Refer to Disassembly
and Assembly, "Control Valve (Stabilizer) - Install".

Bank Valve (Stabilizer) -

Disassemble
Disassembly Procedure
Start By:
a. Remove the stabilizer control valve. Refer to Disassembly
and Assembly, "Control Valve (Stabilizer) - Remove".
b. Remove the electronic pilot valve. Refer to Disassembly
and Assembly, "Electronic Pilot Valve (Stabilizer) - Remove
and Install".
Illustration 290 g00939483 NOTICE
1. Apply a thin coat of 1U-6396 O-Ring Assembly Care must be taken to ensure that fluids are contained
Compound to six O-ring seals (5) and two O-ring during performance of inspection, maintenance, testing,
seals (6) before installing the O-ring seals into adjusting and repair of the product. Be prepared to collect
electronic pilot valve (2). the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
31200308 61

Note: Cleanliness is an important factor. Before you

begin the disassembly procedure, the exterior of the
components should be thoroughly cleaned. This will
help to prevent dirt from entering the internal
components. Precision components can be damaged
by contaminants or dirt. Perform the disassembly
procedure on a clean work surface. Keep components
covered and protected at all times.

Illustration 296 g00936681

4. Remove four O-ring seals (9), O-ring seal (10) and

O-ring seal (11) from control valve (8).

Illustration 293 g00936678

1. Place the bank valve in a suitable soft jawed vise.
Remove four locknuts (1) in order to remove
manifold (2).

Illustration 297 g00936739

5. Slide control valve (8) off studs (7) and manifold
(12).

Illustration 294 g00936679

2. Remove four O-ring seals (3), O-ring seal (4) and
O-ring seal (5) from control valve (6).

Illustration 298 g00936742

6. Remove four O-ring seals (13), O-ring seal (14)
and O-ring seal (15) from manifold (12).
7. Use the following procedure to disassemble control
valve (6) and control valve (8):

Illustration 295 g00936680

3. Slide control valve (6) off studs (7) and control
valve (8).
62 31200308

Illustration 299 g00936743 Illustration 302 g00936786

a. Place the control valve in a suitable soft jawed vise. d. Remove check valve (23) from the control valve. Remove
Remove plug (16) and O-ring seal (17) (not shown). the check valve from the opposite side of the control
valve.

Illustration 300 g00936784

Illustration 303 g00936788
b. Remove spool (18) from the control valve.
e. Remove four bolts (24) in order to remove cover (25) from
the control valve.

Illustration 301 g00936785

c. Remove plug (19) from the control valve. Remove O-ring Illustration 304 g00936987
seal (20), backup ring (21) and O-ring seal (22) from plug f. Remove O-ring seal (26) and O-ring seal (27) from cover
(19). Remove the plug from the opposite side of the control (25). Remove adjusting screw (28) and sealing nut (29).
valve.
31200308 63

Illustration 307 g00937328

Illustration 305 g00936988
g. Slide valve spool (30) out of the control valve. a. Install two collars (32), spring (33) and retainer (31) onto
valve spool (30).

I
Illustration 306 g00936989
h. Remove retainer (31), two collars (32) and spring (33) from Illustration 308 g00937329
valve spool (30). b. Place the control valve in a suitable soft jawed vise.
Lubricate spool (30) with the lubricant that is being sealed
before sliding the spool into the control valve.
Bank Valve (Stabilizer) -
Assemble
Assembly Procedure
Note: Cleanliness is an important factor. Before
assembly, thoroughly clean all parts in cleaning fluid.
Allow the parts to air dry. Do not use wiping cloths or
rags to dry parts. Lint may be deposited on parts which
may cause trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement. Dirt
and other contaminants can damage the precision
components. Perform assembly procedures on a clean Illustration 309 g00937330
work surface. Keep components covered and protected
c. Install adjusting screw (28) with sealing nut (29) into cover
at all times. (25). Apply a thin coat of 1U - 6396 O-Ring Assembly
1. Use the following procedure to assemble control Compound to O-ring seal (26) and O-ring seal (27)
before installing the O-ring seals into the cover.
valve (6) and control valve (8) before the assembly
of the bank valve.
64 31200308

Installation 310 g00937331 Illustration 313 g00937334

d. Position cover (25) onto the control valve and install four g. Lubricate spool (18) with the lubricant that is being sealed
bolts (24). and install the spool into the control valve.

Illustration 311 g00937332 Illustration 314 g00937335

e. Install check valve (23) into the control valve. Install the h. Install O-ring seal (17) (not shown) onto plug (16) and
check valve into the opposite side. install the plug into the control valve. Remove the control
valve from the soft jawed vise.

Illustration 312 g00937333

Illustration 315 g00937336
f. Install O-ring seal (22), backup ring (21) and O-ring seal
(20) onto plug (19). Lubricate the O-ring seals before 2. Place manifold (12) in a suitable soft jawed vise.
installing the plug into the control valve. Install the plug Apply a thin coat of 1U-6396 O-Ring Assembly
into the opposite side of the control valve. Compound to four O-ring seals (13), O-ring seal
(14) and O-ring seal (15) before installing the O-
ring seals into the manifold.
31200308 65

Illustration 316 g00939475

Illustration 319 g00939478
3. Carefully slide control valve (8) onto studs (7) and
6. Apply a thin coat of 1U - 6396 O-Ring Assembly
manifold (12).
Compound to four O-ring seals (3), O-ring seal (4)
and O-ring seal (5) before installing the O-ring seals
into the control valve (6).

Illustration 317 g00939476

4. Apply a thin coat of 1U-6396 O-Ring Assembly
Compound to four O-ring seals (9), O-ring seal (10) Illustration 320 g00939479
and O-ring seal (11) before installing the O-ring
7. Install manifold (2) onto control valve (6). Install
seals into the control valve (8).
four locknut (1) and tighten the locknuts to a
torque of 35 Nm (26 lb ft).
End By:
a. Install the electronic pilot valve. Refer to
Disassembly and Assembly, "Electronic Pilot
Valve (Stabilizer) - Remove and Install".
b. Install the stabilizer control valve. Refer to
Disassembly and Assembly, "Control Valve
(Stabilizer) - Install".

Control Valve (Stabilizer) -Install

Installation Procedure
Illustration 318 g00939477
5. Carefully slide control valve (6) onto studs (7) and Table 11
control valve (8).
Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1
A 8S-7621 Tube 1
8S-8048 Saddle 1
8S-7615 Pin 1
66 31200308

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 324 g00936583

4. Connect four hoses (7) to control valve (5).
Connect tube (6) to the control valve and tighten the
Illustration 321 g00936580
hose clamp.

Illustration 322 g00936581 Illustration 325 g00936584

2. Carefully lift control valve (5) into the stabilizer 5. Connect four hoses (4) to the front of control valve
frame. Position the control valve and install bolts (9) (5).
and the washers. The weight of the control valve is
approximately 20 kg (44 lb).

Illustration 326 g00936585

Illustration 323 g00936582

6. Install cover (3). Start the engine and lift stabilizers
(2). Remove Tooling (A) and shut off the engine.
3. Connect electrical connector (8) to control valve (5).
31200308 67

Stabilizer Cylinder - Remove NOTICE

Care must be taken to ensure that fluids are contained
and Install during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
Removal Procedure the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Table 12
Dispose of all fluids according to local regulations and
Required Tools mandates.
Tool Part Number Part Description Qty Note: A hydraulic oil sample should be obtained
before any maintenance is performed in order to
A 1P-1864 Retaining Ring Pliers 1 establish the system contaminant level. Refer to
appropriate Operation and Maintenance Manual for the
correct location.
1. Put identification marks on all line, on all hoses
and on all wires for installation purposes. Plug all
Personal injury or death can result from improper
lines and all hoses. This helps to prevent fluid loss
lifting or blocking.
and this helps to keep contaminants from entering
When a hoist or jack is used to lift any part or the system.
component, stand clear of the area. Be sure the
2. The following procedure shows the removal of
hoist or jack has the correct capacity to lift a
the left side stabilizer cylinder. Use the same
component. Install blocks or stands before
procedure to remove the stabilizer cylinder from
performance of any work under a heavy
the right side of the machine.
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system. Illustration 327 g00922823
3. Start the engine. Lower the stabilizer to the ground
Make sure all of the attachments have been
but do not lift the machine. Shut off the engine.
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
Ensure all pressure is relieved before removing a
lock valve or disassembling a cylinder.
68 31200308

disconnecting two hoses (6) from the cylinder.

Disconnect electrical connector (7) for pressure
switch (8).

Illustration 331 g00922841

7. Attach a second nylon lifting sling around cylinder
(1). Use the hoist and lift the cylinder so that the
Illustration 328 g00922824
cylinder is horizontal to the ground. Remove bolt
4. Attach a suitable nylon lifting sling around cylinder (9), the washer and the spacer. Remove pin (10)
(1) and to a suitable hoist. Take up the tension in out of stabilizer frame (11) and cylinder (1). Use the
order to support the cylinder. Use Tooling (A) to hoist and remove the cylinder from the machine.
remove circlip (2) from pin (3). Extract the pin out
of stabilizer (4) and cylinder (2). The weight of the
cylinder is approximately 62 kg (137 lb).
5. Start the engine and retract the rod into the
cylinder.

Illustration 332 g00922844

8. Remove bolts (12) and the washers in order to
remove lock valve (13) from cylinder (1). Remove
pressure switch (8) from the cylinder.

Illustration 329 g00922824

Illustration 330 g00922839

6. Place suitable cribbing onto stabilizer (4) and
lower cylinder (1) onto the cribbing. Do not remove
the lifting sling. Remove plastic tie (5) before
31200308 69

Disassembly and Assembly

Information
Table 13

Required Tools
Tool Part Number Part Description Qty

Hydraulic Cylinder
A 1
Repair Stand

Bearing Mount
B 7M-7456 1
Compound
Multipurpose
C 1P-0808 1
Grease
D 4C-8092 Universal Wrench 1

E 9U-7868 Spanner Wrench 1

127-8064 Adapter Plate 1
FT-2802 Plate 1
2J-3507 Full Nut 1
F
3K-5234 Hard Washer 1
4C-9634 Puller Stud 1
6V-4035 Sleeve 1
Double Acting
6V-3175 1
Cylinder
9U-6832 Nut 1

3S-6224 or 8S- Electric Hydraulic

1
8033 Pump Gp

6D-7726 Hose As 2
Slide Hammer
G 1P-0074 1
Puller Gp
H 233-7209 Seal Guide 1

1P-0510 or 1P-
I Driver Gp 1
0520

Note: SERVICE DATA: THE TOOLING IN TABLE 13

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
70 31200308

Illustration 333 g00943775

a. Install bearing (1). Install the bearing to depth (X)
from the bottom face before installing lip seals (2).
Dimension (X).........7 ± 0.5 mm (0.276 ± 0.020 inch)
b. Install bearing (13). The bearing must not extend
beyond either face of the rod eye.
c. Apply Tooling (B) to the seal groove prior to the
installation of the wiper seal (9). Lubricate the lip
of wiper seal (9), seal (8), seal (7) and wear ring
(6) with the lubricant that is being sealed.
d. Lubricate the threads of self-locking nut (2)
with Tooling (C). Use a 65 mm socket for the
removal and for the installation of the self-locking
nut. The torque setting for the self-locking
nut......................1600 ± 160 Nm (1180 ± 120 lb ft)
e. Lubricate piston seals (5) and wear ring (4) with
the lubricant that is being sealed.
f. Lubricate O-ring seal (10), the backup ring and
O-ring seal (11) with the lubricant that is being
sealed.
g. Lubricate the threads of head (12) with Tooling
(C). The torque setting for head. 600 ± 130 Nm
(440 ± 95 lb ft)
31200308 71

Installation Procedure
Table 14

Required Tools

Tool Part Number Part Description Qty

A 1P-1864 Retaining Ring Pliers 1

1. The following procedure shows the installation for

the stabilizer cylinder for the left side of the
machine. Use the same procedure to install the
right side stabilizer cylinder.
Illustration 337 g00922841
2. Clean all parts and inspect all parts. If any parts 5. Move cylinder (1) toward the machine. Align the
are worn or damaged use new Caterpillar parts for bore in the cylinder with the bores in stabilizer
replacement. frame (11) and install pin (10). Install bolt (9) with
the washer and the spacer.
6. Lower cylinder (1) onto suitable cribbing and
remove the lifting sling which is indicated by
the white arrow. Refer to illustration 339 for the
location of the cribbing.

Illustration 335 g00922844

3. Install pressure switch (8) into cylinder (1).
Position lock valve (13) before installing bolts (12)
and the washers.

Illustration 338 g00922839

Illustration 336 g00935409

4. Attach two suitable nylon slings around cylinder (1)
and to a suitable hoist. Make sure that lock valve Illustration 339 g00922825
(13) is on the underside of the cylinder. The weight 7. Connect electrical connector (7) for pressure
of the cylinder is approximately 62 kg (137 lb). switch (8). Connect two hoses (6) to cylinder (1).
8. Take up the tension on the lifting sling and remove
the cribbing.
72 31200308

Ensure all pressure is relieved before removing a

lock valve or disassembling a cylinder.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. The following procedure shows the removal of the
lock valve for the left side stabilizer cylinder. Use
the same procedure to remove the lock valve from
the right side stabilizer cylinder.
2. Put identification marks on all hoses. Plug all
hoses. This helps to prevent fluid loss and this
Illustration 340 g00922824 helps to keep contaminants from entering the
9. With the aid of a second person, start the engine. system.
Extend the rod in cylinder (1) and align the bores in
the rod with the bores in stabilizer frame (4). Install
pin (3) and then use Tool (A) in order to install
circlip (2). Shut of the engine and remove the lifting
sling.

Load Control Valve (Stabilizer

Cylinder) - Remove and Install
Removal Procedure

Illustration 341 g00922982

3. Start the engine. Lower the stabilizer to the ground
Personal injury can result from hydraulic oil but do not lift the machine. Shut off the engine.
pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.

Illustration 342 g00922909

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
31200308 73

Illustration 343 g00922910 Illustration 346 g00922910

4. Disconnect two hoses (2) from lock valve (1).
3. Install two O-ring seals (not shown) into the mating face of
lock valve (1). Position the lock valve onto cylinder (4) and
install bolts (3) with the washers.

Illustration 344 g00923001

5. Remove bolts (3) and the washers in order to
remove lock valve (1) from cylinder (4). Remove
two O-ring seals (not shown) from the lock valve. Illustration 347 g00922909
4. Connect two hoses (2) to lock valve (1).
Installation Procedure
Fuel Tank - Remove
1. The following procedure shows the installation of
the lock valve on left side stabilizer cylinder. Use
the same procedure to install the lock valve on the Removal Procedure
right side stabilizer cylinder.
2. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement. Personal injury or death can result from improper
lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Illustration 345 g00923001

3. Install two O-ring seals (not shown) into the mating
face of lock valve (1). Position the lock valve onto
cylinder (4) and install bolts (3) with the washers.
74 31200308

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the fuel tank into a suitable container for
storage or disposal. The maximum capacity of the
fuel tanks is 110 L (30 US gal). Refer to appropriate
Operation and Maintenance Manual. Illustration 350 g00946162

2. Put Identification marks on all hoses and on all

wires. Plug all hoses. This helps to prevent fluid
loss and this helps to keep contaminants from
entering the system.

Illustration 351 g00946163

5. From the underside of the machine, remove two
bolts (4) and the washers which secure fuel tank (2)
to the side of chassis (5).

Illustration 348 g00946159

3. Loosen the clamps in order to disconnect two
hoses (1) from fuel tank (2). Disconnect electrical
connector (3) for the fuel sender.

Illustration 352 g00946164

6. Remove two bolts (6), two washers (7) and two
mounts (8) from fuel tank (2).

Illustration 349 g00946161

4. Place a suitable floor jack on the underside of fuel
tank (2). If necessary, use cribbing to keep the fuel
tank level on the floor jack. Raise the floor jack and
support the fuel tank.
31200308 75

2. Install two sleeves (10) and two mounts (11) into

fuel tank (2) before sliding the fuel tank onto plate
assembly (9).

Illustration 353 g00946165

7. Use the floor jack and carefully lower fuel tank (2).
Remove the fuel tank from the machine. The
weight of the fuel tank is approximately Illustration 356 g00946165
40 kg (88 lb). 3. Position fuel tank (2) on a suitable floor jack. If
necessary, use cribbing to keep the fuel tank level
on the floor jack. Lift the fuel tank into position. The
weight or the fuel tank is approximately 40 kg
(88 lb).

Illustration 354 g00946296

8. Slide fuel tank (2) out of plate assembly (9).
Remove two sleeves (10) and two mounts (11) from
the fuel tank.
Illustration 357 g00946164
Fuel Tank - Install 4. Install two bolts (6), two washers (7) and two
mounts (8) into fuel tank (2).
Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 358 g00946163

Illustration 355 g00946296

76 31200308

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
Illustration 359 g00946162 shown. Clean all surfaces where parts are to be
5. At the underside of the machine, install two bolts installed.
(4) and the washers which secure fuel tank (2) to
the side of chassis (5). Remove the floor jack from
the underside of the fuel tank.
Personal injury can result from hydraulic oil
pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
Illustration 360 g00946159

6. Connect electrical connector (3) for the fuel

sender. Connect two hoses (1) to fuel tank (2) and
tighten the hose clamps. Personal injury can result from contact with
7. Fill the fuel tank. The maximum capacity of the refrigerant.
fuel tank is 110 L (30 US gal). Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Cab - Remove Protective goggles must always be worn when
refrigerant lines are opened, even if the gauges
Removal Procedure indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Table 15
Slowly loosen the fitting. If the system is still under
Required Tools pressure, release it slowly in a well ventilated area.
Tool Part Number Part Description Qty Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
A 1U-9200 Lever Puller Hoist 1
Inhaling air conditioner refrigerant gas through a lit
B 180-3033 Repair Stand 4 cigarette or other smoking method or inhaling
fumes released from a flame contacting air
Start By:
conditioner refrigerant gas, can cause bodily harm
a. Remove the hydraulic tank. or death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning
system.
31200308 77

NOTICE 6. Disconnect two hoses (2) from master cylinder (3).

Care must be taken to ensure that fluids are contained Loosen the hose clamp and disconnect tube (4).
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Park the machine on level ground. place wheel
blocks in front of the rear wheel and behind the rear
wheels. Disengage the parking brake. Refer to
appropriate Operation and Maintenance Manual.
2. If equipped, recover the air conditioner refrigerant
from the air conditioner system (if equipped). Illustration 363 g00947380

The correct charge is 0.8 kg (1.8 lb). Refer to 7. Disconnect four hoses (5) from the top side of
appropriate Service Manual for the correct manifold (6). Loosen the hose clamp and
procedure. disconnect tube (7).
3. Put identification marks on all hoses for installation
purposes. Plug all hoses. This helps to prevent
fluid loss and this helps to keep contaminants
from entering the system.
4. Drain the coolant from the cooling system into a
suitable container for storage or disposal. The
capacity of the cooling system is approximately
27.5 L (7.3 US gal). Refer to appropriate
Operation and Maintenance Manual.

Illustration 364 g00947381

8. Disconnect hose (8) from the bottom side of
manifold (6). Disconnect hose (9) from metering
pump (10).

Illustration 361 g00940864

5. Remove cover (1).

Illustration 365 g00947382

9. Remove bolt (11) and the washer in order to
disconnect ground strap (12).

Illustration 362 g00947371

78 31200308

Illustration 366 g00947383 Illustration 369 g00947701

10. Remove pin (13) in order to disconnect cable (14)
from the lever on fuel pump (15). Loosen two nuts
(16) and remove the cable from bracket (17). Trace
the cable back to the cab and remove all cable
straps and clips that secure the cable.

Illustration 370 g00947702

13. Loosen two bolts (29) in order to disconnect two
electrical connectors from the underside of the cab.
Remove nut (32) and the washer in order to
disconnect positive cable (31) from the terminal
Illustration 367 g00947385 block which is located on the side of the chassis
11. Remove clip (18) and pin (19) in order to which is near to the exhaust muffler. Trace the
disconnect cable (20) from lever (21). Remove two cable back to the cab and remove all cable straps
bolts (22) and the washers in order to remove and clips that secure the cable. Note the location of
bracket (23) from parking brake (24). Trace the the clips and cable straps for installation purposes.
cable back to the cab and remove all cable straps
and clips that secure the cable. Note the location of
the clips and cable straps for installation purposes.

Illustration 371 g00947709

14. Attach a suitable double chain lifting sling between
a suitable hoist and the lifting brackets which are
Illustration 368 g00947386 located at the rear corners of cab (33). Attach a
12. At the underside of the machine, remove bolt (25) in suitable nylon lifting sling to the lifting brackets
order to disconnect cable (26). Loosen the hose which are located at the front corners of the cab.
clamps and disconnect two heater hoses (27). Attach Tooling (A) between the hoist and the nylon
Disconnect two hoses (28) for the air conditioner (if lifting sling. Take up the tension but do not lift the
equipped). cab at this time. If necessary, adjust Tooling (A).
31200308 79

Illustration 372 g00947710

Front Cab Mounts Illustration 375 g00947759
16. Remove two bolts (39), four washers (40), four
washers (41), two nuts (42) and the two top half's of
mount (43).

Illustration 373 g00947711

15. At the underside of the machine, remove two bolts
(34), two washers (35), two washers (36) and the
bottom half's of mount (37). Illustration 376 g00947794
17. Carefully use the hoist and lift cab (33) from the
machine. Be sure not to foul any loose hoses or
wires. The weight of the cab is approximately 600
kg (1322 lb).

Illustration 374 g00947757

Rear Cab Mount

Illustration 377 g00947795

18. Carefully lower cab (33) onto Tooling (B). Remove
the lifting equipment.
80 31200308

Illustration 378 g00947796 Illustration 380 g00947809

19. Remove the two top half's of mounts (37) and two 1. Place two half's of mounts (43) onto the chassis
sleeve's (38) from the chassis. Refer to illustration and insert two sleeves (44) into the mounts.
373.

Illustration 381 g00947796

Illustration 379 g00947809 2. Install two half's of mounts (37) into the chassis and
20. Remove the two top half's of mounts (43) and two insert two sleeves (38) into the mounts.
sleeve's (44) from the chassis. Refer to illustration
375.

Cab - Install
Installation Procedure
Table 16

Required Tools
Tool Part Number Part Description Qty
A 1U-9200 Lever Puller Hoist 1
B 180-3033 Repair Stand 4 Illustration 382 g00947709

Illustration 383 g00947795

31200308 81

3. Attach a suitable double chain lifting sling between

a suitable hoist and the lifting brackets which are
located at the rear corners of cab (33). Attach a
suitable nylon lifting sling to the lifting brackets
which are located at the front corners of the cab.
Attach Tooling (A) between the hoist and the nylon
lifting sling. Use the hoist and lift the cab off Tooling
(B). The weight of the cab is approximately 600 kg
(1322 lb).

Illustration 387 g00947710

Illustration 384 g00947794

4. Carefully lower cab (33) into position on the
machine.

Illustration 388 g00947711

6. Install two bolts (34), two washers (35), two
washers (36) and the two bottom half's of mounts
(37). Tighten the bolts to a torque of 450 Nm (332
lb ft).
7. Remove the lifting equipment.

Illustration 385 g00947757

Rear Cab Mount

Illustration 389 g00947701

Illustration 386 g00947759

5. Install two bolts (39), four washers (40), four
washers (41), two nuts (42) and the two top half's of
mounts (44). Tighten the nuts and bolts to a torque
of450Nm (332 lb ft).
82 31200308

10. Route cable (20) from the cab to parking brake

(24). Position bracket (23) onto parking brake (24)
and install two bolts (22) and the washers. Align
cable (20) with lever (21) and install pin (19) and
clip (18). Install all cable straps and clips that were
removed and noted in the removal procedure.

Illustration 390 g00947702

8. At the underside of the cab, connect two electrical
connectors (30) and tighten two bolts (29). Route
positive cable (31) to the terminal block which is
located on the side of the chassis which is near to
the exhaust muffler. Install nut (32) and the washer
in order to connect the positive cable to the
Illustration 393 g00947383
terminal block. Install all cable straps and clips that
were removed and noted in the removal procedure. 11. Route cable (14) from the cab to fuel pump (15).
Install cable (14) into bracket (17) and tighten two
nuts (16). Align the cable with the lever on the fuel
pump and install pin (13). Install all cable straps and
clips that were removed and noted in the removal
procedure.

Illustration 391 g00947386

9. Connect two hoses (28) for the air conditioner (if
equipped). Connect two heater hoses (27) and
tighten the hose clamps. Install bolt (25) in order to
connect cable (26).
Illustration 394 g00947382
12. Install bolt (11) and the washer in order to connect
ground strap (12).

Illustration 392 g00947385

Illustration 395 g00947381

13. Connect hose (9) to metering pump (10). Connect
hose (8) to the bottom of manifold (6).
31200308 83

End By:
a. Install the hydraulic tank. Refer to Disassembly and
Assembly, "Hydraulic Tank - Install".

Window Wiper and Wiper

Motor (Front) - Remove and
Install
Removal Procedure
Start By:
a. Turn the battery disconnect switch to the OFF position.
Illustration 396 g00947380 Refer to appropriate Operation and Maintenance Manual.
14. Connect tube (7) to manifold (6) and tighten the 1. Put identification marks on all wires and all
hose clamp. Connect four hoses (5) to the top side connectors for installation purposes.
of the manifold.

Illustration 399 g00929823

Illustration 397 g00947371
2. Remove cover (1).
15. Connect two hoses (2) to master cylinder (3).
Connect tube (4) to the master cylinder and tighten
the hose clamp.

Illustration 400 g00929824

3. Disconnect hose (2) for the window washer. Open
Illustration 398 g00940864
covers (3) for wiper arms (4). Remove two nuts (5)
16. Install cover (1). before removing wiper arms (4).

17. Fill the cooling system. The capacity of the cooling

system is approximately 27.5 L (7.3 US gal). Refer
to appropriate Operation and Maintenance Manual.
18. If equipped, charge the air conditioner system. The
correct charge is 0.8 kg (1.8 lb). Refer to
appropriate Service Manual. for the procedure.
84 31200308

Illustration 401 g00929852 Illustration 404 g00929852

4. Cut cable strap (6) and disconnect electrical 3. Connect electrical connector (7) for wiper motor
connector (7) for wiper motor (8). (8) and install a new cable strap (6).
4. Use the following procedure to install the wiper
arms:
a. If a new wiper motor has been installed
disregard steps 4.b and 4.c.
b. Turn the battery disconnect switch to the ON
position. Refer to appropriate Operation and Maintenance
Manual.
c. Turn the switch for the front window wiper to the ON
position and then turn the switch for the front window
wiper to the Off position. This will make sure that the
wiper motor is in the PARK position. Refer to appropriate
Operation and Maintenance Manual.

Illustration 402 g00929853

5. Remove two caps (9), two nuts (10) and two
washers (11) in order to remove wiper motor (8)
from the machine.

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 405 g00929908

Illustration 403 g00929853

2. Position wiper motor (8) on the machine and install
two washers(11), two nuts (10) and two caps (9).
Tighten the nuts to a torque of 37.5 ± 2.5 Nm
(27.6 ± 1.8 lb ft).
31200308 85

Illustration 406 g00929824 Illustration 408 g00930278

d. Install wiper arm (4) so that the wiper blade 2. Remove six bolts (2) in order to lower cab
is in full contact with the front left side of the headliner (1).
windshield. The wiper blade must be parallel
with the edge of the windshield at a distance of
21 ± 3 mm (0.83 ± 0.12 inch). Note the black
arrows on illustration 405. Tighten nuts (5) to a
torque of 23 ±1 Nm (17 ± 0.7 lb ft).
e. Wait for at least thirty minutes. Do not wait for
more than four hours. Tighten nuts (5) again to
a torque of 23 ± 1 Nm (17 ± 0.7 lb ft). Close
covers (3) for the wiper arm.
f. Connect hose (2) for the window washer.

Illustration409 g00930279
3. Disconnect harness (3) for dome light (4) and harness (5)
for speakers (6) before removing cab headliner (1) from
the cab.

Illustration 407 g00929823

5. Install cover (1).

Window Wiper and Wiper

Motor (Rear) - Remove and
Install
Illustration 410 g00930326
Removal Procedure
4. Disconnect tube (7) for the windshield washer.
Start By: Open cap (8) for wiper arm (9) and remove nut (10)
a. Turn the battery disconnect switch to the OFF position. before removing the wiper arm from the machine.
Refer to appropriate Operation and Maintenance
Manual.
1. Put identification marks on all wires and all
connectors for installation purposes.
86 31200308

Illustration 411 g00930329 Illustration 414 g00930330

2. With the aid of a second person, position wiper
motor (12) and install sealing washer (14), nut
(13), sealing washer (17), nut (16) and cap (15).
Tighten nut (16) to a torque of 7.5 ± .5 Nm (5.5 ±
0.4 lb ft). Connect electrical connector (11).

Illustration 412 g00930330

5. Disconnect electrical connector (11) for wiper
motor (12). With the aid of a second person,
support the wiper motor from the inside of the cab.
At the same time remove nut (13), sealing washer
(14), cap (15), nut (16), and sealing washer (17). Illustration 415 g00930279
Remove the wiper motor from the machine. 3. Position cab headliner (1) in the cab in order to
enable the connection of electrical connector (5) for
Installation Procedure speakers (6) and harness (3) for dome light (4).

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 416 g00930278

4. Lift cab headliner (1) into position and install six
bolts (2).
Illustration 413 g00930329 5. Use the following procedure to install the wiper
arm:
a.If a new wiper motor has been installed
disregard steps 5.b and 5.c.
b.Turn the battery disconnect switch to the ON
position. Refer to appropriate Operation and
Maintenance Manual.
31200308 87

c.Turn the switch for the front window wiper to

the ON position and then turn the switch for the
front window wiper to the Off position. This will
make sure that the wiper motor is in the PARK
position. Refer to appropriate Operation and
Maintenance Manual.

Illustration 419 g00930171

2. Remove six bolts (2) in order to lower cab
headliner (1).

Illustration 417 g00930340

Illustration 420 g00930172

3. Disconnect harness (3) for dome light (4) and
harness (5) for speakers (6) before removing cab
Illustration 418 g00930326 headliner (1) from the cab.
d.Position wiper arm (9) so that the wiper blade
is in full contact with the front left side of the
windshield. The wiper blade must be parallel
with the edge of the windshield at a distance
of 18 ± 3 mm (0.71 ±0.12 inch). Note the
black arrows on illustration 417. Install nut (10)
and tighten the nut to a torque of 23 ± 1 Nm
(17 ± 0.7 lb ft).
e.Wait for at least thirty minutes. Do not wait for
more than four hours. Tighten nuts (10) again
to a torque of 23 ± 1 Nm (17 ± 0.7 lb ft). Close
cover (8) for the wiper arm.
f.Connect hose (7) for the window washer.

Illustration 421 g00930173

Window Wiper and Wiper 4. Disconnect hose (7) for the windshield washer.
Uncouple cap (8) for wiper arm (9) at connector
Motor (Roof) - Remove and (10). Open cap (11) and remove nut (12) and the
Install washer in order to remove wiper arm (9) from the
machine.
Removal Procedure
Start By:
a. Turn the battery disconnect switch to the OFF position.
Refer to appropriate Operation and Maintenance Manual.
1. Put identification marks on all wires and all
connectors for installation purposes.
88 31200308

Illustration 422 g00930174 Illustration 425 g00930175

2. With the aid of a second person, position wiper
motor (14) and install sealing washer (16), nut
(15), sealing washer (19), nut (18) and cap (17).
Tighten nut (18) to a torque of 7.5 ± .5 Nm (5.5 ±
0.4 lb ft). Connect electrical connector (13).

Illustration 423 g00930175

5. Disconnect electrical connector (13) for wiper
motor (14). With the aid of a second person,
support the wiper motor from the inside of the cab.
At the same time remove nut (15), sealing washer
(16), cap (17), nut (18) and sealing washer (19). Illustration 426 g00930172
Remove the wiper motor from the machine. 3. Position cab headliner (1) in the cab in order to
enable the connection of electrical connector (5) for
Installation procedure speakers (6) and harness (3) for dome light (4).

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 427 g00930171

4. Lift cab headliner (1) into position and install six
bolts (2).
5. Use the following procedure to install the wiper
Illustration 424 g00930174
arm:
a.If a new wiper motor has been installed
disregard steps 5.b and 5.c.
b.Turn the battery disconnect switch to the ON
position. Refer to appropriate Operation and
Maintenance Manual.
31200308 89

c.Turn the switch for the front window wiper to

the ON position and then turn the switch for the
front window wiper to the OFF position. This will
make sure that the wiper motor is in the PARK
position. Refer to appropriate Operation and Personal injury can result from contact with
Maintenance Manual. refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when
refrigerant lines are opened, even if the gauges
indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still under
pressure, release it slowly in a well ventilated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a lit
cigarette or other smoking method or inhaling
Illustration 428 g00930228
fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm
or death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning
system.

At operating temperature, the engine coolant is hot

Illustration 429 g00930173
and under pressure.
d.Couple cap (8) onto connector (10) for wiper
arm (9). Position wiper arm (9) so that the Steam can cause personal injury.
wiper blade is in full contact with the front left Check the coolant level only after the engine has
side of the windshield. The wiper blade must
be parallel with the edge of the windshield at a been stopped and the fill cap is cool enough to
distance of 127 ± 3 mm (5 ± 0.1 inch). Note the touch with your bare hand.
black arrows on illustration 428. Install nut (12) Remove the fill cap slowly to relieve pressure.
and tighten the nut to a torque of 23 ± 1 Nm
(17 ±0.7 lb ft). Cooling system conditioner contains alkali. Avoid
e.Wait for at least thirty minutes. Do not wait for contact with the skin and eyes to prevent personal
more than four hours. Tighten nuts (12) again injury.
to a torque of 23 ± 1 Nm (17 ± 0.7 lb ft). Close
cover (11) for the wiper arm. NOTICE
f.Connect hose (7) for the window washer. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
Cab Heater - Remove the fluid with suitable containers before opening any
compartment or disassembling any component
Removal Procedure containing fluids.
Start By: Dispose of all fluids according to local regulations and
mandates.
a. Remove the seat. Refer to Disassembly and
Assembly, "Seat - Remove and Install". 1. Recover the air conditioner refrigerant from
b. Remove the primary air filter and the secondary the air conditioner system (if equipped). The
air filter for the cab. Refer to appropriate Operation and correct charge is 0.8 kg (1.8 lb). Refer to
Maintenance Manual. appropriate Service for the correct procedure.
90 31200308

2. Put identification marks on all hoses for installation

purposes. Plug all hoses. This helps to prevent
fluid loss and this helps to keep contaminants
from entering the system.
3. Drain the coolant from the cooling system into a
suitable container for storage or disposal. The
capacity of the cooling system is approximately
27.5 L (7.3 US gal). Refer to appropriate
Operation and Maintenance Manual.

Illustration 433 g00941759

6. Remove cover (6).

Illustration 430 g00941760

4. Loosen knob (1) in order to remove cushion (2).
Remove cover (3) and cover (4).

Illustration 434 g00941763

Illustration 431 g00941757

Illustration 435 g00941764

7. Remove the bolts and move cover (7) until you are
able to disconnect electrical connector (8). remove
the cover from the machine.

Illustration 432 g00941758

5. Remove the bolts from the outside of the cab in
order to remove cover (5).

Illustration 436 g00941771

31200308 91

8. Remove cover (9).

Illustration 440 g00941833

Illustration 437 g00941762 12. Remove two bolts (16) in order to remove two
9. Remove cover plate (10). relays (17) from the outside of heater(18).

Illustration 441 g00941835

Illustration 438 g00941769
10. At the underside of the machine, remove bolt (11) in 13. Carefully remove heater (18) from the machine.
order to disconnect cable (12). Disconnect two
heater hoses (13). Disconnect two hoses (14) for Cab Heater - Install
the air conditioner (if equipped).
Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 439 g00941772

11. At the underside of the machine, disconnect two
electrical connectors (15).

Illustration 442 g00944898

2. Carefully position heater (18) onto the machine.
92 31200308

Illustration 443 g00941833 Illustration 446 g00941762

3. At the underside of the machine, position two 6. Install cover plate (10).
relays (17) onto the outside of heater (18) before
installing two bolts (16).

Illustration 447 g00941771

7. Install cover (9).
Illustration 444 g00941772
4. Connect two electrical connectors (15).

Illustration 448 g00941764

Illustration 445 g00941769
5. Connect two hoses (14) for the air conditioner (if
equipped). Connect two heater hoses (13). install
bolt (11) in order to connect cable (12).

Illustration 449 g00941763

31200308 93

8. Connect electrical connector (8) before sliding

cover (7) into position.

Illustration 453 g00941760

11. Install cover (4) and cover (3). Install cushion (2)
Illustration 450 g00941759
and tighten knob (1).
9. Install cover (6). 12. Fill the cooling system. The capacity of the cooling
system is approximately 27.5 L (7.3 US gal).
Refer to appropriate Operation and Maintenance
Manual.
13. Charge the air conditioner system (if equipped). The
correct charge is 0.8 kg (1.8 lb). Refer to
appropriate Service Manual for the procedure.
End By:
a. Install the seat. Refer to Disassembly and
Assembly, "Seat - Remove and Install".
b. Install the primary air filter and the secondary
air filter for the cab. Refer to appropriate Operation and
Maintenance Manual.
Illustration 451 g00941758
Heater Coil - Remove and Install
Removal Procedure
Start By:
a. Remove the cab heater. Refer to Disassembly and
Assembly, "Cab Heater - Remove".

Illustration 452 g00941757

10. Position cover (5) before installing the bolts that
secure the cover from the outside of the cab.

Illustration 454 g00944908

1. Remove gasket (1)
94 31200308

Air Conditioner - Install

Installation Procedure

Personal injury can result from contact with

refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Illustration 455 g00944912 Protective goggles must always be worn when
2. Remove two bolts (2) and the washers in order to refrigerant lines are opened, even if the gauges
remove heater coil (3) from heater group (4). indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Installation Procedure Slowly loosen the fitting. If the system is still under
pressure, release it slowly in a well ventilated area.
1. Clean all parts and inspect all parts. If any parts are
Personal injury or death can result from inhaling
worn or damaged, use new Caterpillar parts for
refrigerant through a lit cigarette.
replacement.
Inhaling air conditioner refrigerant gas through a lit
cigarette or other smoking method or inhaling
fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm
or death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning
system.
NOTICE
Care must be taken to ensure that fluids are contained
Illustration 456 g00944912 during performance of inspection, maintenance, testing,
2. Position heater coil (3) into heater group (4) and adjusting and repair of the product. Be prepared to collect
install two bolts (2) and the washers. the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Note: The following procedure gives details of
installing an air conditioner for the first time. The air
conditioner is supplied as a kit and can be purchased
from a Caterpillar Dealer. Refer to the appropriate Parts
Manual. The air conditioner can only be installed with a
cab heater which has been installed at the factory. Use
the Parts Manual and the Electrical Schematic in
conjunction with this procedure.
1. Install the refrigerant condenser. Refer to the
Illustration 457 g00944908
appropriate Disassembly and Assembly and the
3. Install gasket (1). Parts Manuals.
End By: 2. Install the refrigerant compressor. Refer to the
a. Install the cab heater. Refer to Disassembly and appropriate Disassembly and Assembly and the
Assembly, "Cab Heater - Install". Parts Manuals.
31200308 95

3. Install the evaporator coil. Refer to Disassembly

and Assembly, "Evaporator Coil - Install" and the
Parts Manual, "Air Conditioner Ar".

Illustration 461 g00947109

7. Remove three plastic plugs from the base of the
heater group and install the three tubes (6). The
tubes will allow any condensation to drain.
Illustration 458 g00945260 8. Use the following steps to install all hoses, and
4. Install accumulator (1). Refer to illustration 462 for tubes. Refer to illustration 462 which shows
the location and the orientation of the accumulator. the correct routing. Refer to appropriate Parts
Manual for all the part numbers of the
components which include elbows, connectors,
switches and tee's which are installed in the major
components.

Illustration 459 g00945271

5. Remove the plastic cover from the panel. Find the
connector in the main harness for the air
conditioner. Refer to the Electrical Schematic for the
color codes for the connector wires. Install switch
(2).

Illustration 460 g00945334

6. Install thermostatic switch (3) before connecting the
main cab harness (4). Feed capillary tube (5)
through the hole in the heater group to the
evaporator coil. Refer to Disassembly and
Assembly, "Evaporator Coil - Install" for the
installation dimension of the capillary tube.
96 31200308

Illustration 462 g00945913

a.Install hose (a) from the bottom of the b.Install hose (b) from the evaporator coil to the
refrigerant condenser to the evaporator coil. accumulator.
31200308 97

c.Install hose (c) from the accumulator to the

refrigerant compressor.
d.Install hose (d) from the refrigerant compressor
to the top of the refrigerant condenser.
9. Use the following steps to install the air conditioner
harness. Refer to illustration 463 which shows the
correct routing. Refer to appropriate Parts Manual
for all the part numbers of the components. Refer
to illustrations 464 through 468 for the location of
the components.
98 31200308

Illustration 463 g00945252

31200308 99

Illustration 464 g00945267 Illustration 467 g00945269

a. Connect the electrical connector at location (a1) for the d. Connect the electrical connector at location (a4) for the low
high pressure switch. pressure switch.

Illustration 465 g00945268 Illustration 468 g00945270

b. Connect the electrical connector at location (a2) which is e. Connect the electrical connector at location (a5) for the
at the underside of the intake hose from the air cleaner to electronic control group.
the turbocharger. The electrical connector connects the End By:
air conditioner harness to the main harness for the
machine. a. Install the decals for the refrigerant. Refer to appropriate
Operation and Maintenance Manual.
b. Charge the air conditioner system. The correct
charge is 0.8 kg (1.8 lb). Refer to appropriate Service
Manual for the procedure.

Evaporator Coil - Remove and

Install
Removal Procedure
Start By:
a. Remove the cab heater. Refer to Disassembly and
Illustration 466 g00945308 Assembly, "Cab Heater - Remove".
c. Connect the electrical connector at location (a3) at the
compressor clutch.
100 31200308

3. Remove two bolts (4) and the washers in order to

remove evaporator coil (3) from the heater group.

Installation procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 469 g00944908

1. Remove gasket (1).

Illustration 473 g00945049

Illustration 470 g00945043

2. Remove capillary tube (2) for the thermostat switch
out of evaporator coil (3).

Illustration 474 g00945044

2. Position evaporator coil (3) in the heater group and
install two bolts (4) and the washers.

Illustration 471 g00945044

Illustration 475 g00945043

3. Install capillary tube (2) for the thermostat switch
into evaporator coil (3). The capillary tube must be
inserted into the evaporator coil at a minimum of
150 mm (6 inch).

Illustration 472 g00945049

31200308 101

Illustration 476 g00944908 Illustration 478 g00941411

4. Install gasket (1). 2. Disconnect three electrical connectors (5) from
End By: joystick control (6).
a. Install the cab heater. Refer to Disassembly and Assembly,
“Cab Heater - Install”.

Joystick Control - Remove and

Install
Removal Procedure
Start By:
a. Remove the seat. Refer to Disassembly and Assembly,
"Seat - Remove and Install".
Note: Put identification marks on all wires for
Illustration 479 g00941412
installation purposes.
3. Lift boot (7) in order to gain access to the top side
of joystick control (6).

Illustration 477 g00941410

1. Loosen knob (1) in order to remove cushion (2).
Illustration 480 g00941413
Remove cover (3) and cover (4).
4. Remove four bolts (8) and the washers before
carefully removing joystick control (6) from the
machine.
102 31200308

Installation Procedure

Illustration 484 g00941410

4. Install cover (4) and cover (3). Install cushion (2)
Illustration 481 g00941413
and tighten knob (1).
1. Position joystick control (6) and install four bolts (8)
and the washers in order to secure the joystick End By:
control to the machine. a. Install the seat. Refer to Disassembly and Assembly,
"Seat - Remove and Install".
b. Calibrate the joystick control. Refer to appropriate
Systems Operation, Testing and Adjusting Manual.

Seat - Remove and Install

Removal Procedure

Illustration 482 g00941412

2. Install boot (7).

Illustration 485 g00931937

1. At the rear bottom of the seat, disconnect electrical
connector (1).

Illustration 483 g00941411

3. Connect three electrical connectors (5) to joystick
control (6).

Illustration 486 g00931938

2. Remove four bolts (2) and the washers.
31200308 103

Illustration 487 g00931940 Illustration 490 g00931937

3. With the aid of a second person, remove seat (3) 3. At the rear bottom of the seat, connect electrical
from the machine. The weight of the seat is connector (1).
approximately 30 kg (66 lb).
Fender - Remove and Install
Installation Procedure
Removal Procedure

Illustration 488 g00931940

1. With the aid of a second person, install seat (3) into
the cab of the machine. The weight of the seat is Illustration 491 g00926183

approximately 30 kg (66 lb). 1. Remove four nuts (2) and the washers that secure
fender (1) to axle hub (3). Remove the fender from
the machine.
2. Repeat step 1 in order to remove the remaining
fenders.

Installation Procedure

Illustration 489 g00931938

2. Install four bolts (2) and the washers.

Illustration 492 g00926183

1. Position fender (1) on axle hub (3) and install four
nuts (2) with the washers.
104 31200308

2. Repeat step 1 in order to install the remaining Installation Procedure

fenders.

Sump Guard - Remove and

Install
Removal Procedure

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or Illustration 495 g00948342
component, stand clear of the area. Be sure the 1. Use a suitable floor jack to raise the access cover
hoist or jack has the correct capacity to lift a (1) into position. The weight of the access cover is
component. Install blocks or stands before approximately 18 kg (40 lb).
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Illustration 496 g00948341

2. Install the bolts and the washers which secure
access cover (1) to the chassis.
3. Remove the floor jack.

Illustration 493 g00948341

1. Position a suitable floor jack under access cover
Counterweight - Remove and
(1) in order to support the access cover. Install
2. Remove the bolts and washers that secure access
cover (1) to the chassis. Removal Procedure
Table 17

Required Tools
Tool Part Number Part Description Qty
A 6V-6146 Load Leveling Beam 1

Personal injury or death can result from improper

lifting or blocking.
Illustration 494 g00948342
When a hoist or jack is used to lift any part or
3. Use the floor jack to carefully lower and remove component, stand clear of the area. Be sure the
access cover (1). The weight of the access cover is hoist or jack has the correct capacity to lift a
approximately 18 kg (40 lb).
31200308 105

component. Install blocks or stands before 1. Attach Tooling (A) to a suitable hoist. Attach two
performance of any work under a heavy suitable nylon lifting slings around counterweight
component. (1) and to Tooling (A). Take up the tension on the
Approximate weights of the components are lifting slings but do not lift the counterweight at
shown. Clean all surfaces where parts are to be this time. Refer to Table 18 for the weight of the
installed. counterweight.
2. Remove two bolts (2), two washers (3), two
washers (4) and two nuts (5) which secure
counterweight (1) to chassis (6).

Personal injury or death can occur from a

counterweight falling during removal or
installation.
Do not allow personnel under or around the
counterweight during removal or installation.
Make sure that the lifting device is in good
condition and is capable of handling the weight of
the counterweight.

Table 18

Weight Information
Model Part Number Weight
209-4899 440 kg (970 lb)

TH360B 204-5132 610 kg (1345 lb)

204-5133 240 kg (530 lb) (1) Illustration 498 g00946849

(1) Added counterweight which is used in conjunction with 204-5132

Counterweight

Note: If you can not identify the counterweight that is

installed on the machine use lifting equipment which is
suitable to lift the heaviest counterweight.

Illustration 499 g00946850

3. Use the hoist to carefully lift counterweight (1) off
the brackets on chassis (6) which is indicated by
the white arrow.

Illustration 497 g00946848

106 31200308

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Table 20

Weight Information
Illustration 500 g00946853 Model Part Number Weight
4. Some machines have an additional counterweight.
209-4899 440 kg (970 lb)
Use steps 1 through 3 to remove counterweight
(1). Position a suitable floor jack under 204-5132 610 kg (1345 lb)
TH360B
counterweight (7). Raise the floor jack in order to 204-5133 240 kg (530 lb) (1)
support the counterweight before removing two
bolts (8), two washers (9), two washers (10) and (1) Added counterweight which is used in conjunction with 204-5132
two nuts (11). Lower the floor jack and remove the Counterweight
counterweight. Refer to table 18 for the weight of
the additional counterweight.

Installation Procedure
Table 19

Required Tools
Tool Part Number Part Description Qty
A 6V-6146 Load Leveling Beam 1

Personal injury or death can occur from a

counterweight falling during removal or
installation.
Do not allow personnel under or around the
counterweight during removal or installation. Illustration 501 g00946853
Make sure that the lifting device is in good 1. Some machines have an additional counterweight (7)
condition and is capable of handling the weight of and this counterweight must be installed prior to
the counterweight. installing counterweight (1). Place counterweight (7) on a
suitable floor jack. Use the floor jack to raise the
counterweight into position and install two bolts (8), two
washers (9), two washers (10) and two nuts (11). Refer to
Table 20 for the weight of the additional counterweight.
31200308 107

Illustration 502 g00946869 Illustration 504 g00946849

2. Attach Tooling (A) to a suitable hoist. Attach two suitable 3. Install two bolts (2), two washers (3), two washers
nylon lifting slings around counterweight (1) and to (4) and two nuts (5) which secure counterweight
Tooling (A). Use the hoist to carefully lift the counterweight (1) to chassis (6).
onto the brackets on chassis (6) which is indicated by a 4. Remove Tooling (A) and the nylon lifting slings.
white arrow. Refer to Table 20 for the weight of the
additional counterweight.
Quick Coupler - Remove
Removal Procedure
Table 21

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
Illustration 503 g00946848
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
108 31200308

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the Illustration 506 g00928671
filler cap is cool enough to touch with your bare 3. Disconnect two hoses (2) from diverter valve (3).
hand.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all hoses and on all Illustration 507 g00928672
tubes for installation purposes. Plug all hoses and 4. Remove bolt (4) and the washer which secures pin
all tubes. This helps to prevent fluid loss and this (5) to quick coupler (6). Remove the pin out of the
helps to prevent contaminants from entering the quick coupler and cylinder (7).
system.

Illustration 505 g00928669

Illustration 508 g00928674
2. Install Tooling (A) on the underside of boom (1) in
order to support the boom. 5. Remove bolt (8), the washers and the nut which is
used as a lock to retain pin (9) into quick coupler
(6).
31200308 109

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all hoses, on all lines
and on all tubes for installation purposes. Plug all
lines, all hoses and all tubes. This helps to prevent
Illustration 509 g00928676
fluid loss and this helps to keep contaminants from
6. Attach two suitable nylon lifting slings around entering the system.
quick coupler (6) and to a suitable hoist. Take up
the tension in order to support the quick coupler.
The weight of the quick coupler is approximately
122 kg (269 lb).
7. Remove pin (9) out of the quick coupler and boom
head (10). Remove the quick coupler from the
machine.

Quick Coupler - Disassemble

Disassembly Procedure
Table 22

Required Tools
Illustration 510 g00928851
Tool Part Number Part Description Qty 2. Install Tooling (A) at the underside of boom (1).
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Illustration 511 g00928853
Make sure all of the attachments have been 3. Remove cover plate (2) from quick coupler (3).
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
110 31200308

Illustration 512 g00928854 Illustration 515 g00929187

4. Disconnect two hoses (4) from hitch cylinder (5). 7. Remove pin (9) and dowel (10).
Remove tube (6) from the hitch cylinder.

Illustration 516 g00929188

8. Push hitch cylinder (5) toward the right side of the
Illustration 513 g00928855 machine. Use a suitable punch to drive dowel (12)
5. Remove two bolts (7), the washers and retaining through pin (11) as far as possible. Make sure that
plate (8). dowel (12) is clear of the rod of hitch cylinder (5).
Dowel (12) will be still partially installed in pin (11).

Illustration 514 g00928856

6. Rotate hitch cylinder (5) and at the same time Illustration 517 g00929189
push the hitch cylinder toward the left side of the 9. Remove pin (11) and dowel (12).
machine. Use a suitable punch to drive dowel (10)
through pin (9) as far as possible. Make sure that
dowel (10) is clear of the rod of hitch cylinder (5).
Dowel (10) will still be partially installed in pin (9).
31200308 111

Illustration 518 g00929190 Illustration 520 g00929227

10. Remove hitch cylinder (5) from quick coupler (3). 3. Align the hole in the rod end of hitch cylinder (5)
with dowel (12) and the dowel hole in pin (11).
Quick Coupler - Assemble Slide the rod end of the hitch cylinder into the pin.

Assembly Procedure
Table 23

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for Illustration 521 g00929228

replacement. 4. Use a suitable punch to install dowel (12). Make

sure that the dowel does not protrude on either side
of pin (11).

Illustration 519 g00929233

2. Install hitch cylinder (5) into quick coupler (3).
Illustration 522 g00929229
5. Align the hole in the rod end of hitch cylinder (5)
with dowel (10) and the dowel hole in pin (9). Slide
the rod end of the hitch cylinder into the pin.
112 31200308

Illustration 523 g00929230 Illustration 526 g00929445

6. Use a suitable punch to install dowel (10). Make 9. Install cover plate (2) onto quick coupler (3).
sure that the dowel does not protrude on either side
of pin (9).

Illustration 527 g00929446

10. Remove Tooling (A) from the underside of the
Illustration 524 g00929442
boom.
7. Rotate hitch cylinder (5) into position in order to
install retaining plate (8), bolts (7) and the washers.
Quick Coupler - Install
Installation Procedure
Table 24

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1

1. Clean all parts and inspect all parts. If any parts are
Illustration 525 g00929443
worn or damaged, use new Caterpillar parts for
8. Install tube (6) onto hitch cylinder (5). Connect two
replacement.
hoses (4) to the hitch cylinder.
31200308 113

Illustration 528 g00928737 Illustration 531 g00928753

2. Attach two suitable nylon lifting slings around quick 5. Align the bore in cylinder (7) with the bores in
coupler (6) and to a suitable hoist. Carefully lift the quick coupler (6) and install pin (5), bolt (4) and the
quick coupler toward the machine. The weight of washer.
the quick coupler is approximately 122 kg (269 lb).

Illustration 532 g00928759

Illustration 529 g00928724 6. Connect two hoses (2) to diverter valve (3).
3. Align the bores in quick coupler (6) with the bore in
the boom head before installing pin (9). Make sure
that you install the pin so that the groove in the pin is
aligned with the bolt hole in the quick coupler.

Illustration 533 g00928762

7. Remove Tooling (A) from the underside of boom
(1).

Illustration 530 g00928751

4. Install bolt (8), the washers and the nut in order to
lock pin (9) into quick coupler (6).
114 31200308

Boom - Remove Dispose of all fluids according to local regulations and

mandates.
1. Put identification marks on all lines, on all hoses,
Removal Procedure on all tubes and on all wires for installation
Table 25 purposes. Plug all lines, all hoses and all tubes.
This helps to prevent fluid loss and this helps to
Required Tools keep contaminants from entering the system.
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1
B 138-7576 Link Bracket 2

C 6V-6146 Load Leveling Beam 1

Personal injury or death can result from improper

Illustration 534 g00953206
lifting or blocking.
2. Install Tooling (A) at the underside of boom (1).
When a hoist or jack is used to lift any part or Make sure that the boom is parallel with the
component, stand clear of the area. Be sure the ground.
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Illustration 535 g00953207
Hydraulic oil pressure can remain in the hydraulic
3. Attach one end of a suitable nylon lifting sling to a
system after the engine has been stopped. Serious
suitable hoist. Feed the opposite end of the sling
injury can be caused if this pressure is not released
down one side of boom (1). Then feed the sling
before any service is done on the hydraulic system.
around cylinder (2) and up the opposite side of the
Make sure all of the attachments have been boom to the hoist. Take up the tension in order to
lowered to the ground, and the oil is cool before support the cylinder. The weight of the cylinder is
removing any components or lines. Remove the oil approximately 270 kg (595 lb).
filler cap only when the engine is stopped, and the
4. Remove bolt (3), the washer, the spacer and pin
filler cap is cool enough to touch with your bare
(4).
hand.
5. Use the hoist to lower cylinder (2) onto the
NOTICE
chassis. Remove the nylon lifting sling.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
31200308 115

10. Attach Tooling (C) to a suitable hoist. Attach a

suitable double chain lifting sling between Tooling
(B) and Tooling (C). Attach a suitable double chain
lifting sling between Tooling (C) and the lifting
points at the front of boom (1). Take up the tension
on the lifting chains.

Illustration 536 g00953208

6. Attach a suitable nylon lifting sling around
compensating cylinder (5). Take up the tension in
order to support the cylinder. Remove bolt (6) and
the washer. The weight of the cylinder is
approximately 20 kg (44 lb).
Illustration 539 g00953211
11. Remove bolt (8) and the washer. Extract pin (9) out
of chassis (10) and boom (1).

Illustration 537 g00953209

7. Slide compensating cylinder (5) off shaft (7). Use
the hoist to lower the cylinder aside. Remove
washer (8). Illustration 540 g00953212

8. Remove the compensating cylinder from the

opposite side. Refer to steps 6 and 7. 12. Use the hoist to carefully move boom (1)
approximately 300 mm (12 inches) toward the
front of the machine. Use the hoist to raise the
boom in order to gain access to the hoses which
are connected to the underside of the boom. Install
suitable cribbing across the chassis in order to
support the boom before you move onto the next
step. Refer to Table 26 for the approximate weight
of the boom.
Table 26

Model The approximate weight of the Boom

TH360B 2300 kg (5070 lb)

Illustration 538 g00953210

9. Install bolt (6) and the washer in order to attach
Tooling (B) to shaft (7). Install the Tooling to the
opposite side.
116 31200308

e. Remove the telescoping cylinder. Disassembly

and Assembly, "Telescoping Cylinder - Remove
and Install".
f. Release the chain tension for the boom. Refer to
appropriate Operation and Maintenance Manual.

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
Illustration 541 g00953213 hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
13. Disconnect three electrical connectors (11). performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
Illustration 542 g00953214
mandates.
14. Remove bracket (12). Disconnect three hoses
(13). Remove the bracket and the hoses from the
opposite side.
15. Use the hoist and remove boom (1) from the
machine.

Boom - Disassemble
Disassembly Procedure
Table 27

Required Tools
Illustration 543 g00959542
Tool Part Number Part Description Qty
A 1U-6341 Threaded Rod 1 1. Remove two cotter pins (1) and pin (2) in order to
disconnect chain (3) from the chain anchor block on
boom head (4).
Start By:
a. Remove the quick coupler. Refer to Disassembly and
Assembly, "Quick Coupler- Remove".
b. Remove the tilt cylinder. Refer to Disassembly and
Assembly, "Tilt Cylinder - Remove and Install".
c. Remove the Boom. Refer to Disassembly and
Assembly, "Boom - Remove ".
d. Remove the hydraulic oil lines. Refer to
Disassembly and Assembly, "Hydraulic Oil Lines
(Boom) - Remove ".
31200308 117

Illustration 544 g00959543 Illustration 547 g00959546

2. Remove four bolts (5) and the washers in order to 5. Install Tool (A) into wear pad (17). Remove two
remove two wear pads (6) and shims (7) which are bolts (16) and the washers in order to remove wear
located between boom head (4) and inner boom pad (17) and shims (18) which are located on the
section (8). side between inner boom section (8) and outer
boom section (12). Remove the wear pad from the
opposite side.

Illustration 545 g00959544

3. Remove four bolts (9) and the washers in order to
Illustration 548 g00959547
remove two wear pads (10) and shims (11) which
are located between inner boom section (8) and
outer boom section (12).

Illustration 549 g00959548

6. Remove four bolts (19) which secure two wear
pads (20). Install Tool (A). Use a suitable pry bar
Illustration 546 g00959545 between the outer boom section (12) and the inner
4. Install Tool (A) into wear pad (14). Remove two boom section (8) in order to raise the inner boom
bolts (13) and the washers in order to remove wear section before removing the wear pads.
pad (14) and shims (15) which are located on the
side between boom head (4) and inner boom
section (8). Remove the wear pad from the opposite
side.
118 31200308

Illustration 550 g00959551 Illustration 553 g00959554

7. At the front of the boom assembly, remove two nuts 10. Install Tool (A) into wear pad (30). Remove two
(21) and the washer from shackle (22). Remove bolts (29) and the washers in order to remove wear
the shackle out of the outer boom section (12) and pads (30) and shims (31) which are located on the
lay the shackle with chains (23) aside. side between boom head (4) and inner boom
section (8). Remove the wear pad from the opposite
side.

Illustration 551 g00959552

8. Remove bolt (24), the washer and the spacer that
secured pin (25). Remove the pin out of the bores in Illustration 554 g00959555
outer boom section (8) before removing roller (26). 11. Remove four bolts (32) and the washers in order to
remove two wear pads (33) and shims (34) which
are located between boom head (4) and inner
boom section (8).

Illustration 552 g00959553

9. Use a suitable driver and remove two lip seals (27)
and two bearings (28) out of roller (26).
Illustration 555 g00959556
12. Install Tool (A) into wear pad (36). Remove two
bolts (35) and the washers in order to remove wear
pads (36) and shims (37) which are located on the
side between inner boom section (8) and outer
boom section (12). Remove the wear pad from the
opposite side.
31200308 119

Illustration 556 g00960138 Illustration 558 g00964049

13. Remove four bolts (38) and the washers in order to 15. Attach two suitable nylon slings around boom head
remove two wear pads (39) and shims (40) which (4) and to a suitable hoist. Use the hoist and remove
are located between outer boom section (12) and the boom head out of inner boom section (8). Refer
inner boom section (8). to Table 28 for the approximate weight of the boom
head.

Illustration 557 g00964048

Illustration 559 g00964050
14. Attach a suitable nylon lifting sling around the front
of boom head (4) and to a suitable hoist. Use the 16. Place boom head (4) on a suitable stand. At the
hoist to slide the boom head out of inner boom rear of the boom head, remove four bolts (41) and
section (8) until the boom head is approximately the washers in order to remove two wear pads
two-thirds of the way out of the inner boom section. (42).
Remove the nylon lifting sling. Refer to Table 28 for
the approximate weight of the boom head.

Note: Do not slide the boom head more than two-

thirds of the way out of the inner boom section.
Table 28

Approximate Weight of the Boom Head

TH360B 435 kg (959 lb)

Illustration 560 g00964051

17. Remove four screws (44) in order to remove the
ends of chain link (43) from the boom head.
120 31200308

Illustration 561 g00964052 Illustration 564 g00970319

18. Remove four cotter pins (45) and two pins (46) in 21. Attach a suitable nylon lifting sling around the front
order to remove shackle (22) from chains (23). of inner boom section (8) and to a suitable hoist.
Use the hoist to slide the inner boom section out of
outer boom section (12) until the inner boom section
is approximately two-thirds of the way out of the
outer boom section. Remove the nylon lifting sling.
Refer to Table 29 for the approximate weight of the
inner boom section.
Note: Do not slide the inner boom section more than
two-thirds of the way out of the outer boom section.
Table 29

Approximate Weight of the Inner Boom Section

TH360B 394 kg (868 lb)

Illustration 562 g00964053

19. Remove two cotter pins (47) and pin (48) in order to
remove chains (23) from the chain anchor on boom
head (4).

Illustration 565 g00970320

22. Attach two suitable nylon slings around inner boom
section (8) and to a suitable hoist. Use the hoist and
Illustration 563 g00970307 remove the inner boom section out of outer boom
20. Use a suitable driver and remove lip seal (49) and section (12). Refer to Table 29 for the approximate
bearing (50). Remove the lip seal and the bearing weight of the inner boom section.
from the opposite side.
31200308 121

Illustration 566 g00970322 Illustration 569 g00973864

23. Remove four bolts (51) and the washers in order to 26. At the front of outer boom section (12), remove two
remove two wear pads (52) from the front of inner nuts (58) and the washer from shackle (59).
boom section (8). Remove the shackle and chain (3) out of the outer
boom section.

Illustration 567 g00970323

24. Remove two bolts (53), shaft (54) and roller (55) Illustration 570 g00973865
from the bracket at the rear of inner boom section 27. Remove two cotter pins (60) and pin (61) in order to
(8). remove shackle (59) from chain (3).

Illustration 568 g00970325 Illustration 571 g00973866

25. Use a suitable driver and remove two bearings (56) 28. Remove four bolts (62) and the washers in order to
and two lip seals (57) out of roller (55). remove two wear pads (63) from outer boom
section (12).
122 31200308

2. Position outer boom section (12) on suitable

support stands. Refer to Table 32 for the
approximate weight of the outer boom section.
Table 32

Approximate Weight of the Outer Boom Section

TH360B 723 Kg (1593 lb)

Illustration 572 g00974333

29. Use a suitable driver in order to remove lip seal (64)
and bearing (65) from outer boom section (12).
Remove the lip seal and bearing from the opposite
side.
Note: If outer boom section (12) needs to be lifted off
the suitable stand, refer to Table 30 for the
approximate weight of the outer boom section.
Table 30
Illustration 574 g00974970
Approximate Weight of the Outer Boom Section 3. Use Tooling (B) in order to install bearing (65) and
TH360B 723 kg (1593 lb) lip seal (64) into the rear of outer boom section (12).

Boom - Assemble
Assembly Procedure
Table 31

Required Tool

Tool Part Number Part Description Qty

A 1U-6341 Threaded Rod 1

B 1P-0510 Driver Gp 1 Illustration 575 g00973866
4. Position wear pads (62) into the front of outer
1. Clean all parts and inspect all parts. If any parts are
boom section (12). Apply a small amount of 9S-
worn or damaged, use new Caterpillar parts for
3263 Thread Lock Compound to the treads of four
replacement.
bolts (62) before installing the bolts with the
washers in order to secure the wear pads.

Illustration 573 g00974969

Illustration 576 g00973865

31200308 123

5. Align the bores in chain (3) with the bores in

shackle (59) and install pin (61) and two cotter pins
(60).

Illustration 580 g00970323

9. At the rear of inner boom section (8), align the bore
in roller (55) with the bores in the brackets on the
Illustration 577 g00973864
inner boom section. Install shaft (54). Make sure
that the machined flats on the shaft are toward the
6. Lay chain (3) down the center of outer boom
threaded holes in the brackets. Install two bolts
section (12) before installing shackle (59) into the
(53) in order to lock the shaft into position.
bore at the front of the outer boom section. Install
two nuts (58) and the washer. Do not tighten the
nuts at this time.
7. Use a roller with a long handle to apply a layer
of 5P-0960 Molybdenum Grease along the full
length of the inside of the outer boom section (12).

Illustration 581 g00970322

10. Position wear pads (52) into the front of inner
boom section (8). Apply a small amount of
9S-3263 Thread Lock Compound to the treads of
four bolts (51) before installing the bolts with the
washers in order to secure the wear pads.
Illustration 578 g00974971
11. Use a roller with a long handle to apply a layer
8. Use Tooling (B) in order to install two bearings (56)
of 5P-0960 Molybdenum Grease along the full
and two lip seals (57) into roller (55).
length of the inside of the inner boom section (8).

Illustration 579 g00974972

Illustration 582 g00970320
124 31200308

Illustration 585 g00975019

Illustration 583 g00975008
14. Use Tooling (B) in order to install bearing (50) and lip
12. Attach two suitable nylon slings around inner boom
seal (49) into the front of boom head (4). Install the
section (8) and to a suitable hoist. Use the hoist to
bearing and the lip seal into the opposite side.
slide the inner boom section into outer boom
section (12) until the inner boom section is
approximately two-thirds of the way into the outer
boom section. Make sure that roller (55) runs on
chain (3) on installation. Remove the nylon lifting
sling. Refer to Table 33 for the approximate weight
of the inner boom section.
Table 33

Approximate Weight of the Inner Boom Section

TH360B 394 kg (868 lb)

Illustration 586 g00964053

15. Lay two chains (23) on the top side of boom head
(4). Align the bores in the end of the chain with the
bores in the chain anchor at the rear of the boom
head before installing two pins (48) and four cotter
pins (47).

Illustration 584 g00970319

13. Attach a suitable nylon lifting sling around the front
of inner boom section (8) and to a suitable hoist.
Use the hoist to slide the inner boom section into
outer boom section (12). Remove the nylon lifting
sling.
Illustration 587 g00964052
16. 16. Align the bores in the end of chain (23) with the
bores in the shackle (22) at the front of the boom
head before installing two pins (46) and four cotter
pins (45).
31200308 125

Table 34

Approximate Weight of the Boom Head

TH360B 435 kg (959 lb)

Illustration 588 g00964051

17. Position the ends of two chain links (43) at the rear
of boom head (4) and install four screws (44).

Illustration 591 g00964048

20. Attach a suitable nylon lifting sling around the
front of boom head (4) and to a suitable hoist. Use
the hoist to slide the boom head into inner boom
section (8). Remove the nylon lifting sling.
21. Use the following procedure to shim the top wear
pads for the inner boom section to the outer boom
section.

Illustration 589 g00964050

18. Position wear pads (42) at the rear underside of
boom head (4). Apply a small amount of 9S- 3263
Thread Lock Compound to the treads of four bolts
(41) before installing the bolts with the washers in
order to secure the wear pads.

Illustration 592 g00975150

a. Slide wear pads (39) between inner boom
section (8) and outer boom section (12).
Measure the distance between the top of each
wear pad (39) and the outer boom section by
inserting as many shims (40) as possible.
b. When the distance between the wear pads and
the outer boom section has been measured,
remove each set of shims.
c. To achieve the required running clearance
Illustration 590 g00964049 between the inner boom section and the outer
19. Attach two suitable nylon slings around boom head boom section, remove a minimum of 0.75 mm
(4) and to a suitable hoist. Use the hoist to slide the (0.0295 inch) and a maximum of 1.5 mm
boom head into inner boom section (8) until the (0.0591 inch) from each set of shims.
boom head is approximately two-thirds of the way
into the inner boom section. Remove the nylon
lifting slings. Refer to Table 34 for the approximate
weight of the inner boom section.
126 31200308

b. Slide the second wear pad (36) between inner

boom section (8) and outer boom section (12).
Measure the distance between wear pad (36)
and the outer boom section by inserting as
many shims (37) as possible.
c. When the distance between the wear pads and
the outer boom section has been measured,
remove the shims.
d. To achieve the required running clearance
between the inner boom section and the outer
boom section, remove a minimum of 0.75 mm
(0.0295 inch) and a maximum of 1.5 mm
(0.0591 inch) of shims.

Illustration 593 g00960138

d. Use 152 - 9155 Adhesive in order to attach the
remaining shims (40) to the underside of wear
pads (39).
e. Use Tool (A) to position wear pads (39) and
shims (40). Apply a small amount of 9S-3263
Thread Lock Compound onto four bolts (38)
before installing the bolts and the washers.
22. Use the following procedure to shim the side wear
pads for the inner boom section to the outer boom
section.

Illustration 596 g00959556

e. Divide shims (37) equally between each of the wear pads
(36). Use 152 - 9155 Adhesive in order to attach shims
(37) to the underside of wear pads (36).
f. Use Tool (A) to position wear pads (36) and shims (37).
Apply a small amount of 9S-3263 Thread Lock
Compound onto two bolts (35) before installing the bolts
and the washers. Repeat this step for the opposite side.
23. Use the following procedure to shim the top wear
pads for the boom head to the inner boom section.

Illustration 594 g00975404

Illustration 597 g00975407

a. Slide wear pads (33) between boom head
(4) and inner boom section (8). Measure the
Illustration 595 g00975405
distance between the top of each wear pad
(39) and the inner boom section by inserting as
a. Place one wear pad (36) between inner boom many shims (34) as possible.
section (8) and outer boom section (12). At the
opposite side, use a suitable pry bar to push b. When the distance between the wear pads and
the inner boom section against the wear pad. the inner boom section has been measured,
This will jam the wear pad between the two remove each set of shims.
boom sections.
31200308 127

c. To achieve the required running clearance b. Slide the second wear pad (30) between boom
between the boom head and the inner boom head (4) and inner boom section (12). Measure
section, remove a minimum of 0.75 mm the distance between wear pad (30) and the
(0.0295 inch) and a maximum of 1.5 mm inner boom section by inserting as many shims
(0.0591 inch) from each set of shims. (31) as possible.
c. When the distance between the wear pads and
the inner boom section has been measured,
remove the shims.
d. To achieve the required running clearance
between the boom head and the inner boom
section, remove a minimum of 0.75 mm
(0.0295 inch) and a maximum of 1.5 mm
(0.0591 inch) of shims.

Illustration 598 g00959555

d. Use 152 - 9155 Adhesive in order to attach the remaining
shims (34) to the underside of wear pads (33).
e. Use Tool (A) to position wear pads (33) and shims (34).
Apply a small amount of 9S- 3263 Thread Lock
Compound onto four bolts (32) before installing the bolts
and the washers.
24. Use the following procedure to shim the side wear
Illustration 601 g00959554
pads for the boom head to the inner boom section.
e. Divide shims (31) equally between each of the
wear pads (30). Use 152 - 9155 Adhesive in
order to attach shims (31) to the underside of
wear pads (30).
f. Use Tool (A) to position wear pads (30) and
shims (31). Apply a small amount of 9S-3263
Thread Lock Compound onto two bolts (29)
before installing the bolts and the washers.
Repeat this step for the opposite side.

Illustration 599 g00975408

Illustration 602 g00959553

25. Use Tooling (B) in order to install two bearings (28)
and two lip seals (27) into roller (26).

Illustration 600 g00975409

a. Place one wear pad (33) between boom head
(4) and inner boom section (8). At the opposite
side, use a suitable pry bar to push the boom
head against the wear pad. This will jam the
wear pad between the two boom sections.
128 31200308

Illustration 603 g00959552 Illustration 606 g00959547

26. At the front of inner boom section (8), align the bore in 28. Install Tool (A) into wear pad (20). At the rear
roller (26) with the bores in the brackets on the inner of outer boom section (12), use a suitable pry
boom section. Install shaft (25), bolt (24), the washer and bar in order to raise the inner boom section (8).
the spacer. Use tool (A) to slide wear pads (20) into position.
Apply a small amount of 9S- 3263 Thread Lock
Compound to the treads of four bolts (19) before
installing the bolts with the washers in order to
secure the wear pads.
29. Use the following procedure to shim the side wear
pads for the inner boom section to the outer boom
section at the rear.

Illustration 604 g00959551

27. Pull chains (23) into position. At the same time
install shackle (22) into the bore in the front of
outer boom section (12). Install two nuts (21) and
the washer. Do not tighten the nuts at this time.

Illustration 607 g00975485

Illustration 605 g00959548

Illustration 608 g00975486

a. Place one wear pad (17) between inner boom
section (8) and outer boom section (12). At the
opposite side, use a suitable pry bar to push
the inner boom section against the wear pad.
This will jam the wear pad between the two
boom sections.
31200308 129

b. Slide the second wear pad (17) between inner

boom section (8) and outer boom section (12).
Measure the distance between wear pad (17)
and the outer boom section by inserting as
many shims (18) as possible.
c. When the distance between the wear pads and
the outer boom section has been measured,
remove the shims.
d. To achieve the required running clearance
between the inner boom section and the outer
boom section, remove a minimum of 0.75 mm
(0.0295 inch) and a maximum of 1.5 mm
(0.0591 inch) of shims.

Illustration 611 g00975507

a. Place one wear pad (14) between inner boom
section (8) and boom head (4). At the opposite
side, use a suitable pry bar to push the inner
boom section against the wear pad. This will
jam the wear pad between the two boom
sections.
b. Slide the second wear pad (14) between inner
boom section (8) and boom head (4). Measure
the distance between wear pad (14) and the
boom head by inserting as many shims (15)
as possible.
c. When the distance between the wear pads and
Illustration 609 g00959546 the boom head has been measured, remove
e. Divide shims (18) equally between each of the the shims.
wear pads (17). Use 152 - 9155 Adhesive in d. To achieve the required running clearance
order to attach shims (18) to the underside of between the inner boom section and the
wear pads (17). boom head, remove a minimum of 0.75 mm
f. Use Tool (A) to position wear pads (17) and (0.0295 inch) and a maximum of 1.5 mm
shims (18). Apply a small amount of 9S-3263 (0.0591 inch) of shims.
Thread Lock Compound onto two bolts (16)
before installing the bolts and the washers.
Repeat this step for the opposite side.
30. Use the following procedure to shim the side wear
pads for the boom head to the inner boom section.

Illustration 612 g00959545

e. Divide shims (15) equally between each of the
wear pads (14). Use 152-9155 Adhesive in
order to attach shims (15) to the underside of
wear pads (14).
Illustration 610 g00975505
f. Use Tool (A) to position wear pads (14) and
shims (15). Apply a small amount of 9S-3263
Thread Lock Compound onto two bolts (13)
before installing the bolts and the washers.
Repeat this step for the opposite side.
31. Use the following procedure to shim the top wear
pads for the inner boom section to the outer boom
section.
130 31200308

Illustration 613 g00975522 Illustration 615 g00975526

a. Slide wear pads (10) between inner boom a. Slide wear pads (6) between boom head (4)
section (8) and outer boom section (12). and inner boom section (8). Measure the
Measure the distance between the top of each distance between the top of each wear pad
wear pad (10) and the outer boom section by (6) and the inner boom section by inserting as
inserting as many shims (11) as possible. many shims (7) as possible.
b. When the distance between the wear pads and b. When the distance between the wear pads and
the outer boom section has been measured, the inner boom section has been measured,
remove each set of shims. remove each set of shims.
c. To achieve the required running clearance c. To achieve the required running clearance
between the inner boom section and the outer between the boom head and the inner boom
boom section, remove a minimum of 0.75 mm section, remove a minimum of 0.75 mm
(0.0295 inch) and a maximum of 1.5 mm (0.0295 inch) and a maximum of 1.5 mm
(0.0591 inch) from each set of shims. (0.0591 inch) from each set of shims.

Illustration 614 g00959544

Illustration 616 g00959543
d. Use 152 - 9155 Adhesive in order to attach the
remaining shims (11) to the underside of wear d. Use 152 - 9155 Adhesive in order to attach the
pads (10). remaining shims (7) to the underside of wear
pads (6).
e. Use Tool (A) to position wear pads (10) and
shims (10). Apply a small amount of 9S-3263 e. Use Tool (A) to position wear pads (6) and
Thread Lock Compound onto four bolts (9) shims (7). Apply a small amount of 9S-3263
before installing the bolts and the washers. Thread Lock Compound onto four bolts (5)
before installing the bolts and the washers.
32. Use the following procedure to shim the top wear
pads for the boom head to the inner boom section.
31200308 131

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
Illustration 617 g00959542 shown. Clean all surfaces where parts are to be
33. Pull chain (3) into position. Align the bores in the installed.
chain with the bores in the chain anchor block on 1. Clean all parts and inspect all parts. If any parts are
boom head (4) before installing pin (2) and two worn or damaged, use new Caterpillar parts for
cotter pins (1). replacement.
End By:
a. Install the telescoping cylinder. Disassembly and
Assembly, "Telescoping Cylinder - Remove and
Install".
b. Install the hydraulic oil lines. Refer to Disassembly
and Assembly, "Hydraulic Oil Lines (Boom) -
Install".
c. Install the Boom. Refer to Disassembly and
Assembly, "Boom - Install".
d. Install the tilt cylinder. Refer to Disassembly and
Assembly, "Tilt Cylinder- Remove and Install".
e. Install the quick coupler. Refer to Disassembly
and Assembly, "Quick Coupler- Install".
f. Adjust the chain tension for the boom. Refer to Illustration 618 g00953248
appropriate Operation and Maintenance Manual. 2. Install bolt (6) and the washer in order to attach
Tooling (B) to shaft (7). Install the Tooling to the
Boom - Install opposite side.
3. Attach Tooling (C) to a suitable hoist. Attach a
Installation Procedure suitable double chain lifting sling between Tooling
(B) and Tooling (C). Attach a suitable double chain
lifting sling between Tooling (C) and the lifting
Table 35 points at the front of boom (1). Use the hoist to
carefully lift the boom toward the machine. Refer
Required Tools to Table 36 for the approximate weight of the
boom.
Tool Part Number Part Description Qty

4C-6486 Stand 1 Table 36

A 8S-7621 Tube 1
Model The approximate weight of the Boom
8S-7615 Pin 1
TH360B 2300 kg (5070 lb)
B 138-7576 Link Bracket 2
C 6V-6146 Load Leveling Beam 1
132 31200308

Illustration 619 g00953212 Illustration 622 g00953211

4. Install suitable cribbing across the chassis in order 7. Use the hoist to lift boom (1) in order to remove the
to support the boom. Use the hoist to carefully cribbing between the chassis and the boom. Lower
lower the boom until the boom is lightly resting on the boom into position. Align the bore in the boom
the cribbing. The boom must be lower with the bores in the chassis before installing pin
approximately 300 mm (12 inch) toward the front of (9). Install bolt (8) and the washer.
the machine. You will now be able to gain access
to the hoses which are connected to the underside
of the boom.

Illustration 623 g00953206

8. Lower boom (1) onto tooling (A) before removing the

lifting equipment from the machine.
Illustration 620 g00953214
5. Connect three hoses (13) and install bracket (12).
Install the bracket and connect the hoses to the
opposite side.

Illustration 624 g00953209

9. Install washer (8) onto shaft (7). Attach a suitable
nylon lifting sling around compensating cylinder (5).
Use the hoist and lift the cylinder into position. Slide
Illustration 621 g00953213 the cylinder onto the shaft. The weight of the
6. Connect three electrical connectors (11). cylinder is approximately 20 kg (44 lb).
31200308 133

Note: If the bores in the cylinder and the boom do not

align the cylinder will need to be extended or retracted.
With the aid of a second person, start the engine.
Extend or retract the cylinder. When the bores in the
boom are aligned with the bore in the cylinder stop the
engine.

Hydraulic Oil Lines (Boom) -

Remove
Removal Procedure
Illustration 625 g00953208
10. Install bolt (6) and the washer. Remove the lifting
sling.
11. Install the compensating cylinder to the opposite side. Cylinders equipped with lock valves can remain
Refer to Steps 9 and 10. pressurized for very long periods of time, even
with the hoses removed.
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
Ensure all pressure is relieved before removing a
lock valve or disassembling a cylinder.

Personal injury can result from hydraulic oil

pressure and hot oil.
Illustration 626 g00953346 Hydraulic oil pressure can remain in the hydraulic
12. Attach one end of a suitable nylon lifting sling to a system after the engine has been stopped. Serious
suitable hoist. Feed the opposite end of the sling injury can be caused if this pressure is not released
down one side of boom (1). Then feed the sling before any service is done on the hydraulic system.
around cylinder (2) and up the opposite side of the Make sure all of the attachments have been
boom to the hoist. The weight of the cylinder is lowered to the ground, and the oil is cool before
approximately 270 kg (595 lb). removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Illustration 627 g00953207
13. Use the hoist in order to lift cylinder (1) into
position. Align the bore in the cylinder with the
bores in boom (1) before installing pin (4). Install
bolt (3), the washer and the spacer in order to
secure the pin to the boom. Remove the lifting
sling.
134 31200308

Tilt Cylinder Hoses (Boom)

Table 37

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1

Note: The following procedure was carried out after the

boom assembly had been removed from the machine.
Illustration 630 g00953552
This procedure can also be carried out when the
boom assembly is installed on the machine.
1. Put identification marks on all hoses, on all lines
and on all tubes for installation purposes. Plug all
lines, all hoses and all tubes. This helps to prevent
fluid loss and this helps to keep contaminants from
entering the system.

Illustration 631 g00953553

4. Remove cover (2) from the left side of the
machine. Remove cover (3) from the right side of
the machine.

Illustration 628 g00955497

2. Install Tooling (A) in order to support the boom.

Illustration 632 g00952453

5. Disconnect tube (4) from tube (5). Disconnect tube
(6) from tube (7).

Illustration 629 g00952452

3. Remove cover (1).
31200308 135

Illustration 633 g00952454 Illustration 636 g00956074

Left Side 8. Remove cover (18).

Illustration 634 g00952455

Right Side Illustration 637 g00956075
6. Disconnect hose (8) and remove tube (5). 9. Disconnect two hoses (19) from tilt cylinder (20).
Disconnect hose (9) and remove tube (7).

Illustration 638 g00956077

10. Attach two suitable ropes to hoses (19). Wrap
suitable vinyl plastic electrical tape around the
hoses and the rope in order to prevent the hoses
from catching on removal. The ropes will be
needed on the installation of the hoses.

Illustration 635 g00952456

7. Remove four bolts (10), the washers and plate (11)
that secured telescoping cylinder (14) to anchor
bracket (13). Remove 16 bolts (15), the washers
and the nuts in order to remove the anchor bracket
and shims (16) from boom (17). Make a note of the
amount of shims that are removed and the location
of the shims for installation purposes.
136 31200308

Illustration 639 g00956076 Illustration 642 g00956083

11. Use a suitable screwdriver in order to disconnect 13. Disconnect tubes (22) from hoses (19). Remove
chain (21). bolt (23), the washer and clamp (24). Disconnect
tubes (22) from tubes (26) and remove the tubes.
Trace harness (25) toward the rear of the machine
and disconnect the harness. Remove all cable
straps. Note the location of the connector and the
cable straps for installation purposes.

Illustration 640 g00956081

12. Pull hoses (19) through chain (21) and out of boom
(17). At the same time, this will pull the ropes that
were attached in Step 10 into the chain. When the
hoses are completely out of the chain remove the
ropes. The ropes will be used in the installation Illustration 643 g00956085
procedure. 14. Remove four bolts (27).

Illustration 641 g00956082 Illustration 644 g00956234

15. Use a suitable screwdriver to break the seal
between bracket (28) and chain (21) before
removing the bracket. Remove the bracket on the
opposite side of the chain.
31200308 137

Illustration 645 g00956089 Illustration 647 g00955497

16. Slide chain (21) with hoses (19) out of boom (17). 2. Install Tooling (A) in order to support the boom.
Note: Harness (25) runs through the center of chain
(21). The harness is removed with the chain.

Illustration 648 g00952452

3. Remove cover (1).
Illustration 646 g00956090
17. Remove hoses (19) from chain (21).

Auxiliary Hoses (Boom)

Table 38

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1

Illustration 649 g00953552

Note: The following procedure was carried out after the
boom assembly had been removed from the machine.
This procedure can also be carried out when the
boom assembly is installed on the machine.

1. Put identification marks on all hoses, on all lines

and on all tubes for installation purposes. Plug all
lines, all hoses and all tubes. This helps to prevent
fluid loss and this helps to keep contaminants from
entering the system.
138 31200308

Illustration 650 g00953553 Illustration 653 g00952455

4. Remove cover (2) from the left side of the Right Side
machine. Remove cover (3) from the right side of 6. Disconnect hose (8) and remove tube (5).
the machine. Disconnect hose (9) and remove tube (7).

Illustration 651 g00952453

5. Disconnect tube (4) from tube (5). Disconnect tube
(6) from tube (7).

Illustration 654 g00952456

7. Remove four bolts (10), the washers and plate (11)
that secured telescoping cylinder (14) to anchor
bracket (13). Remove 16 bolts (15), the washers
and the nuts in order to remove the anchor bracket
and shims (16) from boom (17). Make a note of the
amount of shims that are removed and the location
of the shims for installation purposes.

Illustration 652 g00952454

Left Side

Illustration 655 g00954218

31200308 139

8. Disconnect two hoses (18) from auxiliary valve

(19). Cut cable strap (20) and remove divider (21).
Disconnect two electrical connectors (22).

Illustration 659 g00955501

Illustration 656 g00954220

9. Attach two suitable ropes to hoses (18). Wrap
suitable vinyl plastic electrical tape around the
hoses and the rope in order to prevent the hoses
from catching on removal. The ropes will be
needed on installation of the hoses.

Illustration 660 g00955502

12. Disconnect tubes (24) from hoses (18). Remove
bolt (25), the washer and clamp (26). Disconnect
tubes (24) from tubes (28) and remove the tubes.
Trace harness (27) toward the rear of the machine
and disconnect the harness. Remove all cable
straps. Note the location of the connector and the
cable straps for installation purposes.
Illustration 657 g00955306
10. Use a suitable screwdriver in order to disconnect
chain (23).

Illustration 661 g00955803

13. Remove four bolts (29).

Illustration 658 g00955500

11. Pull hoses (18) through chain (23) and out of boom
(17). At the same time, this will pull the ropes that
were attached in Step 9 into the chain. When the
hoses are complete out of the chain remove the
ropes. The ropes will be used in the installation
procedure.
140 31200308

Hydraulic Oil Lines (Boom) -

Install
Installation Procedure
Tilt Cylinder Hoses (Boom)
Table 39

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1
Illustration 662 g00955503
14. Use a suitable screwdriver to break the seal A 8S-7621 Tube 1
between bracket (30) and chain (23) before 8S-7615 Pin 1
removing the bracket. Remove the bracket from the
opposite side of the chain.
Note: The following procedure was carried out after the
boom assembly had been removed from the machine.
This procedure can also be carried out when the
boom assembly is installed on the machine.

1. Clean all parts and inspect all parts. If any parts are
worn or damaged, Use new Caterpillar parts for
replacement.

Illustration 663 g00955804

15. Slide chain (23) with hoses (18) out of boom (17).
Note: Harness (27) runs through the center of chain
(23). The harness is removed with the chain.

Illustration 665 g00956090

2. Install two hoses (19) into chain (21).

Illustration 664 g00955805

16. Remove hoses (18) from chain (23).

Illustration 666 g00956089

3. Slide chain (21) with hoses (19) into boom (17).
31200308 141

Note: Harness (25) (not shown) runs through the

center of chain (21). The harness is installed with the
chain.

Illustration 670 g00956083

6. Position two tubes (22). Connect the tubes to two
tubes (26). Connect tubes (22) to two hoses (19).
Illustration 667 g00956221 Install bolt (23), the washer and clamp (24). Route
4. Apply a thin coat of 152-9155 Adhesive to the harness (25) toward the rear of the machine and
outside of the link on the end of chain (21) and connect the harness. Install all cable straps.
bracket (28). Make sure that the bracket is
installed with threaded holes outward. Install the
bracket on the opposite side of the chain.

Illustration 671 g00956081

Illustration 668 g00956085

5. Position brackets (28) (not shown) and install four
bolts (27) and the washers.

Illustration 672 g00956077

7. Attach the two suitable ropes that were installed
in the removal procedure to hoses (19). Wrap
suitable vinyl plastic electrical tape around the
hoses and the rope in order to prevent the hoses
Illustration 669 g00956082 from catching on installation.
8. With the aid of a second person, push two hoses
(19) into chain (21) and boom (17). At the same
time pull the ropes which were installed in the
removal procedure in order to guide the hoses to
the front of the boom. Remove the ropes.
142 31200308

Illustration 673 g00956076

9. Use a suitable screwdriver to aid with the
connection of the two half's of chain (21).

Illustration 676 g00952456

12. Position anchor bracket (13) in boom (17). Install

shims (16) that were removed in the removal
procedure. If it is necessary, add shims or remove
shims. Apply 4C-4030 Thread Lock Compound
to the threads of 16 bolts (15) before installing the
bolts with the washers and the nuts.
13. Apply 4C-4030 Thread Lock Compound to four
bolts (10) before installing the bolts, the washers
and plate (11) in order to secure telescoping
Illustration 674 g00956075
cylinder (14).
10. Connect two hoses (19) to tilt cylinder (20).

Illustration 677 g00952454

Illustration 675 g00956074 Left Side
11. Install cover (18).
31200308 143

Illustration 678 g00952455 Illustration 681 g00953553

Right Side 16. Install cover (3) onto the right side of the machine.
14. Position tube (5) and connect hose (8). Position Install cover (2) onto the left side of the machine.
tube (7) and connect hose (9).

Illustration 682 g00952452

Illustration 679 g00952453 17. Install cover (1).
15. Connect tube (7) to tube (6). Connect tube (5) to
tube (4).

Illustration 683 g00955497

18. Remove Tooling (A).
Illustration 680 g00953552

Auxiliary Hoses (Boom)

Table 40

Required Tools
Tool Part Number Part Description Qty
4C-6486 Stand 1

A 8S-7621 Tube 1
8S-7615 Pin 1
144 31200308

Note: The following procedure was carried out after the

boom assembly had been removed from the machine.
This procedure can also be carried out when the
boom assembly is installed on the machine.
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, Use new Caterpillar parts for
replacement.

Illustration 687 g00955803

5. Position brackets(30) (not shown) and install four
bolts (29) and the washers.

Illustration 684 g00955805

2. Install two hoses (18) into chain (23).

Illustration 688 g00955501

Illustration 685 g00955804

3. Slide chain (23) with hoses (18) into boom (17).
Note: Harness (27) runs through the center of chain
(21). The harness is installed with the chain.

Illustration 689 g00955502

6. Position two tubes (24). Connect the tubes to two
tubes (28). Connect tubes (24) to two hoses (18).
Install bolt (25), the washer and clamp (26). Route
harness (27) toward the rear of the machine and
connect the harness. Install all cable straps.

Illustration 686 g00956139

4. Apply a thin coat of 152-9155 Adhesive to the
outside of the link on the end of chain (23) and
bracket (30). Make sure that the bracket is
installed with threaded holes outward. Install the
bracket on the opposite side of the chain.
31200308 145

Illustration 690 g00955500 Illustration 693 g00954218

10. Connect two electrical connectors (22). Connect two
hoses (18) to auxiliary valve (19). Install divider
(21) and a new cable strap (20).

Illustration 691 g00954220

7. Attach the two suitable ropes that were installed
in the removal procedure to hoses (18). Wrap
suitable vinyl plastic electrical tape around the
hoses and the rope in order to prevent the hoses
from catching on installation.
8. With the aid of a second person, push two hoses
(18) into chain (23) and boom (17). At the same
time pull the ropes which were installed in the Illustration 694 g00952456

removal procedure in order to guide the hoses to 11. Position anchor bracket (13) in boom (17). Install
the front of the boom. Remove the ropes. shims (16) that were removed in the removal
procedure. If it is necessary, add shims or remove
shims. Apply 4C-4030 Thread Lock Compound
to the threads of 16 bolts (15) before installing the
bolts with the washers and the nuts.
12. Apply 4C-4030 Thread Lock Compound to four
bolts (10) before installing the bolts, the washers
and plate (11) in order to secure telescoping
cylinder (14).

Illustration 692 g00955306

9. Use a suitable screwdriver to aid with the
connection of the two half's of chain (23).
146 31200308

Illustration 695 g00952454 Illustration 698 g00953552

Left Side

Illustration 699 g00953553

Illustration 696 g00952455
15. Install cover (3) onto the right side of the machine.
Right Side
Install cover (2) onto the left side of the machine.
13. Position tube (5) and connect hose (8). Position
tube (7) and connect hose (9).

Illustration 700 g00952452

Illustration 697 g00952453

16. Install cover (1).
14. Connect tube (7) to tube (6). Connect tube (5) to
tube (4).
31200308 147

Approximate weights of the components are

shown. Clean all surfaces where parts are to be
installed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
Illustration 701 g00955497 before any service is done on the hydraulic system.
17. Remove Tooling (A). Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
Telescoping Cylinder - Remove removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
and Install filler cap is cool enough to touch with your bare
hand.
Removal Procedure NOTICE
Table 41 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
Required Tools adjusting and repair of the product. Be prepared to collect
Tool Part Number Part Description Qty the fluid with suitable containers before opening any
compartment or disassembling any component
4C-6486 Stand 1 containing fluids.
8S-7621 Tube 1 Dispose of all fluids according to local regulations and
A
8S-7615 Pin 1 mandates.
8S-8048 Saddle 1
Note: The following procedure was carried out after the
boom assembly had been removed from the machine.
This procedure can also be carried out when the
boom assembly is installed on the machine.

Cylinders equipped with lock valves can remain 1. Put identification marks on all hoses, on all lines
pressurized for very long periods of time, even and on all tubes for installation purposes. Plug all
with the hoses removed. lines, all hoses and all tubes. This helps to prevent
Failure to relieve pressure before removing a lock fluid loss and this helps to keep contaminants from
valve or disassembling a cylinder can result in entering the system.
personal injury or death.
Ensure all pressure is relieved before removing a
lock valve or disassembling a cylinder.

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
Illustration 702 g00952452
component. Install blocks or stands before
performance of any work under a heavy 2. Remove cover (1).
component.
148 31200308

Illustration 703 g00953552 Illustration 706 g00952454

Left Side

Illustration 704 g00953553

3. Remove cover (2) from the left side of the Illustration 707 g00952455

machine. Remove cover (3) from the right side of Right Side

the machine. 5. Disconnect hose (8) and remove tube (5).

Disconnect hose (9) and remove tube (7).

Illustration 705 g00952453

4. Disconnect tube (4) from tube (5). Disconnect tube
(6) from tube (7).

Illustration 708 g00952456

31200308 149

6. Remove four bolts (10), the washers and plate (11) 9. Attach two suitable ropes to hoses (18). Wrap
that secured telescoping cylinder (14) to anchor suitable vinyl plastic electrical tape around the
bracket (13). Remove 16 bolts (15), the washers hoses and the rope in order to prevent the hoses
and the nuts in order to remove the anchor bracket from catching on removal. The ropes will be need
and shims (16) from boom (17). Make a note of the on installation of the hoses.
amount of shims that are removed and the location
of the shims for installation purposes.

Illustration 712 g00954221

10. Use a suitable screwdriver in order to disconnect
Illustration 709 g00954218
chain (24).
7. Disconnect two hoses (18) from auxiliary valve
(19). Cut cable strap (20) and remove divider (21).
Disconnect two electrical connectors (22).

Illustration 713 g00954222

11. Pull hoses (18) and harness (23) approximately 1.5
m (4 ft) through chain (24) and out of boom (17).
Illustration 710 g00954219 Lay the harness and hoses aside.
8. Remove electrical connectors (22) from harness
(23). Cover the terminal connectors with suitable
vinyl plastic electrical tape.

Illustration 714 g00954225

12. Remove two bolts (25) and the washers which
Illustration 711 g00954220
secure plug (26) and harness (27) to the boom head.
150 31200308

Illustration 715 g00954226 Illustration 718 g00954229

13. Remove cover (28). 16. Pull hoses (29) and harness (27) approximately 200
mm (8 inch) through chain (31) and out of boom
(17). Lay the hoses and the harness aside.

Illustration 716 g00954227

14. Disconnect two hoses (29) from tilt cylinder (30).
Illustration 719 g00954230
17. Remove four bolts (32), the washers and two plates
(33).

Illustration 717 g00954228

15. Use a suitable screwdriver in order to disconnect
chain (31).

Illustration 720 g00954270

18. Reinstall plate (11), four bolts (10) and the washers
onto telescopic cylinder (14). Attach a suitable
nylon lifting sling through the eye of the cylinder and
to a suitable hoist.
31200308 151

Illustration 721 g00954271 Illustration 724 g00954284

21. Rotate telescopic cylinder (14) through 90 degrees
in a clockwise direction. Make sure that bracket (34)
is toward the left side of the boom.

Illustration 722 g00954282

19. Use the hoist to carefully draw telescopic cylinder
(14) out of boom (17) until bracket (34) makes Illustration 725 g00954350
contact with chain anchor block (35). Install Tooling
(A) and remove the nylon lifting sling. Refer to 22. Use the hoist to move telescopic cylinder (14)
Table 42 for the approximate weight of the toward the left side of the boom. At the same time
telescopic cylinder. remove the cylinder from the boom.
Table 42

Approximate weight of the

Model
Telescopic Cylinder
TH360B 245 kg (540 lb)

Illustration 726 g00954351

23. Remove two bolts (36), the washers and the nuts in
order to remove wear pad (37) from bracket (34).
Remove four bolts (38) and the washers in order to
remove the bracket from telescopic cylinder (14).

Illustration 723 g00954283

20. Attach two suitable nylon lifting slings around
telescopic cylinder (14). Take up the tension and
remove Tooling (A). Refer to Table 42 for the
approximate weight of the telescopic cylinder.
152 31200308

Illustration 727 g00954708

24. Remove four bolts (39) and the washers in order to
remove lock valve (40) from telescopic cylinder
(14). Remove tube (4) and tube (6).

Disassembly and Assembly

Information
Table 43

Required Tools
Tool Part Number Part Description Qty

Hydraulic Cylinder
A 1
Repair Stand

Bearing Mount
B 7M-7456 1
Compound
Multipurpose
C 1P-0808 1
Grease
Thread Lock
D 4C-4030 1
Compound
D 9U-7868 Spanner Wrench 1
E 127-8064 Adapter Plate 1
F 231- Seal Guide 1

Note: SERVICE DATA: THE TOOLING IN TABLE 43

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
31200308 153

Illustration 728 g00944290

a. Apply tooling (B) to the seal groove prior to the installation Table 44
of the wiper seal (10). Lubricate the lip of wiper seal (10),
seal (9), buffer seal (8) and two wear rings (7) with the Required Tools
lubricant that is being sealed.
Tool Part Number Part Description Toy
b. Lubricate two seals (6) with the lubricant that is being
sealed. 4C-6486 Stand 1
c. Lubricate the seal (2) and the two sealing rings with the 8S-7621 Tube 1
lubricant that is being sealed. Lubricate the threads of A
piston (1) with Tooling (D). Use a 46 mm socket for the 8S-7615 Pin 1
removal and for the installation of the piston. The torque 8S-8048 Saddle 1
setting for piston (1)..........1000 ± 100 Nm (735 ± 75 lb ft)
d. Apply Tooling (D) to the thread of set screw (5). The torque 1. Clean all parts and inspect all parts. If any parts are
setting for set screw (5)..................6 ± 1 Nm (53 ± 8 lb in) worn or damaged, use new Caterpillar parts for
e. Lubricate piston seals (3) and wear ring (4) with the replacement.
lubricant that is being sealed.
f. Lubricate O-ring seal (11), the backup ring and O-ring seal
(12) with the lubricant that is being sealed.
g. Lubricate the threads of head (13) with Tooling (C). The
torque setting for head (1) 600 ± 130 Nm (440 ± 95 lb. ft.)

Installation Procedure Illustration 729 g00954708

154 31200308

2. Position lock valve (40) onto telescopic cylinder

(14) and install four bolts (39) with the washers.
Install tube (6) and tube (4). Ensure that the ends of
the tube that are blanked face toward the end of the
cylinder.

Illustration 732 g00954712

6. Install telescopic cylinder (14) into the end of the
boom until bracket (34) is forward of chain anchor
block (35).

Illustration 730 g00954351

3. Position bracket (34) onto the end of telescopic
cylinder (14) and install four bolts (38) and the
washers. Install wear pad (37), two bolts (36), the
washers and the nuts.
Note: Make sure that bracket (34) is installed with the
wear pad on the same side of the cylinder as the tubes
that were installed in Step 2.

Illustration 733 g00954713

7. Rotate telescopic cylinder (14) through 90 degrees
in a counterclockwise direction. The wear pad
which is attached to bracket (34) should be on the
base of the boom and forward of chain anchor
block (35).

Illustration 731 g00954710

4. Attach two suitable nylon lifting slings around telescopic

cylinder (14). Make sure that the wear pad and the tubes
that were previously installed are toward the left side of
the boom. Refer to Table 45 for the approximate weight of
the telescopic cylinder.
Table 45

Approximate weight of the

Model
Telescopic Cylinder
TH360B 245 kg (540 lb.)
Illustration 734 g00954729
8. Lower telescopic cylinder (14) onto Tooling (A) and
remove the two nylon lifting slings.
5. Use the hoist and carefully lift the cylinder toward
boom (17). At the same time move the rear end of
the cylinder toward the left side of the boom.
31200308 155

Illustration 735 g00954271 Illustration 738 g00954229

9. Attach a suitable nylon lifting sling through the eye 12. Push two hoses (29) and harness (27) into chain
of telescopic cylinder (14) and to a suitable hoist. (31) and boom (17).
Take up the tension and remove Tooling (A). Use
the hoist and carefully slide the cylinder into boom
(17).

Illustration 739 g00954228

13. Use a suitable screwdriver to aid with the
connection of two half's of chain (31).
Illustration 736 g00954270
10. Install the lug on telescopic cylinder (14) into the
mounting on the inside of the boom. Remove four
bolts (10), the washers, plate (10) and the nylon
lifting sling.

Illustration 740 g00954227

14. Connect two hoses (29) to tilt cylinder (30).

Illustration 737 g00954230

11. Apply 4C-4030 Thread Lock Compound to the
threads of four bolts (32). Install the bolts, washers
and two plates (33).
156 31200308

Illustration 741 g00954226 Illustration 744 g00954220

15. Install cover (28). 17. With the aid of a second person, push two hoses
(18) and harness (23) into chain (24) and boom
(17). At the same time pull the ropes which were
installed in the removal procedure in order to guide
the hoses to the front of the boom. Remove the
ropes.

Illustration 742 g00954225

16. Position plug (26) and harness (27) and install two
bolts (25) with the washers.

Illustration 745 g00954221

18. Use a suitable screwdriver to aid with the
connection of the two half's of chain (24).

Illustration 743 g00954222

Illustration 746 g00954219

19. Install two electrical connectors (22) onto harness
(23).
31200308 157

Illustration 747 g00954218 Illustration 749 g00952454

20. Connect two electrical connectors (22). Connect Left Side
two hoses (18) to auxiliary valve (19). Install
divider (21) and cable strap (20).

Illustration 750 g00952455

Right Side
23. Position tube (5) and connect hose (8). Position
tube (7) and connect hose (9).

Illustration 748 g00952456

21. Position anchor bracket (13) in boom (17). Install
shims (16) that were removed in the removal
procedure. If it is necessary, add shims or remove
shims. Apply 4C-4030 Thread Lock Compound
to the threads of 16 bolts (15) before installing the
bolts with the washers and the nuts.
22. Apply 4C-4030 Thread Lock Compound to four
bolts (10) before installing the bolts, the washers Illustration 751 g00952453
and plate (11) in order to secure telescoping 24. Connect tube (7) to tube (6). Connect tube (5) to
cylinder (14). tube (4).
158 31200308

Load Control Valve

(Telescoping Cylinder) -
Remove and Install
Removal Procedure

Personal injury can result from hydraulic oil

pressure and hot oil.
Illustration 752 g00953553
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.

Illustration 753 g00953552 Cylinders equipped with lock valves can remain
25. Install cover (3) onto the right side of the machine. pressurized for very long periods of time, even
Install cover (2) onto the left side of the machine. with the hoses removed.
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
Ensure all pressure is relieved before removing a
lock valve or disassembling a cylinder.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Illustration 754 g00952452
26. Install cover (1). Dispose of all fluids according to local regulations and
mandates.
31200308 159

Illustration 755 g00942124 Illustration 758 g00942126

1. Remove cover (1). 2. Apply a thin coat of 1U - 6396 O-Ring Assembly
Compound to O-ring seals (5) before installing the
O-ring seals into lock valve (3).

Illustration 756 g00942125

2. Remove four bolts (2) and the washers in order to
remove lock valve (3) from telescoping cylinder (4). Illustration 759 g00942125
3. Position lock valve (3) onto telescoping cylinder (4)
and install four bolts (2) and the washers.

Illustration 757 g00942126

3. Remove three O-ring seals (5) from lock valve (3).
Illustration 760 g00942124
4. Install cover (1).
Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
160 31200308

Boom Cylinder - Remove and

Install
Cylinders equipped with lock valves can remain
Removal Procedure pressurized for very long periods of time, even
with the hoses removed.
Table 46 Failure to relieve pressure before removing a lock
Required Tools valve or disassembling a cylinder can result in
personal injury or death.
Tool Part Number Part Description Qty
Ensure all pressure is relieved before removing a
4C-6486 Stand 1 lock valve or disassembling a cylinder.
8S-7621 Tube 1 NOTICE
A
8S-8048 Saddle 1 Care must be taken to ensure that fluids are contained
8S-7615 Pin 1 during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
Personal injury or death can result from improper mandates.
lifting or blocking. 1. Put identification marks on all hoses and on all
When a hoist or jack is used to lift any part or tubes for installation purposes. Plug all hoses and
component, stand clear of the area. Be sure the all tubes. This helps to prevent fluid loss, and this
hoist or jack has the correct capacity to lift a helps to keep contaminants from entering the
component. Install blocks or stands before system.
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious Illustration 761 g00921927

injury can be caused if this pressure is not released 2. Start the engine and install Tooling (A) under hitch
before any service is done on the hydraulic system. (1) in order to support the boom assembly. Make
sure that Tooling (A) is fully extended. Shut off the
Make sure all of the attachments have been
engine.
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.

Illustration 762 g00921928

31200308 161

3. Attach one end of a suitable nylon lifting sling to a 8. Attach two suitable nylon lifting slings around
suitable hoist. Feed the opposite end of the sling cylinder (3) and a suitable hoist. Take up the tension
down one side of boom (2). Then feed the sling on the lifting slings but do not lift the cylinder.
around cylinder (3) and up the opposite side of the
boom to the hoist. Take up the tension on the sling
Note: Install a suitable shackle between the eye of the
in order to support the cylinder. The weight of the
nylon lifting sling which is attached to the head end of
cylinder is approximately 270 kg (595 lb).
the cylinder and the hoist. This will lift the cylinder at an
4. Remove bolt (4), the washer and pin (5). angle which will assist in the removal of the cylinder.
5. Start the engine and retract cylinder (3). Shut off
the engine.

Illustration 766 g00922044

Illustration 763 g00921929

6. Place suitable cribbing onto the chassis. Use the
hoist and carefully lower cylinder (3) onto the
cribbing and remove the nylon lifting sling.

Illustration 767 g00922476

9. Remove bolt (7) and the washer which secures
pin (8).
10. Remove pin (8) and two spacers (9) that are
located between cylinder (3) and chassis (10).
Illustration 764 g00921930
7. Disconnect two hose (6) from cylinder (3).

Illustration 768 g00922477

11. Use the hoist and lift cylinder (3) and at the same
Illustration 765 g00922024 time move the cylinder toward the front of the
machine.
162 31200308

Disassembly and Assembly

Information
Table 47

Required Tools
Tool Part Number Part Description Qty

Hydraulic Cylinder
A 1
Repair Stand

Bearing Mount
B 7M-7456 1
Compound
Illustration 769 g00922478 Multipurpose
C 1P-0808 1
12. 12. Remove bolts (11) and the washers in order to Grease
remove lock valve (12) from cylinder (3). Remove two
D 4C-8092 Universal Wrench 1
tubes (13).
9U-7869 Spanner Wrench 1

E 204-6213 Adapter Plate 1

127- 8066 Key 3
FT-2802 Plate 1
2J-3507 Full Nut 1
3K-5234 Hard Washer 1
123-3804 Plate 1
4C-9634 Puller Stud 1
6V-4035 Sleeve 1
F

Double Acting
6V-3175 1
Cylinder
9U-6832 Nut 1

3S-6224 or 8S- Electric Hydraulic

1
8033 Pump Gp

6D-7726 Hose As 2

G 233-7213 Seal Guide 1

1P-0510 or 1P-
H Driver Gp 1
0520

Note: SERVICE DATA: THE TOOLING IN TABLE 47

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
31200308 163

Illustration 770 g00943300

a. Install bearing (1). The bearing must not extend
beyond either face of the cylinder eye.
Installation Procedure
b. Install bearing (11). Install the bearing to depth Table 48
(X) from the bottom face before installing lip
seals (12). Required Tools
Tool Part Number Part Description Qty
Dimension (X) 7 ± 0.5 mm (0.276 ± 0.020 inch)
c. Apply Tooling (B) to the seal groove prior to the 4C-6486 Stand 1
installation of the wiper seal (7). Lubricate the lip 8S-7621 Tube 1
of wiper seal (7), seal (6) and wear ring (5) with A
the lubricant that is being sealed. 8S-8048 Saddle 1
d. (-) Lubricate the threads of self-locking nut (2) with 8S-7615 Pin 1
Tooling (C). Use a 90 mm socket for the removal and
for the installation of the self-locking nut. The torque
setting for the self-locking nut 6500 ± 500 Nm
(4795 ± 370 lb ft) 1. Clean all parts and inspect all parts. If any parts
e. Lubricate piston seals (3) and wear ring (4) with are worn or damaged use new Caterpillar parts for
the lubricant that is being sealed. replacement.
f. Lubricate O-ring seal (8), the backup ring and
O-ring seal (9) with the lubricant that is being
sealed.
g. Lubricate the threads of head (10) with Tooling (C). The
torque setting for head (10).................600 ± 130 Nm
(440 ± 95 lb ft)
164 31200308

5. At the underside of the machine, align the bore in

cylinder (3) with the bores in chassis (10). Insert
two spacer (9) on both sides of the cylinder before
installing pin (8).

Illustration 771 g00922478

2. Install two tubes (13) onto cylinder (3). Position
lock valve (12) and install bolts (11) and the
washers.
Illustration 774 g00922044
6. Install bolt (7) and the washer that secures pin (8).

Illustration 772 g00922477

3. Attach two suitable nylon lifting slings around
cylinder (3) and a suitable hoist. The weight of the
Illustration 775 g00935769
cylinder is approximately 270 kg (595 lb).
7. Lower cylinder (3) onto suitable cribbing and
remove the nylon lifting slings. Refer to illustration
Note: Install a suitable shackle between the eye of the 777 for the location of the cribbing.
nylon lifting sling which is attached to the head end of
the cylinder and the hoist. This will lift the cylinder at an
angle which will assist in the removal of the cylinder.

4. Use the hoist and lift cylinder (3) and at the same
time move the cylinder toward the rear of the
machine.

Illustration 776 g00921930

8. Connect two hoses (6) to cylinder (3).

Illustration 773 g00922478

31200308 165

Load Control Valve (Boom

Cylinder) - Remove and Install
Removal Procedure

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Illustration 777 g00921929 Failure to relieve pressure before removing a lock
9. Attach one end of a suitable nylon lifting sling to a valve or disassembling a cylinder can result in
suitable hoist. Feed the opposite end of the sling personal injury or death.
down one side of the boom. Then feed the sling Ensure all pressure is relieved before removing a
around cylinder (3) and up the opposite side of the lock valve or disassembling a cylinder.
boom to the hoist. Take up the tension on the sling
in order to support the cylinder and remove the
cribbing.
Personal injury can result from hydraulic oil
pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
Illustration 778 g00921928
NOTICE
10. Use the hoist in order to lift the cylinder into
position. With the aid of a second person, start the Care must be taken to ensure that fluids are contained
engine and extend the cylinder. Align the bore in the during performance of inspection, maintenance, testing,
cylinder with the bores in boom (2) before installing adjusting and repair of the product. Be prepared to collect
pin (5). Install bolt (4) and the washer in order to the fluid with suitable containers before opening any
secure the pin to the boom. Stop the engine and compartment or disassembling any component
remove the nylon lifting sling. containing fluids.
Dispose of all fluids according to local regulations and
mandates.

Illustration 779 g00921927

11. Start the engine and remove Tooling (A). Lower the
boom and stop the engine.
Illustration 780 g00927952
166 31200308

1. Remove four bolts (2) and the washers in order to Approximate weights of the components are
remove lock valve (1) from boom cylinder (3). shown. Clean all surfaces where parts are to be
2. Remove three O-ring seals from the mating face installed.
of lock valve (1) (not shown).

Installation Procedure
Personal injury can result from hydraulic oil
1. Clean all parts and inspect all parts. If any parts are pressure and hot oil.
worn or damaged, use new Caterpillar parts for Hydraulic oil pressure can remain in the hydraulic
replacement. system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.

Cylinders equipped with lock valves can remain

Illustration 781 g00927952 pressurized for very long periods of time, even
2. Install three O-ring seals into the mating face of with the hoses removed.
lock valve (1) (not shown). Failure to relieve pressure before removing a lock
3. Position lock valve (1) onto boom cylinder (3) and valve or disassembling a cylinder can result in
install four bolts (2) with the washers. personal injury or death.
Ensure all pressure is relieved before removing a
Tilt Cylinder - Remove and lock valve or disassembling a cylinder.
Install NOTICE
Care must be taken to ensure that fluids are contained
Removal Procedure during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
Table 49 the fluid with suitable containers before opening any
compartment or disassembling any component
Required Tools
containing fluids.
Tool Part Number Part Description Qty
Dispose of all fluids according to local regulations and
4C-6486 Stand 1 mandates.
A 8S-7621 Tube 1
8S-7615 Pin 1 1. Put identification marks on all hoses and on all
tubes for installation purposes. Plug all hoses and
all tubes. This helps to prevent fluid loss and this
helps to prevent contaminants from entering the
system.
Personal injury or death can result from improper
lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
31200308 167

Illustration 782 g00928270 Illustration 785 g00928273

2. Install Tooling (A) on the underside of boom (1) in 5. Disconnect hoses (8) from elbows (9) and remove
order to support the boom. the elbows from cylinder (5).

Illustration 783 g00928271 Illustration 786 g00928286

3. Remove bolt (2) and the washer which secures pin 6. Feed a suitable nylon lifting sling down through
(3) to quick coupler (4). Remove the pin out of the boom head (7). Attach the sling around cylinder (5)
quick coupler and cylinder (5). and to a suitable hoist. Take up the tension in order
to support the cylinder. The weight of the cylinder is
approximately 60 kg (132 lb).

Illustration 784 g00928272

4. Remove cover (6) from boom head (7).
Illustration 787 g00928287
7. Remove bolt (10) and the washer which secures
pin (11) to boom head (7). Remove the pin out of the
boom head and cylinder (5).
168 31200308

Disassembly and Assembly

Information
Table 50

Required Tools
Tool Part Number Part Description Qty

Hydraulic Cylinder
A 1
Repair Stand

Bearing Mount
B 7M-7456 1
Compound
Multipurpose
C 1P-0808 1
Grease
D 4C-8092 Universal Wrench 1
9U-7868 Spanner Wrench 1
E
127-8064 Adapter Plate 1
Illustration 788 g00928316
FT-2802 Plate 1
8. Use the hoist to carefully lower cylinder (5) out of
boom head (7). Remove the cylinder from the 2J-3507 Full Nut 1
machine. 3K-5234 Hard Washer 1
123-3804 Plate 1
4C-9634 Puller Stud 1
6V-4035 Sleeve 1
F Double Acting
6V-3175 1
Cylinder
9U-6832 Nut 1

3S-6224 or 8S- Electric Hydraulic

1
8033 Pump Gp

6D-7726 Hose As 2
G 233-7311 Seal Guide 1

1P-0510 or 1P-
H Driver Gp 1
0520

Note: SERVICE DATA: THE TOOLING IN TABLE 50

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
31200308 169

Illustration 489 g00943486

a. Install bearing (1). The bearing must not extend
beyond either face of the cylinder eye.
Installation Procedure
b. Install bearing (12). Install the bearing to depth Table 51
(X) from the bottom face before installing lip
seals (13). Required Tools
Tool Part Number Part Description Qty
Dimension (X).............. 7 ± 0.5 mm (0.276 ± 0.020 inch)
c. Apply Tooling (B) to the seal groove prior to the 4C-6486 Stand 1
installation of the wiper seal (8). Lubricate the 8S-7621 Tube 1
A
lip of wiper seal (8), seal (6), backup ring (7)
and wear ring (5) with the lubricant that is being 8S-7615 Pin 1
sealed.
d. Lubricate the threads of self-locking nut (2) with Tooling 1. Clean all parts and inspect all parts. If any parts are
(C). Use a 90 mm socket for the removal and for the worn or damaged, use new Caterpillar parts for
installation of the self-locking nut. The torque setting for replacement.
the self-locking nut 6500 ± 100 Nm (4795 ± 75 lb ft).
e. Lubricate piston seals (3) and wear ring (4) with
the lubricant that is being sealed.
f. Lubricate O-ring seal (9), the backup ring and
O-ring seal (10) with the lubricant that is being
sealed.
g. Lubricate the threads of head (11) with Tooling (C). The
torque setting for head (110) 600 ± Nm (440 ± 95 lb ft)
170 31200308

Illustration 793 g00928272

5. Install cover (6) onto boom head (7).

Illustration 790 g00935776

2. Attach a suitable nylon lifting sling around cylinder
(5). Feed the opposite end of the sling through
boom head (7) to a suitable hoist. Use the hoist to
carefully lift the cylinder and at the same time guide
the cylinder into the boom head. The weight of the
cylinder is approximately 60 kg (132 lb).

Illustration 794 g00928271

6. Align the bore in cylinder (5) with the bores in
quick coupler (4) and install pin (3), bolt (2) and the
washer.

Illustration 791 g00928287

3. Align the bore in cylinder (5) with the bores in
boom head (7) and install pin (11), bolt (10) and the
washer. Remove the nylon lifting sling.

Illustration 795 g00928270

7. Remove Tooling (A) from the underside of boom
(1).

Illustration 792 g00928273

4. Install elbows (9) into cylinder (5) before
connecting hoses (8).
31200308 171

Load Control Valve (Tilt

Cylinder) - Remove and Install
Removal Procedure

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
Illustration 796 g00927978
injury can be caused if this pressure is not released
1. Remove cover (1) from the end of boom (2).
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed. Illustration 797 g00927982
2. Remove lock valve (3) from cylinder (4).
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
Ensure all pressure is relieved before removing a
lock valve or disassembling a cylinder.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids. Illustration 798 g00927983

Dispose of all fluids according to local regulations and 3. Remove two backup rings (5), O-ring seal (6), O-
mandates. ring seal (7), backup ring (8), O-ring seal (9) and O-
ring seal (10) from lock valve (3).

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
172 31200308

Frame Leveling Cylinder -

Remove and Install
Removal Procedure

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Illustration 799 g00927983 Failure to relieve pressure before removing a lock
2. Install two backup rings (5), O-ring seal (6), O-ring valve or disassembling a cylinder can result in
seal (7), backup ring (8), O-ring seal (9) and O-ring personal injury or death.
seal (10) onto lock valve (3). Lubricate all O-ring Ensure all pressure is relieved before removing a
seals and all backup rings with the lubricant that is lock valve or disassembling a cylinder.
being sealed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
Illustration 800 g00927982
filler cap only when the engine is stopped, and the
3. Install lock valve (3) into cylinder (4). Tighten the
filler cap is cool enough to touch with your bare
lock valve to a torque of 147 ±5 Nm (108 ±4 lb ft).
hand.

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Illustration 801 g00927978 Approximate weights of the components are
4. Install cover (1) to the end of boom (2). shown. Clean all surfaces where parts are to be
installed.
31200308 173

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

1. Put identification marks on all lines, on all hoses

and on all wires for installation purposes. Plug all
Illustration 804 g00926963
lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering 4. Disconnect harnesses (3) from solenoids (4).
the system.

Illustration 805 g00926965

Illustration 802 g00926552 5. Attach a suitable nylon lifting sling around cylinder
2. Before removing the frame leveling cylinder, install (5) and to a suitable hoist. Take up the tension but
suitable cribbing on both sides of the machine do not lift the cylinder. The weight of the cylinder is
between the chassis and the rear axle. approximately 38 kg (84 lb).

Illustration 803 g00926962 Illustration 806 g00926966

3. Disconnect three hoses (1) from lock valve (2). 6. Remove bolt (6), the washer and the spacer that
secures pin (7) to bracket (8). Remove the pin out of
the bracket and the cylinder (5). Use the hoist and
carefully lift the rod end of the cylinder out of the
bracket.
174 31200308

Disassembly and Assembly

Information
Table 52

Required Tools
Tool Part Number Part Description Qty

Hydraulic Cylinder
A 1
Repair Stand

Bearing Mount
B 7M-7456 1
Compound
Illustration 807 g00926967
Multipurpose
7. Remove bolt (9) and the washer that secures pin C 1P-0808 1
Grease
(10) to chassis (11). Remove the pin out of the
D 4C-8092 Universal Wrench 1
chassis and the cylinder (5). Use the hoist and
carefully lift the cylinder from the machine. 9U-7868 Spanner Wrench 1
E
127-8064 Adapter Plate 1
FT-2802 Plate 1
2J-3507 Full Nut 1
3K-5234 Hard Washer 1
5P-2145 Plate 1

4C-9634 Puller Stud 1

6V-4035 Sleeve 1
F
Double Acting
6V-3175 1
Cylinder
Illustration 808 g00926968
9U-6832 Nut 1
8. Place cylinder (5) on suitable cribbing. Remove four
bolts (12) in order to remove lock valve (2) from the 3S-6224 or 8S- Electric Hydraulic
cylinder. 1
8033 Pump Gp

6D-7726 Hose As 2
233-7208 Seal Guide 1
G

1P-0510 or 1P-
I Driver Gp 1
0520

Note: SERVICE DATA: THE TOOLING IN TABLE 52

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
Illustration 809 g00926969
SERVICEMAN.
9. Remove two O-ring seals (13) from lock valve (2).
31200308 175

Illustration 810 g00943698

a. Install bearing (1). Install the bearing to depth (X) from the
bottom face before installing lip seals (2).

Dimension (X).............. 7 ± 0.5 mm (0.276 ± 0.020 inch)

b. Install bearing (12). The bearing must not extend beyond
either face of the cylinder eye.
c. Apply Tooling (B) to the seal groove prior to the installation
of the wiper seal (8). Lubricate the lip of wiper seal (8),
seal (7), and wear ring (6) with the lubricant that is being
sealed.
d. Lubricate the threads of self-locking nut (3) with Tooling
(C). Use a 65 mm socket for the removal and for the
installation of the self-locking nut. The torque setting for
the self-locking nut 1600 ± 160 Nm (1180 ± 120 lb ft)
Illustration 811 g00926969
e. Lubricate piston seals (4) and wear ring (5) with
the lubricant that is being sealed. 2. Apply a thin coat of 1U - 6396 O-Ring Assembly
f. Lubricate O-ring seal (9), the backup ring and
Compound onto O-ring seals (13) before installing
O-ring seal (10) with the lubricant that is being the seals in lock valve (2).
sealed.
g. Lubricate the threads of head (11) with Tooling (C). The
torque setting for head (11) 600 ± 130 Nm
(445 ± 95 lb ft)

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
176 31200308

Illustration 812 g00926968 Illustration 815 g00926966

3. Position lock valve (2) onto cylinder (5) and install 6. Use the hoist to position the rod end of cylinder
four bolts (12) with the washers. (5). Align the bore in the cylinder with bores in
bracket (8) and install pin (7), bolt (8), the spacer
and the washer. Remove the nylon lifting sling.

Illustration 813 g00935778

4. Attach a suitable nylon lifting sling around cylinder
(5) and to a suitable hoist. Lift the cylinder toward Illustration 816 g00926963
the machine. The weight of the cylinder is
7. Connect harnesses (3) to solenoids (4).
approximately 38 kg (84 lb).
Note: Make sure that lock valve (2) is facing
downward.

Illustration 817 g00926962

8. Connect three hoses (1) to lock valve (2).
Illustration 814 g00926967
5. Use the hoist to position cylinder (5). Align the
bore in the cylinder with bores in chassis (11) and
install pin (10), bolt (9) and the washer.
31200308 177

the fluid with suitable containers before opening any

compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all lines, on all hoses
and on all wires for installation purposes. Plug all
lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.

Illustration 818 g00926552

9. Remove the cribbing that was installed in the
removal procedure between the chassis and the
rear axle on both sides of the machine.

Load Control Valve (Frame

Leveling Cylinder) - Remove
and Install
Removal Procedure Illustration 819 g00926493
2. Before removing the lock valve at the rear, install
suitable cribbing on both sides of the machine
between the chassis and the rear axle.

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
Ensure all pressure is relieved before removing a lock
valve or disassembling a cylinder.

Illustration 820 g00926495

Personal injury can result from hydraulic oil 3. Disconnect three hoses (1) from lock valve (2).
pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
Care must be taken to ensure that fluids are contained Illustration 821 g00926496
during performance of inspection, maintenance, testing, 4. Disconnect harnesses (3) from solenoids (4).
adjusting and repair of the product. Be prepared to collect
178 31200308

Illustration 822 g00926497 Illustration 825 g00926495

5. Remove four bolts (5) and the washers in order to 5. Connect three hoses (1) to lock valve (2).
remove lock valve (2) from cylinder (6).
6. Remove two O-ring seals (not shown) from the
mating face of lock valve (2).

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 826 g00926493

6. Remove the cribbing that was installed in the
removal procedure from both side of the machine
between the chassis and the rear axle.

Compensating Cylinder
Remove and Install
Illustration 823 g00926497 Removal Procedure
2. Install new O-ring seals (not shown) into the
Table 53
mating face of lock valve (2).
3. Position lock valve (2) on cylinder (6) and install Required Tools
four bolts (5) with the washers. Tool Part Number Part Description Qty
1P-0074 Slide Hammer Puller 1
A
8B-7556 Adapter 1

Illustration 824 g00926496

4. Connect harnesses (3) to solenoids (4).
31200308 179

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be Illustration 827 g00924952
installed. 3. Disconnect two hoses (2) from cylinder (1).

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the Illustration 828 g00924954
filler cap is cool enough to touch with your bare 4. Attach a suitable nylon lifting sling around cylinder
hand. (1) and to a suitable hoist in order to support the
NOTICE cylinder. The weight of the cylinder is approximately
Care must be taken to ensure that fluids are contained 20 kg (44 lb).
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.

1. The following procedure shows the removal of

the compensating cylinder on the right side of the
machine. Use the same procedure to remove
the compensating cylinder on the left side of the
Illustration 829 g00924955
machine.
5. Remove bolt (3) and the washer which secures pin
2. Put identification marks on all hoses, on all lines
(4). Install Tooling (A) in order to remove the pin out
and on all tubes for installation purposes. Plug all
of cylinder (1) and the chassis.
lines, all hoses and all tubes. This helps to prevent
fluid loss and this helps to keep contaminants
from entering the system.
180 31200308

FT-2802 Plate 1
2J-3507 Full Nut 1
3K-5234 Hard Washer 1
Double Acting
6V-3175 1
Cylinder
F 9U-6832 Nut 1
4C-9634 Puller Stud 1
6V-4035 Sleeve 1

3S-6224 or 8S- Electric Hydraulic

1
8033 Pump Gp
Illustration 830 g00925025
6. Use the hoist and lift cylinder (1) out of the chassis. 6D-7726 Hose As 2
7. Remove bolt (5), the washer and plate (6).
1P-0510 or 1P-
G Driver Gp 1
0520

Note: SERVICE DATA: THE TOOLING IN TABLE 54

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.

Illustration 831 g00925028

8. Slide cylinder (1) off pin (7) and away from the
machine. Remove spacer (8).

Disassembly and Assembly

Information
Table 54

Required Tools
Tool Part Number Part Description Qty
Bearing Mount
A 7M-7456 1
Compound
Multipurpose
B 1P-0808 1
Grease
9U-7868 Spanner Wrench 1
D
127-8064 Adapter Plate 1
E 9U-6539 Adapter Plate 1
31200308 181

Illustration 832 g00943330

a. Install bearings (1). The bearing must not extend beyond
either face of the cylinder eye or the rod eye.
b. Apply Tooling (A) to the seal groove prior to the installation
of the wiper seal (7). Lubricate the lip of wiper seal (7),
seal (6) and wear ring (5) with the lubricant that is being
sealed.
c. Use a 36 mm socket for the removal and for the installation
of bolt (2). The torque setting for the bolt 850 ± 25 Nm
(625 ± 20 lb ft)
d. Lubricate piston seals (3) and wear ring (4) with the
lubricant that is being sealed.
e. Lubricate O-ring seal (8), the backup ring and O-ring seal
(9) with the lubricant that is being sealed.
f. Lubricate the threads of head (10) with Tooling (B). The Illustration 833 g00935779
torque setting for head (10) 600 ± 130 Nm (440 ± 95 lb ft) 3. Attach a suitable nylon lifting sling around cylinder
(1) and to a suitable hoist. Make sure that the ports
Installation Procedure in the cylinder are pointing upward. Lift the cylinder
toward the machine. The weight of the cylinder is
1. The following procedure shows the installation
approximately 20 kg (44 lb).
for the compensating cylinder on the right side of
the machine. Use the same procedure to install
the compensating cylinder on the left side of the
machine.
2. Clean all parts and inspect all parts. If any parts
are worn or damaged, use new Caterpillar parts
for replacement.
182 31200308

Illustration 834 g00925028 Illustration 837 g00924954

4. Install spacer (8) onto pin (7). Align the bore in 8. Remove the nylon lifting sling from cylinder (1).
cylinder (1) with pin (7) and then slide the cylinder
onto the pin.

Illustration 838 g00924952

9. Connect two hoses (2) to cylinder (1).
Illustration 835 g00925025
5. Install plate (6), bolt (5) and the washer. Axle Lock Cylinder - Remove
6. Carefully lower cylinder (1) into the chassis.
and Install
Removal Procedure

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Failure to relieve pressure before removing a lock
valve or disassembling a cylinder can result in
personal injury or death.
Illustration 836 g00935780 Ensure all pressure is relieved before removing a
7. Align the bore in cylinder (1) with the bores in the lock valve or disassembling a cylinder.
chassis and install pin (4). Install bolt (3) and the
washer which secures the pin.
31200308 183

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the Illustration 839 g00943696
filler cap is cool enough to touch with your bare 2. Before removing the cylinder for the axle lock,
hand. install suitable cribbing on both sides of the
machine between the chassis and the rear axle.

Personal injury or death can result from improper

lifting or blocking.
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be Illustration 840 g00926964
installed. 3. Disconnect two hoses (1) from lock valve (2).
NOTICE 4. Disconnect harness (3) from solenoid (4).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Put identification marks on all lines, on all hoses
and on all wires for installation purposes. Plug all
lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
Illustration 841 g00926973
5. Attach a suitable nylon lifting sling around cylinder
(5) and to a suitable hoist. Take up the tension but
do not lift the cylinder. The weight of the cylinder is
approximately 38 kg (84 lb).
184 31200308

Illustration 842 g00926974 Illustration 845 g00926997

6. Remove bolt (6), the washer and the spacer that 9. Remove two O-ring seals (13) from lock valve (2).
secures pin (7) to bracket (8). Remove the pin out of
the bracket and the cylinder (5). Use the hoist and
carefully lift the rod end of the cylinder out of the
bracket.

Illustration 843 g00926975

7. Remove bolt (9) and the washer that secures pin
(10) to chassis (11). Remove the pin out of the
chassis and the cylinder (5). Use the hoist and
carefully lift the cylinder from the machine.

Illustration 844 g00926996

8. Place cylinder (5) on suitable cribbing. Remove four
bolts (12) in order to remove lock valve (2) from the
cylinder.
31200308 185

Disassembly and Assembly

Information
Table 55

Required Tools
Tool Part Number Part Description Qty

Hydraulic Cylinder
A 1
Repair Stand

Bearing Mount
B 7M-7456 1
Compound
Multipurpose
C 1P-0808 1
Grease
D 4C-8092 Universal Wrench 1
9U-7868 Spanner Wrench 1
E
127-8064 Adapter Plate 1
FT-2802 Plate 1
2J-3507 Full Nut 1
3K-5234 Hard Washer 1
4C-9634 Puller Stud 1
6V-4035 Sleeve 1
F Double Acting
6V-3175 1
Cylinder
9U-6832 Nut 1

3S-6224 or 8S- Electric Hydraulic

1
8033 Pump Gp

6D-7726 Hose As 2
G 233-7206 Seal Guide 1

1P-0510 or 1P-
H Driver Gp 1
0520

Note: SERVICE DATA: THE TOOLING IN TABLE 55

MAY NOT BE IDENTIFIED IN THE FOLLOWING
PHOTOGRAPHS. THIS TOOLING IS SHOWN IN
ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
186 31200308

Illustration 846 g00944212

a. Install bearing (1). Install the bearing to depth (X) from the
bottom face before installing lip seals (2).
Dimension (X) 7 ± 0.5 mm (0.276 ± 0.020 inch)
b. Install bearing (12). The bearing must not extend beyond
either face of the cylinder eye.
c. Apply Tooling (B) to the seal groove prior to the installation
of the wiper seal (8). Lubricate the lip of wiper seal (8),
seal (7) and wear ring (6) with the lubricant that is being
sealed.
d. Lubricate the threads of self-locking nut (3) with Tooling
(C). Use a 60 mm socket for the removal and for the
installation of the self-locking nut. The torque setting for
the self-locking nut 1600 ± 160Nm (1180 ± 120 lb ft).
e. Lubricate piston seals (4) and wear ring (5) with Illustration 847 g00926997
the lubricant that is being sealed. 2. Apply a thin coat of 1U - 6396 O-Ring Assembly
f. Lubricate O-ring seal (9), the backup ring and Compound onto O-ring seals (13) before installing
O-ring seal (10) with the lubricant that is being the seals into lock valve (2).
sealed.
g. Lubricate the threads of head (11) with
Tooling (C). The torque setting for head

Installation Procedure
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
31200308 187

Illustration 848 g00926996 Illustration 851 g00926974

3. Position lock valve (2) onto cylinder (5) and install 6. Use the hoist to position the rod end of cylinder
four bolts (12) with the washers. (5). Align the bore in the cylinder with bores in
bracket (8) and install pin (7), bolt (8), the spacer
and the washer. Remove the nylon lifting sling.

Illustration 849 g00935777

4. Attach a suitable nylon lifting sling around cylinder
(5) and to a suitable hoist. Lift the cylinder toward Illustration 852 g00926964
the machine. The weight of the cylinder is 7. Connect harness (3) to solenoid (4). Connect two
approximately 38 kg (84 lb). hoses (1) to lock valve (2).
Note: Make sure that lock valve (2) is facing upward.

Illustration 853 g00943696

8. Remove the cribbing that was installed in the
Illustration 850 g00926975
removal procedure on both sides of the machine
5. Use the hoist to position cylinder (5). Align the between the chassis and the rear axle.
bore in the cylinder with bores in chassis (11) and
install pin (10), bolt (9) and the washer.
188 31200308

Shutoff Valve (Axle Lock) -

Remove and Install
Removal Procedure

Cylinders equipped with lock valves can remain

pressurized for very long periods of time, even
with the hoses removed.
Failure to relieve pressure before removing a lock Illustration 854 g00946143
valve or disassembling a cylinder can result in 1. Before removing the shutoff valve at the rear,
personal injury or death. install suitable cribbing on both sides of the
Ensure all pressure is relieved before removing a machine between the chassis and the rear axle.
lock valve or disassembling a cylinder.

Personal injury can result from hydraulic oil

pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been
lowered to the ground, and the oil is cool before
Illustration 855 g00946144
removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the 2. Disconnect two hoses (1) from lock valve (2).
filler cap is cool enough to touch with your bare 3. Disconnect harness (3) from solenoid (4).
hand. 4. Remove four bolts (5) and the washers in order to
NOTICE remove lock valve (2) from cylinder (6).
Care must be taken to ensure that fluids are contained 5. Remove two O-ring seals (not shown) from the
during performance of inspection, maintenance, testing, mating face of lock valve (2).
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any Installation Procedure
compartment or disassembling any component
containing fluids. 1. Clean all parts and inspect all parts. If any parts are
Dispose of all fluids according to local regulations and worn or damaged, use new Caterpillar parts for
mandates. replacement.

Note: Put identification marks on all lines, on all hoses

and on all wires for installation purposes. Plug all lines
and all hoses. This helps to prevent fluid loss and this
helps to keep contaminants from entering the system.

Illustration 856 g00946144

31200308 189

2. Install new O-ring seals (not shown) into the

mating face of lock valve (2).
3. Position lock valve (2) on cylinder (6) and install
four bolts (5) with the washers. Personal injury or death can result from improper
lifting or blocking.
4. Connect harness (3) to solenoid (4).
When a hoist or jack is used to lift any part or
5. Connect two hoses (1) to lock valve (2). component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a
component. Install blocks or stands before
performance of any work under a heavy
component.
Approximate weights of the components are
shown. Clean all surfaces where parts are to be
installed.

Personal injury can result from hydraulic oil

pressure and hot oil.
Illustration 857 g00946143
Hydraulic oil pressure can remain in the hydraulic
6. Remove the cribbing that was installed in the system after the engine has been stopped. Serious
removal procedure from both side of the machine injury can be caused if this pressure is not released
between the chassis and the rear axle. before any service is done on the hydraulic system.
Make sure all of the attachments have been
Stabilizer - Remove lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil
Removal Procedure filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
Table 56 hand.
Required Tools
Tool Part Number Part Description Qty NOTICE
4C-6486 Stand 1 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
8S-7621 Tube 1
A adjusting and repair of the product. Be prepared to collect
8S-8048 Saddle 1 the fluid with suitable containers before opening any
8S-7615 Pin 1 compartment or disassembling any component
containing fluids.
B 1U-9200 Lever Puller Hoist 1
Dispose of all fluids according to local regulations and
C 6V-6146 Load Leveling Beam 1 mandates.
D 138-7575 Link Bracket 2 1. Put identification marks on all hoses, on all tubes
E 1U-9200 Lever Puller Hoist 2 and on all wires for installation purposes. Plug all
hoses and all tubes. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
190 31200308

Illustration 858 g00924588 Illustration 861 g00924591

2. Start the engine and install Tooling (A) under hitch 5. Disconnect harness (5) from harness (6). Trace
(1) in order to support the boom assembly. Make harness (5) toward the stabilizer frame and cut any
sure that Tooling (A) is fully extended. Shut off the cable straps which secure the harness.
engine. Remove cover (2). Note: Harness (5) is removed with the stabilizer frame.

Illustration 859 g00924589 Illustration 862 g00924592

3. Attach two suitable nylon lifting slings around 6. Raise the engine hood. Disconnect harness (7)
stabilizer arms (3). Connect Tooling (B) between the from harness (8). Trace harness (7) toward the
slings and take up the tension. This will hold the stabilizer frame and cut any cable straps that
stabilizer arms in a vertical position. secure the harness.
Note: Harness (7) is removed with the stabilizer frame.

Illustration 860 g00924590

4. Remove cover (4). Illustration 863 g00924593
7. At the underside of the chassis near the front axle,
disconnect harness (9) from harness (10). Trace
harness (10) toward the stabilizer frame and cut
any cable straps that secure the harness.
31200308 191

Illustration 864 g00924594

Illustration 867 g00988403
8. Loosen the hose clamp in order to disconnect tube
(12) from control valve (11). Disconnect four hoses 10. Attach two suitable nylon lifting slings around
(13) from the control valve. stabilizer frame (15) and to Tooling (C). Install
Tooling (D) to the stabilizer frame. Attach Tooling (E)
between Tooling (C) and Tooling (D). Take up the
tension on the lifting sling before adjusting Tooling
(E). The weight of the stabilizer is approximately
680 kg (1500 lb).

Illustration 865 g00924595

9. Disconnect electrical connector (14) from control
valve (11).

Illustration 868 g00988404

11. Remove eight bolts (16), the nuts and the washers
that secure stabilizer frame (15) to the chassis.

Illustration 866 g00924704

Illustration 869 g00924705

192 31200308

12. Use the hoist and carefully remove stabilizer frame

(15) from the machine. Make sure that you feed the
hoses and harnesses out of the stabilizer frame.

Stabilizer - Install
Installation Procedure
Stabilizer Kit
Note: The following procedure will give the addition
information that is required when a stabilizer kit is
installed for the first time.

Illustration 870 g00927819

1. Remove termination resistor (a1) for the can data
link from harness (9).
2. Install the stabilizer frame. Refer to Disassembly
and Assembly, "Stabilizer - Install".
3. Install the stabilizer cylinders. Refer to
Disassembly and Assembly, "Stabilizer Cylinder -
Install".
4. Install the lock valves. Refer to Disassembly
and Assembly, "Load Control Valve (Stabilizer
Cylinder) - Remove and Install".
5. Install the stabilizer control valve. Refer to
Disassembly and Assembly, "Stabilizer Control
Valve - Remove and Install".
6. The following steps show the location of all hoses,
all tubes and all harness to install the stabilizer kit.
Refer to appropriate Parts Manual for the part
numbers for all components.
31200308 193

Illustration 871 g00925585

a. Install the harness.

Illustration 873 g00925707

Illustration 872 g00925701 c. Connect the electrical connector at location (a3) to the rear
of the stabilizer control valve. Refer to Step 6 in the
Disassembly and Assembly, "Stabilizer - Install" for
b. Connect the electrical connector at location (a2) at the
additional information.
pressure switch on each stabilizer cylinder. The color of
the left side harness is Gray and Brown. The color of the
right side harness is Brown and Brown.
194 31200308

Illustration 874 g00925710

d. At the underside of the chassis near the front axle,
connect the electrical connector at location (a4) to the
main chassis harness. Refer to step 8 in the Disassembly
and Assembly, "Stabilizer- Install" for additional
information.

Illustration 875 g00925846

e. Remove two plastic covers from the right side
of the instrument panel.
f. Find the connector in the main harness at
location (a5) for the left side stabilizer and
install the switch. The harness has a brown tag.
g. Find the connector in the main harness at
location (a6) for the right side stabilizer and
install the switch. The harness has a yellow tag.
31200308 195

Illustration 876 g00925680

calibration can be started. Refer to appropriate Systems
Operation, Testing and Adjusting Manual.
j. The calibration procedure for the solenoids of the
implement control valve is an automatic calibration. All
of the solenoids for the implement control valve can be
calibrated through the Electronic Technician. Refer to
appropriate Systems Operation, Testing and Adjusting
Manual.

Illustration 877 g00925678

h. Install all hoses and all tubes. Refer to illustration 876
and illustration 877 which indicated the correct locations
of the components and the port connections.
i. The implement electronic control module (ECM) must be
configured when the stabilizer has been installed. The
configuration is only for the machine with electrohydraulic
controls. The ECM needs to be configured before a
196 31200308

Stabilizer 2. Attach two suitable nylon lifting slings around

stabilizer frame (15) and to Tooling (C). Install
Table 57 Tooling (D) to the stabilizer frame. Attach Tooling
(E) between Tooling (C) and Tooling (D).
Required Tools
Note: Tooling (B) was installed in the removal
Tool Part Number Part Description Qty
procedure. If the stabilizer frame is installed for the first
4C-6486 Stand 1 time the stabilizer arms must be held in the vertical
8S-7621 Tube 1 position. Attach two suitable nylon lifting slings around
A the stabilizer arms. Connect Tooling (B) between the
8S-8048 Saddle 1 slings and take up the tension. This will hold the
8S-7615 Pin 1 stabilizer arms in a vertical position. Refer to
Disassembly and Assembly, "Stabilizer - Remove".
B 1U-9200 Lever Puller Hoist 1
3. Take up the tension on the lifting slings before
C 6V-6146 Load Leveling Beam 1
adjusting Tooling (E). Carefully lift the stabilizer
D 138-7575 Link Bracket 2 frame toward the machine. The weight of the
E 1U-9200 Lever Puller Hoist 2 stabilizer frame is approximately 680 kg (1500 lb).
4. Guide the stabilizer frame toward the mounting
face on the chassis. At the same time feed the
1. Clean all parts and inspect all parts. If any parts are hoses and harnesses into the stabilizer frame.
worn or damaged, use new Caterpillar parts for
replacement.

Illustration 880 g00988404

5. Install eight bolts (16), the nuts and the washers in
Illustration 878 g00924912 order to secure stabilizer frame (15) to the chassis.
Remove the lifting equipment.

Illustration 881 g00924916

6. Connect electrical connector (14) to control valve
(11).

Illustration 879 g00924914

31200308 197

Illustration 882 g00924917 Illustration 885 g00924920

7. Connect tube (12) to control valve (11) and tighten 10. Feed harness (5) toward the cab and connect the
the hose clamp. Connect four hoses (13) to the harness to harness (6). Install any cable straps
control valve. which were removed at the removal.

Illustration 883 g00924918 Illustration 886 g00924922

8. At the underside of the chassis near the front axle, 11. Install cover (4).
connect harness (9) to harness (10). Install any
cable straps which were removed at the removal.

Illustration 887 g00924923

12. Remove Tooling (B) and the nylon lifting slings
Illustration 884 g00924919 which are supporting stabilizer arms (3).
9. Feed harness (7) toward the engine enclosure and
connect the harness to harness (8). Install any
cable straps which were removed at the removal.
Close the engine hood.
198 31200308

Illustration 888 g00924924

13. Install cover (2). Start the engine and remove
Tooling (A). Lower the boom and stop the engine.
31200308 199
Index Index

A D
Air Conditioner - Install Diverter Valve (Boom Head) -Remove and Install ............. 57
Installation Procedure................................................... 94 Installation Procedure ................................................... 57
Air Conditioner - Install....................................................... 94 Removal Procedure ...................................................... 57
Axle Lock Cylinder - Remove and Install ......................... 182
E
Disassembly and Assembly Information..................... 185
Installation Procedure................................................. 186 Electronic Pilot Valve - Remove and Install
Removal Procedure.................................................... 182 Installation Procedure ................................................... 21
Removal Procedure ...................................................... 19
B Electronic Pilot Valve - Remove and Install ....................... 19
Bank Valve (Implement) -Assemble Electronic Pilot Valve (Stabilizer) - Remove and Install ..... 59
Assembly Procedure..................................................... 28 Installation Procedure ................................................... 60
Bank Valve (Implement) -Assemble................................... 28 Removal Procedure ...................................................... 59
Bank Valve (Implement) -Disassemble Evaporator Coil - Remove and Install ................................ 99
Disassembly Procedure................................................ 22 Installation procedure ................................................. 100
Bank Valve (Implement) -Disassemble .............................. 22 Removal Procedure ...................................................... 99
Bank Valve (Stabilizer) -Assemble
F
Assembly Procedure..................................................... 63
Bank Valve (Stabilizer) -Assemble..................................... 63 Fender - Remove and Install ............................................ 103
Bank Valve (Stabilizer) -Disassemble ................................ 60 Installation Procedure ................................................. 103
Disassembly Procedure................................................ 60 Removal Procedure .................................................... 103
Boom - Assemble............................................................. 122 Frame Leveling Cylinder -Remove and Install ................. 172
Assembly Procedure................................................... 122 Disassembly and Assembly Information ..................... 174
Boom - Disassemble ........................................................ 116 Installation Procedure ................................................. 175
Disassembly Procedure.............................................. 116 Removal Procedure .................................................... 172
Boom - Install ................................................................... 131 Fuel Tank - Install
Installation Procedure................................................. 131 Installation Procedure ................................................... 75
Boom - Remove ............................................................... 114 Fuel Tank - Install............................................................... 75
Removal Procedure.................................................... 114 Fuel Tank - Remove........................................................... 73
Boom Cylinder - Remove and Install................................ 160 Removal Procedure ...................................................... 73
Disassembly and Assembly Information..................... 162 H
Installation Procedure................................................. 163
Heater Coil - Remove and Install
Removal Procedure.................................................... 160
Installation Procedure ................................................... 94
C Removal Procedure ...................................................... 93
Cab - Install Heater Coil - Remove and Install ....................................... 93
Installation Procedure................................................... 80 Hydraulic Oil Lines (Boom) - Install .................................. 140
Cab - Install ........................................................................ 80 Installation Procedure ................................................. 140
Cab - Remove .................................................................... 76 Hydraulic Oil Lines (Boom) -Remove
Removal Procedure...................................................... 76 Auxiliary Hoses (Boom) .............................................. 137
Cab Heater - Install ............................................................ 91 Removal Procedure .................................................... 133
Installation Procedure................................................... 91 Tilt Cylinder Hoses (Boom) ......................................... 134
Cab Heater - Remove ........................................................ 89 Hydraulic Oil Lines (Boom) -Remove ............................... 133
Removal Procedure...................................................... 89 Hydraulic System Pressure -Release .................................. 5
Compensating Cylinder Remove and Install ........................................................................................ 5
Disassembly and Assembly Information..................... 180 Hydraulic Tank - Install
Installation Procedure................................................. 181 Installation Procedure ................................................... 43
Removal Procedure.................................................... 178 Hydraulic Tank - Install....................................................... 43
Compensating Cylinder Remove and Install .................... 178 Hydraulic Tank - Remove
Control Valve (Stabilizer) -Install........................................ 65 Removal Procedure ...................................................... 42
Installation Procedure................................................... 65 Hydraulic Tank - Remove................................................... 42
Control Valve (Stabilizer) -Remove I
Removal Procedure...................................................... 58
Important Safety Information.................................................ii
Control Valve (Stabilizer) -Remove.................................... 58
Counterweight - Remove and Install J
Installation Procedure................................................. 106 Joystick Control - Remove and Install
Removal Procedure.................................................... 104 Installation Procedure ................................................. 102
Counterweight - Remove and Install ................................ 104 Removal Procedure .................................................... 101
Joystick Control - Remove and Install.............................. 101
200 31200308
Index

L Quick Coupler - Remove .................................................. 107

Load Control Valve (Boom Cylinder) - Remove and Install Removal Procedure .................................................... 107
Installation Procedure ................................................. 166 S
Removal Procedure .................................................... 165
Seat - Remove and Install................................................ 102
Load Control Valve (Boom Cylinder) - Remove and Install165
Installation Procedure ................................................. 103
Load Control Valve (Frame Leveling Cylinder) - Remove and
Install Removal Procedure .................................................... 102
Installation Procedure ................................................. 178 Shutoff Valve (Axle Lock) -Remove and Install................ 188
Removal Procedure .................................................... 177 Installation Procedure ................................................. 188
Load Control Valve (Frame Leveling Cylinder) - Remove and Removal Procedure .................................................... 188
Install................................................................................ 177 Solenoid Valve (Frame Leveling) - Remove and Install ..... 56
Load Control Valve (Stabilizer Cylinder) - Remove and Install Installation Procedure ................................................... 56
Installation Procedure ................................................... 73 Removal Procedure ...................................................... 56
Removal Procedure ...................................................... 72 Solenoid Valve (Steering Mode Selector) - Remove
Load Control Valve (Stabilizer Cylinder) - Remove and Install........................................................................... 37
and Install........................................................................... 72 Installation Procedure ................................................... 38
Load Control Valve (Telescoping Cylinder) - Remove and Removal Procedure ...................................................... 37
Install................................................................................ 158 Stabilizer - Install
Installation Procedure ................................................. 159 Installation Procedure ................................................. 192
Removal Procedure .................................................... 158 Stabilizer ..................................................................... 196
Load Control Valve (Tilt Cylinder) - Remove and Install Stabilizer - Install.............................................................. 192
Installation Procedure ................................................. 171 Stabilizer - Remove.......................................................... 189
Removal Procedure .................................................... 171 Removal Procedure .................................................... 189
Load Control Valve (Tilt Cylinder) - Remove and Install .. 171 Stabilizer Cylinder - Remove and Install ............................ 67
M Disassembly and Assembly Information....................... 69
Installation Procedure ................................................... 71
Main Control Valve (Implement) - Install ............................ 35
Removal Procedure ...................................................... 67
Installation Procedure ................................................... 35
Steering Column - Install .................................................... 14
Main Control Valve (Implement) - Remove ........................ 17
Installation Procedure ................................................... 14
Removal Procedure ...................................................... 17
Steering Column - Remove................................................ 11
Master Cylinder (Brake) - Install
Removal Procedure ...................................................... 11
Installation Procedure ................................................... 40
Steering Wheel - Remove and Install
Master Cylinder (Brake) - Install......................................... 40
Installation Procedure ..................................................... 6
Master Cylinder (Brake) -Remove
Removal Procedure ........................................................ 5
Removal Procedure ...................................................... 39
Steering Wheel - Remove and Install................................... 5
Master Cylinder (Brake) -Remove...................................... 39
Sump Guard - Remove and Install
Metering Pump (Steering) -Install
Installation Procedure ................................................. 104
Installation Procedure ..................................................... 9
Removal Procedure .................................................... 104
Metering Pump (Steering) -Install ........................................ 9
Sump Guard - Remove and Install................................... 104
Metering Pump (Steering) -Remove .................................... 6
Removal Procedure ........................................................ 6 T
P Table of Contents................................................................. 1
Telescoping Cylinder - Remove and Install
Piston Pump (Implement and Steering) - Assemble .......... 50
Disassembly and Assembly Information..................... 152
Assembly Procedure..................................................... 50
Installation Procedure ................................................. 153
Piston Pump (Implement and Steering) - Disassemble
Removal Procedure .................................................... 147
Disassembly Procedure................................................ 46
Telescoping Cylinder - Remove and Install...................... 147
Piston Pump (Implement and Steering) - Disassemble ..... 46
Tilt Cylinder - Remove and Install
Piston Pump (Implement and Steering) - Install................. 55
Disassembly and Assembly Information..................... 168
Installation Procedure ................................................... 55
Installation Procedure ................................................. 169
Piston Pump (Implement and Steering) - Remove............. 44
Removal Procedure .................................................... 166
Removal Procedure ...................................................... 44
Tilt Cylinder - Remove and Install .................................... 166
Q
W
Quick Coupler - Assemble
Window Wiper and Wiper Motor (Front) - Remove
Assembly Procedure................................................... 111 and Install........................................................................... 83
Quick Coupler - Assemble ............................................... 111 Installation Procedure ................................................... 84
Quick Coupler - Disassemble........................................... 109 Removal Procedure ...................................................... 83
Disassembly Procedure.............................................. 109 Window Wiper and Wiper Motor (Rear) - Remove and Install
Quick Coupler - Install...................................................... 112 Installation Procedure ................................................... 86
Installation Procedure ................................................. 112
31200308 201
Index

Removal Procedure...................................................... 85
Window Wiper and Wiper Motor (Rear) - Remove
and Install........................................................................... 85
Window Wiper and Wiper Motor (Roof) - Remove and Install
Installation procedure ................................................... 88
Removal Procedure...................................................... 87
Window Wiper and Wiper Motor (Roof) - Remove
and Install........................................................................... 87
202 31200308
Index
Manufactured by JLG under license from Caterpillar
Wire Description Component Identifiers (CID¹) Component Location
Wire Wire
31200310
Wire Color Description Wire Color Description Module Identifier (MID²) Component
Schematic Machine
Component
Schematic Machine
December 15, 2006
Number Number Location Location Location Location Connector Location
Power Circuits Control Circuits (Continued) Engine Control ACCELERATOR G-6 1 SENSOR - FRONT AXLE CENTER F-2 11
Schematic Machine
101 RD Battery (+) 795 YL Quick Coupler Relay
(MID No. 036) ALARM - BACKUP B-18 2 SENSOR - INTAKE MANIFOLD PRESSURE D-8 E Connector Number
102 BU Head Lamp 797 PU Platform Mode Switch ALARM - MONITOR I-5 3 SENSOR - INTAKE MANIFOLD TEMP D-8 E Location Location
103 RD Head Lamp 798 GN Mode Switch
CID Component
0041 ECM (Electronic Control Module) 8 Volt DC Supply
ALARM - PLATFORM I-2 A SENSOR - LEVER BOOM EXTEND/RETRACT K-3 G CONN 1 M-18 A
105 BR Key Switch 799 WH PHS Valves +10V
ALTERNATOR C-6 4 SENSOR - LEVER BOOM RAISE/LOWER K-3 G
108 RD Battery (+) to Product Link 852 GN Cont Flow 0091 Throttle Position Sensor CONN 2 L-18 A
ANTENNA - MSS TIRIS G-6 C SENSOR - LEVER PLATFORM ROTATE L-3 G
109 RD Alt Output (+) Term 854 PK Boom Angle Switch 0100 Engine Oil Pressure Sensor ANTENNA - RADIO G-6 5 SENSOR - LSI STRAIN D-17 39 CONN 3 D-18 50
111 RD Machine Control Battery (+) 856 GN Trigger Switch Parity
0102 Boost Pressure Sensor ARC SUPPRESSOR - CIRCLE K-4 6 SENSOR - MASTER L-2 G CONN 4 B-18 51
112 PU Main Power Relay Output 863 BU Cab/Platform Indicator Switch
0105 Inlet Manifold Temperature Sensor ARC SUPPRESSOR - CRAB L-4 6 SENSOR - OIL PRESSURE D-8 E CONN 5 B-17 52
114 RD Warning Horn (Forward) 867 PU PHS Joystick Grip Control
ARC SUPPRESSOR - LH STAB LOWER G-1 7 SENSOR - REAR AXLE CENTER C-17 40
116 BR Frame Level/Tow 869 PU Cont Flow Switch 0110 Engine Coolant Temperature Sensor CONN 6 E-17 53
ARC SUPPRESSOR - LH STAB RAISE H-1 7 SENSOR - SHIFT RAIL 1 D-11 F
117 RD Lift Pump Battery (+) 870 OR Frame Interlock Relay 0174 Fuel Temperature Sensor
ARC SUPPRESSOR - RH STAB LOWER F-1 7 SENSOR - SHIFT RAIL 2 C-11 F CONN 7 B-16 52
118 GY Front Wiper Motor 874 GY LSI Sensor 0247 SAE J1939 Data Link
119 PK Wiper Motors Switch Power 892 BR CAT Data Link (+)
ARC SUPPRESSOR - RH STAB RAISE G-1 7 SENSOR - SHIFT RAIL 3 C-11 F CONN 8 E-15 52
0253 Personality Module BASE - ITT GRIP F-5 B SENSOR - SLAVE M-2 G
121 YL Accessory Socket 893 GN CAT Data Link (-) CONN 9 E-15 52
122 BU Fuel Injector Relay 900 PU Transmission Shift Solenoid 0262 5 Volt Sensor Power Supply BATTERY 1 A-6 8 SENSOR - TC OIL TEMPERATURE C-11 F
0266 Crank Without Injection Input BATTERY 2 A-6 8 SENSOR - TC SPEED E-10 F CONN 10 L-15 29
123 WH Cold Start Relay 901 WH Transmission Shift Solenoid
124 GN AC Blower (Low) 902 BR Transmission Shift Solenoid 0320 Speed/Timing Sensor BEACON M-17 9 SENSOR - VLPM E-8 F CONN 11 L-14 29
125 OR RH Tail Lamp 911 YL Steering Mode Switch BLOCK - FUSE F-16 D SENSOR - XMSN INT SPEED 1 E-10 F
0342 Secondary Engine Speed Sensor CONN 12 D-13 53
127 OR Boom Floods 913 BU Front Wiper Switch BLOCK - FUSE I-16 D SENSOR - XMSN OIL TEMPERATURE D-10 F
128 PK AC Blower (High) 944 OR CDL (-)
0774 Secondary Throttle Position Sensor BLOCK - RELAY H-16 D SENSOR - XMSN OUT SPEED D-10 F
CONN 13 E-13 53
130 GN Cab Floods 2 945 BR CDL (+) 1627 Fuel Pump Relay BLOCK - RELAY J-16 D SOCKET - ACCESSORY L-15 29 CONN 14 F-13 53
131 BR Cab Floods 1 958 YL Solenoid QC 1639 Machine Security System Module BREAKER - ALTERNATOR B-7 10 SOCKET - ADAPTER M-17 A CONN 15 F-13 53
133 OR PHS 959 WH Arc Suppressor QC 1684 Fuel Injection Pump BREAKER - MAIN C-7 10 SOLENOID - 1 REVERSE A-11 F
135 BU Radio Power 975 WH Solenoid Return
CONN 16 M-13 54
BREAKER - STARTER B-6 10 SOLENOID - 2 FORWARD A-11 F

TH360B Telehandler
1743 Engine Operation Mode Selector Switch
136 GN Auxiliary Circuit 985 GY Crab Steer Relay BUS BAR D-5 E SOLENOID - A/C COMPRESSOR D-6 E CONN 17 M-12 A
141 PK Seat 986 OR Circle Solenoid
1894 Cruise Control Disengage Switch
COIL - FERRITE D-2 11 SOLENOID - AUX DIV H-1 41 CONN 18 M-12 A
1895 Cruise Control Speed Toggle Switch

Electrical System
144 GN Beacon 987 WH Diverter Solenoid CONTROL - ECM (ACCESS PLATFORM) L-1 G SOLENOID - CIRCLE L-4 6
CONN 19 D-11 F
147 PU Auxiliary Div Power 990 GN Diverter Solenoid Machine Control CONTROL - ENGINE C-9 E SOLENOID - CRAB L-4 6
150 RD Engine ECM Battery (+) 991 WH Shift Rail Sensor CONN 20 H-10 29
157 YL Turn Indicator Switch Power 993 BR Accelerator
(MID No. 039) CONTROL - JOYSTICK G-5 B SOLENOID - DIFFERENTIAL LOCK D-10 F
CONTROL - MACHINE E-3 12 SOLENOID - FRAME LEVEL 1 D-2 42 CONN 21 H-10 29
161 RD Hazard Indicator 994 GY Oil Pressure Sensor CID Component S/N TBH00100 & After
CONTROL - MACHINE SECURITY SYSTEM F-1 11 SOLENOID - FRAME LEVEL 2 C-1 42
165 YL Differential Lock Foot Switch 995 BU Coolant Temperature Sensor 0041 ECM (Electronic Control Module) 8 Volt DC Supply CONN 22 E-9 55
CONTROL - PHS VALVE SSV4 C-17 13 SOLENOID - IMPLEMENT DISABLE C-17 13
167 OR Access Platform ECM 997 OR Not Used 0070 Parking Brake Switch CONTROL - PRODUCT LINK H-5 14 SOLENOID - LEFT STAB LOWER G-1 7
CONN 23 L-8 48
Ground Circuits 999 WH Fuel Injector Pump
0096 Fuel Level Sensor CONTROL - SHIFTER K-8 A SOLENOID - LEFT STAB RAISE H-1 7 CONN 24 L-8 48
200 BK Main Chassis A700 OR Accelerator
0110 Engine Coolant Temperature Sensor DISPLAY CLUSTER J-5 C SOLENOID - LOAD SENSE CONTROL B-5 36 CONN 25 L-8 48
205 BK Chassis A701 GY Not Used
FLASHER L-13 15 SOLENOID - RIGHT STAB LOWER G-1 7
229 BK Engine A702 PU Not Used 0177 Transmission Oil Temperature Sensor CONN 26 C-7 E
FLOOD - BOOM LH H-2 16 SOLENOID - RIGHT STAB RAISE G-1 7
A278 BK Fuel Pump Return A703 BR Not Used 0262 5 Volt Sensor Power Supply CONN 27 D-6 56
FLOOD - BOOM RH H-2 17 SOLENOID - SPEED 1 A-10 F
Basic Machine Circuits A704 GN Not Used
0271 Action Alarm
304 WH Starter Relay No. 1 Output A705 BU Not Used
FLOOD - FRONT LH CAB M-1 18 SOLENOID - SPEED 2 A-10 F CONN 28 D-6 E
0368 Transmission Auto/Manual Switch FLOOD - FRONT RH CAB I-1 19 SOLENOID - SPEED 3 A-10 F
306 GN Starter Relay Coil A706 GY Not Used CONN 29 B-5 57
307 OR Key Switch A707 PU Not Used 0444 Starter Motor Relay FLOOD - REAR LH CAB K-16 20 SOLENOID - SPEED 4 A-10 F
FLOOD - REAR RH CAB G-17 21 SOLENOID - SPEED 5 A-10 F CONN 30 I-5 A
308 YL Main Power Relay Coil A708 BR Not Used 0489 Trigger Switch (Aux.) of Joystick Control
317 YL Cold Start Relay A709 OR Not Used 0490 Implement Lockout Switch FUSE - FUEL PUMP C-6 E SOLENOID - SYNC MOD A-11 F CONN 31 M-4 58
GPS VHF H-5 A SOLENOID -QC H-1 44
321 BR Backup Alarm A710 GY Air Restriction Indicator
0590 Engine Control Module CONN 32 M-4 58
322 GY Warning Horn (Forward) A711 PU Not Used HEATER - COLD START A-7 E SPEAKER - LH L-17 A
0629 Neutralizer Switch HORN J-5 14 SPEAKER - RH H-17 A
CONN 33 G-3 59
323 WH Fuel Pump Power A712 BR Not Used
324 BU Differential Lock Solenoid A746 PK Not Used 0668 Transmission Shift Lever LAMP - ACTION I-1 G SUPPRESSOR - BACKLIGHT SIGNAL H-5 A CONN 34 K-3 60
325 PK Fuel Pump Relay Cut-out C712 BR Right Stabilizer Down Pressure Switch 0702 Transmission Gear Lever Selector Sensor (Switch) LAMP - DOME I-17 A SUPPRESSOR - FRAME LEVEL 1 D-1 35 CONN 35 L-3 G
329 YL Fuel Pump to Switch C713 GY Left Stabilizer Down Pressure Switch 0750 Rear Steering Manual Switch LAMP - HEAD LH M-4 22 SUPPRESSOR - FRAME LEVEL 2 C-1 35
332 BU Shutdown Switch to Shutdown Control C743 PK Parking Brake Switch Disengaged
CONN 36 I-2 13
LAMP - HEAD RH B-1 26 SUPPRESSOR - FRAME LEVEL DUMP POS 1 C-1 35
0811 Gauge Cluster #1
352 BU Start Relay No. 1 Resistor to Diagnostic C744 PU Parking Brake Switch Engaged LAMP - REG PLATE 1 E-18 24 SUPPRESSOR - FRAME LEVEL DUMP POS 2 C-1 35 CONN 37 F-2 35
375 BR Cold Start Relay to Engine ECM C903 BU Stabilizer Relay 1
0826 Torque Converter Oil Temperature Sensor
LAMP - REG PLATE 2 D-18 24 SWITCH - A/C HIGH PRESSURE E-6 E CONN 38 C-2 61
A309 GY Fuel Lift Pump C905 OR Stabilizer Relay 2 1127 Position Sensor - (Fwd./Back Lever) of Joystick Control LAMP - STOP/TAIL/TURN/REV LH E-18 23 SWITCH - AIR RESTRICTION INDICATOR E-7 E
CONN 39 E-1 62
A310 BU Transmission Temperature Switch (V+) C917 YL RH Stabilizer Switch 1128 Position Sensor - (Left/Right) of Joystick Control LAMP - STOP/TAIL/TURN/REV RH B-18 25 SWITCH - BEACON J-8 C
Monitoring Circuits C919 PU LH Stabilizer Switch The connectors shown in this chart are for harness to harness connectors.
1187 Continuous Flow Switch LAMP - STOP/TURN/TAIL/FOG LH F-18 23 SWITCH - BLOWER ON E-6 E
403 GN Alternator Terminal C967 BU Intake Manifold Temperature Sensor Connectors that join a harness to a component are generally located at or near
1189 Position Sensor - (Aux. Hyd.) R Thumb of Joystick Control LAMP - STOP/TURN/TAIL/FOG RH A-18 25 SWITCH - BOOM FLOOD F-9 B
428 OR Opr Mon Transmission Oil Temperature C993 WH Shift Rail Sensor
443 YL Power Train Temperature Gauge E528 PU HVAC Blower 1251 Alternator R-Terminal Signal MODULE - A/C E-6 E SWITCH - CAB FLOOD F-8 B the component. See the Component Location Chart. Volume 1 - EROPS
MODULE - LOAD LIMIT M-3 G SWITCH - CAB PLATFORM SELECT F-10 B
447 PK Fuel Level Gauge E529 YL HVAC Blower 1326 ECM Location Code
MOTOR - BLOWER I-11 28 SWITCH - CONT FLOW H-7 C Manufactured by JLG under license from Caterpillar
A487 PU Opr Mon Fault Alarm No. 2 E798 PK Not Used 1401 Transmission Solenoid 1 MOTOR - FRONT WASHER K-13 29 SWITCH - DEADMAN J-3 G
C444 YL Alternator Indicator Lamp E900 WH Transmission Out Speed Sensor
1402 Transmission Solenoid 2 MOTOR - FRONT WIPER L-4 14 SWITCH - DIFFERENTIAL LOCK FOOT L-7 45
E450 GN Oil Filter Bypass Switch E901 GN Transmission Out Speed Sensor
Accessory Circuits
1403 Transmission Solenoid 3 MOTOR - FUEL LIFT PUMP A-7 E SWITCH - DIMMER J-7 C
E902 PU Transmission Intermediate Speed Sensor
1404 Transmission Solenoid 4 MOTOR - REAR WASHER K-13 28 SWITCH - DISCONNECT A-7 E
500 BR Wiper - Front (Park) E903 YL Transmission Intermediate Speed Sensor
MOTOR - REAR WIPER I-17 30 SWITCH - ENGINE START J-1 G
501 GN Wiper - Front (Low) E908 BR Sensor 1405 Transmission Solenoid 5
502 OR Wiper - Front (Hi) E909 WH Sensor MOTOR - ROOF WASHER K-13 28 SWITCH - ENGINE STOP J-3 G
1406 Transmission Solenoid 6
503 BR Wiper - Rear (Park) E960 OR Engine Shutdown Switch MOTOR - ROOF WIPER J-17 31 SWITCH - FOG LAMP H-8 C
1407 Transmission Solenoid 7 MOTOR - SEAT PUMP G-11 28 SWITCH - FRAME LEVELING H-6 C
504 YL Wiper - Rear (Low) E965 BU Engine Speed Sensor
506 PU Washer - Front E966 YL Engine Speed Sensor
1410 Transmission Solenoid 10 MOTOR - STARTER B-6 32 SWITCH - FRONT WASHER F-7 B
507 WH Washer - Rear F700 BU Not Used 1529 Quick Coupler Switch PUMP - FUEL INJECTOR E-8 E SWITCH - FRONT WIPER F-7 B
19 9 30
508 PU Speaker - Left F701 BR Not Used 1530 Quick Coupler Solenoid RELAY - AUX DIV GROUND G-15 D SWITCH - HAZARD J-6 C 31
RELAY - AUX DIV POWER G-15 D SWITCH - HEAD/SIDE LAMP J-7 C
5
509 WH Speaker - Left (Common) F702 GN Accelerator Signal 1603 Data Link 18 20 21
511 BR Speaker - Right F703 GY Not Used
1658 Position Sensor - Left Thumb Lever of Joystick Control
RELAY - BLOWER HIGH I-11 15 SWITCH - HEAT/AC F-6 B Electrical Schematic Symbols And Definitions
512 GN Speaker - Right (Common) F705 PK Not Used RELAY - BLOWER MEDIUM HIGH I-10 15 SWITCH - HORN K-5 C
513 OR AC Compressor/Refrigerant Pressure Switch F706 PU Not Used 1740 Crab Steering Solenoid RELAY - CIRCLE STEER J-15 D SWITCH - HVAC BLOWER F-6 B
A
515 GY Blower Motor (High) F707 WH Not Used 1741 Circle Steering Solenoid RELAY - COLD START A-7 10 SWITCH - IMPLEMENT DISABLE F-10 B
T
516 GN Blower Motor (Medium) F708 YL Not Used 1763 Operator Station Selector Switch RELAY - CRAB STEER J-16 D SWITCH - KEY START G-6 C 17
Pressure Temperature Level Flow Circuit Breaker
517 BU Blower Motor (Low) F709 BU Not Used RELAY - FRAME LEVEL INTERLOCK G-16 D SWITCH - LH STAB H-6 C
1788 Right Stabilizer Operator Switch 16 Symbol Symbol Symbol Symbol Symbol
518 OR Hazard Flasher to Switch F710 BR Lift Pump RELAY - FUEL PUMP B-6 10 SWITCH - LH STAB PRESSURE H-1 46
1789 Left Stabilizer Operator Switch 38 B
521 YL AC Switch to Refrigerant Switch F711 GN CAN Link + RELAY - LIFT PUMP G-15 D SWITCH - MAN VSC K-8 A 60 33 52
1820 Auxiliary Implement Diverter Relay C
522 WH AC Clutch to Thermostat Switch F712 GY CAN Link - RELAY - MAIN POWER G-13 33 SWITCH - OIL FILTER BYPASS D-7 E 7 12 54 Normally Open switch that will close with an increase of a specific condition (temp-press-etc.).
41 14 The circle indicates that the component has screw terminals and a wire can be disconnected from it.
523 BR Roof Wiper F714 PK Not Used 1823 Position Sensor - Shift Rail No.1 RELAY - QUICK COUPLER POWER J-15 D SWITCH - PARK BRAKE M-13 A
44 6 3 E
524 BU Roof Wiper F715 PU Not Used 1824 Position Sensor - Shift Rail No.2 36 11 58 D
RELAY - REVERSE LAMPS J-15 D SWITCH - PLATFORM MODE J-2 G 10 50 51 Normally Closed switch that will open with an increase of a specific condition.
529 WH Roof Washer F716 WH Not Used 1 34 No circle indicates that the wire cannot be disconnected from the component.
1825 Position Sensor - Shift Rail No.3 RELAY - STABILIZER 1 J-16 D SWITCH - QUICK COUPLER K-7 C 39 48 56 27 23
536 WH Hazard Switch to Turn Switch F717 YL Not Used 53 13
RELAY - STABILIZER 2 G-16 D SWITCH - REAR WIPER F-8 B 47 46 43 24 25
1826 Longitudinal Stability Indicator Sensor 4 29 37
A515 BR Blower Motor No.2 (High) F718 BU Not Used
RELAY - START B-5 10 SWITCH - REV FAN K-6 A 42 45 This indicates that the component has a wire connected to it that is connected to ground.

31200310 VOL 1
A516 PK Blower Motor No.2 (Medium) F719 BR Not Used 1827 Longitudinal Stability System 26 22 59 32 28 49 2
RELAY- QUICK COUPLER GROUND J-15 D SWITCH - RH STAB H-7 C 61 57
C547 OR Blower Motor No. 2 (Medium - Low) F720 GN Not Used 1828 Boon Angle Switch 35 40
RESISTOR - ALTERNATOR C-7 4 SWITCH - RH STAB PRESSURE H-1 47
E554 PK AC Controller to AC Compressor Clutch F721 GY Not Used 1829 Boom Position Status 55 This indicates that the component does not have a wire connected to ground. It is grounded by
Lighting Circuits F722 OR Not Used
RESISTOR - TERMINATING H-5 C SWITCH - ROOF WIPER F-8 B 62 F 8 15 being fastened to the machine.
1830 Boom Telescope Position Status RESISTOR - TERMINATING RES 1A D-17 34 SWITCH - SERVICE BRAKE PRESSURE M-9 1
603 PK Rotary Beacon F727 BU Not Used
604 OR Stop Lamp F729 GN Air Restriction Indicator 1831 Rear Axle Lock Solenoid Switch RESISTOR - TERMINATING RES 2B F-2 35 SWITCH - STEER MODE SELECT K-6 C
RESISTOR - TERMINATING STD A-5 36 SWITCH - STOP LAMP L-8 48 Reed Switch - A switch whose contacts are controlled by a magnet. A magnet closes the
605 YL Turn Lamp - Left F770 BR Fuel Injector Pump 1832 Right Stabilizer Pressure Sensor contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
606 GY Turn Lamp - Right F799 BU Frame Level Dump Position 1/2 SENDER - FUEL E-15 37 SWITCH - TOW HITCH F-9 B
1833 Left Stabilizer Pressure Sensor
608 GN Flood Lamp - Rear F846 PU Machine Security Red LED Signal SENSOR - BOOM LOWERED C-18 2 SWITCH - TURN SIGNAL G-8 A
1834 Ignition Key Switch
610 OR Head Lamp - Basic G757 OR Transmission Neutralizer Switch 2 SENSOR - BOOM RETRACTED M-2 38 SWITCH - XMSN NEUTRAL DISABLE K-7 C Sender - A component that is used with a temperature or pressure gauge. The sender measures
1845 Programmable Hydraulic System Pilot Module #1 SENSOR - COOLANT TEMPERATURE D-8 E THERMOSTAT H-10 28 the temperature or pressure. Its resistance changes to give an indication to the gauge of the
611 PU Head Lamp - Hi G848 GN Machine Security Green LED Signal

42 Page
1846 Programmable Hydraulic System Pilot Module #2 SENSOR - ENGINE SPEED D-8 E
T temperature or pressure.
612 GY Backup Lamp G962 OR Implement Disable Solenoid
614 PU Park/Tail/Dash Lamp G970 BU Flow Control Valve 1847 Programmable Hydraulic System Pilot Module #3 Machine locations are repeated for components located close together.
615 YL Cab Flood Lamp H750 BR Front Axle Center
Access Platform Control A = Located inside of cab. Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity.
616 BU Bucket/Boom Flood Lamps H751 OR Rear Axle Align Switch B = Located inside of right console. It has a coil that makes an electromagnet when current flows through it. The electromagnet can
617 BR Tail/Position Lamp - Left (Road Pkg) Width H764 GY Circle Steer Relay (MID No. 082) C = Located in steering column. open or close the switch part of the relay.
618 YL Tail/Position Lamp - Right (Road Pkg) Width H765 WH Crab Steer Relay CID Component D = Located around relay panel.
619 GN Head Lamp (Low) H802 GY Proportional Driver Return (5-8) 0271 Action Alarm E = Located under engine cowl. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that
627 YL Fog Lamp J755 BU Left Frame Level Solenoid Return F = Located on the transmission.
makes an electromagnet when current flows through it. The electromagnet can open or close
0324 Warning Lamp (Action) 61 a valve or move a piece of metal that can do work.
649 YL Light Switch to Park/Tail Lamp Breaker J756 BR Right Frame Level Solenoid Return G =Located on the access platform. 8
676 PU Auxiliary Active Lamp J757 PU Stabilizer Relay 2
0337 Remote Emergency Stop Switch
4 32
1125 Position Sensor (Handle Control - Boom Raise/Lower) 10
Control Circuits J758 PK Frame Level Solenoid 47 Component, Connector, Harness And Wire Symbols
750 GN Platform Mode Switch J759 GN Stabilizer Relay 1 1127 Position Sensor (Handle Control - Platform Rotate)
751 GN Transmission Shift Solenoid - Forward J760 YL Frame Level Solenoid 22 E
1763 Operator Station Selector Switch 42 56 25 Harness Identification Letter(s):
752 YL Transmission Shift Solenoid - Reverse J764 BR Oil Filter Bypass Switch Wire, Cable, or Harness Assembly Identification:
(A, B, C, ..., AA, AB, AC, ...)
753 GY Cab Platform Select Switch J766 PU Platform Mode Switch 1772 Remote Operator Station Lockout Switch 26 57 Includes Harness Identification Letters and Harness
39 Connector Serialization Codes
754 BU Transmission Shift Solenoid No. 1 or 3 J811 BK On/Off Return 1879 Position Sensor (Handle Control - Boom Extend/Retract) 12 F Harness Connector Serialization Code:
Harness identification code
755 OR Transmission Shift Solenoid No, 4 or 5 J843 BK Machine Security LED Ground 60 50
17 59 This example indicates The "C" stands for "Connector" and the number
756 WH Transmission Lockup Clutch Solenoid J847 GN Monitor Alarm Shift Lever ECM 38 52 wire 135 in harness "AG". Part Number for indicates which connector in the harness. (C1, C2, C3, .....)

757 PU Transmission Neutral Disable Switch J998 BU Action Lamp (MID No. 117) 13 Connector Plug
Part Number For
36 7 35 55 40 2 43 24 C-C4 AG-C3 AG-C4 L-C12 Connector Recepticle
758 GN Boom Lower Switch K791 OR Rev Fan Switch 41 130-6795 130-6795 3E-5179
CID Component 111-7898
759 OR Steer Mode Select Switch L730 OR Oil Pressure Sensor
44 34 325-AL135 PK-14
0168 Electrical System Voltage 16 62 11 325-AG135 PK-14 1 5A
760 PK Steer Mode Select Switch L731 BR Coolant Temperature Sender 51
53
761 GY Steer Mode Select Switch L740 BR Transmission Oil Temperature Sender 0668 Transmission Shift Lever 18 20 Socket
14 B
Pin
Wire Color Receptacle Fuse (5 Amps)
762 YL Boom Retract Switch N805 BU Access Platform Load Limiting 22 54 33 Wire Gauge
763 BU Quick Coupler Switch N806 BR Access Platform
Machine Security 6
C 27 Single Wire Circuit
764 PU Quick Coupler Switch N932 PU Platform Mode Switch (MID No. 124) 1 28 49 23 Connector Identification
Ground
Connection
Plug

765 OR Quick Coupler Switch N957 PK Product Link 3 A 30 Number 2 200-L32 BK-14
CID Component 31 9 Component
766 GN Service Brake Pressure Switch N960 OR Product Link 46 Pin or Socket Part Number
0168 Electrical System Voltage 58 48 D Number
767 WH Lever Platform Rotate N970 YL Product Link 105-9344
29
768 OR LH Stab Pressure Switch N973 BR Product Link 0248 CAT Data Link 45 37
19 15 5 21
769 BU Mn VSC Switch N979 GN Product Link 1 Deutsch connector:
1 Sure-Seal connector:
0817 ECM Internal Backup Battery The plug contains all sockets The plug and receptacle contain
770 GN Boom Extend/Retract P909 PK Man VSC Switch 2 2
and the receptacle contains all pins. both pins and sockets.
772 BR Deadman Switch P916 OR Shift Rail Sensor 1391 Theft Deterrent Output Driver #1
773 GY Deadman Parity Switch P936 GY Frame Level Solenoid 1392 Theft Deterrent Output Driver #2
774 YL Implement Diable T800 OR +8V Digital Sensor Power
¹ The CID is a diagnostic code that indicates which circuit is faulty.
775 BR Left Stab Raise T901 YL Machine Secutriy Exciter Coil (In)
776
778
YL
BR
Left Stab Hold
RH Stab Switch
T902
T941
PK
BR
Machine Security Exciter Coil (Out)
Switch (Note D)
² The MID is a diagnostic code that indicates which electronic control module-
diagnosed the fault. Machine Harness Connector And Component Locations
779 WH RH Stab Switch T942 PK Switch (Note D)
780 PU PHS Joystick Grip Control T943 GY Switch (Note D)
781 PK PHS Joystick Y Axis T944 GN Switch (Note D)
782 GY PHS Joystick X Axis X731 BU Intake Manifold Temperature Sender
783 OR Frame Level Disable Relay X750 OR Fwd./Rev. Solenoid Return from Controller
784 YL Left Stab Lower X753 YL Left/Right Steering Solenoid Return
785 PK Right Stab Lower Y758 PK PHS Address (Out)
786 GN Boom Lowered Y759 YL PHS Address (In)
787 WH RH Stab Pressure Switch Y761 OR PHS Address (In)
788 YL Boom Angle Switch Y787 WH PHS Valve
790 BU Boom Retract Switch Y788 GY PHS Valve
791 PK Lever Boom Raise/Lower Y792 PK Fuel Injector Pump
792 OR PHS Joystick Grip Control Y793 YL Fuel Injector Pump
793 YL Implement Diable Switch Y794 OR CAN High G
794 YL Auxiliary Diverter Relay Y795 GN CAN Low

Failure Mode Identifiers (FMI)¹ Off Machine Switch Specification

FMI No. Failure Description Part No. Function Actuate Deactuate Contact Position
0 Data valid but above normal operational range. 275 to 2800 kPa¹ 170 to 1750 kPa¹
236-6923 A/C Hi Pressure Normally Open²
(40 to 406 psi.) (25 to 254 psi.)
1 Data valid but below normal operational range.
276 ± 28 kPa 179 kPa
2 Data erratic, intermittent, or incorrect. 203-7984 Oil Filter Bypass Normally Open
(40 ± 4 psi.) (26 psi.)
3 Voltage above normal or shorted high. 6598.2 ± 206.8 kPa 3371.5 ± 689 kPa
295-3455 LH Stab Pressure Normally Open
4 Voltage below normal or shorted low. (957 ± 30 psi.) (489 ± 100 psi.)
6598.2 ± 206.8 kPa 3371.5 ± 689 kPa
5 Current below normal or open circuit. 295-3455 RH Stab Pressure Normally Open
(957 ± 30 psi.) (489 ± 100 psi.)
6 Current above normal or grounded circuit.
¹ With increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained
7 Mechanical system not responding properly.
down to 170 kpa (25psi).
8 Abnormal frequency, pulse width, or period.
² Contact postion at the contacts of the harness connector.
9 Abnormal update.
10 Abnormal rate of change.
11 Failure mode not identifiable.
12 Bad device or component.
13 Out of calibration. Access Platform
14 Parameter failures.
15 Parameter failures.
16 Parameter not available.
17 Module not responding.
18 Sensor supply fault. Resistor, Sender and Solenoid Specifications
19 Condition not met.
Part No. Component Description Resistance (Ohms)¹
20 Parameter failures.
134-2540 Resistors: Terminating/Alternator 120
¹The FMI is a diagnostic code that indicates what type of failure has occurred. 295-3421 Sender: Fuel 33² - 240³
178-9570 Solenoid: A/C Compressor 17.6 ± 0.6
212-3350 Solenoid: Aux. Div./QC 3.2 ± 0.224
195-9700 Solenoid: Differential Lock/Speed 10 ± 0.5
201-0315 Solenoid: Frame Level/Stab. Raise/Lower 10.16 ± 0.3
177-7807 Solenoid: Fwd./Rev./Sync. Mod. 2.2 ± 0.2
200-6210 Solenoid: Implement Disable 10 ± 0.5
¹ At room temperature unless otherwise noted.
² Float at Full Position.
³ Float at Empty Position.
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
H2
CAB LH FR FLOOD
P-C4 212-9347
118-F89 GY- 16
CONN 17 123-F212 WH- 16
1552269
T-C1 F-C9 615-P7 YL - 16 WH-18
200-F192 BK- 16 123-F371 WH- 18 BK-18
3E5179 1552252 H1 200-P11 BK- 16
200-F193 BK- 18 308-F127 YL - 18 141-F109 PK - 18
508-T1 PU- 16 508-F180 PU- 18 200-F194 BK- 18
SERV BK PRESS.
200-F183 BK- 14 CONN 31
WIRE GROUP COLOR DESCRIPTIONS COLOR ABBREVIATIONS SYMBOL DESCRIPTION
206-1483
509-T2 WH- 16 509-F181 WH- 18 200-F195 BK- 18 A310-F175 BU- 16 200-F184 BK- 16 F-C77 R-C5 BOOM RETRACTED HF-C2
NOTE B
200-F398 BK- 18 200-F185 BK- 16 1552269 3E3364 295-3452 1552272
603-T6 PK - 16 603-F47 PK - 16 610-F79 OR- 16 200-F196 BK- 14 WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS OFF. CIRCUIT CONNECTED T901-F165 YL - 18 T901-R9 YL - 16 H23
ABBREV COLOR
POWER BR-16 167-HF1 OR- 16
608-T3 GN- 16 608-F45 GN- 16 200-F196 BK- 14 200-F199 BK- 16 T902-F166 PK - 18 T902-R10 PK - 16 SIG NO BK-16 790-HF2 BU- 18 H4
200-T4 BK- 16 200-F185 BK- 16 200-F183 BK- 14 611-F142 PU- 18 200-F204 BK- 16 WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON. CIRCUIT NOT CONNECTED LH HEAD TURN POS LAMP SIG NC WH-16 762-HF4 YL - 18
BEACON
180-3664
615-T11 YL - 16 615-F9 YL - 16 200-F185 BK- 16 766-F154 GN- 16 200-F248 BK- 14
STARTING CIRCUIT. RD RED 295-3380 LH DIP GROUND BU-16 205-HF3 BK- 18
200-T8 BK- 14 200-F183 BK- 14 200-F199 BK- 16 J764-F155 BR- 16 200-F296 BK- 18 ELECTRICAL CONNECTION TO
M PARK BRAKE SW 200-F248
308-F399
BK- 14
YL - 18 118-F89 GY- 16
205-F228 BK- 16
500-F90 BR- 16 GROUND CIRCUIT. WH WHITE MACHINE STRUCTURE
CONN 32 295-3378 RH DIP
M
6G-4195 F-C39 CG-C1 CG-C2
511-T9 BR- 16
512-T10 GN- 16
511-F179
512-F182
BR- 18
GN- 18 508-F180 PU- 18
200-F184
200-F204
BK- 16
BK- 16
501-F92 GN- 16
502-F101 OR- 16 STARTING AID CIRCUIT. OR ORANGE INTERNAL ELECTRICAL CONNECTION
TO SURFACE OF COMPONENT
1552273 3E3382 1552273
200-T14 BK- 16 V-C13
603-T6 PK - 16 C744-F144 PU- 18
CONN 18 509-F181
511-F179
WH- 18
BR- 18
500-F90
501-F92
BR- 16
GN- 16
605-F156 YL - 16
766-F154 GN- 16 CAT DATA LINK. YL YELLOW CONNECTOR
611-F135 PU- 16 611-CG4 PU- 16 BU-18
RD-18
1552273
C743-F143 PK - 18 619-F81 GN- 16 619-CG6 GN- 16 RD-18 167-V28 OR- 18
SOCKET ADAPTER
178-7539
FA-C1
3E3388
F-C8
1552264
512-F182
518-F348
GN- 18
OR- 16
502-F101
605-F156
OR- 16
YL - 16 985-F151 GY- 16
CAN DATA LINK A. PK PINK 617-F58 BR- 16 617-CG3 BR- 16 WH-18 LOAD LIMIT MODULE
BK-18
OR-18
205-V30 BK- 18
J764-F145 BR- 18 H# CIRCUIT GROUPING DESIGNATION 605-F156 YL - 16 605-CG1 YL - 16 YL-18 N805-V39 BU- 18
235-4398
119-FA1
119-FA2
PK - 16
PK - 16
119-F315
119-F57
PK - 16
PK - 16
536-F122
536-F123
WH- 16
WH- 16
611-F135
617-F58
PU- 16
BR- 16
986-F150
J764-F107
OR- 16
BR- 16
CAN DATA LINK B. BK BLACK 200-F204 BK- 16 200-CG2 BK- 16 BK-18
M W BU-18
J766-V49 PU- 18
CONN 16 102-FA3 RD- 16 102-F316 RD- 16 536-F124 WH- 16 619-F81 GN- 16 J764-F145 BR- 18
ENGINE CONTROL CIRCUIT (MASTER ). GY GRAY ATCH WIRE, CABLE, COMPONENT M
N806-V40 BR- 18
CONN 1 PL-C2 F-C57 503-FA4 BR- 16 503-F49 BR- 16 985-F151 GY- 16 J764-F155 BR- 16 M
ACCESS PLATFORM CONTROL
3E3388 1552264
P-C1 T-C2 603-T6 PK - 16
108-PL1 RD- 18 108-F397 RD- 18
504-FA5
200- 6
YL - 16
BK- 16
504-F51
200-F199
YL - 16
BK- 16
603-F47 PK - 16
615-F3 YL - 16
986-F150
T901-F165
OR- 16
YL - 18 118-F89 GY- 16
MACHINE CONTROL. PU PURPLE CIRCUIT CONNECTED
M OR-18
SENSOR SLAVE 295-3388
1552272 3E3376 BK-18 V-C1
608-P1 GN- 16 608-T3 GN- 16 200-T8 BK- 14
200-PL2
308-PL5
BK- 18
YL - 18
200-F398
308-F399
BK- 18
YL - 18
523-FA7
524-FA8
BR- 16
BU- 16
523-F52
524-F53
BR- 16
BU- 16
676-F207 PU- 16 T902-F166 PK - 18
F712-F332 GY- 16
123-F212 WH- 16
123-F371 WH- 18
PRODUCT LINK. BR BROWN BLADE, SPADE, RING OR SCREW
GN-18
YL-18
WH-18
235-4400 1471445
200-P2 BK- 16 200-T4 BK- 16 N806-V40 BR- 18 M m
TERMINAL
615-P3 YL - 16 615-T11 YL - 16 200-T13 BK- 16
H2
403-PL4
944-PL11
GN- 18
OR- 18
403-F401
893-F393
GN- 18
GN- 16
892-F392
892-F402
BR- 16
BR- 16
892-F268 BR- 16 200-F183 BK- 14
200-F185 BK- 16
141-F109 PK - 18
200-F183 BK- 14
MACHINE SECURITY CONTROL CIRCUIT. GN GREEN M
GN-18
YL-18
GN-18 SENSOR MASTER
200-P4 BK- 16 200-T13 BK- 16 M YL-18 235-4399
HEATER AND AIR CONDITIONER CIRCUIT. SPLICE
945-PL12
Y795-PL10
BR- 18
GN- 18
892-F392
F712-F330
BR- 16
GY- 16 893-F393 GN- 16
200-F199 BK- 16
200-F196 BK- 14
200-F184 BK- 16
200-F185 BK- 16
BU BLUE F-C65 893-V20 GN- 16
200-T4 BK- 16 1552273 892-V18 BR- 16
508-T1 PU- 16
Y794-PL15 OR- 18 F711-F331 GN- 16 893-F403 GN- 16 200-F248 BK- 14 200-F196 BK- 14 TURN SIGNAL/WIPER/WASHER CIRCUIT. 770-V37 GN- 18 M
108-F397 RD- 18 893-F254 GN- 16 308-F399 YL - 18 200-F199 BK- 16 501-F92 GN- 16 GN-16 FRONT WIPER MOTOR
CONN 11 121-F247 YL - 14 508-F180 PU- 18 200-F204 BK- 16 ACCESS PLATFORM CONTROL. 200-F197 BK- 16 BK-16
M
187-2734
CONN 2 509-T2 WH- 16
511-T9 BR- 16
K-C2 K-C1 F-C13 200-F192 BK- 16 F711-F331 GN- 16 509-F181 WH- 18 200-F248 BK- 14
167-V28 OR- 18
N-C1 T-C3 9W1951 3E3388 1552264 200-F193 BK- 18 F711-F232 GN- 16 511-F179 BR- 18 200-F296 BK- 18 118-F89 GY- 16 GY-16
512-T10 GN- 16 205-V30 BK- 18
3E3376 1552272 121-K10 YL - 14 F711-K1 GN- 16 F711-F333 GN- 16 200-F194 BK- 18 F712-F203 GY- 16 512-F182 GN- 18 205-F228 BK- 16 500-F90 BR- 16 BR-16
608-T3 GN- 16 N805-V39 BU- 18 798-V34 GN- 18 M W
508-N1 PU- 18 508-T1 PU- 16 200-K3 BK- 14 F712-K2 GY- 16 F712-F332 GY- 16 200-F195 BK- 18 F712-F233 GY- 16 518-F348 OR- 16 500-F90 BR- 16 502-F101 OR- 16 OR-16
615-T11 YL - 16 N806-V40 BR- 18
511-N2 BR- 18 511-T9 BR- 16 200-K3 BK- 14 200-F248 BK- 14 F712-F332 GY- 16 536-F122 WH- 16 501-F92 GN- 16 V-C3 J766-V49 PU- 18
512-T10 GN- 16 893-K7 GN- 16 200-K9 BK- 14 200-K4 BK- 14 200-F248 BK- 14 200-F398 BK- 18 J764-F145 BR- 18 536-F123 WH- 16 502-F101 OR- 16 9W1951
512-N3 GN- 18
509-N4 WH- 18 509-T2 WH- 16 CONN 10 892-K8 BR- 16 121-F247 YL - 14 308-F399 YL - 18 536-F124 WH- 16 605-F156 YL - 16 CONN 23 167-V9 OR- 16
N805-V39 BU- 18 M

F712-K2 GY- 16 121-K10 YL - 14 121-K5 YL - 14 403-F401 GN- 18 603-F47 PK - 16 F-C40 G-C1 G-C2
L F711-K1 GN- 16 121-K6 YL - 14 893-F403
892-F402
GN- 16
BR- 16
506-F91 PU- 18
507-F56 WH- 18 403-F401 GN- 18
615-F3 YL - 16
676-F207 PU- 16
766-F154 GN- 16
J764-F107 BR- 16
1552272 3E3376
102-G1 RD- 16
1082253
STOP LAMP SW 985-F151 GY- 16
205-V17 BK- 16 767-V35 WH- 18 M
L
893-K7 GN- 16 F-C66 893-V21 GN- 16
518-F348 OR- 16 F711-F232 GN- 16 J764-F145 BR- 18 604-G2 OR- 16 105-8034
CAB ROOF 892-K8 BR- 16
529-F55 WH- 18 C743-F143 PK - 18
H17
F712-F233 GY- 16 J764-F155 BR- 16 200-F184 BK- 16 1552269 CONN 35 892-V19 BR- 16 797-V33
772-V31
PU- 18
BR- 18
M
M
W
W
M

536-F122 WH- 16 C744-F144 PU- 18 J764-F145 BR- 18 985-F151 GY- 16 200-F197 BK- 16 985-F131 GY- 16 BK-18 SOLENOID CRAB 893-V21 GN- 16 893-V4 GN- 16
536-F123 WH- 16 F711-F230 GN- 16 892-F268 BR- 16 986-F150 OR- 16 200-F198 BK- 18 200-F128 BK- 18 BK-18 118-7756 893-V20 GN- 16
F-C20 536-F124 WH- 16 893-F254 GN- 16 102-F214 RD- 16 CONN 24 V-C6
E960-V23 OR- 18 M
1116795 676-F207 PU- 16 503-F49 BR- 16 F711-F331 GN- 16 604-F215 OR- 16 F-C10 FC-C1 FC-C2 F-C50
1733047 892-V19 BR- 16 892-V3 BR- 16
ACCESSORY SOCKET 121-K6 YL - 14 518-F348 OR- 16 C743-F143 PK - 18 504-F51 YL - 16 F712-F203 GY- 16 200-F216 BK- 16 1552269 3E3364 2059362 1552269 892-V18 BR- 16
167-V12 OR- 18
178-7539 200-K9 BK- 14 676-F207 PU- 16 C744-F144 PU- 18 506-F91 PU- 18 102-F77 RD- 16 165-F217 YL - 16 165-FC1 YL - 16 BK-18 200-F148 BK- 16 ARC SUPPR CRAB 767-V35 WH- 18
SPEAKER LH FLASHER DIFF LOCK FOOT SW 205-V14 BK- 18
200-F192 BK- 16 F711-F230 GN- 16 507-F56 WH- 18 102-F214 RD- 16 324-F218 BU- 16 324-FC2 BU- 16 BK-18 985-F149 GY- 16 106-8704 791-V36 PK - 18
169-7290 242-7237 204-0775 767-V35 WH- 18
536-F336 WH- 16 536-F123 WH- 16 F711-F232 GN- 16 523-F52 BR- 16 103-F78 RD- 16 123-F167 WH- 18 770-V37 GN- 18
615-P7 YL - 16 773-V32 GY- 18 M
509-N4 WH- 18 536-F122 WH- 16 524-F53 BU- 16 105-F172 RD- 16 205-F168 BK- 18 F-C60 986-F150 OR- 16
200-P11 BK- 16 H1 536-F124 WH- 16 F711-F333 GN- 16 529-F55 WH- 18 108-F239 RD- 18 123-F75 WH- 18 F-C67 LEVER PLATFORM ROTATE
508-N1 PU- 18 1552269 205-V30 BK- 18
SERVICE PORT ROOF WASHER
117-2826 F-C7 F712-F330 GY- 16
608-F45 GN- 16 111-F177 RD- 14
118-F89 GY- 16
123-F211 WH- 18
A310-F175 BU- 16 CONN 25 986-F134 OR- 16
986-F130
1552269
OR- 16 BK-18 SOLENOID CIRCLE
200-5911
205-V14 BK- 18
205-V15 BK- 18
205-V5 BK- 18
205-V13 BK- 18
1171877 F712-F203 GY- 16 615-F3 YL - 16 121-F20 YL - 14 757-F74 PU- 18 TO CAMERA 200-F198 BK- 18 200-F129 BK- 18 BK-18 118-7756 205-V16 BK- 18 205-V2 BK- 16
529-F55 WH- 18 F712-F233 GY- 16 615-F9 YL - 16 615-F2 YL - 16 121-F308 YL - 16 759-F110 OR- 18 V-C5 205-V17 BK- 16 205-V42 BK- 18
M 200-F195 BK- 18 F711-F331 GN- 16 123-F212 WH- 16 760-F111 PK - 18 F-C51 1733047 167-V9 OR- 16
F712-F332 GY- 16 119-F315 PK - 16 119-F46 PK - 16 125-F384 OR- 16 761-F112 GY- 18 1552269 167-V11 OR- 18 167-V28 OR- 18
H9 332-V22 BU- 18 M W
119-F57 PK - 16 119-F50 PK - 16 135-F240 BU- 18 763-F115 BU- 18 200-F133 BK- 18 ARC SUPPR CIRCLE 205-V15 BK- 18 167-V10 OR- 18 167-V8 OR- 16
200-P9 BK- 16 J766-V27 PU- 18 W
J764-F145 BR- 18 119-F48 PK - 16 141-F109 PK - 18 764-F322 PU- 18 986-F134 OR- 16 106-8704 791-V36 PK - 18 167-V11 OR- 18 167-V43 OR- 18
608-P5 GN- 16 REAR WASHER 892-F392 BR- 16 119-F43 PK - 16 144-F319 GN- 16 764-F326 PU- 18 167-V12 OR- 18 167-V44 OR- 18
117-2826 F-C6 892-F402 BR- 16 157-F105 YL - 16 765-F116 OR- 18 LEVER BOOM RAISE/LOWER 167-V41 OR- 18
1171877 119-F54 PK - 16 161-F104 RD- 16 769-F72 BU- 18 200-5911 N805-V39 BU- 18 791-V36 PK - 18 M W
102-F316 RD- 16 507-F56 WH- 18 893-F393 GN- 16 165-F217 YL - 16 K791-F416 OR- 16 N806-V40 BR- 18
M 200-F194 BK- 18 893-F403 GN- 16 102-F316 RD- 16 617-F5 BR- 16 P909-F71 PK - 18 J766-V49 PU-18
P-C2 108-F397 RD- 18 112-F354 PU- 10 108-F397 RD- 18 649-F82 YL - 16
1552269 615-F3 YL - 16 121-F247 YL - 14 799-F385 WH- 18 121-F20 YL - 14
LH REAR FLOOD WH-18 608-P5 GN- 16 111-F177 RD- 14 112-F353 PU- 10 615-F3 YL - 16 870-F117 OR- 16 121-F308 YL - 16

OR- 16
WH- 18
V-C4

BU- 16
PU- 18
212-9347 BK-18 200-P9 BK- 16 FRONT WASHER 985-F151 GY- 16 200-F66 BK- 18

PK - 18

BU- 18

PU- 18
PU- 18

OR- 18

OR- 18

PK - 18

GY- 18
1733047
CAB GROUND

BU- 18

WH- 18
117-2826 F-C5 986-F150 OR- 16 200-F69 BK- 18
K 117-F380 RD- 16 1171877 123-F371 WH- 18 200-F108 BK- 18
167-V10
205-V16
OR- 18
BK- 18 K
118-F89 GY- 16 506-F91 PU- 18 205-F228 BK- 16 200-F152 BK- 18

123-F211

K791-F416
770-V37 GN- 18

757-F74

A310-F175
200-F193 BK- 18 307-F320 OR- 16 614-F62 PU- 18

P909-F71

763-F115

764-F322
764-F326

765-F116

759-F110

760-F111

761-F112
M CAB GROUND STUD (M6) MOUNTED

2285856

2285856

2285856

2285856

2285856
769-F72

123-F75
121-F20 YL - 14 308-F126 YL - 18 614-F65 PU- 18 ON THE SIDE PANEL IN

F-C47

F-C56

F-C55

F-C54

F-C58
308-F141 YL - 16 614-F157 PU- 18 LEVER BOOM EXTEND/RETRACT
FRONT OF THE JOYSTICK NO NOTE A

XMSN NEUTRAL DISABLE SW

200-5911

MOM
121-F308 YL - 16 102-F316 RD- 16 614-F153 PU- 18

MOM
108-F397 RD- 18 324-F218 BU- 16 J764-F360 BR- 18

QUICK COUPLER

STEER MODE SEL

205-V42 BK- 18
799-F25 WH- 18 604-F215 OR- 16 J764-F83 BR- 18

MAN VSC
167-V8 OR- 16
CONN 34

190-8221

202-4208

202-2276

190-8220

260-5889
REV FAN
119-F54 PK - 16 605-F225 YL - 16 J764-F84 BR- 18 J998-V29 BU- 18
NOTE D 167-V44 OR- 18
799-F176 WH- 18 121-F247 YL - 14 J764-F106 BR- 18 HC-C2 V-C2
605-F132 YL - 16 J764-F113 BR- 18 F-C59 SHIFTER
HORN SW 2256741 1740681

MOM
799-F385 WH- 18 605-F156 YL - 16 1552253 261-2208
2T-3360 GN-16 167-V1 OR- 16
121-F249 YL - 14 605-F137 YL - 16 123-F206 WH- 16
GY-16 205-V2 BK- 16
J764-F191 BR- 18 121-F20 YL - 14 605-F136 YL - 16 205-F226 BK- 16
322-F40 GY- 16 200-F42 BK- 18 BR-18 892-V3 BR- 16
606-F147 GY- 16 893-F236 GN- 16

BR - 18

YL - 18

BK - 18

PU- 18
121-F308 YL - 16 H17 H7 WH-18 893-V4 GN- 16

BR - 18

BR - 18

BR - 18
BK - 18

PU- 18
892-F237 BR- 16

BR - 18

YL - 16

BK - 18

PU- 18
N932-V38 PU- 18 m

BK - 18

PU- 18

YL - 14
C903-F169 BU- 16 606-F138 GY- 16
YL-16 307-V6 OR- 16 A487-V47 PU- 18 m
116-F311 BR- 16 102-F316 RD- 16 606-F140 GY- 16 W
M J998-V29 BU- 18 m
116-F312 BR- 16 102-F213 RD- 16 H18 606-F139 GY- 16 893-F254 GN- 16

911-F158

200-F108

614-F157
J764-F83

200-F66

614-F62

J764-F113

J764-F360

J764-F106
J811-F272 BK- 18 102-F304 RD- 16 611-F80 PU- 16 893-F173 GN- 16 200-F190 BK- 14

121-F308

200-F152

614-F153
J764-F84
205-V5 BK- 18

200-F69

614-F65

121-F20
795-F274 YL - 18 617-F242 BR- 16 892-F268 BR- 16 W
205-V13 BK- 18
J811-F273 BK- 18 619-F349 GN- 16 892-F174 BR- 16
167-V43 OR- 18 W
795-F161 YL - 18 627-F395 YL - 16 F-C19 200-F186 BK- 18
102-F77 RD- 16 1552269 200-F187 BK- 18
772-V31 BR- 18
102-F214 RD- 16 757-F74 PU- 18 200-F189 BK- 18
STAB RLY 1 QUICK CPLR GND QUICK CPLR PWR 322-F40 GY- 16 HORN 773-V32 GY- 18 ENGINE START SW
103-F78 RD- 16 759-F110 OR- 18 200-F188 BK- 18
140-9378 140-9378 140-9378 114-F251 RD- 16 164-9425 332-V22 BU- 18 202-2278
105-F172 RD- 16 760-F111 PK - 18 606-F138 GY- 16 200-F183 BK- 14
E960-V23 OR- 18
147-F275 PU- 16 761-F112 GY- 18 ENG STOP SW MOM
ROOF WIPER 764-F114 PU- 18 611-F142 PU- 18 611-F76 PU- 16 213-5091 V-C8
108-F397 RD- 18
191-3027 611-F80 PU- 16 1552267
108-F406 RD- 18 200-F309 BK- 16
958-F301 YL - 16 764-F326 PU- 18 611-F135 PU- 16 200-F184 BK- 16 332-V22 BU- 18
307-V6 OR- 16
959-F302 WH- 16 108-F239 RD- 18 764-F322 PU- 18 200-F199 BK- 16 J766-V24 PU- 18 J766-V24 PU- 18
J FA-C2 200-F276 BK- 16 111-F177 RD- 14 200-F294 BK- 18 763-F115 BU- 18 619-F349 GN- 16 619-F73 GN- 16
H24
E960-V23 OR- 18 J766-V25 PU- 18 J766-V27 PU- 18
167-V7 OR- 18
J
M 1552272 J759-F170 GN- 16 118-F89 GY- 16 765-F116 OR- 18 619-F81 GN- 16 200-F201 BK- 12 J766-V49 PU- 18
200-F289 BK- 18 J766-V26 PU- 18 205-V2 BK- 16
121-F20 YL - 14 766-F154 GN- 16 161-F104 RD- 16 200-F248 BK- 14

YL - 16

RD- 16

YL - 16
GY- 16
BK-16 200-FA9 BK- 16 614-F245 PU- 18

PK - 16

OR- 16
YL - 16

GN- 16

PU- 16
H765-F164 WH- 18 121-F308 YL - 16 769-F72 BU- 18 157-F105 YL - 16 PLATF MODE SW
YL-16 119-FA2 PK - 16 114-F251 RD- 16 892-V3 BR- 16
J811-F160 BK- 18 123-F212 WH- 16 775-F341 BR- 18 603-F47 PK - 16 200-F196 BK- 14 202-2277
GN-16 523-FA7 BR- 16
RD-16 321-F146 BR- 18 125-F384 OR- 16 123-F205 WH- 18 C919-F346 PU- 18 605-F132 YL - 16 200-F307 BK- 14
524-FA8 BU- 16 H9 DEADMAN SW 893-V4 GN- 16
J811-F375 BK- 18 135-F240 BU- 18 200-F227 BK- 18 776-F347 YL - 18 610-F79 OR- 16 200-F276 BK- 16

157-F105

161-F104

605-F132
606-F138
128-F414 PK - 12 V-C9

2285856

2285856

2285856

1387675
603-F47
213-5093 797-V33 PU- 18 V-C11

610-F79
649-F82

619-F73

611-F76
H764-F163 GY- 18 123-F253 WH- 18 778-F344 BR- 18 649-F82 YL - 16 200-F282 BK- 16 1552267

F-C25

F-C52

F-C49

F-C48
2285856
J811-F159 BK- 18 141-F109 PK - 18 200-F16 BK- 18 128-F415 PK - 12 C917-F345 YL - 18 F711-F200 GN- 16
DISPLAY 2A 772-V31 BR- 18 798-V34 GN- 18
144-F319 GN- 16 200-F17 BK- 18 779-F340 WH- 18 200-F28 BK- 16
J766-V25 PU- 18

SW HEAD/SIDE LAMP
CRAB STEER REVERSE LAMPS RLY CIRCLE STER 157-F105 YL - 16 200-F26 BK- 16 784-F262 YL - 18 102-F77 RD- 16 F712-F321 GY- 16 F-C63 295-3375 200-F309 BK- 16
200-F286 BK- 16 OR 295-3376 773-V32 GY- 18 167-V46 OR- 18 167-V7 OR- 18

HAZARD SW
BEACON SW

DIMMER SW
140-9378 140-9378 140-9378 161-F104 RD- 16 200-F28 BK- 16 785-F263 PK - 18 103-F78 RD- 16 7X6222

202-2283

190-8225

202-2280

190-8224
167-V48 OR- 18 167-V45 OR- 18
986-F150 OR- 16 165-F217 YL - 16 200-F29 BK- 18 200-F411 BK- 16 A700-F356 OR- 18 144-F319 GN- 16 111-F177 RD- 14
167-V1 OR- 16
617-F5 BR- 16 200-F30 BK- 18 F702-F358 GN- 18 200-F27 BK- 18 205-F223 BK- 16
167-V41 OR- 18
508-N1 PU- 18 200-FA6 BK- 16 649-F82 YL - 16 200-F31 BK- 18 200-F412 BK- 16 200-F67 BK- 18 205-F222 BK- 16
509-N4 WH- 18 200-FA11 BK- 16 136-F241 GN- 16 799-F385 WH- 18 200-F97 BK- 18 128-F414 PK - 12 F712-F231 GY- 16 200-F68 BK- 18 111-F177 RD- 14 676-F207 PU- 16
V-C10
612-F288 GY- 18 870-F117 OR- 16 200-F98 BK- 18 522-F103 WH- 16 200-F412 BK- 16 J755-F118 BU- 16 200-F100 BK- 18 114-F251 RD- 16 ACTION LAMP
2285856
102-F304 RD- 16 985-F151 GY- 16 200-F183 BK- 14 A515-F285 BR- 16 J756-F119 BR - 16 518-F348 OR- 16 205-F222 BK- 16 212-9870
985-F151 GY- 16 986-F150 OR- 16 200-F184 BK- 16 J758-F121 PK - 16 536-F122 WH- 16 205-F223 BK- 16

RD- 16

RD- 16

OR- 16
J764-F191 BR- 18

GN- 16

OR- 16

WH- 16

BK - 18
BK - 18

PU- 18

BK - 18

BK - 18

PU- 18

PU- 18
PU- 18
136-F317 GN- 16 200-F186 BK- 18 200-F294 BK- 18 128-F415 PK - 12 J760-F120 YL - 16 610-F79 OR- 16 205-F224 BK- 16 167-V46 OR- 18
REAR WIPER F-C1 116-F312 BR- 16 200-F187 BK- 18 119-F43 PK - 16 200-F411 BK- 16 J764-F107 BR- 16 614-F19 PU- 18 308-F127 YL - 18 N932-V38 PU- 18
187-2735 1129609 116-F311 BR- 16 200-F188 BK- 18 119-F46 PK - 16 A516-F287 PK - 16 852-F388 GN- 18 614-F63 PU- 18 200-F42 BK- 18 605-F137 YL - 16
RELAY BLOCK J998-V29 BU- 18

102-F77

103-F78

610-F79
116-F292 BR- 16 200-F189 BK- 18 869-F389 PU- 18 614-F64 PU- 18 A310-F175 BU- 16 606-F139 GY- 16

144-F319

518-F348

536-F122

200-F100
119-F48 PK - 16

200-F27

614-F19

200-F67

200-F68

614-F64

614-F95
614-F63
512-N3 GN- 18 116-F293 BR- 16 200-F196 BK- 14 119-F50 PK - 16 892-F174 BR- 16 614-F95 PU- 18 605-F137 YL - 16 A310-F175 BU- 16
PL-C8 PL-C10 PL-C11 V-C7 167-V45 OR- 18
511-N2 BR- 18 FA-C3 116-F305 BR- 16 116-F310 BR- 16 200-F199 BK- 16 123-F205 WH- 18 893-F173 GN- 16 606-F139 GY- 16
M J759-F170 GN- 16 H10 200-F248 BK- 14 F-C73 K791-F416 OR- 16 111-F177 RD- 14 3E5175 3E5178 3E5175 1552269
1552272 500-F90 BR- 16 F-C74
200-F286 BK- 16 993-F357 BR- 18 205-F223 BK- 16 611-F142 PU- 18 611-F142 PU- 18 M 125-PL26 OR- 18 108-PL3 RD- 18 ALARM PLATFORM BK-18 167-V48 OR- 18 V-C12
BK-16 200-FA10 BK- 16 502-F101 OR- 16 9X1054 9X1054
FRAME LVL/TOW DIFF LOCK WIPER 1 WIPER 2 118-F87 GY- 16 200-F307 BK- 14 516-F409 GN- 14 P909-F71 PK - 18 114-F251 RD- 16 614-F86 PU- 16 MM 200-PL27 BK- 18 200-PL13 BK- 16 243-6361 BK-18 A487-V47 PU- 18 2055471
YL-16 119-FA1 PK - 16 503-F49 BR- 16
GN-16 118-F89 GY- 16 200-F411 BK- 16 506-F91 PU- 18 205-F222 BK- 16 F712-F203 GY- 16 308-PL28 YL - 18 308-PL14 YL - 18
503-FA4 BR- 16
118-F85 GY- 16 200-F412 BK- 16 123-F167 WH- 18 205-F224 BK- 16 F711-F202 GN- 16 403-PL29 GN- 18 403-PL16 GN- 18
RD-16 504-FA5 YL - 16
119-F54 PK - 16 J757-F171 PU- 16
A515-F285 BR- 16
517-F8 BU- 14 BLOWER HIGH RLY BLOWER MED HI 123-F206 WH- 16 308-F127 YL - 18 F711-F200 GN- 16 N957-PL30 PK - 18 ACCESS PLATFORM-ATCH
I 118-F85 GY- 16
165-F217 YL - 16
118-F88 GY- 16 205-F267
500-F90
BK- 18
BR- 16
521-F11 YL - 14
523-F52 BR- 16
115-1615 115-1615
515-F400 GY- 12
123-F205
123-F257
WH- 18
WH- 18
123-F211 WH- 18
123-F212 WH- 16
200-F42 BK- 18
A310-F175 BU- 16
676-F207 PU- 16 F712-F321 GY- 16
N960-PL22 OR- 18 I
112-F353 PU- 10 124-F284 GN- 14 501-F92 GN- 16 608-F45 GN- 16 605-F137 YL - 16 N979-PL23 GN- 18
116-F292 BR- 16 127-F70 OR- 16 502-F101 OR- 16 615-F2 YL - 16 123-F257 WH- 18 606-F139 GY- 16 J847-F221 GN- 18 N970-PL24 YL - 18
114-F251 RD- 16 J759-F170 GN- 16 616-F60 BU- 16 123-F371 WH- 18 611-F142 PU- 18 614-F86 PU- 16 308-F127 YL - 18 W N973-PL25 BR- 18 P-C5
614-F13 PU- 18 750-F34 GN- 18 123-F253 WH- 18 123-F75 WH- 18 614-F32 PU- 18 1552269
BLOWER HIGH BLOWER LOW QC/AUX FUSE ALL WHL STER 128-F415 PK - 12 614-F14 PU- 18 753-F35 GY- 18
H12
200-F28 BK- 16
614-F24 PU- 18 CONN 30 H3 615-P8 YL - 16 WH-18 CAB RH FR FLOOD
128-F413 PK - 12 614-F18 PU- 18 774-F38 YL - 18 614-F178 PU- 18 BK-18
200-F183 BK- 14 200-P12 BK- 16 212-9347
614-F21 PU- 18 793-F37 YL - 18 615-F3 YL - 16
200-F184 BK- 16
136-F298 GN- 16 128-F414 PK - 12 614-F22 PU- 18 T941-F235 BR- 16 617-F5 BR- 16 J847-F221 GN- 18 MONITOR ALARM
DOME LAMP 102-FA3 RD- 16 200-F196 BK- 14
147-F277 PU- 16 614-F23 PU- 18 T942-F314 PK - 16 617-F58 BR- 16 205-F224 BK- 16 9X-5316
084-4277 200-FA11 BK- 16 200-F199 BK- 16
124-F284 GN- 14 130-F59 GN- 16 614-F93 PU- 18 T943-F234 GY- 16 MOTOR BLOWER GP 617-F242 BR - 16 PL-C7 PL-C6
200-F248 BK- 14
112-F353 PU- 10 131-F61 BR- 16 614-F94 PU- 18 T944-F329 GN- 16 174-1227 676-F207 PU- 16 3E3364 1552269
500-F90 BR- 16 H23
128-F413
112-F352
PK - 12
PU- 10
200-F276
200-F282
BK- 16
BK- 16
J764-F39
J764-F41
BR- 18
BR- 18
A516-F287 PK - 16 CONN 20 501-F92 GN- 16
F711-F232 GN- 16 F711-F202 GN- 16
F-C61
REAR/ROOF WIPERS-ATCH 799-F25 WH- 18 J764-F191 BR- 18
200-F227 BK- 18
114-F251 RD- 16
A-C1 F-C12 502-F101 OR- 16
F711-F331 GN- 16 F711-F202 GN- 16
1552267
SW ELEK ACCESS PLATF PHS 799-F176 WH- 18 J764-F269 BR- 18 M 1779649 1779654 114-F251 RD- 16
200-F188 BK- 18 200-F99 BK- 18
F711-F200 GN- 16
F711-F219 GN- 16
TERMINATING RES
CONN 36 HG-C2
J764-F191 BR- 18 J764-F366 BR- 18 J757-F171 PU- 16 515-A4 GY- 12 515-F400 GY- 12 F712-F233 GY- 16 F712-F321 GY- 16 F712-F220 GY- 16 HA-C2 HG-C1 1552269

WH- 18
200-F98 BK- 18 200-F100 BK- 18 134-2540

YL - 18

PU- 18

PK - 16

YL - 16
BR - 16

BU- 16
200-F313 BK- 16 J764-F367 BR- 18 200-A1 BK- 12 516-A5 GN- 14 516-F409 GN- 14 F712-F231 GY- 16 F712-F203 GY- 16 BK-18

GN- 18

PU- 18
3E3376 1552272 987-HG3 WH- 16 AUX DIV SOL

YL - 16

PK - 18

BR - 18

WH- 18

YL - 18

YL - 18

BR - 18
SPEAKER RH 200-F411 BK- 16 200-F69 BK- 18
133-F355 OR- 14 J757-F171 PU- 16 J759-F170 GN- 16 C547-A8 OR- 14 517-F8 BU- 14 F712-F332 GY- 16 990-HG4 GN- 16 BK-18 212-3350
169-7290 200-F313 BK- 16 200-F68 BK- 18 F-C18 987-HA3 WH- 16 987-HG3 WH- 16
112-F351 PU- 10 109-F324 RD- 10 128-F414 PK - 12 200-A3 BK- 12 200-A3 BK- 12 200-F201 BK- 12 F712-F203 GY- 16
200-F189 BK- 18 1552272 990-HA4 GN- 16 990-HG4 GN- 16 HG-C3
167-F299 OR- 16 109-F325 RD- 10 128-F415 PK - 12 200-A2 BK- 14 200-F42 BK- 18 627-F395 YL - 16 617-F242 BR- 16

799-F385
512-N3 GN- 18 E528-F266 PU- 14 200-F30 BK- 18 958-HA1 YL - 16 958-HG1 YL - 16

C917-F345

C919-F346
CONN 21

J758-F121

J760-F120
J756-F119

J755-F118
1552269

852-F388

869-F389
109-F372 RD- 10 200-F201 BK- 12 200-F152 BK- 18 775-F341 BR - 18 617-F58 BR- 16

627-F395

785-F263

778-F344

779-F340

784-F262

776-F347

775-F341
2285856

2285856

2285856

2285856
2285856
511-N2 BR- 18 E528-F265 PU- 14 200-F16 BK- 18 959-HA2 BU- 16 959-HG2 WH- 16
123-F212 WH- 16 200-F411 BK- 16 A-C2 F-C11 200-F108 BK- 18 C919-F346 PU- 18 617-F5 BR- 16 617-F4 BR- 16 BACKLIGHT SIG COM 958-HG1 YL - 16 BK-18 SOL QC

F-C68

F-C15

F-C16

F-C43
F-C31
E528-F208 PU- 18 200-F289 BK- 18
112-F354 PU- 10 111-F209 RD- 12 200-F412 BK- 16 3E3363 1552269 200-F296 BK- 18 776-F347 YL - 18 615-F3 YL - 16 172-9200 959-HG2 WH- 16 BK-18 212-3350
H11 E528-F291 PU- 18 200-F294 BK- 18
111-F318 RD- 12 517-F8 BU- 14 778-F344 BR - 18 614-F1 PU- 16

MOM

MOM
517-A6 BU- 14 U 200-F29 BK- 18 200-F383 BK- 18 N973-PL17 BR- 18

MOM

FRAME LEVELING SW
TURN IND BOOM FLOODS CAB FLOODS 1 CAB FLOODS 2 111-F177 RD- 14 522-F103 WH- 16 E528-F264 PU- 14 C917-F345 YL - 18 614-F24 PU- 18
522-A7 WH- 14 522-F103 WH- 16 200-F186 BK- 18 200-F66 BK- 18 N970-PL18 YL - 18

FOG LAMP SW

CONT FLOW
112-F350 PU- 10 A515-F285 BR- 16 200-F289 BK- 18 779-F340 WH- 18 614-F32 PU- 18
200-F17 BK- 18 200-F256 BK- 18 N957-PL19 PK - 18

212-9878

212-9873

203-7845

203-7846

190-8219
RH STB
112-F351 PU- 10 A516-F287 PK - 16 124-F284 GN- 14 784-F262 YL - 18 614-F178 PU- 18

LH STB
200-F227 BK- 18 200-F27 BK- 18 N960-PL20 OR- 18 LH BOOM FLOOD
130-F59 GN- 16 112-F352 PU- 10 116-F310 BR- 16 785-F263 PK - 18 CA-C2 212-9348 L-C9
200-F31 BK- 18 200-F67 BK- 18 N979-PL21 GN- 18 LH STAB PRESS SW
112-F350 PU- 10 119-F43 PK - 16 118-F87 GY- 16 799-F385 WH- 18 PRODUCT LINK 1552267

MOM

MOM
200-F97 BK- 18 200-F255 BK- 18 1552269 295-3455
131-F61 BR- 16 133-F355 OR- 14 119-F46 PK - 16 118-F88 GY- 16 J755-F118 BU- 16 PL151 209-6416 PL-C1 WH-18 J764-L37 BR - 18 BK-18
200-F187 BK- 18 200-F387 BK- 18 616-CA3 BU- 16
H 127-F70 OR- 16
157-F105 YL - 16 136-F246 GN- 16
119-F48 PK - 16
119-F50 PK - 16
127-F70 OR- 16
130-F59 GN- 16
THERMOSTAT 200-F26 BK- 16 200-F185 BK- 16
J756-F119
J758-F121
BR- 16
PK - 16
PL201 209-6417 7X6222
200-CA5 BK- 16 BK-18 C713-L20 GY- 18 RD-18 H
3E-5464 200-F286 BK- 16 200-F204 BK- 16 768-L28 OR- 18 BU-18
136-F241 GN- 16 503-F49 BR- 16 131-F61 BR- 16 J760-F120 YL - 16
200-F307 BK- 14 200-F238 BK- 18

PU- 18
F-C2 136-F317 GN- 16 504-F51 YL - 16 200-F16 BK- 18 852-F388 GN- 18
200-F412 BK- 16 200-F216 BK- 16 RH BOOM FLOOD

GN- 18

GN- 18

PU- 18
BR - 18
1249636 136-F298 GN- 16 506-F91 PU- 18 200-F17 BK- 18 869-F389 PU- 18
FUSE BLOCK

BK - 18

PU- 18

BK - 18

PU- 18

OR- 16
OR- 16

BK - 18

PU- 18

BK - 18

PU- 18
205-F228 BK- 16 616-CA1 BU- 16 CA-C3 212-9349

BK - 16

BK - 18

PU- 18
507-F56 WH- 18 200-F26 BK- 16 125-F384 OR- 16 Y794-PL15 OR- 18 1552269 L-C8 RH STAB PRESS SW
205-F226 BK- 16
31200310 VOL 1

147-F277 PU- 16 523-F52 BR- 16 200-F29 BK- 18 200-F28 BK- 16 1552267 295-3455
BLOWER-UNDER SEAT-ATCH 205-F224 BK- 16 RD- 18 108-PL1 RD- 18 616-CA4 BU- 16 WH-18

J757-F359
524-F53 BU- 16 200-F30 BK- 18 200-F99 BK- 18 BK-18 J764-L26 BR - 18 J764-L38 BR - 18 BK-18
205-F267 BK- 18 205-F223 BK- 16 BK - 18 200-PL2 BK- 18 200-CA2 BK- 16 200-CA6 BK- 16

J759-F250

J759-F261

J757-F361
147-F275 PU- 16

J764-F390
529-F55 WH- 18 200-F31 BK- 18 200-F255 BK- 18

200-F256

614-F328

200-F255

614-F327

870-F117
RD-18

125-F384

200-F383

614-F382

200-F387

614-F386
C712-L10 BR - 18

200-F28

200-F99

614-F96
205-F222 BK- 16 W YL - 18 308-PL5 YL - 18 108-PL1 RD- 18
799-F210 WH- 18 147-F278 PU- 16 608-F45 GN- 16 200-F97 BK- 18 200-F256 BK- 18 787-L25 WH- 18 BU-18
205-F168 BK- 18 M GN- 18 403-PL4 GN- 18 200-PL2 BK- 18
783-F295 OR- 18 615-F2 YL - 16 200-F98 BK- 18 200-F383 BK- 18
200-P9 BK- 16 614-F245 PU- 18 614-F19 PU- 18 OR - 18 308-PL5 YL - 18
794-F279 YL - 18 150-F306 RD- 14 J759-F170 GN- 16 200-F309 BK- 16 H13 200-F387 BK- 18
200-P11 BK- 16 614-F13 PU- 18 614-F64 PU- 18 BR - 18 LEFT STAB RAISE
X753-F376 YL - 18 116-F310 BR- 16 501-F92 GN- 16 614-F328 PU- 18 GPS VHF
614-F94 PU- 18 614-F327 PU- 18 W Y795-PL10 GN- 18 403-PL4 GN- 18 L-C7 201-0315
794-F280 YL - 18 118-F87 GY- 16 504-F51 YL - 16 614-F96 PU- 18 207-6798
608-P5 GN- 16 614-F23 PU- 18 614-F63 PU- 18 Y794-PL15 OR - 18 945-PL12 BR- 18 1552269
X753-F377 YL - 18 150-F381 RD- 16 118-F88 GY- 16 507-F56 WH- 18 614-F327 PU- 18
615-P7 YL - 16 614-F386 PU- 18 944-PL11 OR- 18 BK-18
150-F303 RD- 14 114-F251 RD- 16 524-F53 BU- 16 614-F382 PU- 18 C919-L33 PU- 16 C919-L1 PU- 16
614-F24 PU- 18 Y795-PL10 GN- 18 CM-C33 L-C1
608-P1 GN- 16 608-P5 GN- 16
FRAME LVL INTLK
140-9378
AUX DIV GND
140-9378
AUX DIV PWR
140-9378
U 529-F55 WH- 18
614-F178 PU- 18
614-F386 PU- 18
F-C41
CONN 33 1673693 1673692
775-L34 BR - 16 775-L2 BR - 16 BK-18
C903-F169 BU- 16 124-F284 GN- 14 614-F13 PU- 18 J759-F250 GN- 18
608-P6 GN- 16 200-P10 BK- 16 614-F382 PU- 18 1552269 L-C12
147-F278 PU- 16 127-F70 OR- 16 614-F14 PU- 18 J759-F261 GN- 18
608-P6 GN- 16 614-F93 PU- 18 614-F328 PU- 18 MSS TIRIS ANTENNA ANTENNA RADIO 784-CM27 YL - 18 1552269
167-F299 OR- 16 128-F414 PK - 12 614-F18 PU- 18 J757-F359 PU- 18 605-F136 YL - 16 T901-F165 YL - 18

2285856
615-P3 YL - 16 615-P7 YL - 16 614-F157 PU- 18 8E-1118 768-CM298 OR- 18 768-L28 OR- 18 775-L3 BR - 16 ARC SUPPR LH STAB RAISE
321-F146 BR- 18 128-F415 PK - 12 614-F21 PU- 18 J757-F361 PU- 18 606-F140 GY- 16 T902-F166 PK - 18 205-8257
F-C17

F-C64
615-P8 YL - 16 614-F153 PU- 18 C713-CM203 GY- 18 C713-L20 GY- 18 C919-L4 PU- 16 106-8704
987-F281 WH- 16 130-F59 GN- 16 614-F22 PU- 18 J764-F390 BR- 18 785-CM30 PK - 16
C905-F229 OR- 16 3E3364 614-F96 PU- 18
990-F300 GN- 16 BK-18 131-F61 BR- 16 614-F23 PU- 18 870-F117 OR- 16
200-P2 BK- 16 200-P9 BK- 16 RH REAR FLOOD 308-F141 YL - 16 614-F14 PU- 18 614-F65 PU- 18 F-C78 775-CM25 BR- 18 775-CM1 BR- 16 LEFT STAB LOWER
P-C3 200-F282 BK- 16 BK-18 200-F276 BK- 16 614-F93 PU- 18 308-F126 YL - 18
200-P10 BK- 16 212-9347 200-F286 BK- 16 614-F21 PU- 18 614-F95 PU- 18 1552272 L-C6 201-0315
1552269 116-F293 BR- 16 200-F282 BK- 16 614-F94 PU- 18 308-F127 YL - 18
614-F18 PU- 18 614-F62 PU- 18 TURN SIGNAL 1552269
870-F117 OR- 16 A309-F374 GY- 16 799-F25 WH- 18 799-F25 WH- 18 308-F141 YL - 16 308-F125 YL - 16 YL-16 KEY SWITCH 775-CM505 BK- 16
200-P4 BK- 16 200-P12 BK- 16 WH-18 608-P6 GN- 16 112-F351 PU- 10 109-F323 RD- 2 614-F22 PU- 18 614-F32 PU- 18 202-2281 295-3351 COAX CABLE 779-CM7 WH- 16 C712-CM202 BR- 18 C712-L10 BR- 18 784-L36 YL - 16 784-L5 YL - 16 BK-18
C905-F229 OR- 16 612-F288 GY- 18 799-F176 WH- 18 J764-F39 BR- 18 308-F399 YL - 18 PU-16
200-P11 BK- 16 BK-18 200-P10 BK- 16 112-F350 PU- 10 109-F372 RD- 10 199-3387 779-CM29 WH- 18 776-L31 YL - 16 776-L6 YL - 16 BK-18
116-F305 BR- 16 618-F243 YL - 16 J764-F191 BR- 18 J764-F41 BR- 18 J759-F170 GN- 16 J759-F250 GN- 18 105-F172 RD- 16 307-F320 OR- 16 OR-16
112-F352 PU- 10 109-F324 RD- 10 787-CM299 WH- 18 787-L25 WH- 18
F710-F369 BR- 18 783-F295 OR- 18 200-F313 BK- 16 863-F33 BU- 18 J759-F261 GN- 18 307-F320 OR- 16 105-F172 RD- 16 BR-16 779-CM180 WH- 16 L-C10
109-F325 RD- 10 779-CM180 WH- 16 779-L27 YL - 16
150-F381 RD- 16 200-F286 BK- 16 308-F126 YL - 18 778-CM19 BR- 16 1552269
MAIN PWR RLY 614-F245 PU- 18 J757-F359 PU- 18 778-CM503 BR- 16 778-L30 BR- 16
42 Page

794-F283 YL - 16 521-F11 YL - 14 308-F127 YL - 18 778-CM28 BR- 18

615-P8 YL - 16 241-8367 J757-F171 PU- 16 J757-F361 PU- 18 776-CM502 YL - 16 776-L31 YL - 16 776-L7 YL - 16 ARC SUPPR LH STAB LOWER
522-F103 WH- 16 123-F253 WH- 18 308-F141 YL - 16 778-CM503 BR- 16
G 200-P12 BK- 16 STAB RLY 2 LIFT PUMP 140-9378
794-F280
794-F279
YL - 18
YL - 18
109-F325
109-F324
RD- 10
RD- 10
616-F60 BU- 16
750-F34 GN- 18
J764-F39
J764-F366
BR- 18
BR- 18 J764-F106 BR- 18
308-F399
A700-F356
YL - 18
OR- 18
536-F123
536-F124
WH- 16
WH- 16
F-C14
1552267 COAX CABLE
776-CM26 YL - 18
776-CM60 YL - 16
C917-CM500 YL - 18
C919-CM501 PU- 18
C917-L32 YL - 16
C919-L33 PU- 16
784-L8 YL - 16 106-8704
GH
G
140-9378 140-9378 NOTE D 109-F372 RD- 10 241-4938 J764-CM504 BR- 16 J764-L26 BR- 18
753-F35 GY- 18 205-F267 BK- 18 J764-F191 BR - 18 J764-F155 BR- 16 F702-F358 GN- 18 A700-F356 OR- 18 RD-18 776-CM502 YL - 16 L-C5
ACCELERATOR 775-CM505 BK- 16 775-L34 BR- 16
200-F286 BK- 16 F-C88 774-F38 YL - 18 J764-F367 BR- 18 J764-F113 BR- 18 993-F357 BR- 18 993-F357 BR- 18 BK-18 1552269
295-3355 785-CM30 PK - 16 785-L35 PU- 16
H3 521-F11 YL - 14 3E3364 780-F258 PU- 18 J764-F83 BR- 18 F702-F358 GN- 18 YL-18 F-C42 C917-L32 YL - 16 C917-L9 YL - 16 BK-18
795-F162 YL - 16 522-F103 WH- 16 781-F259 PK - 18 1552264 136-CM116 GN- 16 779-L27 YL - 16 779-L17 YL - 16 BK-18
K791-F416 OR- 16 K791-RF416 OR- 16 784-CM27 YL - 18 784-L36 YL - 16
795-F274 YL - 18 616-F60 BU- 16 782-F260 GY- 18 509-F181 WH- 18
SEAT PUMP G970-CM507 BU- 18 G970-L40 BU- 18
117-F380 RD- 16 795-F161 YL - 18 750-F34 GN- 18 J764-F335 BR- 16 T901-F165 YL - 18 508-F180 PU- 18 U J764-CM245 BR- 16 L-C14
213-4579 X753-CM508 YL - 18 X753-L39 YL - 18
A309-F374 GY- 16 753-F35 GY- 18 200-F286 BK- 16 792-F36 OR- 18 780-F258 PU- 18 J764-F41 BR- 18 J764-F390 BR- 18 T902-F166 PK - 18 200-CM227 BK- 16 1552269
H14 200-F238 BK- 18
200-F313 BK- 16 774-F38 YL - 18 793-F37 YL - 18 J764-F269 BR- 18 J764-F360 BR- 18 200-CM237 BK- 16 779-L11 YL - 16 ARC SUPPR RH STAB RAISE
RADIO 111-CM96 RD- 12 200-CM238 BK- 16
J757-F171 PU- 16 780-F258 PU- 18 308-F141 YL - 16 781-F259 PK - 18 J764-F84 BR- 18 108-F239 RD- 18 108-F239 RD- 18 D C917-L12 YL - 16 106-8704
799-F290 WH- 18 AFTERMARKET
F-C3 781-F259 PK - 18 782-F260 GY- 18 F-C37 J764-F145 BR- 18 135-F240 BU- 18 135-F240 BU- 18 111-CM93 RD- 14
M GH OW
1129609 799-F210 WH- 18 782-F260 GY- 18 856-F405 GN- 18 1552269 J764-F107 BR- 16 200-F238 BK- 18 512-F182 GN- 18 111-CM94 RD- 14 H14
RELAY BLOCK 799-F385 WH- 18
799-F25 WH- 18 H15 792-F36 OR- 18
CONN 15 863-F33 BU- 18
867-F404 PU- 18
792-F36 OR- 18 BR-16 141-F109 PK - 18 141-F109 PK - 18 508-F180
509-F181
PU- 18
WH- 18
511-F179 BR- 18 G N 111-CM92 RD- 14
324-CM49 BU- 16
L-C4
1552269
F-C32 CM-C40 OR-16 200-F296 BK- 18 200-F296 BK- 18 111-CM274 RD- 14
799-F176 WH- 18 793-F37 YL - 18 T941-F235 BR- 16 799-F176 WH- 18 511-F179 BR- 18 785-L35 PU- 16 785-L13 PK - 16 BK-18
1779641 1779646
T942-F314 PK - 16 J764-F269 BR- 18 512-F182 GN- 18 136-CM116 GN- 16 403-CM290 GN- 18 778-L30 BR - 16 778-L14 BR - 16 BK-18
KEYSW HAZARD HEADLAMP 2 HEADLAMP 1 F710-F369
H764-F163
BR- 18
GY- 18 856-F405 GN- 18
111-F209 RD- 12 111-CM96 RD- 12
T943-F234
T944-F329
GY- 16
GN- 16
J764-F366
J764-F367
BR- 18
BR- 18
DASH PHS JOYSTICK
200-CM237 BK- 16
403-CM279 GN- 18 L-C13
1552269
102-F213 RD- 16
H765-F164 WH- 18 863-F33 BU- 18
867-F404 PU- 18
CONN 14 856-F405
867-F404
GN- 18
PU- 18
230-5591
ITT GRIP X753-CM508 YL - 18 778-L15 BR - 16 ARC SUPPR RH STAB LOWER
F-C35 CM-C5

PU- 18
785-L16 PK - 16 106-8704

BR - 16
109-F324 RD- 10 X753-F378 YL - 18 T944-F329 GN- 16 BASE 221-3064 205-CM239 BK- 14

PU- 18
1673693 1673692

BK - 18
PK - 16
GY- 16

BR - 16
GN- 16

PK - 16

PU- 14
103-F78 RD- 16 T942-F314 PK - 16 109-F323 RD- 2 205-CM241 BK- 16 F711-CM267 GN- 16

BK - 18
PU- 14
L-C16

BU- 14
161-F104 RD- 16 X753-F376 YL - 18 T943-F234 GY- 16 F-C80 205-CM242 BK- 16 1552269

WH- 18

BU- 18

OR- 16

YL - 14
205-F228 BK - 16 205-CM144 BK- 16

BU- 16

GN- 16
GY- 18

GN- 18

YL - 18

YL - 18

BR - 16

PK - 16

PK - 16

BR - 16

PK - 16

PK - 16

PU- 18

BR - 16
105-F172 RD- 16 T941-F235 BR- 16 1552273 BASE CONN 205-CM243 BK- 16 F712-CM268 GY- 16
CONN 41

YL - 16
307-F320 OR- 16 307-CM211 OR- 16 X753-L39 YL - 18

E528-F291
A515-F285
X753-F377 YL - 18

E528-F208

200-F294
308-F126 YL - 18 308-CM263 YL - 18 123-F253 WH- 18 G970-L40 BU- 18

A516-F287
T943-F234

T941-F235
T944-F329

T942-F314

E528-F265
TO FLOW CTRL VALVE

200-F227
307-CM10 OR- 16 J764-CM504 BR- 16

E528-F266
324-F218 BU - 16 324-CM49 BU- 16 205-F267 BK- 18

517-F8
BEACON FUSE ACC SOCKET 1 SEAT RADIO SW 403-F401 GN- 18 308-CM265 YL - 18

123-F205

913-F102

502-F101

521-F11
2285856
782-F260 GY- 18

2285856

2285856

2285856

2285856

2285856

2285856

2285856

2285856

2285856
403-F401 GN- 18 403-CM279 GN- 18 123-CM258 WH- 18

616-F60

608-F45
WM

753-F35

750-F34

774-F38

793-F37

503-F49

119-F48

119-F43

523-F52

119-F50

119-F46

506-F91

500-F90
615-F2
C743-F143 PK - 18 324-CM49 BU- 16 J764-CM230 BR- 16

F-C30
604-F215 OR- 16

F-C26

F-C29

F-C24

F-C53

F-C28

F-C27

F-C46

F-C45

F-C21
604-CM63 OR- 16
135-F240 BU- 18
J811-F270
J811-F159
BK- 18
BK- 18 C744-F144 PU- 18
605-F225 YL - 16 605-CM114 YL - 16 200-F28 BK- 16
200-F183 BK- 14
781-F259 PK - 18 WM
403-CM290 GN- 18
J764-CM148 BR- 18
STABILIZERS-ATCH

MOM
MOM

MOM
H17 606-F147 GY - 16 606-CM111 GY- 16 150-CM253 RD- 14

MOM
BOOM FLOOD SW
CAB PLATFORM SEL
112-F354 PU- 10 J811-F160 BK- 18 200-F184 BK- 16 403-CM279 GN- 18 J764-CM247 BR- 16 R-C1 MACHINE SECURITY SYS
F

FRONT WIPER SW
F711-CM99 GN- 16

ROOF WIPER SW

HVAC BLOWER
611-F80 PU - 16 611-CM59 PU- 16 308-CM264 YL - 18
F

REAR WIPER SW
CAB FLOOD

HEAT AC SW
FR WASHER
156-6155

TOW HITCH
141-F109 PK - 18 J811-F272 BK- 18 200-F186 BK- 18 447-CM189 PK - 18

IMP DISABLE
617-F242 BR - 16 617-CM126 BR- 16 F-C69 1506766

202-2277

190-8217

206-2607

202-2282

190-8216

190-8227

190-8218

190-8222

190-8223

246-3460

246-3461

2285856
121-F249 YL - 14 J811-F273 BK- 18 F711-F230 GN- 16 200-F187 BK- 18 1552252 G ONN 750-CM33 GN- 18 J764-CM226 BR- 18 F711-CM267 GN- 16 111-R11 RD- 14

F-C62
619-F349 GN- 16 619-CM62 GN- 16 CM-C13
LH STOP TURN TAIL FOG 144-F319 GN- 16 J811-F375 BK- 18 757-F74 PU - 18 757-CM5 PU- 18 200-F188 BK- 18 799-F176 WH- 18 W WM 753-CM34 GY- 18 J764-CM78 BR- 16 205-R3 BK- 16
200-F189 BK- 18 757-CM5 PU- 18 J764-CM245 BR- 16 F712-CM100 GY- 16 1552267
195-0194

MOM
759-F110 OR- 18 759-CM11 OR- 18 J764-F269 BR- 18 WM
LH TAIL LAMP RH TAIL LAMP ENG RUN 958-F301 YL - 16 123-F371 WH- 18 H16 200-F196 BK- 14 780-F258 PU- 18 WM 759-CM11 OR- 18 F711-CM97 GN- 16 T901-R8 YL - 16
760-F111 PK - 18 760-CM12 PK - 18 A309-CM266 GY- 16 TERMINATING RES 2B
959-F302 WH- 16 205-F228 BK- 16 H14 760-CM12 PK - 18 F712-CM268 GY- 16 F712-CM98 GY- 16
STOP 761-F112 GY - 18 761-CM13 GY- 18 778-CM28 BR- 18 134-2540
987-F281 WH- 16 307-F320 OR- 16 200-F199 BK- 16 E529-F2 J764-F366 BR- 18 761-CM13 GY- 18

GN- 14
763-F115 BU - 18 763-CM22 BU- 18 521-CM118 YL - 16 W
990-F300 GN- 16 200-F201 BK- 12 763-CM22 BU- 18 CM-C12

BR - 18

GN- 14
W

BR - 18

BR - 16

BK - 16
764-F114 PU - 18 764-CM23 PU- 18

BK - 16
522-CM119 WH- 16 1552267

GN- 16
BU- 18

WH- 18

BK - 18

PU- 18

OR- 16

PU- 18

BR - 16

BK - 18

PU- 18

YL - 16

WH- 18

BK - 18

PU- 18

BU- 16

WH- 18

BK - 18

PU- 18

GY- 16

BK - 18

PU- 18

GN- 16

GY- 16

BK - 18

PU- 18

BK - 18

PU- 18
109-F372 RD- 10 308-F126 YL - 18 765-F116 OR- 18 765-CM24 OR- 18 200-F307 BK- 14 J764-F367 BR- 18 W 764-CM23 PU- 18
TAIL A700-CM249 OR- 18

U
117-F380 RD- 16 308-F141 YL - 16 200-F276 BK- 16 765-CM24 OR- 18 136-CM116 GN- 16 RD-18

U
766-F154 GN- 16 766-CM67 GN- 16 F702-CM251 GN- 18 W
FRONT AXLE CENTER J843-R14 BK- 18
618-F243 YL - 16 200-F282 BK- 16 766-CM67 GN- 16 Y787-CM152 WH- 16 200-CM238 BK- 16 BK-18

124-F244
MATE TO 769-F72 BU - 18 769-CM275 BU- 18 F710-CM255 BR- 18 867-F408 PU- 18 W
199-0704 308-R5 YL - 16 W
125-F384 OR- 16 324-F218 BU- 16 200-F248 BK- 14 769-CM275 BU- 18 H750-CM205 BR- 18 YL-18

124-F284
CM-C22

200-F26
116-F310

200-F309
J764-F39
792-F36 OR- 18 403-R7 GN- 18

J764-F41
892-F174 BR - 16 892-CM102 BR- 16 F711-CM103 GN- 16 W M
TURN

130-F59
863-F33

799-F25

200-F31

614-F23

127-F70

614-F18

131-F61

200-F17

614-F14

504-F51

507-F56

200-F30

614-F22

524-F53

529-F55

200-F29

614-F21

118-F88

200-F97

614-F94

501-F92

118-F87

200-F98

614-F93

200-F16

614-F13
617-F5 BR- 16 604-F215 OR- 16 893-F173 GN- 16 200-F309 BK- 16 856-F405 GN- 18 W 774-CM35 YL - 18 Y788-CM153 GY- 16 W
893-CM121 GN- 16 F712-CM104 GY- 16
649-F82 YL - 16 J764-F191 BR- 18 605-F225 YL - 16 G757-CC1 OR- 18 G O 867-F407 PU- 18 WM 775-CM25 BR- 18 308-R6 YL - 16 W
993-CM250 BR- 18
606-F147 GY- 16 J755-F118 BU - 16 J755-CM53 BU- 16 776-CM26 YL - 18 892-CM273 BR- 16
FOG
RADIO UNSW HORN FUSE A4E1 ECM A4M1 ECM 611-F80 PU- 16 J756-F119 BR - 16 J756-CM52 BR- 16 778-CM28 BR- 18 H5 893-R1 GN- 16
617-F242 BR- 16 J758-F121 PK - 16 J758-CM51 PK - 16 779-CM29 WH- 18 893-CM271 GN- 16 892-R2 BR- 16
111-CM96 RD- 12
619-F349 GN- 16 J760-F120 YL - 16 J760-CM50 YL - 16 867-F404 PU- 18 780-CM84 PU- 18
111-CM274 RD- 14
627-F395 YL - 16
757-F74 PU- 18
J764-F107
P909-F71
BR - 16
PK - 18
J764-CM78 BR- 16
P909-CM6 PK - 18
136-CM116 GN- 16
200-CM237 BK- 16
RH CONSOLE 781-CM85 PK - 18
782-CM86 GY- 18
J811-CM228 BK- 18 A4M1 MACHINE CONTROL
295-3460 T902-R15 PK - 16
111-F318 RD- 12 759-F110 OR- 18 H24 783-CM83 OR- 18 CM-C3
J811-F270 BK - 18 J811-CM128 BK- 18
109-F325 RD- 10 760-F111 PK - 18 784-CM27 YL - 18 1471445
205-CM239 BK- 14 F846-R12 PU- 18
LH STOP TAIL TURN REV
150-F303
114-F251
RD- 14
RD- 16
761-F112 GY- 18
763-F115 BU- 18
CONN 13 307-CM10 OR- 16 785-CM30 PK - 16 308-CM265 YL - 18 W G848-R13 GN- 18
F-C36 CM-C6 308-CM265 YL - 18 792-CM36 OR- 18 E900-CM32 WH- 18 M
295-3381 108-F406 RD- 18 764-F114 PU- 18 H8
F-C4 2253861 2253854 324-CM49 BU- 16 793-CM43 YL - 18 E901-CM31 GN- 18 M W
1249636 765-F116 OR- 18 794-CM88 YL - 16
STOP
CM-C22 FUSE BLOCK F-C76
1552269
766-F154 GN- 16
769-F72 BU- 18
167-F299
321-F146
OR- 16
BR- 18
167-CM169 OR- 16
321-CM124 BR- 18 403-CM290 GN- 18 109-FR323 RD- 2 795-CM69 YL - 16
C743-CM82 PK - 18 E902-CM2 PU- 18 M M
308-R4 YL - 16
1552273 521-F11 YL - 14 521-CM118 YL - 16 403-CM279 GN- 18
J764-F191 BR- 18 775-F341 BR- 18 X-C9 C744-CM81 PU- 18 E903-CM3 YL - 18 M M
604-CM172 OR- 16 522-F103 WH- 16 522-CM119 WH- 16 447-CM189 PK - 18
TAIL
617-CM131 BR- 16 CONN 9 447-F271 PK - 18 776-F347 YL - 18
C919-F346 PU- 18 612-F288 GY- 18 612-CM174 GY- 16 750-CM33 GN- 18
XXX-XXXX
A/C COMPRESSOR C917-CM500 YL - 18
605-CM115 YL - 16 CM-C14 HA-C1 753-CM34 GY- 18 Y793-X54 YL - 18 C919-CM501 PU- 18 308-R4 YL - 16
616-F60 BU- 16 616-CM145 BU- 16
E TURN
627-CM277 YL - 16 1552272 3E3376 778-F344 BR- 18
C917-F345 YL - 18 618-F243 YL - 16 618-CM127 YL - 16 757-CM5 PU- 18
CONN 22 Y792-X45 PK - 18 C905-CM55 OR- 16
C903-CM54 BU- 16
893-CM122 GN- 16
CM-C37 R-C2
308-R5 YL - 16
E
612-CM176 GY- 16 200-CM137
200-CM234
BK- 16
BK- 16
958-CM167 YL - 16 YL - 16
H5
627-F395 YL - 16 627-CM248 YL - 16 759-CM11 OR- 18
W-C16 W-C28 CM-C9 FUEL INJ PUMP
BLOWER ON REPLACES HEAT A/C SW (F-6) H764-CM46 GY- 18 321-CM107 BR- 18 M CONN 37 3E5179 1552252
308-R6 YL - 16
200-CM137 BK- 16 959-CM165 WH- 16 BU - 16 750-F34 GN- 18 750-CM33 GN- 18 760-CM12 PK - 18
604-CM172 OR- 16 1552269 1673692 1673693 247-5539 WHEN A/C IS NOT INSTALLED H765-CM47 WH- 18 205-CM241 BK- 16 M 893-CM272 GN- 16 893-R1 GN- 16
987-CM164 WH- 16 WH- 16 753-F35 GY- 18 753-CM34 GY- 18 761-CM13 GY- 18 F770-X1 BR- 18 225-5173
REV 605-CM115 YL - 16 SENDER FUEL H18 J764-CM78 BR- 16 F799-CM44 BU- 16 M 892-CM270 BR- 16 892-R2 BR- 16
990-CM159 GN- 16 GN- 16 774-F38 YL - 18 774-CM35 YL - 18 763-CM22 BU- 18 XMSN INTMED SP SNSR 1 BK-18 E903-W32 YL - 18 E908-W59 BR- 18 E908-CM21 BR- 18 A278-X89 BK- 14 H19
612-CM176 GY- 16 295-3421 189-9801 E908-CM21 BR- 18 308-CM269 YL - 16 308-R4 YL - 16
780-F258 PU- 18 780-CM84 PU- 18 764-CM23 PU- 18 BK-18 E902-W33 PU- 18 P916-W45 OR- 18 P916-CM9 OR- 18 329-X90 YL - 14 200-E72 BK- 14 205-CM201 BK- 16
765-CM24 OR- 18 OND U OW 991-W3 WH- 18 991-CM4 WH- 18 999-X55 WH- 18 X753-CM509 YL - 18 E909-CM20 WH- 18 205-CM201 BK- 16 205-R3 BK- 16
779-F340 WH- 18 781-F259 PK - 18 781-CM85 PK - 18 521-E6 YL - 16 111-CM274 RD- 14
617-CM131 BR- 16 X753-CM508 YL - 18 111-CM274 RD- 14
CONN 8 784-F262 YL - 18 782-F260 GY- 18 782-CM86 GY- 18 766-CM67 GN- 16 C993-W4 WH- 18 C993-CM8 WH- 18 522-E7 WH- 16 308-CM269 YL - 16 111-R11 RD- 14
CONN 6 617-CM156
627-CM277
BR- 16
YL - 16 CM-C35 HF-C1 785-F263 PK - 18 783-F295 OR- 18 783-CM83 OR- 18 769-CM275 BU- 18 W-C17
1552269
T800-W19 OR- 18 T800-CM225 OR- 18 X-C10
1779654 AF-C5
A/C MOD
212-2204
AF-C3
3E3376 X753-CM48 YL - 18
403-CM290 GN- 18
CL-C1 CL-C3 CM-C23 1552272 3E3376 784-F262 YL - 18 784-CM27 YL - 18 774-CM35 YL - 18 755-W7 OR- 18 755-CM15 OR- 18 892-CM270 BR- 16
A700-F356 OR- 18 1684999 852-CM282 GN- 18 892-CM120 BR- 16
1552269 3E3364 1552269 785-F263 PK - 18 785-CM30 PK - 16 775-CM25 BR- 18 TC SP SNSR BK-18 E909-W51 WH- 18 975-W12 WH- 18 975-CM66 WH- 18 323-X68 WH- 14 RD-14 GN 513-AF4 OR- 16 893-CM272 GN- 16
167-CM216 OR- 16 167-HF1 OR- 16 F702-F358 GN- 18 W 856-CM283 GN- 18 L740-CM75 BR- 18
792-F36 OR- 18 792-CM36 OR- 18 776-CM26 YL - 18 W D 191-8305 BK-18 E908-W59 BR- 18 443-W38 YL - 18 443-CM235 YL - 18 329-X90 YL - 14 OR-14 VLPM 513-AF4 OR- 16 W RD 521-AF3 YL - 16
REG PLATE LAMP 1 BK-18 617-CL3 BR- 16 617-CL1 BR- 16 617-CM156 BR- 16 790-CM223 BU- 18 790-HF2 BU- 18 H4 443-CM235 YL - 18 M
793-F37 YL - 18 793-CM43 YL - 18 778-CM28 BR- 18 E909-W51 WH- 18 E909-CM20 WH- 18 A278-X89 BK- 14 BR-14 216-2621 AIR RESTRICTION IND 522-AF1 WH- 16 BK 200-AF5 BK- 14
196-0030 BK-18 200-CL4 BK- 16 200-CL2 BK- 16 200-CM234 BK- 16 762-CM261 YL - 18 762-HF4 YL - 18 F712-F231 GY- 16 863-CM45 BU- 18 403-CM290 GN- 18 403-R7 GN- 18
863-F33 BU- 18 863-CM45 BU- 18 779-CM29 WH- 18 E901-W34 GN- 18 E901-CM31 GN- 18 200-X67 BK- 14 BK-14 151-8367 E-C5 BU E554-AF7 PK - 14
205-CM217 BK- 18 205-HF3 BK- 18
987-F281 WH- 16 987-CM164 WH- 16 780-CM84 PU- 18 CONN 19 428-W39 OR- 18 428-CM72 OR- 18 1166158 867-CM284 PU- 18
869-CM281 PU- 18
W
W
R-C4
990-F300 GN- 16 990-CM159 GN- 16 C903-CM54 BU- 16 752-W15 YL - 18 752-CM41 YL - 18 BK-18 A/C HIGH PRESS SW 1552269
A710-E48 GY- 18 892-CM120 BR- 16 758-CM260 GN- 18
F710-F369 BR- 18 F710-CM255 BR- 18 781-CM85 PK - 18 751-W1 GN- 18 751-CM42 GN- 18 X-C1 236-6923 AF-C2 M W W
H19 BK-18 F729-E60 GN- 18 WH-18 T901-R8 YL - 16
754-W6 BU- 18 1696870 1552269 893-CM122 GN- 16 P909-CM6 PK - 18 M W M
F711-F230 GN- 16 F711-CM103 GN- 16 782-CM86 GY- 18 754-CM14 BU- 18 BK-18 T902-R15 PK - 16
F712-F231 GY- 16 F712-CM104 GY- 16 783-CM83 OR- 18 901-W9 WH- 18 901-CM17 WH- 18 L730-X84 OR- 18 RD-18 A/C COMPRESSOR GP GN-14 E554-AF7 PK - 14 P909-CM6 PK - 18 769-CM275 BU- 18 M W
J755-F118 BU- 16 FERRITE COIL R-C3
H764-F163 GY- 18 H764-CM46 GY- 18 784-CM27 YL - 18 J764-W55 BR- 18 J764-CM226 BR- 18 L731-X81 BR- 18 BK-18 178-9570 GN-14 200-AF6 BK- 14 222-3870 1552269
J756-F119 BR- 16 W-C19 H22 F799-CM44 BU- 16 447-CM189 PK - 18
T943-F234 GY- 16 785-CM30 PK - 16 E900-W35 WH- 18 E900-CM32 WH- 18 X731-X13 BU- 18 YL-18 BK-18 T902-R10 PK - 16
CM-C21 J758-F121 PK - 16 1552269
CL-C2 3E3376 J760-F120 YL - 16 T941-F235 BR- 16 OIL FILTER BYPASS SW WH-18 T901-R9 YL - 16
W INTAKE MANIFOLD PRESS SNSR 321-CM107 BR- 18
1552269 T944-F329 GN- 16 792-CM36 OR- 18 XMSN OUT SP SNSR BK-18 E901-W34 GN- 18 324-W53 BU- 16 324-CM49 BU- 16 203-7984 E-C6
REG PLATE LAMP 2 BK-18 617-CL5 BR- 16 LSI STRAIN SNSR
T800-CM146 OR- 18
J764-CM148 BR- 18 167-CM216 OR- 16
J764-F107
K791-F416
BR- 16
OR- 16 T942-F314 PK - 16 793-CM43 YL - 18 189-5746 BK-18 E900-W35 WH- 18 200-W54 BK- 16 200-CM227 BK- 16 X-C2
1552269
203-4344
1552269 CONN 27 352-CM136 BU- 18
758-CM260 GN- 18
757-CM5 PU- 18
762-CM261 YL - 18
M
M W
W

295-3382 BK-18 227-4455 794-CM88 YL - 16 756-W52 WH- 18 756-CM141 WH- 18 BK-18 E450-E9 GN- 18 E-C7 AF-C1
200-CL6 BK- 16 874-CM288 GY- 18 J811-CM128 BK- 18 852-F388 GN- 18 M UM 762-CM261 YL - 18 E450-CM191 GN- 18 M
795-CM69 YL - 16 H802-W29 GY- 18 H802-CM73 GY- 18 C967-X29 BU- 18 INTAKE MANIFOLD TEMP SNSR BK-18 J764-E33 BR- 16 1552272 3E3376 H23
869-F389 PU- 18
205-CM217 BK- 18 CONN 12 L731-X82 BR- 18 191-6563 786-CM221 GN- 18 R-C6
LEDS IN CAB

RD- 2
892-F174 BR- 16 522-E7 WH- 16 Y761-CM56 OR- 18
133-CM108 OR- 14 F-C33 CM-C7 C743-CM82 PK - 18 W-C20 1552267
167-CM216 OR- 16 893-F173 GN- 16 W D 200-E72 BK- 14 200-AF2 BK- 14 200-AF6 BK- 14 790-CM223 BU- 18 111-CM92 RD- 14 W
CONN 3 205-CM217 BK- 18
136-CM95 GN- 16
167-CM169 OR- 16 123-F371
1673692
WH- 18
1673693
123-CM258 WH- 18
C744-CM81 PU- 18 1552269 E903-W32 YL - 18
E902-W33 PU- 18
E903-CM3
E902-CM2
YL - 18
PU- 18
200-AF5 BK- 14 799-CM90 WH- 16 111-CM93 RD- 14 W F846-R12 PU- 18
J843-R14 BK- 18
CP-C1 CN-C2 CN-C1 CM-C34 133-CM147 OR- 14 762-CM261 YL - 18 C905-CM55 OR- 16 XMSN OIL TEMP 428-W39 OR- 18 521-E6 YL - 16 521-AF3 YL - 16 H751-CM204 OR- 18 775-CM1 BR- 16

109-F323
1552269 3E3364 3E3364 1552267 133-F355 OR- 14 133-CM108 OR- 14 L740-W27 BR- 18 L740-CM75 BR- 18 G848-R13 GN- 18
133-CM182 OR- 14 790-CM223 BU- 18 200-CM133 BK- 16 130-9811 L740-W27 BR- 18 X-C3 Y758-CM194 PK - 18 W
C917-CM500 YL - 18 X750-W16 OR- 18 X750-CM65 OR- 18
D 614-CP1 PU- 18
200-CP2 BK- 18
617-CN1 BR- 18
617-CN2 BK- 18 TERMINATING RES 1A Y787-CM157
Y788-CM158
WH- 16
GY- 16
205-CM154 BK- 14
205-CM184 BK- 14
958-CM167
959-CM165
YL - 16
WH- 16
200-CM139 BK- 16 993-F357
P909-F71
BR- 18
PK - 18
136-F246
150-F306
GN- 16
RD- 14
136-CM117 GN- 16
150-CM253 RD- 14 902-W25 BR- 18 902-CM18 BR- 18 1552269
Y787-CM152 WH- 16
776-CM60 YL - 16
790-CM223 BU- 18 M
W
W D
134-2540 447-F271 PK - 18 447-CM189 PK - 18 C919-CM501 PU- 18 900-W8 PU- 18 900-CM16 PU- 18 995-X14 BU- 18 COOLANT TEMP SNSR
Y761-CM56 OR- 18 987-CM164 WH- 16 191-6563 123-CM258 WH- 18 H8 Y788-CM153 GY- 16 T800-CM213 OR- 18 W
O ON G 775-F341 BR- 18 775-CM25 BR- 18 H764-CM46 GY- 18 L731-X80 BR- 18
ON H H H 799-CM89 WH- 18 990-CM159 GN- 16 200-CM232 BK- 14 H765-CM47 WH- 18 150-CM253 RD- 14 J764-CM245 BR- 16
111-F209 RD- 12 776-F347 YL - 18 776-CM26 YL - 18
J764-CM78 BR- 16 308-CM264 YL - 18 874-CM288 GY- 18
200-CM137 BK- 16 C919-F346 PU- 18 C919-CM501 PU- 18
799-CM90 WH- 16 X753-CM48 YL - 18 W-C23 A309-CM266 GY- 16 892-CM273 BR- 16 111-CM94 RD- 14 W
133-F355 OR- 14 778-F344 BR- 18 778-CM28 BR- 18 NOTE C
200-CM138 BK- 16 X-C5 521-CM118 YL - 16 893-CM271 GN- 16 754-CM14 BU- 18 M
799-CM91 WH- 18 133-CM108 OR- 14 136-F246 GN- 16 C917-F345
779-F340
YL - 18
WH- 18
C917-CM500 YL - 18
779-CM29 WH- 18
852-CM282
856-CM283
GN- 18
GN- 18 SHUTTLE XMSN-ATCH DIFF LOCK SOL BK-18
1552269
324-W53 BU- 16 200-X67 BK- 14 1552269
200-E72 BK- 14
522-CM119 WH- 16 J811-CM132 BK- 18 755-CM15 OR- 18 M MACHINE SECURITY SYS-ATCH
200-CM170 BK- 14 195-9700 BK-18 200-W54 BK- 16 E966-X38 YL - 18 BK-18 ENGINE SPEED SNSR 200-E74 BK- 14 A700-CM249 OR- 18 J811-CM228 BK- 18 975-CM66 WH- 18 M
150-F306 RD- 14 794-F283 YL - 16 794-CM88 YL - 16 RF-C89 H16 J758-CM37 PK - 16
799-CM183 WH- 18 863-CM45 BU- 18 323-X68 WH- 14 E965-X46 BU- 18 BK-18 192-7359 F702-CM251 GN- 18 J764-CM148 BR- 18 900-CM16 PU- 18 M
CM-C16 133-CM147 OR- 14 167-F299 OR- 16 795-F162 YL - 16 795-CM69 YL - 16 1552269 J758-CM311 PK - 16
2312295 Y758-CM194 PK - 18
133-CM182 OR- 14
200-CM234 BK- 16 321-F146 BR- 18 799-F290 WH- 18 799-CM91 WH- 18 867-CM284 PU- 18 CONN 28 K791-RF416 OR- 16
229-E21 BK- 14 F710-CM255
F711-CM103
BR- 18
GN- 16
G962-CM140 OR- 18 901-CM17 WH- 18
428-CM72 OR- 18
M
M M
852-F388 GN- 18 852-CM282 GN- 18 869-CM281 PU- 18 W-C25 329-X90 YL - 14 TO REV FAN ATCH FRAME LVL SOL1 CM-C43
Y759-CM199 YL - 18 136-CM95 GN- 16 200-CM142 BK- 14 1552272 200-RF2 BK- 16 BUS BAR 1 F712-CM104 GY- 16 T800-CM146 OR- 18 X750-CM65 OR- 18 WM W CM-C30 1552269
856-F405 GN- 18 856-CM283 GN- 18 892-CM120 BR- 16 TH220B ONLY 375-E49 BR- 18 201-0315
Y761-CM56 OR- 18 BK-18 T800-W56 OR- 18 A278-X89 BK- 14 X-C6 114-4516 993-CM250 BR- 18 X753-CM509 YL - 18 WM 1552269
200-CM133 BK- 16 C903-F169 BU- 16 867-F404 PU- 18 867-CM284 PU- 18 893-CM122 GN- 16 W T800-CM225 OR- 18 J756-CM310 BR- 16 FRAME LVL SUPPR 1
Y787-CM150 WH- 16 200-CM171 BK- 14 BK-18 J764-W48 BR- 18 1552267 A710-E48 GY- 18
200-CM137 BK- 16 C905-F229 OR- 16 869-F389 PU- 18 869-CM281 PU- 18 P909-CM6 PK - 18 J758-CM308 PK - 16 BK-18 J758-CM311 PK - 16 106-8704
799-CM89 WH- 18 BK-18 991-W3 WH- 18 L730-X84 OR- 18 L730-X85 OR- 18 RD-18 205-CM242 BK- 16 M
200-CM139 BK- 16 958-F301 YL - 16 958-CM167 YL - 16 F799-CM44 BU- 16 OIL PRESSURE SNSR T800-CM213 OR- 18 H21 J758-CM51 PK - 16 J756-CM309 BR- 16 BK-18
205-CM154 BK- 14 Y787-CM150 WH- 16 205-CM154 BK- 14 BK-18 L731-X83 BR- 18 BK-18 F729-E60 GN- 18 902-CM18 BR- 18 M
Y788-CM151 GY- 16 200-CM234 BK- 16 A309-F374 GY- 16 959-F302 WH- 16 959-CM165 WH- 16 190-0809 306-CM200 GN- 18
205-CM134 BK- 14 L730-X85 OR- 18 994-X23 GY- 18 YL-18 756-CM141 WH- 18 M M
Y787-CM157 WH- 16 205-CM154 BK- 14 447-F271 PK - 18 993-F357 BR- 18 993-CM250 BR- 18 SHIFT RAIL SNSR 1 109-E25 RD- 2 403-CM278 GN- 18 754-CM14 BU- 18 J756-CM52 BR- 16
Y759-CM199 YL - 18 205-CM184 BK- 14 H802-CM61 GY- 16 WM
205-CM184 BK- 14 612-F288 GY- 18 A309-F374 GY- 16 A309-CM266 GY- 16 111-CM274 RD- 14 214-8970 150-E43 RD- 14 E450-CM191 GN- 18 200-CM227 BK- 16
133-CM147 OR- 14 Y787-CM187 WH- 16 205-CM233 BK- 16 W-C26 443-W38 YL - 18 L731-X80 BR- 18 123-E51 WH- 18 P936-CM64 GY- 16 M J756-CM310 BR- 16
618-F243 YL - 16 A700-F356 OR- 18 A700-CM249 OR- 18 200-CM236 BK- 16 F712-CM268 GY- 16 324-CM49 BU- 16
352-CM136 BU- 18 205-CM289 BK- 14 205-CM201 BK- 16 1552272 751-W1 GN- 18 150-E55 RD- 14 WM
PHS VALVE SSV4 CM-C19 783-F295 OR- 18 C743-F143 PK - 18 C743-CM82 PK - 18 F711-CM267 GN- 16 H22 428-CM72 OR- 18
295-3450 2312295 Y787-CM188 WH- 16
Y761-CM56
604-CM172
OR- 18
OR- 16
307-CM208
321-CM124
OR- 16
BR- 18 794-F283 YL - 16 C744-F144 PU- 18 C744-CM81 PU- 18 308-CM269 YL - 16 W BK-18 T800-W42 OR- 18 752-W15 YL - 18 L731-X82 BR- 18 CONN 26 150-E56 RD- 16
150-E55 RD- 14
150-E56 RD- 16 443-CM235 YL - 18
793-CM43 YL - 18
774-CM35 YL - 18
M M
M M
W
W
CM-C46
F702-F358 GN- 18 F702-CM251 GN- 18 403-CM290 GN- 18 BK-18 J764-W49 BR- 18 754-W6 BU- 18 X-C7 E-C9 308-E40 YL - 18 751-CM42 GN- 18 1552269
605-CM115 YL - 16 795-F162 YL - 16 J811-CM228 BK- 18 G970-CM507 BU- 18 W F799-CM38 BU- 16
H765-F164 WH- 18 H765-CM47 WH- 18 606-CM109 GY- 16 BK-18 C993-W4 WH- 18 755-W7 OR- 18 L731-X83 BR- 18 1673692 1673693 308-E69 YL - 18 752-CM41 YL - 18 J758-CM37 PK - 16 FRAME LVL DUMP POS 1
Y759-CM199 YL - 18 Y787-CM152 WH- 16 612-CM176 GY- 16 604-CM63 OR- 16 799-F290 WH- 18 J764-CM230 BR- 16 794-CM88 YL - 16 F799-CM44 BU- 16 F799-CM40 BU- 16
C903-F169 BU- 16 C903-CM54 BU- 16 611-CM59 PU- 16 BK-18 756-W52 WH- 18 323-E46 WH- 14 755-CM15 OR- 18 F799-CM38 BU- 16 106-8704
Y787-CM188 WH- 16 616-CM145 BU- 16 H20 F710-F369 BR- 18 150-X52 RD- 18 150-E43 RD- 14 892-CM273 BR- 16 751-CM42 GN- 18 M W
Y788-CM158 GY- 16 C905-F229 OR- 16 C905-CM55 OR- 16 618-CM129 YL - 16 SHIFT RAIL SNSR 2 X750-W16 OR- 18 L731-X81 BR- 18 150-X52 RD- 18 RESISTOR ALT 325-E47 PK - 18 756-CM141 WH- 18
799-CM183 WH- 18 617-CM131 BR- 16 604-CM172 OR- 16 H764-F163 GY- 18 229-X64 BK- 18 229-E21 BK- 14 134-2540 893-CM271 GN- 16 752-CM41 YL - 18 M
Y788-CM151 GY- 16 X753-F378 YL - 18 X753-CM48 YL - 18 619-CM62 GN- 16 H21 214-8970 900-W8 PU- 18 200-X67 BK- 14 200-E74 BK- 14 A309-E52 GY- 16 J764-CM226 BR- 18
205-CM184 BK- 14 617-CM156 BR- 16 604-CM173 OR- 16 H765-F164 WH- 18 W-C27 325-X39 PK - 18 325-E47 PK - 18 799-CM90 WH- 16 W
J755-CM53 BU- 16 901-W9 WH- 18 308-E69 YL - 18 E450-E9 GN- 18 X750-CM65 OR- 18 CM-C47
Y788-CM186 GY- 16 627-CM277 YL - 16 604-CM178 OR- 16 X753-F378 YL - 18 1552272 200-X67 BK- 14 200-E74 BK- 14 205-CM243 BK- 16 M
J756-CM52 BR- 16 902-W25 BR- 18 229-X64 BK- 18 229-E21 BK- 14 C444-E67 YL - 18 521-E6 YL - 16 900-CM16 PU- 18 1552269
Y758-CM194 PK - 18 Y788-CM185 GY- 16 308-X66 YL - 18 308-E68 YL - 18 CM-C4
799-CM90 WH- 16 F799-CM44 BU- 16 J758-CM51 PK - 16 W BK-18 T800-W41 OR- 18 991-W3 WH- 18 308-X66 YL - 18 522-E7 WH- 16 901-CM17 WH- 18 J760-CM39 YL - 16 FRAME LVL DUMP POS 2
133-CM182 OR- 14 605-CM113 YL - 16 J811-F270 BK- 18 A4E1 ENGINE CONTROL X-C8 F710-X28 BR- 18 F710-E59 BR- 18 1471446
799-CM91 WH- 18 J760-CM50 YL - 16 BK-18 J764-W50 BR- 18 E-C4 A700-E58 OR- 18 902-CM18 BR- 18 F799-CM40 BU- 16 106-8704
958-F301 YL - 16 190-0416 1471445 375-X40 BR- 18 375-E49 BR- 18 307-CM10 OR- 16 W
C Y788-CM186 GY- 16
H751-CM204 OR- 18 605-CM115 YL - 16 959-F302
987-F281
WH- 16
WH- 16
136-CM95 GN- 16
892-CM270
893-CM272
BR- 16
GN- 16
BK-18
BK-18
P916-W45 OR- 18 C993-W4 WH- 18
P916-W45 OR- 18 M F770-X1 BR- 18
323-X68 WH- 14
323-X68 WH- 14
F715-X33 PU- 18
323-E46 WH- 14 1552267 F702-E57 GN- 18
F710-E59 BR- 18
975-CM66 WH- 18
991-CM4 WH- 18
G962-CM140 OR- 18 M
J760-CM39
J760-CM315
YL - 16
YL - 16 C
J764-CM148 BR- 18 606-CM110 GY- 16 136-CM116 GN- 16 W A709-X77 OR- 18 308-E68 YL - 18 F711-E62 GN- 16 795-CM69 YL - 16
990-F300 GN- 16 SHIFT RAIL SNSR 3 F709-X11 BU- 18 C993-CM8 WH- 18
Y788-CM153 GY- 16 Y758-CM194 PK - 18 606-CM112 GY- 16 136-CM117 GN- 16 W 325-X39 PK - 18 F711-E63 GN- 16 352-CM136 BU- 18 M J760-CM50 YL - 16 J760-CM312 YL - 16
CM-C18 214-8970 F707-X12 WH- 18 E900-CM32 WH- 18
F799-CM44 BU- 16 W-C18 893-X3 GN- 18 375-X40 BR- 18 308-E69 YL - 18 F712-E65 GY- 16 H764-CM46 GY- 18
1552269 F708-X22 YL - 18 101-EY1 RD- 2 W E901-CM31 GN- 18
Y787-CM152 WH- 16 612-CM174 GY- 16 1552269 H765-CM47 WH- 18

NOTE C
205-CM144 BK- 16 892-X4 BR- 18 A700-X16 OR- 18 308-E40 YL - 18 F712-E64 GY- 16 150-E56 RD- 16 E902-CM2 PU- 18 J755-CM53 BU- 16
IMP DISABLE SOL BK-18 G962-CM140 OR- 18 Y788-CM153 GY- 16 200-F286 BK- 16 A709-X77 OR- 18 ALTERNATOR (90A) 306-CM200 GN- 18
205-CM149 BK- 14 TC OIL TEMP 443-W38 YL - 18 WM A701-X62 GY- 18 J764-E33 BR- 16 E903-CM3 YL - 18 CM-C44
200-6210 BK-18 352-CM136 BU- 18 874-CM288 GY- 18 612-CM175 GY- 16 308-F141 YL - 16 A700-E58 OR- 18 A700-E58 OR- 18 207-6035 J811-CM132 BK- 18
205-CM154 BK- 14 130-9811 J764-W40 BR- 18 WM A702-X61 PU- 18 323-E46 WH- 14 101-E29 RD- 10 308-E69 YL - 18 E908-CM21 BR- 18 1552269
T800-CM146 OR- 18 612-CM176 GY- 16 893-X3 GN- 18 893-E24 GN- 16 ATCH (120A) 869-CM281 PU- 18 W J755-CM313 BU- 16
CM-C36 308-F141 YL - 16 133-CM108 OR- 14 J764-W55 BR- 18 WM A703-X60 BR- 18 325-E47 PK - 18 892-E53 BR- 16 E909-CM20 WH- 18 J755-CM314 BU- 16 FRAME LVL SUPPR 2
CM-C20 G962-CM140 OR- 18 205-CM184 BK- 14 892-X4 BR- 18 892-E53 BR- 16 211-6802 783-CM83 OR- 18 M
1552272 136-CM95 GN- 16 W A711-X8 PU- 18 A704-X59 GN- 18 375-E49 BR- 18 893-E24 GN- 16 323-E46 WH- 14 P916-CM9 OR- 18 J755-CM314 BU- 16 J760-CM315 YL - 16 106-8704
1552267 616-CM145 BU- 16 200-F286 BK- 16 205-CM201 BK- 16 993-X41 BR- 18 993-E34 BR- 18 C903-CM54 BU- 16
BR-16 109-F324 RD- 10 167-CM169 OR- 16 J764-W50 BR- 18 W F720-X9 GN- 18 A705-X63 BU- 18 A700-E58 OR- 18 993-E34 BR- 18
W 167-CM212 OR- 16 OR-18 136-CM95 GN- 16 617-CM131 BR- 16 A746-X17 PK - 18 H802-CM61 GY- 16 C905-CM55 OR- 16
REAR AXLE CENTER 307-CM10 OR- 16 200-CM170 BK- 14 J764-W40 BR- 18 W F718-X10 BU- 18 A706-X51 GY- 18 A710-E48 GY- 18 308-E69 YL - 18 325-E47 PK - 18
BOOM LOWERED BK-16 786-CM221 GN- 18 BK-18 200-CM139 BK- 16 200-CM142 BK- 14 617-CM156 BR- 16 109-F325 RD- 10 F703-X78 GY- 18 FUSE FUEL PUMP H802-CM73 GY- 18 H802-CM57 GY- 16 Y758-CM194 PK - 18 CM-C31
199-0704 109-F372 RD- 10 307-CM208 OR- 16 200-CM171 BK- 14 J764-W48 BR- 18 F709-X11 BU- 18 A707-X58 PU- 18 F702-E57 GN- 18 MAIN BKR 403-E3 GN- 18
295-3452 WH-16 758-CM260 GN- 18 WH-18 H751-CM204 OR- 18 617-CM179 BR- 16 997-X42 OR- 18 232-6312 403-CM190 GN- 18 M 1552269
112-F350 PU- 10 200-CM232 BK- 14 J764-W49 BR- 18 F707-X12 WH- 18 F710-E59 BR- 18 216-4970 109-E25 RD- 2 101-E29 RD- 10 L740-CM75 BR- 18
BU-16 205-CM218 BK- 18 205-CM217 BK- 18 618-CM130 YL - 16 F716-X25 WH- 18 852-CM282 GN- 18 W BK-18 FRAME LVL SOL2
112-F351 PU- 10 307-CM211 OR- 16 205-CM134 BK- 14 X731-X13 BU- 18 A708-X50 BR- 18 F729-E60 GN- 18
618-CM177 YL - 16 F719-X18 BR- 18 122-E45 BU- 12 874-CM288 GY- 18 BK-18 201-0315
308-CM263 YL - 18 205-CM154 BK- 14 T800-W19 OR- 18 995-X14 BU- 18 A709-X77 OR- 18 E-C14
CONN 5 205-CM218 BK- 18 112-F352 PU- 10
308-CM264 YL - 18 205-CM184 BK- 14 WM F702-X15 GN- 18 A710-X21 GY- 18
A710-X21 GY- 18
F718-X10 BU- 18
A710-E48 GY- 18
892-E53 BR- 16 9X1054 CONN 29 M M
627-CM248 YL - 16 751-W1 GN- 18 T800-W41 OR- 18 A700-X16 OR- 18 A711-X8 PU- 18 E-C1 CM-C8 768-CM298 OR- 18 W W
CA-C1 CM-C29 308-CM265
308-CM269
YL - 18
YL - 16
205-CM233 BK- 16
205-CM289 BK- 14 752-W15 YL - 18 T800-W56 OR- 18
m
A746-X17 PK - 18 A712-X35 BR- 18
F717-X19 YL - 18 893-E24
993-E34
GN- 16
BR- 18 1673692 1673693 863-CM45 BU- 18 M W CONN 38
3E3364 1552269 205-CM233 BK- 16 627-CM276 YL - 16 F721-X27 GY- 18 150-E56 RD- 16 M CM-C1 CF-C1 CF-C2
321-CM107 BR- 18 307-CM208 OR- 16 T800-W42 OR- 18 W F719-X18 BR- 18 A746-X17 PK - 18 306-E1 GN- 18 306-CM200 GN- 18
H6 616-CA1 BU - 16 616-CM145 BU- 16 F702-X15 GN- 18 F702-E57 GN- 18 CBL-JJ1 E-C15 325-E47 PK - 18 M 1552273 3E3382 1552273
BACKUP ALARM 321-CM125 BR- 18 321-CM124 BR- 18 605-CM113 YL - 16 321-CM124 BR- 18 754-W6 BU- 18 W F717-X19 YL - 18 E798-X43 PK - 18 J811-E2 BK - 18 J811-CM228 BK- 18
200-CA2 BK 16 200-CM133 BK- 16 321-CM107 BR- 18 F729-X34 GN- 18 F729-E60 GN- 18 2254950 323-E46 WH- 14
170-0950 J811-CM135 BK- 18 627-CM277 YL - 16 605-CM114 YL - 16 604-CM63 OR- 16 755-W7 OR- 18 975-W12 WH- 18 W F722-X20 OR- 18 F700-X36 BU- 18 F711-E62 GN- 16 403-E3 GN- 18 403-CM278 GN- 18
321-CM124 BR- 18 F727-X26 BU- 18 306-CM200 GN- 18 792-CM36 OR- 18 W W 611-CM59 PU- 16 611-CF4 PU- 16 BU-18 RH HEAD TURN POS LAMP
605-CM115 YL - 16 605-CM113 YL - 16 756-W52 WH- 18 W A710-X21 GY- 18 F701-X44 BR- 18 F711-E63 GN- 16 521-E6 YL - 16 521-CM118 YL - 16
799-CM91 WH- 18 F711-X49 GN- 18 F711-E61 GN- 18 101-E41 RD- 12 E450-CM191 GN- 18 H751-CM204 OR- 18 W 619-CM62 GN- 16 619-CF6 GN- 16 RD-18 195-0191 LH DIP
605-CM115 YL - 16 900-W8 PU- 18 975-W22 WH- 18 F708-X22 YL - 18 F702-X15 GN- 18 522-E7 WH- 16 522-CM119 WH- 16
604-CM178 OR- 16 892-CM101 BR- 16 F712-X57 GY- 18 F712-E66 GY- 18 FUEL PUMP RL F711-CM267 GN- 16 759-CM11 OR- 18 M 618-CM129 YL - 16 618-CF3 YL - 16 WH-18 195-0189 RH DIP
CK-C1 CONN 4 605-CM113 YL - 16 893-CM123 GN- 16
RR TT VV
606-CM109 GY- 16
606-CM110 GY- 16 901-W9 WH- 18
902-W25 BR- 18
975-W24
975-W23
WH- 18
WH- 18
994-X23
F703-X78
GY- 18
GY- 18
F703-X78 GY- 18
F705-X47 PK - 18 F711-E61 GN- 18
CBL-JJ2 115-1615
J764-E33 BR - 16
E450-E9 GN- 18
J764-CM230
E450-CM191
BR- 16
GN- 18
NOTE C
F712-CM268 GY- 16 760-CM12 PK - 18 M 606-CM109 GY- 16 606-CF1 GY- 16 YL-18
8I5176 CK-C2 CM-C26 606-CM112 GY- 16 J811-CM128 BK- 18 J764-CM230 BR- 16 761-CM13 GY- 18 M 200-CM236 BK- 16 200-CF2 BK- 16 BK-18
606-CM110 GY- 16 606-CM112 GY- 16 X750-W16 OR- 18 975-W21 WH- 18 m L730-X24 OR- 18 F706-X56 PU- 18 ALT BRKR 150-E55 RD- 14 150-CM253 RD- 14
3E3382 1552273 617-CM179 BR- 16 958-CM167 YL - 16 F712-E65 GY- 16 CBL-CC2 RD- 2 NOTE A 892-CM273 BR- 16 H750-CM205 BR- 18 W
606-CM111 GY- 16 612-CM174 GY- 16 F707-X12 WH- 18 171-2212 F710-E59 BR- 18 F710-CM255 BR- 18
605-CK1 YL - 16 605-CM113 YL - 16 618-CM177 YL - 16 959-CM165 WH- 16 ENGINE ENGINE CHASSIS CAB 975-W23 WH- 18 H802-W29 GY- 18 W F716-X25 WH- 18 F708-X22 YL - 18 F712-E64 GY- 16 ATCH (135A) A309-E52 GY- 16 A309-CM266 GY- 16 893-CM271 GN- 16 779-CM7 WH- 16
606-CM112 GY- 16 616-CM145 BU- 16
200-CK2 WH-14 200-CM142 BK- 14 987-CM164 WH- 16 975-W21 WH- 18 W F727-X26 BU- 18 F709-X11 BU- 18 171-2213 F702-E57 GN- 18 F702-CM251 GN- 18 J811-CM228 BK- 18 W
617-CM131 BR- 16
606-CK3 GN-16 606-CM112 GY- 16 758-CM260 GN- 18 990-CM159 GN- 16 975-W22 WH- 18 H802-W57 GY- 18 W F721-X27 GY- 18 F710-X28 BR- 18 F712-E66 GY- 18 101-E29 RD- 10 A700-E58 OR- 18 A700-CM249 OR- 18 778-CM19 BR- 16 W
617-CM126 BR- 16 617-CM156 BR- 16
618-CK4 BR-16 618-CM177 YL - 16 786-CM221 GN- 18 975-W24 WH- 18 H802-W58 GY- 18 F710-X28 BR- 18 F711-X49 GN- 18 101-E27 RD- 10 993-E34 BR - 18 993-CM250 BR- 18 403-CM278 GN- 18 781-CM85 PK - 18 MM 276-4644 00
617-CM179 BR- 16
B 604-CK5 RD-16
617-CK6 BK-16