TH330B Service Manual

TH220B & TH330B
Telehandler Service Manual

31200262
S/N TBF00100 & After
S/N TBG00100 & After
Section Title Manual No.
Service Manual Contents 31200263

Torque Specifications 31200268
Engine
Disassembly & Assembly Engine Supplement 31200269
Power Train
Systems Operation, Testing & Adjusting Power Train 31200270
Disassembly & Assembly Power Train 31200271
Vehicle Systems
Schematic Hydraulic System 31200275
Systems Operation, Testing & Adjusting Hydraulic System 31200272
Systems Operation, Testing & Adjusting Steering System 31200273
Systems Operation, Testing & Adjusting Brake System 31200274
Machine Components Specs Machine Systems 31200276
Disassembly & Assembly Machine Systems 31200277
Electrical Systems
Schematic Electrical System 31200278
Machine Troubleshooting Hydrostatic Transmission 31200279
Electronic Control System
Systems Operation, Testing & Adjusting LSI System 31200280
Systems Operation, Testing & Adjusting Monitoring System 31200281
31200263 A
31200268
December 15, 2006
Specifications
Torque Specifications - TH220B, TH330B,
TH360B, TH560B & TH580B Telehandlers
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 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
Metric (ISO) Fasteners

Metric (ISO) Nuts and Bolts
Illustration 2 g00908932
Table 3
Thread Size
Torque
mm
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
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)
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)
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
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
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
• 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
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
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
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%)
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
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
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
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)

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
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 12 when the fitting or the port material is nonferrous.
31200268 11
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
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
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)
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)
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
Flare Fittings Note: Use 50 percent of the torque values from Table 21
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
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)
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)
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
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)
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.
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
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
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.
(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
31200269
December 15, 2006
Disassembly and
Assembly
TH220B and TH330B Telehandlers Engine
Supplement

presented.
this publication.

and material.

injury or death.
31200269 1
Table of Contents
Table of
Table of Contents
Disassembly and Assembly Section
Battery - Remove and Install ................... 3
Removal Procedure............................. 3
Installation Procedure.......................... 4
Alternator - Remove and Install ............... 4
Electric Starting Motor -Remove and Install
................................................................. 5
Air Cleaner - Remove and Install............. 6
Muffler - Remove and Install.................... 7
Expansion Tank - Remove and Install..... 9
Radiator - Remove ................................ 10
Removal Procedure........................... 10
Radiator - Install .................................... 14
Installation Procedure........................ 14
Fan Guard - Remove and Install ........... 17
Fan - Remove and Install ...................... 17
Engine Mount - Remove and Install ...... 18
Refrigerant Compressor -Remove and
Install ..................................................... 22
Refrigerant Condenser -Remove and
Install ..................................................... 23
Engine Enclosure - Remove and Install 25
Engine - Remove................................... 27
Engine - Install....................................... 33
2 31200269
Table of Contents
31200269 3
Disassembly and
Assembly Section
Battery - Remove and Install

Removal Procedure
Batteries give off flammable fumes that can explode 3. Pull back the terminal cover (1) in order to
resulting in personal injury. disconnect positive cable (2). Pull back the
terminal cover (3) in order to disconnect negative
Prevent sparks near the batteries. They could cause
cable (4).
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.
Always connect the positive (+) to positive (+) and the
negative (-) to negative (-).
Jump start only with an energy source with the same
voltage as the stalled machine.
Turn off all lights and accessories on the stalled 4. 4. Remove nuts (5), the washers and hold down
machine. Otherwise, they will operate when the energy bracket (6).
source is connected.
1. Turn the battery disconnect switch to the OFF

position. Refer to Operation and Maintenance
Manual, "Battery Disconect Switch (if equipped)".
5. 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).
2. 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 31200269
Installation Procedure
4. Connect positive cable (2) and slide terminal cover
(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
same procedure when you are installing the rear 5. Turn the battery disconnect switch to the ON
battery. position. Refer to Operation and Maintenance
Manual, "Battery Disconect Switch (if equipped)".
Alternator - Remove and Install

Removal Procedure
1. Turn the battery disconnect switch to the OFF
Manual, "Battery Disconnect Switch (if equipped)".
2. Put identification marks on all wires for installation
purposes.
2. Install studs (8). With the aid of a second person

or with the aid of a suitable lifting device, install
battery (7). The weight of the battery is
approximately 25 kg (55 lb).
3. Remove belt (1) from alternator (2). Refer to

Operation and maintenance Manual, "Belts -
Inspect/Adjust/Replace".
4. Disconnect wires (3) and positive cable (4).
Illustration 7 g00909235 5. Remove bolt (5), the washer, nut (6), bolt (7) and
3. Install hold down bracket (6), nuts (5), and the the washers before removing alternator (2) from
washers. the machine.
31200269 5
Installation Procedure 2. Disconnect wire clamp(1). Disconnect wire

assembly (2) from electric starting motor (3).
1. Clean all parts and inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for
replacement.
3. Remove bolts (4). Remove electric starting motor

(3).
2. Position alternator (2) onto the machine. Install
bolt (7), nut (6) and washers. Install bolt (5) and
the washer. Installation Procedure
3. Connect wires (3) and positive cable (4) to 1. Install electric starting motor (3) into the machine.
alternator (2).
4. Install belt (1) from alternator (2). Refer to
Operation and maintenance Manual, "Belts -
5. Turn the battery disconnect switch to the ON
Manual, "Battery Disconnect Switch (if equipped)".
Electric Starting Motor -Remove

and Install
Removal Procedure 2. Install bolts (4) in order to secure electric starting

motor (3) to the engine.
Note: Put identification marks on all wires for
Note: Do not tighten the center bolt at this time.
installation purposes.
1. Move the battery disconnect switch to the OFF
position.
3. Install wire assembly (2) onto electric starting
Illustration 11 g01010265 motor (3).
6 31200269
4. Install wire clamp (1). Tighten center bolt (4) at

this time.
Air Cleaner - Remove and Install

Removal Procedure
1. Disconnect inlet duct (2) from air cleaner assembly
(1).
4. Remove nuts (6), bolts (7) and the washers
before removing air cleaner assembly (1) from the
engine.
replacement.
2. Remove hose clamp (3) and disconnect inlet hose
(4) from air cleaner assembly (1).
3. Disconnect hose (5) from air cleaner assembly (1).
31200269 7
2. Position air cleaner assembly (1) on the engine and 5. Connect inlet duct (2) to air cleaner assembly (1).
install bolts (7), nuts (6) and the washers.
Muffler - Remove and Install

Removal Procedure
Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.
3. Connect hose (5) to air cleaner assembly (1).
1. 1. Remove bolts (2) and the washers in order to

remove cover assembly (1).
4. Connect inlet hose (4) to air cleaner assembly (1)
and install hose clamp (3).
8 31200269
2. Remove clamp (3) from exhaust pipe (4).
1. Install exhaust pipe (4) onto muffler (6). Install the
muffler and the exhaust pipe into position.
3. Remove bolts (5) from muffler (6).
2. Install bolts (5) into muffler (6). Tighten bolts (5) to a
torque of 44 ± 6 Nm (32 ± 4 lb ft).
4. Remove exhaust pipe (4) from muffler (6). Remove
muffler (6).
3. Install clamp (3) onto exhaust pipe (4).
31200269 9
1. Drain the coolant from the radiator into a suitable

container so that the level of the coolant in the
radiator is below the level of the expansion tank.
The capacity of the cooling system is
approximately 27.5 L (7.3 US gal).
4. Install cover assembly (1). Secure the cover
assembly with bolts (2).
Expansion Tank - Remove and Illustration 33 g00914256

2. Loosen the hose clamps and disconnect hose (1)
Install and hose (2) from expansion tank (3).
3. Disconnect hose (4) from filler cap (5).
Removal Procedure
At operating temperature, the engine coolant is hot

and under pressure.
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. Illustration 34 g00914264
4. Loosen the hose clamp and disconnect hose (6)
from expansion tank (3).
NOTICE
5. Remove bolts (7) and the washers in order to
Care must be taken to ensure that fluids are contained remove expansion tank (3).
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.
10 31200269
Installation Procedure Radiator - Remove

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7375 Link Bracket 1
9U-7090 Plug 68
ZZ 9U-7094 Plug 87
1. Position expansion tank (3) and install bolts (7)
and the washers. 9U-7088 Plug 57
2. Connect hose (6) to expansion tank (3) and 9U-7067 Plug 8

tighten the hose clamp.
Start By:
1. Remove the engine enclosure. Refer to
Disassembly and Assembly, "Engine Enclosure
- Remove and Install".
2. Remove the air cleaner. Refer to Disassembly and
Assembly, "AirCleaner- Remove and Install".

and under pressure.
3. Connect hose (4) to filler cap (5). stopped and the fill cap is cool enough to touch with
4. Connect hose (1) and hose (2) to expansion tank your bare hand.
(3) and tighten the hose clamps. Remove the fill cap slowly to relieve pressure.
5. Fill the cooling system. The capacity of the cooling Cooling system conditioner contains alkali. Avoid
system is approximately 27.5 L (7.3 US gal). contact with the skin and eyes to prevent personal injury.
NOTICE
Care must be taken to ensure that fluids are contained
containing fluids.
mandates.
31200269 11
Note: Service Data: Tooling (ZZ) will not be identified

in photographs in the removal or the installation. This
tooling is shown in order to assist the experienced
serviceman.
5. Disconnect harness assembly (3).
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).
3. Remove bolts (1). Move panel (2) aside. Illustration 40 g01010878
6. Remove bolts (4).
4. 4. Install Tooling (A) to fender (6). Attach Tooling (A)
to a suitable lifting device. 7. Remove bolts (5). Remove fender (6).
Note: The lifting device will hold fender (6) while the
various bolts are removed.
12 31200269
Illustration 42 g01010978 11. 11. Disconnect hose (11).
8. Remove air conditioning condenser (7) from
radiator assembly (8). Move the air conditioning
condenser to the side.
12. Disconnect hose (12).
13. Disconnect hose (14). Remove bolt (13).
31200269 13
Illustration 48 g01011115 Illustration 51 g01011196

14. Remove bolts (15) from fan shroud (16). 17. Remove bolt (19).

15. Remove nuts (17) from fan shroud (16). 18. Remove bolt (20).
19. Remove radiator assembly (8). The weight of the
radiator is 38.5 kg (85 lb).
Note: Use two people to remove the radiator assembly.
16. Remove bolt (18).
21. Repeat Step 20 for the opposite side.
22. Separate radiator (21) from aftercooler (23).
14 31200269
Radiator - Install
Table 2
Required Tools
Part
Tool Part Description Qty
Number

5. Install bolt (19).
1. Connect aftercooler (23) to radiator (21) with bolts Illustration 57 g01011119
(22). 6. Install bolt (19).
2. Repeat Step 1 on the opposite side.
Illustration 55 g01011217 7. Place fan shroud (16) in place on the radiator
3. Install radiator assembly (8). The weight of the assembly. Secure the fan shroud with bolts (17).
radiator is 38.5 kg (85 lb).
Note: Use two people to install the radiator assembly.
31200269 15

8. Install bolts (15) in order to secure fan shroud (16). 11. Connect hose (11).
.

9. Install bolt (13). Connect hose (14). 12. Connect hose (10)/
10. Connect hose (12). Illustration 64 g01010979
13. Connect hose (9).

16 31200269

14. Move air conditioning condenser (7) into position in 17. Install bolts (4).
front of radiator assembly (8).
I
15. Install Tooling (A) to fender (6). 18. Connect harness assembly (3).
I
19. Install panel (2) into position. Secure panel (2)
16. Install fender (6) into position. Secure fender (6) with with bolts (1).
bolts (5).
20. Fill the cooling system with coolant. The capacity
of the cooling system is approximately 27.5 L
(7.3 US gal).
End By:
a.Install the engine enclosure. Refer to Disassembly
and Assembly, "Engine Enclosure - Remove and
Install".
b.Install the air cleaner. Refer to Disassembly and
Assembly, "Air Cleaner- Remove and Install".
31200269 17
Fan Guard - Remove and Install Fan - Remove and Install

Removal Procedure Removal Procedure
Start By:
a. Remove the fan guard. Refer to Disassembly and
Assembly, "Fan Guard - Remove and Install".
Note: 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.
1. Remove bolts (1) and the washers in order to Illustration 73 g01011952
remove fan guard (2) from shroud (3).
1. Release the tension on the fan drive belt (1).
1. Position fan guard (2) on shroud (3) and install
bolts (1) and the washers.
18 31200269

3. Remove spacer (4). Remove pulley (5). 5. Install fan drive belt (1) into position. Apply tension
4. Move fan drive belt (1) to the side. Remove fan (3). to the fan drive belt.
Note: Check the fan drive belt for wear. End By:
a. Install the fan guard. Refer to Disassembly and
Installation Procedure Assembly, "Fan Guard - Remove and Install".
1. Install fan drive belt (1) onto the engine. Do not
apply tension at this time.
Engine Mount - Remove and
Install
Removal Procedure
Start By:
a. Remove the engine enclosure. Refer to
b. Remove the air cleaner. Refer to Disassembly and
Engine Mount (Rear)
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.
2. Install pulley (5), spacer (4) and fan (3) into Clean all surfaces where parts are to be installed.
position.
1. The following procedure is used to remove the
3. Install one bolt (2) through the fan, the spacer and engine mount from the right side of the machine.
the pulley in order to align. Do not tighten this bolt Use the same procedure to remove the engine
at this time. mount from the left side of the machine.
4. Install additional bolts (2) through the components. Note: Rear will refer to the rear of the machine.
Tighten bolts (2).
31200269 19

2. 2. Remove bolt (1), the washers, the nut, the lower 6. Remove the upper half of mount (2) from chassis
half of mount (2) and washers (3). (7).
Engine Mount (Front)

or blocking.
commponent, 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
Illustration 79 g00921570 work under a heavy component.
Clean all surfaces where parts are to be installed.
3. Attach a suitable lifting chain to the bracket on the
rear side of the engine and to a suitable hoist. Illustration 82 g00984274
4. Use the hoist to carefully lift the engine until 1. Attach a suitable lifting chain to the bracket on the
bracket (4) is just clear of the upper half of mount engine and to a suitable hoist. Take up the tension
(2). on the chain but do not try to lift the engine at this
5. Remove four nuts (5) and the washers in order to time.
remove mounting bracket (4) from engine block
(6).
20 31200269
3. The engine is supported by a suitable hoist and

suitable lifting chain.
2. Remove bolt (1), two washers (2), nut (3), washer
(4), the lower half of mount (5) and sleeve (6).
3. Use the hoist to carefully lift the engine and the Illustration 86 g00921904
transmission until bracket (7) is just clear of the 4. Install the upper half of mount (2) into chassis (7).
upper half of mount (5). The combined weight of
the engine and the transmission is approximately
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.
Engine Mount (Rear)
1. The following procedure is used to install the
engine mount on the right side of the machine. Illustration 87 g00921906
Use the same procedure to install the engine 5. Position mounting bracket (4) onto engine block
mount on the left side of the machine. (6) and install four nuts (5) and the washers.
2. Clean all parts and inspect all parts. If any parts 6. Use the hoist and lower the engine and bracket
are worn or damaged, use new Caterpillar parts (4) onto the upper half of mount (2). Remove the
for replacement. hoist and lifting chain
31200269 21

7. Install the lower half of mount (2), washers (3), bolt 3. Install the upper half of mount (5) into the engine
(1), the washer and the nut. Tighten the bolt to a frame. Position bracket (7 ) onto the engine and
torque of 220 ±20 N m ( 1 6 2 ±1 5 lb ft). install four bolts (8) and the washers.
4. Use the hoist to carefully lower the engine until
bracket (7) is seated on the upper half of mount
Engine Mount (Front) (5).
1. Clean and inspect all parts. If any parts are worn or 5. Install sleeve (6), the lower half of mount (5),
damaged, use new Caterpillar parts for washer (4), bolt (1), two washers (2) and nut
replacement. (3). Tighten the nut and the bolt to a torque of
775±20Nm(572± 15 lb ft).
6. 6.Remove the lifting chain.
End By:
a. Install the air cleaner. Refer to Disassembly and
b. Install the engine enclosure. Refer to Disassembly
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.
The combined weight of the engine and the
transmission is approximately 780 kg (1720 lb).
22 31200269
Refrigerant Compressor -
Remove and Install
Removal Procedure
Start By:
a. Remove the air cleaner. Refer to Disassembly and
Assembly, "Air Cleaner- Remove and Install".
3. 4. Remove bolt (1), the washers, the nut, the lower
Personal injury can result from contact with refrigerant. half of mount (2) and plate (3). This will enable
Contact with refrigerant can cause frost bite. Keep face access to the rear of refrigerant compressor (4).
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 fumes
released from a flame contacting air conditioner
refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or
4. 5. Disconnect two tubes (5) from refrigerant
wherever refrigerant gas may be present.
compressor (4).
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.
2. Recover the air conditioner refrigerant from the air
conditioner system. The correct charge is 0.8 kg
(1.8 lb). Remove the fan drive belt. Refer to
Operation and Maintenance Manual, "Belts -
5. Disconnect harness (6) from refrigerant
compressor (4).
6. Remove four bolts (7) and the washers in order
to remove refrigerant compressor (4) from the
machine.
31200269 23
Installation Procedure 6. Charge the air conditioner system. The correct

charge is 0.8 kg (1.8 lb).
7. Install the fan drive belt. Refer to Operation
and Maintenance Manual, "Belts -
replacement.
End By:
a. Install the air cleaner. Refer to Disassembly and
Assembly, "Air Cleaner- Install".
Refrigerant Condenser -
Remove and Install
Illustration 95 g00921517 Removal Procedure
2. Position refrigerant compressor (4) onto the
machine and install four bolts (7) and the washers.
3. Connect harness assembly (6) for 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.
Slowly loosen the fitting. If the system is still under
pressure, release it slowly in a well ventilated area.
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.
4. Connect two tubes (5) to refrigerant compressor
(4).
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning
system.
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±20Nm(572± 15 lb ft).
24 31200269
1. Recover the air conditioner refrigerant from the air Installation Procedure
(1.8 lb).

2. 2. Disconnect two hoses (1) from condenser (2).
Illusytration 102 g00910954

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

3. Release latch assembly (3). Tilt condenser (2) 2. Connect two hoses (1) to condenser (2).
toward the front of the machine before removing the 3. Charge the air conditioner system. The correct
condenser. charge is 0.8 kg (1.8 lb).
31200269 25
Engine Enclosure - Remove and

Install
Removal Procedure

or blocking.
jack has the correct capacity to lift a component. Illustration 106 g00919669
Install blocks or stands before performance of any 3. Remove bolts (4) and the washers which secure
work under a heavy component. hood (1) to mounting brackets (5).
Approximate weights of the components are shown. 4. Use a suitable lifting device and remove hood
Clean all surfaces where parts are to be installed. (1) from the machine. The weight of the hood is
Hood
Panel Group

1. Raise hood (1). Attach a suitable nylon lifting
device around the hood and to a suitable lifting
device. Take up the tension in order to support the 1. Remove bolts (1) and the washers in order to
hood. remove rear panel (2) from the machine.

2. Disconnect gas spring assembly (2) from bracket 2. Remove bolts (3) and the washers in order to
(3). remove front panel (4) from the machine.
26 31200269
Panel Group

2. Align hood (1) with mounting brackets (5) and
install bolts (4) with the washers in order to secure
the hood.
1. Position front panel (4) and install bolts (3) with the
washers.
3. Connect gas spring assembly (2) to bracket (3).

Illustration 110 g00919670 4. Remove the nylon lifting sling and the lifting device
2. Position front panel (2) and install bolts (1) with the before closing the hood.
washers.
Hood

1. Attach a suitable nylon lifting device around hood
(1) and to a suitable lifting device. Lift the hood into
position on the machine. The weight of the hood is
31200269 27
Engine - Remove
Removal Procedure Personal injury or death can result from improper lifting
or blocking.
Table 3
Required Tools component, stand clear of the area. Be sure the hoist or
Part under a heavy component.
Number Approximate weights of the components are shown.
B 1U-7505 Transmission Jack 1
C 9U-6198 Crankshaft Turning Tool 1 At operating temperature, the engine coolant is hot
and under pressure.
9U-7068 Plug 6 Steam can cause personal injury.

9U-7069 Plug 1 stopped and the fill cap is cool enough to touch with
your bare hand.
9U-7070 Plug 1
9U-7072 Plug 2
(9U-7073) Plug 1 contact with the skin and eyes to prevent personal injury.
(9U-7074) Plug 2
(9U-7075) Plug 1 NOTICE
ZZ Care must be taken to ensure that fluids are contained
(9U-7078) Plug 1
(9U-7080) Plug 1 adjusting and repair of the product. Be prepared to collect
(9U-7087) Plug 2 the fluid with suitable containers before opening any
(9U-7088) Plug 1 containing fluids.
(9U-7089) Plug 1 Refer to Special Publication, "Caterpillar Tools and Shop
(9U-7090) Plug 1
(9U-7091) Plug 1
(9U-7095) Plug 3 mandates.
Start By:
Note: Service Data: Tooling (ZZ) will not be identified
a. Remove the engine enclosure. Refer to
in photographs in the removal or the installation. This
tooling is shown in order to assist the experienced
serviceman.
b. Remove the air cleaner. Refer to Disassembly and
c. Remove the muffler. Refer to Disassembly and
Assembly, "Muffler- Remove and Install".
d. Remove the electric starting motor. Refer to
Disassembly and Assembly, "Electric Starting Motor -
Remove and Install".
28 31200269

27.5 L (7.3 US gal). Refer to Operation and
Maintenance Manual, "Cooling System Coolant
(ELC) - Change".

6. Remove clips (4). Remove fender (1).

3. Install Tooling (A) to rear fender (1). Attach Tooling
(A) to a suitable lifting device. Apply tension.

7. Disconnect hoses (5).


8. Disconnect hoses (7). Remove bolts (8). remove
tank (6).

31200269 29

9. Disconnect hose (10). Disconnect hose (11). 12. Disconnect harness assembly (14). Remove cable
Remove clip (9). strap (15).
10. Remove bolts (12). 13. Disconnect hose (16).

11. Disconnect ground strap (13). 14. Disconnect harness assemblies (17).
30 31200269

15. Disconnect harness assemblies (18). 18. Disconnect harness assembly (22).

16. Remove bolts (20). Position bracket assembly (19) 19. Disconnect cable (23). Disconnect harness
out of the way. assemblies (24). Position harness assemblies (24)
out of the way. Position cable (23) out of the way.

17. Remove cable strap (21). Illustration 131 g01012651
20. Disconnect hose assemblies (25).
31200269 31

21. Remove clips (26). Position hose assemblies (25) 24. Remove bracket (33). Move accumulator (32) out of
out of the way. the way.

22. Remove clip (29). Remove bolts (28). Remove
bracket (27).

26. Remove bolts (35). Remove pump (36). Position
23. Disconnect tube assembly (30) from turbocharger
pump (36) out of the way.
(31). Position tube (30) out of the way.
32 31200269

This photograph is for information. This photograph displays the
27. Remove bolts (38). Remove pump mounting (37). positions of the bolts.
30. Remove bolts (41) from torque converter (42). Use

Tooling (C) in order to rotate the flywheel to the
correct position.
Note: Bolts (41) are removed through the hole in
transmission housing (39) after plug (40) is removed.

28. Install Tooling (B) under transmission housing (39).

31. Remove sensor (44). Remove bolts (43) from
transmission housing (39).

29. Remove plug (40). Plug (40) is located on the
bottom of transmission housing (39).

32. Attach a suitable lifting device to engine (45). Apply
tension to the lifting device.
31200269 33

33. Remove the oil filter and base (46). 38. Remove hose (52).
34. Remove mounting bolt (47). 39. Remove exhaust pipe (51).
Illustration 145 g01012985 40. Remove engine (45) from the machine. The weight
36. Disconnect harness assembly (48). of the engine is 408 kg (900 lb).
Engine - Install
Table 4
Required Tools
Part
Number

37. Remove mounting bolt (50).
B 1U7505 Transmission Jack 1
C 9U-6198 Crankshaft Turning Tool 1

34 31200269

or blocking.
under a heavy component.
1. Clean all parts and inspect all parts. If any parts are Illustration 151 g01012990
worn or damaged, use new Caterpillar parts for 5. Install mounting bolt (50), the washers, the nuts, the
replacement. lower half of the mounts and the washer. This will
secure the engine to the engine frame. Tighten
mounting bolt (50) to a torque of 220 ± 20 Nm (162
±1 5 lb ft).

2. Attach a suitable double chain lifting sling to the
lifting brackets on the front and on the rear of the
engine and to a suitable hoist. Use the hoist to Illustration 152 g01012985
carefully lift engine (45) toward the machine and 6. 6. Repeat Step 5 for mounting bolt (49).
into the engine frame. Be careful not to catch on
any loose hoses or wires on installation. The
weight of the engine is approximately 408 kg (900
lb).

7. Repeat Step 5 for mounting bolt (47).
8. Connect harness assembly (48).
Illustration 150 g01013001 9. Install the oil filter and base (46).
3. Install exhaust pipe (51).
4. Install hose (52).
31200269 35

10. Position transmission housing (39) to the engine.
Install bolts (43) through transmission housing (39) 13. Install plug (40). Plug (40) is located on the bottom
and into the engine. Install sensor (44). of transmission housing (39).

This photograph is for information. This photograph displays the 14. Install pump mounting (37). Install bolts (38).
position of the bolts.
11. Position torque converter (42) into position. Use
Tooling (C) in order to rotate the flywheel into the
proper position. Install bolts (41) through torque
converter (42) into the flywheel.
Note: Bolts (41) will be installed through the hole in the
bottom of transmission housing (39).

15. Install pump (36) in position. Secure pump (36) with
bolts (35)

12. Remove Tooling (B) under transmission housing
(39).
36 31200269

19. Install bracket (27) into position. Secure bracket
16. Connect hose (34). Secure hose (34) with the hose (27) with bolts (28). Install clip (29).
clamp.

Illustration 161 g01012762 20. Place hose assemblies (25) in the correct position.
17. Place accumulator (32) into position. Install bracket Install clips (26) in order to secure the hose
(33). Bracket (33) secures accumulator (32). assemblies.

18. Connect tube assembly (30) onto turbocharger (31). 21. Connect hose assemblies (25). Secure the hose
assemblies with hose clamps.
31200269 37

22. Place harness assemblies (24) into position. 25. Install bracket assembly (19) into position. Secure
Connect harness assemblies (24). Place cable(23) bracket assembly with bolts (20).
into position. Connect cable (23).
Illustration 167 g01012537 26. Connect harness assemblies (18).

Illustration 168 g01012531 27. Connect harness assemblies (17).

24. Install cable strap (21).
38 31200269

28. Connect hose (16). 31. Install bolts (12).

29. Connect harness assembly (14). Install cable strap 32. Connect hose (11). Connect hose (10). Secure
(15). hoses with the hose clamps. Install clip (9).

30. Connect ground strap (13). 33. Install tank (6) into position. Connect hoses (7) onto
tank (6). Secure the hoses with the hose clamps.
Secure tank (6) with bolts (8).
31200269 39

34. Connect hoses (5). Secure the hoses with the hose 37. Install bolt (2).
clamps. 38. Install clips (4) onto fender (1).
39. Fill the coolant in the cooling system. The capacity
of the cooling system is approximately 27.5 L (7.3
US gal). Refer to Operation and Maintenance
Manual, "Cooling System Coolant (ELC) - Change".
End By:
a. Install the electric starting motor. Refer to
Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
b. Install the muffler. Refer to Disassembly and
Assembly, "Muffler- Remove and Install".
c. Install the air cleaner. Refer to Disassembly and
Illustration 179 g01012230 Assembly, "Air Cleaner- Remove and Install".
35. Install Tooling (A) onto rear fender (1). Attach
d. Install the engine enclosure. Refer to Disassembly
Tooling (A) to a suitable lifting device. Install the
fender into position.
Install".

40 31200269
31200269 41
Index Index
A
Air Cleaner - Remove and Install ......................................... 6
Installation Procedure..................................................... 6
Removal Procedure........................................................ 6
Alternator - Remove and Install............................................ 4
B
Battery - Remove and Install................................................ 3
E
Electric Starting Motor -Remove and Install......................... 5
Engine - Install ................................................................... 33
Installation Procedure................................................... 33
Engine - Remove ............................................................... 27
Removal Procedure...................................................... 27
Engine Enclosure - Remove and Install ............................. 25
Engine Mount - Remove and Install ................................... 18
Expansion Tank - Remove and Install ................................. 9
F
Fan - Remove and Install ................................................... 17
Fan Guard - Remove and Install ........................................ 17
I
Important Safety Information.................................................ii
M
Muffler - Remove and Install ................................................ 7
R
Radiator - Install ................................................................. 14
Radiator - Remove ............................................................. 10
Refrigerant Compressor -Remove and Install.................... 22
Refrigerant Condenser -Remove and Install...................... 23
T
Table of Contents................................................................. 1
42 31200269
Index
31200270
December 15, 2006
Power Train System

Testing & Adjusting
TH220B, TH330B, TH360B, TH560B and

TH580B Telehandler

presented.
this publication.

and material.

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
(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
Introduction
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
General Information
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
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:
• 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
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
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
(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.
Machines with a Power Shuttle transmission are

equipped with transmission neutralizer switch (1). The
8 31200270
Transmission Direction Control Differential Lock Switch (if

Lever (Power Shuttle Transmission) Equipped
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
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)
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
Solenoid Valves Transmission Neutralizer Override

Switch
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.
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
Torque Converter
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
(1)Transmission charge pump
(2)Torque converter
(3)Hydraulic oil cooler
Transmission Charge Pump
Hydraulic oil cooler (3) is located inside the engine
enclosure to the right of the transmission. The
hydraulic oil cooler cools the hydraulic oil.
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
Electrical Input Components
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
Speed Sensors Transmission Output Speed Sensor
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)
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
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)
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)
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.
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
Transmission Neutralizer Override Switch Switch (Transmission Neutralizer)
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
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
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.
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
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
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 -
Transmission - Speed
58 PWM
Clutch 5 (3)
(continued)
18 31200270
(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.
(3) Machines equipped with a Power Synchro 37 Switch To Ground
Disengage
Transmission
(4) Machines equipped with manual transmissions 38 Switch To Ground
Parity
Table 2 Differential Lock Engaged
39 Switch To Ground
Switch
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
49 Shift Rail Position Sensor 1 (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
Electrical Output Components
31200270 21
Table 3
Solenoid Function
This solenoid controls the
Transmission Solenoid 1
reverse direction clutch.
This solenoid controls the
forward direction clutch.
This solenoid engages the
first synchronizer.
second synchronizer.
third synchronizer.
fourth synchronizer.
fifth synchronizer.
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)
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
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.
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
24 31200270
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).
(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
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
Torque Converter
(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
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
Transmission
31200270 29
(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
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
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
Clutch Operation
(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
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
Synchronizer for the First Speed and

Second Speed
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
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
Synchronizer for the Third Speed and

Fourth Speed
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)
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
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
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
• 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
• 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
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
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
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
Transmission Power Flow
(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
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)
Second Speed Forward synchronizer (X) with
second gear(21)
Third Speed Forward synchronizer (Y) with third
gear (22)
Fourth Speed Forward (1) synchronizer (Y) with fourth
gear (23)
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)
Second Speed Reverse synchronizer (X) with
second gear(21)
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
Examples of Power Flow Through

the Transmission
First Speed Forward
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
Second Speed Reverse
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)
• Reverse clutch (R)
• Reverse primary gear (10)
• Gear (11)
• Reverse idler shaft (12)
• Gear (13)
• Second gear (countershaft) (17)
• Second gear (output shaft) (21)
• Synchronizer (X)
44 31200270
Fifth Speed Forward (If Equipped)
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
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.
• Synchronizer (Z)
• Fifth gear (countershaft) (19)
• Fifth gear (output shaft) (24)
31200270 45
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.
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

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

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
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
Hydraulic Schematic (Power

Train System)
Neutral (Power Shuttle
Transmission)
(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
Neutral (Powersynchro
Transmission)
(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
Neutral into First Gear (Start of shift)
(8) Synchronizer solenoids (19) Filter (27) Shift rail position sensor 1
(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
Neutral Into First Gear (End of Shift)

(FORWARD)
(8) Synchronizer solenoids (19) Filter (27) Shift rail position sensor 1
(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
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
Configuration Parameters
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
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.
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
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.
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.
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
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
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
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
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
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
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
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
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
9U-7400 Multitach Tool Group 1
procedures:

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).
31200270 63
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
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.
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
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
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
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
The number two clutch is the forward clutch.
The second clutch is calibrated automatically after the

first clutch is calibrated.
68 31200270
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
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
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.
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
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
Required Tools
Qty Part Number Description
1 9U-7400 Multitach Tool Group 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
to Special Instruction, NEHS0605 for further
information on the use of this equipment.
the fluid with suitable containers before opening any Warming the Transmission Oil
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:
mandates.
2. Run the engine for 2 minutes at Low Idle. Then,
run the engine for 2 minutes at High Idle.
70 31200270
3. Disengage the parking brake. Ensure that Table 11

the switch that disables the transmission
Direct Drive Transmission Arrangement
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
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
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.
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
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.
speed is 2350 ± 25 (rpm). Check that the water
mandates.
temperature gauge and the oil temperature gauge
are showing the correct reading.
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
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
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
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
Pressure Test Points for the Power

Shuttle Transmission
(10) Pressure test point (forward clutch)
(11) Pressure test point (reverse clutch)
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
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.
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
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).
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
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
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
position.
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)
(4) Pressure test point (synchronizer for the second speed)
(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
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
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
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
B 203-4348 Pinion Depth Gauge 1 to the ground.
204-9319 Bar 1
6J-2819 Bolt 2
6V-6106 Dial Indicator Group 1 engine is operated.
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
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
containing fluids.

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

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
(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
(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
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
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
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
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
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
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
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
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
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
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.
to the ground.
engine is operated.
82 31200270
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
(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.
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)

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

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.

Tooling (D)
(15) Rod
(16) Socket
(17) Socket assembly
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
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.
Rear Axle Differential position.
Introduction 4. Lower the boom. If equipped, lower the work tool

to the ground.
The following procedure controls the differential
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.
Required Tools
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
containing fluids.
mandates.

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
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.

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

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
(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
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
and pinion gear. Recheckthe backlash and the
rolling resistance. 6. If the machine is in a confined area, ensure that
engine is operated.
Axle Housing and Bearing
Preload - Adjust before you perform any of the following
procedures:
Introduction
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
containing fluids.
mandates.
When testing and adjusting the transmission and

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
Adjustment Procedure

(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.
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
(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
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
31200271
December 15, 2006
Disassembly and
Assembly
TH220B and TH330B Telehandlers

Power Train

presented.
this publication.

and material.

injury or death.
31200271 1
Table of Contents
Table of
Table of Contents Axle Housing and Flange -Assemble ..... 90
Disassembly and Assembly Section Assembly Procedure.......................... 90
Transmission Control (Select Lever) - Axle Housing and Flange Install ............ 92
Remove and Install .................................. 3 Installation Procedure ........................ 92
Removal Procedure............................. 3 Axle Shaft - Remove and Install............. 95
Installation Procedure.......................... 5 Removal Procedure ........................... 95
Drive Shaft (Front) - Remove and Install . 6 Installation Procedure ........................ 96
Removal Procedure............................. 6 Axle Housing (Service Brakes, Differential
Installation Procedure.......................... 7 and Bevel Gear) (Front) - Remove......... 97
Drive Shaft (Rear) - Remove and Install.. 7 Removal Procedure ............................... 97
Removal Procedure............................. 7 Axle Housing (Service Brakes, Differential
Installation Procedure.......................... 8 and Bevel Gear) (Front) - Disassemble . 98
Transmission and Torque Converter - Disassembly Procedure..................... 98
Remove ................................................... 8 Axle Housing (Service Brakes, Differential
Removal Procedure............................. 8 and Bevel Gear) (Front) - Assemble .... 104
Transmission - Disassemble ................. 13 Assembly Procedure........................ 104
Disassembly Procedure .................... 13 Axle Housing (Service Brakes, Differential
Transmission - Assemble ...................... 41 and Bevel Gear) (Front) - Install .......... 113
Assembly Procedure ......................... 41 Installation Procedure ...................... 113
Transmission and Torque Converter - Axle Housing (Differential and Bevel Gear)
Install ..................................................... 69 (Rear) - Remove .................................. 114
Installation Procedure........................ 69 Removal Procedure ......................... 114
Drive and Steering Axle (Front) - Remove Axle Housing (Differential and Bevel Gear)
............................................................... 73 (Rear) - Assemble ................................ 115
Removal procedure ........................... 73 Assembly Procedure........................ 115
Drive and Steering Axle (Front) - Install 75 Axle Housing (Differential and Bevel Gear)
Installation Procedure........................ 75 (Rear) -Disassemble ............................ 120
Drive and Steering Axle (Rear) - Remove Disassembly Procedure................... 120
............................................................... 76 Axle Housing (Differential and Bevel Gear)
Removal procedure ........................... 76 (Rear) - Install ...................................... 124
Drive and Steering Axle (Rear) - Install . 78 Installation Procedure ...................... 124
Installation Procedure........................ 78 Brake Cylinder (Master) Remove and
Tie Rod (Steering) - Remove and Install 80 Install.................................................... 124
Removal Procedure........................... 80 Removal Procedure ......................... 124
Installation procedure ........................ 81 Installation Procedure ...................... 126
Steering Cylinder - Remove and Install . 81 Parking Brake Control -Remove and
Removal Procedure........................... 81 Install.................................................... 127
Installation Procedure........................ 83 Removal Procedure ......................... 127
Final Drive Planetary - Remove............. 84 Installation Procedure ...................... 128
Removal Procedure........................... 84 Parking Brake - Remove ...................... 129
Final Drive Planetary Disassemble........ 84 Removal Procedure ......................... 129
Disassembly Procedure .................... 84 Parking Brake - Disassemble............... 129
Final Drive Planetary - Assemble .......... 85 Disassembly Procedure................... 129
Assembly Procedure ......................... 85 Parking Brake - Assemble ................... 131
Final Drive Planetary - Install................. 85 Assembly Procedure........................ 131
Installation Procedure........................ 85 Parking Brake - Install .......................... 133
Axle Housing and Flange Remove ........ 85 Installation Procedure ...................... 133
Removal Procedure........................... 85 Tire and Rim - Remove and Install....... 134
Axle Housing and Flange -Disassemble 88 Removal Procedure ......................... 134
Disassembly Procedure .................... 88 Installation Procedure ...................... 135
2 31200271
Table of Contents
31200271 3
Disassembly and 3. Carefully lower cover (1) and loosen the hose clamp
before disconnecting heater hose (2). Loosen retaining
Assembly Section nut (4) and remove key start switch (3) from cover (1).
Lay the key start switch aside. Remove cover (1) from the
machine.
Transmission Control (Select
Lever) - Remove and Install
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.
4. Remove the bolts that secure cover (5).
5. Carefully lift cover (5) in order to disconnect harness
assembly (7) from switches (6). Remove the cover.
4 31200271

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

7. Carefully lift display module (8) and loosen bolt (9) in 10. From the underside of transmission control (16),
order to disconnect harness assembly (10). Remove the disconnect harness assembly (15).
display module.
11. Remove screws (17) in order to remove transmission
control (16) from steering column (18).
8. Disconnect harness assembly(11) from switch (12) for
directional turn signal control.
31200271 5
4. Connect harness assembly (11) to switch (12) for the
Illustration 13 g00934520 directional turn signal control.
1. Position transmission control (16) onto steering
column (18) and install screws (17).
5. Position display module (8) in order to connect harness
Illustration 14 g00934522 assembly (10) before tightening bolt (9).
2. Connect harness assembly (15) to transmission control
(16).
6. Install the bolts in order to secure display module (8).

3. Carefully feed harness assembly (14) through housing
(13) before positioning the housing onto the steering
column. Install the bolts in order to secure the housing.
6 31200271

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.
7. Position cover (5) in order to connect harness
assemblies (7) to switches (6).
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".
Drive Shaft (Front) - Remove

and Install
Removal Procedure
Table 1
8. Install the bolts to secure cover (5).
Required Tools
Part
Number
A 155-3597 Wheel Chock 1
1. Install Tooling (A) against the front tires in order to

prevent machine movement after the removal of the
drive shaft.
31200271 7
2. Remove bolts (1). Remove strap (2). 2. Install drive shaft (5) into position. Install strap (4). Secure
strap (4) with bolts (3).
3. Remove bolts (3). Remove strap (4) from the Illustration 28 g01030817
opposite end of drive shaft (5). 3. Install strap (2). Secure strap (2) with bolts (1) on
the opposite end of drive shaft (5).
Note: Support the drive shaft in order to prevent the
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 2
Removal Procedure
Required Tools
Table 3
Part
Number Required Tools
A 155-3597 Wheel Chock 2 Part

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.
8 31200271

2. Remove bolts (1). Remove strap (2). 2. Install drive shaft (5) into position. Install strap (4). Secure
strap (4) with bolts (3).
3. Remove bolts (3). Remove strap (4) from the Illustration 32 g01030856
opposite end of the drive shaft.
3. Install drive shaft (5) on the opposite end. Install strap
Note: Support the drive shaft in order to prevent the (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).
Transmission and Torque
Converter - Remove
Table 4
Required Tools Removal Procedure

Part Table 5
Number
Required Tools
A 155-3597 Wheel Chock 2
1. Align the drive shaft universal joint with the drive
shaft yoke. 1U-7519 Hydraulic Pump 1
8S-7611 Tube As 1
A
8S-7615 Pin 1
8S-7650 Cylinder 1
1U-7498 Stand 4
B
1U-7501 Tube 4
C 138-7573 Link Bracket 1

31200271 9
D 9U-6198 Turning Tool 1 NOTICE

E 1U-7505 Transmission Jack 1
9U-7069 Tapered Cap/Plug 1
9U-7070 Tapered Cap/Plug 1 compartment or disassembling any component
containing fluids.
9U-7072 Tapered Cap/Plug 2 Refer to Special Publication, "Caterpillar Tools and Shop
9U-7074 Tapered Cap/Plug 1 and contain fluids on Caterpillar products.
9U-7075 Tapered Cap/Plug 2 Dispose of all fluids according to local regulations and
mandates.
9U-7077 Tapered Cap/Plug 1 Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE
IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL
ZZ 9U-7079 Tapered Cap/Plug 1 OR THE INSTALLATION. THIS TOOLING IS SHOWN
IN ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
6V-9510 Tapered Cap/Plug 2 1. Put identification marks on all lines, on all hoses
6V-9831 Tapered Cap/Plug 2 lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering
6V-9507 Tapered Cap/Plug 1 the system.
6V-9509 Tapered Cap/Plug 1
Start By:
a. Remove the sump guard. Refer to Disassembly
and Assembly, "Sump Guard - Remove and
Install".
b. Remove the Implement pump. Refer to
Disassembly and Assembly, "Implement Pump-Remove
and Install".
c. Remove the front drive shaft. Refer to Disassembly Illustration 33 g01031349
and Assembly, "Drive Shaft (Front) - Remove and 2. Install Tooling (A) in order to raise the rear of the
Install". machine approximately 305 mm (12.0 inch) above
d. Remove the rear drive shaft. Refer to Disassembly the ground.
and Assembly, "Drive Shaft (Rear) - Remove and 3. Install Tooling (B) in order to support the rear of
Install". the machine.
e. Remove the hydraulic oil cooler. Refer to 4. Repeat Steps 2 and 3 in order to raise the front of the
Disassembly and Assembly, "Hydraulic Oil Cooler- machine.
f. Remove the alternator. Refer to Disassembly and
Assembly, "Alternator- Remove and Install".
g. Remove the engine enclosure. Refer to
Disassembly and Assembly, "Engine Enclosure-Remove
and Install".
h. Remove the refrigerant compressor. Refer to Disassembly
and Assembly, "Air Conditioner -Remove and Install".
i. Remove the fan guard. Refer to Disassembly and
Assembly, "Fan Guard- Remove and Install".
j. Remove the fan. Refer to Disassembly and Assembly,
"Fan - Remove and Install".
10 31200271
9. Remove bolts (7). Remove cover (8) of the muffler.
6. Remove bolts (2). Remove base (3).
10. Remove clips (9).
7. Disconnect hose assembly (4). Loosen hose clamp.
Disconnect hose (5).
11. Install Tooling (C) to rear fender (10). Attach a suitable
lifting device and apply tension.
8. Remove caps (6).
31200271 11
12. Remove bolts (11). Remove fender (10).
Illustration 42 g01031372 17. Remove bolts (18). Position bracket assembly (17) out of
13. Install Tooling (D) to engine crankshaft (12). the way.
14. Rotate engine crankshaft (12) in order to allow 18. Disconnect harness assembly (19).
access to bolt (14). Remove bolt (14) and washer
(13).
15. Repeat Step 14 in order to remove additional
bolts (14) and washers (13).
19. Disconnect hose assembly (20). Remove hose (21).
16. Remove bolts (16). Remove plate (15).
12 31200271
20. Disconnect harness assembly (23). Remove sensor (22).
21. Disconnect hose assembly (24). Disconnect hose (25).
25. Install Tooling (E) under transmission (30).
22. Remove bolts (26). Remove hub assembly (27).
26. Remove bolts (31) from transmission (30).
23. Remove belt tensioner (28). 27. Lower transmission (30). The transmission should be
lowered approximately 152 mm (6.0 inches). Remove
cable strap (32).
31200271 13
Transmission - Disassemble
Disassembly Procedure
Table 6
Required Tools

B 1U-7262 Telescoping Magnet 1
C 1U-8241 Lifting Sling 1
28. Disconnect hose (33). D 1P-2320 Combination Puller 1
E 1P-1857 Retaining Ring Pliers 1
F 156-7100 Slide Hammer Puller Gp 1
G 1P-0510 Driver Gp 1
H 1P-1856 Retaining Ring Pliers 1
J 1P-2321 Combination Puller 1
K 4C-8359 Eyebolt (M12) 1
L 1P-1860 Retaining Ring Pliers 1
8B-7550 Push-Puller Leg 1
M
8H-0663 Bearing Puller Gp 1
Illustration 57 g01031406 N 1P-0074 Slide Hammer Puller Gp 1
29. Disconnect harness assembly (34). Remove
transmission (30). The weight of the transmission is Start By:
approximately 230 kg (506 lb). a. Remove the transmission. Refer to Disassembly
and Assembly, "Transmission - Remove".
b. Remove the torque converter. Refer to
Disassembly and Assembly, "Torque Converter -
Disassemble".
Personal injury or death can result from improper

lifting or blocking.
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.
14 31200271
NOTICE
containing fluids.
mandates.
NOTICE Transmission Position Sensor and Actuator on the Fifth Speed
Keep all parts clean from contaminants. a. Use a suitable allen wrench to remove allen head screws
(3) in order to remove sensor (4) for the shift rail.
Contaminants may cause rapid wear and shortened
component life.
1. Attach Tooling (A) to the transmission and use a
suitable lifting device in order to lift the Personal injury can result from being struck by parts
transmission onto a suitable work bench. The propelled by a released spring force.
weight of the transmission is approximately 350 kg
(772 lb). Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all

recommended tooling to release the spring force.
Personal injury can result from being struck by parts
propelled by a released spring force.
Make sure to wear all necessary protective equipment.

b. Use a suitable allen wrench in order to remove cap
(5).
2. Use a suitable allen wrench to remove allen head
screws (1) in order to remove sensors (2) from the
transmission housing.
3. Machines that are equipped with five speeds have
additional components that need to be removed.
31200271 15

e. Remove allen head screw (11) that is shown in
Illustration 63. Remove locking plate (12) in
order to remove solenoid (13) from actuator (9).
Remove O-ring seals (14) and (15) from the
Personal injury can result from being struck by parts spool and inspect the O-ring seals for damage.
propelled by a released spring force. Replace the O-ring seals, if necessary.
Make sure to wear all necessary protective equipment. f. Remove actuator piston (17) from the actuator,
and remove O-ring seals (16) and (18). Inspect
Follow the recommended procedure and use all the O-ring seals for damage and replace the
recommended tooling to release the spring force. O-ring seals, if necessary.

c. Remove spring (6) and use Tooling (B) in order to remove
detent ball (7) from the transmission.
4. Remove bolts (21) that secure actuator (20) to
transmission housing (19). Remove the actuator from the
transmission housing and take care not to lose the O-ring
seals that are between the actuator and the
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 O-ring seals that are
between the actuator and the transmission cover.
5. Remove O-ring seals (22) from actuator (20) and inspect
the O-ring seals for damage. Replace the O-ring seals, if
necessary.
16 31200271

6. Remove neutralizing piston (23) and actuator piston 11. Remove bolts (35) that secure actuator (36) to
(24) from actuator (20). Remove O-ring seals (25) and transmission cover (10). Remove the actuator
(26) from the pistons and inspect the O-ring seals for from the transmission cover and take care not
damage. Replace the O-ring seals, if necessary. to lose the O-ring seals that are between the
actuator and the transmission cover.
12. Repeat Step 5 to Step 10 for actuator (36).
7. Repeat Step 6 for neutralizing piston (27) and actuator
piston (28). Illustration 71 g01033899
8. Remove allen head screw (30) and locking plate (31) in
order to remove solenoids (29) from actuator (20).
13. Remove bolts (37) and (40) and washers (38) and (41) in
Illustration 69 g01033897 order to remove drive yokes (39) and (42) from both ends
9. Remove O-ring seals (33) and (34) from the spool of the output shaft.
and inspect the O-ring seals for damage. Replace
the O-ring seals, if necessary.
10. Repeat Step 8 and Step 9 for solenoid (32).
31200271 17
14. Attach Tooling (C) around the middle of the transmission 17. Remove bolts (47) in order to remove access panel (48)
and take care not to stress any of the solenoids. Use from transmission cover (10).
Tooling (C) and a suitable lifting device in order to
carefully lift the transmission. The weight of the
18. Remove bolt (49) and washer (50) from the pump drive
shaft. Remove ring (52) from the top of roller bearing (51).
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 74.
19. Remove temperature sensor (55) from
20. Remove bolt (54) in order to remove speed
sensor (53).
16. Remove bolt (46) and washer (45) in order to remove fan
drive (44) from the fan drive shaft.
18 31200271

21. Remove O-ring seal (56) from speed sensor (55) and 24. Remove valve (65) from modulating valve (58). Remove
inspect the O-ring seal for damage. Replace the O-ring O-ring seals (63) and (64) from the valve spool and
seal, if necessary. inspect the O-ring seals for damage. Replace the O-ring
seals, if necessary.
22. Remove bolts (57) that secure modulating valve (58) to Illustration 83 g00893230
transmission cover (10). Remove the modulating valve 25. Remove allen head screws (66) in order to remove idler
from the transmission cover and take care not to lose (67) for the fan drive.
the three O-ring seals that are between the modulating
valve and the transmission cover.
23. Remove O-ring seals (62) from modulating valve (58) and
inspect the O-ring seals for damage. Replace the O-ring
seals, if necessary. Remove nut (59) and washer (60) in
order to remove solenoid (61).
31200271 19

26. Use a suitable press in order to take the load off retaining
ring (68) that secures bearing (69) and remove the
retaining ring.
27. Use a suitable press in order to press the bearing from Personal injury can result from being struck by parts
mounting flange (70). propelled by a released spring force.

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.
28. Use Tooling (D) and a suitable bench vise in order to
remove bearing (69) from idler (67).
30. Use a suitable M4 screw to remove cap (75).
20 31200271

31. Make sure that shift rail (76) and shift rail (78) are in the 35. Remove O-ring seals (81) from transmission housing
NEUTRAL position. Use Tooling (B) in order to remove (19) and inspect the O-ring seals for damage. Replace
detent balls (77) from the cavity. the O-ring seals, if necessary.

Note: Record the positions of clips (79) for the harness 36. Use Tooling (E) in order to remove retaining ring (82).
before removing bolts (80). Remove bearing (83) for the pump drive shaft from
transmission cover (10).
32. Remove bolts (80) that secure the transmission cover to
the transmission housing.
33. Attach Tooling (A) to the 10 mm holes that are shown in
illustration 92.
34. Use Tooling (A) 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 (19).
Note: Ensure that the transmission cover is lifted square in
order to smoothly disengage the two locating pins that are
between the interface of the transmission cover and the
31200271 21

37. Use Tooling (F) to remove bearing cups (84), (85), (86), 39. Use Tooling (G) in order to remove seals (91) and (92)
and (87). Remove any shims that are under the bearing from transmission cover (10). Inspect the seals for
cups. damage and replace the seals, if necessary.

38. Use tooling (F) in order to remove bearing cup (88) for 40. Remove bearing carrier (93) for the input shaft and
the fan drive shaft from transmission cover (10). Remove inspect the bearing carrier. Replace the bearing carrier, if
shims (89) and use Tooling (E) in order to remove necessary.
retaining ring (90).

Illustration 99 g01035170 41. Remove allen head screws (95) in order to
remove oil tube (94).
Note: There is an O-ring seal at both ends of the oil 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.
22 31200271

Cover of a transmission with four speeds 44. Remove input shaft (102) from the transmission.
a. Remove allen head screws (97) in order to remove oil tube
(96).

45. Use Tooling (H) in order to remove retaining ring (103),
Illustration 104 g01033964 and remove gear (104) from input shaft (102).
Cover of a transmission with five speeds
b. Remove allen head screws (99) in order to remove oil tube
(98).
Note: There is an O-ring seal at both ends of the oil tube.
Inspect each seal and replace the seals, if necessary.

46. Remove ring seal (105) from input shaft (102) and
inspect the ring seal for damage. Replace the ring seal, if
necessary.

43. Remove thrust bearing (100) and sleeve (101) for the
thrust bearing from the end of input shaft (102).
31200271 23
50. Remove bearing cup (109) for the fan drive shaft from

47. Use a suitable press in order to remove bearing race
(106) from input shaft (102). Illustration 113 g00893610
51. Remove ring seal (110) from fan drive shaft (108) and
inspect the split seal for damage. Replace the ring seal, if
necessary.

48. Remove roller bearing (107) for the input shaft from
52. Use Tooling (J) in order to remove idler gear (113), thrust
washer (112), and bearing cone (111) from fan drive shaft
(108).

49. Remove fan drive shaft (108) from the transmission.

53. Remove needle bearing (114) and thrust washer (115)
from fan drive shaft (108).

24 31200271

54. Use Tooling (J) in order to remove drive gear (117) and 58. Remove needle bearings (124) and thrust washer (123)
bearing cone (116) from the other end of fan drive shaft from pump drive shaft (118).
(108).

Illustration 117 g00893953 59. Use Tooling (H) in order to remove retaining ring (125)
55. Remove pump drive shaft (118) from the transmission. from pump drive shaft (118).

56. Remove O-ring seal (122) from pump drive shaft (118)and 60. Use a suitable press in order to remove pump drive gear
check the O-ring seal for damage.Replace the O-ring (126) from pump drive shaft (118).
seal, if necessary. 61. Transmissions with five speeds are equipped with
57. Use Tooling (J) in order to remove idler gear a shift rail and a fork for the fifth speed.
(121), thrust washer (120), and bearing carrier (119)from
pump drive shaft (118).
31200271 25

a. Remove guide rail (127) and use a suitable drift and a 64. Raise forward/reverse shaft (134) and output shaft (132)
hammer in order to remove pin (128). sufficiently in order to remove reverse idler shaft (135)
from the transmission. The weight of the reverse idler
shaft is 6 kg (13 lb).

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 126 g01035363
seal, if necessary. 65. Slide countershaft (136) into the former position
of the reverse idler shaft, and lift the countershaft
from the transmission. The weight of the
countershaft is approximately 14 kg (31 lb).
66. Remove forward/reverse shaft (134) from the
transmission. The weight of the forward/reverse
shaft is approximately 20 kg (44 lb).

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 approximately 26 kg (56 lb).
63. Place a pry bar under input drive gear (133) of
forward/reverse shaft (134). Use the pry bar in Illustration 127 g01035369
order to raise the forward/reverse shaft at the
same time as using a suitable lifting device to
raise the output shaft.
26 31200271

67. Remove output shaft (132), selector forks (137) 71. Use Tooling (J) in order to remove first gear (145), thrust
and (138), and shift rails (139) and (140) from the washer (144), and bearing (143) from output shaft (132).
transmission.
68. Remove selector forks (137) and (138) and shift
rails (139) and (140) from output shaft (132).

72. Remove needle bearings (146) from output shaft (132).

69. Use a suitable hammer and a pin punch in order to
remove pin (141) before removing fork (138) from shift
rail (140) for the third speed and fourth speed.

73. Use Tooling (L) in order to remove retaining ring (147) that
retains synchronizer (148) for the first speed and second
speed.

70. Use a suitable hammer and a pin punch in order to
remove pin (142) before removing fork (137) from shift
rail (139) for the first speed and second speed.
31200271 27

74. Use a suitable screwdriver in order to lift synchronizer 77. Remove friction ring (151) from the synchronizer.
(148) for the first speed and second speed from output
shaft (132).
Note: Lift synchronizer (148) in one piece in order to prevent
losing internal parts.

Example of Damaged Inner Cone (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 with a
Illustration 135 g00894027 new part if any of the following damage is found:
75. Remove dog tooth plate (149) from the synchronizer. • Scuffing
• Burn marks

76. Remove inner cone (150) from the synchronizer.
79. Remove outer cone (152) from the synchronizer.
28 31200271
80. Remove three connecting blocks (153) from the 84. Remove needle bearings (160) from output shaft (132).
synchronizer.
81. Turn the synchronizer onto the other side and repeat Step
75 to Step 79.

85. Use Tooling (M) in order to remove taper roller
bearing (161) from the other end of output shaft
(132).
86. Remove tachometer drive (163) 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
Spring force can cause personal injury or death. with four speeds.
Do not repair until you have read the Operation and
Maintenance Manual.
82. Remove outer ring (154) from inner sprocket (155).
Note: Take care not to lose three energizers (156),
three locating pins (157) and three springs (158) when
the outer ring is removed from the inner sprocket.

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

83. Remove second gear (159) from output shaft (132).
31200271 29

Output Shaft of a Transmission with Five Speeds 88. Remove fourth gear (167) from output shaft (132).
b. Lift tachometer drive (163) and fifth gear (164) off output
shaft (132).

89. Remove needle bearings (168) and spacer (169) from
Illustration 147 g01047955 output shaft (132).

87. Use a suitable press in order to take the load off retaining 90. Use Tooling (L) in order to remove retaining ring (170) that
ring (165). Use Tooling (L) in order to remove the secures synchronizer (171) to output shaft (132).
retaining ring.
Note: Take care not to lose washer (166) that is located

between spacer (162) and tachometer drive (163).
Note: The spacer in Step 87 is replaced by a fifth gear for
transmissions that are equipped with five speeds.

30 31200271
91. Remove synchronizer (171) for the third speed and fourth Note: When outer ring (174) is removed, take care not to
speed from output shaft (132). lose energizers (177), springs (175), or steel balls (176).
Note: Lift the synchronizer in one piece in order to prevent
losing internal parts.

96. Remove third gear (178) and needle bearings (179) from
Illustration 153 g00894609 output shaft (132).
92. Remove dog tooth plate (172) from the synchronizer.

Illustration 154 g00894610 97. Remove ring seals (180) from forward/reverse shaft
93. Remove outer cone (173) from the synchronizer. (134). Check the ring seals for damage and replace the
94. Turn the synchronizer onto the other side and ring seals, if necessary.
repeat Step 92 and Step 93.
Illustration 155 g01035504 98. Use Tooling (J) in order to remove input drive gear (133),
spacer (182) and bearing cone (181) from forward/
reverse shaft (134).
Spring force can cause personal injury or death.
Do not repair until you have read the Operation and

Maintenance Manual.
95. Remove outer ring (173) that is shown in Illustration 154
in order to remove energizers (177), springs (175) and
steel balls (176).
31200271 31
102.Remove top plate (189) from the clutch assembly.

99. Remove thrust bearing (183) from the top of forward Illustration 163 g00894726
primary gear (184). 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.

100.Remove forward primary gear (184), needle bearings
(185), spacer (186) and thrust washer (187).
Typical Example of Tooling (L)


105.Use a suitable press in order to take the load off retaining
Illustration 161 g00894711 ring (192) and remove the retaining ring with Tooling (L).
101.Use a suitable screwdriver in order to remove retaining
ring (188).

106.Remove piston spring (194), support (195), the piston
Illustration 162 g00894719 spring, and spring retainer (193) from clutch assembly.
32 31200271

107.Use a suitable air line in order to lift the piston. 110. Remove thrust washer (198) and thrust bearing (199) from
Note: A restraining device above the piston is forward/reverse shaft (134).
required in order to prevent injury or damage when the
piston is removed. Place the restraining device into
position prior to the use of any air pressure.

111. Remove reverse primary gear (200) from forward/reverse
shaft (134).
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.

112. Remove needle bearings (201) and thrust
washer (202) from forward/reverse shaft (134).
113. Turn the forward/reverse shaft onto the opposite
end and repeat Step 101 to Step 108.
109.Use Tooling (M) in order to remove bearing cone (197)
from forward/reverse shaft (134).
31200271 33

114. Use Tooling (M) in order to remove bearing cones (203) Countershaft of a Transmission with Four Speeds
and (204) from the ends of reverse idler shaft (135). a. Use Tooling (M) in order to remove bearing cone (206)
from countershaft (136). Then remove spacer (207) from
the countershaft.

115. Use Tooling (M) in order to remove bearing (205)
from countershaft (136). Illustration 176 g01042516
Countershaft of a Transmission with Five Speeds
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.

Countershaft of a Transmission with Five Speeds
b. Use Tooling (J) in order to remove fifth gear
(210), synchronizer (209) for the fifth speed,
and bearing cone (208). Then remove needle
Illustration 174 g00895231 bearings (211).
Countershaft of a Transmission with Four Speeds
c. Repeat Step 92 and Step 93 for the
synchronizer for the fifth speed.
34 31200271

d. Turn the synchronizer onto the other side and 119. Use a suitable allen wrench in order to remove allen head
remove retaining ring (212). screw (217) and washer (218). Remove bolt (219) and
e. Repeat Step 95 for the synchronizer for the washer (220).
fifth speed.

Illustration 179 g01042521 120.Remove baffle plate (221) from transmission
117. Use a suitable allen wrench in order to remove four allen housing (19).
head screws (213) that secure oil tube (214) to the inside 121.Remove bolts (222) that secure scavenge pump
of transmission housing (19). (223) to transmission housing (19).

118. Remove oil tube (214). Remove two O-ring seals (215) 122.Remove suction pipe (224) from scavenge pump (223).
and (216). Inspect the O-ring seals for damage. Replace
the O-ring seals, if necessary.
31200271 35
126.Remove gerotor (226) of the scavenge pump.

123.Remove scavenge pump (223) from transmission Illustration 188 g00895992
housing (19). 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.

124.Rotate scavenge pump (223) to the other side. Use a
suitable allen wrench in order to remove the allen head
screw.
129.Attach Tooling (A) onto transmission housing (19). Use
the tooling 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).

125.Remove back plate (225) of the scavenge pump.

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

36 31200271

131.Remove charge pump (229) from transmission housing 134.Use Tooling (H) in order to remove retaining ring (236) that
(19) and remove O-ring seal (230). Check the O-ring seal secures bearing (237) in cover plate (233).
for damage and replace the O-ring seal, if necessary.

Illustration 192 g00896087 135.Use a suitable press in order to remove pump coupling
132.Remove O-ring seal (231) and check the O-ring seal for (238) and the bearing from the cover plate (233).
damage. Replace the O-ring seal, if necessary. Use a
suitable allen wrench in order to remove allen head screw
(232).

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

31200271 37
137.Install bolt (49) and washer (50) from the end of the
pump drive shaft onto the end of pump coupling (238) in
order to allow the use of Tooling (D). Use Tooling (D) in
order to remove bearing (237) from the pump coupling.

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

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

143.Remove pump drive gear (245).

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

38 31200271
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.

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

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

149.Remove bolts (251) that secure valve housing (43) to

146.Use a suitable allen wrench in order to remove allen head
screws (248) that secure support (249).

150.Valve housing (43) is seated on locating dowels. Use a
suitable screwdriver in order to separate the valve
housing from transmission housing (19). Do not lose the
Illustration 207 g01042675 O-ring seals that are behind the valve housing.
147.Use a mallet and a suitable drift in order to punch the
support from transmission housing (19).
31200271 39

151.Remove O-ring seals (252) from valve housing (43) and 154.Use Tooling (N) in order to remove bearing cups
inspect the O-ring seals for damage. Replace the O-ring (263) and (261) from transmission housing (19).
seals, if necessary. Remove any shims from the valve 155.Remove bolts (262) that secure cover (260)
housing. for the output shaft and the countershaft to

152.Use a suitable allen wrench in order to remove allen head Illustration 215 g01036075
screw (255) and locking plate (254). Remove solenoid 156.Cover (260) is seated on locating dowels. Use a suitable
(253) and refer to Step 9 for details of removing the O- screwdriver in order to separate the cover from
ring seals. transmission housing (19).

153.Remove nuts (259) and washers (258) in order to remove 157.Use Tooling (G) in order to remove seal (264) that is
solenoids (256) and (257). Refer to Step 24 for details of shown in Illustration 215 from cover (260).
removing the spools and the O-ring seals.
40 31200271

158.Use Tooling (N) in order to remove bearing cups (265) and 161.Remove torque converter relief valve (273) from
(266) from transmission housing (19). transmission housing (19).

159.Use a suitable allen wrench in order to remove two allen 162.Remove O-ring seals (274) and (275) from torque
head bolts (267) that secure speed sensors (268) and converter relief valve (273). Inspect the O-ring seals for
(269) to transmission housing (19). Remove bolt (270) damage and replace the O-ring seals, if necessary.
that secures speed sensor (271) and remove the three
sensors from the transmission housing.

163.Remove pressure regulator valve (276) from transmission
Illustration 219 g00896542 housing (19).
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.
31200271 41

installed.
NOTICE
containing fluids.
Illustration 223 g01036143 Products Guide" for tools and supplies suitable to collect
164.Remove O-ring seals (277) and (278) from pressure and contain fluids on Caterpillar products.
regulator valve (276). Inspect the O-ring seals for Dispose of all fluids according to local regulations and
damage and replace the O-ring seals, if necessary. mandates.
NOTICE
Transmission - Assemble
Keep all parts clean from contaminants.
Assembly Procedure component life.
Table 7
Required Tools

B 1U-7262 Telescoping Magnet 1
C 1U-8241 Lifting Sling 1
D 1P-2320 Combination Puller 1
E 1P-1857 Retaining Ring Pliers 1
F 156-7100 Slide Hammer Puller Gp 1 Illustration 224 g01036143
G 1P-0510 Driver Gp 1 1. Install O-ring seals (277) and (278) onto pressure
regulator valve (276).
H 1P-1856 Retaining Ring Pliers 1
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
P 8T-5096 Dial Indicator Gp 1

2. Install pressure regulator valve (276) into transmission
housing (19).
component.
42 31200271

3. Install O-ring seals (274) and (275) onto torque converter 6. Use Tooling (G) in order to install seal (264) that is shown
relief valve (273). in Illustration 228 into cover (260).

4. Install torque converter relief valve (273) into 7. Install O-ring seals (64) and (63) onto valve spool (65).
transmission housing (19). Install the spool into modulating valve (58).

5. Use a suitable drift in order to remove core plug (279) 8. Install solenoid (61), washer (60) and nut (59). Install O-
from transmission housing (19). ring seals (62) onto modulating valve (58).
Note: It is necessary to remove the core plug in order to shim
the forward/reverse shaft.

31200271 43
9. Install O-ring seals (33) and (34) onto the valve spool of
solenoid (32).

13. Repeat Step 12 in order to install neutralizing piston (27)
Illustration 233 g01049581 and actuator piston (28).

10. Install solenoid (29), locking plate (31) and allen 14. Install four O-ring seals (22) onto actuator (20).
head screw (30) onto actuator (20). 15. Repeat Step 9 to Step 14 in order to assemble
11. Repeat Step 9 and Step 10 in order to install the actuator for the second and fourth speeds.
solenoid (32) onto actuator (20).

Illustration 235 g01033887 16. Refer to Step 7 for details of installing the O-ring
12. Install O-ring seals (25) and (26) onto neutralizing piston seals on the spools of solenoids (256) and (257).
(23) and actuator piston (24). Then install the two pistons 17. Install the spools and solenoids (256) and (257)
into actuator (20). into valve housing (43). Install nuts (259) and
washers (258) in order to secure the solenoids
to the spools.
44 31200271

18. Refer to Step 9 for details of installing the O-ring 23. Install Tooling (A) onto transmission housing (19) and use
seals on the spool of solenoid (253). Tooling (A) and a suitable lifting device in order to turn
19. Install solenoid (253), locking plate (254), and the transmission housing so that the bell housing is
allen head screw (255) onto valve housing (43). facing downward. Lower the transmission housing onto
suitable cribbing. The approximate weight of the
transmission housing is approximately 135 kg (298 lb).

20. Install O-ring seals (252) into valve housing (43).
24. Install bearing cups (261), (263), (265), and (266) into

21. Install cover (260) and bolts (262) onto
22. Install valve housing (43) and bolts (251) onto
31200271 45
27. Install gerotor (226) of the scavenge pump. Ensure that

the chamfered edge of the gerotor is facing downward.

28. Install back plate (225) of the scavenge pump. Ensure
that the bolt holes are correctly aligned.
Note: The back plate will align properly in only one
position.

25. Use Tooling (G) and a suitable mallet in order to install
needle bearing (240) for the pump drive shaft. The
needle bearing must be installed 5.00 mm (0.197 inch)
below the edge of transmission housing (19).

29. Rotate scavenge pump (223). Use a suitable allen wrench
in order to install the allen head screw that secures the
back plate to scavenge pump (223).

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

30. Invert scavenge pump (223). Install the scavenge pump
onto transmission housing (19) in the orientation that is
shown in Illustration 251.
31. Install suction pipe (224) onto scavenge pump (223).

46 31200271

35. Install O-ring seals (215) and (216), and oil tube (214).

32. Install bolts (222) in order to secure suction pipe Illustration 256 g01042521
(224) and scavenge pump (223) to transmission 36. Use a suitable allen wrench in order to install allen head
housing (19). screws (213) that secure oil tube (214) to the inside of
Note: The bolts that secure the suction pipe are longer than transmission housing (19).
the other bolts.
33. Install baffle plate (221) into transmission housing
(19).

37. Install needle bearings (179) and third gear (178) onto
output shaft (132).
34. Use a suitable allen wrench in order to install allen head
screw (217) and washer (218). Install bolt (219) and
washer (220).

31200271 47
Personal injury can result from being struck by

parts propelled by a released spring force.
Make sure to wear all necessary protective
equipment.

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

38. Install springs (175), steel balls (176) and
energizers (177) 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.
39. Install outer cone (173) so that the lugs on the
outer cone are aligned with the energizers. 43. Use Tooling (L) in order to install retaining ring (170) that
secures synchronizer (171) to output shaft (132).

40. Install dog tooth plate (172) for the synchronizer.
44. Install spacer (169) and needle bearings (168) onto
41. Turn the synchronizer onto the other side and output shaft (132).
repeat Step 39 and Step 40.

48 31200271
45. Install fourth gear (167) onto output shaft (132).
Illustration 265 g01035476 Output Shaft of a Transmission with Five Speeds

b. Install tachometer drive (163) and fifth gear (164) onto
output shaft (132).

46. Install washer (166) between spacer (162) and
tachometer drive (163). Use a suitable press and Illustration 269 g00900540
Tooling (L) in order to install retaining ring (165). 48. Use a suitable press in order to install taper roller bearing
(161) onto output shaft (132).
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.

49. Install two needle bearings onto the other end of output
shaft (132).

a. Install tachometer drive (163) and spacer (162) onto output
shaft (132).
31200271 49

50. Install second gear (159) onto output shaft (132). Example of Damaged Inner Core (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

Make sure to wear all necessary protective equipment. 54. Install friction ring (151) for the synchronizer.
51. Begin the assembly of the synchronizer for the first
speed and second speed by positioning locating pins
(157), springs (158) and energizers (156) around the
edge of inner sprocket (155). Install outer ring (154) over
the inner sprocket at the same time as holding the
locating pins, springs and energizers in position.

55. Install inner cone (150) for the synchronizer.

52. Install outer cone (152) so that the lugs on the outer cone
are aligned with the three energizers.
50 31200271

56. Install dog tooth plate (149) for the synchronizer. 60. Use Tooling (L) in order to install retaining ring (147) that
retains synchronizer (148) for the first speed and second
speed.

57. Turn the synchronizer onto the other side and
install connecting blocks (153). Illustration 281 g00900854
58. Repeat Step 52 to Step 56 for the second side of 61. Install needle bearings (146) onto output shaft (132).
the synchronizer.
Illustration 279 g00900603 62. Install first gear (145) and thrust washer (144) onto
59. Install synchronizer (148) for the first speed and second output shaft (132) and then use a suitable press in order
speed onto output shaft (132). to install bearing cone (143) onto the output shaft.
31200271 51

63. Use a suitable press in order to install bearing b. Install needle bearings (211) and fifth gear
cone (205) onto the first gear end of countershaft (210).
(136). c. Repeat Step 38 and Step 40 for the synchronizer for the
64. Install the components onto the other end of the fifth speed.
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.

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

e. Install synchronizer (209) for the fifth speed and then use
Illustration 285 g00991739 a suitable press in order to install bearing cone (208).
a. Install spacer (207) onto countershaft (136). Then use a
suitable press in order to install bearing cone (206) onto
the countershaft.
52 31200271

65. Use a suitable press in order to install bearing cone (203) 67. Install piston spring (194), support (195) for the piston
onto reverse idler shaft (135). Invert the shaft and install spring, and spring retainer (193) into the clutch
bearing cone (204) (not shown). assembly. Use a suitable press in order to compress the
spring. Then use Tooling (L) in order to install retaining
ring (192).

66. Install piston (196) into the forward clutch assembly.
68. Install clutch plate (191) and friction plate (190).

69. Use forward primary gear (184) in order to align
Personal injury can result from being struck by the clutch plate and the friction plate.
parts propelled by a released spring force. 70. Repeat Step 68 and Step 69 until the clutch
plates and friction plates are installed.
equipment.
31200271 53
74. Install thrust bearing (183) onto the top of forward primary
gear (184).

71. Install top plate (189) into the clutch assembly.
75. Install input drive gear (133) and spacer (182)
onto forward/reverse shaft (134). Ensure that the
boss of the input drive gear is facing downward.
76. Use a suitable press in order to install bearing
cone (181) onto forward/reverse shaft (134).
77. Turn the forward/reverse shaft onto the opposite
end and repeat Step 66 to Step 72 for the reverse
clutch assembly.

72. Use a suitable screwdriver in order to install retaining ring
(188).

78. Install thrust washer (202) and needle bearings (201)
onto forward/reverse shaft (134).

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

79. Install reverse primary gear (200) onto forward/reverse
shaft (134).

54 31200271

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

81. Heat taper roller bearing (197) to a maximum of 135 °C Illustration 306 g00900908
(275 °F). Install the bearing onto forward/reverse shaft 84. Use a suitable hammer to install pin (141) in order to
(134). Reset the bearing with a suitable driver after the install fork (138) onto shift rail (140) for the third speed
mating parts have reached a uniform temperature. and fourth speed.

82. Install split seals (180) onto forward/reverse shaft (134). 85. Install selector forks (137) and (138) and shift rails (139)
and (140) onto output shaft (132).
31200271 55
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.

91. Lower output shaft (132) and forward/reverse shaft into
the bearing cups. Then remove the pry bar and Tooling
(K). Ensure that the bearings on the bottoms of the
following shafts are properly seated in the bearing cups:
• Reverse idler shaft (135)
Illustration 309 g01043643 • Forward/reverse shaft (134)

86. Install Tooling (K) on the end of output shaft (132) and 92. Ensure that the ends of shift rails (139) and (140)
use a suitable lifting device to lift the output shaft, shift are properly located in transmission housing (19).
rails and selector forks into transmission housing (19). 93. Transmissions with five speeds are equipped with
The weight of the output shaft is approximately 28 kg (62 a shift rail and a fork for the fifth speed.
lb). Move the output shaft into position but do not lower
the output shaft fully into the bearing sleeve.
87. Install forward/reverse shaft (134) into
transmission housing (19). The weight of the
forward/reverse shaft is approximately 20 kg
(44 lb).
88. Install countershaft (136) into the position for the
reverse idler shaft. The weight of the countershaft

a. Install O-ring seal (131) onto shift rail (129),
and selector fork (130) onto the shift rail.
b. Install shift rail (129) into the hole in
transmission housing (19). At the same time
engage selector fork (130) with synchronizer
(209) for the fifth speed.

89. Place a pry bar under input drive gear (133) of
forward/reverse shaft (134). Use the pry 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 310.
56 31200271
96. Install thrust washer (123) and two needle

bearings (124) onto pump drive shaft (118).
97. Install O-ring seal (122) onto pump drive shaft
(118).

c. Install guide rail (127) into transmission housing (19) and
use a suitable hammer in order to install pin (128).

98. Install idler gear (121) and thrust washer (120) onto
pump drive shaft (118). Use a suitable press in order to
install bearing carrier (119) onto the pump drive shaft.

94. Use a suitable press in order to install drive gear (126)
onto pump drive shaft (118).

99. Install pump drive shaft (118) into the transmission.
Ensure that the tangs on the rotor of 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.

95. Use Tooling (L) in order to install retaining ring(125) onto
pump drive shaft (118).

100.Use a suitable press in order to install drive gear (117) and
bearing cone (116) onto fan drive shaft (108).
Note: Ensure that the boss of drive gear (116) faces the
middle of fan drive shaft (108).
31200271 57

101.Install thrust washer (115) onto fan drive shaft (108). 104.Install ring seal (110) onto fan drive shaft (108).
Ensure that the pin on the fan drive shaft engages with
the slot in the thrust washer.

105.Install bearing cup (109) for the fan drive shaft into
Illustration 321 g00901259 transmission housing (19).
102.Install needle bearing (114) onto fan drive shaft (108).

Illustration 322 g01048490 106.Install fan drive shaft (108) into transmission housing (19).
103.Install idler gear (113) and thrust washer (112) and then
use a suitable press in order to install bearing cone (111)
onto fan drive shaft (108).

107.Install roller bearing (107) for the input shaft into
58 31200271

108.Use a suitable press in order to install bearing race (106) 111. Install input shaft (102) into transmission housing (19).
onto input shaft (102).

Illustration 328 g00901265 112. Install sleeve (101) and thrust bearing (100) onto the end
109.Install ring seal (105) onto input shaft (102). of input shaft (102).

110. Install gear (104) onto input shaft (102) and use Tooling
(L) in order to install retaining ring (103).
Note: Ensure that the boss of gear (104) is at the same side
as retaining ring (103).

113. Use Tooling (G) in order to install seals (91) and
(92) into transmission cover (10).
31200271 59
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.

116. Install bearing carrier (93) for the input shaft into the
transmission cover.

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

117. Use Tooling (E) in order to install retaining ring (90). Use
Tooling (G) in order to install bearing cup (88).
Note: Shims (89) will be installed in a later step after
measurements have been taken.

Cover of a Transmission with Five Speeds
b. Install an O-ring seal at both ends of oil tube (99). Install
transmission cover.

118. Install bearing cups (84), (85), (86), and (87) into the
transmission cover.

115. Install an O-ring seal at both ends of oil tube (94). Install
transmission cover.
60 31200271

119. Install O-ring seals (81) into transmission housing (19). 123.Install supports (79) for the harness and bolts (80) in
order to secure the transmission cover to the

120.Install Tooling (A) to the 10 mm holes in transmission
cover (10). Use a suitable lifting device and Tooling (A) Illustration 344 g01048562
in order to lift the transmission cover. The weight of the 124.Install fan drive (44), O-ring seal (45b), washer (45a) and
transmission cover is approximately 42 kg (93 lb). bolt (46) on the end of fan drive shaft (108).

121.Use Tooling (A) and the lifting device in order to 125.Install Tooling (P) and place a suitable screwdriver
lower transmission cover (10) onto transmission between fan drive (44) and transmission cover (10) in
housing (19). On transmissions with four speeds, order to check the shaft end play on the fan drive shaft.
shift rails (139) and (140) will engage with the The shaft end play must be between 0.0254 and 0.0762
transmission cover first. On transmissions with mm (0.00100 and 0.00300 inch). If the shaft end play is
five speeds, the shift rail for the fifth speed will not within these parameters you must complete the
engage with the transmission cover first. following procedure:
122.Use a suitable lifting device to fully lower a. Remove the components that were installed in Step 124
transmission cover (10) onto transmission housing and Step 123. Then Refer to Step 121 in order to remove
(19). Ensure that the locating pins that are the transmission cover from the transmission housing.
between the interface of the transmission cover
and the transmission housing are engaged.
31200271 61

b. Turn over transmission cover (10) and remove
bearing cup (88). Install the required thickness
of shims against retaining ring (90) and then
install the bearing cup on top of the shims.
c. Repeat Step 121 to Step 125.

Illustration 347 g01049317 parts propelled by a released spring force.
126.Make sure that shift rail (76) and shift rail (78) are in the Make sure to wear all necessary protective
neutral position, and install detent balls (77) into the equipment.
cavity.
128.Install O-ring seals (74) onto spring retainers (71). Install
detent balls (73), springs (72) and spring retainers (71)
into transmission cover (10).

127.Install cap (75) into transmission cover (10).

129.Install bolts (57) in order to install modulating valve (58)
onto transmission cover (10).
62 31200271

130.Use a suitable press in order to install bearing (69) onto 133.Install bolt (54) and speed sensor (55).
idler (67). Then use the press in order to install mounting 134.Install temperature sensor (53) into transmission
flange (70) on the bearing. Install retaining ring (68) that housing (19).
secures the bearing inside the mounting flange.

135.Install roller bearing (51) onto the end of pump drive shaft
131.Install allen head screws (66) through mounting flange (118) and use Tooling (E) in order to install retaining ring
(70) in order to install idler (67) for the fan drive. (82).

132.Install O-ring seal (56) onto speed sensor (55). 136.Install ring (52), washer (50) and bolt (49) onto the
end of pump drive shaft (118).
31200271 63

137.Install bolts (47) and access panel (48) onto transmission 141.Install an M12 bolt that is at least 80 mm long into the
cover (10). 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. The
bearings must be seated in order to check the shaft end
play.

138.Install Tooling (A) and use a suitable lifting device in order
to lift the transmission. The weight of the transmission is
approximately 350 kg (772 lb). Rotate the transmission to
the orientation that is shown in Illustration 360 and then Illustration 362 g00902808
lower the transmission. 142.Install Tooling (P) and place a suitable pinch bar
between the bolt head and valve housing (43) in
order to check the shaft end play on the reverse
idler shaft. The shaft end play must be between
0.0254 and 0.0762 mm (0.001 and 0.003 inch).
143.Install a hose fitting onto the lube port of valve
housing (43). Insert a 60 mm long M12 bolt into
the end of the fitting.

139.Install Tooling (C) and use a suitable hoist in
order to lift the transmission. The weight of the
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.
144.Install Tooling (P) and pass a suitable
140.Remove the plug from valve housing (43). screwdriver through the hole for the core plug.
Use the screwdriver as a lever and check the
shaft end play on the forward/reverse shaft. The
float must be between 0.0254 and 0.0762 mm
(0.001 and 0.003 inch).
64 31200271
145.If the shaft end play on the reverse idler shaft 146.Install an 80 mm long M12 bolt through cover (263) onto
or on the forward/reverse shaft is not between the end of the countershaft. Install Tooling (P) and pass
0.0254 and 0.0762 mm (0.001 and 0.003 inch) a suitable screwdriver through the hole for the
complete the following procedure: transmission speed sensor. Use the screwdriver as a
lever and check the float on the countershaft. The float
must be between 0.0254 and 0.0762 mm (0.001 and
0.003 inch).

a. Remove bolts (251) in order to remove valve housing (43)
from transmission housing (19).
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
shaft end play on the output shaft. The float
must be between0.0254 and 0.0762 mm
(0.001 and 0.003 inch).
148.If the shaft end play on the countershaft or on the
output shaft is not between 0.0254 and 0.0762 mm
(0.001 and 0.003 inch) complete the following
procedure:

b. Install shims or spacers for reverse idler shaft
(135) and forward/reverse shaft (134), as
required.
c. Add sealant to the mating surface of
d. Refer to Illustration 364 in order to install bolts
(251) and valve housing (43) onto transmission
housing (19).

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

31200271 65
b. Install shims or spacers for countershaft (136) Note: Ensure that the bolt holes of the cover plate and the bolt
and output shaft (132), as required. holes of the housing are aligned.
c. Add sealant to the mating surface of
d. Refer to Illustration 367 in order to install
bolts (262) and cover (263) onto transmission
housing (19).

152.Turn the charge pump onto the other side, and install allen
head screw (232) in order to secure cover plate (233) to
the housing of the charge pump. Install O-ring seal
(231).
149.Use a suitable press in order to install bearing (237) onto
pump coupling (238). Then use Tooling (L) in order to
install retaining ring (239) that secures the bearing to the
pump coupling.

153.Install O-ring seal (230) in the groove on transmission
housing (19).

150.Use a suitable press in order to install bearing (237) and
pump coupling (238) into cover plate (233). Then use
Tooling (H) in order to install retaining ring (236) that
secures the bearing to the cover plate.

154.Use bolts (228) in order to install charge pump (229) onto
transmission housing (19). Tighten the bolts diagonally.
Note: Ensure that the bolt holes in the charge pump are
aligned with the four bolt holes in the transmission housing.

151.Install gerotor (234) and rotor (235) into the housing of
charge pump (229). Ensure that the chamfered edge of
the rotor and the chamfered edge of the gerotor are
facing downward. Then fit cover plate (233) onto the
housing of the charge pump.
66 31200271

155. Install thrust washer (250) onto support (249). Ensure 158.Install O-ring seal (246) onto pump drive gear (245).
that the rough side of the thrust washer is facing outward,
and ensure that the small pin on the support is engaged
with the hole in the thrust washer.

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

156.Install support (249) into transmission housing (19).
Ensure that the oil galleries on the support are aligned
with the holes in the transmission housing.

160.Install thrust bearing (243) onto the rear of cover (242) for
the pump drive gear. Ensure that the two small pins on the
cover engage with the holes in the thrust bearing.

157.Install support (249) onto transmission housing (19) with
allen head screws (248).

31200271 67
161.Install cover (242) for the pump drive gear onto

transmission housing (19) with bolts (241). Tighten
the bolts in a diagonal pattern.

164.Install actuator (20) and bolts (19) onto
Illustration 383 g01033899 165.Transmissions with five speeds have additional
components that need to be assembled and
installed.

162.Install drive yokes (39) and (42), washers (38) and (41)
and bolts (37) and (40) onto both ends of the output shaft. Illustration 387 g01033830
Note: Ensure that the yokes are installed with the same phase a. Install O-ring seals (16) on actuator (9) and
angle. install O-ring seal (18) on piston (17). Then
install the piston into the actuator.
b. Install O-ring seals (14) and (15) onto the valve
spool of solenoid (13).

163.Install actuator (36) and bolts (35) onto transmission
cover (10).
c. Install solenoid (13), locking plate (12) and allen head
screw (11) onto actuator (9). Then use bolts (8) in order to
install the actuator onto transmission cover (10).
68 31200271

f. Install sensor (4) for the shift rail and allen head screws (3)
onto transmission cover (10).


d. Install detent ball (7) and spring (6) into the cavity of

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


recommended tooling to release the spring force. 167.Install O-ring seals (272) onto speed sensors (268), (269)
and (271).
e. Use a suitable allen wrench in order to install cap (5) onto

31200271 69
168.Install speed sensors (268), (269) and (271) into

transmission housing (19). Install allen head bolts (267)
Transmission and Torque
and bolt (270) in order to secure the sensors to the Converter - Install
Note: The speed sensors differ from each other, and each one
must be installed in the correct location that is shown in
Illustration 394. Table 8
Required Tools
Part
Number
1U-7519 Hydraulic Pump 1
8S-7611 Tube As 1
A
8S-7615 Pin 1
8S-7650 Cylinder 1
169.Use allen head screws (1) in order to install position 1U-7498 Stand 4
sensors (2) onto transmission housing (19). B
1U-7501 Tube 4
C 138-7573 Link Bracket 1

D 9U-6198 Turning Tool 1
E 1U-7505 Transmission Jack 1

170.Remove Tooling (A) from the transmission.
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". Illustration 397 g01031397
1. Install transmission (30) onto Tooling (E). Secure the
transmission to Tooling (E). The weight of the

70 31200271
Illustration 399 g01031404 6. Remove Tooling (E) from transmission (30).

Illustration 400 g01031403 7. Install hose (29).

4. Raise transmission (30). The transmission should be
raised approximately 152 mm (6 inches). Install cable
strap (32).

8. Install belt tensioner (28).

5. Install bolts (31) into transmission (30). Secure
transmission (30) to the engine.

9. Install hub assembly (27). Install bolts (26).
31200271 71

10. Connect hose (25). Connect hose assembly (24). 14. Install bracket assembly (17) in position. Install bolts (18).

11. Install sensor (22). Connect harness assembly (23). 15. Install plate (15). Install bolts (16).

12. Install hose (21). Connect hose assembly (20).15. Install 16. Install Tooling (D) to engine crankshaft (12).
plate (15). Install bolts (16).

Illustration 409 g01031384 17. Rotate the engine crankshaft in order to allow
13. Connect harness assembly (19).16. Install Tooling (D) to access to bolt (14). Install bolt (14) and washer
engine crankshaft (12). (13).
72 31200271
18. Repeat Step 17 in order to remove additional bolts (14)

and washers (13).

22. Install cover (8) of the muffler. Install bolts (7).
19. Install Tooling (C) to rear fender (10). Attach a suitable
lifting device and apply tension. Place rear fender (10)
into position.

23. Install caps (6).

20. Install rear fender (10). Install bolts (11).

24. Connect hose (5). Connect hose assembly (4).

21. Install clips (9).

25. Install base (3). Install bolts (2).
31200271 73
Drive and Steering Axle (Front) -

Remove
Removal procedure
Table 9
Required Tools
Part
Number
Illustration 421 g01031354 1U-7519 Hydraulic Pump 1

8S-7611 Tube As 1
A
8S-7615 Pin 1
8S-7650 Cylinder 1
B 180-3034 Stand 2

ZZ
27. Lower the rear of the machine to the ground. Lower the 6V-9829 Tapered Cap/Plug 4
front of the machine to the ground. Remove Tooling (A)
and Tooling (B) from the machine. Start By:
End By: a. Remove the drive shaft (front). Refer to Disassembly and
Assembly, "Drive Shaft (Front) - Remove and Install".
a. Install the fan. Refer to Disassembly and Assembly, "Fan -
Remove and Install". NOTICE
b. Install the fan guard. Refer to Disassembly and Assembly, Care must be taken to ensure that fluids are contained
"Fan Guard- Remove and Install". during performance of inspection, maintenance, testing,
c. Install the refrigerant compressor. Refer to Disassembly adjusting and repair of the product. Be prepared to collect
and Assembly, "Air Conditioner - Remove and Install". the fluid with suitable containers before opening any
d. Install the engine enclosure. Refer to Disassembly compartment or disassembling any component
and Assembly, "Engine Enclosure - Remove and containing fluids.
Install".
e. Install the alternator. Refer to Disassembly and Assembly, Refer to Special Publication, "Caterpillar Tools and Shop
"Alternator- Remove and Install". Products Guide" for tools and supplies suitable to collect
f. Install the hydraulic oil cooler. Refer to Disassembly and and contain fluids on Caterpillar products.
Assembly, "Hydraulic Oil Cooler- Remove and Install". Dispose of all fluids according to local regulations and
g. Install the rear drive shaft. Refer to Disassembly and mandates.
Assembly, "Drive Shaft (Rear) - Remove and Install".
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE
h. Install the front drive shaft. Refer to Disassembly and IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL
OR THE INSTALLATION. THIS TOOLING IS SHOWN
i. Install the Implement pump. Refer to Disassembly and IN ORDER TO ASSIST THE EXPERIENCED
Assembly, "Implement Pump - Remove and Install".
SERVICEMAN.
j. Install the sump guard. Refer to Disassembly and
Assembly, "Sump Guard - Remove and Install". 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.
74 31200271


7. Remove clip (6). Remove pin (5). Remove bolts (7).

2. Install Tooling (A) under axle (1). Raise the
machine. Install Tooling (B) under the frame of
the machine.
3. Remove the tires and rims. Refer to Disassembly and
8. Remove bracket (8) from brake caliper (9).
Assembly, "Tires and Rims - Remove and Install".

9. Attach a suitable lifting device to axle (1). Remove nuts
(12). Remove bolts (10) and remove plate (11).
10. Repeat Step 9 on the opposite side of the axle.

31200271 75

11. Lower axle (1) to the ground. The weight of axle (1) is 2. Install plate (11) into position. Install bolts (10)
approximately 499 kg (1100 lb). and nuts (12). Tighten bolts (10) to a torque of
569 N-m (420 lb ft).
Drive and Steering Axle (Front) - 3. Repeat Step 2 on the opposite side of the axle.
Install
Table 10
Required Tools
Part
Number

8S-7611 Tube As 1 4. Install bracket (8) onto caliper (9).
A
8S-7615 Pin 1
8S-7650 Cylinder 1
B 180-3034 Stand 2

5. Install bolts (7). Install pin (5) and install clip (6).

1. Use a suitable lifting device in order to position axle (1)
into position on the machine. The weight of axle (1) is

76 31200271
6. Connect hose assemblies (4).

Drive and Steering Axle (Rear) -
Remove
Removal procedure
Table 11
Required Tools
Part
Number
Illustration 436 g01049677 8S-7610 Tube As 1

8. Connect hose assemblies (2). A
9. Install the tires and rims. Refer to Disassembly and 8S-7615 Pin 1
8S-7650 Cylinder 1
1U-7499 Stand 2
B
1U-7500 Tube 2
C 1U-9570 Puller 1

ZZ
Start By:
a. Remove the drive shaft (rear). Refer to Disassembly and
b. Remove the control valve (trailer and towing hitch). Refer to
Disassembly and Assembly, "Control Valve (Trailer and
Towing Hitch) - Remove and Install".
NOTICE
Illustration 438 g01031893 during performance of inspection, maintenance, testing,
10. Use Tooling (A) in order to raise the machine. Remove adjusting and repair of the product. Be prepared to collect
Tooling (B) from the machine. the fluid with suitable containers before opening any
End By: compartment or disassembling any component
a. Install the drive shaft (front). Refer to Disassembly and
containing fluids.
Assembly, "Drive Shaft (Front) - Remove and Install". Refer to Special Publication, "Caterpillar Tools and Shop
mandates.
31200271 77

SERVICEMAN.
1. Put identification marks on all lines, on all hoses and on

Note: Take note of the routing of harness assembly (6).

2. Install Tooling (A) under axle (1). Raise the machine.
Install Tooling (B) under the frame of the machine.
3. Remove the tires and rims. Refer to Disassembly and

8. Remove bolts (7). Remove cover (8).

9. Remove tube assemblies (9).

10. Attach a suitable lifting device to axle (1).
78 31200271

11. Remove bolt (10). 14. Move axle (1) onto stable cribbing.

12. Install Tooling (C) to pin assembly (11). Remove pin 15. Remove seals (12) and bushing (13) from axle (1).
assembly (11). Note: Bushings (13) will be destroyed upon removal.
Drive and Steering Axle (Rear) -

Install
Table 12
Required Tools
Part
Number
13. Lower axle (1) to the ground. The weight of axle (1) 1U-7519 Hydraulic Pump 1
Note: Take note of the position of shims. 8S-7610 Tube As 1
Note: Retain Tooling (B) under the frame of the A
machine. 8S-7615 Pin 1
8S-7650 Cylinder 1
1U-7499 Stand 2
B
1U-7500 Tube 2
D 1P-0510 Driver Gp 1
31200271 79
3. Install the shims from the removal procedure.

4. Align the axle with the frame. Install pin assembly (11).
5. Install bolt (10) in order to secure pin assembly (11).

1. Use Tooling (D) in order to install bushings (13). Use
Tooling (D) in order to install seals (12).
Note: Do not apply lubricants or sealants to the
bushing. Illustration 455 g01032315
6. Connect tube (9).

7. Install cover (8). Secure cover (8) with bolts (7).

2. Attach a suitable lifting device to axle (1). Remove axle
(1) from the cribbing. Install the axle onto the machine.
The weight of axle (1) is approximately 454 kg (1000 lb).
80 31200271

Tie Rod (Steering) - Remove
and Install
Removal Procedure
Table 13
Required Tools
Illustration 458 g01032306 A 1P-2320 Puller Group 1

10. Connect harness assembly (3). 1. Loosen locknut (1). Do not remove the locknut at this
time.

2. Install Tooling (A). Remove ball joint (2) from
12. Install the tires and rims. Refer to Disassembly and steering knuckle (3).
Assembly, "Tire and Rim - Remove and Install".
3. Remove locknut (1) and the tie rod after the tie rod
13. Use Tooling (A) in order to raise axle (1). Remove Tooling has been loosened with Tooling (A).
(B). Lower the machine. Remove Tooling (A).
End By:
a. Remove the control valve (trailer and towing hitch). Refer to
Disassembly and Assembly, "Control Valve (Trailer and
Towing Hitch) - Remove and Install".
b. Remove the drive shaft (rear). Refer to Disassembly and
31200271 81
2. Adjust tie rod (5) to Dimension (X). Dimension (X) is 443

± 2.0 mm (17.0 ± 0.07 inch).
Note: Dimension (X) is measured from the center to the
center.

4. Loosen jam nut (4).

3. After the proper adjustment is made, tighten jam
nut (4) to a torque of 250 Nm (184 lb ft).

5. Remove tie rod (5).
Installation procedure
4. Install ball joint (2) into steering knuckle (3).
5. Install locknut (1). Tighten locknut (1) to a torque of 250
Nm (184 lb ft).
Steering Cylinder - Remove and

Install
Removal Procedure
Table 14
1. Install tie rod (5) into position. Do not tighten at this time. Required Tools
Part
Number

ZZ

82 31200271
Start By:
a. Remove the tie rods. Refer to Disassembly and Assembly,
"Tie Rods - Remove and Install".
NOTICE
containing fluids.
Products Guide" for tools and supplies suitable to collect Illustration 471 g01032674
and contain fluids on Caterpillar products. 4. Loosen clamps (5). Remove sensor (6).
mandates.
SERVICEMAN.
1. Put identification marks on all lines, on all hoses and on

5. Remove bolts (7). Remove steering cylinder assembly
(8). The weight of steering cylinder assembly (8) is

2. Disconnect hose assembly (1). Remove fitting (2).

6. Remove ball joints (9) from steering cylinder assembly
(8.).

3. Disconnect harness assembly (3). Disconnect hose
assembly (4).
31200271 83
Installation Procedure 2. Install steering cylinder assembly (8) into the axle
housing. The weight of steering cylinder assembly (8) is
approximately 20 kg (45 lb). Install bolts (7).

1. Install ball joints (9) onto the ends of steering cylinder Illustration 477 g01032674
assembly (8). Tighten ball joints (9) to a torque of 190 Nm 3. Install sensor (6). Secure sensor (6) with clamps (5).
(140 lb ft).

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

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".

84 31200271
Final Drive Planetary - Remove Final Drive Planetary

Disassemble
Removal Procedure
Start By: Disassembly Procedure
a. Remove the tire and rim. Refer to Disassembly and Table 15
Assembly, "Tire and Rim - Remove and Install".
NOTICE Required Tools
Care must be taken to ensure that fluids are contained Tool Part Number Part Description Qty
A 1P-1863 Retaining Ring Pliers 1
containing fluids. Start By:
Refer to Special Publication, "Caterpillar Tools and Shop a. Remove the final drive planetary. Refer to Disassembly
and Assembly, "Final Drive Planetary - Remove".
mandates.
1. Drain the oil from the final drive planetary. Refer to
Operation and Maintenance Manual, "Final Drive Oil -
Change".

1. Use Tooling (A) and remove retaining ring (1).
Remove washer (2), needle bearings (3) and
planetary gear (4).
2. Repeat Step 1 for the remaining planetary gear
assemblies.

2. Remove screws (3) and remove planetary carrier
assembly (4) from wheel flange (1). Remove O-ring seal
(2) from wheel flange (1).
31200271 85
Final Drive Planetary - Final Drive Planetary - Install

Assemble
Assembly Procedure
Table 16
Required Tools

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).
Position planetary carrier assembly (4) onto wheel
flange (1). Install screws (3). Tighten screws (3)
to a torque of 25 Nm (18 lb ft).
2. Fill the final drive planetary with oil. Refer to
Operation and Maintenance Manual, "Capacities
(Refill)" and refer to Operation and Maintenance
1. Apply a thin layer of suitable grease onto needle Manual, "Final Drive Oil - Change".
bearings (3). This will help to hold needle bearings
(3) in position. Install half of needle bearings (3)
End By:
into planetary gear (4). Install planetary gear (4). a. Install the tire and rim. Refer to Disassembly and
Install the remaining half of needle bearings (3) Assembly, "Tire and Rim - Remove and Install".
into planetary gear (4). Install washer (2). Use
Tooling (A) and install retaining ring (1). Axle Housing and Flange
2. Repeat Step 1 for the remaining planetary gear
assemblies. Remove
End By:
a. Install the final drive planetary. Refer to Disassembly and Removal Procedure
Assembly, "Final Drive Planetary - Install".
Table 17
Required Tools
A 1P-2320 Combination Puller 1

B 230-7923 Spanner Wrench 1
C 246-5254 Spanner Wrench 1
D 2P-8312 Retaining Ring Pliers 1
Start By:
a. Remove the final drive planetary. Refer to Disassembly
and Assembly, "Final Drive Planetary - Remove".
86 31200271

1. Loosen nut (2). Do not remove nut (2) at this time. 3. Remove retaining ring (4). Remove dowel pin (5). Use
Install Tooling (A). Remove tie rod end (1) from the Tooling (C) in order to remove spanner nut (3).
taper of the knuckle. Remove nut (2) and remove tie
rod end (1).
Note: Follow Step 2 or Step 3 for the correct
procedure for the axle that is being serviced.

2. Remove bolts (5) and remove locking plate (4). Use
Tooling (B) in order to remove spanner nut (3).
31200271 87

4. Use a suitable pry bar and push the double U-joint toward 6. Remove wheel flange (10).
the wheel flange. This will make the removal of retaining Note: Bearing cone (11) will fall out of wheel flange (10)
ring (8) easier. Use Tooling (D) and remove retaining ring
when wheel flange (10) is removed.
(8). Remove thrust washer (7) and washer (6).

5. Remove ring gear (9).

7. Remove bolts (12). Remove pin assembly (13) and
shims (14). Remove bolts (16) and pin assembly (15).
88 31200271

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

Disassemble
Table 18
Required Tools
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".
31200271 89

1. Remove retaining ring (1) and ring gear hub (2) from ring 3. Remove bearing cone (9) and seal (10) from pin
gear (3). assembly (11). Repeat for the other pin assembly.

2. Remove seal (4) from wheel flange (7). Use Tooling (B) 4. Remove seal (12) from knuckle (13).
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).

90 31200271

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

6. Use Tooling (A) and a suitable hammer in order to remove 2. Use Tooling (A) and a suitable hammer and install
the bushing from knuckle (13). the bushing into knuckle (13).
Axle Housing and Flange -

Assemble
Assembly Procedure
Table 19
Required Tools
B 1P-0520 Driver Gp 1
31200271 91

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).
3. Use Tooling (A) and install seal (12) into knuckle (13).

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.
92 31200271

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
Install".
Axle Housing and Flange Install

Table 20
Required Tools
B 230-7923 Spanner Wrench 1

C 246-5254 Spanner Wrench 1
D 2P-8312 Retaining Ring Pliers 1

31200271 93

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

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

2. Do not install shims (14) at this time. Install pin 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).
94 31200271

4. Install ring gear (9). 6. Use Tooling (B) and install spanner nut (3).
Note: Follow Step 5 or Step 6 for the correct Tighten spanner nut (3) to a torque of 1000 Nm
procedure for the axle that is being serviced. (738 lb ft). Install locking plate (4) and bolts (5).
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.

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).
Note: If dowel pin (5) does not line up with the hole in spanner Illustration 511 g01023074
nut (3), tighten spanner nut (3) until dowel pin (5) and the hole
are aligned.
31200271 95

7. Use a suitable pry bar and push the double U-joint 9. Install tie rod end (1) into the axle housing. Install nut (2).
toward the wheel flange. This will make the installation of Tighten nut (2) to a torque of 250 Nm (184 lb ft).
retaining ring (8) easier. Install washer (6) and thrust End By:
washer (7). Use Tooling (D) 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
Remove".
NOTICE
containing fluids.
Illustration 513 g01029956 Refer to Special Publication, "Caterpillar Tools and Shop
8. Insert a suitable pry bar and move the knuckle up and Products Guide" for tools and supplies suitable to collect
down while you tighten bolts (12). Tighten bolts (12) until and contain fluids on Caterpillar products.
there is no end play. Use a suitable feeler gauge and
measure the clearance between pin assembly (13) and Dispose of all fluids according to local regulations and
the knuckle. Measure the clearance at several points mandates.
and average the measurement. Use shims (14) that 1. Drain the oil from the axle. Refer to Operation and
equal the measurement. Install correct shims (14) and Maintenance Manual, "Differential Oil - Change".
tighten bolts (12) to a torque of 300 Nm (221 lb ft).
96 31200271
Table 21
Required Tools
NOTICE
Illustration 515 g01023934 adjusting and repair of the product. Be prepared to collect
2. Remove axle shaft (1) from axle housing (2). the fluid with suitable containers before opening any
containing fluids.

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

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

4. If necessary, remove the upper and lower bearing cups
(5).
31200271 97
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".
NOTICE
Illustration 519 g01026864 containing fluids.
2. Use Tooling (A) and install bushing (4) and seal (3) into Refer to Special Publication, "Caterpillar Tools and Shop
axle housing (2). Products Guide" for tools and supplies suitable to collect
mandates.
1. Drain the oil from the axle. Refer to Operation and
Maintenance Manual, "Differential Oil - Change".

3. Install axle shaft (1) into axle housing (2).
4. Fill the axle with oil. Refer to Operation and Maintenance
Manual, “Differential Oil - Change” 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”.
98 31200271
Note: Put location marks on the axle housing, brake cylinder

assemblies, and the center housing for assembly purposes. Differential and Bevel Gear)
2. Position wood blocks under the drive and steering axle in
order to support the sections during removal. Attach a
(Front) - Disassemble
suitable lifting device onto the axle housing. The weight
of the axle housing is approximately 170 kg (375 lb). Disassembly Procedure
Remove bolts (1).
Table 22
Required Tools
A 235-2797 Spanner Socket 1

B 1P-2321 Combination Puller 1
C 1P-1859 Retaining Ring Pliers 1
D 235-5784 Pinion Wrench 1
E 8H-0663 Bearing Puller Gp 1
Start By:
a. Remove the axle housing. Refer to Disassembly and
Assembly, "Axle Housing (Service Brakes, Differential
and Bevel Gear) (Front) - Remove".
3. Remove axle housing (2) from brake cylinder assembly

(3).
4. Repeat Steps 2 through 3 for the other side.
31200271 99

1. Remove plates (1), brake discs (2), and coupling 3. Remove bolts (9) from brake cylinder assembly (4).
(3) from brake cylinder assembly (4).
Illustration 524 g01024444 4. Remove brake cylinder assembly (4). Remove the
differential and bevel gear assembly from the right side of
the center housing.

equipment.
2. Remove bolts (7). Remove bolts and springs (8). Use a
suitable pry bar and remove brake piston (6) from brake
cylinder assembly (4). Remove O-ring seals (5) from
brake piston (6).
100 31200271

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).

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

8. Push collar (17) inward. Use Tooling (C) and remove
Illustration 528 g01024629 retaining ring (19). Remove plate (18) and remove collar
6. Use Tooling (B) and remove bearing cone (14). (17). Remove pins (16).
31200271 101

9. Lock the differential in a vise. Remove bolts (20) and 11. Remove thrust washers (27), gears (28) and spider (29).
remove bevel gear (21) from the differential. Remove side gear (31) and thrust washer (30).

10. Remove cover (22). Remove thrust washer (23) and side 12. Straighten nut (32) out of the locking tab.
gear (24). Use a suitable punch and a hammer and drive
out locking pins (25). Remove planetary shafts (26).
102 31200271

13. Use Tooling (D) in order to hold the pinion flange and 15. Remove lip seal (36) from the center housing.
remove nut (32).

Illustration 536 g01047690 16. Tap the end of pinion shaft (37) with a soft hammer in
14. Remove washer (35) and O-ring seal (34). Remove order to remove pinion shaft (37) from the center housing.
brake disc (33).
31200271 103

17. Remove bearing cone (40), washers (38), and collapsible
spacer (39) from pinion shaft (37).

equipment.
19. Remove bolts (42), cover (43), O-ring seal (44), spring
(45), washer (46), and retaining ring (47) from the center
housing. Remove bolts (57), cover (56), O-ring (55),
piston (54), O-ring seals (53), retaining ring (52), bushing
(51), spring (50), and shaft (49) from the center housing.
Illustration 540 g01047692 Remove fork (48) 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.
104 31200271

20. Use a suitable hammer and a punch and remove bearing 1. Use Tooling (F) and install bearing cups (58) into the
cups (58) from the center housing. center housing.

(Front) - Assemble
Assembly Procedure
Table 23
Required Tools

D 235-5784 Pinion Wrench 1
F 1P-0520 Driver Gp 1
G 235-2788 False Pinion 1 2. Install bearing cones (40) and (41). Install Tooling (G).
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
31200271 105

3. Align the location marks that were made during the
removal procedure. Position brake cylinder (4) and
temporarily install bolts (9). Repeat for the other side.

5. Use Tooling (J) in order to measure Distance (A).
Distance (B) equals 145 mm (5.7 inch). Distance (C)
Illustration 546 g01047702 equals 50 mm (2.0 inch). Use the following formula in
4. Install Tooling (H) into the center housing. Make sure that order to calculate Measurement (X): A mm + C mm - B
Tooling (H) is inserted into both brake cylinders. mm = X mm. Record Measurement (X).
106 31200271

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
mm = S mm.
7. Among the available list of shims, choose the shim
with the thickness of Measurement (S). Illustration 551 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).

8. Remove Tooling (H). Remove brake cylinders (4).
Remove the nut and the washer from Tooling (G) and
remove Tooling (G). Remove bearing cones (40) and
(41). Illustration 552 g01033145
10. Install washers (38) and collapsible spacer (39) onto
pinion shaft (37).
31200271 107

11. Install pinion shaft (37) into the center housing. Raise the Note: Check the O-ring seal for wear or for damage. If
temperature of bearing cone (40) and install bearing cone necessary, replace the O-ring seal.
13. Install brake disc (33), O-ring seal (34), washer (35), and
nut (32).

12. Install seal (36) into the center housing. Illustration 556 g01047714
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).
108 31200271

15. Use a suitable hammer and a punch and stake nut (32). 17. Install thrust washer (30) and side gear (31). Install
spider (29), gears (28), and thrust washers (27).

16. Install pins (16). Install collar (17), and plate (18). Use Illustration 560 g01038164
Tooling (C) and install retaining ring (19). 18. Install planetary shafts (26). Install locking pins (25).
Install side gear (24) and thrust washer (23). Install cover
(22).
31200271 109

19. Raise the temperature of bearing cones (14) and (15). Note: Check the O-ring seals for wear or for damage. If
install bearing cones (14) and (15). 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).

20. Install bevel gear (21) onto the differential. Apply
Tooling (K) to the threads of bolts (20). Install bolts
(20) and tighten bolts (20) to a torque of 70 Nm
(52 lb ft).

22. Install brake piston (6) into brake cylinder (4). Make sure
that the holes on brake piston (6) align with the holes in
brake cylinder (4).
110 31200271

25. Use Tooling (A) and install spanner nut (12) into brake
cylinder (4).
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).

26. Apply Tooling (L) to the mating surfaces of the 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).

24. Position brake cylinder (4) on a flat surface. Use Tooling
(F) and install bearing cup (13).
31200271 111

28. Install the differential into the right side of the center
housing.
Improper assembly of parts that are spring loaded can

cause bodily injury.
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 (42) and install bolts (42). Tighten bolts Illustration 571 g01029530
(42) and (57) to a torque of 23 Nm (17 lb ft). 29. Apply Tooling (L) to the mating surfaces of the center
housing and the right 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). Use Tooling (A) and install spanner nut
(12).
112 31200271

30. Oscillate the pinion shaft and use Tooling (A) to
advance the spanner nuts until there is slight
backlash with no end play.

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).

31. Install a dial type torque wrench onto the pinion
shaft. 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 14. TRT = P + 0.280
Nm (2.48 lb in) to P + 0.467 Nm (4.13 lb in)
32. If the total rotating torque (TRT) is less than Illustration 575 g01029595
the specified amount tighten both spanner nuts 34. If the backlash is not within the specification, retract one
equally. If the total rotating torque (TRT) is greater spanner nut and advance the opposite spanner nut
than the specified amount, loosen both spanner equally. This will maintain the bearing preload. If the
nuts equally. Be sure to always maintain slight backlash is less than the specified amount, move the
backlash. bevel gear in Direction (A). If the backlash is greater than
the specified amount, move the bevel gear in Direction
(B).
31200271 113

(Front) - Install
Table 24
Required Tools
A Loctite 270 1
NOTICE
35. Install retainer (10) and bolt (11) into both brake cylinders the fluid with suitable containers before opening any
(4). Tighten bolts (11) to a torque of 1 3 N m ( 1 0 lb ft). compartment or disassembling any component
containing fluids.
mandates.

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".
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).
114 31200271

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)".
End By:
a. Install the drive and steering axle onto the machine.
Refer to Disassembly and Assembly, "Drive and Steering
Axle (Front) -
Axle Housing (Differential and

Bevel Gear) (Rear) - Remove
Removal Procedure
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.
31200271 115
Axle Housing (Differential and 2. Install bearing cone (33) onto Tooling (F). Install Tooling
(F). Install bearing cone (29), washer (24), and nut (22).
Bevel Gear) (Rear) - Assemble Tighten nut (22) until there is no backlash.
Assembly Procedure
Table 25
Required Tools

C 235-2784 Pinion Wrench 1
E 1P-0520 Driver Gp 1
F 235-2789 False Pinion 1
G 235-2795 Disc 2
H 238-0287 Shaft 1
J 6V-2012 Depth Micrometer 1
K Loctite 270 1 Illustration 583 g01034156
L 8T-5096 Dial Indicator Gp 1 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).

1. Use Tooling (E) and install bearing cups (31) and
(32).

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).

116 31200271

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).

10. Install pinion shaft (30), washers (27), collapsible spacer
(28), and bearing cone (29).

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

11. Install lip seal (26).
31200271 117

14. Use a suitable hammer and a punch and stake nut (22).

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).

15. Install thrust washer (20) and side gear (21). Install
spider (19), gears (18), and thrust washers (17).

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).

16. Install planetary shafts (16). Install locking pins (15).
Install side gear (14) and thrust washer (13). Install cover
(12).
118 31200271

17. Raise the temperature of bearing cones (8) and (9). 19. Install bearing cups (6) and (7) and install the differential
Install bearing cones (8) and (9). into the axle housing.

18. Install bevel gear (11) onto the differential. Apply Tooling 20. Install caps (5) and install bolts (4). Slightly tighten bolts
(K) to the threads of bolts (10). Install bolts (10) and (4). Do not torque bolts (4) at this time.
tighten bolts (10) to a torque of 70 Nm (52 lb ft).
31200271 119

21. Use Tooling (A) and install spanner nuts (3). 25. Mount Tooling (L) onto the differential housing, as shown.
22. Oscillate the pinion shaft and use Tooling (A) Measure the backlash between the pinion and the bevel
to advance spanner nuts (3) until there is slight gear. The proper backlash setting is 0.180 to 0.230 mm
backlash and no end play on the bearings. (0.0071 to 0.0091 inch).

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 601 g01029595
24. If the total rotating torque (TRT) is less than the 26. If the backlash is not within the specification, retract one
specified amount, tighten the spanner nuts. If spanner nut and advance the opposite spanner nut
the total rotating torque (TRT) is greater than the equally. This will maintain the bearing preload. If the
specified amount, loosen the spanner nuts. Be backlash is less than the specified amount, move the
sure to always maintain a slight backlash. bevel gear in Direction (A). If the backlash is greater than
the specified amount, move the bevel gear in Direction
(B).
120 31200271

Bevel Gear) (Rear) -
Disassemble
Table 26
Required Tools

27. Install retainers (2) and bolts (1). Tighten bolts (1) to a
torque of 13 Nm (10 lb ft). B 1P-2321 Combination Puller 1
C 235-2784 Pinion Wrench 1
D 8H-0663 Bearing Puller Gp 1
Start By:
a. Remove the rear axle differential and bevel gear from the
axle housing. Refer to Disassembly and Assembly, "Axle
Housing (Differential and Bevel Gear) (Rear) - Remove".

28. Tighten bolts (4) to a torque of 266 Nm (196 lb ft).
End By:
a. Install the rear axle differential and bevel gear into the
axle housing. Refer to Disassembly and Assembly, "Axle 1. Make reference marks on the caps and the housing for
Housing (Differential and Bevel Gear) (Rear) - Install". installation purposes.

2. Remove bolts (1) and retainers (2).
31200271 121

3. Use Tooling (A) and remove spanner nuts (3). 5. Remove the differential from the differential housing.
Remove bearing cups (6) and (7).

4. Remove bolts (4) and caps (5).

122 31200271

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).


10. Remove thrust washers (17), gears (18), and spider (19).
Remove side gear (21) and thrust washer (20).

8. Remove bolts (10) and remove bevel gear (11).

11. Straighten nut (22) out of the locking tab.
31200271 123

12. Use Tooling (C) in order to hold pinion flange (23) and 15. Tap the end of pinion shaft (30) with a soft hammer in
remove nut (22). order to remove pinion shaft (30) from the differential
housing. Remove bearing cone (29), washers (27), and
collapsible spacer (28).

16. Use a suitable hammer and a punch and remove bearing
cups (31) and (32).

13. Remove washer (24) and O-ring seal (25). Remove
pinion flange (23).

14. Remove lip seal (26) from the differential housing.
124 31200271
17. Use Tooling (D) and a suitable press in order to remove

bearing cone (33) from pinion shaft (30). Remove the
Brake Cylinder (Master)
shim that is positioned under bearing cone (33). Check the Remove and Install
shim for wear. If necessary, replace the shim.
Removal Procedure
Bevel Gear) (Rear) - Install Table 28
Required Tools
Installation Procedure Part
Table 27 Number
Required Tools A 1P-1855 Retaining Ring Pliers 1

Part
Number
A 4C-9507 Retaining Compound 1
component.
installed.
NOTICE
containing fluids.
1. Attach a suitable lifting device onto the differential and Products Guide" for tools and supplies suitable to collect
bevel gear housing (1). The weight of differential and and contain fluids on Caterpillar products.
bevel gear housing (1) is approximately 100 kg (220 lb).
Install the differential and bevel gear housing (1) into the Dispose of all fluids according to local regulations and
rear axle housing. Apply Tooling (A) to the threads of bolts mandates.
(2). Install bolts (2). Tighten bolts (2) to a torque of 169
Nm (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".

1. Remove cover (1).
31200271 125
4. Carefully lower cover (5) and loosen the hose clamp

before disconnecting heater hose (6). Loosen retaining
nut (8) and remove key start switch (7) from cover (5).
Move the key start switch aside. Remove cover (5) from
the machine.

2. Disconnect hose assemblies (2) from brake cylinder (3).
Loosen the hose clamp and disconnect hose (4).

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).


6. With the aid of a second person, support brake cylinder
(3). at the same time remove two locknuts (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.

126 31200271
Installation Procedure 2. Align the holes in linkage (11) with the hole in lever (12)
before installing pin (10). Use Tooling (A) in order to
Table 29
install retaining ring (9) onto pin assembly (10).
Note: If necessary, adjust the brake pedal. Refer to Systems
Required Tools Operation, Testing and Adjusting, " Service Brake Control
(pedal) - Adjust".
Part
Number
NOTICE
Keep all parts clean from contaminants.
component life.
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.

1. With the aid of a second person, position brake cylinder
(3) on the machine and install locknuts (13) with the
washers.

4. Carefully lift cover (5) and install the bolts that secure the
cover.

31200271 127

5. Connect hose (4) to brake cylinder (3) and tighten the 2. Turn grip (1) in a counterclockwise direction in order to
hose clamp. Connect hose assemblies (2). 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 harness
assembly (4) before removing the cover from the
machine.

6. Install cover (1).
7. Purge the air from the brake system. Refer to Systems
Operation, Testing and Adjusting, "Service Brake Air -
Purge" for the proper procedure.
3. Remove screws (5) in order to remove limit switch (6).
Lay the limit switch aside.
Parking Brake Control -Remove
and Install
Removal Procedure
1. Park the machine on level ground. Place blocks in front of
the rear wheel and behind the rear wheels.

4. Remove nuts (9), the washers, bolts (7), and spacers (8)
in order to remove hand control (10) from mounting
bracket (11).

128 31200271

2. Align the holes in hand control (10) with the holes in
brake cable (12) and install pin (13), washers (15), and
cotter pin (14).

5. Remove cotter pin (14), pin (13) and washers (15) in
order to disconnect brake cable (12) from hand control
(10). Compress the fingers on spring clip (16) and Illustration 646 g01029423
remove brake cable (12) from hand control (10). 3. Position hand control (10) onto mounting bracket (11)
and install bolts (7), spacers (8), nuts (9), and the
Installation Procedure washers.

4. Position limit switch (6) and install screws (5).
1. Install brake cable (12) into hand control (10).
Make sure that the fingers on spring clip (16) have
locked the brake cable into the hand control.
31200271 129
2. Remove clip (2) and pin (7) in order to disconnect cable

(1) from lever (6). Remove bolts (4) and the washers in
order to remove bracket (3) from parking brake (5).

3. Loosen two bolts (9). Unscrew the bolts until the bolts
are clear of the axle housing. Carefully lift parking brake
(5) off brake disc (8) and away from the machine.
Parking Brake - Disassemble

Start By:
Illustration 649 g00931612 a. Remove the parking brake. Refer to Disassembly and
5. Connect harness assembly (4) before sliding cover (3) Assembly, "Parking Brake - Remove".
over hand control into position. Install bolts (2). Rotate
grip (1) in a clockwise direction in order to adjust the
tension on the parking brake cable. Refer to Systems
Operation, Testing and Adjusting, "Parking Brake Control
- Check and Adjust".
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".

equipment.
1. Remove retaining spring (1) from the parking
brake.

130 31200271

2. Turn the parking brake onto the opposite side and remove 5. Slide cam assembly (15) off bolt (16) and torque plate
brake linings (2). (4).

3. Slide bolts (3) out of torque plate (4) and torque plate (5). 6. Remove boot (17) and boot (18) from cam assembly
Remove nut (8) and sleeve (7) from bolts (3). Remove (15).
seals (6) that are installed between the torque plates.

Illustration 655 g01032107 7. Remove cam ring (19), ball bearing and retainer (20)
4. Clamp the torque plate (not shown) in a suitable soft from cam ring (21).
jawed vise. Remove nut (9), nut (10), washer (11), washer
(12), thrust (13), and lever (14).
31200271 131

8. Slide torque plate (4) off bolt (16). 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.

9. Remove bolt (16) from torque plate (5).
3. Clamp torque plate (5) in a suitable soft jawed vise.
Parking Brake - Assemble Install torque plate (4) onto bolt (16).
Assembly Procedure
Table 30
Required Tools
A 1P-0808 Multipurpose Grease 1
worn or damaged, use new Caterpillar parts for Illustration 663 g00951226
replacement. 4. Apply a thin coat of Tooling (A) to the ball bearings and
retainer (20). Install the ball bearings and the retainer onto
the paths in cam ring (21). Install cam ring (19) onto the
ball bearings and the retainer.
132 31200271
7. Align the dowel holes in lever (14) with the dowels on

the cam assembly. Install the lever into position. Refer to
illustration 667 for the correct position. Install thrust (13),
washer (12), washer (11), nut (10) and nut (9).
Note: Nut (10) and nut (9) 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.

5. Install boot (18) and boot (17) onto cam assembly (15).

8. Install seals (6) between torque plate (4) and
torque plate (5). Install sleeve (7) and nut (8) onto
two bolts (3). Apply a thin coat of Tooling (A) onto
the sleeves before sliding the bolts and sleeves
into the torque plates.
9. Nut (8) can only be adjusted when the parking
Illustration 665 g00951230 brake is installed on the machine. Refer to
6. Slide cam assembly (15) over bolt (16) and onto torque Disassembly and Assembly, "Parking Brake -
plate (4). Make sure that you align the dowels on the Install" for the correct adjustment procedure.
cam assembly with the dowel holes in the torque plate.

Illustration 666 g01032107 10. Install brake linings (2) into the parking brake.

31200271 133

equipment.
11. Turn the parking brake onto the opposite side and install
retaining spring (1).
End By:
a. Install the parking brake. Refer to Disassembly and
Assembly, "Parking Brake - Install". a. Use a suitable feeler gauge to measure the distance
between locknuts (10) and sleeves (11). If necessary,
adjust the locknuts in order to set the gap to 0.6350 ±
Parking Brake - Install 0.3810 mm (0.02500 ± 0.01500 inch) before tightening
bolts (9) to a torque of 150 Nm (110 lb ft).

b. Loosen nut (13). Turn nut (12) in a clockwise
Illustration 671 g01029593 direction. This action will apply the parking brake.
1. Slide parking brake (5) onto brake disc (8) and Tighten the nut to a torque of 11 ±2 Nm (100 ±20
install bolts (9). Do not tighten the bolts at this lb in).
time. c. When the correct torque is achieved, turn nut
(12) in a counterclockwise direction by 300
2. Use the following procedure to adjust the parking degrees ± 60 degrees. This action will release
brake: the parking brake and the parking brake lever
will be set correctly.
d. Tighten nut (13) against nut (12). Tighten the
nut to a torque of 68 ±6 Nm (50 ±5 lb ft).

3. Position bracket (3) onto parking brake (5) and
install bolts (4) with the washers. Align cable (1)
with lever (6) and install pin (7) and clip (2).
134 31200271
4. Adjust the parking brake. Refer to Systems

Operation, Testing and Adjusting, "Parking Brake
Control - Check and Adjust.".
Tire and Rim - Remove and

Install
Removal Procedure
Table 31
Required Tools
2. Remove nuts (4). Remove fender assembly (5).
A 180-3033 Stand Group 1

8S-7650 Cylinder Group 1
8S-7610 Base Assembly 1
B
3S-6224 Pump Assembly 1
8S-7615 Pin 1

3. Loosen lug nuts (6). Do not remove the lug nuts at this
time.

4. Install Tooling (B) in order to raise the machine. Install
Tooling (A).

1. Remove bolts (1). Move chassis lamp (2) out of the
way. Secure chassis lamp with cable straps (3).

31200271 135
5. Install a suitable lifting device in order to remove tire and

rim assembly (7). Apply tension to the lifting device.
Remove lug nuts (6).

2. Install tire and rim assembly (7) onto the machine. The
weight of the tire and rim assembly is approximately 191
Illustration 682 g01030000 kg (420 lb).
6. Remove tire assembly (7) from the machine. The weight 3. Install lug nuts (6). Tighten lug nuts (6) to a torque of 240
of the tire and rim assembly is approximately 191 kg Nm (177 lb ft).
(420 lb).
Table 32
Required Tools
A 180-3033 Stand Group 1

8S-7650 Cylinder Group 1 Illustration 685 g01029992
8S-7610 Base Assembly 1 4. Install fender assembly (5). Secure the fender assembly
B with nuts (4).
3S-6224 Pump Assembly 1
8S-7615 Pin 1

5. Remove cable straps (3). Place chassis lamp (2) into
position.
1. Install a suitable lifting device to tire and rim
assembly (7). Place the tire and rim assembly into
position on the axle.
136 31200271

6. Install bolts (1) in order to secure chassis lamp (2).

7. Remove Tooling (A) and Tooling (B).
31200271 137
Index Index
A Drive and Steering Axle (Front) - Remove

Axle Housing (Differential and Bevel Gear) (Rear) - Assemble Removal procedure ...................................................... 73
Assembly Procedure................................................... 115 Drive and Steering Axle (Front) - Remove ......................... 73
Axle Housing (Differential and Bevel Gear) (Rear) - Drive and Steering Axle (Rear) - Install
Assemble ......................................................................... 115 Installation Procedure ................................................... 78
Axle Housing (Differential and Bevel Gear) (Rear) - Install Drive and Steering Axle (Rear) - Install.............................. 78
Installation Procedure................................................. 124 Drive and Steering Axle (Rear) - Remove
Axle Housing (Differential and Bevel Gear) (Rear) - Install124 Removal procedure ...................................................... 76
Axle Housing (Differential and Bevel Gear) (Rear) - Drive and Steering Axle (Rear) - Remove.......................... 76
Remove............................................................................ 114 Drive Shaft (Front) - Remove and Install.............................. 6
Removal Procedure.................................................... 114 Installation Procedure ..................................................... 7
Axle Housing (Differential and Bevel Gear) (Rear) - Removal Procedure ........................................................ 6
Disassemble
Drive Shaft (Rear) - Remove and Install
Disassembly Procedure.............................................. 120
Installation Procedure ..................................................... 8
Axle Housing (Differential and Bevel Gear) (Rear) -
Disassemble..................................................................... 120 Removal Procedure ........................................................ 7
Axle Housing (Service Brakes, Differential and Bevel Gear) Drive Shaft (Rear) - Remove and Install .............................. 7
(Front) - Assemble
F
Assembly Procedure................................................... 104
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary - Assemble
(Front) - Assemble ........................................................... 104 Assembly Procedure..................................................... 85
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary - Assemble ....................................... 85
(Front) - Disassemble Final Drive Planetary - Install
Disassembly Procedure................................................ 98 Installation Procedure ................................................... 85
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary - Install ............................................. 85
(Front) - Disassemble......................................................... 98
Final Drive Planetary - Remove
Axle Housing (Service Brakes, Differential and Bevel Gear)
(Front) - Install Removal Procedure ...................................................... 84
Installation Procedure................................................. 113 Final Drive Planetary - Remove ......................................... 84
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary Disassemble
(Front) - Install.................................................................. 113 Disassembly Procedure................................................ 84
Axle Housing (Service Brakes, Differential and Bevel Gear) Final Drive Planetary Disassemble .................................... 84
(Front) - Remove
Removal Procedure...................................................... 97 I
Axle Housing (Service Brakes, Differential and Bevel Gear) Important Safety Information.................................................ii
(Front) - Remove................................................................ 97
Axle Housing and Flange -Assemble ................................. 90 P
Assembly Procedure..................................................... 90 Parking Brake - Assemble
Axle Housing and Flange -Disassemble Assembly Procedure................................................... 131
Disassembly Procedure................................................ 88 Parking Brake - Assemble................................................ 131
Axle Housing and Flange -Disassemble ............................ 88 Parking Brake - Disassemble
Axle Housing and Flange Install Disassembly Procedure.............................................. 129
Installation Procedure................................................... 92 Parking Brake - Disassemble ........................................... 129
Axle Housing and Flange Install......................................... 92 Parking Brake - Install ...................................................... 133
Axle Housing and Flange Remove..................................... 85 Installation Procedure ................................................. 133
Removal Procedure...................................................... 85 Parking Brake - Remove .................................................. 129
Axle Shaft - Remove and Install Removal Procedure .................................................... 129
Installation Procedure................................................... 96 Parking Brake Control -Remove and Install
Removal Procedure...................................................... 95 Installation Procedure ................................................. 128
Axle Shaft - Remove and Install......................................... 95 Removal Procedure .................................................... 127
Parking Brake Control -Remove and Install ..................... 127
B
Brake Cylinder (Master) Remove and Install S
Installation Procedure................................................. 126 Steering Cylinder - Remove and Install
Removal Procedure.................................................... 124 Removal Procedure ...................................................... 81
Brake Cylinder (Master) Remove and Install ................... 124 Steering Cylinder - Remove and Install.............................. 81
D T
Disassembly and Assembly Section .................................... 3 Table of Contents................................................................. 1
Drive and Steering Axle (Front) - Install Tie Rod (Steering) - Remove and Install
Installation Procedure................................................... 75 Installation procedure ................................................... 81
Drive and Steering Axle (Front) - Install ............................. 75 Removal Procedure ...................................................... 80
138 31200271
Index
Tie Rod (Steering) - Remove and Install............................ 80

Tire and Rim - Remove and Install
Installation Procedure ................................................. 135
Removal Procedure .................................................... 134
Tire and Rim - Remove and Install................................... 134
Transmission - Assemble................................................... 41
Assembly Procedure..................................................... 41
Transmission - Disassemble .............................................. 13
Disassembly Procedure................................................ 13
Transmission and Torque Converter - Install
Installation Procedure ................................................... 69
Transmission and Torque Converter - Install ..................... 69
Transmission and Torque Converter - Remove ................... 8
Removal Procedure ........................................................ 8
Transmission Control (Select Lever) - Remove and Install.. 3
Component Locations
Description
Part Machine Schematic 31200275 FLUID POWER SYMBOLS
Number Location Location
December 15, 2006 BASIC COMPONENT SYMBOLS
Cooler & Mtg Gp - (12kW) 206-5502
1 A-5
Hydraulic Oil (Xmsn) (Option) (20kW) 194-0952
Cylinder Gp - (220) 278-2112 MAIN AUX.
PUMP: VARIABLE and
Boom (Raise) (330) 253-2574 2 G-4 PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)
Cylinder Gp - Brake (Master) 295-3424 3 B-2

Cylinder Gp - Coupler (220/330) 295-3374
4 H-6, H-7 18 23 24 25 14 15 2 7 29 8 VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(340) 295-3419 (ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED
Cylinder Gp - (220) 187-3694 26 28 32 33 31 34 12 38 VALVES

Tilt (330) 295-3372 5 G-5 VALVE ENVELOPES VALVE PORTS
ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

Cylinder Gp - (220) 187-3695
Hydraulic (330) 187-3699 7 G-5 5 16 17 27 CONTROL VALVES CHECK VALVES
(Compensating)
AB AB
Cylinder Gp - (220) 283-6315
Telescoping (330) 295-3463 8 G-7 P T P T
22 NORMAL POSITION SHIFTED POSITION INFINITE POSITION
BASIC SPRING SHUTTLE PILOT
SYMBOL LOADED CONTROLLED
Filter Gp - Oil (Power Train) 191-1060 9 B-5
Motor Gp - MEASUREMENT ROTATING SHAFTS
Fan (Reversing Motor) (220/330) 256-2843 10 I-10
Pump Gp -
Fan (Reversing Fan) (220/330) 256-7180 11 I-9
PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL
Pump Gp - Metering
233-6072 12 F-9 4 21
(Steering - HMU)
FLUID STORAGE RESERVOIRS
Pump Gp -
TH220B & TH330B Telehandler

Piston (Main) 295-3457 13 B-10
Strainer - (Tank Filter) 202-5350 14 A-8
Hydraulic System
Tank As - Hydraulic (202/330) 216-2258 VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL
15 A-8
Valve & Mtg Gp - Diverter (Dual Auxiliary) 222-4662 16 H-8 9 13 19 20 35 39 1 3 6 30 COMBINATION CONTROLS
Valve As - (Tilt Cylinder Lock) (Cartridge) 295-3372 17 F-6
Valve Gp - Bank 4 (Implement)
Valve Gp - Check (Xmsn)
295-3450
257-4830
18
19
B-7
B-6
TH220B:
SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT
Valve Gp - Check (Back Pressure) 225-1912 20 B-9 5 17 S/N TFB00100 & After or MANUAL and PILOT PILOT or MANUAL
Valve Gp -
Check (Coupler
Cylinder Check)
(220/330) 190-3611 21 H-5, H-6 TH330B: MANUAL CONTROL SYMBOLS
6 30
Valve Gp - S/N TBG00100 & After
Combination (Trailer Services (202/330) 215-2303 22 H-2
Valve) (Option) 2 7 8 PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING
Valve Gp - Control (Aux) 227-1207 23 D-6 1 13 19 PILOT CONTROL SYMBOLS

29 31 34
Valve Gp - RELEASED PRESSURE REMOTE SUPPLY PRESSURE
227-1206 24 D-7
Control (Boom Extend, Retract) 20 35 39
Valve Gp - Control (Boom Raise, Lower) 227-1209 25 D-5
Valve Gp - Control (Quick Coupler Tilt) 227-1208 26 D-6 12 14 15 38 EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL
Valve Gp - Diverter (Single Auxiliary) 295-3437 27 H-8, I-5 SUPPLY PRESSURE
9
Valve Gp - Electronic Pilot 247-7829 28 B-4 CROSSING AND JOINING LINES
3 ACCUMULATORS HYDRAULIC AND PNEUMATIC CYLINDERS
Valve Gp -
Load Control (220/330) 229-2004
29 G-3
(Boom Raise Lock)
4 21 SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING
HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

Valve Gp - Load Control (Tele Cylinder) 252-5652 31 F-6
Valve Gp - Manifold (Inlet) 227-1203 32 D-8 FIXED VARIABLE DISPLACEMENT
16 27 DISPLACEMENT NON-COMPENSATED
FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO
Valve Gp - Manifold (Outlet) 227-1205 33 D-4 DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION
Valve Gp - Pilot (Anti Kick) 216-4237 34 G-5 UNIDIRECTIONAL UNIDIRECTIONAL
FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION
Machine Component Locations

Valve Gp -
(220/330) 264-0047 36 H-9
Relief (Reversing Fan)
Last Modified: 05/10/2004
Valve Gp -
Solendoid (Reversing Fan) (220/330) 264-0048 37 I-10
© 2006 Caterpillar Printed in U.S.A.
Valve Gp - Solendoid (Steer Mode Select) 210-7217 38 E-10
All Rights Reserved
XMSN Gp - (5spPsy) 206-4386
(Option) (4spPsy) 206-4387 39 A-6
(4spPsh) 206-4388
Tap Locations
Pressure, Sampling, and Sensor
Tap
Description
Schematic
Electrical Symbols Table
Number Location
AA Main Pump Pressure C-9
BB Load Sensor Pressure C-9
Hydraulic Symbols (Electrical)
Outlet
CC Implement Pilot Pressure C-3
Manifold
DD SOS Oil Sample Port B-5 Inlet
M
Manifold
Auxiliary Diverter Sol.
G
The hydraulic system for the trailer and the towing
hitch contains the following items: towing Hitch BB Transducer Transducer Generator Electric Motor
Group, electrically controlled Combination Valve (Fluid) (Gas / Air)
Group, hitch control Cable Group, trailer socket,
additional oil lines, and control switch that is
mounted in the cab.
A
Towing Hitch Group
16 Pressure Switch Pressure Switch Temperature Switch Electrical Wire
(Adjustable)
31200275
AA Electrical Symbols (Electrical)
27
VIEW OF AREA A
Inlet
Manifold Tele
24 Page
T
Quick Coulper Sol. Auxiliary
Pressure Temperature Level Flow
Tilt Symbol Symbol
Symbol Symbol
Boom
Towing Hitch Group.
The Towing Group is mounted to the rear frame.

BB
Outlet
Hitch control Cable Group moves the hooks that Manifold
Wire Number Identification Codes
release the hitch. A cylinder, that is located inside
the Towing Hitch Group, lowers the hitch when the Valve & Mtg Gp - Diverter (Dual Auxiliary) Electrical Schematic Example Hydraulic Schematic Example
operator activates the control switch that is located 18
inside the cab. The cylinder also raises the hitch Current Standard Current Standard
when the operator activates the control switch in the Harness identification code
opposite direction. CC
This example indicates
wire 135 in harness "AG". Wire
Circuit Number
Quick Coulper Sol. Identification
Wire Color
Combination Valve Group 325-AG135 PK-14
B 325-PK
27 Circuit Identification
Number
Wire Color Wire Gauge
28 Previous Standard
Location of
Implement Disable Sol. Wire Color
Wire
Valve Gp - Implement Asy 4-Bank (15), 325-PK-14

Main Pump Pressure Port (AA),
22 Load Sensor Pressure Port (BB, B A
B Implement Pilot Pressure Port (CC) Circuit Number Wire Gauge
VIEW B-B Identification (EXAMPLE VALVE)
Combination Valve Group is mounted to the rear

of the frame. The oil lines attach to the outlet manifold
Valve Gp - Diverter (Single Auxiliary) Valve Gp - Bank 4 (Implement) Last Modified: 10/15/2003
of the main control valve. The oil lines route pressure

oil, load sensing oil, and return oil to the combination
valve.
Diverter Valve (auxiliary single) Control Valve (dual auxiliary)
Frame Leveling Cylinder
The frame leveling cylinder is located at the front of
the machine on the right side. The head end of the
16 The quick coupler cylinder is located in the cylinder is attached to the machine frame, and the
22 hydraulically operated quick coupler. rod end is attached to the front axle.
21 6
27 The hydraulic quick coupler allows the operator to The frame leveling cylinder allows the machine frame
change the work tools on the quick coupler without to be levelled in order to improve the stability of the
leaving the cab. machine during operation.
27
The rods of the quick coupler cylinder serve as pins. Lock Valve (Frame Leveling Cylinder)
The rods extend out of the cylinder in order to engage
the work tool that is attached to the quick coupler and The lock valve is attached to the casing of the frame
4 the rods retract into the cylinder in order to disengage leveling cylinder.
On TH220B standard machines, a single Diverter The single valve diverts the oil flow from the auxiliary the work tool that is attached to the quick coupler. 30
The brake oil for the trailer is supplied by an oil line Valve (auxiliary single) is installed. A dual Control circuit section of the implement main control valve to
The valve controls the flow of oil into the cylinder and
that is connected to the front axle brake. Valve (dual auxiliary) is installed as an option on either the quick coupler cylinder or through Fitting
out of the cylinder. The valve also locks oil into both
the TH220B machines. The single Diverter Valve Assembly (quick disconnect) to a work tool cylinder.
sides of the cylinder in order to hold the cylinder in
(auxiliary single) and the dual Control Valve (dual The dual diverter valve provides an oil flow to an
Trailer and Towing Hitch auxiliary) are available options on the TH330B
machines.
additional auxiliary service.
position when the frame leveling system is in HOLD.
Hydraulic System (Option) Diverter Valve Quick Coupler Cylinder Frame Leveling
31200272
December 15, 2006
Systems Operation
Testing and
Adjusting
TH220B and TH330B
Telehandler Hydraulic System

presented.
this publication.

and material.

injury or death.
31200272 1
Table of Contents
Table of
Table of Contents Compensator Valve ........................... 18
Systems Operation Section Main Control Valve Group
Graphic Color Codes ............................... 3 (Implement)........................................ 18
Introduction.............................................. 4 Inlet Manifold ..................................... 18
General Information................................. 5 Outlet Manifold................................... 19
Main Control Valve Group (Implement)5 Trailer and Towing Hitch Hydraulic
Electronic Pilot Valve Group System (Option)................................. 19
(Implement) ......................................... 6 Boom Cylinder ................................... 20
Machine ECM...................................... 7 Load Control Valve (Boom Cylinder
Electronic Joystick............................... 8 Lock) .................................................. 21
Operator Switches............................... 9 Telescoping Cylinder ......................... 21
Piston Pump (Implement and Steering)9 Load Control Valve (Telescoping
Hydraulic Oil Tank ............................... 9 Cylinder Lock).................................... 21
Hydraulic Oil Filter ............................... 9 Tilt Cylinder........................................ 21
System Operation.............................. 10 Lock for Load Control Valve (Tilt
Load Independent Flow Division Cylinder) ............................................ 22
(LIFD) ................................................ 11 Compensating Cylinder ..................... 22
Location of Electrical Components.... 11 Load Control Valve (Compensating
Switch (Lockout Control) ................... 11 Cylinder Lock).................................... 22
Joystick Control ................................. 11 Frame Leveling Cylinder.................... 22
Sensor (Boom Raise/Lower) ............. 12 Lock Valve (Frame Leveling Cylinder)23
Sensor For Boom Extend And Boom Diverter Valve .................................... 23
Retract Or Boom Tilt Forward And Quick Coupler Cylinder...................... 23
Rackback........................................... 12 Electrical Input Components .................. 24
Switch (Continuous Auxiliary Flow) ... 12 Switches ............................................ 25
Switch For Boom Extend and Boom Joystick Control ................................. 25
Retract Or Boom Tilt Forward And Auxiliary Switches.............................. 25
Rackback........................................... 12 Thumb Slider ..................................... 25
Switch (Auxiliary Actuator in the + Boom Critical Angle Switch................ 25
Direction) ........................................... 12 Frame Leveling Switch ...................... 25
Switch (Auxiliary Actuator in the - Boom Retracted Switch ..................... 25
Direction) ........................................... 12 Quick Coupler Switch ........................ 26
Switch (Auxiliary Services 1 or 2)...... 12 Continuous Flow Switch .................... 26
Switch (Quick Coupler)...................... 13 Implement Lockout Switch................. 26
Switch (Frame Level) ........................ 13 Boom Lowered Switch ....................... 26
Switch (Fully Lowered Boom)............ 13 Electronic Control Module ...................... 27
Switch (Critical Angle) ....................... 14 Inputs ................................................. 27
Switch (Fully Retracted Boom).......... 14 Outputs .............................................. 27
Switch (Reversing Fan (If Equipped)) 14 Data Links.......................................... 27
Machine (ECM) ................................. 14 Input/Output ....................................... 27
Main Control Valve (Implement)........ 15 Electrical Output Components ............... 29
Solenoids (Frame Level) ................... 15 Relays................................................ 30
Solenoid (Diverter Valve) .................. 15 Solenoids ........................................... 30
Relay (Frame Level).......................... 16 Electrical Function Requirements .......... 31
Relays (Diverter Valve) ..................... 16 Transmission Neutralizer ................... 31
Relays (Quick Coupler) ..................... 16 Solenoid Outputs ............................... 31
Location of Hydraulic Components........ 17 System Voltage.................................. 31
Hydraulic Tank .................................. 17 Shuttle Shift for the Power Shuttle
Piston Pump (Implement and Transmission ..................................... 31
Steering)............................................ 17
2 31200272
Table of Contents
Shift Lever (Cat Data Link) for Hydraulics)......................................... 65

Powersynchro Transmission ..............31 Quick Coupler.................................... 65
Rear Axle Lock (if equipped)..............31 Quick Coupler Circuit DISENGAGED 66
Machine Security System ..................31 Quick Coupler Pins ENGAGED......... 67
Parking Brake ....................................31 Relief Valves and Makeup Valves ..... 67
Service Brake Pressure Switch for the Compensating System........................... 68
Transmission Neutralizer ...................31 Trailer and Towing Hitch Hydraulic
More Electrical Function System................................................... 72
Requirements.....................................31 Introduction........................................ 72
Steering..............................................32 Towing Hitch Cylinder LOWER ......... 74
The Neutral Start Is Disabled .............32 Towing Hitch Cylinder RAISE............ 76
Stabilizer Raise/Lower (if equipped) is Trailer DUMP..................................... 79
Disabled .............................................32 Trailer LOWER .................................. 81
Boom Raise/Lower Is Disabled ..........33 Service Brakes ENGAGED ............... 84
The Boom Extend/Retract Is Disabled33 Hydraulic System Schematic ................. 85
Disable The Rackback And Dump .....33 Configuration Parameters...................... 88
The Frame Level (if equipped) is Testing and Adjusting Section
Disabled .............................................33 Testing and Adjusting ............................ 89
Disable the Quick Coupler .................34 Joystick Control - Calibrate................ 89
Miscellaneous ....................................34 Main Control Valve (Implement) -
Electrical Schematic ...............................35 Calibrate .............................................. 109
Programmable Hydraulic System Programmable Hydraulic System (PHS)
(PHS) .................................................36 Valve Calibrations............................ 109
Piston Pump (Implement and Steering) .37 Manual Adjustment After Calibrating The
Piston Pump.......................................37 Valves.............................................. 118
Compensator Valve ...........................38 Hydraulic System Pressure -Release .. 118
Low Pressure Standby .......................39 Relieving Pressure in the Hydraulic
Upstroke.............................................40 System ............................................ 119
Constant Flow ....................................41 Location of the Load Control Valve
Destroke.............................................42 (Lock) .............................................. 119
High Pressure Stall ............................44 Relieving Pressure from the Load
Main Control Valve (Implement) ........45 Control Valves (Lock) ...................... 120
Manifold Valve (Inlet) .........................47 Hydraulic System Pressures -Test and
Check and Relief Valves ........................49 Adjust................................................... 123
Manifold Valve (Outlet)...........................49 Test and Adjustment Procedures .... 123
Pilot Hydraulic System ...........................51 Pilot Pressure (Pressure Reducing Valve) -
Telescoping System ...............................53 Test and Adjust.................................... 123
Valve for the Telescoping Cylinder in the Pilot Pressure Test .......................... 123
HOLD Position ...................................53 Pressure Reducing Valve
Valve for the Telescoping Cylinder in the Adjustment ...................................... 125
EXTEND Position...............................55 Relief Valve (Implement) - Test and
Valve for the Telescoping Cylinder in the Adjust................................................... 125
RETRACT Position ............................57 Auxiliary Pressure Test (Port A and
Hydraulic Fan System ............................58 Port B) ............................................. 125
Reversing Fan (If Equipped) ..............58 Auxiliary Relief Valve Adjustments .. 127
Auxiliary Hydraulic System.....................60 Hydraulic Oil Contamination -Test ....... 127
Auxiliary Control (Combined Circuit) ..61 Hydraulic Oil Contamination ............ 127
Auxiliary Circuit 1 ...............................63 Flushing the Sampling Valve ........... 127
Auxiliary Circuit 2 ...............................64 Obtaining the Sample ...................... 128
Continuous Flow (Auxiliary General Information Table ................... 129
31200272 3
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,
(G) Blue.................................................................. Trapped oil
(H) Green ............................................ Tank, sump or return oil
(I) Brown.............................................................. Lubricating oil
(J) Orange Crosshatch ........................... Second reduction in
(K) Yellow ............................ Moving or activated components
(L) Purple ............................................... Pneumatic pressure
(M) Light Gray..................................................... Surface color

may not require all of the colors in Illustration 1.
4 31200272
Introduction
This module discusses the features and operation of The implement hydraulic system includes the
the implement hydraulic system. In addition, the major following features:
electrical components and hydraulic components are • Closed center spools in the control valves for the
also discussed. The following Telehandler B-Series boom extend/retract, boom raise/lower and coupler
Machines are covered in this module: tilt
• TH220B
• Open center spools from cylinder to tank in the
• TH330B control valves for the auxiliary system
Hydraulic System • Load sensing
The hydraulic system supplies oil flow to the following • Pressure and flow compensation
systems:
• Load independent flow division (LIFD)
• Steering
When the flow demand of the implements exceeds the
• Braking output of the hydraulic pump, the system will reduce
• Power Train flow to each of the active circuits. The flow from each
circuit will be reduced by the same percentage of the
• Implements (Including the Boom, Work Tools, and flow that is commanded.
Trailer and Towing Hitch Hydraulic System)
31200272 5
General Information Main Control Valve Group

The hydraulic system includes the following main
(Implement)
components:
• Main Control Valve Group (Implement)
• Machine ECM
• Electronic joystick
• Operator Switches
• Piston Pump (Implement and Steering)
• Hydraulic oil tank
• Hydraulic oil filter
(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
(8) (7) Electronic Pilot Valve
(9) Pilot Shutoff Solenoid
(10) Pilot Valve ECM 1
6 31200272
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 Group
• Auxiliary circuits (1) (Implement).
• Coupler Tilt (2) • Control Manifold Group (Pilot ECM2) (9) controls
• Boom EXTEND/RETRACT (3) the auxiliary functions and the boom EXTEND/
RETRACT. Pilot ECM2 is located on the Electronic
• Boom RAISE/LOWER (4) 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.
(7) Electronic Pilot Valve (Implement)
31200272 7
Machine ECM
The machine ECM (24) makes decisions based on the • The electronic control modules that are on the
operator inputs, the machine conditions and the Electronic Pilot Valve Group (Implement)
parameters that are programmed into the machine
CAT data link (31) is used in order to communicate
ECM in order to provide proper control of the hydraulic
with the following components:
system.
• .Machine ECM (24)
The machine ECM communicates to the other
components on the machine via the CAT data link (31), • The Diagnostic Connector
the CAN data link (32) and a CAN/ADDRESS data link • Engine ECM (34) (if equipped)
(30) that is dedicated for the electronic control modules
that are on the Electronic Pilot Valve Group (Implement). • Product Link ECM (35) (if equipped)
CAN/ADDRESS data link (30) is used in order to • Machine Security System ECM (36) (if equipped)
communicate with the following components:
8 31200272
CAN data link (32) 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
• Machine ECM (24) movement of the hydraulic implements.
Interlock for the Machine Security System
• Engine ECM (34) (if equipped)
When the interlock for the machine security system is
• Instrument Cluster (33)
active, the following functions may be disabled:
The machine ECM stores the diagnostic codes and the
• Boom RAISE/LOWER
event codes that are generated from the hydraulic
system. • Boom EXTEND/RETRACT
• Trailer circuits
Inputs to the Machine ECM
• Transmission
Inputs to the machine ECM include the following
components:
Electronic Joystick
• The joystick (11)
• The operator switches (15), (17), (20), and (23)
• The switches for machine condition (26) and (27)
• Engine and transmission speed sensors (28) and
(29)
• Machine Security System ECM (36) (if equipped)
• Product Link ECM (35) (if equipped)
Outputs from the Machine ECM

Outputs from the machine ECM include the following
components:
• Pilot ECM 1 (9)
• Pilot ECM 2 (10)
• Instrument cluster (33)
• Relays for quick coupler (21), diverter valve (18)
for the auxiliary functions (if equipped) and trailer Illustration 6 g01009772
circuits (13) (if equipped) (11) Joystick
(37) Thumb Slider
(38) Auxiliary Buttons
• Machine Security System ECM (36) (if equipped) (39) Trigger Switch
• Product Link ECM (35) (if equipped) The joystick (11) is located on the right side of the
operator seat. The joystick contains one thumb slider
• Pilot shutoff solenoid (25) switch (37), two auxiliary buttons (38) and one trigger
switch (39).
Interlocks
The lateral movement of the joystick and the
The machine ECM monitors the switches of the longitudinal movement of the joystick is monitored by
Machine condition in order to control the hydraulic two sensors that are mounted in the base of the
system correctly. Switches for machine condition would joystick. These sensors send signals to the machine
include the following components: ECM (24) in order to operate the selected functions.
• Switch for Critical angle (26) The signals that are sent to the machine ECM are
• Parking brake switch (27) proportional to the distance of the joystick movement.
Thumb slider switch (37) also sends a proportional
• Engine speed sensors (28)
signal to the machine ECM for the function that is
• Transmission speed sensors (29) assigned to the thumb switch.
The machine ECM also receives information regarding The two auxiliary buttons (38) control the auxiliary
the machine condition from other electronic control functions. The trigger switch (39) is used in order to
modules that are equipped on the machine. select the auxiliary circuit, if more than one auxiliary
circuit is installed.
31200272 9
The joystick is calibrated in ET in order to ensure the Hydraulic Oil Tank

proper input from the joystick to the machine ECM.
The hydraulic oil tank supplies oil for two hydraulic
The joystick has two modes of operation. Table 1
circuits that operate independently.
shows the configurations and the functions that are
controlled by the joystick. The configuration of the • The hydraulic system
joystick is selected in ET. • The transmission system
Table 1
The hydraulic system contains the implement system,
Configuration of the Joystick the braking system, the system for the trailer circuits
and the steering system.
Construction Bucket
The transmission system includes the hydraulic oil
Joystick forward Boom RAISE/ Boom RAISE/
cooler, the torque converter, and the hydraulic oil filter.
and backward LOWER LOWER
Coupler Tilt
Joystick left and Boom EXTEND/
FORWARD and
Hydraulic Oil Filter
right RETRACT
Tilt BACKWARD The filter for the hydraulic system is located in the
Coupler Tilt transmission section. Oil from the hydraulic oil tank
Thumb slider Boom EXTEND/
FORWARD and passes through the hydraulic oil filter before entering
switch RETRACT
Tilt BACKWARD the transmission. The oil is then returned to the
hydraulic oil tank.
Operator Switches
The following switches are located in the cab. These
switches provide direct input to the machine ECM in
order to control some of the functions of the hydraulic
system:
• Quick coupler switch (17)
• Continuous flow switch (20)
• Differential lock switch (23)
The switch for trailer circuits (15) is also located in the
cab but the switch for the trailer circuits does not
provide direct input to the machine ECM. The control
valve (16) for the trailer circuits contains two solenoids.
The switch controls the two solenoids directly. The
hydraulic system for the trailer circuits is enabled by the
machine ECM through the relay for the interlock of the
trailer circuits (12).
Piston Pump (Implement and

Steering)
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.
10 31200272
System Operation
Hydraulic pump (42) draws oil from the hydraulic oil When the operator selects a function that is controlled by
tank (41). The pump is a variable displacement piston ECM (9) or by ECM (10), a signal is sent to the
pump with permanent drive. The output of the pump is machine ECM (24) by the joystick. The signal is in the
controlled by the highest load sensing oil pressure that form of a pulse width modulation (PWM). The machine
is present in the hydraulic system. ECM makes decisions based on operator input,
Pump supply oil flows into the inlet manifold of the Main machine conditions and the programmed parameters in
Control Valve Group (implement). The pump supply oil the machine ECM. The machine ECM then sends a
flows to the steering priority valve and the pressure signal to the proper Pilot ECM. The ECM for the pilot
reducing valve. The pressure reducing valve supplies valve sends a proportional signal to the pilot solenoid
oil to the pilot system and the braking system. valve of that function. When the solenoid opens, oil
moves past the open spool in order to operate the
The steering priority valve gives flow priority to the function. Oil is returned to the tank through the control
steering system over the rest of the hydraulic system. valve.
When the demands of the steering system have been
met, excess oil is then diverted by the priority valve to A load sensing oil relief valve is located in the load
the Main Control Valve Group (implement) (7). The oil sensing oil line. This load sensing oil relief valve limits
flows into the control valve (16) for the trailer circuits (if the pressure of the load sensing oil to the hydraulic
equipped). pump in order to limit the maximum system pressure.
31200272 11
Load Independent Flow Division Switch (Lockout Control)

(LIFD)
The control valve (implement) on these machines
utilizes Load Independent Flow Division (LIFD). The
(LIFD) system operates in one of two modes. Oil flow
that is demanded from the attached implement
determines the mode of operation for the (LIFD)
system. The (LIFD) system is similar to the proportional
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 Group (implement) is less than the Illustration 8 g00996978
Switch (lockout control)
maximum output of the pump.
The switch is located at the right side of the seat.
In this condition, the flow demand for each implement
control valve will be met. The switch signals the ECM that the operator wants to
disable the following functions:
Condition Two • Fork control
The flow that is demanded by the Main Control • Boom raise/lower
Valve Group (implement) is more than the
maximum output of the pump. • Boom extend/retract
In this condition, the pressure compensator in each • Quick coupler pins
individual valve will restrict the flow proportionally to the • Auxiliary actuators
flow that is commanded by each valve. This will bring
the flow demand in line with the pump output.
Joystick Control
Location of Electrical Components
The electronic system for the hydraulics consists of
the following components:
• Switch (Lockout Control)
• Joystick Control
• Switch (Continuous Auxiliary Flow)
• Switch (Quick Coupler)
• Switch (Fully Lowered Boom)
• Switch (Frame Level)
• Switch (Critical Angle)
• Switch (Fully Retracted Boom) Joystick control
• Switch (Reversing Fan (If Equipped)) The joystick is located at the right side of the seat. The
joystick controls the following operations:
• Machine ECM
• Boom raise/lower
• Main Control Valve (Implement)
• Boom extend/retract
• Solenoid (Frame Level)
• Tilt forward and rackback
• Solenoid (Diverter Valve)
• Auxiliary actuator + and - directions
• Relays (Frame Level)
• Auxiliary services 1 and 2
• Relays (Diverter Valve)
• Relays (Quick Coupler)
12 31200272
Sensor For Boom Extend And Boom

Retract Or Boom Tilt Forward And
Rackback
Sensor (2) is located in the base of the joystick control.
The sensor signals the ECM to operate the function for
the boom extend/retract or the sensor signals the ECM
to operate the function for tilt forward and for the tilt
rackback.
Switch (Continuous Auxiliary Flow)

Illustration 10 g00942111 Reference: See Systems Operation/Testing and
(1) Sensors for boom raise/lower Adjusting, "General Information" for more information.
(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
Switch For Boom Extend and Boom
(5) Switch for auxiliary actuator - direction Retract Or Boom Tilt Forward And
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 tilt forward and for the tilt
rackback.
information.
Switch (Auxiliary Actuator in the +

Direction)
Switch (4) is located on the top of the joystick control.
(6) Toggle switch for auxiliary services 1 or 2
The joystick control can be configured for the following The switch signals the ECM to operate the function for
two different operating arrangements. the auxiliary actuator in the + direction.
First Arrangement - Sensor (2) controls the function Reference: See Systems Operation/Testing and
for the coupler tilt. Switch (3) controls the function for Adjusting, "Electrical Input Components" for more
the boom extend/retract. information.
Second Arrangement - Sensor (2) controls the

function for the boom extend/retract. Switch (3)
Switch (Auxiliary Actuator in the -
controls the function for the coupler tilt. Direction)
Both Arrangements - Sensor (1) controls the Switch (5) is located on the top of the joystick control.
function for the boom raise/lower. Switch (4) controls
The switch signals the ECM to operate the function for
the auxiliary actuator in the + direction. Switch (5)
the auxiliary actuator in the - direction.
controls the auxiliary actuator in the - direction. Switch
(6) selects either the auxiliary services 1 or 2 function. Reference: See Systems Operation/Testing and
Sensor (Boom Raise/Lower) information.
Sensor (1) is located in the base of the joystick control. Switch (Auxiliary Services 1 or 2)
The sensor signals the ECM to operate the function for
Switch (6) is located on the front of the joystick control.
the boom raise or the boom lower.
The switch allows the operator to toggle between
auxiliary services 1 and 2.
Adjusting, "General Information" for more information.
information.
31200272 13
Switch (Frame Level)
Switch (continuous auxiliary flow)
The switch is located on the right side of the Illustration 14 g00902794

instrument cluster. Switch (Frame level)
The switch signals the ECM that a continuous flow of The switch is located on the right side of the
hydraulic oil is required for the auxiliary services. The instrument cluster.
continuous flow switch will allow a maximum of 60 L/ The switch controls the solenoids in the frame leveling
min (16 US gpm). 90 L/min (24 US gpm) is possible by valve.
pressing the switch for four or five seconds.
Reference: See Systems Operation/Testing and Switch (Fully Lowered Boom)
Adjusting, "Electronic Input Components" for more
information.
Switch (Quick Coupler)
Switch (fully lowered boom)
The switch is located inside the main frame at the rear
of the boom on the right side.
Illustration 13 g00997104 The switch signals the machine ECM that the boom is in
Switch (quick coupler) the stored position or the position for travelling the
The switch is located on the left side of the instrument machine.
cluster.
The switch signals the ECM that the operator wants to
actuate the locking pins for the quick coupler.
information.
14 31200272
Switch (Critical Angle) Reference: See Systems Operation/Testing and

information.
Switch (Reversing Fan (If

Equipped))
Switch (Critical angle)
The switch that detects the critical angle is located
inside the main frame at the rear of the boom.
The switch signals the ECM when the angle of the
boom is above 40 degrees. The ECM then sends a Illustration 18 g01171612
signal in order to activate the following: Switch (Reversing Fan)
• Rear axle lock (if equipped) The switch controls the fan in the reverse motion.
• Disable the frame leveling Note: Refer to the appropriate Operation & Safety
manual for the proper operation of the switch.
• The transmission is neutralized.
•Reference: See Systems Operation/Testing and Machine (ECM)
Adjusting, "Rear Axle Lock" for further information.
Switch (Fully Retracted Boom)
Location of Machine ECM
The machine ECM is located on the inside of the

engine enclosure.
The machine ECM receives information from
Switch (fully retracted boom) switches, sensors and other electronic controls on the
The switch is located on the front left side of the fixed machine via the following electronic links.
boom section. • CAT data link
The switch signals the ECM to lock out the following • CAN PHS data link
functions when the boom is extended:
• CAN data link (Machine)
• Frame leveling
The ECM then processes all of the information in order
• Rear axle lock after 40 degrees to activate the various outputs.
31200272 15
Main Control Valve (Implement) Solenoids (Frame Level)

(7) Electronic Pilot Valve (Implement) Solenoids (frame level)
(8) Valve ECM (Implement) The solenoids are located on the lock valve for the
Electronic Pilot Valve (Implement) frame leveling cylinder. The lock valve is attached to the
frame leveling cylinder.
Electronic pilot valve (implement) (7) is attached to the
The machine ECM controls the state of the relays for
bank valve 4 (implement). The main control valve is
the frame leveling valve. The solenoids are then
located inside the main frame at the rear of the
energized or de-energized by the relays. The solenoids
machine.
shift the spool in the control valve which sends pump oil
Pilot valve (7) includes four pairs of pilot solenoids. to the frame leveling cylinder.
Each pair of solenoids control one of the spools in the
bank valve 4 (implement) that control the machine Solenoid (Diverter Valve)
functions. The solenoids control the spools in the bank
valve 4 (implement) in response to electronic signals Solenoid (Diverter Valve for Auxiliary
from the pilot valve ECM's (8).
Services 1)
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
ECM.
Reference: See Systems Operation/Testing and Illustration 22 g00941838
Adjusting, "General Information" for more information. Solenoid (diverter valve for auxiliary services 1)
The solenoid is located in the diverter valve. The
diverter valve is installed on the left side of the boom
head. On standard machines, a single diverter valve is
installed.
The machine ECM energizes the relays for the
solenoid on the diverter valve. The relays then
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
services 1, or to the hydraulic actuator for the quick
coupler pins.
16 31200272
Solenoid (Diverter Valve for Auxiliary Relays (Diverter Valve)

Services 2)
Illustration 23 g00902806 Relay (diverter valve)
Solenoid (auxiliary diverter valve for auxiliary services 2) The relays are located in the fuse panel. The fuse panel
A second diverter valve is installed as an option to is located behind an access cover in the left side of the
direct oil to a second auxiliary service. cab arrangement.
The machine ECM energizes the relay for the The machine ECM energizes the relays for the
solenoid on the diverter valve. The relay then solenoid on the diverter valve. The relay then
energizes the solenoid on the diverter valve. The energizes the solenoid on the diverter valve.
solenoid moves the spool in the diverter valve. The The relay on the left is for the ground function. The relay
spool controls the flow of oil to an actuator for the on the right is for the power function.
auxiliary services 2.
Relays (Quick Coupler)
Relay (Frame Level)
Illustration 24 g00941811 Relay (quick coupler)
Relay (frame level)
The relays are located in the fuse panel. The fuse panel
The relay is located in the fuse panel. The fuse panel is is located behind an access cover in the left side of the
located behind an access cover in the left side of the cab arrangement.
cab arrangement.
The machine ECM energizes the relays for the
The machine ECM energizes the relay for the solenoid solenoid on the quick coupler valve. The relay then
in the frame leveling valve. The relay then energizes energizes the solenoid on the quick coupler valve.
the solenoid on the lock valve for the frame leveling
The relay on the left is for the ground function. The
valve when the switch for the frame level on the
relay on the right is for the power function.
instrument cluster is operated.
31200272 17
Location of Hydraulic The tank supplies oil to the following machine

systems:
Components • Steering
The system for the implement hydraulics consists of • Braking
the following components:
• Transmission
• Hydraulic Tank
• Implements (Including the Boom, Work Tools, and
• Piston Pump (Implement and Steering) Trailer and Towing Hitch Hydraulic System)
• Main Control Valve Group (Implement)
• Boom Cylinder Group
• Load Control Valve Group (Boom Cylinder Lock)
Steering)
• Telescoping Cylinder Group
• Load Control Valve Group (Telescoping Cylinder)
• Tilt Cylinder Group
• Load Control Valve Group (Tilt Cylinder Lock)
• Compensating Cylinder Group
• Load Control Valve Group (Compensating Cylinder
Lock)
• Frame Leveling Cylinder
• Load Control Valve (Frame Leveling Cylinder)
(Lock)
• Diverter Valve Group Illustration 28 g00902945
Piston pump (implement and steering)
• Coupler Cylinder Group (If equipped) The pump is mounted on the transmission case.
• Combination Valve Group (If equipped) The pump has permanent drive. Pump output is
• Hitch Cylinder Group (If equipped) controlled by steering pressure or implement pressure
and flow.
Hydraulic Tank The pump delivers oil to the following systems:
• Steering
• Braking
• Implements (Including the Boom, Work Tools, and
Trailer and Towing Hitch Hydraulic System)
Adjusting, "Piston Pump (Implement and Steering)" for
more information.
Hydraulic tank
The hydraulic tank is located at the rear of the operator
compartment.
18 31200272
Compensator Valve Reference: See Systems Operation/Testing and

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
Illustration 29 g00902949 • Outlet Manifold
Compensator Valve (piston pump)
The compensator valve is bolted to the piston pump. Inlet Manifold
The compensator regulates the pump output flow in
response to the following oil pressures:
• Load sensing oil pressure
• Supply oil pressure from the pump outlet
Note: Load sensing oil pressure is sometimes referred
to as signal oil. The two terms have the same meaning
throughout this story.
The compensator valve also serves as a backup for
limiting the maximum system pressure.
Main Control Valve Group

(Implement)
Valve Assembly (Steering priority)
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.
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.
31200272 19
Relief Valve (Load Sensing Oil) Note: Load sensing oil pressure is sometimes referred
Outlet Manifold
Relief Valve (Pressure Reducing Valve)
Relief Valve (Load sensing oil)
The load sensing relief valve is located in the inlet

section for the control valve.
The Relief Valve (load sensing oil) is used to limit the
maximum system pressure. The relief valve is Illustration 34 g00902954
adjustable. Relief Valve (pressure reducing valve)
Note: Relief Valve (load sensing oil) is sometimes The pressure reducing valve is located in the outlet
referred to as the signal limiter valve. The two terms manifold for the control valve.
have the same meaning throughout this story.
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, "Main Control Valve Group (Implement)" for pump supply pressure.
more information.
Flow Control Valve Group (Dump Valve Trailer and Towing Hitch Hydraulic
for Load Sensing Oil) System (Option)
Combination Valve Group (Trailer and
Towing Hitch Hydraulic System)
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 Illustration 35 g00998874
control valve. (1) Combination Valve Group
The flow control valve provides a drain back to the (2) Towing Hitch Group
(3) Cable Group
hydraulic tank for the load sensing oil after the load has
(4) Trailer Socket
gone.
Adjusting, "Main Control Valve Group (Implement)" for
more information.
20 31200272
The hydraulic system for the trailer and the towing hitch The brake oil for the trailer is supplied by an oil line that
contains the following items: electrically controlled is connected to the front axle brake.
Combination Valve Group (1), Towing Hitch Group (2),
hitch control Cable Group (3), trailer socket (4),
additional oil lines, and control switch that is mounted in
the cab.
Towing Hitch Group
The Towing Hitch Group is mounted to the rear frame.
Hitch control Cable Group (3) moves the hooks that
Illustration 36 g00998873 release the hitch. A cylinder, that is located inside the
Location of the Combination Valve Group Towing Hitch Group, lowers the hitch when the operator
activates the control switch that is located inside the
cab. The cylinder also raises the hitch when the
operator activates the control switch in the opposite
direction.
Boom Cylinder
(1) Combination Valve Group
(3) Hitch Control Cable Group
Boom Cylinder
The cylinder is located under the boom. The cylinder

head end is attached to the machine frame and the
cylinder rod end is attached to the boom.
The cylinder is a double acting cylinder. The cylinder is
used to raise the boom. The cylinder is also used to
lower the boom.
Combination Valve Group (1) is mounted to the rear of
the frame. The oil lines attach to the outlet manifold of the
main control valve. The oil lines route pressure oil, load
sensing oil, and return oil to the combination valve.
31200272 21
Load Control Valve (Boom Cylinder Load Control Valve (Telescoping

Lock) Cylinder Lock)

Load Control valve (boom cylinder lock) Load control valve (telescoping cylinder lock)
The load control valve is attached to the lower end of The load control valve is attached to the rear of the
the boom cylinder. telescoping cylinder.
The load control valve locks oil into the head end of the The load control valve locks oil into the head end of the
cylinder in order to hold the cylinder in position when cylinder in order to hold the cylinder in position when
the cylinder is stationary. the cylinder is stationary.
The load control valve prevents the boom cylinder The load control valve prevents the telescoping
from lowering in the event of a loss of hydraulic power. cylinder from retracting in the event of a loss of
The load control valve also prevents the boom cylinder hydraulic power. The load control valve also prevents
from collapsing if a hydraulic hose bursts. the telescoping cylinder from collapsing if a hydraulic
hose bursts.
Adjusting, "Load Control Valves (Lock Valves)" for more Reference: See Systems Operation/Testing and
information. Adjusting, "Load Control Valves (Lock Valves)" for more
information.
Telescoping Cylinder
Tilt Cylinder
Telescoping cylinder Illustration 44 g00902960
Tilt cylinder
The cylinder is located inside the boom. The cylinder
assembly is attached to the rear of the outer section of The tilt cylinder is mounted inside the boom head. The
the boom by a trunnion. The rod end is attached to the cylinder head end is attached to the boom head and the
inner boom section. The cylinder is supported by a pad rod end is attached to the linkage for the quick coupler.
and slides inside the boom. The cylinder is a double acting cylinder that is used to
The cylinder is a double acting cylinder. The cylinder is tilt the carriage forward and backward.
used to extend the boom. The cylinder is also used to
retract the boom.
22 31200272
Reference: See Systems Operation/Testing and when the boom is raised and lowered. The
Adjusting, "Main Hydraulic System" for more compensating cylinder and the tilt cylinder utilize the
information. same oil lines and the same control valve.
Lock for Load Control Valve (Tilt Adjusting, "Main Hydraulic System" for more
Cylinder) information.
Load Control Valve (Compensating

Cylinder Lock)
Load control valve (tilt cylinder) (lock)
The load control valve is installed into the head end of

the tilt cylinder. Illustration 47 g00999113
The load control valve locks oil into the head end of the Load control valve (compensating cylinder lock)
cylinder in order to hold the cylinder in position when The load control valve is installed onto the bottom of the
the cylinder is stationary. outer section of the boom.
The load control valve also prevents the tilt cylinder The load control valve prevents high pressure in the
from collapsing if a hydraulic hose bursts. head end of the tilt cylinder from entering into the head
Reference: See Systems Operation/Testing and end of the compensating cylinder.
Adjusting, "Load Control Valves (Lock Valves)" for more
information. Frame Leveling Cylinder
Compensating Cylinder
Frame leveling cylinder
The frame leveling cylinder is located at the front of the
Compensating cylinder machine on the right side. The head end of the cylinder
The cylinder is located at the bottom of the boom at the is attached to the machine frame, and the rod end is
rear of the machine. The head end of the cylinder is attached to the front axle.
attached to the outer section of the boom and the rod The frame leveling cylinder allows the machine frame to
end is attached to the machine frame. be levelled in order to improve the stability of the
The cylinder is a double acting cylinder. The machine during operation.
compensating cylinder works with the tilt cylinder in
order to maintain the selected angle of the carriage
31200272 23

Adjusting, "Frame Leveling System" for more
information.
Lock Valve (Frame Leveling

Cylinder)
Control valve (dual auxiliary)
The diverter valve is installed on the left side of the
boom head.
On TH220B standard machines, a single Diverter
Valve (auxiliary single) is installed. A dual Control Valve
(dual auxiliary) is installed as an option on the TH220B
machines. The single Diverter Valve (auxiliary single)
and the dual Control Valve (dual auxiliary) are available
Lock valve (frame leveling cylinder)
options on the TH330B machines.
The lock valve is attached to the casing of the frame
leveling cylinder. The single valve diverts the oil flow from the auxiliary
circuit section of the implement main control valve to
The valve controls the flow of oil into the cylinder and either the quick coupler cylinder or through Fitting
out of the cylinder. The valve also locks oil into both Assembly (quick disconnect) to a work tool cylinder.
sides of the cylinder in order to hold the cylinder in The dual diverter valve provides an oil flow to an
position when the frame leveling system is in HOLD. additional auxiliary service.
Diverter Valve Adjusting, "Auxiliary Control (Combined Circuit)" for
more information.
Quick Coupler Cylinder
Diverter Valve (auxiliary single)
Quick Coupler cylinder
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
24 31200272
the work tool that is attached to the quick coupler and

the rods retract into the cylinder in order to disengage
the work tool that is attached to the quick coupler.
Adjusting, "Auxiliary Control (Combined Circuit)" for
more information.
31200272 25
Switches Thumb Slider

Switches provide information to the ECM (15). The thumb slider (6) can be configured in one of two
Switches are two state devices. The switches are modes.
either open or the switches are closed. This is true for The thumb slider sensor is configured in the North
each of the terminals on the switch. The terminals are American Construction configuration. Then, the thumb
inverse of each other when a switch has two terminals slider sensor is configured for the coupler tilt. The
that are connected. The implement disable switch is an telescope in and the telescope out is configured for the
example of this type of switch. side-to-side movement of the joystick.
Closed - The switch closes the circuit to ground or the The thumb slider sensor is configured in the Bucket
switch closes the circuit to the battery. mode configuration. The thumb slider sensor is
Open - The switch opens a circuit to the ECM input. configured for the telescope in and the telescope out.
Then, the side to side motion of the joystick is for the
Joystick Control coupler tilt.

If equipped, the boom critical angle switch (3) will signal
the ECM when the angle of the boom is above the
critical angle of 40 degrees. The signal from the boom
critical angle switch is required in order to actuate the
rear axle lock.
Note: If the critical angle switch fails, a diagnostic
code will be generated and the rear axle will be locked.
When this situation occurs, the function for the boom
raise is still operational provided that the parking brake
is applied. The transmission will also be in the disabled
mode.
Frame Leveling Switch
The three auxiliary switches and the thumb slider are
located in the joystick control.
Auxiliary Switches Illustration 55 g00939831
The auxiliary select switch (7) allows the operator to The frame leveling switch (12) sends a signal to the
choose the auxiliary one circuit or the auxiliary two machine ECM. There are two solenoids for the frame
circuit. The auxiliary plus switch (2) controls the circuit leveling cylinder. One solenoid pushes the valve spool
in a positive direction and uses port A flow. The and one solenoid pulls the valve spool. The machine
auxiliary negative switch (4) controls the circuit in a ECM energizes the solenoid. This is dependent on the
negative direction and port B for flow. position of the frame leveling switch.
Boom Retracted Switch

The switch (5) signals the machine ECM when the
boom is retracted. In order for the machine to be
roaded, the boom must be retracted.
26 31200272
Quick Coupler Switch Implement Lockout Switch

The quick coupler switch (13) allows the operator to The implement lockout switch (16) 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.
Continuous Flow Switch
Boom Lowered Switch
Table 2
Boom Lowered Switch

Pin Description
1 Power
2 Normally Open
3 Normally Closed
4 Ground
The boom lowered switch (10) signals the machine

ECM that the boom is in the store or the travel
Illustration 57 g00903130 position.
The continuous flow switch (13) signals the ECM that a
continuous flow of hydraulic oil is required for the
actuators of the work tools. This is done on the auxiliary
circuit only.
31200272 27
Electronic Control Module 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 3 and table 4.
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 3 and table 4.
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
Illustration 59 g00785019 communications between the machine ECM and any
other ECM on the machine.
Input/Output
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.
The electronic control module is located on the inside of
the engine enclosure.
connectors (J1 and J2). The ECM sends the
information to the Caterpillar Electronic Technician on
the CAT data link.
failure of the ECM is diagnosed.
Inputs
28 31200272
Table 3 Table 4
Contact Description J1(1) Contact Description J2(1)

No.(2) Function Type No.(2) Function Type
10 Cat Data Link + CDL + 3 Quick Coupler Relay 2A On/Off Std -2
13 Machine Ground Battery - 9 Continuous Flow LED 300mA Sink 1
20 Cat Data Link - CDL - 10 Frame Level Interlock Relay 300mA Sink 2
Boom Retracted Switch Rear Axle Lock Return Side
34 Switch To Ground 11 300mA Sink 3
Parity Relay
40 Left Stabilizer Raise Switch To Ground 12 Engine Run Relay 300mA Sink 4
41 Left Stabilizer Hold Switch To Ground 13 PHS Address Out 300mA Sink 5
42 Left Stabilizer Lower Switch To Ground 15 Continuous Flow Switch Switch To Ground
43 Boom Retracted Switch Switch To Ground 23 Auxillary 2 Select Switch Switch To Ground
45 Switch To Ground Return 8V Sensor Return 29 Right Stabilizer Raise Switch To Ground
Rear Axle Lock & Auxiliary Pulse Width 30 Right Stabilizer Hold Switch To Ground
55
Diverter Valve Return Modulation
31 Right Stabilizer Lower Switch To Ground
57 Machine Ground - Battery -
Joystick Longitudinal Pulse Width
32
Implement Disable Switch - Command Modulation
63 Switch To Ground
Enable
Joystick Thumb Slider Pulse Width
33
Implement Disable Switch - Command Modulation
64 Switch To Ground
Disable
Pulse Width 36 Switch To Ground
65 Rear Axle Lock Solenoid Engage
Modulation
Pulse Width 37 Switch To Ground
66 Auxiliary Diverter Valve Disengage
Modulation
10 Volt Power 38 Quick Coupler Switch -Parity Switch To Ground
69 10 Volt PHS Valve Power
Supply
Pulse Width
40 Joystick Lateral Command
70 Machine Ground (-) Battery - Modulation
(1) The ECM responds to an active input only when all the necessary 41 Auxillary (+) Switch To Ground
conditions are satisfied.
Right Stabilizer Pressure
(2) The connector contacts that are not listed are not used. 44 Switch To Ground
Switch
Left Stabilizer Pressure
45 Switch To Ground
Switch
47 Boom Critical Angle Switch Switch To Ground
55 PHS Address (IN) Switch To Ground
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.
31200272 29
30 31200272
Relays
There are five relays in the valve system.
• The interlock relay (2) for the frame level.
• One relay for the quick coupler (8) is for the power
Implement control valve
and the other relay is for the ground.
• One relay for the auxiliary diverter valve (11) is for
the power and the other relay is for the ground.
The relays are activated directly by the machine ECM
(9).
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 Illustration 64 g00913862

ECM 1 (23) controls the solenoids for the following
The diverter valve solenoid (12) operates the diverter
implements:
valve. The diverter valve diverts the oil flow from the
auxiliary section of the implement control valve to either • Boom lower and boom raise
the quick coupler cylinder or through push on couplers • Coupler tilt forward and coupler tilt backward
to a work tool cylinder. An optional dual diverter valve
provides an oil flow to an additional auxiliary service. ECM 2
ECM 1 ECM 2 (24) controls the solenoids for the following
implements:
• Auxiliary port (21) and auxiliary port (22).
• Boom retract and boom extend
Other Outputs
The machine ECM (9) also sends information to the
dash panel cluster (16) and the service connector (17)
via the CAT data link (14).
31200272 31
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 Machine Security System
interlock. See the appropriate service manual for
information concerning the machine configuration. • An incorrect key is being used.
Transmission Neutralizer Parking Brake

The following subject titles will cause the transmission to If the parking brake is on or if there is a failure the
be neutralized. transmission is neutralized. If a failure is noticed on the
inputs for the parking brake, the ECM will use the last
Solenoid Outputs valid communications for 2.5 seconds as the signal is
returning to an initial state. Once the time has elapsed
Directional Solenoid and Modulation Valve for the the system will default. The parking brake will be
Synchronizer enabled electrically and the transmission will be
• Any active short to ground or open circuit fault neutralized. Once the parking brake failure is resolved
the technician needs to cycle the parking brake from the
• The command to the solenoid is off and there is a applied position to the released position in order to
fault for a short to the battery. return the machine to normal operation. The shift lever
Solenoids for the Synchronizers for the needs to be moved from neutral to a valid direction in
Powersynchro Transmission order to engage the transmission.
• The command to the solenoid is off. There is a
fault for a short to the ground or there is a fault for Service Brake Pressure Switch for the
a open circuit. Transmission Neutralizer
• Any active short to the battery fault The transmission neutralizer pressure switch is used to
neutralize the transmission when the service brakes
System Voltage are applied. This feature will help reduce the wear of the
service brakes.
Overvoltage Condition
The transmission is neutralized when any of the
The control shuts off all the solenoids when the voltage following conditions are true for the brake.
in the system is 16 DCV. The transmission will be
placed into neutral. Normal operation can take place • If you release the service brake within three
after the voltage drops below 15.5 DCV and the shift minutes the machine will go into gear. If you
lever is placed in neutral. depress the brake longer than three minutes in
order to move in gear the shuttle lever is placed
Undervoltage Condition
into neutral and then back into gear.
The control will maintain any solenoid which is
• The neutralizer switch for the brake has been
currently on when the voltage is below 10 DCV for
grounded and the service brake pedal is
more than 30 seconds. All the solenoids will be turned
depressed.
off if a new solenoid is engaged. The loss of the
solenoids will cause the transmission to be placed in
neutral. More Electrical Function
Requirements
Shuttle Shift for the Power Shuttle
Additional electrical function requirements are included
Transmission in the following topics.
• Any active faults
32 31200272
Steering than one minute from the switch to the battery is a short
to ground. When a failure exists for the key start switch
The machine will default to two-wheel steer mode the system will be unable to start.
under the following conditions.
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
link. If any of the outputs from the shuttles provide a
• The machine is in two-wheel steer mode and there
switch to battery signal or if any of the switch to ground
is a diagnostic code for a short to ground or a open
signal to the ECM, the ECM will prevent the start relay
circuit on the relay for either the circle steer or crab
coil from being energized.
steer.
The following conditions will allow the neutral start to
• The last valid steering mode is not known.
become disabled:
• There is a diagnostic code for both relays for the • A start relay has a failure.
steering for a short to the battery.
• The transmission is NOT in the neutral position.
• The feature for the auto alignment is installed. the
machine is in the two-wheel steering mode, and • The engine speed is NOT zero rpm.
both sensors for the alignment are not detecting • An invalid key was entered for the machine security
the centered position. system (MSS).
The machine will default to circle steer mode under the
following conditions. Stabilizer Raise/Lower (if equipped) is
• The machine is in circle steer mode and there is a Disabled
diagnostic code for a short to ground or an open
circuit on the relay for the crab steer. The stabilizer raise or stabilizer lower will be disabled
when any of the following conditions are true.
• Circle steer is the last valid steering mode and
there is an active diagnostic on the selector switch • The status for the initialization screen for the
for the steering mode. Programmable Hydraulic System (PHS) is not
equal to "Complete".
• The relay for the circle steer mode has a diagnostic
code for a short to the battery. • The implement lockout switch is enabled or an
active failure exists for the switch.
• The auto sensors for the alignment do not detect
the centered position. • The machine is not placed into the neutral position
during the system powerup or after the system
The machine will default to crab steer mode under the powerup.
following conditions.
• An active diagnostic code exists for the inputs on
• The machine is in crab steer mode and there is a
the stabilizer control.
diagnostic for an active short to ground or an open
circuit on the relay for the circle steer. • An active diagnostic code exists for the solenoid
that raises the stabilizer.
• Crab steer is the last valid steering mode and there
is an active diagnostic on the selector switch for • An active diagnostic code exists for the solenoid
the steering mode. on the stabilizer lower.
• The relay for the crab steer has a diagnostic code • The feature for locking the rear axle is in the
for a short to the battery. "Locked Axle Mode".
• The feature for the auto alignment is installed and • An invalid key was entered for the machine security
the machine is in the crab steer mode. Neither of system (MSS).
the two sensors for alignment are detecting the • The "Lateral Stability Adjustment Inhibit" feature
centered position. is installed and the boom is not retracted. The
"Lateral Stability Adjustment Inhibit" feature is for
The Neutral Start Is Disabled the "French" market.
The ECM monitors the system for shorts to the battery

for the key start switch. There is a limitation to the length
of time for cranking the starter. Input that lasts longer
31200272 33
Boom Raise/Lower Is Disabled • The machine is not placed into the neutral position
during the system powerup after system powerup.
The boom raise or the boom lower will be disabled
• An active diagnostic code exists for the control.
• An active diagnostic code exists for the rack
• The status for the initialization screen for the PHS
actuator solenoid.
is not equal to "Complete".
• 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 The Frame Level (if equipped) is
during powerup or after powerup.
Disabled
• A failure exists for the inputs to the control for the
boom raise or the boom lower. The feature for the frame level will be disabled when
• An active diagnostic code exists for the solenoid any of the following conditions are true.
that is used for lowering the boom. • The feature for the rear axle lock is in the "Locked
• An active diagnostic code exists for the solenoid Axle Mode".
for the boom raise. • The "Lateral Stability Adjustment Inhibit" feature
is installed and the boom is not retracted. The
• The boom exceeds the critical angle.
• The machine is in the Free Axle Mode or the the "French" market.
machine is in the Limited Free Axle Mode.
• An invalid entry is made into the machine security
system.
The Boom Extend/Retract Is

Disabled
The boom extend or the boom retract will be disabled
• Both the stabilizers are not extended.
• The limit for the extension of the boom is active.
• The implement lockout switch is enabled or an
• The machine is not placed into the neutral position
powerup.
• An active diagnostic code exists for the boom
extend solenoid.
retract solenoid.
system.
Disable The Rackback And Dump

The rack or the dump will be disabled when any of the
conditions are true.
34 31200272
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.
31200272 35
The electrical system for the trailer and the hitch is available for the TH220B and TH330B series machines
36 31200272
Note: The trailer or the hitch switch is one switch. The

switch works with either the trailer or the hitch. When
the hydraulic hoses from the hitch are connected to the
Combination Valve Group (Trailer and Towing Hitch
Hydraulic System), the switch operates the hitch. If the
hoses from the trailer are connected to the quick
disconnects of the Combination Valve Group (Trailer
and Towing Hitch Hydraulic System), the switch
operates the trailer up and down.
Programmable Hydraulic System

(PHS)
These schematics are simplified schematics of the
Programmable Hydraulic System (PHS) that is
electrically correct. These schematics do 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.
31200272 37

Steering)
Piston Pump
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
rotates whenever the engine is running. The pistons

Piston pump (1) has the following characteristics: move oil into the barrel and out of the barrel.
• variable displacement Shaft (4) - The rotation of the pump is
• load sensing counterclockwise when the pump is viewed from the
drive end. The piston and barrel assembly is splined to
• compensation for pressure
the drive shaft.
• compensation for flow
Bias spring (5) - If there is no pressure on the right
This piston type pump has variable flow and pressure. side of the actuator piston, the bias spring will hold the
The flow and pressure are dependent on the system swashplate at the maximum angle.
demands that are sensed by pressure and flow Swashplate (6) - The displacement of the pump is
compensator valve (2). controlled by the angle of the swashplate. The angle of
Note: Load sensing oil pressure is sometimes referred the swashplate causes the pistons to move in and out of
to as signal oil. The two terms have the same meaning the rotating barrel.
throughout this story. Actuator piston (7) - When oil pressure increases
The piston pump has the following components: behind the actuator piston, the piston will overcome the
Piston and barrel assembly (3) - The cylinder barrel force of the bias spring. This causes the angle of the
contains nine pistons. The cylinder barrel assembly swashplate to be reduced.
38 31200272
Pressure and flow compensator valve (2) - The Pressure compensator spool (14) is used as a backup
pressure and flow compensator valve controls the to limit the maximum system pressure to
delivery of oil and the return of oil to the actuator 27500 ± 500 kPa (3988 ± 73 psi) if the load sensing oil
piston. relief valve fails.
When the engine is OFF, pressure and flow Pressure and flow compensator valve (2) has orifice
compensator valve (2) does not receive load sensing oil (15) in the load sensing oil passage to actuator piston
pressure (8) or supply pressure from pump outlet (9). (16). Orifice (15) is used in order to regulate the
Margin spring (10) pushes flow compensator spool response rate of the actuator piston by creating a
(11) completely downward. Any pressure that is on the consistent leak path.
right side of actuator piston (7) is vented to the case The load sensing oil relief valve in the TH330B is set at
drain across flow compensator spool (11). 22800 kPa (3300 psi) and the margin pressure is set at
When there is no pressure behind actuator piston (7), 2200 kPa (320 psi). The maximum system pressure is
bias spring (5) is able to hold swashplate (6) at the 25000 ± 500 kPa (3625 ± 75 psi).
maximum angle. Pressure compensator spool (14) is used as a backup
When the engine is started, shaft (4) starts to rotate. Oil to limit the maximum system pressure to
flows into the piston bore from pump inlet (12). Oil is 27500 ± 500 kPa (3988 ± 73 psi) on the TH220B and
forced out of pump outlet (9) and into the system as the 26000 ± 500 kPa (3770 ± 73 psi) on the TH330B if the
piston and barrel assembly (3) rotates. load sensing oil relief valve fails.
Note: If the load sensing oil relief valve is operating
Compensator Valve correctly the load sensing oil relief valve controls the
maximum system pressure. Maximum system
Pressure and flow compensator valve (2) is bolted to pressure should be the pressure of the load sensing oil
the top of the piston pump. Pressure and flow relief valve plus the margin pressure. If the load
compensator valve (2) compensates for pressure sensing oil relief valve is not adjusted correctly the
variations and flow variations in the implement pressure compensator acts as a backup.
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).
31200272 39
Low Pressure Standby
Steering and Implement Pump (Low Pressure Standby)
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.
40 31200272
Upstroke
Steering and Implement Pump (Upstroke)
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
If another implement hydraulic circuit is activated at an
increased pump output flow is routed to the position
initial operating pressure of 6900 kPa (1000 psi), the
of a main control spool of a hydraulic control valve
maximum pressure of the load sensing oil will still be
that demands the oil.
13800 kPa (2000 psi). The supply oil pressure will
decrease momentarily.
31200272 41
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
Steering and Implement Pump (Constant Flow)
As the pump increases flow or decreases flow in order Once the pressures become equal on each end of the
to match the change in the flow requirements, the spool, flow compensator spool (11) will meter oil to
forces above the flow compensator spool and below actuator piston (7). Bias spring (5) will be compressed
the flow compensator spool will equalize. and the system will stabilize.
The following pressures will act on the top end of Swashplate (6) is held at a relative constant angle in
flow compensator spool (11): order to maintain the required flow.
• Margin spring (10)
The following pressure will act on the bottom end of
flow compensator spool (11):
• •Supply pressure from pump outlet (9)
42 31200272
Destroke
Steering and Implement Pump (Destroke)
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:
• 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)
31200272 43
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.
44 31200272
High Pressure Stall
Steering and Implement Pump (Maximum System Pressure)
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 256500 ± 500 kPa
(3843 ± 75 psi) for the TH220B and 25000 ± 500 kPa
(3625 ± 75 psi) for the TH330B.
31200272 45
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 for the load sensing signal)
(4) Control Valve (tilt) (11) Relief Valve (Pressure reducing valve) (17) Check Valve (Return oil back pressure)
(5) Control Valve (auxiliary) (12) Screw
(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 • (4) Control Valve (tilt)
rear of the machine. The main control valve is pilot
• (3) Control Valve (boom raise/lower)
operated. The Electronic Pilot Valve (implement) (1) is
directly mounted to the side of the Control Valve • (10) Manifold Valve (outlet)
(implement) (2). Pilot valve (1) consists of two Control The manifold valve (inlet) includes the following
Manifolds (Pilot ECM) (7), eight proportional solenoids components:
and eight pressure reducing valves. The machine ECM
• (14) Valve Assembly (Steering priority)
sends commands that are activated by the operator to
the correct pilot ECM (7). Pilot ECM (7) controls the • (15) Relief Valve (Load sensing signal)
proportional solenoids. The proportional solenoids
• (16) Flow Control Valve Group (Dump valve for the
control the pilot reducing valves. Pilot valve (1) contains
load sensing signal)
four pair of proportional pilot solenoid valves. Each pair
of proportional pilot solenoid valves are used to actuate • (17) Check Valve (Return oil back pressure)
an individual spool within the Control Valve (implement) • Orifice Check valve
(2). Relief Valve (pressure reducing valve) (11) supplies
pilot pressure to the ends of the spools in proportion to • Screens (75 and 100 micron)
the current that is supplied to the solenoid. Note: Relief Valve (Load sensing signal) is sometimes
Control Valve (implement) (2) includes the following referred to as the signal limiter valve. The two terms
sections: have the same meaning throughout this story.
• (9) Manifold Valve (inlet) Reference: See Systems Operation/Testing and
Adjusting, "Manifold Valve (Inlet)" for more information.
• (6) Control Valve (boom extend/retract)
• (5) Control Valve (auxiliary)
46 31200272
The valve sections for the telescoping cylinder, Note: Refer to the Operation and Maintenance Manual,
auxiliary services, coupler tilt and the boom "Boom Retracting and Boom Lowering without
cylinder include the following components: Hydraulic 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 canThe
hydraulic oil to the machine implements. manifold valve (outlet) includes the following
determine the function that has the highest demand
components:
in all of the valves. Then, the load sensing signal
pressure for the highest demand is sent to the pump.•
(8) Solenoid Valve (Shutoff for the Pilot oil)
The pump uses the load sensing signal pressure in
order to determine the amount of flow that is required.•
(11) Relief Valve (Pressure reducing valve)
Note: Load sensing signal pressure is sometimes
referred to as signal oil. The two terms have the
Adjusting, "Manifold Valve (Outlet)" for more
same meaning throughout this story.information.
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
The spools for the Control Valve are shown in the HOLD Position.
additional system. These characteristics aid smooth
(T) Passage to hydraulic tank
machine operation when more than one system is in
The control valve spools for the boom extend/retract operation.
(telescoping), coupler tilt, and boom raise/lower for the Each implement control valve section includes the
Control Valve (implement) are closed to the hydraulic following positions:
tank (T) when the joystick control is in the HOLD The positions for the boom extend/retract
position. The main spool in the section for the auxiliary (telescoping) function:
circuits is open to the hydraulic tank (T) when the
joystick control is in the HOLD position. • Extend
In the event of a loss of hydraulic power, oil locked into • Hold

the telescoping cylinder and the boom cylinder will • Retract
prevent the boom from lowering. The cylinders can not
The positions for the auxiliary circuits function:
be lowered or retracted until the lock valves on the
cylinders are overridden. The implement control valve • Open
for the telescoping cylinder and the implement control • Hold
valve for the boom cylinder are equipped with screws
for manually moving the main spools. • Close
After the lock valves on the cylinders are overridden, The positions for the tilt cylinder function:
the main spools are moved into the position that allows • Tilt forward
the blocked oil in the cylinders to return to the hydraulic
• Hold
tank. The telescoping cylinder and the boom cylinders
can then be lowered or retracted. • Tilt rearward
The positions for the boom raise/lower cylinder function:
31200272 47
• Raise
• Hold
• Lower.
Adjusting, "Compensating System" for more
information.
Manifold Valve (Inlet)
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 system (16) Flow Control Valve (Dump valve for the load sensing signal)
(6) Line to metering pump
The manifold valve (inlet) is attached to the main

control valve. The main control valve is located at the
rear of the machine.
48 31200272
The manifold valve (implement) includes the Screens

following components: The manifold valve (inlet) of the implement control valve
• (1) Check valve contains three screens (7). The screens are dedicated
to the following circuits:
• (3) Valve Assembly (Steering priority)
• The system for the pilot supply (75 micron)
• (7) Screens (75 and 100 micron)
• Load sensing signal system for the priority valve
• (12) Relief Valve (Load sensing signal)
(100 micron)
• (14) Check Valve (Return oil back pressure)
• Drain for the load sensing signal for the implement
• (16) Flow Control Valve Group (Dump valve for the system (100 micron)
load sensing signal)
Note: Relief Valve (Load sensing signal) is sometimes
Valve Assembly (Steering Priority) referred to as the signal limiter valve. The two terms
Valve Assembly (steering priority) (3) divides the flow of have the same meaning throughout this story.
oil from the hydraulic piston pump between the Relief Valve (Load sensing signal) (12) limits the load
demands from the steering system and the demands sensing signal to the pressure and flow compensator
from the implement system. valve on the piston pump. The pressure and flow
Oil from the hydraulic piston pump enters the manifold compensator valve controls the pump output pressure.
valve (inlet) and flows to the steering priority valve. The The pump output pressure is proportional to the load
oil then flows through the open spool of the steering sensing signal pressure. The relief valve has a
priority valve and flows to the metering pump through maximum pressure setting of 22800 kPa (3300 psi).
line (6). Check Valve (Return oil back pressure)
When the steering wheel is stationary, the spool in the Check Valve (Return oil back pressure) (14) is located in
steering metering unit is spring centered and the oil is the return oil circuit for the main implements. The back
blocked at the spool. The pressure then builds up in pressure valve maintains a minimum pressure in the
the line (6). The increased pressure acts upon the top return oil system. The back pressure valve has a
of the priority valve spool. The spool proportionally pressure setting of 3.5 ± .5 kPa (0.50 ± 0.1 psi).
moves down against the force of spring (4). The mid-
Flow Control Valve Group (Dump valve for the load
position of the spool allows oil flow to the steering system
sensing signal)
and to the implement control system. Further movement
of the spool in the steering priority valve closes off the Note: Load sensing signal pressure is sometimes
supply of oil to the steering system. All oil flow through referred to as signal oil. The two terms have the same
the priority valve is then supplied to the implement meaning throughout this story.
system through line (2). Flow Control Valve Group (Dump valve for the load
The steering priority valve ensures that the steering sensing signal) (16) is installed in order to provide a
system has oil flow priority. When the steering wheel is drain back to the hydraulic tank for the load sensing
turned, load sensing signal pressure is transmitted signal once the load has been reduced on the
through line (8) to a chamber at the bottom of the machine requirements. The drain valve is pressure
steering priority valve. The pressure in load sensing compensated.
signal line (8) combines with the force of spring (4) in
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.
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,
pressure from the top side of the spool is exhausted
through check valve (1) into line (6).
31200272 49
Check and Relief Valves Manifold Valve (Outlet)

Reference: See Systems Operation/Testing and The manifold valve (outlet) is attached to the main control
Adjusting, "Compensating System" for more information valve. The main control valve is located at the rear of the
about the check and relief valves. machine.
Schematic of Check and Relief Valves
(1) Relief valve
(2) Line to implement control valve
(3) Line to implement control valve
(4) Relief valve
(5) Check valve
(6) Check valve
(7) Return to tank passage
Relief Valve (Load sensing signal)

Combined relief and check valves are installed in the
implement control valves for the auxiliary circuits and the
coupler tilt. The valves serve a dual purpose. The
valves limit the maximum oil pressure in the circuit. The
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.
50 31200272
Manifold Valve (outlet)
(2) Return oil from trailer and towing hitch hydraulic system (if equipped)
(3) Load sensing signal passage
(4) Load sensing signal from trailer and towing hitch hydraulic system (if equipped)
(5) Pump supply passage
(6) Manifold valve (outlet)
(7) Pressure reducing valve
(8) Pilot oil passage
(9) Shutoff valve for the pilot oil
(10) Supply oil from the passage of the steering priority valve
(11) Supply oil to the trailer and towing hitch hydraulic system (if equipped)
(12) Return oil from Electronic Pilot Valve (implement)
(13) Return oil from brake circuit
(14) Return to tank oil line
(15) Supply oil to brake circuit
The manifold valve (outlet) includes the following pump supply oil from the hydraulic piston pump to 3450
components: ± 145 kPa (500 ± 20 psi).
• (7) Pressure reducing valve This oil is used as pilot oil for the implement system
• (9) Shutoff valve for the pilot oil and supply oil for the braking system. Part of the
reduced pressure oil flows from valve (7) through
Pressure Reducing Valve internal passages and through line (15) to the master
Pump supply oil flows through a 100 micron filter that is cylinder for the brake system. The rest of the reduced
located in the manifold valve (inlet), and through line pressure oil flows from valve (7) through internal
(5) into pressure reducing valve (7). Valve (7) reduces passages to shutoff valve (9).
Shutoff Valve for the Pilot Oil
31200272 51
Shutoff valve (9) provides a means of cutting off pilot oil

pressure to the main control valve. During normal
operation, the pilot oil flows through the shutoff valve
into passage (8). The oil then flows through passage (8)
to the electronic pilot valves.
If an actuator for an implement malfunctions, or if a
fault occurs in the electronic system for the
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
Main Control Valve Group (Implement)
(1) Inlet Manifold (5) Relief Valve (Pressure reducing valve) (9) Proportional pilot reducing valves
(2) Valve Assembly (Steering priority) (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, "Inlet Manifold" for more information.
flows to Valve Assembly (Steering priority) (2) that is
also located in the inlet manifold.
52 31200272
Part of the oil flows through the steering priority valve

and part of the oil flows through the main body of the
main control valve group. This oil flows into outlet
manifold (4). The oil then flows to Relief Valve
(Pressure reducing valve) (5) that is located in the
outlet manifold.
Adjusting, "Outlet Manifold" for more information.
The Relief Valve (Pressure reducing valve) reduces
the high pressure of the pump supply to 3450 ±150
kPa (500 ± 20 psi). The reduced pressure oil is used as
pilot oil in the implement hydraulic system and as
brake oil in the brake hydraulic system. Part of this oil
flows through an internal passage into supply oil to
brake circuit (11). The rest of the reduced pressure oil
flows through Solenoid Valve Group (Pilot oil shutoff) (6)
into pilot oil passage (8).
The excess oil from pump supply (7) flows out of
Relief Valve (Pressure reducing valve) (5) and into
return oil line (10).
The main control valve is pilot operated. The
Electronic Pilot Valve Group (implement) is directly
mounted to the side of the Main Control Valve Group
(implement). The pilot valve consists of two Control
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.
Adjusting, "Operation of the Implement Control Valve"
for more information.
31200272 53
Telescoping System
Valve for the Telescoping Cylinder in
the HOLD Position
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.
54 31200272
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
no oil pressure against the pressure compensating
valve the valve remains in the down position.
Illustration 88 g01009187 Each implement section contains pressure
(1) Pilot oil passage compensating valve (19). All pressure compensating
(2) Passage to cylinder head end valves are interconnected. The pressure
(3) Passage to cylinder rod end compensating valves allow the oil flow to be
(4) Electronic Pilot Valve (implement)
proportionally divided between each of the operating
(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
(8) Chamber
hydraulic actuators will continue to function. However,
(9) Tank return passage the actuators will operate at a reduced speed.
(10) Load sensing signal passage Also, the pressure compensating valves can
(11) Spring determine the function that has the highest demand in
(12) Passage
all of the valve sections. Load sensing signal pressure
(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
(16) Oil passage
pump controller adjusts the pump output in order to
(17) Spring maintain the required demand. Load sensing passage
(18) Chamber (10) is a common passage through all the sections of
(19) Pressure compensator the Control Valve (implement). The pump uses the load
(20) Pump supply passage sensing signal in order to determine the amount of flow
(21) Proportional pilot reducing valve that is required.
(22) Chamber
(23) Solenoid
(24) Screen
referred to as signal oil. The two terms have the same
(25) Pilot oil passage meaning throughout this story.
The pressure compensating valves maintain cylinder
speeds which are proportional to the position of the
Solenoids (6) or (23) and proportional pilot reducing
joystick control. The cylinder speed will not increase if
valves (7) or (21) are part of Electronic Pilot Valve
the engine speed is increased in order to engage an
(implement) (4). When the joystick control is in the
additional system. These characteristics aid smooth
31200272 55
machine operation when more than one system is in Valve for the Telescoping Cylinder in
operation.
the EXTEND Position
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).
(2) Passage to cylinder head end
(3) Passage to cylinder rod end
(6) Solenoid
(8) Chamber
(10) Load sensing signal passage
(11) Spring
(12) Passage
(15) Passage
(16) Oil passage
(17) Spring
(18) Chamber
(19) Pressure compensator
(22) Chamber
(23) Solenoid
(24) Screen
56 31200272
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.
meaning throughout this story.
31200272 57
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 90 g01009220 tank passage (5). The return to tank passage (5) is a
(1) Pilot oil passage common passage through the Electronic Pilot Valve.
(2) Passage to cylinder head end Supply oil from the hydraulic pump flows through pump
(3) Passage to cylinder rod end supply passage (20) and into the valve section for the
telescoping cylinder. Supply passage (20) is a common
passage through the Control Valve (implement).
(6) Solenoid
(7) Proportional pilot reducing valve The force of the pilot oil in chamber (22) overcomes the
(8) Chamber tension of spring (11). This action causes control valve
(9) Return to tank passage spool (13) to move upward. This allows supply oil from
(10) Load sensing signal passage the hydraulic pump to flow past control valve spool
(11) Spring (13) into chamber (18). The pressure in chamber (18)
(12) Passage
causes the spool in pressure compensator (19) to
move up.
(15) Passage A portion of the pump supply oil flows through
(16) Oil passage pressure compensator (19) into oil passage (16). The
(17) Spring oil flows through passage (16) into load sensing oil
(18) Chamber passage (10). Load sensing signal passage (10) is a
(19) Pressure compensator
common passage through the Control Valve
(implement). The load sensing oil is routed to the
compensator valve that is mounted on the hydraulic
(22) Chamber
(23) Solenoid
pump. This causes the pump to upstroke.
(24) Screen
58 31200272
Note: Load sensing signal pressure is sometimes Hydraulic Fan System

meaning throughout this story.
Reversing Fan (If Equipped)
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.
(1) Hydraulic fan motor
(2) Switch (fan reversing)
(3) Solenoid valve
(4) Hydraulic fan group
(5) Check valve
(6) Relief valve
(7) Hydraulic pump
(8) Pump supply oil
(9) Return to tank
(10) Hydraulic tank
Hydraulic pump (7) draws oil from hydraulic tank (10).
The pump supply oil (8) flows to the solenoid valve (3).
The solenoid valve controls the direction of hydraulic
fan motor (1). When the solenoid is not energized the
oil flows through the solenoid valve to the hydraulic fan
motor. The hydraulic fan motor will then rotate in a
clockwise rotation. After the hydraulic oil flows through
the hydraulic fan motor the oil returns to tank (9).
Check valve (5) will open if the oil pressure in the
return line is at a higher pressure than the pump
pressure. The check valve is used in order to slow the
fan motor when the machine is shutdown. Relief valve
31200272 59
(6) controls the maximum pressure of hydraulic fan

group (4).
(1) Hydraulic fan motor
(2) Switch (fan reversing)
(3) Solenoid valve
(4) Hydraulic fan group
(5) Check valve
(6) Relief valve
(7) Hydraulic pump
(8) Pump supply oil
(9) Return to tank
(10) Hydraulic tank
Note: Refer to the appropriate Operation and

Maintenance Manual, for the proper operation of the
switch.
When the switch (fan reversing) (2) is held down the
solenoid becomes energized. The valve spool shifts
and the oil flows through the solenoid valve. The oil is
directed to the hydraulic fan motor through the opposite
port. The fan motor will then rotate in reverse in a
counterclockwise rotation.
60 31200272
Auxiliary Hydraulic System

Introduction
Auxiliary Hydraulic System in the HOLD Position
(1) Quick disconnect (auxiliary circuit) for Port B (7) Relief Valve (Pressure reducing valve)
(2) Quick disconnect (auxiliary circuit) for Port A (8) Solenoid Valve Group (Pilot oil shutoff)
(3) Relief Valve (Line and anticavitation valve) (9) Main control valve spool
(4) Relief Valve (Line and anticavitation valve) (10) Proportional pilot reducing valve
(5) Proportional pilot reducing valve (11) Pressure compensator
(6) Pump supply passage (12) Pilot oil passage

Diverter Valve (auxiliary single) Control Valve (dual auxiliary)
31200272 61
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
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.
Illustration 96 g00902967 On TH220B machines, a Diverter Valve (auxiliary
Quick coupler single) is installed. The diverter valve allows the
The auxiliary hydraulic system provides a supply of operator to alternate between the hydraulic quick
oil to a diverter valve that is located on the boom coupler function and the auxiliary circuit 1 function. The
head for the operation of the following functions: function for auxiliary circuit 1 allows the operator to
• Quick coupler (hydraulically actuated pins) control the flow of oil to a work tool that is attached to
(standard on TH220B machines, optional on the quick coupler. The Diverter Valve (auxiliary single)
TH330B machines) is optional on the TH330B machines.
A Control Valve (dual auxiliary) is installed as an option
• Auxiliary 1 circuit (single) (standard on TH220B
on both TH220B machines and TH330B machines. The
machines, optional on TH330B machines)
Control Valve (dual auxiliary) provides oil flow to an
• Auxiliary 2 circuit (option on all machines) additional auxiliary circuit 2.
The auxiliary hydraulic control system consists of Note: The auxiliary circuits cannot be used
the following main components: simultaneously. Only one auxiliary circuit may be
• The spool of the main control valve (9), pressure selected at any one time.
compensator (11), and Relief Valves (Line and
anticavitation valve) (3) and (4) that are located in Auxiliary Control (Combined Circuit)
the Main Control Valve Group (implement)
Auxiliary Circuit 1 and 2
• Proportional pilot reducing valves (5) and (10) that
are located in the Control Manifold Group (Pilot
ECM)
• Diverter Valve (auxiliary single) (standard on
TH220B machines, optional on TH330B machines)
• Control Valve (dual auxiliary) that is optional on
both machines
• Quick coupler cylinder (standard on TH220B
machines, optional on TH330B machines)
• Optional work tools
The auxiliary hydraulic system provides the
following arrangements:
. Auxiliary 1 (ON/OFF) (1) Trigger switch
(2) Control switch for port "A"
•Auxiliary 1 (ON/OFF with continuous flow) (3) Control switch for port "B"
•Auxiliary 1 (ON/OFF with continuous flow and

quick coupler)
Selection between the auxiliary circuit 1 and the
auxiliary circuit 2 is achieved by trigger switch (1). The
•Auxiliary 1 and 2 (ON/OFF) switch is located on the front of the joystick control.
•Auxiliary 1 and 2 (ON/OFF with continuous flow)
•Auxiliary 1 and 2 (ON/OFF with continuous flow

and quick coupler)
62 31200272
(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.
31200272 63
Auxiliary Circuit 1
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 97 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 97 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 93 for
additional information.
64 31200272
Auxiliary Circuit 2

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)
The schematic shows a system for a machine that is to flow past the spool and flow into port "B" (6). The oil
equipped with a Control Valve (dual auxiliary) and a flows through the diverter valve for auxiliary circuit 2 (7)
hydraulic quick coupler. The schematic shows an and on to the auxiliary circuit 2 system. Return oil flows
energized solenoid on diverter valve (7) and a de- back to the hydraulic tank through the diverter valve,
energized solenoid on diverter valve (5). Oil flow to the through port "A" (5) and through the auxiliary section of
auxiliary circuit 1 and the hydraulic quick coupler the Main Control Valve Group (implement).
cylinder is blocked at the auxiliary circuit 2 diverter Control of the spool in the auxiliary valve section from
valve. the joystick control is not proportional. The machine
When switch (1) activates the auxiliary circuit 2, the ECM will ramp up the command to the ECM of the
solenoid on diverter valve (7) is energized. Switch (1) is auxiliary valve section when either switch (2) or (3) is
a momentary switch. The solenoid moves the spool in pressed.
diverter valve (7) to the right which opens a path for the
oil to flow to quick disconnects (8) for the auxiliary
circuit 2. Refer to Illustration 97 for the location of the
switch.
When switch (3) is activated an electrical signal is sent
to the ECM. Refer to Illustration 97 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 93 for
additional information.
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
31200272 65
Continuous Flow (Auxiliary Hydraulics) 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
(12) Continuous flow switch
the OFF position. To engage the pins, press and hold
(13) Lock for quick coupler switch
the bottom of the switch. Release the switch when the
(14) Quick coupler switch
quick coupler pins are fully engaged into the work tool.
Switch (12) for the continuous flow (auxiliary
In order to disengage the quick coupler pins, move
hydraulics) is located on the right side of the dash panel.
sliding red locking device (13) downward and press the
The continuous flow function operates with the top of the switch. Hold the switch until the coupler pins
auxiliary controls. The function allows the operator to are fully disengaged. Refer to Illustration 101 for the
select a constant flow rate and flow direction. The flow location of switches.
rate and flow direction is also maintained without
Note: When quick coupler switch (14) is selected, the
continued use of the switches on the joystick controls.
solenoid on diverter valve (9) is de-energized.
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 97 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).
66 31200272
Quick Coupler Circuit DISENGAGED

Quick Coupler Circuit DISENGAGED
(5) Port A (return oil to the auxiliary control valve) (8) Quick disconnects (Auxiliary circuit 2) (11) Quick coupler cylinder
(6) Port B (supply oil from the auxiliary control valve) (9) Diverter valve (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 101 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.
pilot oil to one side of the spool in the auxiliary valve
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
31200272 67
Quick Coupler Pins ENGAGED

Quick Coupler Circuit ENGAGED
(5) Port A (supply oil to the auxiliary control valve (8) Quick disconnects (Auxiliary circuit 2) (11) Quick coupler cylinder
(6) Port B (return oil from the auxiliary control valve (9) Diverter valve (Auxiliary circuit 1)
When the bottom of switch (14) is pressed, the Relief Valves and Makeup Valves
machine ECM sends a predetermined command to the
ECM of the proportional pilot reducing valves. Refer to
Illustration 101 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.
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 Illustration 104 g01024839
the diverter valve for auxiliary circuit 2 (7) and through (1) Relief valve
the diverter valve for auxiliary circuit 1 (9). The oil (2) Oil line from auxiliary circuit
pressure opens the check valve and the oil enters the (3) Oil line from auxiliary circuit
head end of quick coupler cylinder (11) in order to (4) Relief valve
engage the pins. (5) Makeup valve

(6) Oil line from the Main Control Valve Group (implement)
Return oil from the rod ends of the cylinder is returned to (7) Oil line from the Main Control Valve Group (implement)
the hydraulic tank through the two diverter valves, port (8) Makeup valve
"B" (6) and the auxiliary section of the Main Control (9) Tank passage
Valve Group (implement).
68 31200272
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.
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 cylinder
• 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 end of the compensating cylinder is
attached to the boom and the cylinder ends are
attached to the machine frame. The piston rod of the
compensating cylinder extend when the boom is raised.
The piston rod of the compensating cylinder 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 cylinder 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 cylinder. The rod end of the tilt cylinder
and the rod end of the compensating cylinder are
similarly matched. Therefore, movement of the tilt
cylinder will be in proportion to the movement of the
compensating cylinder.
31200272 69

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 cylinder (12) Makeup Valve (16) Lock valve
(6) Lock valve (13) Block at tilt control valve
Boom Lower
When the boom is being lowered, compensating
cylinder (3) is retracting due to the movement of the
boom. Oil is displaced from the head end of the
compensating cylinder 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 end of the compensating
cylinder.
70 31200272

Boom Raise
(1) Load control valve (7) Check valve (14) Block at tilt control valve
(2) Tilt cylinder (10) Spring (15) Check valve
(3) Compensating cylinder (12) Makeup Valve (16) Lock valve
(6) Lock valve (13) Block at tilt control valve (17) Load control valve
Boom Raise
When the boom is being raised, compensating cylinder
(3) is extending due to the movement of the boom and
the oil which is displaced from the rod end of the
compensating cylinder 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.
31200272 71

Pressure Relief and Makeup Valves
(1) Load control valve (5) Relief valve (9) Line
(2) Tilt cylinder (6) Lock valve (10) Spring
(3) Compensating cylinder (7) Check valve (11) Tank gallery
(4) Relief valve (8) Line (12) Makeup valve
Pressure Relief and Makeup Valves

If the quick coupler is tilted fully forward or if the quick Relief valve (4) and relief valve (5) also have
coupler is tilted fully backward and the boom is still anticavitation features which allow makeup oil to flow
moving the compensating cylinder would continue to into the compensating system from the return gallery of
move with the boom. In this event, the pressure in the the implement control valve, if the pressure in the
lines between the compensating cylinder and the tilt compensating system falls below the return oil
cylinder would rise sharply. In order to limit the pressure.
pressure in the system, relief valves (4) and (5) are If the pressure in line (8) or (9) falls below the pressure
installed in the implement section of the control valve for in tank gallery (11), then oil at tank pressure will unseat
the coupler tilt. Relief valve (5) will operate when the makeup valve (12) against the force of a spring. Oil
boom is being raised. Relief valve (4) will operate when then enters line (8) or (9) from tank gallery (11). The
the boom is being lowered. increase in the pressure in line (8) or (9) will prevent
A sharp pressure rise in line (8) or line (9) acts on relief cavitation in the supply lines to the implements.
valve (4) or (5). As the pressure rises above the setting When the oil pressure between line (8) or (9) and tank gallery
of the relief valve, the valve unseats against the force (11) has been equalized, the makeup valve (12) is reseated by
of spring (10). The pressure oil is then relieved to the the spring.
tank through gallery (11).
When the oil pressure returns to a level below the
pressure setting, spring (10) closes the valve.
72 31200272
Trailer and Towing Hitch

Hydraulic System
Introduction

Trailer and Towing Hitch Hydraulic System
(1) Outlet manifold (9) Trailer dump cylinder (if equipped) (17) Quick disconnect for “A” port
(2) Relief Valve (Pressure reducing valve) (10) Pump supply passage (18) Brake pedal
(3) Return oil from Trailer and Towing Hitch Hydraulic System (11) Pilot oil (19) Front axle brakes for the machine
(4)Load sensing oil from Trailer and Towing Hitch Hydraulic System (12) Quick disconnect for “B” port (20) Return oil from the brake circuit
(5) Brake oil line from front axle (13) Towing hitch cylinder (21) Supply oil to the brake circuit
(6) Trailer brakes (if equipped) (14) Solenoid Valve Group (Pilot oil shutoff) (22) Brake master cylinder for the machine
(7) Quick disconnect for the brake oil (15) Pump supply oil line
(8) Combination Valve Group (16) Solenoid Valve Gap
31200272 73
The hydraulic system for the optional trailer and the

towing hitch allows the machine owner to attach a non-
Caterpillar implement to the machine. The following
items are the main components of the hydraulic
system for the trailer and the towing hitch: Combination
Valve Group (8), towing hitch cylinder (13), trailer
brakes (6), and trailer dump cylinder (9). The hydraulic
system for the trailer and for the towing hitch is not being
utilized and the service brakes are disengaged in this
schematic.

Cable Group control knob
(26) Cable Group control knob
Cable Group (24) is activated by Cable Group control
knob (26). The control knob is mounted on the floor
inside the cab on the right side of the seat.

Control switch
(23) Control switch

Rear of the machine
(13) Towing hitch cylinder
(24) Cable Group
(25) Lock lever and hooks
Cable Group (24) and the control switch for system
(23) are additional components of the hydraulic system
for the trailer and the towing hitch. The lock lever and
hooks (25) are additional components of the hydraulic
system for the trailer and the towing hitch. The control
switch is mounted in the console on the right side of the
cab next to the operator's seat.
74 31200272
Towing Hitch Cylinder LOWER

Towing Hitch Cylinder LOWER
31200272 75
Control switch (23) is a three-position switch. The

control switch is spring loaded in order to return to the
OFF position when the operator releases the switch.
When the operator pushes the left side of control
switch (23) an electrical signal is sent to the bottom
solenoid of Solenoid Valve Gp (16). Solenoid Valve Gp
(16) is installed in Combination Valve Group (8).
The valve spool moves up and routes pump supply oil
in line (15) to quick disconnect for "B" port (12). The
hose to the head end of towing hitch cylinder (13) is
connected to port (12) so the high pressure oil flows into
the cylinder. This high pressure oil causes the rod to
move down.
Rear of the machine The oil also flows into a double check valve. The oil
(13) Towing hitch cylinder causes the ball to move up. The oil now flows to the
(24) Cable Group other double check valve. The oil forces that ball to
(25) Lock lever and hooks move left. The oil forces the load sensing check valve off
the check valve seat. The oil then flows into load
sensing oil line (4). This oil flows into outlet manifold (1)
that is a part of the Main Control Valve Group
(Implement). The oil flows through the Main Control
Valve Group (Implement) back to the control group for
the implement pump. The double check valves are
installed in the Combination Valve Group.
Oil in the rod end of cylinder (13) flows through the
hose that is attached to the quick disconnect for "A"
port (17). The oil then flows to the Load Control Valve
Group that is installed in the Combination Valve Group.
The Load Control Valve Group has a setting of 35000
kPa (5075 psi). The pilot ratio for the valve is 4:1. The
Illustration 117 g01020083 Load Control Valve Group allows increased capability
Cable Group control knob
to hold the load and the valve allows more stable
(26) Cable Group control knob
control of the cylinder.
In order to attach a trailer to the hitch, the operator
must disengage the lock lever and hooks (25). The lock The oil flows past the spool in Solenoid Valve Gp (16)
lever and hooks secure the towing hitch. The lock lever into return oil line (3). The oil next flows into outlet
and hooks also prevent the cylinder from drifting. When manifold (1) that is a part of the Main Control Valve
the operator pulls up on control knob (26) the Cable Group (Implement). The oil flows through the Main
Group (24) causes the lock lever and hooks to Control Valve Group (Implement) back to the hydraulic
disengage the hitch. tank.
The hitch is now lowered and ready to be connected to
the trailer.

Control switch
(23) Control switch
76 31200272
Towing Hitch Cylinder RAISE

Towing Hitch Cylinder RAISE
31200272 77

Control switch Rear of the machine
(23) Control switch (13) Towing hitch cylinder

(24) Cable Group
After the trailer is connected to the towing hitch the (25) Lock lever and hooks
operator pushes the right side of control switch (23) and
an electrical signal is sent to the top solenoid of
Solenoid Valve Gp (16). Solenoid Valve Gp (16) is
installed in Combination Valve Group (8).
The valve spool moves down and routes pump supply
oil in line (15) to the Load Control Valve Group that is
installed in the Combination Valve Group. The oil opens
the check ball that is a part of the Load Control Valve
Group and flows to quick disconnect for "A" port (17).
The hose to the rod end of towing hitch cylinder (13) is
connected to port (17) so the high pressure oil flows
into the cylinder. This high pressure oil causes the rod
to move up.
The oil also flows into a double check valve and the oil Illustration 122 g01020083
causes the ball to move down. The oil then flows to the Cable Group control knob
other double check valve and the oil forces that ball to (26) Cable Group control knob
move left. The oil forces the load sensing check valve The operator continues to push the right side of
off the check valve seat. The oil then flows into load control switch (23) until the lock lever and hooks (25)
sensing oil line (4). This oil flows into outlet manifold (1) engages the hitch. The lock lever and hooks are spring
that is a part of the Main Control Valve Group loaded in order to allow the hitch to become engaged
(Implement). The oil flows through the Main Control without requiring the operator to pull on Cable Group
Valve Group (Implement) back to the control group for control knob (26). When the hitch is secured by the
the implement pump. The double check valves are lock lever and hooks release the switch. The control
installed in the Combination Valve Group. switch is a three-position switch. The control switch is
spring loaded in order to return to the OFF position
Oil in the head end of cylinder (13) flows through the
when the operator releases the switch.
hose that is attached to the quick disconnect for "B" port
(12). The oil flows past the spool in Solenoid Valve Gp Reference: See Operation And Maintenance Manual,
(16) into return oil line (3). The oil next flows into outlet "Towing Hitch Control" for more information.
manifold (1) that is a part of the Main Control Valve Ensure that the lock lever and hooks have engaged the
Group (Implement). The oil flows through the Main towing hitch cylinder. The lock lever and hooks secure
Control Valve Group (Implement) back to the hydraulic the towing hitch and the lock lever and hooks prevent
tank. The pressure of the oil forces the towing hitch the cylinder from drifting downward.
and the tongue of the trailer that is attached to the hitch
to move upward.
78 31200272

Connection for the trailer brakes
(27) Quick disconnect for the trailer brake oil
If the trailer is equipped with brakes, connect the oil
line for the trailer brakes to quick disconnect (27).
Trailer brakes (6) are activated whenever the operator
pushes brake pedal (18) in order to engage brake
master cylinder for the machine (22). Once the trailer
brakes have been connected to the machine the trailer
is ready for towing.
When the hitch is raised through the spring loaded
hooks, the trailer needs to be positively lowered onto
the hooks. The weight of the trailer needs to be carried
by the hooks. The weight of the trailer can not be
carried by the load control valve. Also before you
change the quick disconnects, the hitch must be
lowered on the hooks. If the hitch is held on the load
control valve and the quick couplers are disconnected,
pressure will be trapped in the hydraulic line.
31200272 79
Trailer DUMP

Trailer DUMP
80 31200272
cylinder (9) through a hose that is connected to port

(17). This high pressure oil causes the rod to move up.
The oil also flows into a double check valve. This oil
causes the ball to move down. The oil then flows to the
other double check valve and the oil forces that ball to
move left. The oil forces the load sensing check valve
off the check valve seat. The oil then flows into load
Location of the quick disconnects The operator continues to push the right side of
(12) Quick disconnect for “B” port control switch (23) until the load is dumped. Once the
(13) Towing hitch cylinder load is dumped, the operator must release the switch.
(17) Quick disconnect for “A” port The control switch is a three-position switch. The
If the trailer is equipped with a dump cylinder control switch is spring loaded in order to return to the
disconnect the hydraulic oil lines for towing hitch OFF position when the operator releases the switch.
cylinder (13) from quick disconnect for "B" port (12) and
from quick disconnect for "A" port (17). Cap the
hydraulic oil lines for towing hitch cylinder (13).
Connect the hose for single acting trailer dump cylinder
(9) to the quick disconnect for "A" port (17). If the trailer
dump cylinder is a double acting cylinder then connect
the hose in order to dump the trailer to the quick
disconnect for "A" port (17). Connect the hose in order
to lower the trailer to the quick disconnect for "B" port
(12). Once the dump cylinder has been connected to
the machine the trailer is ready for towing.

Control switch
(23) Control switch
The operator pushes the right side of control switch

(23) in order to dump the trailer. When the switch is
pushed an electrical signal is sent to the top solenoid of
The valve spool moves down and routes pump supply
oil in line (15) to the Load Control Valve Group that is
installed in the Combination Valve Group. The oil opens
the check ball that is a part of the Load Control Valve
Group and flows to quick disconnect for "A" port (17).
The high pressure oil flows into the head end of dump
31200272 81
Trailer LOWER

Trailer LOWER
82 31200272

Control switch
(23) Control switch
The operator pushes the left side of control switch (23)

in order to dump the trailer. When the switch is pushed
an electrical signal is sent to the bottom solenoid of
The valve spool moves up and routes pump supply oil
in line (15) to the quick disconnect for "B" port (12).
The valve spool routes the oil from the quick
disconnect for "A" port (17) to return oil line (3).
Combination Valve Group
(3) Return oil from Trailer and Towing Hitch Hydraulic System
(4) Load sensing oil from Trailer and Towing Hitch Hydraulic System
(5) Brake oil line from front axle
(7) Quick disconnect for the brake oil
(9) Trailer dump cylinder (if equipped)
(12) Quick disconnect for "B" port
(13) Towing hitch cylinder
(15) Pump supply oil line
(16) Solenoid Valve Gp
(17) Quick disconnect for "A" port
(28) Pilot passage
(29) Pilot passage
(30) Check valve
(31) Load Control Valve Group
Because cylinder (9) is a single acting cylinder, there is
no hose that is connected to the quick disconnect for
port (12). The high pressure oil is blocked by the quick
disconnect and flows into pilot passage (28) that is a
part of Load Control Valve Group (31). At the same
time, because the rod end of cylinder (9) is attached to
the trailer bed, the weight of the bed causes the rod to
retract. As the rod retracts, the oil that is in the head
end of the cylinder is forced to flow through the quick
disconnect for "A" port (17).
The head end oil flows to Load Control Valve Group
(31) and the flow is blocked by check valve (30) that is a
part of the Load Control Valve Group. The oil also flows
into pilot passage (29) that is also in the Load Control
Valve Group. The oil that is in pilot passage (29)
combines with the high pressure oil that is in pilot
passage (28). These combined oils act against the load
control valve which causes the load control valve to
31200272 83
open. The Load Control Valve Group has a setting of

35000 kPa (5075 psi). The pilot ratio for the valve is 4:1.
The Load Control Valve Group allows increased
capability to hold the load and the valve allows more
stable control of the cylinder.
Since the valve spool in Solenoid Valve Gp (16) is open
to return oil line (3), the oil flows through the Load
Control Valve Group, past the spool in Solenoid Valve
Gp (16) and into return oil line (3). The oil flows through
Load Control Valve Group (31) in a metered state that
allows the trailer to lower at a controlled rate. The oil
next flows into outlet manifold (1) that is a part of the
Main Control Valve Group (Implement). The oil flows
through the Main Control Valve Group (Implement)
back to the hydraulic tank.
The oil also flows into a double check valve. The oil
causes the ball to move up. The oil then flows to the
other double check valve. The oil forces that ball to
move left. The oil forces the load sensing check valve off
the check valve seat. The oil then flows into load
When the trailer has been fully lowered, and the
operator releases the switch the electrical signal to
Solenoid Valve Gp (16) stops. The centering springs on
each side of the valve spool cause the spool to move
up into the center position. Oil that is in "B" port (12),
and the oil that is in "A" port (17) flows into return oil line
(3).
84 31200272
Service Brakes ENGAGED

Service Brakes ENGAGED
31200272 85
If the trailer is equipped with brakes the brakes are

controlled by brake master cylinder for the machine
(22). When the operator depresses brake pedal (18) in
order to engage front axle brakes for the machine (19),
part of the brake oil flows through brake oil line (5) into
the Brake Control Valve Group that is a part of
Combination Valve Group (8). The brake oil acts
against the spool that is in the Brake Control Valve
Group. This opens a path for the oil to flow to the quick
disconnect for the brake oil (7).
The oil then flows to trailer brakes (6) that causes the
brakes for the trailer to engage. The trailer brake oil
also flows to the double check valve. The oil forces the
ball to move to the right. The oil forces the load sensing
check valve off the check valve seat. The oil then flows
into load sensing oil line (4). This oil flows into outlet
manifold (1) that is a part of the Main Control Valve
Group (Implement). The oil flows through the Main
Control Valve Group (Implement) back to the control
group for the implement pump. The double check
valves are installed in the Combination Valve Group.
When the operator releases brake pedal (18) springs in
brake master cylinder for the machine (22) force the
pistons for the master cylinder to the left. The pressure
that is in the brake hydraulic circuit is released when
the pistons move left. The Brake Control Valve Group
spool opens a path to return oil line (3) when the
pressure is released. The oil flows past the spool in the
Brake Control Valve Group into return oil line (3). The
oil next flows into outlet manifold (1) that is a part of the
Main Control Valve Group (Implement). The oil flows
through the Main Control Valve Group (Implement)
back to the hydraulic tank.
Reference: See Systems Operation, "Brake Cylinder
(Master)" for more information.
Hydraulic System Schematic

The schematic shows all of the implement control
valves in the HOLD position.
86 31200272

31200272 87
(1) Main Control Valve Group (Implement) The hydraulics of the main control valves are similar to
(2) Outlet Manifold the former machines. The valves are similar to PPPC
(3) Return pilot oil from Trailer and Towing Hitch Hydraulic System
hydraulic system that is used in other Caterpillar
(4) Return oil from Trailer and Towing Hitch Hydraulic System
machines. The system that is shown incorporates the
(5) Load signal from Trailer and Towing Hitch Hydraulic System
(6) Relief Valve (Pressure reducing valve)
flow control and the resolver into one component called
(7) Solenoid Valve Group (Pilot shutoff)
a pressure compensator valve. This is different from
(8) Supply oil to Trailer and Towing Hitch Hydraulic System other hydraulic systems that had resolvers. The
(9) Pilot oil to Trailer and Towing Hitch Hydraulic System pressure compensator acts as a resolver to compare
(10) Return oil from brake circuit the different port pressures. The pressure compensator
(11) Supply oil to brake circuit sends signal pressure that is equal to the highest
(12) Boom Cylinder Group circuit pressure back to the pump. As shown, another
(13) Load Control Valve Group (Boom Cylinder Lock) circuit has been activated. The load sensing oil flows to
(14) Control Valve (boom raise/lower) the compensator valve. The oil then causes the
(15) Load Control Valve Group (Compensating Cylinder Lock)
compensator valve to move down. The compensator
(16) Compensating Cylinder Group
valve sends part of the supply oil through the signal
(17) Relief Valve (Line and anticavitation valve)
passage. The oil then becomes signal oil. The signal
(18) Control Valve (tilt)
(19) Tilt Cylinder Group
network consists of all of the pressure compensator,
(20) Load Control Valve Gp (Tilt Cylinder Lock) internal passages and signal lines. This signal is sent to
(21) Relief Valve (Line and anticavitation valve) the pump control and to all of the other pressure
(22) Control Valve (auxiliary) compensator valves. Also, passages in the valve drain
(23) Quick disconnects (auxiliary circuits) will allow oil to flow back to the tank. The passages
(24) Proportional pilot reducing valve prevent pressure from building up. High pressure
(25) Electronic Pilot Valve Group (implement) leakage around the spool may cause an increase in the
(26) Control Valve (boom extend/retract) pressures in the ports.
(27) Load Control Valve Gp (Telescoping Cylinder)
(28) 100 micron filter Note: The passages are shown for the control valve in
(29) Telescoping Cylinder Group HOLD.
(30) 75 micron filter
(31) Flow Control Valve Group (Dump valve for the load sensing oil)
(32) Inlet manifold
(33) Valve Assembly (Steering priority)
(34) Relief Valve (Load sensing oil)
(35) 100 micron filter
(36) Line to metering pump
(37) Return oil line to tank
(38) Load sensing oil from steering
(39) Pump supply
(40) Load sensing oil to pump
(41) Check Valve (Return oil back pressure)
The illustration shows the standard implement valve

that is used in all the B - Series Telehandlers.
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.
88 31200272

Reference: Refer to the appropriate service manual
for further instructions on configuring the ECM for your
machine.
31200272 89
Testing and Adjusting

Section
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 137 g00898916
machine. This is the location of the service connector that contains the Cat Data Link.
The connector is located to the side of the seat.
Table 5
Required Tools
Part Number Description Quantity
Caterpillar Electronic
JEBD3003 1
Technician (ET)
Communications Adapter
171-4400 1
II
The Caterpillar Electronic Technician service tool (ET)

is used to access the calibration procedures. A
to the Manual that is provided with the ET for more
information about ET.
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.
90 31200272

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.
31200272 91

Set up conditions have not been met. The parking brake
has not been set. After the parking brake is set, press
the "Next" button.
92 31200272
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.
31200272 93
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.
94 31200272
moved full REWARD position.
Move the lever to the full LEFT position and press the
"Next" button.
31200272 95
moved full LEFT position.
Move the lever to the full RIGHT position and press the
"Next" button.
96 31200272
moved full RIGHT position.
Release the lever and press the "Next" button.
31200272 97
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.
98 31200272
This screen shows that the set up conditions have been

met.
Press the "Next" button in order to continue with the
calibration procedure.
31200272 99

Move the right hand left thumb wheel to the UP
position. Then press the "Next" button.
100 31200272
The ECM now knows the signal input when the

thumbwheel is moved into the Up position.
Move the thumb wheel to the DOWN position and press
the "Next" button.
31200272 101

thumbwheel is moved into the Down position.
Release the thumb wheel and press the "Next" button.
102 31200272

31200272 103
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 6. After
correcting the problem, the calibration is repeated by
pressing the "Restart" button. Complete the process by
clicking on the "Finish" button.
ECM.
Table 6
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.
104 31200272
This screen shows that the set up conditions have been

met.
Press the "Next" button in order to continue with the
calibration procedure.
31200272 105

Move the right hand right thumb wheel to the UP
position. Then press the "Next" button.
106 31200272

thumbwheel is moved into the Up position.
Move the thumb wheel to the DOWN position and press
the "Next" button.
31200272 107

thumbwheel is moved into the Down position.
Release the thumb wheel and press the "Next" button.
108 31200272
The calibration procedure for the thumb wheel was

successful. A window will appear if a failure occurs.
failure. The error codes are listed in table 7. After
correcting the problem, the calibration is repeated by
pressing the "Restart" button. Complete the process by
clicking on the "Finish" button.
ECM.
31200272 109
Table 7
Joystick Control Calibration Error Codes

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 Restart the calibration.
during the calibration process.
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 out of
0103 than 40% or greater than 60% at the movement is correct, check the
range
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 8
Required Tools
Part Number Description Quantity
Caterpillar Electronic
JEBD3003 1
Technician (ET)
Communications Adapter
171-4401 1
II
The Caterpillar Electronic Technician service tool (ET) This is the location of the service connector that contains the CAT data
is used to access the calibration procedures. A link. The connector is behind the seat.
to the Manual that is provided with the ET for more
information about ET.
110 31200272
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.
31200272 111
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".
112 31200272
Click on the "Next" button after the conditions for the

setup are met.
31200272 113
This is the screen that appears if you click the "Next"

button and all the conditions for the setup are not met.
114 31200272
Release all of the implement controls and click on the

“Next” button in order to continue with the calibration.
31200272 115
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.
116 31200272
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 166 appears.
31200272 117
The calibration for the boom raise valve has failed.

failure. The error codes are listed in table 9.
Click on "Continue" in order to calibrate the next
pending function.

118 31200272
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.
ECM.
Table 9
PHS Valve Calibration Error Codes

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 10
flow to the coils.
Required Tools
Reference: Refer to the appropriate Service Manual
Part Number Description Qty
for information concerning the machine configuration.
36 mm Deep
242-0779 1
Socket
31200272 119
Location of the Load Control Valve

(Lock)
Personal injury can result from hydraulic oil Care must be taken when you are removing lock valves
pressure and hot oil. from the load control valve.
Hydraulic oil pressure can remain in the hydraulic Lock valves are installed in the load control valves on
system after the engine has been stopped. Serious the following cylinders:
injury can be caused if this pressure is not released • Telescoping Cylinder
before any service is done on the hydraulic system.
• Boom Cylinder (Boom Raise/Lower)
Make sure all of the attachments have been
• Tilt Cylinder
lowered, oil is cool before removing any
components or lines. Remove the oil filler cap only • Frame Leveling (If Equipped)
when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
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 Illustration 167 g01000745
Load control valve for the telescoping cylinder
Care must be taken to ensure that fluids are contained (1) The lock valve is on the front side of the control valve.
containing fluids.
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. Illustration 168 g01000501
Before you start any maintenance on the boom, Load control valve for the boom cylinder (boom raise/lower)
(2) Lock valve
support the boom on a suitable stand. Refer to the
"Tools and Shop Products Guide" for information on
stands that are available.
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.
6. Relieve the system pressure from the shutoff
valve and for the axle.
120 31200272
• Boom retract without hydraulic power

• Maintenance on load control valves
• Maintenance on hydraulic cylinders
Note: For information regarding machine operation
without hydraulic power, refer to the appropriate
Operation and Maintenance Manual.
The Following Procedure Should Be
Used for the Telescoping Cylinder

This is an example of the location for the load control valve and the lock valve
for the tilt cylinder on the TH220B and the TH330B series machines.

Load control valve
(1) Lock valve is on the back side of the control valve.
(5) Adjusting screw
(6) Locknut
Illustration 168 g01000875 1. Measure the distance from the head of adjusting
Load control valve for the tilt cylinder screw (5) to the body of control valve. Record this
(3) Lock valve measurement. This measurement will be required
The lock valve for the tilt cylinder is a cartridge type later when the adjusting screw (5) is reset.
valve. Lock valve (3) is located in the cartridge which is
1. Fully loosen locknut (6). Turn adjusting screw (5)
screwed directly into the cylinder.
as far as possible in a clockwise direction by hand.
1. Attach a wrench to adjusting screw (5) and turn
adjusting screw (5) for an additional two full turns
in a clockwise direction. The pressure must now
be relieved from the implement control valve in
order to release the pressure from the lock valve.
1. Refer to the appropriate Operation and
Maintenance Manual, for information on releasing
the pressure from the implement control valve.
1. Reset the lock valve after all the pressure
has been relieved. Refer to the appropriate
Operation and Maintenance Manual, for
information on resetting the lock valve.
Illustration 169 g01013263 1. Loosen the lock valve slowly in order to release
Lock valve for the frame leveling cylinder any pressure that remains in the lock valve.
(4) Lock valve
Ensure that all the hydraulic pressure is released
from the lock valve before you remove the lock
Relieving Pressure from the Load valve from the load control valve. Remove the lock
Control Valves (Lock) valve from the load control valve.
The procedures in this section may be used in the

following operations:
• Boom lowering without hydraulic power
31200272 121

Used for the Boom Cylinder (Boom
Raise/Lower).

Load control valve for the boom cylinder
(2) Lock valve
(7) Screw
(8) Locknut
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 (7) to the body of lock valve (2). Record this
measurement. This measurement will be required
later when adjusting screw (7) is reset.
3. Fully loosen locknut (8). Turn adjusting screw (7)
as far as possible in a clockwise direction by hand.
4. Attach a wrench to adjusting screw (7) and turn
adjusting screw (7) for an additional two full turns
in a clockwise direction. The pressure in the lock
valve will now be directed to the implement control
valve. The pressure must now be relieved from
the implement control valve in order to release the
pressure from the lock valve.
5. Refer to the appropriate Operation and Maintenance
Manual, for information on releasing the
pressure from the implement control valve.
6. Reset the lock valve after all the pressure
has been relieved. Refer to the appropriate Operation
and Maintenance Manual, for information on resetting the
lock valve.
7. Loosen the lock valve slowly in order to release
any pressure that remains in the lock valve.
valve from the load control valve. Remove the lock
valve from the load control valve.
122 31200272

Used for the Tilt Cylinder.

Lock valve for the tilt cylinder
(9) Cap
(10) Adjusting Screw
The Following Procedure is for the Machine With A adjusting screw should move out of the body of
Two-Section Boom the lock valve. The pressure in the lock valve will
now be relieved.
1. Place the front coupler in a horizontal position and
4. Reset the lock valve after all the pressure has
support the front coupler on the ground in order to
been relieved.
ensure no movement of the function, when the
lock valve is removed. 5. Remaining residual pressure that is sustained
within the spool will be released in two to five
2. Remove cap (9). minutes. Use the tool 242-0779 36 mm Deep
3. Turn adjustment screw (10) counterclockwise in Socket and loosen the lock valve slowly in order
order to relieve the pressure. Record the number to release any pressure that remains in the lock
of turns in order to reset the lock valve later. The valve. Ensure that all the hydraulic pressure is
adjusting screw should move out of the body of released from the lock valve before you remove
the lock valve. The pressure in the lock valve will the lock valve from the cylinder.
now be relieved.
4. Reset the lock valve after all the pressure has
been relieved. Used for the Frame Leveling Cylinder (If
5. The remaining residual pressure that is sustained Equipped)
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.
valve from the cylinder.
The Following Procedure is for the Machine With A
Three-Section Boom.
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. Illustration 175 g01027290
2. Remove cap (9). The following procedures should be used for the
removal of the frame leveling valve.
3. Turn adjusting screw (10) counterclockwise in
order to relieve the pressure. Record the number 1. Turn the wheels to a full LEFT position. This will
of turns in order to reset the lock valve later. The allow access to the frame leveling valve.
31200272 123
2. Place a jack under the front axle. Raise the front • Low Pressure Standby Test
wheels of the machine from the ground.
• Low Pressure Standby Adjustment
3. Place two stands under either end of the front
plate of the chassis. Lower the chassis onto the
stands. This will prevent the machine from tipping. Pilot Pressure (Pressure
4. Support the wheel on the side of the axle with the
frame leveling by placing a block under the wheel.
Reducing Valve) - Test and
This will help prevent any oil pressure that would Adjust
be caused by the weight of the wheel.
5. Before you remove the hoses locate three plugs
that will be used for plugging the hoses. Remove
the three hoses that are connected to the valve
(11). Plug the hose ends.
6. Disconnect the two solenoid connections. Mark
the connections and the solenoids in order
7. to make the correct connections during the installation of
the new valve.
8. Carefully loosen the four bolts (12) that hold the
valve down. Ensure that any oil that may leak is
collected properly.
9. Continue to remove the four bolts and the valve.
10. Install a new valve.
11. 10.Reconnect the hoses and the solenoid
Location of the Pressure Reducing Valve in the Main Control Valve (Implement)
connections.
(1)Outlet section
Verifying the Correct Setting of the Load (2)Pressure reducing valve
Control Valves The pilot pressure for the main control valve
(implement) is controlled by pilot reducing valve (2) in
The procedure for verifying the correct setting of the
outlet section (1) of the main control valve (implement).
load control valves can be found in the following
reference Operation and Maintenance Manual,
"Equipment Lowering with Loss of Hydraulic Power". Pilot Pressure Test
Introduction
Hydraulic System Pressures - The test indicates if the pressure reducing valve in the
Test and Adjust 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
Test and Adjustment Procedures the main control valve (implement), and the control
• For information on the TH220B and the TH330B valve Gp (stabilizer), if equipped.
models with the reversing fan, refer to the appropriate Reference: See Systems Operation/Testing and
service manual. Adjusting, "Outlet Manifold" for more information.
For information on pump pressure settings and the Required Tools
following procedures, refer to the appropriate service
manual. Use the following test equipment in order to
perform the following procedure:
• Steering Pressure Test
• Appropriate pressure gauges
• Steering Pressure Adjustment
Table 1 provides a list of the tools that are required in
• Margin Pressure order to perform the following test procedure.
• Margin Pressure Adjustment Table 11
• Test for the Implement Relief Valve (Load Sensing Required Tools
Oil or Signal Oil)
Part
• Adjustment for the Implement Relief Valve (Load Tool Part Description Qty
Number
Sensing Oil or Signal Oil)
A 6V-7830 Pressure Gauge 1
• Test for Pressure Compensator
• Pressure Compensator Adjustment
124 31200272
Warming the Transmission Oil 1. Ensure that the hydraulic oil is at the correct
temperature.
In order to ensure that the transmission oil is at the
normal operating temperature of 60° ± 10°C (140° ± 2. Retract the boom and lower the boom. Ensure
that the frame is level.
18°F), complete the following procedure:
3. Stop the engine. Move the steering wheel from
1. Apply the service brakes and start the engine. left to right. This procedure helps purge pressure
2. Run the engine for 2 minutes at Low Idle. Then, from the hydraulic system.
run the engine for 2 minutes at High Idle.
3. Disengage the parking brake. Ensure that
to the Operation and Maintenance Manual,
4. Move the transmission control to the FOURTH
transmission oil temperature gauge in the cab Illustration 177 g00945668
reads 3/4 of the way to the red line. 4. Connect Tooling (A) to test fitting (3).
Note: To ensure that the transmission oil does not get Note: Ensure the use of 6V-7830 Pressure Gauge.
too hot, do not keep the torque converter in a full stall During engine start-up, a 17250 kPa (2500 psi)
condition for more than 10 seconds. pressure spike is possible.
6. Move the transmission control to the NEUTRAL 5. Start the engine and operate the engine at low idle.
6. The pressure gauge should read 3450 ± 150 kPa
until the needle of the transmission oil temperature
gauge returns to the middle of the scale. (500 ± 20 psi). If the pressure is not within the
specification, adjust the pressure reducing valve. Refer to
7. Repeat Step 5 and Step 6 until the proper Testing and Adjusting, "Pressure Reducing Valve
hydraulic oil temperature is obtained. Adjustment" for your machine.
Test Procedure 7. If the pressure is within the specification, stop the
engine and remove the tooling.
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
relieved.
NOTICE
containing fluids.
mandates.
Note: Ensure the use of 6V-7830 Pressure Gauge.
During engine start-up, a 17250 kPa (2500 psi)
pressure spike is possible.
31200272 125
Pressure Reducing Valve Relief Valve (Implement) - Test

Adjustment and Adjust
Introduction
Use the following procedure to adjust the setting for the
pressure reducing valve.
Adjustment Procedure

1. Turn off the engine.
2. To increase the pressure setting on the pressure
reducing valve, loosen locknut (4) and use an
allen wrench to turn adjusting screw (5) clockwise.
To decrease the pressure setting, loosen locknut
(4) and turn adjusting screw (5) counterclockwise.
One turn equals approximately 700 kPa (100 psi). Illustration 179 g01003786
3. While you hold adjusting screw (5) from turning, Location of line relief valves in the auxiliary section of the main control valve
tighten locknut (4). (1) Control valve (boom raise/lower)
(2) Control valve (tilt)
4. Recheck the pressure settings.
(3) Relief valve
(4) Control valve (auxiliary)
(5) Control valve (boom extend/retract)
(6) Relief valve
(A) Work port
(B) Work port
The pressure for the auxiliary services is controlled by line

relief valves (3) and (6) in the implement section. A relief
valve is installed for each work port.
Note: Refer to the Operation and Maintenance Manual for

more information on the operation of the control switches that
are used in this procedure.
Auxiliary Pressure Test (Port A and

Port B)
Introduction
The test indicates if the pressure relief valves in work
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 13 for
the pressure.
Note: The following test is performed with a quick
coupler that is hydraulically actuated. The test can be
126 31200272
performed with any work tool that is operated by a Test Procedure

hydraulic actuator.
Required Tools
Use the following test equipment in order to
perform the following procedure: Personal injury can result from removing hoses or
Table 1 provides a list of the tools that are required in injury.
order to perform the following test procedure.
Table 12
Required Tools relieved.
Part NOTICE
Number Care must be taken to ensure that fluids are contained
8T-0860 Pressure Gauge 1 during performance of inspection, maintenance, testing,
6V-3989 Test fitting 1
A the fluid with suitable containers before opening any
177-7861 Hose 1 compartment or disassembling any component
6V-4143 Coupler 2
containing fluids.
Warming the Transmission Oil mandates.
In order to ensure that the transmission oil is at the 1. Ensure that the hydraulic oil is at the correct
normal operating temperature of 60° ± 10°C (140° ± temperature.
18°F), complete the following procedure: 2. Retract the boom and lower the boom. Ensure
1. Apply the service brakes and start the engine. that the frame is level.
2. Run the engine for 2 minutes at Low Idle. Then, 3. Stop the engine. Move the steering wheel from
run the engine for 2 minutes at High Idle. left to right. This procedure helps purge pressure
3. Disengage the parking brake. Ensure that
from the hydraulic system.
to the Operation and Maintenance Manual,
4. Move the transmission control to the FOURTH
transmission oil temperature gauge in the cab
reads 3/4 of the way to the red line.
Note: To ensure that the transmission oil does not get Illustration 180 g01003812
too hot, do not keep the torque converter in a full stall 4. Connect tooling (A) to test fitting (7).
condition for more than 10 seconds. 5. Ensure that the switch on the front of the joystick
control is toggled to the auxiliary services 1
position.
until the needle of the transmission oil temperature Reference: Refer to Systems Operation, "Auxiliary
gauge returns to the middle of the scale. Control (Combined Circuit)" for further information.
7. Repeat Step 5 and Step 6 until the proper 6. Start the engine and operate the engine at low
hydraulic oil temperature is obtained. idle.
7. Move the sliding red portion of the quick coupler
switch downward and press the top of the switch.
Press and hold the switch in order to disengage
the quick coupler pins. Hold the switch in this
position until the auxiliary control valve is stalled.
Refer to Table 13 for the pressure. Release the
switch.
31200272 127
8. Press and hold the bottom of the quick coupler Pressure Adjustment for Engaging the
switch in order to engage the quick coupler pins.
Hold the switch in this position until the auxiliary Quick Coupler
control valve is stalled. Refer to Table 13 for the
pressure.
Table 13
Hydraulic Specifications
Model
Description
TH220B TH330B
21000 ± 500 kpa 21000 ± 500 kpa
Auxiliary Pressure
(3045 ± 73 psi) (3045 ± 73 psi)
9. Stop the engine and remove the test equipment.
Auxiliary Relief Valve Adjustments Illustration 182 g01024132

1. Turn off the engine.
Introduction 2. To increase the pressure setting on the relief valve,
Use the following procedures to adjust the setting for loosen locknut (9) and use an allen wrench to
the auxiliary relief valves. turn adjusting screw (10) clockwise. To decrease
the pressure setting, loosen locknut (11) and turn
Pressure Adjustment for Disengaging adjusting screw (10) counterclockwise.
the Quick Coupler 3. While you hold adjusting screw (10) from turning,
tighten locknut (11).
4. Start the engine.
Hydraulic Oil Contamination -

Test
Hydraulic Oil Contamination
Introduction
The steering system and the transmission system use
Illustration 181 g01024114 hydraulic oil from the hydraulic tank. Caterpillar
1. Turn off the engine. recommends the use of the SOS oil analysis program
in order to monitor the condition of your equipment.
2. To increase the pressure setting on the relief
valve, loosen locknut (9) and use an allen wrench If the oil becomes contaminated, premature
to turn adjusting screw (8) clockwise. To decrease component failure could result. Contaminated oil can
the pressure setting, loosen locknut (9) and turn also contribute to overheating. Use the following
adjusting screw (8) counterclockwise. procedure to sample the oil in the system.
3. While you hold adjusting screw (8) from turning, Reference: See Operation and Maintenance Manual,
tighten locknut (9). "SOS Fluid Analysis" for further information about this
4. Start the engine. SOS oil analysis program.
Flushing the Sampling Valve

Do not allow hot oil or components to contact
skin.
128 31200272
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any the fluid with suitable containers before opening any
compartment or disassembling any component compartment or disassembling any component
containing fluids. containing fluids.
Dispose of all fluids according to local regulations and Dispose of all fluids according to local regulations and
mandates. mandates.
In order to obtain a representative oil sample, it is first Once the sampling valve has been flushed, carry out
necessary to flush the sampling valve. the following procedure in order to obtain an oil sample:
Required Tools Required Tools
Use the following equipment in order to Flush the Use the following equipment in order to obtain the
Sampling Valve: Sample:
Table 14 Table 15
Required Tools Required Tools

Part Part
Tool Part Description Qty Tool Part Description Qty
Number Number
8T-9208 Probe Assembly 1 Fluid Sampling Cap and
177-9343 1
A Probe Gp
6K-0713 Hose 1 B
169-7373 Bottle 1
1. Shift the transmission to NEUTRAL and engage
the parking brake. 1. Attach the probe from the 177-9343 Fluid
Sampling Cap and Probe Gp to a 169-7373
Bottle.
3. Extend the boom and retract the boom several
times in order to warm the hydraulic oil. 2. Draw a 50 mL (1.7 fl oz) oil sample from the
4. Operate each implement several times in order to sampling valve.
circulate the warm oil. Rotate the steering wheel Maximum Contamination Levels
from stop to stop several times.
The level of contaminants that is found in the hydraulic
5. Allow the engine to run on low idle.
system must meet the ISO 18/15 cleanliness level.
6. Open the engine enclosure.
The following table contains the maximum
7. Locate the sampling valve that is positioned at the
acceptable contamination levels:
top of the hydraulic oil filter. Remove the rubber
cap from the sampling valve. Table 16
8. Attach the 8T-9208 Probe Assembly to the Hydraulic Oil Contamination
6K-0713 Hose.
Maximum Number of
9. Direct the hose into a container for fluid waste.
Particle Size (Microns) Particles in a 50 mL (1.7 fl
Remove approximately 30 mL (1 fl oz) of fluid
oz) Sample
from the sampling valve.
10 to 20 48000
Obtaining the Sample 21 to 50 2580
51 to 100 150
100 or more 20

skin.
31200272 129
General Information Table

Table 19
Hydraulic Specifications
Pressures
Description Model
TH220B TH330B
Steering Signal Pressure 16250 ± 750 kPa (2355 ± 110 psi) 16250 ± 750 kPa (2355 ± 110 psi)
Margin Pressure 2200±100kPa(320±15psi) 2200 ± 100 kPa (320 ± 15 psi)
Load Sensing Pressure 24300 ± 500 kPa (3524 ± 72 psi) 22800 ± 500 kPa (3300 ± 72 psi)
Maximum Pump Pressure 26500 ± 500 kPa (3843 ± 73 psi) 25000 ± 500 kPa (3626 ± 73 psi)
Standby Pressure 4500 ± 1000 kPa (650 ± 145 psi) 4500 ± 1000 kPa (650 ± 145 psi)
Pressure Reducing Valve (Pilot Oil

3450 ± 150 kPa (500 ±22 psi) 3450 ± 150 kPa (500 ± 22 psi)
Pressure at Standby)
Pressure Reducing Valve (Pilot Oil
3450 ± 150 kPa (500 ±22 psi) 3450 ± 100 kPa (500 ± 15 psi)
Pressure at Stall)
Auxiliary Pressure 21000 ± 500 kPa (3045 ± 73 psi) 21000 ± 500 kPa (3045 ± 73 psi)
Hoist Pressure for Trailer 25000 ± 500 kPa (3625 ± 72 psi) 25000 ± 500 kPa (3625 ± 72 psi)
Braking pressure for Trailer 13500 ± 1500 kPa (1950 ± 220 psi) 13500 ± 1500 kPa (1950 ± 220 psi)
Implement Oil Temperature 55° ± 10°C(131°± 18°F) 55° ± 10°C(131°± 18°F)

Flow Rate
Auxiliary Flow Rate (high idle) 60 ± 5 L/min (16 ± 1.3 US gpm) 60 ± 5 L/min (16 ± 1.3 US gpm)
Reference: For more information about implement oil,

see Operation and Maintenance Manual, "Lubricant
Viscosities" for your machine.
Table 20
Pressure of the Fan Pump and Speed of the Fan Motor

Speed of the Fan
Engine Speed Pump Pressure
Motor
4000 ± 200 kPa
Low Idle 1230±50RPM
(580 ± 30 psi)
15000 ± 200 kPa
High Idle 2400 ± 50 RPM
(2175 ± 30 psi)
Fan Motor in Reverse or Counterclockwise Direction
4000 ± 200 kPa
Low Idle 1230±50RPM
(580 ± 30 psi)
14500 ± 200 kPa
High Idle 2840 ± 50 RPM
(2100 ±30 psi)
130 31200272
Note: Refer to the appropriate Operation and

Maintenance Manual, for the proper operation of the
reverse switch.
Table 21
Cycle Times for Implement Functions (Seconds)

Engine at high idle and the hydraulic oil temperature above 45 °C (113 °F)
Function Model
TH220B TH330B
Boom Raise 4-6 6-8
Boom Lower 3-5 5-7
Boom Extend 4-6 5-7
Boom Retract 4-6 5-7
Coupler Tilt Backward 2-3 2-3
Coupler Tilt Forward 2-3 2-3
Frame Level Left to Right N/A N/A
Frame Level Right to Left N/A N/A
Table 22
Cycle Time for Steering (Seconds)

Min Lock to Lock Cycle
Mode
Time
Two-Wheel Steer 2-4
Crab Steer 2-5
Circle Steer 2-5
31200272 131
Index Index
A Electronic Control Module .................................................. 27

Auxiliary Hydraulic System Data Links..................................................................... 27
Auxiliary Circuit 1 .......................................................... 63 Input/Output .................................................................. 27
Auxiliary Circuit 2 .......................................................... 64 Inputs ............................................................................ 27
Auxiliary Control (Combined Circuit)............................. 61 Outputs ......................................................................... 27
Continuous Flow (Auxiliary Hydraulics) ........................ 65 G
Introduction................................................................... 60
General Information
Quick Coupler ............................................................... 65
Electronic Joystick .......................................................... 8
Quick Coupler Circuit DISENGAGED........................... 66
Electronic Pilot Valve Group (Implement) ....................... 6
Quick Coupler Pins ENGAGED .................................... 67
Hydraulic Oil Filter .......................................................... 9
Relief Valves and Makeup Valves ................................ 67
Hydraulic Oil Tank .......................................................... 9
Auxiliary Hydraulic System................................................. 60
Joystick Control ............................................................ 11
C Load Independent Flow Division (LIFD) ....................... 11
Check and Relief Valves .................................................... 49 Location of Electrical Components ............................... 11
Compensating System ....................................................... 68 Machine (ECM) ............................................................. 14
Configuration Parameters .................................................. 88 Machine ECM ................................................................. 7
Main Control Valve (Implement) ................................... 15
E Main Control Valve Group (Implement) .......................... 5
Electrical Function Requirements Operator Switches .......................................................... 9
Boom Raise/Lower Is Disabled..................................... 33 Piston Pump (Implement and Steering) .......................... 9
Disable the Quick Coupler ............................................ 34 Relay (Frame Level) ..................................................... 16
Disable The Rackback And Dump................................ 33 Relays (Diverter Valve)................................................. 16
Machine Security System ............................................. 31 Relays (Quick Coupler)................................................. 16
Miscellaneous............................................................... 34 Sensor (Boom Raise/Lower)......................................... 12
More Electrical Function Requirements........................ 31 Sensor For Boom Extend And Boom Retract Or Boom Tilt
Parking Brake ............................................................... 31 Forward And Rackback ................................................ 12
Rear Axle Lock (if equipped) ........................................ 31 Solenoid (Diverter Valve) .............................................. 15
Service Brake Pressure Switch for the Transmission Solenoids (Frame Level)............................................... 15
Neutralizer .................................................................... 31 Switch (Auxiliary Actuator in the + Direction)................ 12
Shift Lever (Cat Data Link) for Powersynchro Switch (Auxiliary Actuator in the -Direction).................. 12
Transmission ................................................................ 31 Switch (Auxiliary Services 1 or 2) ................................. 12
Shuttle Shift for the Power Shuttle Transmission ......... 31 Switch (Continuous Auxiliary Flow) .............................. 12
Solenoid Outputs .......................................................... 31 Switch (Critical Angle)................................................... 14
Stabilizer Raise/Lower (if equipped) is Disabled .......... 32 Switch (Frame Level) .................................................... 13
Steering ........................................................................ 32 Switch (Fully Lowered Boom) ....................................... 13
System Voltage............................................................. 31 Switch (Fully Retracted Boom) ..................................... 14
The Boom Extend/Retract Is Disabled.......................... 33 Switch (Lockout Control)............................................... 11
The Frame Level (if equipped) is Disabled ................... 33 Switch (Quick Coupler) ................................................. 13
The Neutral Start Is Disabled........................................ 32 Switch (Reversing Fan (If Equipped))........................... 14
Transmission Neutralizer .............................................. 31 Switch For Boom Extend and Boom Retract Or Boom Tilt
Electrical Function Requirements ...................................... 31 Forward And Rackback ................................................ 12
Electrical Input Components .............................................. 24 System Operation ......................................................... 10
Boom Critical Angle Switch........................................... 25 General Information Table ............................................... 129
Boom Lowered Switch.................................................. 26 General Information ............................................................. 5
Boom Retracted Switch ................................................ 25 Graphic Color Codes............................................................ 3
Continuous Flow Switch ............................................... 26
H
Frame Leveling Switch ................................................. 25
Implement Lockout Switch............................................ 26 Hydraulic Fan System ........................................................ 58
Joystick Control ............................................................ 25 Reversing Fan (If Equipped) ......................................... 58
Quick Coupler Switch ................................................... 26 Hydraulic Oil Contamination -Test
Switches ....................................................................... 25 Flushing the Sampling Valve ...................................... 127
Thumb Slider ................................................................ 25 Hydraulic Oil Contamination ....................................... 127
Electrical Output Components Obtaining the Sample ................................................. 128
Relays........................................................................... 30 Hydraulic Oil Contamination -Test ................................... 127
Solenoids ...................................................................... 30 Hydraulic System Pressure -Release .............................. 118
Electrical Output Components ........................................... 29 Location of the Load Control Valve (Lock).................. 119
Electrical Schematic Relieving Pressure from the Load Control Valves
(Lock).......................................................................... 120
Programmable Hydraulic System (PHS) ...................... 36
Relieving Pressure in the Hydraulic System ............... 119
Electrical Schematic........................................................... 35
132 31200272
Index
Hydraulic System Pressures -Test and Adjust R

Test and Adjustment Procedures ............................... 123 Relief Valve (Implement) - Test and Adjust
Hydraulic System Pressures -Test and Adjust................. 123 Auxiliary Pressure Test (Port A and Port B) ............... 125
Hydraulic System Schematic ............................................. 85 Auxiliary Relief Valve Adjustments ............................. 127
I Relief Valve (Implement) - Test and Adjust...................... 125
Important Safety Information................................................. ii S

Introduction .......................................................................... 4 Systems Operation Section.................................................. 3
L T
Location of Hydraulic Components Table of Contents................................................................. 1
Boom Cylinder .............................................................. 20 Telescoping System
Compensating Cylinder ................................................ 22 Valve for the Telescoping Cylinder in the EXTEND
Compensator Valve ...................................................... 18 Position ......................................................................... 55
Diverter Valve ............................................................... 23 Valve for the Telescoping Cylinder in the HOLD
Frame Leveling Cylinder............................................... 22 Position ......................................................................... 53
Hydraulic Tank.............................................................. 17 Valve for the Telescoping Cylinder in the RETRACT
Position ......................................................................... 57
Inlet Manifold ................................................................ 18
Telescoping System ........................................................... 53
Load Control Valve (Boom Cylinder Lock).................... 21
Load Control Valve (Compensating Cylinder Lock)...... 22
Joystick Control - Calibrate........................................... 89
Load Control Valve (Telescoping Cylinder Lock).......... 21
Testing and Adjusting Section............................................ 89
Lock for Load Control Valve (Tilt Cylinder) ................... 22
Testing and Adjusting......................................................... 89
Lock Valve (Frame Leveling Cylinder).......................... 23
Trailer and Towing Hitch Hydraulic System
Main Control Valve Group (Implement) ........................ 18
Introduction ................................................................... 72
Outlet Manifold ............................................................. 19
Service Brakes ENGAGED........................................... 84
Piston Pump (Implement and Steering)........................ 17
Towing Hitch Cylinder LOWER..................................... 74
Quick Coupler Cylinder................................................. 23
Towing Hitch Cylinder RAISE ....................................... 76
Telescoping Cylinder .................................................... 21
Trailer DUMP ................................................................ 79
Tilt Cylinder................................................................... 21
Trailer LOWER ............................................................. 81
Trailer and Towing Hitch Hydraulic System (Option).... 19
Trailer and Towing Hitch Hydraulic System ....................... 72
Location of Hydraulic Components .................................... 17
M
Main Control Valve (Implement) - Calibrate ..................... 109
Manual Adjustment After Calibrating The Valves ....... 118
Programmable Hydraulic System (PHS)
Valve Calibrations....................................................... 109
Manifold Valve (Outlet)....................................................... 49
P
Pilot Hydraulic System ....................................................... 51
Pilot Pressure (Pressure Reducing Valve) - Test and Adjust
Pilot Pressure Test ..................................................... 123
Pressure Reducing Valve Adjustment ........................ 125
Pilot Pressure (Pressure Reducing Valve) -
Test and Adjust ................................................................ 123
Piston Pump (Implement and Steering)
Compensator Valve ...................................................... 38
Constant Flow............................................................... 41
Destroke ....................................................................... 42
High Pressure Stall ....................................................... 44
Low Pressure Standby.................................................. 39
Main Control Valve (Implement) ................................... 45
Manifold Valve (Inlet) .................................................... 47
Piston Pump ................................................................. 37
Upstroke ....................................................................... 40
Piston Pump (Implement and Steering) ............................. 37
31200273
December 15, 2006
Systems Operation
Testing and
Adjusting
TH580B Telehandlers Steering System

presented.
this publication.

and material.

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

(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,
(G) Blue.................................................................. Trapped oil
(H) Green ............................................ Tank, sump or return oil
(I) Brown ............................................................. Lubricating oil

(J) Orange Crosshatch ........................... Second reduction in
(K) Yellow............................ Moving or activated components
(M) Light Gray..................................................... Surface color
may not require all of the colors in Illustration 1.
4 31200273
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
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.
(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
Introduction

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
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
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
Front Position Sensor
(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
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
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.
Adjusting, "Position Sensor (Steering)" for more Solenoid for Circle Steer
information.
Electronic Control Module
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.
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.
Adjusting, "Electronic Control Module" for more
information.
Solenoid for Crab Steer
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.
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
Relay (Circle Steer)
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.
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
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
Metering Pump Line for the Signal Limiter Valve for

the Steering
Metering pump (2) is located at the front of the cab at
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.
Adjusting, "Metering Pump (Steering)" for more
information. Priority Valve
Piston Pump
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
Control Valve (Steering) Hydraulic Tank
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.
Adjusting, "Control Valve (Steering)" for more
information.
Steering Cylinders
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.
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
Hydraulic Oil Level Indicator Electrical Input Components
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.
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.
Hydraulic tank drain plug (11) is located on the bottom
of the hydraulic tank.
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.
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
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.
failure is diagnosed.
Inputs
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
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

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
necessary conditions are satisfied.
Electronic Control Module (ECM)
(2) The connector contacts that are not listed are not used.
connectors (J1 and J2). The ECM is located on the
14 31200273
Electrical Output Components Data Link
Relays
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
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.
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.
Inlet Manifold
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
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
Steering Not Activated
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
Steering Activated
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
(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.
location of the hydraulic components in the steering
system.
Adjusting, "Location of Electrical Components" for the
location of the electrical components in the steering
system.
operating information.
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
Steering in Neutral
(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
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
Right Turn in Two-Wheel Steer Mode
31200273 23
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
Left Turn in Circle Steer Mode
31200273 25
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 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
Left Turn in Crab Steer Mode
31200273 27
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 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
Hydraulic Schematic (Steering

System)
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

Steering)
Piston Pump
(1) Piston pump (8) Load Sensing Oil Pressure (15) Orifices
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.
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
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:
• 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
Low Pressure Standby
Steering and Implement Pump (Low pressure Standby)
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
Upstroke
Steering and Implement Pump (Upstroke)
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
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
Steering and Implement Pump (Constant Flow)
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.
Swashplate (6) is held at a relative constant angle in
• Margin spring (10) order to maintain the required flow.
The following pressure will act on the bottom end of
34 31200273
Destroke
Steering and Implement Pump (Destroke)
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:
• 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
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
High Pressure Stall
Steering and Implement Pump (Maximum System Pressure)
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
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.
location of the control valve.
"Steering Mode" for the operating information of the
steering modes.
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)
(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
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.
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
Hold
(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
Right Turn
(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
Left Turn
(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
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
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.
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.
(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
This is a summary screen
Reference: Refer to the appropriate service manual
for further instructions on configuring the ECM for your
machine.
44 31200273
31200273 45
1. Shift the transmission to NEUTRAL and engage

Testing and Adjusting the parking brake.
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.
"SOS Fluid Analysis" for further information about this
SOS oil analysis program.
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.
during performance of inspection, maintenance, testing, Obtaining the Sample
containing fluids.
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
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
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
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
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
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.
Method for determining flow loss
skin.
31200273 47
NOTICE
containing fluids.
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
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).
Table 10
A low pressure setting on the pressure compensator
x 100 = Percent of valve will also cause a low high pressure stall. The
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.
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
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).
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.
8. If the pressure is within the specification, stop the
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
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.
containing fluids.
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
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
Table 11 provides a list of required tools if pressure
gauges will be used to perform the following test
procedure.
Test Procedure

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
pressure setting.
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.
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).
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
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
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
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.
information.
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
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
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

injury.
Illustration 63 g01001360 relieved.
Relief valve (load sensing oil or signal oil)
NOTICE
containing fluids.
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
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.
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
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
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.
(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
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
injury.
relieved.
NOTICE
containing fluids.
mandates.
information.
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
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.

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.
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
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.
56 31200273

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.
(4) Position sensor
(5) Clamp
6. Slacken two clamps (5) that secure position sensor
(4).
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
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
Checking the Wheel Alignment With

Wheels In Place
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
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.
(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
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
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
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
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
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
31200274
December 15, 2006
Systems Operation
Testing and
Adjusting
TH580B Telehandlers Braking System

presented.
this publication.

and material.

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

(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,
(G) Blue.................................................................... Trapped oil
(H) Green............................................. Tank, sump or return oil
( I ) Brown ........................................................... Lubricating oil
(J) Orange Crosshatch ................. Second reduction in pilot,
(K) Light Gray...................................................... Surface color
(M) Light Gray ..................................................... Surface color
The information that is covered in this manual may not
require all of the colors in Illustration 1.
4 31200274
Introduction

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
General Information
(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
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
The stoplight switch is located in the operator's

compartment below steering wheel.
The stoplight switch causes the stop lights to
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
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
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
Parking brake lever
The parking brake lever is located to the left side of the

operator seat.
Service brake pedal
The service brake pedal is located to the left of the

accelerator control in operator's compartment.
8 31200274
Brake Cylinder Service Brake

Service Brake
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

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
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
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)
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
The Service Brake System with the

Brakes Disengaged
(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
The Service Brake System with the

Brakes Engaged
(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
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.
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
• 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
Disengaging the Parking Brake
Parking Brake Disengaged
(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
(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
Brake Cylinder with the Brakes

Disengaged
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
Brakes disengaged.
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
Brake Cylinder with the Brakes

Engaged
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
Brakes disengaged.
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
Hydraulic Schematic (Braking

System)
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
This is a summary screen.

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
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
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
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
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
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 implement lockout switch is enabled or an is not equal to "Complete".
• The machine is not placed into the neutral position active failure exists for the switch.
powerup.
• An active diagnostic code exists for the inputs on powerup.
the stabilizer control.
• An active diagnostic code exists for the solenoid extend solenoid.
that raises the stabilizer.
• An active diagnostic code exists for the solenoid retract solenoid.
on the stabilizer lower.
• 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.
the "French" market.
Boom Raise/Lower Is Disabled active failure exists for the switch.
The boom raise or the boom lower will be disabled
during the system powerup after system powerup.
• 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.

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
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
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 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
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.
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).
Brake cylinder
(1) Pushrod
(2) Locknut
1. Loosen locknut (2) on pushrod (1).

31200274 27
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
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
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.
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.)
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
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.
13. Repeat Step 8 through Step 11.
mandates. 14. Repeat the purging procedure if the brakes
appear soft.
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
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
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
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.
Adjusting, "Location of Components (Braking)" for the
location of the parking brake control lever and the
brake caliper.
31200274 31
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.
(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.
(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
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
Graphic Color Codes............................................................ 3
Graphic Color Codes............................................................ 3 T
H Table of Contents................................................................. 1
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
31200276
December 15, 2006
Specifications
TH220B & TH330B Telehandlers Machine

Systems

presented.
this publication.

and material.

injury or death.
31200276 1
Table of Contents
Table of
Table of Contents 271 -6424 Drive and Steering
Specifications Section Axle Gp .............................................. 38
Hydraulic Tank......................................... 3 Drive and Steering Axle (Rear) .............. 40
Piston Pump (Implement and Steering)... 4 168-7441 Drive and Steering Axle Gp40
Solenoid Valve (Pilot Selector) ................ 5 Differential and Bevel Gear Group ......... 41
Frame ...................................................... 8 Axle Housing and Flange Group ............ 42
Boom ....................................................... 9 Axle Housing and Flange Group ............ 42
Boom Cylinder ....................................... 10 Final Drive Planetary Group................... 43
Boom Cylinder ....................................... 11 Axle Housing Group (Differential and Brake
Boom Cylinder ....................................... 12 Cylinder)................................................. 44
Load Control Valve (Boom Cylinder) 238-5225 Axle Housing Gp with a
(Lock)..................................................... 13 Locking Differential ............................ 44
Compensating Cylinder ......................... 14 231 -0737 Axle Housing Gp without a
Compensating Cylinder ......................... 15 Locking Differential ............................ 45
Telescoping Cylinder ............................. 16 Brake Cylinder (Master) ......................... 47
Telescoping Cylinder ............................. 17 Parking Brake Control ............................ 48
Load Control Valve (Telescoping Cylinder) Parking Brake ........................................ 49
(Lock)..................................................... 18 Fender.................................................... 49
Tilt Cylinder............................................ 19 Wheel (Tire and Rim) ............................. 50
Tilt Cylinder............................................ 20 Fuel Tank (Auxiliary) .............................. 51
Load Control Valve (Tilt Cylinder) (Lock)21 Fuel Tank ............................................... 52
Diverter Valve ........................................ 21 Engine Enclosure ................................... 53
Diverter Valve ........................................ 22 Engine and Transmission Mounting....... 55
Towing Hitch .......................................... 23 Air Cleaner ............................................. 56
Towing Hitch .......................................... 23 Engine Oil Drain ..................................... 58
Towing Hitch .......................................... 23 Muffler .................................................... 59
Towing Hitch .......................................... 23 Suction Fan ............................................ 60
Towing Hitch .......................................... 24 Battery.................................................... 61
Towing Hitch .......................................... 24 Coolant Lines Group .............................. 62
Piston Pump (Hydraulic Fan)................. 25 Coolant Recovery Group ....................... 63
Piston Pump Gp ................................ 25 Cab ........................................................ 64
Relief Valve ....................................... 25 Latch Adjustment ............................... 65
Elbow................................................. 25 Cab Mounting......................................... 66
Solenoid Valve Gp............................. 25 Cab Door................................................ 67
Fan Drive Mounting Group .................... 26 Access Door........................................... 69
Metering Pump (Steering) ..................... 27 Joystick Control...................................... 70
Solenoid Valve (Steering Mode Steering Wheel and Column .................. 71
Selector) ................................................ 27 Window Wiper and Wiper Motor ............ 72
Position Sensor (Steering)..................... 27 Window Washer Tank ............................ 73
Flexible Coupling Drive.......................... 28 Rear View Mirror .................................... 74
Transmission ......................................... 29 Work Tool Linkage ................................. 74
Transmission ......................................... 31 Carriage Cylinder (Rotate) ..................... 75
Position Sensor (Transmission)............. 32 Carriage Cylinder (Sideshift) .................. 75
Oil Filter ................................................. 33 Hydraulic Cylinder (Multipurpose
Hydraulic Oil Cooler............................... 35 Bucket) ................................................... 76
Drive Shaft............................................. 36 Grapple Cylinder .................................... 77
Drive Shaft............................................. 36
Drive and Steering Axle (Front) ............. 37
168-7440 Drive and Steering Axle Gp37
2 31200276
Table of Contents
31200276 3
Hydraulic Tank
(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 ± 4 lb ft)
4 31200276

Steering)
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......... 45cc/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
31200276 5
Solenoid Valve (Pilot Selector)
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)
6 31200276
31200276 7
(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 N-m (15 ± 1 lb ft)
(7) Torque for the valve ............. 55 ± 5 N-m (40 ± 5 lb ft)
(8) Torque for four nuts ........................ 35 N-m (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 N-m
(33.2 ± 3.3 lb ft)
(11) Torque for valve cap .........20 ± 2 N-m (15 ± 1 lb ft)
(12) Drain Port
(13) Torque for eight bolts......... 3 ±0.3 N-m (27 ±3 lb in)
(14) Torque for eight bolts......... 3 ±0.5 N-m (27 ±4 lb in)
(15) Torque for the valves .................. 20 N-m (15 lb ft)
(16) Torque for the valves ................. 60 N-m (44 lb ft)
8 31200276
Frame
(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).
31200276 9
Boom
(2) Torque for the four bolts ....... 75 ± 5 Nm (55 ± 4 lb ft)

(3) Torque for the two bolts ................ 75 Nm (55 lb ft)
(4) Torque for the four bolts ....100 ±5 Nm (74 ± 4 lb ft)
10 31200276
Boom Cylinder
TH220B
Part No.: 278-2112
Cylinder stroke .............................. 1042 mm (41.0 inch)

(1) Torque setting for self-locking
nut ................................ 2700 ± 50 Nm (1990 ± 37 lb ft)
Lubricate the threads of the self-locking nut with clean
grease.
(2A) Diameter of piston .................... 107.45 ± 0.03 mm
(4.230 ± 0.001 inch)
(2B) Bore of piston ........................ 44.465 ± 0.025 mm
(1.7506 ±0.0010 inch)
(3) Bore of cylinder............................ 107.95 ± 0.08 mm
(4.250 ± 0.003 inch)
(4) Diameter of piston rod .............. 79.950 ± 0.038 mm
(3.1476 ±0.0015 inch)
(5) Bore of head ................................. 80.33 ± 0.03 mm
(3.163 ±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 of the seals with clean lubricant that
is being sealed.
(8) 216-5860 Sleeve Bearing
Diameter ........................................ 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore ............................................... 60.315 ±0.025 mm
(2.3746 ±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.
31200276 11
Boom Cylinder
TH220B
Part No.: 253-1681
Cylinder stroke.............................. 1042 mm (41.0 inch)

nut .............................. 3000 ± 100 Nm (2213 ± 74 lb ft)
grease.
(2A) Diameter of piston ..................... 99.55 ± 0.03 mm
(3.919 ±0.001 inch)
(1.7506 ±0.0010 inch)
(3) Bore of cylinder................................. 100 ±0.08 mm
(3.937 ± 0.003 inch)
2.7539 ±0.0015 inch)
(5) Bore of head ................................. 70.33 ± 0.03 mm
(2.7689 ±0.0012 inch)
(6) Torque setting for the head................600 ± 130 Nm
(440 ± 95 lb ft)
assembly.
is being sealed.
Diameter........................................ 73.165 ± 0.025 mm
2.8805 ±0.0010 inch)
Bore ............................................... 60.315 ±0.025 mm
(2.3746 ±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)
Mount Compound.
12 31200276
Boom Cylinder
TH330B
Part No.: 253-2574
Cylinder stroke .............................. 1336 mm (52.6 inch)

nut ................................ 2700 ± 50 Nm (1990 ± 37 lb ft)
grease.
(2A) Diameter of piston .................... 107.45 ± 0.03 mm
(4.230 ± 0.001 inch)
(1.7506 ±0.0010 inch)
(3).............................Bore of cylinder 107.95 ± 0.08 mm
(4.250 ± 0.003 inch)
(4) ................. Diameter of piston rod 79.95 ± 0.038 mm
(3.1476 ±0.0015 inch)
(5).................................... Bore of head 80.33 ± 0.03 mm
(3.163 ±0.001 inch)
(6) ................. Torque setting for the head600 ± 130 Nm
(440 ± 95 lb ft)
assembly.
is being sealed.
Diameter ........................................ 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore ............................................... 60.315 ±0.025 mm
(2.3746 ±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)
Mount Compound.
31200276 13
Load Control Valve (Boom

Cylinder) (Lock)
(1) Damper screw
The recommended torque for the mounting bolts is 23 ±
1 Nm (204 ± 9 lb in).
Typical example of a Load Control Valve (Boom Cylinder)
(1) Damper screw

The recommended torque for the mounting bolts is 23 ±
1 Nm (204 ± 9 lb in).
14 31200276
TH220B
Cylinder stroke .................................697 mm (27.5 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 .......................63.00 ± 0.03 mm
(2.480 ± 0.001 inch)
(2B) Bore of piston ............................26 mm (1.02 inch)
(3) Bore of cylinder............................... 63.5 ± 0.08 mm
(2.500 ± 0.003 inch)
(1.7697 ±0.0015 inch)
(5) Bore of head ................................. 45.33 ± 0.03 mm
(1.7846 ±0.0012 inch)
(440 ± 95 lb ft)
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)
Mount Compound.
(9216-2774 Sleeve Bearing
Diameter .... 50.095 ± 0.025 mm (1.9722 ±0.0010 inch)
Bore ........... 40.195 ±0.025 mm (1.5825 ±0.0010 inch)
31200276 15
TH330B
Cylinder stroke............................... 769 mm (30.3 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 ..................... 64.55 ± 0.03 mm
(2.541 ± 0.001 inch)
(2B) Bore of piston .........................26.0 mm (1.02 inch)
(3) Bore of cylinder............................. 65.00 ± 0.08 mm
(2.559 ± 0.003 inch)
(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)
assembly.
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)
Mount Compound.
(9)216-2774 Sleeve Bearing
Diameter.... 50.095 ± 0.025 mm (1.9722 ±0.0010 inch)
Bore ........... 40.195 ±0.025 mm (1.5825 ±0.0010 inch)
16 31200276
TH220B
Cylinder stroke ...............................2150 mm (84.7 inch)

(1) Diameter of piston ......................69 mm (2.72 inch)
Torque setting for piston (1) ................. 1000 ± 100 Nm
(735 ± 75 lb ft)
Lubricate the threads of the piston with clean grease.
(3) Bore of cylinder ............................. 70 mm (2.8 inch)
(4) Diameter of piston rod ................ 50 mm (1.97 inch)
(5) Bore of head .................................. 51 mm (2.0 inch)
(6) Torque setting for the head............... 600 ± 130 Nm
(440 ± 95 lb ft)
Apply sealant to the wiper seal groove (7) prior to
assembly.
being sealed.
31200276 17
TH330B
Cylinder stroke .............................2575 mm (101.4 inch)

(1) Diameter of piston ........................ 69 mm (2.7 inch)
Torque setting for piston (1) ................. 1000 ± 100 Nm
(735 ± 75 lb ft)
Lubricate the threads of the piston with clean grease.
(3) Bore of cylinder ............................. 70 mm (2.8 inch)
(4) Diameter of piston rod ................ 50 mm (1.97 inch)
(5) Bore of head.................................. 51 mm (2.0 inch)
(6) Torque setting for the head ...............600 ± 130 Nm
(440 ± 95 lb ft)
Apply sealant to the wiper seal groove (7) prior to
assembly.
being sealed.
18 31200276
Load Control Valve

(Telescoping Cylinder) (Lock)
(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)
31200276 19
Tilt Cylinder
TH220B
Cylinder stroke............................... 329 mm (13.0 inch)

(1) Torque setting for nut .....................6500 ± 100 Nm
(4800 ± 75 lb ft)
Lubricate the threads of the nut with clean grease.
(2A) Diameter of piston.......................119.50 ± 0.03 mm
(4.705 ± 0.001 inch)
(2.2505 ±0.0010 inch)
(4.724 ± 0.003 inch)
(4) Diameter of piston rod ................ 84.95 ± 0.038 mm
(3.3445 ±0.0015 inch)
(5) Bore of head ................................. 85.33 ± 0.03 mm
(3.359 ± 0.001 inch)
(6) Torque setting for the head ...............600 ± 100 Nm
(445 ± 75 lb ft)
assembly.
being sealed.
Diameter.... 73.165 ± 0.025 mm (2.8805 ±0.0010 inch)
Bore ........... 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)
Mount Compound.
20 31200276
Tilt Cylinder
TH330B
Cylinder stroke ............................... 329 mm (13.0 inch)

(1) Torque setting for nut ..................... 6500 ± 100 Nm
(4800 ± 75 lb ft)
(2A) Diameter of piston ...................... 129.5±0.03mm
(5.0984 ±0.0012 inch)
(2.2505 ±0.0010 inch)
(5.118 ±0.003 inch)
(3.5413 ±0.0015 inch)
(5) Bore of head ................................. 90.33 ± 0.03 mm
(3.556 ± 0.001 inch)
(445 ± 75 lb ft)
assembly.
being sealed.
(8)216-6855 Sleeve Bearing
Diameter .... 73.165 ± 0.025 mm (2.8805 ±0.0010 inch)
Bore ........... 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)
Mount Compound.
31200276 21
Load Control Valve (Tilt

Cylinder) (Lock)
Dual diverter valve
Technical data
Maximum operating pressure....... 21000 kPa (3045 psi)
Maximum flow ..............................90 L/min (25 US gpm)
(1) Installation torque ........... 150 ± 8 Nm (110 ±6 lb ft)
(1) Torque for fastener ...............8 ± 1 Nm (70 ± 9 lb in)
Set pressure .................................33000 kPa (4800 psi)
(2) Torque for cartridge ............ 26 ± 1 Nm (20 ±1 lb ft)
Pilot ratio..............................................................................4.2:1
(3) Torque for mounting bolts.... 14 ± 1 Nm (10 ± 1 lb ft)
Diverter Valve
Single diverter valve
22 31200276
Diverter Valve
Conversion kit for the diverter valve
(1) 226-6494 Diverter valve
(2) 179-1867 Diverter valve
(3) Components from original assembly
(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)
31200276 23
Towing Hitch Towing Hitch

Part No.: 211-8360 Part No.: 211-8358
(1) Torque for Six Nuts ..... 530 ± 70 Nm (390 ± 50 lb ft) (1) 200-2142 Hitch Group
(2) Torque for Six Nuts ....... 530±70N-m (390 ± 50 lb ft)
Towing Hitch Towing Hitch

Part No.: 211-8359 Part No.: 211-8357
(1) 200-2141 Hitch Gp (1) 200-2142 Hitch Group

(2) Torque for Six Nuts...... 53 0±70Nm (390 ± 50 lb ft) (2) Torque for Six Nuts ...... 5 30±70Nm (390 ± 50 lb ft)
24 31200276
Towing Hitch
Part No.: 211-2381
(1) Torque for Two Nuts530±70N-m (390 ± 50 lb ft)
Towing Hitch
Part No.: 211-9381
(1) Torque for Six Nuts530±70N-m (390 ± 50 lb ft)

31200276 25
Piston Pump (Hydraulic Fan)
Pump and Mounting Gp
Piston Pump Gp Solenoid Valve Gp

(1) Hydraulic piston pump (5) Solenoid valve
Shaft rotation ....................................................clockwise (6) Torque for the nut ........................... 7 Nm (62 lb in)
Pump displacement for one (7) Torque for the solenoid ................... 34 Nm (25 lb ft)
revolution ............................................ 11.23 cc (0.685 in3)
Maximum continuous pump
pressure
TH220B..........................................26500 kPa (3843 psi)
TH330B..........................................25000 kPa (3600 psi)
Maximum peak pressure .............30000 kPa (4350 psi)
(2) Torque for the five bolts........ 15 ± 3 Nm (11 ±2 lb ft)
Relief Valve
(3) Torque for the relief valve ............... 27 Nm (20 lb ft)
Elbow
(4) Torque for the four bolts......... 6 ± 1 Nm (53 ± 9 lb in)
26 31200276
Fan Drive Mounting Group
(1) Piston pump (Hydraulic Fan)

Shaft rotation ............................................... bidirectional
Pump displacement for one
revolution .............................................11.23 cc (0.685 in3)
Maximum continuous pump
pressure ..........................................15000 kPa (2175 psi)
Maximum peak pump
pressure .......................................20000 kPa (2900 psi)
(2) Torque for three bolts . . . . . . . 1 5 ±3 N m ( 11 ± 2 lb ft)
31200276 27
Metering Pump (Steering) Solenoid Valve (Steering Mode

Selector)
Capacity per revolution ...................... 250 cc (15.26 in3)
Torque for the fastener............... 4 ± 1 Nm (35 ± 9 lb in)
Current at 12 VDC .....................................................1.56A
(2) Resistance at 20 °C (68 °F) .................................7.7Q
Maximum pressure ......................32000 kPa (4640 psi)
Position Sensor (Steering)
(1) Adjustment for the Relief pressure of the Steering

Pressure
The switch is a magnetic position sensor.

28 31200276
Table 1
Pin Circuit Color

A (+) Bat Brown
B (-) Bat Blue
C Signal Black
Specifications for the position sensor

Maximum operating range of
the sensor .......................................... 7 mm (0.28 inch)
Nominal current draw .......................................... 800 mA
Length of the cable ............................250 mm (9.8 inch)
Flexible Coupling Drive
(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.
31200276 29
Transmission
Part No.: 216-2272, 268-9320
(1) 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....13 ± 1.5 Nm (110 ± 13 lb in)
(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 6 bolts ........25 ± 6.5 Nm (18 ± 5 lb ft)
(10) Torque for the bolt........... 24 ± 3.5 Nm (17 ± 3 lb ft)
(11) Torque for the 2 bolts .......25 ±6 Nm (19 ± 4 lb ft)
30 31200276
(12) Torque for the bolts ........ 55 ± 9.5 Nm (40 ± 7 lb ft) (26) Torque for the bolt...........25 ± 6.5 Nm (18 ± 5 lb ft)
(13) Torque for the 3 bolts. . . .. . 25 ±6 . 5Nm (18 ±5 lb ft) (27) Torque for the bolt............25± 6.5 Nm (18 ± 5 lb ft)
(14) Torque for the 2 bolts . . . . 2 5 ±6 . 5 N m (18 ± 5 lb ft)
(15) Torque for the sensor . . . . . . 4 7 ±7 N m ( 3 5 ±5 l b f t )
(16) Torque for the bolts. . . . . . . 2 5 ±6 . 5 N m ( 1 8 ±5 l b ft )
(17) Torque for the cap. . . . . . . . 2 5 ±6 . 5 N m ( 1 8 ±5 l b ft )
(18) Torque for the bolt............55 ± 9.5 Nm (40 ± 7 lb ft)
(19) Torque for the 2 bolts ....... 78±10N-m(58±7lbft)
(20) Torque for the plug ........ 24 ± 3.5 Nm (17 ± 3 lb ft)
(21) Torque for the bolts .......... 5 ± 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 3 modulating
valves .........................................50 ± 5 Nm (37 ± 4 lb ft)
31200276 31
Transmission
Part No.: 268-9319
(1) Torque for the plug............ 24 ± 3.5 Nm (17 ± 3 lb ft) (13) Torque for the 3 bolts ..... 25 ± 6.5 Nm (18 ± 5 lb ft)
(2) Torque for the 2 bolts ........25 ± 6.5 Nm (18 ± 5 lb ft) (14) 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) (15) Torque for the sensor ....... 47 ±7 Nm (35 ± 5 lb ft)
(4) Torque for the plugs ..........24 ± 3.5 Nm (17 ± 3 lb ft) (16) Torque for the 3 bolts ..... 25 ± 6.5 Nm (18 ±5 lb ft)
(5) Torque for the torque converter inlet relief (17) Torque for the 2 bolts...... 25 ± 6.5 Nm (18 ±5 lb ft)
valve ..................................... 27 ± 3.5 Nm (20 ± 3 lb ft) (18) Torque for the bolt...........55 ± 9.5 Nm (40 ± 7 lb ft)
(6) Torque for the pressure (19) Torque for the 2 bolts .......78 ± 10 Nm (58 ±7 lb ft)
regulator................................ 55 ± 9.5 Nm (40 ± 7 lb ft)
(20) Torque for the plug .........24 ± 3.5 Nm (17 ± 3 lb ft)
(7) Torque for the sensor .......... 47 ± 7 Nm (35 ± 5 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)
(10) Torque for the 6 bolts...... 55 ± 9.5 Nm (40 ± 7 lb ft)
(24) Torque for the bolts ............ 9± 1.5 N-m (6 ± 1 lb ft)
(11) Torque for the 2 bolts ....... 25 ±6 Nm (19 ±4 lb ft)
(25) Torque for the 3 modulating
(12) Torque for the bolts .........55 ± 9.5 Nm (40 ± 7 lb ft) valves .......................................50 ± 5 Nm (37 ± 4 lb ft)
32 31200276
(26) Torque for the two nuts.... 78 ± 10 Nm (58 ± 7 lb ft)
Position Sensor (Transmission)
The position sensor is a pulse width modulated sensor Nominal current draw ........................... 7 mA at 8 VDC
(PWM).
Table 2
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
31200276 33
Oil Filter
(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)
34 31200276
(3) Torque for the bolts30 ± 7 Nm (22 ± 5 lb ft)

31200276 35
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)
36 31200276
Drive Shaft Drive Shaft

TH220B TH330B
(1) Replacement 117-9887 Spider and Bearing Kit (1) Replacement 117-9887 Spider and Bearing Kit
(A) Rear drive shaft 216-4177 Shaft (A) Front drive shaft 216-4175 Shaft
As ................................. 968 ± 36 mm (38.1 ±1.4 inch) As ................................. 866 ± 36 mm (34.1 ± 1.4 inch)
(A) Front drive shaft 216-4174 Shaft (A) Rear drive shaft 216-4178 Shaft
As ................................. 815 ±36 mm (32.1 ±1.4 inch) As ............................... 1018 ±36 mm (40.1 ±1.4 inch)
31200276 37
Drive and Steering Axle (Front)

168-7440 Drive and Steering Axle
Gp
(1) Torque for 8 bolts ........................ 300 Nm (220 lb ft) (5) Torque for the plug.......................... 50 Nm (35 lb ft)
(2) Torque of the locknut for the steering (5A) Torque for the plug (not shown) .. 50 Nm (35 lb ft)
stop ............................................... 150 Nm (110 lbft) (6) Torque for tie rod nut ................. 280 Nm (205 lb ft)
(2A) Torque of the locknut for the steering (7) Torque for four kingpin bolts ........250 Nm (184 lb ft)
stop....................................................150 Nm (110 lb ft) (8) Torque for locknut....................... 250 Nm (184 lb ft)
(3) Torque for three bolts .................. 190 Nm (140 lb ft) (9) Torque for the ball joint................ 300 Nm (221 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to (10) Torque for breather....................... 10 Nm (90 lb in)
installing the bolts. Install the breather so that the slot in the breather is
(4) Torque of the purging screw for the parallel with the axle half shaft.
brake................................................ 12 Nm (106 lb in) (11) Torque for 26 axle housing bolts . 190 Nm (140 lb ft)
(4A) Torque of the purging screw for the Note: Apply Loctite 270 sealant to the threads prior to
brake................................................ 12 Nm (106 lb in) installing the bolts.
38 31200276
(12) Torque for two bolts ...................... 60 Nm (44 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) 174-4641 Plate
Thickness of
plate.................... 5.00 ± 0.05 mm (0.197 ±0.002 inch)
(17) 217-2895 Brake Disc
Thickness of
disc....................... 4.80 ± 0.05 mm (0.189 ±0.002 inch)
Minimum allowable thickness
of disc ......................................... 3.95 mm (0.156 inch)
271 -6424 Drive and Steering Axle

Gp
(1) Torque for 8 bolts ........................ 300 Nm (220 lb ft) (2) Torque of the locknut for the
steering stop .................................. 150 Nm (110 lbft)
31200276 39
(2A) Torque of the locknut for the steering stop (not

shown) ...............................................150 Nm (110 lb ft)
(3) 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.
(4) Torque for three bolts .................. 190 Nm (140 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 .................................................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 ................. 250 Nm (185 lb ft)
(8) Torque for four kingpin bolts.........300 Nm (220 lb ft)
(9) Torque for locknut ....................... 250 Nm (185 lb ft)
(10) Torque for the ball joint ............. 300 Nm (220 lb ft)
(11) Torque for the thirteen axle housing bolts on
each side ......................................... 190 Nm (140 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 the 30 mm (1.18 inch) plug (not
shown) ................................................. 60 Nm (45 lb ft)
assembly) ........................................... 25 Nm (20 lb ft)
assembly) ........................................... 60 Nm (45 lb ft)
(16) 174-4641 Plate
Thickness of
plate.................... 5.00 ± 0.05 mm (0.197 ±0.002 inch)
(17) 217-2895 Brake Disc
Thickness of disc. 4.80 ± 0.05 mm (0.189 ±0.002 inch)
Minimum allowable thickness
of disc ........................................ 3.95 mm (0.156 inch)
40 31200276
Drive and Steering Axle (Rear)

168-7441 Drive and Steering Axle
Gp
(1) Torque for the 8 bolts .................. 300 Nm (220 lb ft) (11) Torque for plug (each carrier
(2) Torque of the locknut for the steering assembly) .......................................... 25 Nm (20 lb ft)
stop ...............................................150 Nm (110 lb ft) (12) Torque for plug (each carrier
Note: Apply Loctite 270 sealant to the threads. assembly) ........................................... 60 Nm (45 lbft)
(3) 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.
(4) Torque for three bolts .................. 190 Nm (140 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(5) Torque for tie rod nut ................. 250 Nm (184 lbft)
(6) Torque for four kingpin bolts.........300 Nm (220 lb ft)
(7) Torque for locknut ....................... 250 Nm (184 lb ft)
(8) Torque for the ball joint .............. 300 Nm (221 lb ft)
(9) Torque for the plug.......................... 60 Nm (45 lb ft)
(10) Torque for ten axle housing
bolts ............................................. 169 Nm (125 lb ft)
31200276 41
Differential and Bevel Gear

Group
(1) Backlash .. 0.18 to 0.32 mm (0.0071 to 0.0126 inch) Note: Apply Loctite 638 4C-9507 Retaining
(2) Torque for four bolts.................... 266 Nm (196 lb ft) Compound to the mounting surface of the bevel gear.
(3) Before assembly, apply anti-seize compound to Note: Apply Loctite 271 155-0695 Thread Lock
the seal. Compound to the bolts (6).
(4) Shims for the pinion (7) Torque the screw for the bearing..... 13 Nm (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 ............ 105 Nm (78 lb ft)
42 31200276
Axle Housing and Flange Group

Part No.: 174-4310
(1) Torque for spanner nut ............ 1000 Nm (740 lb ft)

(2) Torque for the three lock bolts ........ 70 Nm (52 lb ft)
Axle Housing and Flange Group

Part No.: 231-0741
(1) Torque for the spanner nut.........1000 Nm (740 lb ft)

(2) Torque for the 3 lock bolts ............. 70 Nm (52 lb ft)
31200276 43
Final Drive Planetary Group
(1) Assemble the three bearings so that the radius is

facing in the direction of the arrow.
44 31200276
Axle Housing Group

(Differential and Brake
Cylinder)
238-5225 Axle Housing Gp with a
Locking Differential
(1) Bearing nut (4) Fork

(2) Brake cylinder assembly (5) Torque for the ring gear bolts.........105 Nm (75 lb ft)
(3) Apply Loctite 638 4C-9507 Retaining Compound Note: Apply Loctite 271 155-0695 Thread Lock
to the dowel pin. Each brake cylinder assembly Compound to the bolts.
contains two dowel pins.
31200276 45
(6) Gear backlash ........................ 0.18 mm to 0.32 mm

(0.007 inch to 0.013 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)
231 -0737 Axle Housing Gp without a

Locking Differential
(1) Bearing nut (2) Brake cylinder assembly

46 31200276
(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 ...... 105 Nm (75 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock
Compound to the bolts.
(5) Gear backlash ........................ 0.18 mm to 0.32 mm
(0.007 inch to 0.013 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)
31200276 47
(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.
48 31200276
Parking Brake Control
(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)
31200276 49
Parking Brake
Adjust mounting bolt (4) and jam nut (2) in order to Fender
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)
(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.
50 31200276
Wheel (Tire and Rim)
Clean the hardware and dry the hardware. Apply one

drop of lubrication oil to the threads.
(1) Torque of the 40 nuts .. 4 6 0±6 0 Nm (339 ± 44 lb ft)
31200276 51
Fuel Tank (Auxiliary)
(1) Torque of plug ....................... 9 ± 1 Nm (80 ± 9 lb in)

(2) Length of hose............ 780 ± 5 mm (30.7 ± 0.2 inch)
(3) Length of hose ............. 210 ±5 mm (8.3 ±0.2 inch)
(4) Torque for the fittings ............ 9 ± 1 Nm (80 ± 9 lb in)
52 31200276
Fuel Tank
(1) Torque for the six

bolts .............................. 2.25 ± 0.25 Nm (20 ± 2 lb in)
(2) Torque for the two plugs......... 9 ± 1 Nm (80 ± 9 lb in)
31200276 53
Engine Enclosure
(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.
54 31200276
(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.
31200276 55
Engine and Transmission

Mounting
(1) Torque for the two bolts2 2 0 ± 2 0 N m (162 ± 15 lb ft)

(2) Torque for the bolt .......775 ± 20 Nm (572 ± 15 lb ft)
56 31200276
Air Cleaner
(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)
31200276 57
(3) Torque for the clamp ............ 5 ± 1 Nm (44 ± 9 lb in)
(4) Torque for the bracket ..................... 2 Nm (1.5 lb ft)

58 31200276
Engine Oil Drain
(1) Torque for shutoff valve........40 ±5 Nm (30 ±4 lb ft)

(2) Length of hose.............. 130 ± 5 mm (5.1 ± 0.2 inch)
31200276 59
Muffler
(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 107 in order to position the
clamp.
60 31200276
Suction Fan
(1) Torque for the three

bolts ................................ 10 ±2 Nm (7.5 ± 1.5 lb ft)
31200276 61
Battery
(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 ................................ 23 ± 4 Nm (17 ±3 lb ft)
(6) Torque for the two nuts 6 . 8 ±1 . 4 N m (60 ± 12 lb in)
62 31200276
Coolant Lines Group
(1) Torque for the bolt................ 30 ± 7 Nm (22 ± 5 lb ft)

(2) Length of trim.................200 ± 5 mm (7.9 ± 0.2 inch)
31200276 63
Coolant Recovery Group
(1) Torque for the two bolts . 1 0 ± 2 N m (89 ± 18 lb in)

(2) Torque for the four bolts...10 ±2 Nm (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 .............. 1000 kPa (145 psi)
Working temperature of tank .................. 110 °C (230 °F)
64 31200276

(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 113.
Cab
(1) Use a urethane adhesive for bonding the glass. (2) Tighten the knob hand tight.
Note: Equally space rubber spacers in order to Note: Apply 4C-4030 Thread Lock Compound.
maintain the 5 adhesive gap for bonding.
31200276 65
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).
4. Adjust the position of the clevis on the rod end
so that the release lever is perpendicular to the
B post.
66 31200276
Cab Mounting
(1) Torque for the 4 bolts ................. 450 Nm (332 lb ft)

31200276 67
Cab Door
(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 ............. 836 ± 5 mm (32.9 ± 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.
68 31200276
(6) Torque for the nut ............. 4 ± 1 Nm (35 ± 9 lb in)

Note: Use a urethane adhesive for bonding the glass.
31200276 69
Access Door
(1) Torque for the 4 nuts ............ 6 ± 1 Nm (53 ± 9 lb in)

(2) Torque for the 4 nuts. . . . . . . . . 1 5 ±3 N m ( 11 ± 2 lb ft)
70 31200276
Joystick Control
(1) Torque for the

screws ..................1.92 ± 0.20 Nm (17.00 ± 1.78 lb in)
31200276 71
Steering Wheel and Column
(1) Torque for the nut ............. 48 ±5 N-m (35 ±4 lb ft)

(2) Torque for the nut and the
bolt .................................. 22.5 ±2.5 N-m (17 ±2 lb ft)
72 31200276
Window Wiper and Wiper Motor
(1) Torque for the nut ...... 23 ± 1 N m ( 1 7 ± 1 lb ft) (6) Length of hose ......... 2351 ± 5 mm (92.6 ± 0.2 inch)
(2) Torque for the nut of the
wiper motor . . . . . . . . . . . . . . . 9 ± 1 Nm (80 ± 9 lb in)
(3) Torque for the nut .7.5 ± 0.5 Nm (62 ±4.4 lb in)
(4) Length of hose.............. 163 ± 3 mm (6.4 ± 0.1 inch)
(5) Length of hose .............. 112 ±3 mm (4.4 ±0.1 inch)
31200276 73
Window Washer Tank
(1) Torque for the fitting ............. 8 ± 1 Nm (71 ± 9 lb in)

74 31200276
Rear View Mirror
(1) Torque for the two bolts....... 28 ± 7 Nm (20 ± 5 lb ft)
Work Tool Linkage
(1) Torque for the bolt...............75 ± 5 Nm (55 ± 4 lb ft) Apply 4C-4030 Thread Lock Compound to all threads.
31200276 75
Carriage Cylinder (Rotate)
Length of the stroke.......................... 123 mm (4.8 inch) (2) Bore of the cylinder....................... 80 mm (3.2 inch)
(1) Diameter of the rod ........................ 45 mm (1.8 inch)
Carriage Cylinder (Sideshift)
Cylinder stroke .................................. 300 mm (11.8 inch) (6) Torque setting for the
(1) Torque setting for head ............................. 600 ± 130 Nm (440 ± 95 lb ft)
bolt .................................. 850 ± 25 Nm (625 ± 20 lb ft) Lubricate the threads of the head with clean grease.
Lubricate the threads of the bolt with clean grease. Apply sealant to wiper seal groove (7) prior to
(2A) Diameter of assembly.
piston............. 75.69 ± 0.03 mm (2.9799 ±0.0012 inch) Note: Lubricate all seals with clean lubricant that is
(2B) Bore of piston .................... 26.97 mm (1.062 inch) being sealed.
(3) Bore of cylinder .................... 76.20 mm (3.000 inch) (8) 9T-4007 Bearing
(4) Diameter of piston rod......... 38.05 mm (1.4980 inch) Diameter ...... 36.088 ±0.013 mm (1.4208 ±0.0005 inch)
Bore...............30.153 ±0.013 mm (1.1871 ±0.0005 inch)
(5) Bore of head.. 38.38 ± 0.03 mm (1.511 ±0.001 inch)
76 31200276
Hydraulic Cylinder
(Multipurpose Bucket)
Cylinder stroke ...............................260 mm (10.24 inch)

(1) Torque setting for bolt . 850 ± 25 Nm (625 ± 20 lb ft)
(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)
assembly.
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)
31200276 77
Grapple Cylinder
(A) Open ...................................... 710 mm (28.0 inch)

(A) Closed ...................................... 490 mm (19.3 inch)
(B) Diameter ....................................... 85 mm (3.4 inch)
78 31200276
31200276 79
Index Index
A H
Access Door....................................................................... 69 Hydraulic Cylinder (Multipurpose Bucket) .......................... 76
Air Cleaner ......................................................................... 56 Hydraulic Oil Cooler ........................................................... 35
Axle Housing and Flange Group ........................................ 42 Hydraulic Tank ..................................................................... 3
Axle Housing Group (Differential and Brake Cylinder)
I
231 -0737 Axle Housing Gp without a Locking
Differential..................................................................... 45 Important Safety Information.................................................ii
238-5225 Axle Housing Gp with a Locking
Differential..................................................................... 44 J
Axle Housing Group (Differential and Brake Cylinder)....... 44 Joystick Control.................................................................. 70
B L
Battery................................................................................ 61 Load Control Valve (Boom Cylinder) (Lock)....................... 13
Boom Cylinder........................................................ 10, 11, 12 Load Control Valve (Telescoping Cylinder) (Lock)............. 18
Boom.................................................................................... 9 Load Control Valve (Tilt Cylinder) (Lock) ........................... 21
Brake Cylinder (Master) ..................................................... 47
M
C Main Control Valve (Implement)........................................... 6
Cab Metering Pump (Steering) .................................................. 27
Latch Adjustment .......................................................... 65 Muffler ................................................................................ 59
Cab Door............................................................................ 67
O
Cab Mounting..................................................................... 66
Cab..................................................................................... 64 Oil Filter .............................................................................. 33
Carriage Cylinder (Rotate) ................................................. 75 P
Carriage Cylinder (Sideshift) .............................................. 75
Parking Brake Control ........................................................ 48
Compensating Cylinder................................................ 14, 15
Parking Brake..................................................................... 49
Coolant Lines Group .......................................................... 62
Piston Pump (Hydraulic Fan)
Coolant Recovery Group.................................................... 63
Elbow ............................................................................ 25
D Piston Pump Gp............................................................ 25
Differential and Bevel Gear Group ..................................... 41 Relief Valve................................................................... 25
Diverter Valve............................................................... 21, 22 Solenoid Valve Gp ........................................................ 25
Drive and Steering Axle (Front) Piston Pump (Hydraulic Fan) ............................................. 25
168-7440 Drive and Steering Axle Gp.......................... 37 Piston Pump (Implement and Steering) ............................... 4
271 -6424 Drive and Steering Axle Gp ......................... 38 Position Sensor (Steering) ................................................. 27
Drive and Steering Axle (Front).......................................... 37 Position Sensor (Transmission) ......................................... 32
Drive and Steering Axle (Rear) R
168-7441 Drive and Steering Axle Gp.......................... 40
Rear View Mirror ................................................................ 74
Drive and Steering Axle (Rear) .......................................... 40
Drive Shaft ......................................................................... 36 S
E Solenoid Valve (Pilot Selector)............................................. 5
Solenoid Valve (Steering Mode Selector) .......................... 27
Engine and Transmission Mounting................................... 55
Specifications Section .......................................................... 3
Engine Enclosure ............................................................... 53
Steering Wheel and Column .............................................. 71
Engine Oil Drain ................................................................. 58
Suction Fan ........................................................................ 60
F
T
Fan Drive Mounting Group................................................. 26
Fender................................................................................ 49
Telescoping Cylinder.................................................... 16, 17
Final Drive Planetary Group............................................... 43
Tilt Cylinder ........................................................................ 19
Flexible Coupling Drive ...................................................... 28
Tilt Cylinder ........................................................................ 20
Frame................................................................................... 8
Towing Hitch ................................................................ 23, 24
Fuel Tank (Auxiliary) .......................................................... 51
Transmission...................................................................... 31
Fuel Tank ........................................................................... 52
Transmission...................................................................... 29
G
W
Grapple Cylinder ................................................................ 77
Wheel (Tire and Rim) ......................................................... 50
Window Washer Tank ........................................................ 73
Window Wiper and Wiper Motor ........................................ 72
Work Tool Linkage ............................................................. 74
80 31200276
Index
31200277
December 15, 2006
Disassembly and
Assembly
TH220B and TH330B Telehandlers

Machine Systems

presented.
this publication.

and material.

injury or death.
31200277 1
Table of Contents
Table of
Table of Contents Installation Procedure ........................ 50
Disassembly and Assembly Section Telescoping Cylinder - Remove and
Hydraulic System Pressure -Release ...... 3 Install...................................................... 52
Release Procedure.............................. 3 Removal Procedure ........................... 52
Bottom Guard - Remove and Install ........ 3 Installation Procedure ........................ 56
Removal Procedure............................. 3 Diverter Valve (Boom Head) -Remove and
Installation Procedure.......................... 4 Install...................................................... 60
Hydraulic Tank - Remove ........................ 4 Removal Procedure ........................... 60
Removal Procedure............................. 4 Installation Procedure ........................ 61
Hydraulic Tank - Install ............................ 6 Load Control Valve (Boom Cylinder) -
Installation Procedure.......................... 6 Remove and Install ................................ 62
Piston Pump (Implement and Steering) - Removal Procedure ........................... 62
Remove ................................................... 7 Installation Procedure ........................ 63
Removal Procedure............................. 7 Boom Cylinder - Remove and Install...... 65
Disassemble ............................................ 8 Installation Procedure ........................ 68
Disassembly Procedure ...................... 8 Coupler Cylinder - Remove and Install .. 70
Assemble ............................................... 13 Installation Procedure ........................ 72
Assembly Procedure ......................... 13 Quick Coupler (Hydraulic) -Remove and
Piston Pump (Implement and Steering) - Install...................................................... 74
Install ..................................................... 18 Removal Procedure ........................... 74
Installation Procedure........................ 18 Installation Procedure ........................ 76
Main Control Valve (Implement) - Work Tool Linkage - Remove and Install77
Remove ................................................. 19 Removal Procedure ........................... 77
Removal Procedure........................... 19 Installation Procedure ........................ 78
Electronic Pilot Valve - Remove and Boom - Remove ..................................... 79
Removal Procedure........................... 22 Boom - Disassemble .............................. 83
Installation Procedure........................ 23 Disassembly Procedure..................... 83
Bank Valve (Implement) -Disassemble . 24 Boom -Assemble.................................... 88
Disassembly Procedure .................... 24 Assembly Procedure.......................... 88
Bank Valve (Implement) -Assemble ...... 31 Boom - Install ......................................... 92
Assembly Procedure ......................... 31 Installation Procedure ........................ 92
Main Control Valve (Implement) - Install 37 Hydraulic Oil Cooler (Transmission and
Installation Procedure........................ 37 Hydraulic System) - Remove and Install 95
Tilt Cylinder - Remove and Install.......... 39 Removal Procedure ........................... 95
Installation Procedure........................ 41 Transmission Oil Cooler .................... 97
Control Valve (Compensating Cylinder) - Hitch Cylinder - Remove and Install....... 97
Remove and Install ................................ 42 Removal Procedure ........................... 97
Installation Procedure........................ 43 Towing Hitch (Hydraulic) -Remove and
Compensating Cylinder Remove and Install...................................................... 99
Removal Procedure........................... 44 Installation Procedure ...................... 100
Installation Procedure........................ 46 Control Valve (Trailer and Towing Hitch) -
Load Control Valve (Telescoping Cylinder) Remove................................................ 101
Remove and Install ................................ 48 Removal Procedure ......................... 101
2 31200277
Table of Contents
Control Valve (Trailer and Towing Hitch) - Heater Core - Remove and Install ....... 141
Disassemble.........................................102 Removal Procedure......................... 141
Disassembly Procedure ...................102 Installation Procedure...................... 141
Control Valve (Trailer and Towing Hitch) - Air Conditioner - Remove .................... 142
Assemble..............................................105 Removal Procedure......................... 142
Assembly Procedure ........................105 Air Conditioner - Install ........................ 147
Control Valve (Trailer and Towing Hitch) - Installation Procedure...................... 147
Install ....................................................108 Evaporator Coil - Remove and Install .. 153
Installation Procedure ......................108 Removal Procedure......................... 153
Fuel Tank - Remove.............................109 Installation procedure ...................... 153
Removal Procedure .........................109 Blower Motor (Air Conditioner and Heater) -
Fuel Tank - Install.................................110 Remove and Install .............................. 154
Steering Wheel - Remove and Install...112 Installation procedure ...................... 157
Removal Procedure .........................112 Cab - Remove...................................... 160
Steering Column - Remove ..................113 Cab - Install.......................................... 166
Removal Procedure .........................113 Installation Procedure...................... 166
Steering Column - Install ......................116 Fender - Remove and Install ............... 171
Solenoid Valve (Steering Mode Selector) - Installation Procedure...................... 171
Remove and Install...............................119
Removal Procedure .........................119
Installation Procedure ......................120
Metering Pump (Steering) -Remove.....121
Metering Pump (Steering) -Install.........124
Window Wiper and Wiper Motor (Front) -
Window Wiper and Wiper Motor (Rear) -
Window Wiper and Wiper Motor (Roof) -
Installation procedure.......................132
Joystick Control - Remove and Install ..133
Seat - Remove and Install ....................134
Cab Heater - Remove ..........................136
Cab Heater - Install ..............................138
31200277 3
Disassembly and 5. If equipped, place the implement lockout switch in

the UNLOCKED position.
Assembly Section 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
Hydraulic System Pressure - system.
Release 7. Turn the engine start switch to the OFF position.
8. Depress the brake pedal repeatedly. This will
Release Procedure relieve any pressure that may be present in the
brake system.
9. Remove the hydraulic tank filler cap slowly in
order to relieve the tank pressure.
10. After all the pressure has been released, tighten
Personal injury can result from hydraulic oil the filler cap on the hydraulic tank.
pressure and hot oil.
Note: Hydraulic cylinders and lock valves may contain
Hydraulic oil pressure can remain in the hydraulic internal pressure. Refer to specific instructions for
system after the engine has been stopped. Serious each hydraulic component before performing any work
injury can be caused if this pressure is not released on each hydraulic component.
Make sure all of the attachments have been Bottom Guard - Remove and
lowered to the ground, and the oil is cool before
removing any components or lines. Remove the oil Install
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare Removal Procedure
hand.
Table 1
Required Tools
Cylinders equipped with lock valves can remain
pressurized for very long periods of time, even A 1U-9744 Hydraulic Jack 1
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 Personal injury or death can result from improper
lock valve or disassembling a cylinder. lifting or blocking.
NOTICE When a hoist or jack is used to lift any part or
Care must be taken to ensure that fluids are contained component, stand clear of the area. Be sure the
during performance of inspection, maintenance, testing, hoist or jack has the correct capacity to lift a
adjusting and repair of the product. Be prepared to collect component. Install blocks or stands before
the fluid with suitable containers before opening any performance of any work under a heavy
compartment or disassembling any component component.
containing fluids.
Refer to Special Publication, "Caterpillar Tools and Shop Clean all surfaces where parts are to be installed.
mandates.
1. Lower the boom to the ground.
2. Engage the parking brake.
3. Stop the engine.
4. Turn the engine start switch to the ON position
after the engine stops.
4 31200277
1. Use Tooling (A) to raise the bottom guard (1) into

position. The weight of the access cover is
1. Position Tooling (A) under access cover (1) in
order to support the bottom guard.
2. Remove the bolts and washers that secure bottom Illustration 4 g01028458
guard (1) to the chassis.
2. Install the bolts and the washers which secure
bottom guard (1) to the chassis.
3. Remove Tooling (A).
Hydraulic Tank - Remove

Removal Procedure
Table 3
Required Tools
3. Use the Tooling (A) to carefully lower and remove
bottom guard (1). The weight of the access cover is
approximately 18 kg (40 lb). 9U-7068 Plug 3
9U-7069 Plug 3
9U-7080 Plug 2
Table 2 ZZ
9U-7081 Plug 2
Required Tools
9U-7088 Plug 1
9U-7090 Plug 1
A 1U-9744 Hydraulic Jack 1
Start By:
a. Release the pressure in the hydraulic system.
Refer to Disassembly and Assembly, "Hydraulic
System Pressure - Release".
b. Remove the fuel tank. Refer to Disassembly and
Assembly, "Fuel Tank - Remove and Install".
31200277 5

skin.
Personal injury can result from hydraulic oil

Hydraulic oil pressure can remain in the hydraulic Illustration 5 g01014366
system after the engine has been stopped. Serious
injury can be caused if this pressure is not released 3. Remove bolts (1). Reposition tank assembly (2) in
before any service is done on the hydraulic system. order to access hose assembly (3).
removing any components or lines. Remove the oil
filler cap is cool enough to touch with your bare
hand.
NOTICE
containing fluids.
Refer to Special Publication, "Caterpillar Tools and Shop 4. Disconnect hose assembly (3). Remove tank
Products Guide" for tools and supplies suitable to collect assembly (2).
mandates.
SERVICEMAN.
2. Drain the hydraulic tank into a suitable container for
storage or disposal. The capacity of the hydraulic
tank for the TH220B and the TH330B is
approximately 66 L (17.4 US gal). Refer to
Operation and Maintenance Manual, "Hydraulic
System Oil - Change" for the correct draining
procedure.
6 31200277
Hydraulic Tank - Install

1. Place hydraulic tank (8) into position. Use two

people in order to install hydraulic tank (8). The
weight of the hydraulic tank is approximately 25 kg
(55 lb).
Note: The weight of the hydraulic tank is an empty
weight. Any fluid remaining in the hydraulic tank will
add to the weight.
2. Install bolts (6).
8. Remove bolts (7). Use two people to support

hydraulic tank (8).
9. Use two people in order to remove hydraulic
tank (8). The weight of the hydraulic tank is
3. Connect hoses (5).

31200277 7

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
Disassembly and Assembly, "Sump Guard -
Illustration 14 g01014421 Remove and Install".
4. Connect hoses (4).

Hydraulic oil pressure can remain in the hydraulic
injury can be caused if this pressure is not released
removing any components or lines. Remove the oil
Illustration 15 g01014394 filler cap is cool enough to touch with your bare
hand.
5. Install tank assembly (2). Connect hose assembly
NOTICE
(3).
containing fluids.
mandates.
1. Drain the hydraulic tank into a suitable container
Illustration 16 g01014366 for storage or disposal. The capacity of the
hydraulic tank for the TH220B and the TH330B
6. Position tank assembly (2) in the correct position, is approximately 66 L (17.4 US gal). Refer to
install the bolts (1). Operation and Maintenance Manual, "Hydraulic
7. Fill the hydraulic tank. The capacity of the System Oil - Change" for the correct draining
hydraulic tank for the TH220B and the TH330B procedure.
is approximately 66 L (17.4 US gal). Refer to 2. Put identification marks on all hose assemblies
Operation and Maintenance Manual, "Hydraulic and on all tube assemblies. Plug all hoses and
System Oil - Change" for the correct filling all tubes. This will prevent fluid loss and this will
procedure. prevent contaminants from entering the system.
End By:
a. Install the fuel tank. Refer to Disassembly and
Assembly, "Fuel Tank - Remove and Install".
8 31200277
3. At the underside of the machine, disconnect tube 4. Remove bolts (7) and the washers in order to
assembly(1) and hose assembly (2) from piston remove piston pump (3) from adapter plate (8) and
pump (3). Loosen the clamp and disconnect hose at the same time remove O-ring seal (9). The
(4) from the piston pump. Disconnect hose weight of the piston pump for the TH220B and the
assembly (5) from compensator valve (6). TH330B is approximately 20 kg (44 lb).

Steering) - Disassemble
Table 4
Required Tools
B 1P-1854 Retaining Ring Pliers 1
Start By:
a. Remove the implement and steering pump from the
"Piston Pump (Implement and Steering) -Remove".
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.
31200277 9


1. Remove the four allen head screws (2). Remove

the compensator valve (1) from housing (3).
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).
2. Remove plugs (4) and (5) from compensator valve

(1). Remove fittings (6) from compensator valve (1).
10 31200277
8. Remove the shim for the bearing preload (27) from

shaft (24).
5. Remove allen head screws (20) and remove port

block (21) from housing (3).
9. Remove rotating group (28) from housing group

(3). Carefully retain the rotating group (28) in
housing group(3). Turn the rotating assembly
upside-down. Slowly lift housing group(3) off
Illustration 25 g00923933 rotating group (28).
6. Remove O-ring seal (22). Remove plate (23) from
port block (21).
7. Remove bearing cone (26) from shaft (24).

Remove O-ring seals (25).
31200277 11

equipment.
11. Use Tooling (A) and a press in order to compress
spring (34) until the snap ring (33) can be removed
Illustration 30 g00923940 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).
equipment.
Note: Mark the location of pistons for assembly
purposes.
10. Remove plate (29) and pistons (30) from barrel

(31). Remove retaining ball (32).
12. Remove plug (37) and the O-ring seal
13. Remove piston (38) from housing (3).
12 31200277
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 cone (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
swash plate (39).
19. Use Tooling (C) in order to remove snap ring (45)

from housing (3).
15. Remove swashplate (39) from housing (3). Check

the condition of socket (41).
20. Remove seal (46) from housing.
16. Remove two bearings (42).

17. Remove spring (43).
31200277 13
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)
Table 5
on top of seal (46).
3. Use Tooling (A) in order to press snap ring (45)
Required Tools and seal (46) into housing (3). Press snap ring
Tool Part Number Part Description Qty (45) and seal (46) until snap ring (45) is installed
in the groove in housing (3).
B 1P-1854 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 43 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 cone is seated properly. Install shaft
during reassembly. This will also provide lubrication to
(24) into housing (3).
the dust seals and to the shaft seals.
5. Install bearings (42) and spring (43) into housing

(3).
14 31200277
Note: Caution must be used when you install the plate.

Do not dislodge the spring or the bearings.
6. Install swashplate (39) in housing (3). Check the
condition of socket (41).
Illustration 46 g00885503 Improper assembly of parts that are spring loaded

can cause bodily injury.
7. Install rod (40) in the bore and engage rod (40) in
socket (41). To prevent possible injury, follow the established
assembly procedure and wear protective
equipment.
10. Install three pressure pins (36), retaining disc (35),
and spring (34) in barrel (31).
8. Install piston (38) in the bore.
9. Install plug (37) and the O-ring seal. Tighten plug

(37) to 90 ± 15 Nm (66 ±11 lb ft).
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).
31200277 15
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).
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 0.0 to
0.05 mm (0.0000 to 0.0020 inch).
13. Do not install shim (27). Install bearing cone (26)

onto shaft (24). Assemble the pump without shim
(27) in order to check the preload of bearing cone
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).
16 31200277
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.
21. Install shim (27).
19. Remove bolts (20), port block (21), and the bearing. Illustration 61 g00885494
22. Install bearing (26) on shaft (24). Install O-ring seals

(25).
Note: All parts must be in the proper position.

20. Wrap the nine pistons (30) with string but do not tie Illustration 62 g00885493
the string. Hold the string tight and carefully install
rotating group (28) in housing (3). The splines on 23. Install O-ring seal (22) and plate (23) to the port
shaft (24) must engage with splines in retaining ball block (21).
(32).
31200277 17
Improper assembly of parts that are spring loaded

can cause bodily injury.
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).
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).
28. Install fittings (6) to compensator valve (1). Install

plugs (4) and (5) to compensator valve (1).
18 31200277
29. Position the compensator valve (1) on housing (3).

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
"Piston Pump (Implement and Steering) - Install".

Steering) - Install
Installation Procedure 2. Apply a thin coat of Tooling (A) to O-ring seal (9)
Table 6 and install the O-ring onto the flange of piston
pump (3). Align the spline's on the piston pump
Required Tools with the spline's on the gear which is located
behind mounting plate (8). Install the piston pump
onto the mounting plate and install bolts. The
Tool Part Number Part Description Qty weight of the piston pump for the TH220B and the
TH330B is approximately 20 kg (44 lb) (7) and the
washers.
O-Ring Assembly
A 1U-6396 1
Compound
worn or damaged, use new Caterpillar parts for i01949815
replacement.
31200277 19
Main Control Valve (Implement) -

Remove
Removal Procedure
Table 7
Required Tools
9U-7068 Face Seal Plug 2
6V-9507 Face Seal Plug 3

3. Connect hose assembly (5) to compensator valve
(6). Connect hose (4) to piston pump (3) and 6V-9511 Face Seal Plug 1
tighten the clamp. Connect hose assembly (2) and ZZ 6V-9512 Face Seal Plug 1
tube assembly (1) to the piston pump.
4. Fill the hydraulic tank. The capacity of the 6V-9828 Face Seal Plug 3
hydraulic tank for the TH220B and the TH330B 6V-9830 Face Seal Plug 11
is approximately 66 L (17.4 US gal). Refer to
System Oil - Change" for the correct filling 6V-9833 Face Seal Plug 1
procedure.
End By: Start By:
a. Install the guard for the sump. Refer to a. Release hydraulic pressure. Refer to Disassembly
Disassembly and Assembly, "Sump Guard -Remove and Assembly, "Hydraulic Pressure - Release".
and Install".

and under pressure.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
contact with the skin and eyes to prevent personal
injury.
20 31200277

removing any components or lines. Remove the oil Illustration 71 g01014717
filler cap is cool enough to touch with your bare 3. Remove cover (1).
hand.
NOTICE
containing fluids.
Dispose of all fluids according to local regulations and Illustration 72 g01014721
mandates.
SERVICEMAN.
2. Drain the hydraulic tank into a suitable container
for storage or disposal. The capacity of the
hydraulic tank for the TH220B and the TH330B
is approximately 66 L (17.4 US gal). Refer to
Operation and Maintenance Manual, "Hydraulic Illustration 73 g01014723
procedure. 5. Remove cover (3).
31200277 21
6. Disconnect harness assembly (4). 9. Disconnect tube assemblies (9). Disconnect hose
assembly (10).
10. Remove hose (8). Disconnect harness assembly
(7).
7. Remove clamp (5).
12. Disconnect tube assemblies (12). Disconnect hose

assemblies (13).
22 31200277
13. Remove bolt (14). 15. Install Tooling (A) and a suitable lifting device to
control valve (16). Remove main control valve
(16). The weight of the control valve is
Electronic Pilot Valve - Remove

and Install
Removal Procedure
Start By:
a. Release hydraulic pressure. Refer to Disassembly
Illustration 81 g01014748 and Assembly, "Hydraulic Pressure - Release".

and under pressure.
Illustration 82 g01016948 contact with the skin and eyes to prevent personal
injury.
31200277 23
NOTICE
containing fluids.
mandates. Illustration 86 g01015153
1. Put identification marks on all hoses for installation 4. Remove bolts (6).
purposes. Plug all hoses. This helps to prevent Note: Some bolts are hidden.
fluid loss, and this helps to keep contaminants 5. Remove electronic pilot valve (5) from control
from entering the system. valve (4).
2. Remove bolts (1). Remove panel (2).
6. Remove O-ring seals (7).

7. Remove O-ring seals (8) from electronic pilot valve
(5).
3. Disconnect harness assemblies (3).
1. Install O-ring seals (8) into electronic pilot valve

(5).
24 31200277
2. Install O-ring seals (7). Bank Valve (Implement) -

Disassemble
Start By:
a. Remove the main control valve. Refer to
Disassembly and Assembly, "Main Control Valve
(Implement) - Remove".
NOTICE
3. Install electronic pilot valve (5) onto control valve compartment or disassembling any component
(4). containing fluids.
Refer to Special Publication, "Caterpillar Tools and
Note: Some bolts are hidden. Shop Products Guide" for tools and supplies suitable
to collect and contain fluids on Caterpillar products.
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.
5. Connect harness assemblies (3).
1. Remove eight bolts (1) in order to remove

electronic pilot valve (2) from bank valve (3). Refer
to Disassembly and Assembly, "Electronic Pilot
Illustration 91 g01015015 Valve - Remove and Install".
6. Install panel (2). Install bolts (1).

31200277 25
2. Position bank valve (3) on suitable cribbing so that 5. Remove O-ring seals (10), O-ring seal (11) and O-
locknuts (4) are facing upward. Remove the four ring seal (12) from control valve (13).
locknut in order to remove manifold (5).
3. Place manifold (5) in a suitable soft jawed vise and 6. Slide control valve (13) off studs (14) and control
remove pressure reducing valve (6). valve (15).
7. Place control valve (13) in a suitable soft jawed

4. Remove O-ring seals (7), backup rings (8) and O-
vise. Remove plug (16) and O-ring seal (17) (not
ring seal (9) from pressure reducing valve (6).
shown).
26 31200277
8. Remove compensator spool (18) from control valve

11. Remove bolts (24) in order to remove cover (25)
(13).
from the control valve (13).

9. Remove plug (19) from control valve (13). Remove
O-ring seal (20), backup ring (21) and O-ring seal 12. Remove O-ring seal (26) and O-ring seal (27) from
(22) from plug (19). Remove the plug from the cover (25). Remove adjusting screw (28) and
opposite side of the control valve. sealing nut (29).
10. Remove check valve (23) from control valve (13). 13. Slide valve spool (30) out of the control valve (13).
Remove the check valve from the opposite side of
the control valve.
31200277 27
16. Slide control valve (15) off studs (14) and control
valve (37).

Personal injury can result from being struck by parts vise. Remove plug (38) and O-ring seal (39) (not
propelled by a released spring force. shown).

14. Remove retainer (31), collars (32) and spring (33)

from valve spool (30).
18. Remove compensator spool (40) from control valve

(15).
15. Remove O-ring seals (34), O-ring seal (35) and O-

ring seal (36) from control valve (15).
19. Remove relief valve (41) from control valve (15).

Remove the relief valve from the opposite side of
the control valve.

28 31200277
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.

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.
22. Remove bolts (46) in order to remove cover (47) Personal injury can result from being struck by
from the control valve (15). parts propelled by a released spring force.
equipment.
25. Remove retainer (53), two collars (52), and spring

(51) from valve spool (50).
31200277 29
26. Remove O-ring seals (54), O-ring seal (55) and O- 30. Slide control valve (57) off studs (14) and manifold
ring seal (56) from control valve (37). (61).
31. Refer to steps 7 through 14 for the procedure to
disassemble control valve (57).
27. Slide control valve (37) off studs (14) and control Illustration 121 g00949709
valve (57).
32. Remove O-ring seal (62), O-ring seal (63) and O-
28. Refer to steps 17 through 25 for the procedure to
ring seal 64) from manifold (61).
disassemble control valve (37).

33. Clamp manifold (61) in a suitable soft jawed vise.
29. Remove O-ring seals (58), O-ring seal (59) and O- Remove load signal relief valve (65) from the
ring seal (60) from control valve (57). manifold.
30 31200277
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).

35. Remove flow control valve (69) from manifold (61).

equipment.
38. Remove O-ring seal (74) from cap (73). Remove
valve spool (75), spring (76), guide (77) and shims
(78) from the manifold.
36. Remove O-ring seal (70), backup ring (71) and O-

ring seal (72) from flow control valve (69).
31200277 31
Bank Valve (Implement) -

Assemble
Assembly Procedure parts propelled by a released spring force.
Table 8
Required Tools equipment.
1. Clamp manifold (61) in a suitable soft jawed vise.
Install valve spool (75), spring (76), guide (77) and
O-Ring Assembly shims (78) into manifold (61). Apply a thin coat of
A 1U-6396 1 Tooling (A) to O-ring seal (74) before installing the
Compound
O-ring into cap (73). Install the cap into the
Note: Cleanliness is an important factor. Before manifold. Tighten the cap to a torque of 100 ± 10
assembly, thoroughly clean all parts in cleaning fluid. Nm (75 ± 7 lb ft).
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
replacement. Dirt and other contaminants can damage
precision components. Perform assembly procedures
on a clean work surface. Keep components covered
and protected at all times.
2. Install O-ring seal (70), backup ring (71) and O-

ring seal (72) onto flow control valve (69).
Lubricate the O-ring seals and the backup ring with
the lubricant that is being sealed.
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).
32 31200277
4. Install O-ring seal (66), backup ring (67) and O- 7. Slide control valve (57) onto studs (14) and
ring seal (68) onto load signal relief valve (65). manifold (61).
Lubricate the O-ring seals and the backup ring with 8. Refer to Steps 24 through 31 for the procedure to
the lubricant that is being sealed. assemble control valve (57).

5. Install load signal relief valve (65) into the 9. Install O-ring seals (58), O-ring seal (59) and O-
manifold. Tighten the signal relief valve to a torque ring seal (60) into control valve (57).
o f4 5 ±5 N m( 33 ±3 l b ft).
6. Position manifold (61) on suitable cribbing so that 10. Slide control valve (37) onto studs (14) and
studs are facing upward. Install O-ring seals (62), control valve (57).
O-ring seal (63) and O-ring seal (64) into manifold 11. Refer to Steps 13 through 21 for the procedure to
(61). assemble control valve (37).
31200277 33

vise. Slide valve spool (50) into the control valve.
12. Install O-ring seals (54), O-ring seal (55) and O-ring
seal (56) into control valve (37).
15. Apply a thin coat of Tooling (A) to O-ring seal (48)
and O-ring seal (49) before installing the O-ring
seals into cover (47).
Personal injury can result from being struck by 16. Position cover (47) onto control valve (15) and
parts propelled by a released spring force. install bolts (46).
equipment.
13. Install retainer (51), two collars (52) and spring (53)
onto valve spool (50).
17. Install check valve (45) from control valve (15).

Install the check valve into the opposite side of the
control valve.

34 31200277
18. Install O-ring seal (42), backup ring (43) and O-ring 21. Install O-ring seal (39) (not shown) onto plug (38)
seal (44) onto relief valve (41). Lubricate the O-ring and install the plug into control valve (15). Remove
seals and the backup ring with the lubricant that is control valve (15) from the soft jawed vise.
being sealed. Repeat the procedure for the second
relief valve.
Illustration 145 g00949397 22. Slide control valve (15) onto studs (14) and control
valve (37).
19. Install relief valve (41) into control valve (15). Install
the relief valve into the opposite side of the control
valve.
23. Install O-ring seals (34), O-ring seal (35) and O-ring
seal (36) into control valve (15).
20. Install compensator spool (40) into control valve

(15).
31200277 35
26. Apply a thin coat of Tooling (A) to O-ring seal (26)

and O-ring seal (27) before installing the O-ring
seals into cover (25). Install adjusting screw (28)
and sealing nut (29).
Personal injury can result from being struck by parts Illustration 153 g00949209
27. Position cover (25) onto control valve (13) and
Make sure to wear all necessary protective equipment. install bolts (24).
24. Install retainer (31), two collars (32) and spring (33)
onto valve spool (30).
28. Install check valve (23) into control valve (13).

Install the check valve into the opposite side of the
control valve.

vise. Slide valve spool (30) into the control valve.
29. Install O-ring seal (20), backup ring (21) and O-ring
seal (22) onto plug (19). Lubricate the O-ring seals
Illustration 152 g00949211 and the backup ring with the lubricant that is being
sealed. Install plug (19) into control valve (13).
Install the plug into the opposite side of the control
valve.
36 31200277
30. Install compensator spool (18) into control valve 33. Install O-ring seals (10), O-ring seal (11) and O-ring
(13). seal (12) into control valve (13).

34. Install two O-ring seals (7), two backup rings (8) and
31. Install O-ring seal (17) (not shown) onto plug (16) O-ring seal (9) onto pressure reducing valve (6).
and install the plug into control valve (13). Remove Lubricate the O-ring seals and the backup rings
control valve (13) from the soft jawed vise. with the lubricant that is being sealed.

32. Slide control valve (13) onto studs (14) and control
valve (15). 35. Place manifold (5) in a suitable soft jawed vise and
install pressure reducing valve (6). Tighten the
pressure reducing valve to a torque of 55 ± 5 Nm
(40 ± 4 lb ft).
31200277 37
NOTICE
containing fluids.
Shop Products Guide" for tools and supplies suitable to
collect and contain fluids on Caterpillarproducts.
mandates.
36. Install manifold (5) and locknuts (4). Tighten the

locknuts to a torque of 35 Nm (26 lb ft).
Illustration 164g01016948
37. Position electronic pilot valve (3) onto bank valve (2)
and install eight bolts (1). Refer to Disassembly and
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".
1. Use Tooling (A) and a suitable lifting device in

Main Control Valve (Implement) - order to install control valve (16) in position. The
weight of the control valve is approximately 40 kg
Install (88 lb).
Table 9
Required Tools

38 31200277
3. Install bolt (14). 6. Connect tube assemblies (9). Connect hose

assembly (10).
7. Install hose (8). Connect harness assembly (7).
4. Connect tube assemblies (12). Connect hose

assemblies (13). Illustration 171 g01014738

9. Install clamp (5).

31200277 39


14. Fill the hydraulic tank. The capacity of the
hydraulic tank for the TH220B and the TH330B is
approximately 66 L (17.4 US gal). Refer to
procedure.
Tilt Cylinder - Remove and

Install
Removal Procedure
Table 10
Required Tools
Part
Number

ZZ
Start By:
Illustration 175 g01014721 a. Release hydraulic pressure. Refer to Disassembly
and Assembly, "Hydraulic Pressure - Release".

pressurized for very long periods of time, even
lock valve or disassembling a cylinder.
40 31200277

components or lines. Remove the oil filler cap only Illustration 179 g01021981
enough to touch with your bare hand. 4. Attach a suitable lifting device to tilt cylinder (4).
SERVICEMAN.
1. Remove the work tool linkage.
5. Remove bolt (5). Remove pin assembly (6).
2. Remove bolts (1) and remove cover (2).
6. Use a suitable lifting device, and remove the tilt

cylinder from the machine. The weight of the tilt
cylinder is approximately 79 kg (175 lb).

31200277 41
7. Remove load control valve (7). 3. Install tilt cylinder (4) into the machine. The weight
of the tilt cylinder is approximately 79 kg (175 lb).
Table 11
Required Tools
Part
Number
4. Apply a coating of Tooling (A) onto pin assembly

(6). Install pin assembly (6). Secure pin (6) with
bolt (5).
1. Install load control valve (7) into the tilt cylinder.

2. Use a suitable lifting device in order to install tilt

cylinder (4) onto the machine.
42 31200277


7. Install the work tool linkage.
Control Valve (Compensating Hydraulic oil pressure can remain in the hydraulic
Cylinder) - Remove and Install injury can be caused if this pressure is not released
Removal Procedure Make sure all of the attachments have been
Table 12
components or lines. Remove the oil filler cap only
Required Tools when the engine is stopped, and the filler cap is cool
Part
Number Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE
8S-7640 Stand 1 OR THE INSTALLATION. THIS TOOLING IS SHOWN
8S-8048 Saddle 1 SERVICEMAN.
A 8S-7641 Tube 1
1. Remove the work tool.
8S-7615 Pin 1

ZZ
Start By:
2. Raise the boom. Install Tooling (A) under quick

coupler (1). Lower the boom into tooling (A).
31200277 43
3. Disconnect tube assemblies (2). Disconnect hose 6. Remove hose assembly (4). Remove all fittings (7)
assembly (3). from the valve.
4. Disconnect hose assembly (4). Illustration 194 g01022493
1. Install fittings (7) and install hose (4) onto the

valve.
5. Remove bolts (5). Remove control valve assembly

(6).
2. Install control valve assembly (6) into position.

Secure the valve assembly with bolts (5).
44 31200277
Remove and Install
Removal Procedure
Table 13
Required Tools
Part
Number
8S-7630 Stand 1
8S-8048 Saddle 1
3. Connect hose assembly (4).
A
8S-7641 Tube 1
8S-7615 Pin 1
B 1U-9570 Puller Group 1

ZZ
Start By:
b. Remove the work tool. Refer to Disassembly and
4. Connect hose assembly (3). Connect tube
Assembly, "Work Tool - Remove and Install".
assemblies (2).

Illustration 198 g01022376 components or lines. Remove the oil filler cap only
5. Raise the boom. Remove Tooling (A) from quick enough to touch with your bare hand.
coupler (1).
6. Install the work tool.
31200277 45

IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL 3. Disconnect hose assembly (3).
SERVICEMAN.

1. Install Tooling (A) under quick coupler (1).
5. Attach a suitable lifting device to compensating

Illustration 200 g01026343 cylinder (6).
2. Disconnect hose assembly (2).
46 31200277
Table 14
Required Tools
Part
Number
8S-7630 Stand 1
8S-7641 Tube 1
A
8S-7615 Pin 1
6. Remove bolt (8). 8S-8048 Saddle 1
C 1P-0808 Multipurpose Grease 1
7. Install Tooling (B) in order to remove pin assembly

1. Use a suitable lifting device in order to move

compensating cylinder (6) into position. The weight
of compensating cylinder (6) is approximately 29
kg (65 lb).

Remove compensating cylinder (6). The weight of
compensating cylinder (6) is approximately 29 kg
(65 lb). Illustration 208 g01026359
2. Install compensating cylinder (6) into position.

Apply Tooling (C) to pin assembly (10). Install pin
assembly (10). Secure pin assembly (10) with bolt
(9).
31200277 47

3. Move compensating cylinder into position on the
opposite end. Apply Tooling (C) to pin assembly 6. Connect hose assembly (2).
(7). Install pin assembly (7). Secure pin assembly
(7) with bolt (8).
Illustration 210 g01026354 7. Remove Tooling (A) from quick coupler (1).
End By:
4. Install panel (5) into position. Secure panel (5) with
bolts (4). a. Install the work tool. Refer to Disassembly and

48 31200277
Load Control Valve

(Telescoping Cylinder) Remove
and Install Cylinders equipped with lock valves can remain
Removal Procedure with the hoses removed.
Table 15 Failure to relieve pressure before removing a lock
Required Tools personal injury or death.
Part Ensure all pressure is relieved before removing a
Number lock valve or disassembling a cylinder.
A 1P-1861 Snap Ring Pliers 1 Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE
4C-6486 Stand 1 OR THE INSTALLATION. THIS TOOLING IS SHOWN
8S-8048 Saddle 1 SERVICEMAN.
B
8S-7631 Tube 1
8S-7615 Pin 1

ZZ
Start By:
1. Extend inner boom (1) in order to allow access to

pin assembly (2).

2. Remove bolt (3). Remove panel (4).

31200277 49
3. Disconnect tube assembly (5). 6. Use Tooling (A) in order to remove retaining ring (8).
Remove pin assembly (2).
4. Disconnect tube assembly (6). 7. Remove nuts (10) from bolts (9). Take note of the
position of shims (11). Remove the shims (11).
5. Disconnect tube assemblies (5) and (6) from

telescoping cylinder (7).
50 31200277
Table 16
Required Tools
Part
Number
A 1P-1861 Snap Ring Pliers 1
8S-7630 Stand 1
8S-8048 Saddle 1
B
8S-7631 Tube 1
8. Attach a suitable lifting device to telescoping
cylinder (7). Remove telescoping cylinder (7) from 8S-7615 Pin 1
the rear of the boom. The telescoping cylinder (7)
should be moved approximately 1219 mm (4 ft) C 1P-0808 Multipurpose Grease 1
on to Tooling (B).

1. Install O-ring seals (14) into load control valve (13).

9. Remove bolts (12). Remove load control valve (13)
from the telescoping cylinder.
2. Install load control valve (13) into position. Secure

Illustration 224 g01028797 load control valve (13) to the telescoping cylinder
with bolts (12).
10. Rotate load control valve (13) to the opposite side.
Remove O-ring seals (14).
31200277 51
5. Apply Tooling (C) to pin assembly (2). Install pin

(2). Secure pin assembly (2) with retaining ring (8).
Use Tooling (A).

cylinder (7). Remove telescoping cylinder (7) from Illustration 231 g01027876
Tooling (B). Move the telescoping cylinder into the
rear of the boom. 6. Connect tube assemblies (5) and (6) to telescoping
cylinder (7).

4. Install shims (11) into position. Install nuts (10) onto
bolts (9). 7. Connect tube assembly (6).
52 31200277
Telescoping Cylinder - Remove

and Install
Removal Procedure
Table 17
Required Tools
Part
Number

8S-7630 Stand 1
8. Connect tube assembly (5).
8S-8048 Saddle 1
B
8S-7631 Tube 1
8S-7615 Pin 1

ZZ
Start By:
Illustration 234 g01027873 b. Remove the work tool. Refer to Disassembly and
9. Install panel (4). Secure panel (4) with bolt (3).
End By:
a. Install the work tool. Refer to Disassembly and
31200277 53

when the engine is stopped, and the filler cap is cool 3. Disconnect tube assembly (5).
SERVICEMAN.
4. Disconnect tube assembly (6).
1. Extend inner boom (1) in order to allow access to

pin assembly (2).
5. Disconnect tube assemblies (5) and (6) from


54 31200277
6. Use Tooling (A) in order to remove retaining ring (8). 8. Attach a suitable lifting device to telescoping
Remove pin assembly (2). cylinder (7). Remove telescoping cylinder (7) from
the rear of the boom. The telescoping cylinder (7)
should be moved approximately 1219 mm (4 ft)
onto Tooling (B).
7. Remove nuts (10) from bolts (9). Take note of the

position of shims (11). Remove the shims (11). Illustration 244 g01028062
9. Attach a suitable lifting device to inner boom (1).

Move the inner boom into the boom (12).

31200277 55

14. Remove screws (17). Remove chain assembly (18).


15. Remove cable straps (19) in order to remove spacer

12. Separate chain links (16).
(20). Move harness assembly (21) and hose
assemblies (22) into boom (1).

13. Remove hose assemblies (15) from boom (1).
16. Separate chain link (23).
56 31200277
17. Move harness assembly (21) and hose assemblies 20. Remove bolts (24). Remove plate (25). Remove
(22). bracket (26) from the telescoping cylinder.

18. Move telescoping cylinder (7). Install the 21. Remove bolts (27). Remove plate (28).
telescoping cylinder onto Tooling (B).
Table 18
Required Tools
Part
Number
8S-7630 Stand 1
8S-8048 Saddle 1
Illustration 254 g01028014 B
8S-7631 Tube 1
cylinder (7). Remove telescoping cylinder (7). The 8S-7615 Pin 1
weight of the telescoping cylinder is approximately
109 kg (240 lb). C 1P-0808 Multipurpose Grease 1
31200277 57

1. Install plate (28) onto the telescoping cylinder. 4. Move telescoping cylinder (7) from Tooling (B) into
Secure plate (28) with bolts (27). the boom.

2. Install the telescoping cylinder into bracket (26). 5. Move chain assembly (18) into position in the
Install plate (25) onto bracket (26). Secure plate
boom. Secure chain assembly (18) with screws
(25) with bolts (24).
(17).

3. Attach a suitable lifting device to telescoping 6. Move harness assembly (21) and hose assembly
cylinder (7). Install Tooling (B). The weight of the (22) into chain link (23).
telescoping cylinder is approximately 109 kg (240
lb).
Note: Chain link (23) is a portion of chain assembly
(18).
58 31200277
7. Connect chain link (23). 10. Connect chain links (16).
8. Move hose assemblies (22) and harness 11. Connect hoses (15).
assembly (21) through the boom. Install spacer
(20). Install cable straps (19).
12. Install panel (14). Secure panel (14) with bolts (13).
9. Move hose assemblies (15) into chain link (16).

Move the hose assemblies (15) into the boom.
31200277 59


cylinder (7). Remove telescoping cylinder (7) from
Tooling (B). Move the telescoping cylinder into the
rear of the boom.

Move inner boom (1) into position within boom
Note: Take note of the position of pin assembly (2).

15. Install shims (11) into position. Install nuts (10) onto
bolts (9).
16. Apply Tooling (C) to pin assembly (2). Install pin (2).
Secure pin assembly (2) with retaining ring (8).
60 31200277

20. Install panel (4). Secure panel (4) with bolts (3).
17. Connect tube assemblies (5) and (6) to
End By:
Diverter Valve (Boom Head) -

Remove and Install
Removal Procedure
Table 19
Required Tools
Part
Illustration 276 g01027875 Number

18. Connect tube assembly (6).
ZZ
Start By:

19. Connect tube assembly (5). pressure and hot oil.
31200277 61

IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL 3. Remove bolts (5). Remove diverter valve (6).
SERVICEMAN.
1. Disconnect hose assemblies (1). Disconnect hose 1. Install diverter valve (6) into position. Secure
assemblies (2). diverter valve (6) with bolts (5).

2. Remove cable straps (3). Disconnect harness
assembly (4). 2. Connect harness assembly (4). Install cable straps
(3).
62 31200277

Illustration 284 g01026700 components or lines. Remove the oil filler cap only
3. Connect hose assemblies (2). Connect hose enough to touch with your bare hand.
assemblies (1).

Load Control Valve (Boom pressurized for very long periods of time, even
Cylinder) - Remove and Install with the hoses removed.
Removal Procedure valve or disassembling a cylinder can result in
Start By: Ensure all pressure is relieved before removing a
a. Release hydraulic pressure. Refer to Disassembly lock valve or disassembling a cylinder.
b. Remove the boom cylinder. Refer to Disassembly
and Assembly, "Boom Cylinder - Remove and
Install".
1. Remove bolts (1). Remove load control valve (2).

31200277 63
4. Rotate load control valve (2). Remove O-ring seals

(3).
1. Install O-ring seals (3) into load control valve (2).

2. Rotate load control valve (2). Place the load
control valve into position on the boom cylinder.
64 31200277
3. Secure the load control valve (2) with bolts (1).
End By:
a. Install the boom cylinder. Refer to Disassembly and
Assembly, "Boom Cylinder - Remove and Install".
31200277 65
Boom Cylinder - Remove and

Install
Removal Procedure Cylinders equipped with lock valves can remain
Table 20 with the hoses removed.
Required Tools Failure to relieve pressure before removing a lock
Part personal injury or death.
Number
8S-7630 Stand 1 lock valve or disassembling a cylinder.
8S-7631 Tube 1 IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL
A OR THE INSTALLATION. THIS TOOLING IS SHOWN
8S-7615 Pin 1 IN ORDER TO ASSIST THE EXPERIENCED
SERVICEMAN.
8S-8048 Saddle 1
B 138-73573 Link Bracket 1
C 1U-9202 Hoist (Lever) 1

ZZ

Start By:
a. Release hydraulic pressure. Refer to Disassembly 1. Install Tooling (A) under quick coupler (1).

lowered, oil is cool before removing any 2. Remove bolts (2). Remove cover (3) from the
components or lines. Remove the oil filler cap only muffler.
66 31200277

6. Loosen fitting (8).

3. Install Tooling (B) onto fender (4). Attach a suitable
lifting device. Apply tension.

7. Disconnect hose assembly (11) from tube
4. Remove bolts (5). Remove fender (4). The weight assembly (10). Move hose assembly (10) away
offender (4) is approximately 34 kg (75 lb). from pin assembly (9).
5. Remove bolts (6). Remove cover (7). 8. Attach a suitable lifting device to boom cylinder
(12). Apply tension to the boom cylinder.
31200277 67
9. Remove bolt (13) and pin assembly (14). 12. Install Tooling (C) to boom cylinder (12). Apply
tension.

10. Lower boom cylinder (12) onto suitable cribbing.
Remove boom cylinder (12). The weight of the
boom cylinder is approximately 204 kg (450 lb).

68 31200277
Table 21
Required Tools
Part
Number
8S-7630 Stand 1
8S-7631 Tube 1
A
8S-7615 Pin 1
8S-8048 Saddle 1
3. Align boom cylinder (12) with the boom. Apply
B 138-73573 Link Bracket 1 Tooling (D) to pin assembly (9). Install pin
assembly (9). Secure pin assembly (9) with bolt
C 1U-9202 Hoist (Lever) 1 (16).
D 1P-0808 Multipurpose Grease 1

1. Use Tooling (C) in order to install boom cylinder

(12) into position. The weight of the boom cylinder
5. Attach a suitable lifting device to boom cylinder

(12). Apply tension to the boom cylinder.
2. Lower boom cylinder (12) onto suitable cribbing.

31200277 69
6. Align boom cylinder (12) with the boom. Apply 9. Install cover (7). Secure cover (7) with bolts (6).
Tooling (D) to pin assembly (14). Install pin
assembly (14). Secure pin (14) with bolt (13).
Illustration 31 1g01026944
10. Install Tooling (B) onto fender (4). Attach a suitable

lifting device.
7. Connect hose assembly (11) to tube assembly (10).

11. Install fender (4). Secure fender (4) with bolts (5).
8. Tighten fitting (8). The weight offender (4) is approximately 34 kg (75
lb).
70 31200277
Coupler Cylinder - Remove and

Install
Removal Procedure
Table 22
Required Tools
Part
Number
8S-7630 Stand 1
8S-7631 Tube 1
12. Install cover (3). Secure cover (3) with bolts (2). A
8S-7615 Pin 1

ZZ
Start By:
13. Remove Tooling (A) from quick coupler (1). Assembly, "Work Tool - Remove and Install".
End By:
a. Remove the work tool. Refer to Disassembly and

31200277 71

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE Illustration 317 g01025999

SERVICEMAN.
4. Remove dowel (5). Remove pin (6).

Illustration 315 g01025730 5. Repeat Step 4 on the opposite end.
1. Install Tooling (A) under boom (1).
Illustration 316 g01025998 6. Remove bolts (7). Remove plate (8). Remove
coupler cylinder (9).
2. Remove bolts (2) and cover (3).
72 31200277
7. Remove tube assemblies (10). 10. Remove O-ring seals (13) from check valve (12).
Table 23
Required Tools
Part
Number
8S-7630 Stand 1
A 8S-7631 Tube 1
8S-7615 Pin 1
8. Remove all fittings (11).

9. Remove check valve (12).
1. Install O-ring seals (13) onto check valve (12).
31200277 73
2. Install check valve (12) into the coupler cylinder. 5. Install coupler cylinder (9) into position. Install plate
(8). Secure plate (8) with bolts (7).
3. Install fittings (11) into the coupler cylinder. Illustration 329 g01026000
6. Install pin (6). Install dowel (5).

4. Install tube assemblies (10).


74 31200277
Quick Coupler (Hydraulic) -

Remove and Install
Removal Procedure
Table 24
Required Tools
Part
Number
8S-7630 Stand 1
A 8S-7631 Tube 1
9. Install cover (3) into position. Secure cover (3) with
bolts (2). 8S-7615 Pin 1

ZZ
Start By:
SERVICEMAN.
10. Remove Tooling (A) from the boom.
End By:
1. Install Tooling (A) under boom (1).

31200277 75
2. Disconnect hose assemblies (2). 6. Remove pin (6). Align coupler assembly in order to
allow removal of pin (6).
Note: Use a hammer and a large drift in order to
remove pin (6). Remove pin (6) from the opposite end of
the grease fitting.
3. Attach a suitable lifting device to coupler assembly

(3). Apply tension.

8. Remove coupler assembly (3). The weight of
coupler assembly (3) is approximately 181 kg
(400 lb).

76 31200277
Table 25
Required Tools
Part
Number
8S-7630 Stand 1
A 8S-7631 Tube 1
8S-7615 Pin 1
B 1P-0808 Multipurpose Grease 1
3. Align the coupler assembly in order to install pin
(6). Apply Tooling (B) to pin (6). Install pin (6).
Note: Use a hammer and a large drift in order to install
pin (6). Install pin (6) from the opposite end of the
grease
fitting.
1. Attach a suitable lifting device and move coupler

assembly (3) into position. The weight of coupler
assembly (3) is approximately 181 kg (400 lb).
4. Install plate (5). Secure plate (5) with bolts (4).

2. Apply Tooling (B) to pin assembly(8). Install pin

assembly (8). Install bolt (7) in order to secure pin
assembly (8). Illustration 343 g01025742

31200277 77
7. Remove Tooling (A) from boom (1). 1. Remove bolt (1). Remove pin assembly (2).
Remove link (3).
Work Tool Linkage - Remove

and Install
Removal Procedure
Start By:
a. Remove the quick coupler. Refer to Disassembly
and Assembly, "Quick Coupler - Remove and
Install".
2. Attach a suitable lifting device to lever assembly (4).


78 31200277
4. Remove bolt (7). Remove pin assembly (8). 2. Install lever assembly (4) into position. The weight
of lever assembly (4) is approximately 29 kg (65
lb).
5. Remove lever assembly (4). The weight of lever Illustration 352 g01025532
assembly (4) is approximately 29 kg (65 lb).
3. Apply Tooling (A) to pin assembly (8). Install pin
assembly (8) into position. Secure pin assembly (8)
Installation Procedure with bolt (7).
Table 26
Required Tools
4. Apply Tooling (A) to pin assembly (6). Install pin

assembly (6) into position. Secure pin assembly (6)
with bolt (5).1.
1. Attach a suitable lifting device to lever assembly (4).

31200277 79
Boom - Remove
Removal Procedure
Table 27
Required Tools
Part
Number
8S-7640 Stand 1
8S-8048 Saddle 1
A
8S-7641 Tube 1
5. Install link (3) into position. Apply Tooling (A) to pin
assembly (2). Install pin assembly (2) into position.
8S-7615 Pin 1
Secure pin assembly (2) with bolt (1).
End By: 8S-7630 Stand 1
a. Install the quick coupler. Refer to Disassembly and
Assembly, "QuickCoupler- Remove and Install". 8S-8048 Saddle 1
B
8S-7621 Tube 1
8S-7615 Pin 1

ZZ
Start By:
b. Remove the quick coupler. Refer to Disassembly
and Assembly, "Quick Coupler - Remove and
Install".
c. Remove the work tool linkage. Refer to
Disassembly and Assembly, "Work Tool Linkage
80 31200277

2. Apply a suitable lifting device to boom cylinder (2).

Apply tension.

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE Illustration 357 g01023028
OR THE INSTALLATION. THIS TOOLING IS SHOWN 3. Remove bolt (3) and pin assembly (4).
SERVICEMAN.
Illustration 355 g01022897 4. Lower boom cylinder (2) from the boom. Place the
boom cylinder onto suitable cribbing.
1. Install Tooling (A) under boom (1). Install Tooling (A)
at a level of approximately 1829 mm (6 ft).
31200277 81

5. Disconnect hose assemblies (5). 9. Lower boom (1). Install Tooling (B). Set Tooling (B)
at approximately 1016 mm (40 inches).

6. Attach a suitable lifting device to compensating
cylinder (6). 10. Remove bolts (9) and cover (10).
7. Remove bolt (7) and pin assembly (8). Lower
compensating cylinder (6).
Illustration 361 g01023071 11. Disconnect harness assembly (11).

8. Attach a suitable lifting device to boom (1). Apply
tension. Raise the boom and remove Tooling (A).
82 31200277
12. Remove cable strap (12). Disconnect harness 17. Attach a suitable lifting device to boom (1). Apply
assembly (13). tension.
13. Disconnect tube assemblies (14). Remove nuts 18. Remove bolt (19) and pin assembly (20).
(15). Remove hose assemblies (16) from boom
assembly (1).
14. Repeat Step 13 on the other side of the machine.
19. Remove boom (1). The weight of boom (1) is

Illustration 367 g01023144 20. Place boom (1) on Tooling (B).
15. Remove bolts (17). Position chassis lamp (18) out
of the way.
31200277 83
Boom - Disassemble
Table 28
Required Tools
Part system after the engine has been stopped. Serious
Tool Part Description Qty injury can be caused if this pressure is not released
Number
A 1P-1861 Snap Ring Pliers 1 Make sure all of the attachments have been
8S-7640 Stand 2
8S-8048 Saddle 2 when the engine is stopped, and the filler cap is cool
B enough to touch with your bare hand.
8S-7621 Tube 2 Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE
8S-7615 Pin 2 OR THE INSTALLATION. THIS TOOLING IS SHOWN
6V-9508 Tapered Cap/Plug 2 SERVICEMAN.

ZZ
Start By:
a. Remove the boom. Refer to Disassembly and
Assembly, "Boom - Remove and Install".
b. Remove the diverter valve. Refer to Disassembly
and Assembly, "Diverter Valve - Remove and
Install".
1. Remove nuts (1). Remove flood lamp gp (2).

Cylinders equipped with lock valves can remain 2. Remove cable straps from harness assemblies
pressurized for very long periods of time, even (3).
3. Remove bolts (4). Remove indicator group (5).

84 31200277
4. Use Tooling (A) in order to remove retaining ring (6). 7. Attach a suitable lifting device to telescoping
Remove pin (7). cylinder (10).
Note: Note the position of shims (11).
5. Remove tube assemblies (8). Illustration 377 g01023963
8. Remove telescoping cylinder (10) from boom (12).

9. Install Tooling (B) in order to support telescoping
cylinder (10).

31200277 85

11. Disconnect link (14). Remove hose assemblies (15) 15. Remove screws (20). Remove bracket (21).
from boom (12).

12. Remove connector (16) from harness assembly cylinder (10). The weight of telescoping cylinder
(17). (10) is approximately 113 kg (250 lb).

17. Move inner boom (13) from boom (12). Position
13. Disconnect link (18). inner boom (13) approximately 2.1 m (7 ft) from the
boom. Install Tooling (B).
14. Remove hose assemblies (19). Remove harness
assembly (17).
86 31200277
19. Remove wear pads (24). Remove shims (23). Illustration 388 g01024317
22. Remove bolts (27). Remove wear pads (25).

Remove shims (26).
Note: Note the position of shims (26).

21. Remove inner boom (13).
31200277 87
26. Disconnect tube assemblies (31) and (33).

Disconnect hose assembly (37). Remove bolts (35).
Remove control valve assembly (36).
23. Remove bolts (28). Remove wear pads (29).

Remove shims (30).
Note: Note the position of shims (30) to boom (12).
27. Remove hose assemblies (15). Remove harness

assembly (17). Remove guide (38). Remove guide
(39) from boom (12).
24. Remove bolts (34). Remove strap (32).

Disconnect hose assemblies (15) and (19) from
tube assemblies (31) and (33).
25. Remove tube assembly (31). Remove tube
assembly(33).
88 31200277
Boom -Assemble
Assembly Procedure
Table 29
Required Tools
Part
Number
8S-7640 Stand 2
8S-8048 Saddle 2
B 4. Connect hose assembly (37). Connect tube
8S-7621 Tube 2 assemblies (33) and (31).
5. Install strap (32). Secure strap (32) with bolts (34).
8S-7615 Pin 2
C 9S-3263 Sealant 1
6. Measure the wear surfaces of inner boom (13).

Measure the inside of boom (12). Measure the
thickness of wear pads (29) and (26). Add the
dimension of the wear pads to the measurement of
1. Install hose assemblies (15) into guide (39). Install the inner boom. Allow additional thickness to
hose assemblies (17) into guide (38). Install prevent binding of inner boom during operation.
harness assembly (17) into guide (38). The measurements will determine the shims.
2. Install guide (38) and (39) into boom (12).
3. Install control valve assembly (36) into position.

Secure control valve assembly (36) with bolts (35).
31200277 89
7. Install shims (29) that are required into position.

Install wear pads (30). Apply Tooling (C) to bolts
(28). Secure the wear pads with bolts (28). Tighten
bolts (28) to a torque of 75 ± 5 Nm (55 ± 4 lb ft).
8. Install shims (26) that are required into position.

(27). Secure the wear pads with bolts (27). Tighten
bolts (27) to a torque of 75 ± 5 Nm (55 ± 4 lb ft).
9. 9.Attach a suitable lifting device to inner boom (13).

10. 10.Install inner boom (13) into boom (12).
90 31200277

13. Install bracket (21). Secure bracket (21) with screws

(20).
11. Install shims (23) that are required into position. Illustration 404 g01024101
(22). Secure the wear pads with bolts (22). Tighten 14. Install hose assemblies (19). Install harness
bolts (22) to a torque of 75 ± 5 Nm (55 ± 4 lb ft). assembly (17).
15. Connect link (18).
12. Attach a suitable lifting device and move inner Illustration 405 g01024077
boom (13) from Tooling (B) into boom (12). Check
the inner boom for clearance and binding. 16. Install connector (16) onto harness assembly (17).
31200277 91
17. Install hose assemblies (15). 21. Install telescoping cylinder (10) into the inner
18. Connect link (14). boom and the boom.
22. Install shims (11) onto telescoping cylinder (10).

23. Secure telescoping cylinder (10) and shims (11) with
bolts (9).

cylinder (10). The weight of telescoping cylinder Illustration 411 g01023740
(10) is approximately 113 kg (250 lb).
24. Install tube assemblies (8).
92 31200277
Boom - Install
Table 30
Required Tools
Part
Number
8S-7640 Stand 1
8S-8048 Saddle 1
Illustration 412 g01023729 A
8S-7641 Tube 1
25. Install pin (7). Use Tooling (A) in order to install
retaining ring (6). 8S-7615 Pin 1
8S-7640 Stand 1
8S-8048 Saddle 1
B
8S-7621 Tube 1
8S-7615 Pin 1
C 1P-0808 Multipurpose Grease 1
26. Install indicator group (5) into position. Secure the

indicator group with bolts (4).
1. Remove boom (1) from Tooling (B).
27. Install flood lamp gp (2) into position. Secure

flood lamp gp with nuts (1).
28. Install cable straps onto harness assemblies (3).
End By:
a. Remove the diverter valve. Refer to Disassembly
and Assembly, "Diverter Valve - Remove and
Install".
b. Remove the boom. Refer to Disassembly and
Assembly, "Boom - Remove and Install".
31200277 93
2. Install boom (1) into position on the machine. The 7. Install hose assemblies (16) onto boom (1). Install
weight of boom (1) is 1134 kg (2500 lb). nuts (15). Connect tube assemblies (14).
3. Lower boom (1). Install Tooling (B). Set Tooling 8. Repeat Step 7on the other side of the machine.
(B) at approximately 1016 mm (40 inches).

9. Connect harness assembly (13). Secure harness
4. Install Tooling (C) to pin assembly (20). Install pin assembly with cable strap (12).
assembly (20) into boom (1). Install bolt (19) in
order to secure pin assembly (20).
Illustration 418 g01023144 10. Connect harness assembly (11).
5. Install chassis lamp (18) into position. Secure

chassis lamp (18) with bolts (17).
94 31200277
11. Install cover (10). Secure cover (10) with bolts (9). 13. Attach a suitable lifting device to compensating
cylinder (6). Install compensating cylinder into
position.
14. Install Tooling (C) onto pin assembly (8). Install
pin assembly (8). Secure pin (8) with bolt (7).
12. Attach a suitable lifting device to boom (1). Apply

tension. Raise the boom and install Tooling (A).

31200277 95

(Transmission and Hydraulic
System) - Remove and Install
Removal Procedure
Start By:
a. Remove the access plate. Refer to Disassembly
and Assembly, "Sump Guard - Remove and
Install".
b. Release hydraulic pressure. Refer to Disassembly
16. Attach a suitable nylon strap to boom cylinder (2).
Move boom cylinder from cribbing into position.

17. Apply Tooling (C) to pin assembly (4). Install pin Personal injury can result from hydraulic oil
assembly (4). Secure pin assembly (4) with bolt (3). pressure and hot oil.
End By: Hydraulic oil pressure can remain in the hydraulic
a. Install the quick coupler. Refer to Disassembly system after the engine has been stopped. Serious
and Assembly, "Quick Coupler - Remove and injury can be caused if this pressure is not released
Install". before any service is done on the hydraulic system.
b. Install the work tool linkage. Refer to Disassembly Make sure all of the attachments have been
and Assembly, "Work Tool Linkage - Remove and lowered, oil is cool before removing any
Install". components or lines. Remove the oil filler cap only

and under pressure.
contact with the skin and eyes to prevent personal
injury.
96 31200277
NOTICE
containing fluids.
mandates.
1. Put Identification marks on all hoses for installation
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 Operation and radiator (2).
Maintenance Manual, "Cooling System Coolant
2. Remove all hose clips and any cable straps which
(ELC) - Change".
secure hose (3).
from water pump (4).
from expansion tank (5) before removing the hose
from the machine.
Install Components
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 Gp - Coolant" for the part numbers for all
components.
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.
Oil Cooler (High Ambient Temperature
Cooling Arrangement)
Note: The following procedure will give additional
information that is required to install an oil cooler for the
high ambient temperature cooling arrangement.

Remove Components
31200277 97
2. Connect a new hose (3) to expansion tank (5) and Hitch Cylinder - Remove and
tighten the hose clamp.
3. Connect hose (3) to water pump (4) and tighten Install
the hose clamp.
4. Install all hose clips and any cable straps which Removal Procedure
secure hose (3).
Start By:
Note: A new hose clamp (6) is installed as part of the
installation procedure for the oil cooler. Refer to a. Remove the towing hitch. Refer to Disassembly
and Assembly, "Towing Hitch (Hydraulic) -
Disassembly and Assembly, "Transmission Oil Cooler -
Install".
b. Release hydraulic pressure. Refer to Disassembly
5. Connect a new hose (1) to radiator (2). and Assembly, "Hydraulic Pressure - Release".
Note: A new hose clamp (6) is installed as part of the
installation procedure for the oil cooler. Refer to
Disassembly and Assembly, "Transmission Oil Cooler -
Install".
Transmission Oil Cooler pressure and hot oil.
1. Clean all parts and inspect all parts. If any parts are Hydraulic oil pressure can remain in the hydraulic
worn or damaged, use new Caterpillar parts for system after the engine has been stopped. Serious
replacement. injury can be caused if this pressure is not released

2. At the underside of the machine, position oil cooler valve or disassembling a cylinder can result in
(2) and install bolts (4) and the washers. personal injury or death.
3. Connect hoses (3) and tighten the hose clamps. Ensure all pressure is relieved before removing a
4. Connect hoses (1) and tighten the hose clamps. lock valve or disassembling a cylinder.
5. Fill the cooling system. The capacity of the cooling
system is approximately 27.5 L (7.3 US gal). Refer
to Operation and Maintenance Manual, "Cooling
System Coolant (ELC) - Change".
End By:
a. Install the access plate. Refer to Disassembly and
Assembly, "Sump Guard - Remove and Install".
1. Remove spring pin (1). Remove pin (2).

98 31200277
2. Release latch (3). Remove slide assembly (5) from 5. Remove cylinder (10) from slide assembly (5).
hitch assembly (4).
3. Remove bolts (7). Remove hook assembly (6) from

slide assembly (5). Illustration 439 g01025295
1. Install cylinder (10) into slide assembly (5).
4. Remove spring pin (8). Remove pin (9). Illustration 440 g01025293
2. Install pin (9) into slide assembly (5) and through

cylinder (10). Install spring pin (8).
31200277 99
Towing Hitch (Hydraulic) -

Remove and Install
Removal Procedure
Table 31
Required Tools
Part
Number

Illustration 441 g01034105 ZZ
3. Install hook assembly (6) onto slide assembly (5).
Secure hook assembly (6) with bolts (7).
Start By:

system after the engine has been stopped.
Serious injury can be caused if this pressure is not
Illustration 442 g01025291 released before any service is done on the
hydraulic system.
4. Install slide assembly (5) into hitch assembly (4).
Engage latch (3). Make sure all of the attachments have been
when the engine is stopped, and the filler cap is
cool enough to touch with your bare hand.
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT
BE IDENTIFIED IN PHOTOGRAPHS IN THE
REMOVAL OR THE INSTALLATION. THIS
TOOLING IS SHOWN IN ORDER TO ASSIST THE
EXPERIENCED SERVICEMAN.
5. Install pin (2) into slide assembly and through

cylinder (10). Install spring pin (1).
End By:
a. Install the towing hitch. Refer to Disassembly and
Assembly, "Towing Hitch (Hydraulic) - Remove
and Install".
100 31200277
1. Disconnect two hose assemblies (1). Remove 4. Remove pin assembly (7). Remove towing hitch
hose assemblies(1). (6). The weight of the towing hitch is approximately
113 kg (250 lb).
2. Remove pin (2). Loosen nut (3). Remove clip (5).

Remove cable assembly (4). Move cable
assembly (4) out of the way. Illustration 449 g01025104
1. Attach a suitable lifting device to towing hitch (6).

Install towing hitch (6) into position on the
machine. The weight of the towing hitch is
3. Attach a suitable lifting device to towing hitch (6).

Apply tension to the lifting device.
2. Install pin assembly (7).

31200277 101
Control Valve (Trailer and

Towing Hitch) - Remove
Removal Procedure
Table 32
Required Tools

9U-7076 Face Seal Plug 2
3. Move cable assembly (4) into position. Install clip
(5). Tighten nut (3). Install pin (2). 9U-7077 Face Seal Plug 4
ZZ 6V-9508 Face Seal Plug 1

Start By:
b. Remove the towing hitch. Refer to Disassembly
4. Install hose assemblies (1). and Assembly, "Towing Hitch - Remove".
NOTICE
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.
Shop Products Guide" for tools and supplies suitable
mandates.
5. Connect hose assemblies (1). BE IDENTIFIED IN PHOTOGRAPHS IN THE

102 31200277
2. Remove tube assemblies (1) 5. Remove fittings (5). Remove bolts (6). Remove
control valve (7).
Control Valve (Trailer and Towing

Hitch) - Disassemble
Start By:
a. Remove the control valve (trailer and towing hitch).
Refer to Disassembly and Assembly,
"Control Valve (Trailer and Towing Hitch) - Remove
and Install".
3. Disconnect harness assemblies (2).
1. Remove bolts (1). Remove solenoid valve group

(2).
31200277 103
2. Remove fasteners (3). 5. Remove shaft (8), spring (9) and spacer (10).
6. Repeat Steps 2 through 5 on the opposite end.

3. Remove O-ring seal (4). Remove solenoid (5).
7. Remove spool (11).
4. Remove O-ring seal (6). Remove cartridge Illustration 464 g01021458

assembly (7).
8. Remove O-ring seals (12).
104 31200277
9. Remove load valve (13). 12. Remove O-ring seals (16) from the brake control
valve (15).

equipment.
10. Remove O-ring seals (14) from load valve (13).
13. Remove check valve (17).
11. Remove brake control valve (15).

31200277 105

Towing Hitch) - Assemble
Assembly Procedure
14. Remove nut (18) and remove O-ring seal (19).

Remove spring (20) and remove poppet (21) from
check valve (17).
1. Install plugs (22) into the valve body.
15. Remove plugs (22).

2. Install poppet (21) and spring (20) into check

valve (17). Install nut (18) and O-ring seal (19)
onto check valve (17).

equipment.
106 31200277

3. Install check valve (17) into the valve body.

6. Install O-ring seals (14) onto load valve (13).

4. Install O-ring seals (16) onto brake control valve 7. Install load valve (13) into the valve body.
(15).

8. Install O-ring seals (12) into the valve group.
5. Install brake control valve (15) into the valve
body.
31200277 107

9. Install spool (11) into the valve group.
12. Install solenoid (5) and install O-ring seal (4) onto
the valve group.
10. Install spacer (10), spring (9) and shaft (8) into the
valve group.
13. Install fastener (3).
14. Repeat Steps10 through13 on the opposite end.
11. Install O-ring seal (6). Install cartridge assembly

(7) into the valve group. Tighten cartridge
assembly to a torque of 20 ± 2 Nm (15 ± 1 lb ft). Illustration 485 g01021362
15. Install solenoid valve group (2). Install bolts (1).
End By:
a. Install the control valve (trailer and towing hitch).
Refer to Disassembly and Assembly, "Control Valve
(Trailer and Towing Hitch) - Remove and Install".
108 31200277

Towing Hitch) - Install
1. Clean all parts and inspect all parts. If any parts
are worn or damaged, use new Caterpillar parts
for replacement.
5. Install tube assemblies (1) to the control valve.
End By:
a. Install the towing hitch. Refer to Disassembly and
Assembly, "Towing Hitch - Install".
2. Install control valve (7) into position. Secure

valve (7) with bolts (6). Install fittings (5) onto
control valve (7).
3. Install plate (4) into position. Secure plate (4) with

bolts (3).
4. Connect harness assemblies (2).

31200277 109
Fuel Tank - Remove

Removal Procedure
Table 33
Required Tools
Part
Number
A 1U-7505 Transmission Jack 1

ZZ
4. Disconnect hoses (2). Disconnect harness
9U-7075 Tapered Cap/Plug 1 assembly (1).
Fuel leaked or spilled onto hot surfaces or

electrical components can cause a fire. Clean up
fuel spills immediately.
NOTICE
testing, adjusting and repair of the product. Be Illustration 491 g01016201
before opening any compartment or disassembling 5. Install Tooling (A) under fuel tank assembly (3).
any component containing fluids. Raise Tooling (A) in order to provide support.
mandates.
BE IDENTIFIED IN PHOTOGRAPHS IN THE
position. Illustration 492 g01016215
2. Put identification marks on all hoses and harness
assemblies for installation purposes. Plug all 6. Remove bolts (4).
hoses. This helps to keep contaminants from
entering the system.
3. Drain the fuel tank in order to remove this fuel
tank. The weight of the empty fuel tank assembly
is approximately 29.4 kg (65 lb). Any fuel in the
tank will increase this weight.
110 31200277
7. Remove bolts (5). 10. Remove bolt (11). Position strap (10) out of the
way.

8. Remove bolts (6). Remove fuel tank assembly (3)
from the machine. 11. Remove bolts (12). Position straps (13) out of the
way.
12. Remove fuel tank (9) from the fuel tank support.
Fuel Tank - Install

Table 34
Required Tools
Part
Number
A 1U-7505 Transmission Jack 1
9. Disconnect hose (7). Disconnect hose (8).
Fuel leaked or spilled onto hot surfaces or

electrical components can cause a fire. Clean up
fuel spills immediately.
31200277 111
NOTICE
mandates.
4. Connect hose (8). Connect hose (7).

1. Install fuel tank (9) onto the fuel tank support.
2. Place straps (13) into position. Secure straps (13) 5. Install Tooling (A) under fuel tank assembly (3).
and fuel tank (9) with bolts (12).
Illustration 499 g01016251 6. Install fuel tank assembly (3) into position on the
machine. The weight of the fuel tank assembly is
3. Place straps (10) into position. Secure straps (10) 29 kg (65 lb). Install bolts (6). Any fuel in the tank
and fuel tank (9) with bolt (11). will increase this weight.
112 31200277
Steering Wheel - Remove and

Install
Removal Procedure
Table 35
Required Tools
Slide Hammer Puller

Illustration 503 g01016216 156-7100 1
Gp
7. Install bolts (5). A 7X-2534 Bolt 2
9X-8256 Washer 2

position.

9. Remove Tooling (A).
2. Remove horn button (1) from the center of

steering wheel (2).
10. Connect hoses (2). Connect harness assembly

(1).
11. Fill the fuel tank. Check the fuel tank for leaks.
12. Move the battery disconnect switch to the ON Illustration 507 g01034138
position.
3. Disconnect wire (5) from horn button (1).
Remove screw (4) in order to disconnect wire (3)
from steering wheel (2). Remove the horn button.
31200277 113
2. Install the steering wheel onto the splined tapered

shaft on the steering column. Install nut (6) and
tighten the nut to a torque of 48 ± 5 Nm (35 ± 4
lb ft).
4. Loosen nut (6). Back off the nut by two full turns.
Do not remove the nut at this time.
3. Position horn button (1). Connect wire (5) to the

center of steering wheel (2) with screw (4).
Connect wire (3) to horn button (1).
5. Install Tooling (A). Use the tooling to pull steering

wheel (2) off the splined tapered shaft on the
steering column. When the steering wheel is
loose, remove Tooling (A), nut (6) and then
steering wheel (2).
4. Install horn button (1) into the center of steering

wheel (2).
5. Move the battery disconnect switch to the ON
Installation Procedure position.
Steering Column - Remove

Removal Procedure
Start By:
a. Remove the steering wheel. Refer to Disassembly
and Assembly, "Steering Wheel - Remove and
Install".
1. Feed wire (5) through the center of steering wheel position.
(2). 2. Put identification marks on all wires and on all
harnesses for installation purposes.
114 31200277
3. Remove the bolts that secure cover (1). 5. Remove the bolts that secure cover (5).

Right Side

Left Side
4. Carefully lower cover (1) and loosen the hose
clamp before disconnecting heater hose (2). 6. Carefully lift cover (5) in order to disconnect
Loosen retaining nut (3) and remove key start harness assembly (7) from switches (6). Remove
switch (4) from cover (1). Lay the key start switch the cover.
aside. Remove cover (1) from the machine.
31200277 115
7. Remove the bolts that secure display module (8). 10. Remove the bolts that secure housing (13).
Carefully remove the housing and at the same
time feed harness assembly (14) out of the
housing.
8. Carefully lift display module (8) and loosen bolt

(9) in order to disconnect harness assembly (10).
Remove the display module.
11. Carefully remove cover (15) and at the same time
feed harness assembly (14) and harness
assembly (16) out of the cover.
9. Disconnect harness assembly (11) from switch

(12) for directional turn signal control.
12. Disconnect harness assembly (17) from

transmission control (18). Disconnect wire (19).
116 31200277
Steering Column - Install

13. Remove bolts (20) and the locknut that secures

universal joint (21) to shaft (22).
1. Carefully lift steering column (24) into position

inside the cab.
14. Remove bolts (23) that secure steering column

(24) to mounting plate (25).
2. Align universal joint (21) with shaft (22) before

sliding the universal joint onto the shaft.
15. Carefully lift steering column (24) out of the cab.
3. Install bolts (23) in order to secure steering

column (24) to mounting plate (25).
31200277 117

4. Align the groove in shaft (22) with the bolt holes in

7. Carefully feed harness assembly (14) through
universal joint (21) before installing bolts (20) and
housing (13) before positioning the housing onto
the locknut. Tighten the bolt and the locknut to a
the steering column. Install the bolts in order to
tor que of 23±Nm(17±2 lb ft) .
secure the housing.
5. Connect harness assembly (17) to transmission 8. Connect harness assembly (11) to switch (12) for
control (18). Connect wire (19). the directional turn signal control.
6. Carefully feed harness assembly (16) and 9. Position display module (8) in order to connect
harness assembly (14) through cover (15) before harness assembly (10) before tightening bolt (9).
positioning the cover onto the steering column.
118 31200277
10. Install the bolts in order to secure display module 12. Install the bolts to secure cover (5).
(8).

Right Side

Left Side 13. Position cover (1) in order to install key start
switch (4) and retaining nut (3). Connect heater
11. Position cover (5) in order to connect harness hose (2) to cover (1) and tighten the hose clamp.
assemblies (7) to switches (6).
31200277 119

Selector) - Remove and Install
Removal Procedure


14. Carefully lift cover (1) and install the bolts in order Serious injury can be caused if this pressure is not
released before any service is done on the
to secure the cover.
hydraulic system.
15. Move the battery disconnect switch to the ON
position. Make sure all of the attachments have been
End By: removing any components or lines. Remove the
a. Install the steering Wheel. Refer to Disassembly oil filler cap only when the engine is stopped, and
and Assembly, "Steering Wheel - Remove and the filler cap is cool enough to touch with your
Install". bare hand.
NOTICE
mandates.
1. Put identification marks on all wires for installation

purposes.

120 31200277
Table 36
Required Tools
O-Ring Assembly
A 1U-6396 1
Compound
Illustration 545 g00939790 1. Clean all parts and inspect all parts. If any parts
3. Disconnect harness assemblies (2) from solenoid for replacement.
valve (3).

2. Apply a thin coat of Tooling (A) to O-ring seals (8)

4. Remove bolts (4) in order to remove solenoid
before installing the O-ring seals into solenoid
valve (3) from manifold (5).
valve (3). Install coils (7) and fasteners (6).
Tighten the fasteners to a torque of 4 ± 1 Nm
(35 ± 8.8 lb in).

5. Remove fasteners (6) in order to remove coils (7)
from solenoid valve (3). Remove O-ring seals (8).
3. Position solenoid valve (3) onto manifold (5) and
install bolts (4).
31200277 121
Metering Pump (Steering) -

Remove
Removal Procedure
Start By:

4. Connect harness assemblies (2) to solenoid pressure and hot oil.
valve (3).
Serious injury can be caused if this pressure is not
released before any service is done on the
hydraulic system.
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
5. Install cover (1). testing, adjusting and repair of the product. Be
mandates.
1. Put identification marks on all lines, on all hoses

lines and all hoses. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
122 31200277
2. Remove cover (1). 5. Disconnect harness assemblies (9) from solenoid

valve (10).

3. Disconnect hose assemblies (2) from the top
side of manifold (3). Loosen the hose clamp and 6. Remove the bolts that secure cover (11).
disconnect hose (4).

7. Carefully lower cover (11) and loosen the hose
clamp before disconnecting heater hose (12).
4. Disconnect hose assembly (5) from the bottom
side of manifold (3). Disconnect hose assembly Note: Hose (12) is a vent hose. Hose (12) does not
(7) from metering pump (8). contain coolant.
31200277 123
8. Loosen retaining nut (13) and remove key start 10. Use two people in order to support metering pump
switch (14) from cover (11). Set the key start switch (8) and at the same time remove locknuts (18),
aside. Remove cover (11) from the machine. washers (19), washers (20) and the outer half's of
mount (21). Carefully remove the metering pump
from the machine.
9. Remove bolt (15) and the locknut that secures

universal joint (16) to shaft (17).
11. Remove bolts (22) in order to remove manifold (3)
with solenoid valve (10) from metering pump (8).
12. Remove O-ring seals (23) from manifold (3).

124 31200277

2. Align the splines on shaft (17) with splines in
13. Remove washers (24) and the inner half's of metering pump (8) and install the shaft.
mounts (21) from plate (25). Remove seal (26).
Remove bolts (27) in order to remove plate (25).
Illustration 565 g00940112 3. Install plate (25) and bolts (27). Install seal (26).
Install mounts (21) and washers (24).
14. Remove shaft (17) from metering pump (8).
Metering Pump (Steering) -

Install
Table 37
Required Tools
Part
Tool Part Description Qty 4. Apply a thin coat of Tooling (A) to O-ring seals
Number
(23) before installing the O-ring seals into manifold
(3).
O-Ring Assembly
A 1U-6396 1
Compound

for replacement.
31200277 125
5. Position manifold (3) with solenoid valve (10) 7. Align the groove in shaft (17) with the bolt holes in
onto metering pump (8) and install bolts (22). universal joint (16) before installing bolt (15) and
the locknut. Tighten the bolt and the locknut to a
torque of 23 ±3 Nm (17 ± 2 lb ft).
6. With the aid of a second person, position Illustration 574 g00940137

metering pump (8) onto the machine. Align shaft
(17) with universal joint (16) before installing 8. Position cover (11) in order to install key start
mount (21), washers (20), washers (19) and switch (14) and retaining nut (13). Tighten the
locknuts (18). retaining nut to a torque of 13.6 ± 4 Nm (120 ±
35 lb in). Connect heater hose (12) and tighten
the hose clamp.
126 31200277
9. Carefully lift cover (11) and install the bolts in 12. Connect hose assembly (4) and tighten the hose
order to secure the cover. clamp. Connect hose assemblies (2) to the top
side of manifold (3).

10. Connect harness assemblies (9) to solenoid valve
(10). 13. Install cover (1).
Window Wiper and Wiper

Motor (Front) - Remove and
Install
Removal Procedure
Start By:

a. Turn the battery disconnect switch to the OFF
11. Connect hose assembly (7) to metering pump (8). Manual, "Battery Disconnect Switch".
Connect hose (5) to the bottom side of manifold
(3). 1. Put identification marks on all wires and all
connectors for installation purposes.
31200277 127
2. Remove cover (1). 5. Remove caps (9), nuts (10) and washers (11) in
order to remove wiper motor (8) from the machine.
are worn or damaged, use new Caterpillar parts for
replacement.
3. Disconnect hose (4) for the window washer. Open

covers (2) for wiper arms (3). Remove nuts (5)
before removing wiper arms (2).
2. Position wiper motor (8) on the machine and

install washers (11), nuts (10) and caps (9).
Tighten the nuts to a torque of 38 ± 3 Nm (28 ± 2
lb ft).
4. Cut cable strap (6) and disconnect harness

assembly (7) for wiper motor (8).
3. Connect harness assembly (7) for wiper motor (8)

and install a new cable strap (6).
128 31200277
4. Use the following procedure to install the wiper f. Connect hose (4) for the window washer.
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
Manual, "Battery Disconnect Switch".
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
Manual, "Window Wiper and Washer Control".

Motor (Rear) - Remove and
Install
Removal Procedure
Start By:
1. Put identification marks on all wires and all

d. Install wiper arm (3) so that the wiper blade Illustration 589 g00930278
is in full contact with the front left side of the
windshield. The wiper blade must be parallel 2. Remove bolts (2) in order to lower cab headliner
with the edge of the windshield at a distance of (1).
21 ± 3 mm (0.83 ± 0.12 inch). Note the black
arrows on illustration 586. 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 (2) for the wiper arm.
31200277 129

3. Disconnect harness (3) for dome light (4) and 5. Disconnect harness assembly (11) for wiper
harness (6) for speakers (5) before removing cab motor (12). Use two people in order to support the
headliner (1) from the cab. wiper motor from the inside of the cab. At the
same time remove nut (13), sealing washer (14),
cap (17), nut (16), and sealing washer (15).
Remove the wiper motor from the machine.
replacement.
4. Disconnect hose (8) for the windshield washer.

Open cap (9) for wiper arm (10) and remove nut
(17) before removing the wiper arm from the
machine.

130 31200277
2. Use two people in order to position wiper motor

(12) and install sealing washer (14), nut (13),
sealing washer (15), nut (16) and cap (17). Tighten
nut (16) to a torque of 8 ± 1 Nm (5.5 ± 0.4 lb ft).
Connect harness assembly (11).
3. Position cab headliner (1) in the cab in order to

enable the connection of harness assembly (5)
for speakers (6) and harness (3) for dome light
(4).
d. Position wiper arm (10) 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 598. Install nut (7)
and tighten the nut to a torque of 23 ± 1 Nm
(17 ± 0.7 lb ft).
more than four hours. Tighten nuts (7) again to
4. Lift cab headliner (1) into position and install bolts a torque of 23 ± 1 Nm (17 ± 0.7 lb ft). Close
(2). cover (9) for the wiper arm.
5. Use the following procedure to install the wiper f. Connect hose (8) for the window washer.
arm:
a. If a new wiper motor has been installed End By:
disregard Steps 5.b and 5.c. a. Turn the battery disconnect switch to the ON
b. Turn the battery disconnect switch to the ON position. Refer to Operation and Maintenance
position. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch".
front window wiper to the Off position. This will
31200277 131

Motor (Roof) - Remove and
Install
Removal Procedure
Start By:
1. Put identification marks on all wires and all Illustration 602 g01033035

4. Disconnect hose (12) for the windshield washer.
Uncouple cap (11) for wiper arm (7) at connector
(8). Open cap (9) and remove nut (10) and the
washer in order to remove wiper arm (7) from the
machine.
2. Remove bolts (2) in order to lower cab headliner

(1).
3. Disconnect harness (3) for dome light (4) and Illustration 604 g01027522
harness (6) for speakers (5) before removing cab
headliner (1) from the cab. 5. Disconnect harness assembly (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). Remove the wiper motor from the
machine.
132 31200277
replacement.
4. Lift cab headliner (1) into position and install bolts

(2).
5. Use the following procedure to install the wiper
Illustration 605 g01027522 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
front window wiper to the OFF position. This will
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 8 ± 1 Nm (5.5 ±
0.4 lb ft). Connect harness assembly (13).
3. Position cab headliner (1) in the cab in order to

enable the connection of harness assembly (6)
for speakers (5) and harness (3) for dome light
(4).
31200277 133
d. Couple cap (8) onto connector (10) for wiper

arm (9). 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 127 ± 3 mm (5 ± 0.1 inch). Note the
black arrows on illustration 609. Install nut (12)
and tighten the nut to a torque of 23 ± 1 Nm
(17 ±0.7 lb ft).
more than four hours. Tighten nuts (12) again
to a torque of 23 ± 1 Nm (17 ± 0.7 lb ft). Close
cover (11) for the wiper arm.
f. Connect hose (7) for the window washer. Illustration 612 g01027504
End By: 2. Disconnect harness assemblies (5) from joystick

control (6).
a. Turn the battery disconnect switch to the ON
Joystick Control - Remove and

Install
Removal Procedure
Start By:
a. Remove the seat. Refer to Disassembly and
Assembly, "Seat - Remove and Install". Illustration 613 g00941412
Note: Put identification marks on all wires for 3. Lift boot (7) in order to gain access to the top side
installation purposes. of joystick control (6).

4. Remove bolts (8) and the washers before
1. Loosen knob (1) in order to remove cushion (2). carefully removing joystick control (6) from the
Remove cover (3) and cover (4). machine.
134 31200277
4. Install cover (4) and cover (3). Install cushion (2)

and tighten knob (1).
1. Position joystick control (6) and install bolts (8) 5. Calibrate the joystick control. Refer to Systems
and the washers in order to secure the joystick Operation, Testing and Adjusting, "Main Control
control to the machine. Valve (Implement) - Calibrate".
End By:
a. Install the seat. Refer to Disassembly and
Assembly, "Seat - Remove and Install".
Seat - Remove and Install

Removal Procedure
2. Install boot (7).
1. At the rear bottom of the seat, disconnect harness

assembly (1).
3. Connect harness assemblies(5) to joystick control

(6).
31200277 135
2. Remove bolts (2) and the washers. 2. Install bolts (2) and the washers.
3. With the aid of a second person, remove seat (3) Illustration 624 g00931937
from the machine. The weight of the seat is

3. At the rear bottom of the seat, connect harness
assembly (1).
1. With the aid of a second person, install seat (3)

into the cab of the machine. The weight of the
seat is approximately 30 kg (66 lb).
136 31200277
Cab Heater - Remove NOTICE

Removal Procedure testing, adjusting and repair of the product. Be
Start By: prepared to collect the fluid with suitable containers
mandates.
Personal injury can result from contact with
refrigerant. 1. Remove the primary air filter and the secondary
air filter for the cab. Refer to Operation and
Contact with refrigerant can cause frost bite. Keep Maintenance Manual, "Cab Air Filter -Clean/
face and hands away to help prevent injury. Replace".
Protective goggles must always be worn when 2. Recover the air conditioner refrigerant from
refrigerant lines are opened, even if the gauges the air conditioner system (if equipped). The
indicate the system is empty of refrigerant. correct charge is 0.8 kg (1.8 lb). Refer to Service
Always use precaution when a fitting is removed. Manual, "Air Conditioning and
Slowly loosen the fitting. If the system is still Heating Systems with R-134a Refrigerant" for the
under pressure, release it slowly in a well correct procedure. Refer to Special Publication,
ventilated area. "Air Conditioning Tools" for the
Personal injury or death can result from inhaling correct tools.
refrigerant through a lit cigarette. 3. Put identification marks on all hoses for installation
Inhaling air conditioner refrigerant gas through a purposes. Plug all hoses. This helps to prevent
lit cigarette or other smoking method or inhaling fluid loss and this helps to keep contaminants
fumes released from a flame contacting air from entering the system.
conditioner refrigerant gas, can cause bodily 4. Drain the coolant from the cooling system into a
harm or death. suitable container for storage or disposal. The
Maintenance Manual, "Cooling System (ELC) -
Use a certified recovery and recycling cart to Change".
properly remove the refrigerant from the air
conditioning system.
At operating temperature, the engine coolant is

hot and under pressure.
Cooling system conditioner contains alkali. Avoid 5. Loosen knob (1) in order to remove cushion (2).
contact with the skin and eyes to prevent personal Remove cover (3) and cover (4).
injury.
31200277 137

6. Remove the bolts from the outside of the cab in 8. Remove the bolts and move cover (7) until you are
order to remove cover (5). able to disconnect harness assembly (8). remove
the cover from the machine.

138 31200277
10. Remove cover plate (10). 14. Raise heater (16). Position suitable cribbing
11. Remove the cable straps. under the heater.
15. Remove bolts (17) in order to remove two relays
(18) from the outside of heater (16).
12. At the underside of the machine, remove bolt (11)

in order to disconnect cable (12). Disconnect Illustration 636 g01020474
heater hoses (13). Disconnect hose assemblies
(14) for the air conditioner (if equipped). 16. Carefully remove heater (16) from the machine.
Cab Heater - Install

for replacement.
13. At the underside of the machine, disconnect two

harness assemblies (15).

31200277 139
2. Carefully position heater (16) onto the machine.

6. Install cover plate (10).
3. At the underside of the machine, position relays 7. Install cable straps.
(18) onto the outside of heater (16) before
installing bolts (17).

5. Connect hose assemblies (14) for the air

conditioner (if equipped). Connect heater hoses
(13). Install bolt (11) in order to connect cable (12).
140 31200277
9. Connect harness assembly (8) before sliding 11. Position cover (5) before installing the bolts that
cover (7) into position. secure the cover from the outside of the cab.

12. Install cover (4) and cover (3). Install cushion (2)
and tighten knob (1).
13. Fill the cooling system. The capacity of the cooling
system is approximately 27.5 L (7.3 US gal). Refer
to Operation and Maintenance Manual, "Cooling
System (ELC) - Change".
14. Charge the air conditioner system (if equipped).
The correct charge is 0.8 kg (1.8 lb). Refer to
Service Manual, "Air Conditioning
and Heating Systems with R-134a Refrigerant"
for the procedure. Refer to Special Publication,
"Air Conditioning Tools".
15. Install the primary air filter and the secondary
air filter for the cab. Refer to Operation and
Maintenance Manual, "Cab Air Filter -Clean/
Replace".
End By:
31200277 141
Heater Core - Remove and Installation Procedure

Install 1. Clean all parts and inspect all parts. If any parts
for replacement.
Removal Procedure
Start By:
a. Remove the cab heater. Refer to Disassembly and
Assembly, "Cab Heater - Remove".
2. Position heater coil (3) into heater group (4) and

install bolts (2) and the washers.
1. Remove gasket (1).
3. Install gasket (1).
Illustration 650 g00944912 End By:
2. Remove bolts (2) and the washers in order to a. Install the cab heater. Refer to Disassembly and
Assembly, "Cab Heater - Install".
remove heater coil (3) from heater group (4).
142 31200277
Air Conditioner - Remove 2. Refer to Illustration 653 and Illustration 659 in

order to display the location and the routing of
hose assemblies and sensors.
Removal Procedure NOTICE
refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Shop Products Guide" for tools and supplies suitable to
Protective goggles must always be worn when collect and contain fluids on Caterpillar products.
mandates.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well
ventilated area.
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.
Use a certified recovery and recycling cart to
Note: Put identification marks on all tubes, on all hose
assemblies, and on all wires for installation purposes.
Plug all hose assemblies, and tube assemblies. This
helps to prevent fluid loss and this helps to keep
contaminants from entering the system. 0
Note: Recover the refrigerant before any hose
assemblies are loosened or any bolts are loosened.
Note: The following procedure gives details of
removal of an air conditioner. The air conditioner is
supplied as a kit and can be purchased from a
Caterpillar Dealer. Refer to the Parts Manual, "Air
Conditioner Ar". The air conditioner can only be
removed 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. Recover the air conditioner refrigerant from the air
(2.0 lb). Refer to Service Manual, "Air
Conditioning and Heating Systems with R-134a
Refrigerant" for the procedure. Refer to Special
Publication, "Air Conditioning Tools"
for the tools.
31200277 143

The upper illustration is a top view. The lower illustration is a side view.
144 31200277
3. Use the following steps to remove the air

conditioner harness. Refer to illustration 653 which
shows the correct routing. Refer to Parts Manual,
"Air Conditioner Ar" for all the part numbers of the
components.
d. Disconnect the harness assembly at location (4) for

the high pressure switch.
a. Disconnect the harness assembly at location (1) for

the low pressure switch.
e. Disconnect the harness assembly at location (5) for

the electronic control group.
b. Disconnect the harness assembly at location (2) at

the compressor clutch.
c. Disconnect the harness assembly at location (3)

which is at the underside of the intake hose from the
air cleaner to the turbocharger. The harness
assembly connects the air conditioner harness to the
main harness for the machine.
31200277 145

The upper illustration is a top view. The lower illustration is a side view.
146 31200277
4. Use the following steps to install all hoses, and

tubes. Refer to illustration 659 which shows the
correct routing. Refer to Parts Manual, "Air
Conditioner Ar" for all the part numbers of the
components which include elbows, connectors,
switches and tee's which are installed in the major
components.
a. Disconnect hose (6) from the bottom of the
refrigerant condenser to the evaporator coil.
b. Disconnect hose (7) from the accumulator to
the refrigerant compressor.
c. Disconnect hose (8) from the evaporator coil to
the accumulator. Illustration 662 g01029298
d. Disconnect hose (9) from the refrigerant
compressor to the top of the refrigerant 7. Remove the plastic cover from the panel. Find
condenser. the connector in the main harness for the air
conditioner. Refer to the Electrical Schematic for
the color codes for the connector wires. Remove
switch (14).
5. Remove the three tubes (10). The tubes will

allow any condensation to drain. Remove three
plastic plugs from the base of the heater group.
8. Disconnect accumulator (15). Refer to illustration
659 for the location and the orientation of the
accumulator.
9. Remove the evaporator coil. Refer to Disassembly
and Assembly, "Evaporator Coil - Remove" and
the Parts Manual, "Air Conditioner Ar".
10. Remove the refrigerant compressor. Refer
to Disassembly and Assembly, "Refrigerant
Compressor- Remove" and the Parts
Manual, "Air Conditioner Ar".
11. Remove the refrigerant condenser. Refer to
Disassembly and Assembly, "Refrigerant
Illustration 661 g01029297 Condenser - Remove" and the Parts Manual, "Air
Conditioner Ar".
6. Remove thermostatic switch (11) before
disconnecting the main cab harness (13). Feed
capillary tube (12) through the hole in the heater
group to the evaporator coil. Refer to Disassembly
and Assembly, "Evaporator Coil - Remove" for the
installation dimension of the capillary tube.
31200277 147
Air Conditioner - Install 1. Install the refrigerant condenser. Refer to

Condenser - Install" and the Parts Manual, "Air
Installation Procedure Conditioner Ar".
2. Install the refrigerant compressor. Refer to
Compressor- Install" and the Parts Manual, "Air
Conditioner Ar".
Personal injury can result from contact with 3. Install the evaporator coil. Refer to Disassembly
refrigerant. and Assembly, "Evaporator Coil - Install" and the
Contact with refrigerant can cause frost bite. Keep Parts Manual, "Air Conditioner Ar".
face and hands away to help prevent injury.
Slowly loosen the fitting. If the system is still
ventilated area.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling Illustration 664 g01033331
conditioner refrigerant gas, can cause bodily 4. Install accumulator (15). Refer to illustration 668
harm or death. for the location and the orientation of the
Do not smoke when servicing air conditioners or accumulator.
NOTICE
Shop Products Guide" for tools and supplies suitable to Illustration 665 g01029298
collect and contain fluids on Caterpillar products.

5. Remove the plastic cover from the panel. Find
Dispose of all fluids according to local regulations and the connector in the main harness for the air
mandates. conditioner. Refer to the Electrical Schematic for
Note: The following procedure gives details of the color codes for the connector wires. Install
installing an air conditioner for the first time. The air switch (14).
conditioner is supplied as a kit and can be purchased
from a Caterpillar Dealer. Refer to the Parts Manual,
"Air Conditioner Ar". 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.
148 31200277
6. Install thermostatic switch (11) before connecting

the main cab harness (13). Feed capillary tube
(12) 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.
7. Remove three plastic plugs from the base of the

heater group and install the three tubes (10). The
tubes will allow any condensation to drain.
8. Use the following steps to install all hoses, and
tubes. Refer to illustration 668 which shows
the correct routing. Refer to Parts Manual, "Air
components which include elbows, connectors,
switches and tee's which are installed in the major
components.
31200277 149

150 31200277
a. Connect hose (9) from the refrigerant

compressor to the top of the refrigerant
condenser.
b. b.Connect hose (8) from the accumulator to the
refrigerant compressor.
c. c.Connect hose (7) from the evaporator coil to
the accumulator.
d. d.Connect hose (6) from the bottom of the
refrigerant condenser to the evaporator coil.
9. Use the following steps to install the air conditioner
harness. Refer to illustration 669 which shows the
correct routing. Refer to Parts Manual, "Air
components.
31200277 151

152 31200277

d. Connect the harness assembly at location (2) at
a. Connect the harness assembly at location (5) for the compressor clutch.
the electronic control group.

e. Connect the harness assembly at location (1) for

b. Connect the harness assembly at location (4) for the low pressure switch.
the high pressure switch.
10. Install the decals for the refrigerant. Refer to
Operation and Maintenance Manual, "Safety
Section - Additional Messages".
11. Charge the air conditioner system. The correct
charge is 0.8 kg (1.8 lb). Refer to Service Manual,
"Air Conditioning and Heating Systems with
R-134a Refrigerant" for the procedure. Refer to
Special Publication, "Air Conditioning
Tools".
c. Connect the harness assembly at location (3)

which is at the underside of the intake hose from
the air cleaner to the turbocharger. The harness
assembly connects the air conditioner harness to
the main harness for the machine.
31200277 153
Evaporator Coil - Remove and

Install
Removal Procedure
Start By:
a. Remove the cab heater. Refer to Disassembly and
Assembly, "Cab Heater - Remove".
3. Remove bolts (4) and the washers in order to

remove evaporator coil (3) from the heater group.
for replacement.
1. Remove pad (1).
2. Remove capillary tube (2) for the thermostat

switch out of evaporator coil (3).
2. Position evaporator coil (3) in the heater group

and install bolts (4) and the washers.
154 31200277
Blower Motor (Air Conditioner

and Heater) - Remove and
Install
Removal Procedure
Start By:
1. Remove the primary air filter. Remove the
secondary air filter. Refer to Operation and
Maintenance Manual, "Primary and Secondary
3. Install capillary tube (2) for the thermostat switch Air Filter- Remove and Install".
into evaporator coil (3). The capillary tube must be
inserted into the evaporator coil at a minimum of
150 mm (6 inch).
4. Install pad (1).
End By:
a. Install the cab heater. Refer to Disassembly and
Assembly, "Cab Heater - Install".

The photo of cover (2) is from the inside of the cab
2. Remove bolts (1) and cover (2).

31200277 155
3. Remove bolts (3) and cover (4). 5. Remove knob (8). Remove armrest (9). Remove
grip (10).

4. Remove bolts (5). Move cover (6) in order to

allow access to harness assembly (7). Illustration 690 g01019238
Disconnect harness assembly (7). Remove cover
(6). 7. Remove bolts (13). Remove cover (14).
156 31200277
8. Remove bolts (15). Remove cover (16). 11. Disconnect harness assembly (21).
9. Cut cable straps (17). Cable straps (17) secure 12. Remove bolt (22).
harness assembly (18). Move harness assembly
(18) out of the way.

13. Remove pad (23). Disconnect harness assembly
10. Remove bolts (19). Remove panel (20). (25). Remove bolts (24).
31200277 157
14. Remove capillary tube (26) from evaporator coil 2. Install blower motor (28) into position. Install
(27) of the air conditioner. Remove blower motor capillary tube (26) onto evaporator coil (27).
(28).

3. Install bolts (24). Install pad (23). Connect
15. Remove screws (29). Remove blower motor (28) harness assembly (25).
from panel (30).
1. Install blower motor (28) onto panel (30). Secure

blower motor (28) with screws (29).
158 31200277
5. Connect harness assembly (21). 8. Install cover (16). Secure cover (16) with bolts
(15).

6. Install panel (20). Secure panel (20) with bolts
(19). 9. Install cover (14). Secure cover (16) with bolts
(13).
7. Move harness assembly (18) into position. Illustration 708 g01019234

Secure harness assembly with cable straps (17).
10. Install cover (12). Secure cover (16) with bolts
(11).
31200277 159
11. Install grip (10). Install armrest (9). install knob (8). 13. Install cover (4). Secure cover (4) with bolts (3).


12. Connect harness assembly (7). Install cover (6).
Secure cover (6) with bolts (5). 14. Install cover (2). Secure cover (2) with bolts (1).
15. Install the primary air filter. Remove the secondary
air filter. Refer to Operation and Maintenance
Manual, "Primary and Secondary Air Filter -
End By:
160 31200277
Cab - Remove
Removal Procedure
Table 38
refrigerant.
Required Tools
Contact with refrigerant can cause frost bite. Keep
Tool Part Number Part Description Qty face and hands away to help prevent injury.
9U-7068 Plug 2 Protective goggles must always be worn when
9U-7069 Plug 2
ZZ indicate the system is empty of refrigerant.
9U-7073 Plug 2
9U-7074 Plug 2 Slowly loosen the fitting. If the system is still
ventilated area.
Start By: Personal injury or death can result from inhaling
a. Remove the hydraulic tank. Refer to Disassembly refrigerant through a lit cigarette.
and Assembly, "Hydraulic Tank-Remove". Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
conditioner refrigerant gas, can cause bodily
harm or death.
component. Install blocks or stands before NOTICE
performance of any work under a heavy Care must be taken to ensure that fluids are contained
component. during performance of inspection, maintenance,
Approximate weights of the components are testing, adjusting and repair of the product. Be
shown. Clean all surfaces where parts are to be prepared to collect the fluid with suitable containers
installed. before opening any compartment or disassembling
Personal injury can result from hydraulic oil mandates.
Hydraulic oil pressure can remain in the hydraulic BE IDENTIFIED IN PHOTOGRAPHS IN THE
system after the engine has been stopped. REMOVAL OR THE INSTALLATION. THIS
Serious injury can be caused if this pressure is not TOOLING IS SHOWN IN ORDER TO ASSIST THE
released before any service is done on the EXPERIENCED SERVICEMAN.
hydraulic system.
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.
31200277 161
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 Operation and Maintenance Manual, "Parking
Brake - Check".
2. If equipped, recover the air conditioner refrigerant
from the air conditioner system (if equipped).
The correct charge is 0.8 kg (1.8 lb). Refer to
Service Manual, "Air Conditioning and
Heating Systems with R-134a Refrigerant" for the
correct procedure. Refer to Special Publication,
"Air Conditioning Tools" for the
correct tools. Illustration 717 g01027633
purposes. Plug all hoses. This helps to prevent 7. Disconnect hose assemblies (5) from the top
fluid loss and this helps to keep contaminants side of manifold (6). Loosen the hose clamp and
from entering the system. disconnect hose (7).
Maintenance Manual, "Cooling System (ELC) -
Change".
8. Disconnect hose assembly (8) from the bottom

side of manifold (6). Disconnect hose assembly
(9) from metering pump (10).
9. Remove bolt (11) and the washer in order to

disconnect ground strap (12).
6. Disconnect hose assemblies (2) from master

cylinder (3). Loosen the hose clamp and
disconnect hose (4).
162 31200277
10. Remove cable assembly (13) from the towing 13. Remove clip (17) and pin (20) in order to
hitch. disconnect cable (16) from lever (22). Remove
bolts (19) and the washers in order to remove
bracket (18) from parking brake (21). Trace the
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.
14. Disconnect hose assemblies (24). Disconnect

hose assemblies (23). Hose assemblies (23) are
for the air conditioner, if equipped.
12. Make a note of the routing of cable assembly

(13) prior to complete removal from the machine.
Trace the cable back to the cab and remove all
cable straps and clips that secure the cable.

31200277 163
15. Loosen bolts (25) in order to disconnect harness

assemblies (26) from the underside of the cab.
Disconnect harness assembly (27). Remove nut
(28) and the washer in order to disconnect positive
cable (29) from the terminal block which is located
on the side of the chassis which is near to the
exhaust muffler. Trace the 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.
16. Attach a suitable lifting device to cab (30).

164 31200277
Front Cab Mounts
17. At the underside of the machine, remove bolts (35),

washers (34), washers (33) and the bottom half's of
mount (32).

Rear Cab Mounts
31200277 165

Rear Cab Mounts
18. Remove bolts (36), washers (37), washers (39),

nuts (41) and the top half's of mount (38).

Front Cab Mounts
19. Carefully use a suitable lifting device and lift cab

20. Remove the two top half's of mounts (42) and two
(30) from the machine. Be sure not to foul any
sleeve's (31) from the chassis. Refer to Illustration
loose hoses or wires. The weight of the cab is
728.
166 31200277

Rear Cab Mounts
2. Install two half's of mounts (42) into the chassis and
21. Remove the two top half's of mounts (43) and two insert two sleeves (31) into the mounts.
sleeve's (40) from the chassis. Refer to Illustration
730.
Cab - Install
3. Attach a suitable lifting device between a suitable

hoist and the lifting brackets which are located at
the front and rear corners of cab (30). Attach a
suitable lifting device to the cab. The weight of the
cab is approximately 600 kg (1322 lb).
4. Carefully lower cab (30) into position on the
machine.
1. Place two half's of mounts (43) onto the chassis

and insert two sleeves (40) into the mounts.
31200277 167
5. Install bolts (36), washers (37), washers (39), nuts

(41) and the top half's of mounts (38). Tighten the
nuts and bolts to a torque of 450 Nm (332 lb ft).
168 31200277
6. Install bolts (35), washers (34), washers (33) and

the bottom half's of mounts (32). Tighten the bolts
to a torque of 450 Nm (332 lb ft).
8. At the underside of the cab, connect harness

assemblies (26) and tighten bolts (25). Connect
harness assembly (27). Route positive cable (29)
7. Remove the lifting equipment from cab (30). to the terminal block which is located on the side
of the chassis which is near to the exhaust muffler.
Install nut (28) and the washer in order to connect
the positive cable to the terminal block. Install all
cable straps and clips that were removed and
noted in the removal procedure.

31200277 169

12. Install panel (15) into position. Secure panel (15)

9. Connect hose assemblies (23) for the air
conditioner (if equipped). Connect two heater with bolts (14).
hoses (24) and tighten the hose clamps.

13. Install cable assembly (13).
10. Route cable (16) from the cab to the parking brake.
Position bracket (18) onto parking brake (21) and
install bolts (19) and the washers. Align cable (16)
with lever (22) and install pin (20) and clip (17).
Install all cable straps and clips that were removed
and noted in the removal procedure.
14. Install ground strap (12) into position. Secure

ground strap with the washer and bolt (11).
11. Route cable (13) from the cab. Install all cable
straps that were removed and noted in the
removal procedure.
170 31200277
15. Connect hose assembly (9) to metering pump 18. Install cover (1).
(10). Connect hose assembly to the bottom side 19. Fill the cooling system with coolant. The capacity
of manifold (6). of the cooling system is approximately 27.5 L
(7.3 US gal). Refer to Operation and Maintenance
Manual, "Cooling System (ELC) - Change".
20. If equipped, charge the air conditioner system
with refrigerant. The correct charge is 0.8 kg
(1.8 lb). Refer to Service Manual, "Air
Conditioning and Heating Systems with R-134a
Refrigerant" for the correct procedure. Refer to
Special Publication, "Air Conditioning
Tools" for the correct tools.
End By:
a. Install the hydraulic tank. Refer to Disassembly
Illustration 750 g01027633 and Assembly, "Hydraulic Tank - Remove".
16. Connect hose (7). Secure hose (7) with a hose

clamp. Connect hose assemblies (5) to the top
side of manifold (6).
17. Connect hose (4). Secure hose (4) with a hose

clamp. Connect hose assemblies (2) to brake
control valve (3).
31200277 171
Fender - Remove and Install

Removal Procedure
1. Remove 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.
1. Position fender (1) on axle hub (3) and install nuts

(2) with the washers.
2. Repeat Step 1 in order to install the remaining
fenders.
172 31200277
31200277 173
Index Index
A Removal Procedure ...................................................... 42

Air Conditioner - Install Control Valve (Compensating Cylinder) - Remove and
Install.................................................................................. 42
Installation Procedure................................................. 147
Control Valve (Trailer and Towing Hitch) - Assemble
Air Conditioner - Install..................................................... 147
Assembly Procedure................................................... 105
Air Conditioner - Remove
Control Valve (Trailer and Towing Hitch) - Assemble ...... 105
Removal Procedure.................................................... 142
Control Valve (Trailer and Towing Hitch) - Disassemble.. 102
Air Conditioner - Remove................................................. 142
Disassembly Procedure.............................................. 102
B Control Valve (Trailer and Towing Hitch) - Install
Bank Valve (Implement) -Assemble Installation Procedure ................................................. 108
Assembly Procedure..................................................... 31 Control Valve (Trailer and Towing Hitch) - Install............. 108
Bank Valve (Implement) -Assemble................................... 31 Control Valve (Trailer and Towing Hitch) - Remove
Bank Valve (Implement) -Disassemble Removal Procedure .................................................... 101
Disassembly Procedure................................................ 24 Control Valve (Trailer and Towing Hitch) - Remove......... 101
Bank Valve (Implement) -Disassemble .............................. 24 Coupler Cylinder - Remove and Install
Blower Motor (Air Conditioner and Heater) - Remove and Installation Procedure ................................................... 72
Install Removal Procedure ...................................................... 70
Installation procedure ................................................. 157 Coupler Cylinder - Remove and Install .............................. 70
D
Blower Motor (Air Conditioner and Heater) -
Remove and Install .......................................................... 154 Disassembly and Assembly Section .................................... 3
Boom - Disassemble Diverter Valve (Boom Head) -Remove and Install
Disassembly Procedure................................................ 83 Installation Procedure ................................................... 61
Boom - Disassemble .......................................................... 83 Removal Procedure ...................................................... 60
Boom - Install Diverter Valve (Boom Head) -Remove and Install ............. 60
E
Boom - Install ..................................................................... 92
Boom - Remove Electronic Pilot Valve - Remove and Install
Removal Procedure...................................................... 79 Installation Procedure ................................................... 23
Boom - Remove ................................................................. 79 Removal Procedure ...................................................... 22
Boom -Assemble Electronic Pilot Valve - Remove and Install ....................... 22
Assembly Procedure..................................................... 88 Evaporator Coil - Remove and Install
Boom -Assemble................................................................ 88 Installation procedure ................................................. 153
Boom Cylinder - Remove and Install Removal Procedure .................................................... 153
Installation Procedure................................................... 68 Evaporator Coil - Remove and Install .............................. 153
Removal Procedure...................................................... 65 F
Boom Cylinder - Remove and Install.................................. 65
Fender - Remove and Install
Bottom Guard - Remove and Install..................................... 3
Fender - Remove and Install ............................................ 171
C Fuel Tank - Install
Cab - Install Installation Procedure ................................................. 110
Installation Procedure................................................. 166 Fuel Tank - Install............................................................. 110
Cab - Install ...................................................................... 166 Fuel Tank - Remove
Cab - Remove Removal Procedure .................................................... 109
Removal Procedure.................................................... 160 Fuel Tank - Remove......................................................... 109
Cab - Remove .................................................................. 160 H
Cab Heater - Install
Heater Core - Remove and Install
Installation Procedure................................................. 138
Cab Heater - Install .......................................................... 138
Cab Heater - Remove
Heater Core - Remove and Install.................................... 141
Hitch Cylinder - Remove and Install
Cab Heater - Remove ...................................................... 136
Compensating Cylinder Remove and Install
Removal Procedure ...................................................... 97
Hitch Cylinder - Remove and Install ................................... 97
Hydraulic Oil Cooler (Transmission and Hydraulic System) -
Compensating Cylinder Remove and Install ...................... 44 Remove and Install
Control Valve (Compensating Cylinder) - Remove and Install Installation Procedure ................................................... 96
Installation Procedure................................................... 43 Removal Procedure ...................................................... 95
174 31200277
Index
Hydraulic Oil Cooler (Transmission and Hydraulic System) - S

Remove and Install ............................................................ 95
Seat - Remove and Install................................................ 134
Hydraulic System Pressure -Release
Release Procedure ......................................................... 3
Hydraulic System Pressure -Release .................................. 3
Solenoid Valve (Steering Mode Selector) - Remove and Install
Hydraulic Tank - Install
Hydraulic Tank - Install......................................................... 6
Solenoid Valve (Steering Mode Selector) -
Hydraulic Tank - Remove Remove and Install .......................................................... 119
Removal Procedure ........................................................ 4 Steering Column - Install
Hydraulic Tank - Remove..................................................... 4 Installation Procedure ................................................. 116
I Steering Column - Install .................................................. 116
Steering Column - Remove
Important Safety Information................................................. ii
J Steering Column - Remove.............................................. 113
Joystick Control - Remove and Install Steering Wheel - Remove and Install
Installation Procedure ................................................. 134 Installation Procedure ................................................. 113
Removal Procedure .................................................... 133 Removal Procedure .................................................... 112
Joystick Control - Remove and Install.............................. 133 Steering Wheel - Remove and Install............................... 112
L T
Load Control Valve (Boom Cylinder) - Remove and Install Table of Contents................................................................. 1
Installation Procedure ................................................... 63 Telescoping Cylinder - Remove and Install
Removal Procedure ...................................................... 62 Installation Procedure ................................................... 56
Load Control Valve (Boom Cylinder) - Remove and Install 62 Removal Procedure ...................................................... 52
Load Control Valve (Telescoping Cylinder) Remove and Install Telescoping Cylinder - Remove and Install........................ 52
Installation Procedure ................................................... 50 Tilt Cylinder - Remove and Install
Removal Procedure ...................................................... 48 Installation Procedure ................................................... 41
Load Control Valve (Telescoping Cylinder) Remove and Removal Procedure ...................................................... 39
Install.................................................................................. 48 Tilt Cylinder - Remove and Install ...................................... 39
Towing Hitch (Hydraulic) -Remove and Install
M
Main Control Valve (Implement) - Install Removal Procedure ...................................................... 99
Installation Procedure ................................................... 37 Towing Hitch (Hydraulic) -Remove and Install ................... 99
Main Control Valve (Implement) - Install ............................ 37
Metering Pump (Steering) -Install W
Installation Procedure ................................................. 124 Window Wiper and Wiper Motor (Front) - Remove and Install
Metering Pump (Steering) -Install .................................... 124 Installation Procedure ................................................. 127
Metering Pump (Steering) -Remove Removal Procedure .................................................... 126
Removal Procedure .................................................... 121 Window Wiper and Wiper Motor (Front) -
Metering Pump (Steering) -Remove ................................ 121 Remove and Install .......................................................... 126
Window Wiper and Wiper Motor (Rear) - Remove and Install
P Installation Procedure ................................................. 129
Piston Pump (Implement and Steering) - Disassemble Removal Procedure .................................................... 128
Disassembly Procedure.................................................. 8 Window Wiper and Wiper Motor (Rear) -
Piston Pump (Implement and Steering) - Disassemble ....... 8 Remove and Install .......................................................... 128
Piston Pump (Implement and Steering) - Install Window Wiper and Wiper Motor (Roof) - Remove and Install
Installation Procedure ................................................... 18 Installation procedure ................................................. 132
Piston Pump (Implement and Steering) - Install................. 18 Removal Procedure .................................................... 131
Piston Pump (Implement and Steering) - Remove Window Wiper and Wiper Motor (Roof) -
Remove and Install .......................................................... 131
Work Tool Linkage - Remove and Install
Piston Pump (Implement and Steering) - Remove............... 7
Q Removal Procedure ...................................................... 77
Quick Coupler (Hydraulic) -Remove and Install Work Tool Linkage - Remove and Install ........................... 77
Removal Procedure ...................................................... 74
Quick Coupler (Hydraulic) -Remove and Install ................. 74
31200278
Wire Description Component Identifiers (CID¹) Component Location Connector Location December 15, 2006
Wire Wire Module Identifier (MID²) Component
Schematic Machine
Component
Schematic Machine Schematic Machine
Wire Color Description Wire Color Description Location Location Location Location Connector Number
Number Number Engine Control Location Location
ACCELERATOR G-6 1 SENSOR - COOLANT TEMPERATURE D-8 E
Power Circuits Control Circuits (Continued) (MID No. 036) CONN 1 M-18 A
101 RD Battery (+) 852 GN Cont Flow ALARM - BACKUP C-18 2 SENSOR - ENGINE SPEED D-8 E
CID Component CONN 2 L-18 A
102 BU Head Lamp 854 PK Boom Angle Switch ALARM - MONITOR I-5 3 SENSOR - FRONT AXLE CENTER E-2 11
0041 ECM (Electronic Control Module) 8 Volt DC Supply CONN 3 B-18 51
ALTERNATOR C-6 4 SENSOR - INTAKE MANIFOLD PRESSURE D-8 E
103 RD Head Lamp 856 GN Trigger Switch Parity 0091 Throttle Position Sensor
105 BR Key Switch 863 BU Cab/Platform Indicator Switch
ANTENNA - MSS TIRIS G-6 C SENSOR - INTAKE MANIFOLD TEMP D-8 E CONN 4 B-17 52
0100 Engine Oil Pressure Sensor ANTENNA - RADIO G-6 5 SENSOR - LSI STRAIN E-17 39
108 RD Battery (+) to Product Link 867 PU PHS Joystick Grip Control CONN 5 E-17 53
0102 Boost Pressure Sensor ARC SUPRESSOR - CRAB L-4 6 SENSOR - OIL PRESSURE D-8 E
109 RD Alt Output (+) Term 869 PU Cont Flow Switch CONN 6 E-15 52
0105 Inlet Manifold Temperature Sensor ARC SUPRESSOR - CIRCLE L-4 6 SENSOR - REAR AXLE CENTER B-17 40
111 RD Machine Control Battery (+) 870 OR Frame Interlock Relay CONN 7 L-15 29
0110 Engine Coolant Temperature Sensor BASE - ITT GRIP F-5 B SENSOR - SHIFT RAIL 1 D-11 F
112 PU Main Power Relay Output 874 GY LSI Sensor CONN 8 L-14 29
0174 Fuel Temperature Sensor BATTERY 1 A-6 8 SENSOR - SHIFT RAIL 2 C-11 F
114 RD Warning Horn (Forward) 892 BR CAT Data Link (+)
0247 SAE J1939 Data Link BATTERY 2 A-6 8 SENSOR - SHIFT RAIL 3 C-11 F CONN 9 D-13 53
116 BR Frame Level/Tow 893 GN CAT Data Link (-)
0253 Personality Module BEACON M-17 9 SENSOR - TC OIL TEMPERATURE C-11 F CONN 10 E-13 53
117 RD Lift Pump Battery (+) 900 PU Transmission Shift Solenoid
0262 5 Volt Sensor Power Supply BLOCK - FUSE F-16 D SENSOR - TC SPEED E-10 F CONN 11 F-13 53
118 GY Front Wiper Motor 901 WH Transmission Shift Solenoid
0266 Crank Without Injection Input BLOCK - FUSE I-16 D SENSOR - VLPM E-8 F
119 PK Wiper Motors Switch Power 902 BR Transmission Shift Solenoid CONN 12 G-13 53
0320 Speed/Timing Sensor BLOCK - RELAY G-16 D SENSOR - XMSN INT SPEED 1 E-10 F
121 YL Accessory Socket 911 YL Steering Mode Switch
BLOCK - RELAY J-16 D SENSOR - XMSN OIL TEMPERATURE D-10 F
CONN 13 M-13 54
0342 Secondary Engine Speed Sensor
122 BU Fuel Injector Relay 913 BU Front Wiper Switch CONN 14 M-12 A
BREAKER - ALTERNATOR B-7 10 SENSOR - XMSN OUT SPEED D-10 F
0774 Secondary Throttle Position Sensor
123 WH Cold Start Relay 944 OR CDL (-) CONN 15 M-12 A
BREAKER - MAIN C-7 10 SOCKET - ACCESSORY L-15 29
124 GN AC Blower (Low) 945 BR CDL (+) 1627 Fuel Pump Relay
BREAKER - STARTER B-6 10 SOCKET - ADAPTER M-17 A CONN 16 D-11 F
125 OR RH Tail Lamp 958 YL Solenoid QC 1639 Machine Security System Module
TH220B & TH330B

BUS BAR D-5 E SOLENOID - 1 REVERSE A-11 F
1684 Fuel Injection Pump CONN 17 H-10 29
127 OR Boom Floods 959 WH Arc Suppressor QC COIL - FERRITE E-2 11 SOLENOID - 2 FORWARD A-11 F
1743 Engine Operation Mode Selector Switch CONN 18 H-10 29
Telehandler
128 PK AC Blower (High) 975 WH Solenoid Return CONTROL - ENGINE C-9 E SOLENOID - A/C COMPRESSOR D-6 E
130 GN Cab Floods 2 985 GY Crab Steer Relay 1894 Cruise Control Disengage Switch
CONTROL - JOYSTICK G-5 B SOLENOID - AUX DIV I-1 41
CONN 19 E-9 55
1895 Cruise Control Speed Toggle Switch
Electrical System
131 BR Cab Floods 1 986 OR Circle Solenoid CONTROL - MACHINE E-3 12 SOLENOID - CIRCLE L-4 6 CONN 20 L-8 48
133 OR PHS 987 WH Diverter Solenoid Machine Control CONTROL - MACHINE SECURITY SYSTEM F-1 11 SOLENOID - CRAB L-4 6 CONN 21 L-8 48
135 BU Radio Power 990 GN Diverter Solenoid (MID No. 039) CONTROL - PHS VALVE SSV4 D-17 13 SOLENOID - DIFFERENTIAL LOCK D-10 F CONN 22 L-8 48
136 GN Auxiliary Circuit 991 WH Shift Rail Sensor
141 PK Seat 993 BR Accelerator
CID Component CONTROL - PRODUCT LINK
CONTROL - SHIFTER
H-5
K-8
14
A
SOLENOID - FRAME LEVEL 1
SOLENOID - FRAME LEVEL 2
D-2
C-2
42
42
CONN 23 C-7 E TH220B:
0041 ECM (Electronic Control Module) 8 Volt DC Supply
144 GN Beacon 994 GY Oil Pressure Sensor 0070 Parking Brake Switch DISPLAY CLUSTER I-5 C SOLENOID - IMPLEMENT DISABLE B-17 13
CONN 24 D-6 56 S/N TFB00100 & After
147 PU Auxiliary Div Power 995 BU Coolant Temperature Sensor FLASHER L-13 15 SOLENOID - LOAD SENSE CONTROL B-5 36 CONN 25 D-6 E
0096 Fuel Level Sensor
CONN 26 B-5 57
150 RD Engine ECM Battery (+) 997 OR Not Used
0110 Engine Coolant Temperature Sensor
FLOOD - BOOM LH H-2 16 SOLENOID - SPEED 1 A-10 F
TH330B:
157 YL Turn Indicator Switch Power 999 WH Fuel Injector Pump FLOOD - BOOM RH H-2 17 SOLENOID - SPEED 2 A-10 F CONN 27 I-5 A
161 RD Hazard Indicator A700 OR Accelerator
0177 Transmission Oil Temperature Sensor
FLOOD - FRONT LH CAB M-1 18 SOLENOID - SPEED 3 A-10 F CONN 28 M-4 58
0262 5 Volt Sensor Power Supply
165 YL Differential Lock Foot Switch A701 GY Not Used FLOOD - FRONT RH CAB I-1 19 SOLENOID - SPEED 4 A-10 F
0271 Action Alarm CONN 29 M-4 58
Ground Circuits A702 PU Not Used FLOOD - REAR LH CAB K-16 20 SOLENOID - SPEED 5 A-10 F
0368 Transmission Auto/Manual Switch CONN 30 I-2 13
200 BK Main Chassis A703 BR Not Used FLOOD - REAR RH CAB G-17 21 SOLENOID - SYNC MOD A-11 F
0444 Starter Motor Relay CONN 31 C-2 61
205 BK Chassis A704 GN Not Used FUSE - FUEL PUMP C-6 E SOLENOID - TRAILER DOWN A-18 43
0489 Trigger Switch (Aux.) of Joystick Control GPS VHF H-5 A SOLENOID - TRAILER UP A-18 43 CONN 32 E-1 62
229 BK Engine A705 BU Not Used
0490 Implement Lockout Switch HEATER - COLD START A-7 E SOLENOID -QC H-1 44
A278 BK Fuel Pump Return A706 GY Not Used The connectors shown in this chart are for harness to harness connectors.
0590 Engine Control Module HORN J-5 14 SPEAKER - LH L-16 A
Basic Machine Circuits A707 PU Not Used Connectors that join a harness to a component are generally located at or near
0629 Neutralizer Switch LAMP - DOME I-17 A SPEAKER - RH H-17 A the component. See the Component Location Chart.
304 WH Starter Relay No. 1 Output A708 BR Not Used
0668 Transmission Shift Lever LAMP - HEAD LH M-4 22 SUPPRESSOR - BACKLIGHT SIGNAL H-5 A
306 GN Starter Relay Coil A709 OR Not Used
0702 Transmission Gear Lever Selector Sensor (Switch) LAMP - HEAD RH C-1 26 SUPPRESSOR - FRAME LEVEL 1 D-1 35
307 OR Key Switch A710 GY Air Restriction Indicator
308 YL Main Power Relay Coil A711 PU Not Used
0750 Rear Steering Manual Switch LAMP - REG PLATE 1 E-18 24 SUPPRESSOR - FRAME LEVEL 2 C-1 35
0811 Gauge Cluster #1 LAMP - REG PLATE 2 D-18 24 SUPPRESSOR - FRAME LEVEL DUMP POS 1 D-1 35
317 YL Cold Start Relay A712 BR Not Used
0826 Torque Converter Oil Temperature Sensor LAMP - STOP/TAIL/TURN/REV LH E-18 23 SUPPRESSOR - FRAME LEVEL DUMP POS 2 C-1 35
321 BR Backup Alarm A746 PK Not Used
1127 Position Sensor - (Fwd./Back Lever) of Joystick Control LAMP - STOP/TAIL/TURN/REV RH B-18 25 SWITCH - A/C HIGH PRESSURE E-6 E
322 GY Warning Horn (Forward) C743 PK Parking Brake Switch Disengaged
1128 Position Sensor - (Left/Right) of Joystick Control LAMP - STOP/TURN/TAIL/FOG LH F-18 23 SWITCH - AIR RESTRICTION INDICATOR E-7 E
323 WH Fuel Pump Power C744 PU Parking Brake Switch Engaged
LAMP - STOP/TURN/TAIL/FOG RH A-18 25 SWITCH - BEACON J-8 C
1187 Continuous Flow Switch
324 BU Differential Lock Solenoid C903 BU Stabilizer Relay 1
1189 Position Sensor - (Aux. Hyd.) R Thumb of Joystick Control
MODULE - A/C E-6 E SWITCH - BOOM FLOOD F-9 B Volume 1 - EROPS
325 PK Fuel Pump Relay Cut-out C905 OR Stabilizer Relay 2
MOTOR - BLOWER H-11 28 SWITCH - CAB FLOOD F-8 B Manufactured by JLG under license from Caterpillar
329 YL Fuel Pump to Switch C967 BU Intake Manifold Temperature Sensor 1251 Alternator R-Terminal Signal
MOTOR - FRONT WASHER K-13 29 SWITCH - BLOWER ON E-6 B
352 BU Start Relay No. 1 Resistor to Diagnostic C993 WH Shift Rail Sensor 1326 ECM Location Code
MOTOR - FRONT WIPER L-4 14 SWITCH - CAB PLATFORM SELECT F-10 B
375 BR Cold Start Relay to Engine ECM E528 PU HVAC Blower 1401 Transmission Solenoid 1
MOTOR - FUEL LIFT PUMP A-7 E SWITCH - CONT FLOW H-7 C
A309 GY Fuel Lift Pump E529 YL HVAC Blower 1402 Transmission Solenoid 2
MOTOR - REAR WASHER K-13 28 SWITCH - DIFFERENTIAL LOCK FOOT L-7 45
A310 BU Transmission Temperature Switch (V+) E798 PK Not Used 1403 Transmission Solenoid 3 MOTOR - REAR WIPER I-17 30 SWITCH - DIMMER J-7 C
Monitoring Circuits E900 WH Transmission Out Speed Sensor 1404 Transmission Solenoid 4 MOTOR - ROOF WASHER K-13 28 SWITCH - DISCONNECT A-7 E
403 GN Alternator Terminal E901 GN Transmission Out Speed Sensor 1405 Transmission Solenoid 5 MOTOR - ROOF WIPER J-17 31 SWITCH - FOG LAMP H-8 C
428 OR Opr Mon Transmission Oil Temperature E902 PU Transmission Intermediate Speed Sensor 1406 Transmission Solenoid 6 MOTOR - SEAT PUMP G-11 28 SWITCH - FRAME LEVELING H-6 C
443 YL Power Train Temperature Gauge E903 YL Transmission Intermediate Speed Sensor 1407 Transmission Solenoid 7 MOTOR - STARTER B-6 32 SWITCH - FRONT WASHER F-7 B
447 PK Fuel Level Gauge E908 BR Sensor 1410 Transmission Solenoid 10 PUMP - FUEL INJECTOR E-8 E SWITCH - FRONT WIPER F-7 B 19
31 9 30
C444 YL Alternator Indicator Lamp E909 WH Sensor 1529 Quick Coupler Switch RELAY - AUX DIV GROUND G-15 D SWITCH - HAZARD J-6 C 5
18 20 21
E450 GN Oil Filter Bypass Switch E965 BU Engine Speed Sensor 1530 Quick Coupler Solenoid RELAY - AUX DIV POWER G-15 D SWITCH - HEAD/SIDE LAMP J-7 C Electrical Schematic Symbols And Definitions
Accessory Circuits E966 YL Engine Speed Sensor 1603 Data Link RELAY - BLOWER HIGH I-11 15 SWITCH - HEAT/AC F-6 B
500 BR Wiper - Front (Park) F700 BU Not Used 1658 Position Sensor - Left Thumb Lever of Joystick Control RELAY - BLOWER MEDIUM HIGH I-10 15 SWITCH - HORN K-5 C A
501 GN Wiper - Front (Low) F701 BR Not Used 1740 Crab Steering Solenoid RELAY - CIRCLE STEER J-15 D SWITCH - HVAC BLOWER F-6 B T
17
502 OR Wiper - Front (Hi) F702 GN Accelerator Signal 1741 Circle Steering Solenoid RELAY - COLD START A-7 10 SWITCH - IMPLEMENT DISABLE F-10 B Pressure Temperature Level Flow Circuit Breaker
503 BR Wiper - Rear (Park) F703 GY Not Used RELAY - CRAB STEER J-16 D SWITCH - KEY START G-6 C 16 Symbol Symbol Symbol Symbol Symbol
1763 Operator Station Selector Switch
504 YL Wiper - Rear (Low) F705 PK Not Used RELAY - FRAME LEVEL INTERLOCK G-16 D SWITCH - LH STAB H-6 C B 33
1788 Right Stabilizer Operator Switch C
506 PU Washer - Front F706 PU Not Used RELAY - FUEL PUMP B-6 10 SWITCH - MAN VSC K-8 A 12 Normally Open switch that will close with an increase of a specific condition (temp-press-etc.).
1789 Left Stabilizer Operator Switch 41 54
RELAY - LIFT PUMP G-15 D SWITCH - OIL FILTER BYPASS D-7 E 14 The circle indicates that the component has screw terminals and a wire can be disconnected from it.
507 WH Washer - Rear F707 WH Not Used E
1820 Auxiliary Implement Diverter Relay 44 36 6 3 D
508 PU Speaker - Left F708 YL Not Used RELAY - MAIN POWER G-13 33 SWITCH - PARK BRAKE M-13 A 11 58 Normally Closed switch that will open with an increase of a specific condition.
10 51
1823 Position Sensor - Shift Rail No.1 1 34 No circle indicates that the wire cannot be disconnected from the component.
509 WH Speaker - Left (Common) F709 BU Not Used RELAY - QUICK COUPLER POWER J-15 D SWITCH - QUICK COUPLER K-7 C 39 48 56 27 23
1824 Position Sensor - Shift Rail No.2 53 13
24 25
31200278 VOL 1
511 BR Speaker - Right F710 BR Lift Pump RELAY - REVERSE LAMPS J-15 D SWITCH - REAR WIPER F-8 B 29 43
1825 Position Sensor - Shift Rail No.3 42 45 4 37
RELAY - STABILIZER 1 J-16 D SWITCH - REV FAN K-6 A 32 28 49 2 This indicates that the component has a wire connected to it that is connected to ground.
512 GN Speaker - Right (Common) F711 GN CAN Link + 26 22
1826 Longitudinal Stability Indicator Sensor RELAY - STABILIZER 2 G-16 D SWITCH - RH STAB H-7 C 61 57
513 OR AC Compressor/Refrigerant Pressure Switch F712 GY CAN Link - 35 40
1827 Longitudinal Stability System RELAY - START B-5 10 SWITCH - ROOF WIPER F-7 B This indicates that the component does not have a wire connected to ground. It is grounded by
515 GY Blower Motor (High) F714 PK Not Used 55
1828 Boon Angle Switch 62 F 8 15 being fastened to the machine.
516 GN Blower Motor (Medium) F715 PU Not Used RELAY- QUICK COUPLER GROUND J-15 D SWITCH - SERVICE BRAKE PRESSURE M-9 1
1829 Boom Position Status RESISTOR - ALTERNATOR C-7 4 SWITCH - STEER MODE SELECT K-6 C
517 BU Blower Motor (Low) F716 WH Not Used
1830 Boom Telescope Position Status RESISTOR - TERMINATING H-5 C SWITCH - STOP LAMP L-8 48 Reed Switch - A switch whose contacts are controlled b y a magnet. A magnet closes the
518 OR Hazard Flasher to Switch F717 YL Not Used
1831 Rear Axle Lock Solenoid Switch RESISTOR - TERMINATING RES 1A D-17 34 SWITCH - TOW HITCH F-9 B contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.
521 YL AC Switch to Refrigerant Switch F718 BU Not Used
1832 Right Stabilizer Pressure Sensor RESISTOR - TERMINATING RES 2B F-2 35 SWITCH - TURN SIGNAL G-8 A
522 WH AC Clutch to Thermostat Switch F719 BR Not Used
1833 Left Stabilizer Pressure Sensor RESISTOR - TERMINATING STD A-5 36 SWITCH - XMSN NEUTRAL DISABLE K-7 C Sender - A component that is used with a temperature or pressure gauge. The sender measures
523 BR Roof Wiper F720 GN Not Used
SENDER - FUEL E-15 37 THERMOSTAT H-10 28 the temperature or pressure. Its resistance changes to give an indication to the gauge of the
524 BU Roof Wiper F721 GY Not Used 1834 Ignition Key Switch
42 Page
T temperature or pressure.
1845 Programmable Hydraulic System Pilot Module #1 Machine locations are repeated for components located close together.
529 WH Roof Washer F722 OR Not Used
A = Located inside of cab.
536 WH Hazard Switch to Turn Switch F727 BU Not Used 1846 Programmable Hydraulic System Pilot Module #2
B = Located inside of right console. Relay (Magnetic Switch) - A relay is an electrical component that is activated by electricity.
A515 BR Blower Motor No.2 (High) F729 GN Air Restriction Indicator 1847 Programmable Hydraulic System Pilot Module #3 It has a coil that makes an electromagnet when current flows through it. The electromagnet can
C = Located in steering column. open or close the switch part of the relay.
A516 PK Blower Motor No.2 (Medium) F770 BR Fuel Injector Pump Shift Lever ECM D = Located around relay panel.
C547 OR Blower Motor No. 2 (Medium - Low) F799 BU Frame Level Dump Position 1/2 (MID No. 117) E = Located under engine cowl. Solenoid - A solenoid is an electrical component that is activated by electricity. It has a coil that
E554 PK AC Controller to AC Compressor Clutch F846 PU Machine Security Red LED Signal
CID Component F = Located on the transmission. makes an electromagnet when current flows through it. The electromagnet can open or close
Lighting Circuits G757 OR Transmission Neutralizer Switch 2 61 a valve or move a piece of metal that can do work.
0168 Electrical System Voltage 8
603 PK Rotary Beacon G848 GN Machine Security Green LED Signal 4
0668 Transmission Shift Lever 10 32
604 OR Stop Lamp G962 OR Implement Disable Solenoid Component, Connector, Harness And Wire Symbols
605 YL Turn Lamp - Left H750 BR Front Axle Center Machine Security
22 E
606 GY Turn Lamp - Right H751 OR Rear Axle Align Switch (MID No. 124) 42 56 25
Wire, Cable, or Harness Assembly Identification:
Harness Identification Letter(s):
608 GN Flood Lamp - Rear H764 GY Circle Steer Relay (A, B, C, ..., AA, AB, AC, ...)
CID Component 26 57 Includes Harness Identification Letters and Harness
39 Connector Serialization Codes
610 OR Head Lamp - Basic H765 WH Crab Steer Relay 0168 Electrical System Voltage F
12 Harness identification code Harness Connector Serialization Code:
611 PU Head Lamp - Hi H802 GY Proportional Driver Return (5-8) 17 This example indicates The "C" stands for "Connector" and the number
0248 CAT Data Link wire 135 in harness "AG". Part Number for indicates which connector in the harness. (C1, C2, C3, .....)
612 GY Backup Lamp J755 BU Left Frame Level Solenoid Return
0817 ECM Internal Backup Battery 13 Connector Plug
614 PU Park/Tail/Dash Lamp J756 BR Right Frame Level Solenoid Return 36 35 55 40 2 43 24 C-C4 AG-C3 L-C12
Part Number For
AG-C4 Connector Recepticle
615 YL Cab Flood Lamp J757 PU Stabilizer Relay 2 1391 Theft Deterrent Output Driver #1 41 130-6795 130-6795 111-7898 3E-5179
44 34 325-AL135 PK-14
616 BU Bucket/Boom Flood Lamps J758 PK Frame Level Solenoid 1392 Theft Deterrent Output Driver #2 16 62 11 325-AG135 PK-14 1 5A
51
53
617 BR Tail/Position Lamp - Left (Road Pkg) Width J759 GN Stabilizer Relay 1 ¹ The CID is a diagnostic code that indicates which circuit is faulty. 18 20 Socket
14 B
Pin
Receptacle Fuse (5 Amps)
618 YL Tail/Position Lamp - Right (Road Pkg) Width J760 YL Frame Level Solenoid ² The MID is a diagnostic code that indicates which electronic control module- 22 54 33 Wire Color Wire Gauge
6 27
619 GN Head Lamp (Low) J764 BR Oil Filter Bypass Switch diagnosed the fault. C Single Wire Circuit Plug
1 28 49 23 Connector Identification
Ground
627 YL Fog Lamp J811 BK On/Off Return 30 Connection 2 200-L32 BK-14
3 A Number
649 YL Light Switch to Park/Tail Lamp Breaker J843 BK Machine Security LED Ground 31 9 Component
Pin or Socket Part Number
676 PU Auxiliary Active Lamp J847 GN Monitor Alarm 58 48 D Number 105-9344
29
Control Circuits K791 OR Rev Fan Switch 45 37
19 15 5 21
750 GN Platform Mode Switch L730 OR Oil Pressure Sensor 1 Deutsch connector:
1 Sure-Seal connector:
The plug contains all sockets The plug and receptacle contain
751 GN Transmission Shift Solenoid - Forward L731 BR Coolant Temperature Sender 2 and the receptacle contains all pins. 2 both pins and sockets.
752 YL Transmission Shift Solenoid - Reverse L740 BR Transmission Oil Temperature Sender
753 GY Cab Platform Select Switch N957 PK Product Link
754 BU Transmission Shift Solenoid No. 1 or 3 N960 OR Product Link
755
756
OR
WH
Transmission Shift Solenoid No, 4 or 5
Transmission Lockup Clutch Solenoid
N970
N973
YL
BR
Product Link
Product Link
Machine Harness Connector And Component Locations
757 PU Transmission Neutral Disable Switch N979 GN Product Link
758 GN Boom Lower Switch P909 PK Man VSC Switch
759 OR Steer Mode Select Switch P916 OR Shift Rail Sensor
760 PK Steer Mode Select Switch P936 GY Frame Level Solenoid
761 GY Steer Mode Select Switch T800 OR +8V Digital Sensor Power
763 BU Quick Coupler Switch T901 YL Machine Secutriy Exciter Coil (In)
764 PU Quick Coupler Switch T902 PK Machine Security Exciter Coil (Out)
765 OR Quick Coupler Switch T941 BR Switch (Note D)
766 GN Service Brake Pressure Switch T942 PK Switch (Note D)
769 BU Mn VSC Switch T943 GY Switch (Note D)
774 YL Implement Diable T944 GN Switch (Note D)
780 PU PHS Joystick Grip Control X731 BU Intake Manifold Temperature Sender
781 PK PHS Joystick Y Axis X750 OR Fwd./Rev. Solenoid Return from Controller
782 GY PHS Joystick X Axis Y758 PK PHS Address (Out)
783 OR Frame Level Disable Relay Y759 YL PHS Address (In)
786 GN Boom Lowered Y761 OR PHS Address (In)
788 YL Boom Angle Switch Y787 WH PHS Valve
792 OR PHS Joystick Grip Control Y788 GY PHS Valve
793 YL Implement Diable Switch Y792 PK Fuel Injector Pump
794 YL Auxiliary Diverter Relay Y793 YL Fuel Injector Pump Failure Mode Identifiers (FMI)¹ Off Machine Switch Specification
795 YL Quick Coupler Relay Y794 OR CAN High 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
799 WH PHS Valves +10V Y795 GN CAN Low 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.
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
4 Voltage below normal or shorted low. down to 170 kpa (25psi).
5 Current below normal or open circuit. ² Contact postion at the contacts of the harness connector.
6 Current above normal or grounded circuit.
7 Mechanical system not responding properly.
8 Abnormal frequency, pulse width, or period.
9 Abnormal update.
10 Abnormal rate of change.
11 Failure mode not identifiable.
12 Bad device or component.
13 Out of calibration.
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
295-3421 Sender: Fuel 33² - 240³
¹The FMI is a diagnostic code that indicates what type of failure has occurred.
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 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 1552269
CONN 14 123-F212 WH- 16 615-P7 YL - 16 1 WH-18
T-C1 F-C9 200-F192 BK- 16 123-F371 WH- 18 200-P11 BK- 16 BK-18
H1 2
3E5179 1552252
508-T1 PU- 16 508-F180 PU- 18
200-F193
200-F194
BK- 18
BK- 18
SERV BK PRESS 308-F127 YL - 18 141-F109 PK - 18
200-F183 BK- 14
WIRE GROUP COLOR DESCRIPTIONS COLOR ABBREVIATIONS SYMBOL DESCRIPTION CONN 28
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
NOTE B WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS OFF. CIRCUIT CONNECTED 1552269 3E3364
603-T6 PK - 16 603-F47 PK - 16
200-F398 BK- 18
610-F79 OR- 16
200-F185 BK- 16
200-F196 BK- 14 WIRES THAT HAVE SYSTEM VOLTAGE WHEN THE KEY SWITCH IS ON. ABBREV COLOR T901-F165 YL - 18 1 T901-R9 YL - 16 H23
608-T3 GN- 16 608-F45 GN- 16 200-F196 BK- 14 200-F199 BK- 16 CIRCUIT NOT CONNECTED T902-F166 PK - 18 2 T902-R10 PK - 16
200-T4 BK- 16 200-F185 BK- 16 200-F183 BK- 14 611-F142 PU- 18 200-F204 BK- 16 STARTING CIRCUIT. RD RED LH HEAD TURN POS LAMP
BEACON 615-T11 YL - 16 615-F9 YL - 16 200-F185 BK- 16 766-F154 GN- 16 200-F248 BK- 14 ELECTRICAL CONNECTION TO
180-3664 200-T8 BK- 14 200-F183 BK- 14 200-F199 BK- 16 J764-F155 BR- 16 200-F296 BK- 18 GROUND CIRCUIT. WH WHITE MACHINE STRUCTURE
195-0192 LH DIP
195-0190 RH DIP
M PARK BRAKE SW
200-F248 BK- 14 205-F228 BK- 16
OR ORANGE INTERNAL ELECTRICAL CONNECTION CONN 29 M
6G-4195
308-F399 YL - 18 118-F89 GY- 16 500-F90 BR- 16 STARTING AID CIRCUIT. TO SURFACE OF COMPONENT F-C39 CG-C1 CG-C2
511-T9 BR- 16 511-F179 BR- 18 200-F184 BK- 16 501-F92 GN- 16 1552273 3E3382 1552273
200-T14 BK- 16 512-T10 GN- 16 512-F182 GN- 18 508-F180 PU- 18 200-F204 BK- 16 502-F101 OR- 16 CAT DATA LINK. YL YELLOW CONNECTOR 5 5
C744-F144 PU- 18 509-F181 WH- 18 500-F90 BR- 16 605-F156 YL - 16
603-T6 PK - 16
C743-F143 PK - 18 511-F179 BR- 18 501-F92 GN- 16 766-F154 GN- 16 CAN DATA LINK A. PK PINK 611-F135 PU- 16
619-F81 GN- 16
4
6
611-CG4
619-CG6
PU- 16
GN- 16
4
6
BU-18
RD-18
SOCKET ADAPTER
178-7539 J764-F145 BR- 18
CONN 15 512-F182
518-F348
GN- 18
OR- 16
502-F101
605-F156
OR- 16
YL - 16 985-F151 GY- 16 CAN DATA LINK B. BK BLACK
H# CIRCUIT GROUPING DESIGNATION 617-F58 BR- 16 3 617-CG3 BR- 16 3 WH-18
FA-C1 F-C8 605-F156 YL - 16 1 605-CG1 YL - 16 1 YL-18
3E3388 1552264 536-F122 WH- 16 611-F135 PU- 16 986-F150 OR- 16
CONN 13 119-FA1 PK - 16 119-F315 PK - 16
536-F123 WH- 16 617-F58 BR- 16 J764-F107 BR- 16 ENGINE CONTROL CIRCUIT (MASTER ). GY GRAY ATCH WIRE, CABLE, COMPONENT 200-F204 BK- 16 2 200-CG2 BK- 16 2 BK-18
536-F124 WH- 16 619-F81 GN- 16 J764-F145 BR- 18
CONN 1 PL-C2
3E3388
F-C57
1552264
119-FA2
102-FA3
PK - 16
RD- 16
119-F57
102-F316
PK - 16
RD- 16
985-F151 GY- 16 J764-F155 BR- 16 MACHINE CONTROL. PU PURPLE CIRCUIT CONNECTED
P-C1 T-C2 603-F47 PK - 16 986-F150 OR- 16
1552272 3E3376
603-T6 PK - 16
108-PL1 RD- 18 108-F397 RD- 18 503-FA4
504-FA5
BR- 16
YL - 16
503-F49
504-F51
BR- 16
YL - 16
615-F3 YL - 16 T901-F165 YL - 18 118-F89 GY- 16 PRODUCT LINK. BR BROWN BLADE, SPADE, RING OR SCREW
608-P1 GN- 16 608-T3 GN- 16 200-T8 BK- 14 200-PL2 BK- 18 200-F398 BK- 18 676-F207 PU- 16 T902-F166 PK - 18 123-F212 WH- 16 TERMINAL
200-P2 BK- 16 200-T4 BK- 16 308-PL5 YL - 18 308-F399 YL - 18 200-FA6 BK- 16 200-F199 BK- 16 F712-F332 GY- 16 123-F371 WH- 18 MACHINE SECURITY CONTROL CIRCUIT. GN GREEN
403-PL4 GN- 18 403-F401 GN- 18 523-FA7 BR- 16 523-F52 BR- 16 892-F392 BR- 16 892-F268 BR- 16 200-F183 BK- 14 141-F109 PK - 18
615-P3 YL - 16 615-T11 YL - 16 200-T13 BK- 16 HEATER AND AIR CONDITIONER CIRCUIT. SPLICE
200-P4 BK- 16 200-T13 BK- 16 H2 944-PL11 OR- 18 893-F393 GN- 16 524-FA8 BU- 16 524-F53 BU- 16 892-F402 BR- 16 200-F185 BK- 16 200-F183 BK- 14 BU BLUE
945-PL12 BR- 18 892-F392 BR- 16 200-F199 BK- 16 200-F184 BK- 16
Y795-PL10 GN- 18 F712-F330 GY- 16 893-F393 GN- 16 200-F196 BK- 14 200-F185 BK- 16 TURN SIGNAL/WIPER/WASHER CIRCUIT. F-C65
200-T4 BK- 16 L
Y794-PL15 OR- 18 F711-F331 GN- 16 893-F403 GN- 16 200-F248 BK- 14 200-F196 BK- 14 1552273
508-T1 PU- 16 GND
GN-16
CONN 8 108-F397 RD- 18
121-F247 YL - 14
893-F254 GN- 16 308-F399 YL - 18
508-F180 PU- 18
200-F199 BK- 16
200-F204 BK- 16
501-F92 GN- 16
200-F197 BK- 16
4
2 BK-16 MOTOR
H FRONT WIPER MOTOR
187-2734
509-T2 WH- 16
CONN 2 511-T9 BR- 16
K-C2
9W1951
K-C1
3E3388
F-C13
1552264
200-F192 BK- 16 F711-F331 GN- 16 509-F181 WH- 18 200-F248 BK- 14 1
GY-16
T°
N-C1 T-C3 512-T10 GN- 16 200-F193 BK- 18 F711-F232 GN- 16 511-F179 BR- 18 200-F296 BK- 18 118-F89 GY- 16 6 P
B+
3E3376 1552272 608-T3 GN- 16 121-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 3 BR-16
508-N1 PU- 18 508-T1 PU- 16 615-T11 YL - 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 CONN 20 502-F101 OR- 16 5 OR-16
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 F-C40 G-C1 G-C2
512-N3 GN- 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 1552272 3E3376 1082253
509-N4 WH- 18 4 509-T2 WH- 16 CONN 7 892-K8 BR- 16
F712-K2 GY- 16 121-K10 YL - 14 121-K5 YL - 14
121-F247 YL - 14 308-F399 YL - 18
403-F401 GN- 18
536-F124 WH- 16
603-F47 PK - 16
605-F156 YL - 16 102-G1 RD- 16 STOP LAMP SW
604-G2 OR- 16 105-8034
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- 16 985-F151 GY- 16 L
893-K7 GN- 16 F-C66
518-F348 OR- 16 F711-F232 GN- 16 J764-F145 BR- 18
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
536-F122 WH- 16 C744-F144 PU- 18 J764-F145 BR- 18 985-F151 GY- 16 200-F197 BK- 16 985-F131 GY- 16 1 BK-18 SOLENOID CRAB
BK-18
F-C20
536-F123 WH- 16
536-F124 WH- 16
F711-F230 GN- 16 892-F268 BR- 16
893-F254 GN- 16
986-F150 OR- 16
102-F214 RD- 16
CONN 21 200-F198 BK- 18 200-F128 BK- 18 2 118-7756
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
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
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 2 ARC SUPPR CRAB
SPEAKER LH FLASHER DIFF LOCK FOOT SW
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 1 106-8704
169-7290 242-7237 204-0775
536-F336 WH- 16 536-F123 WH- 16 F711-F232 GN- 16 523-F52 BR- 16 103-F78 RD- 16 123-F167 WH- 18
509-N4 WH- 18 615-P7 YL - 16 H1 536-F122 WH- 16 524-F53 BU- 16 105-F172 RD- 16 205-F168 BK- 18 986-F150 OR- 16
F-C60 F-C67
508-N1 PU- 18 200-P11 BK- 16 536-F124 WH- 16 F711-F333 GN- 16 529-F55 WH- 18 108-F239 RD- 18 123-F75 WH- 18 1552269
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 22 986-F134 OR- 16
986-F130
1552269
OR- 16 1 BK-18 SOLENOID CIRCLE
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 2 BK-18 118-7756
529-F55 WH- 18 F712-F233 GY- 16 615-F9 YL - 16 615-F2 YL - 16 121-F308 YL - 16 759-F110 OR- 18
M 200-F195 BK- 18 F711-F331 GN- 16 123-F212 WH- 16 760-F111 PK - 18 F-C51
F712-F332 GY- 16 119-F315 PK - 16 119-F46 PK - 16 125-F384 OR- 16 761-F112 GY- 18 1552269
119-F57 PK - 16 119-F50 PK - 16 135-F240 BU- 18 763-F115 BU- 18 200-F133 BK- 18 2 ARC SUPPR CIRCLE
200-P9 BK- 16 J764-F145 BR- 18 119-F48 PK - 16 H9 141-F109 PK - 18 764-F322 PU- 18 986-F134 OR- 16 1 106-8704
608-P5 GN- 16 REAR WASHER 892-F392 BR- 16 119-F43 PK - 16 144-F319 GN- 16 764-F326 PU- 18
117-2826 F-C6 892-F402 BR- 16 157-F105 YL - 16 765-F116 OR- 18
1171877 119-F54 PK - 16 161-F104 RD- 16 769-F72 BU- 18
102-F316 RD- 16 507-F56 WH- 18 893-F393 GN- 16 165-F217 YL - 16 K791-F416 OR- 16
LH REAR FLOOD M 200-F194 BK- 18 893-F403 GN- 16 102-F316 RD- 16 617-F5 BR- 16 P909-F71 PK - 18
P-C2 108-F397 RD- 18 112-F354 PU- 10 108-F397 RD- 18 649-F82 YL - 16
212-9347
1552269 615-F3 YL - 16 121-F247 YL - 14 799-F385 WH- 18 121-F20 YL - 14
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
BU- 16
PU- 18
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
F-C5
CAB GROUND
BU- 18
WH- 18
117-2826 986-F150 OR- 16 200-F69 BK- 18
K 118-F89 GY- 16
117-F380 RD- 16 1171877
506-F91 PU- 18
123-F371 WH- 18
205-F228 BK- 16
200-F108
200-F152
BK- 18
BK- 18
K
123-F211
K791-F416
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
769-F72
123-F75
2285856
2285856
2285856
2285856
2285856
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 FRONT OF THE JOYSTICK
MOvvv
NOTE A NOTE A
XMSN NEUTRAL DISABLE SW

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

799-F25 WH- 18 604-F215 OR- 16 J764-F83 BR- 18
MAN VSC
190-8221
202-4208
202-2276
190-8220
260-5889
REV FAN
119-F54 PK - 16 605-F225 YL - 16 J764-F84 BR- 18
799-F176 WH- 18 121-F247 YL - 14 J764-F106 BR- 18 NOTE D
605-F132 YL - 16 J764-F113 BR- 18 F-C59 SHIFTER
HORN SW
MOM
799-F385 WH- 18 605-F156 YL - 16 1552253 261-2208
2T-3360
121-F249 YL - 14 605-F137 YL - 16 123-F206 WH- 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
606-F147 GY- 16 893-F236 GN- 16
BR - 18
YL - 18
BK - 18
PU- 18
121-F308 YL - 16
BR - 18
BR - 18
BR - 18
BK - 18
PU- 18
892-F237 BR- 16
BR - 18
YL - 16
BK - 18
PU- 18
BK - 18
PU- 18
YL - 14
C903-F169 BU- 16 606-F138 GY- 16
116-F311 BR- 16 102-F316 RD- 16 606-F140 GY- 16 W
116-F312 BR- 16 102-F213 RD- 16 606-F139 GY- 16 893-F254 GN- 16 M
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
200-F69
614-F65
121-F20
795-F274 YL - 18 617-F242 BR- 16 892-F268 BR- 16 W
J811-F273 BK- 18 619-F349 GN- 16 892-F174 BR- 16
795-F161 YL - 18 H17 627-F395 YL - 16 F-C19 200-F186 BK- 18
102-F77 RD- 16 1552269 200-F187 BK- 18
102-F214 RD- 16 H18 757-F74 PU- 18 200-F189 BK- 18
STAB RLY 1 QUICK CPLR GND QUICK CPLR PWR 322-F40 GY- 16 HORN
103-F78 RD- 16 759-F110 OR- 18 200-F188 BK- 18
140-9378 140-9378 140-9378 114-F251 RD- 16 164-9425
105-F172 RD- 16 760-F111 PK - 18 606-F138 GY- 16 200-F183 BK- 14
147-F275 PU- 16 761-F112 GY- 18
ROOF WIPER 108-F397 RD- 18 764-F114 PU- 18 611-F142 PU- 18 611-F76 PU- 16
191-3027 108-F406 RD- 18 611-F80 PU- 16
200-F309 BK- 16
958-F301 YL - 16 764-F326 PU- 18 611-F135 PU- 16 200-F184 BK- 16
959-F302 WH- 16 108-F239 RD- 18 764-F322 PU- 18 200-F199 BK- 16
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
J
M 1552272 J759-F170 GN- 16 118-F89 GY- 16 765-F116 OR- 18 619-F81 GN- 16 200-F201 BK- 12
200-F289 BK- 18
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
YL-16 H765-F164 WH- 18 121-F308 YL - 16 769-F72 BU- 18 157-F105 YL - 16
119-FA2 PK - 16 114-F251 RD- 16
GN-16 J811-F160 BK- 18 123-F212 WH- 16 775-F341 BR- 18 603-F47 PK - 16 200-F196 BK- 14
523-FA7 BR- 16
321-F146 BR- 18 125-F384 OR- 16 123-F205 WH- 18 128-F414 PK - 12 C919-F346 PU- 18 605-F132 YL - 16 200-F307 BK- 14
RD-16 524-FA8 BU- 16
J811-F375 BK- 18 135-F240 BU- 18 H9 200-F227 BK- 18 776-F347 YL - 18 610-F79 OR- 16 200-F276 BK- 16
157-F105
161-F104
605-F132
606-F138
603-F47
610-F79
649-F82
619-F73
611-F76
2285856
2285856
2285856
1387675
H764-F163 GY- 18 123-F253 WH- 18 128-F415 PK - 12 778-F344 BR- 18 649-F82 YL - 16 200-F282 BK- 16
F-C25
F-C52
F-C49
F-C48
J811-F159 BK- 18 141-F109 PK - 18 200-F16 BK- 18 C917-F345 YL - 18 F711-F200 GN- 16
144-F319 GN- 16 200-F17 BK- 18 200-F286 BK- 16 779-F340 WH- 18 DISPLAY 2A 200-F28 BK- 16
SW HEAD/SIDE LAMP
CRAB STEER REVERSE LAMPS RLY CIRCLE STEER F-C63 191-0912
157-F105 YL - 16 200-F26 BK- 16 784-F262 YL - 18 102-F77 RD- 16 F712-F321 GY- 16 200-F309 BK- 16
OR 192-0072
HAZARD SW
BEACON SW
DIMMER SW
140-9378 140-9378 140-9378 161-F104 RD- 16 200-F28 BK- 16 200-F411 BK- 16 785-F263 PK - 18 103-F78 RD- 16 7X6222
202-2283
190-8225
202-2280
190-8224
986-F150 OR- 16 165-F217 YL - 16 200-F29 BK- 18 A700-F356 OR- 18 144-F319 GN- 16 111-F177 RD- 14
617-F5 BR- 16 200-F30 BK- 18 200-F412 BK- 16 F702-F358 GN- 18 200-F27 BK- 18 205-F223 BK- 16
508-N1 PU- 18 200-FA6 BK- 16 649-F82 YL - 16 200-F31 BK- 18 200-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- 18 522-F103 WH- 16 128-F414 PK - 12 F712-F231 GY- 16 200-F68 BK- 18 111-F177 RD- 14 676-F207 PU- 16
612-F288 GY- 18 870-F117 OR- 16 200-F98 BK- 18 200-F412 BK- 16 J755-F118 BU- 16 200-F100 BK- 18 114-F251 RD- 16
102-F304 RD- 16 985-F151 GY- 16 200-F183 BK- 14 J764-F191 BR- 18 A515-F285 BR- 16 J756-F119 BR - 16 518-F348 OR- 16 205-F222 BK- 16
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
GN- 16
OR- 16
WH- 16
BK - 18
200-F294 BK- 18
BK - 18
PU- 18
BK - 18
BK - 18
PU- 18
PU- 18
PU- 18
136-F317 GN- 16 200-F186 BK- 18 119-F43 PK - 16 128-F415 PK - 12 J760-F120 YL - 16 610-F79 OR- 16 205-F224 BK- 16
REAR WIPER F-C1 116-F312 BR- 16 200-F187 BK- 18 119-F46 PK - 16 200-F411 BK- 16 J764-F107 BR- 16 614-F19 PU- 18 308-F127 YL - 18
187-2735 1129609 116-F311 BR- 16 200-F188 BK- 18 119-F48 PK - 16 A516-F287 PK - 16 852-F388 GN- 18 614-F63 PU- 18 200-F42 BK- 18 605-F137 YL - 16
RELAY BLOCK
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-F50 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- 14 123-F205 WH- 18 892-F174 BR- 16 614-F95 PU- 18 605-F137 YL - 16 A310-F175 BU- 16
511-N2 BR- 18 116-F305 BR- 16 116-F310 BR- 16 200-F199 BK- 16 893-F173 GN- 16 606-F139 GY- 16 PL-C8 PL-C10 PL-C11
FA-C3 500-F90 BR- 16
M J759-F170 GN- 16 200-F248 BK- 14 F-C73 K791-F416 OR- 16 111-F177 RD- 14 3E5175 3E5178 3E5175
1552272 502-F101 OR- 16 F-C74
BK-16 200-F286 BK- 16 503-F49 BR- 16 9X1054 9X1054 993-F357 BR- 18 205-F223 BK- 16 611-F142 PU- 18 611-F142 PU- 18 M 125-PL26 OR- 18 1 108-PL3 RD- 18
200-FA10 BK- 16
YL-16 FRAME LVL/TOW DIFF LOCK WIPER 1 WIPER 2 118-F87 GY- 16 200-F307 BK- 14 506-F91 PU- 18 516-F409 GN- 14 P909-F71 PK - 18 114-F251 RD- 16 614-F86 PU- 16 MM 200-PL27 BK- 18 2 200-PL13 BK- 16
119-FA1 PK - 16
118-F89 GY- 16 H10 200-F411 BK- 16 A515-F285 BR- 16 205-F222 BK- 16 F712-F203 GY- 16 308-PL28 YL - 18 3 308-PL14 YL - 18
GN-16 503-FA4 BR- 16
RD-16 118-F85 GY- 16 200-F412 BK- 16 517-F8 BU- 14 123-F167 WH- 18 205-F224 BK- 16 F711-F202 GN- 16 403-PL29 GN- 18 4 403-PL16 GN- 18
504-FA5 YL - 16
119-F54 PK - 16 J757-F171 PU- 16 521-F11 YL - 14 BLOWER HIGH RLY BLOWER MED HI 123-F206 WH- 16 308-F127 YL - 18 F711-F200 GN- 16 N957-PL30 PK - 18 5
I 118-F85 GY- 16
165-F217 YL - 16
118-F88 GY- 16 205-F267 BK- 18
500-F90 BR- 16
523-F52 BR- 16
608-F45 GN- 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
6
7
P-C5
1552269
I
112-F353 PU- 10 124-F284 GN- 14 501-F92 GN- 16 615-F2 YL - 16 605-F137 YL - 16 N979-PL23 GN- 18 8
116-F292 BR- 16 127-F70 OR- 16 502-F101 OR- 16 123-F257 WH- 18 606-F139 GY- 16 J847-F221 GN- 18 N970-PL24 YL - 18 9 H3 615-P8 YL - 16 1 WH-18 CAB RH FR FLOOD
616-F60 BU- 16
114-F251 RD- 16 J759-F170 GN- 16 123-F371 WH- 18 611-F142 PU- 18 614-F86 PU- 16 308-F127 YL - 18 W N973-PL25 BR- 18 10 200-P12 BK- 16 2 BK-18 212-9347
750-F34 GN- 18
614-F13 PU- 18 753-F35 GY- 18 H12 123-F253 WH- 18 123-F75 WH- 18 614-F32 PU- 18 11
BLOWER HIGH BLOWER LOW QC/AUX FUSE ALL WHL STER 128-F415
128-F413
PK - 12
PK - 12
614-F14 PU- 18
614-F18 PU- 18
774-F38 YL - 18 200-F28 BK- 16
614-F24 PU- 18
614-F178 PU- 18
CONN 27 12
793-F37 YL - 18 200-F183 BK- 14 H23
614-F21 PU- 18 T941-F235 BR- 16 615-F3 YL - 16
200-F184 BK- 16
136-F298 GN- 16 128-F414 PK - 12 614-F22 PU- 18 T942-F314 PK - 16 617-F5 BR- 16 J847-F221 GN- 18 MONITOR ALARM
200-F196 BK- 14
DOME LAMP
084-4277
102-FA3 RD- 16 147-F277 PU- 16 614-F23 PU- 18 T943-F234 GY- 16 200-F199 BK- 16
617-F58 BR- 16 205-F224 BK- 16 9X-5316 CONN 30 HG-C2
200-FA11 BK- 16 124-F284 GN- 14 130-F59 GN- 16 614-F93 PU- 18 T944-F329 GN- 16 617-F242 BR - 16 PL-C7 PL-C6 1552269
200-F248 BK- 14 HA-C2 HG-C1
112-F353 PU- 10 131-F61 BR- 16 614-F94 PU- 18 A516-F287 PK - 16 676-F207 PU- 16 3E3364 1552269 3E3376 1552272 987-HG3 WH- 16 1 BK-18 AUX DIV SOL
500-F90 BR- 16
128-F413
112-F352
PK - 12
PU- 10
200-F276
200-F282
BK- 16
BK- 16
J764-F39
J764-F41
BR- 18
BR- 18
200-F227 BK- 18 CONN 17 501-F92 GN- 16
F711-F232 GN- 16 F711-F202 GN- 16
F-C61 1 987-HA3 WH- 16 1 987-HG3 WH- 16 990-HG4 GN- 16 2 BK-18 212-3350
REAR/ROOF WIPERS-ATCH 799-F25 WH- 18 J764-F191 BR- 18

114-F251 RD- 16 A-C1
1779649
F-C12
1779654
502-F101 OR- 16
114-F251 RD- 16
F711-F331 GN- 16 F711-F202 GN- 16
F711-F219
1552267
GN- 16
2 990-HA4
958-HA1
GN- 16
YL - 16
2
3
990-HG4
958-HG1
GN- 16
YL - 16
HG-C3
SW ELEK PHS 799-F176 WH- 18 J764-F269 BR- 18 M F711-F200 GN- 16 A 1552269
J757-F171 PU- 16 200-F188 BK- 18 200-F99 BK- 18 TERMINATING RES 959-HA2 BU- 16 4 959-HG2 WH- 16
J764-F191 BR- 18 J764-F366 BR- 18 515-A4 GY- 12 515-F400 GY- 12 F712-F233 GY- 16 F712-F321 GY- 16 F712-F220 GY- 16 B 958-HG1 YL - 16 1 BK-18 SOL QC
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
GN- 18
PU- 18
C 959-HG2 WH- 16 BK-18 212-3350
YL - 16
PK - 18
BR - 18
WH- 18
YL - 18
YL - 18
BR - 18
200-F411 BK- 16 200-F69 BK- 18 2
SPEAKER RH 133-F355 OR- 14 J757-F171 PU- 16 J757-F171 PU- 16 J759-F170 GN- 16 C547-A8 OR- 14 517-F8 BU- 14 F712-F332 GY- 16
200-F313 BK- 16 200-F68 BK- 18 F-C18
169-7290 112-F351 PU- 10 109-F324 RD- 10 128-F414 PK - 12 MOTOR BLOWER GP 200-A3 BK- 12 200-F201 BK- 12 F712-F203 GY- 16 LH BOOM FLOOD
200-F189 BK- 18 1552272
109-F325 RD- 10 128-F415 PK - 12 174-1227 200-A2 BK- 14 200-F42 BK- 18 627-F395 YL - 16 617-F242 BR- 16 CA-C2 212-9348
799-F385
512-N3 GN- 18 E528-F266 PU- 14 200-F30 BK- 18
CONN 18
C917-F345
C919-F346
J758-F121
J760-F120
J756-F119
J755-F118
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
1 1552269
2285856
511-N2 BR- 18 E528-F265 PU- 14 200-F16 BK- 18
2285856
2285856
2285856
2285856
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 2 BACKLIGHT SIG COM 616-CA3 BU- 16 1 WH-18
F-C31
E528-F208 PU- 18 200-F289 BK- 18
F-C43
F-C68
F-C15
F-C16
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 3 172-9200 200-CA5 BK- 16 2 BK-18
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 4
MOM
MOM
517-A6 BU- 14 517-F8 BU- 14 200-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 RH BOOM FLOOD
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- 18 616-CA1 BU- 16 CA-C3 212-9349
130-F59 GN- 16 112-F352 PU- 10 116-F310 BR- 16 785-F263 PK - 18 1552269
200-F31 BK- 18 200-F67 BK- 18 N979-PL21 GN- 18
112-F350 PU- 10 119-F43 PK - 16 118-F87 GY- 16 799-F385 WH- 18 PRODUCT LINK
MOM
MOM
200-F97 BK- 18 200-F255 BK- 18 616-CA4 BU- 16 1 WH-18
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 200-CA2 BK- 16 200-CA6 BK- 16 2 BK-18
200-F187 BK- 18 200-F387 BK- 18
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
3E-5464
200-F26 BK- 16 200-F185 BK- 16
J756-F119
J758-F121
BR- 16
PK - 16
PL201 209-6417 7X6222 H
200-F286 BK- 16 200-F204 BK- 16 RS-232 PORT 1-DCD 1
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
RS-232 PORT 1-DTR 2
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
GN- 18
GN- 18
PU- 18
RS-232 PORT 1-TXD 3
BR - 18
1249636 136-F298 GN- 16 506-F91 PU- 18 200-F17 BK- 18 869-F389 PU- 18
BK - 18
PU- 18
BK - 18
PU- 18
OR- 16
OR- 16
BK - 18
PU- 18
BK - 18
PU- 18
FUSE BLOCK 205-F228 BK- 16 RS-232 PORT 1-RXD 4
BK - 16
BK - 18
PU- 18
507-F56 WH- 18 200-F26 BK- 16 125-F384 OR- 16 Y794-PL15 OR- 18
205-F226 BK- 16
31200278 VOL 1
RS-232 PORT 1 GND 5

147-F277 PU- 16 523-F52 BR- 16 200-F29 BK- 18 200-F28 BK- 16
BLOWER-UNDER SEAT-ATCH 205-F224 BK- 16 RD- 18 108-PL1 RD- 18
J757-F359
BATT + 6
524-F53 BU- 16 200-F30 BK- 18 200-F99 BK- 18
205-F267 BK- 18 205-F223 BK- 16 BATT - 7 BK - 18 200-PL2 BK- 18
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
125-F384
200-F383
614-F382
200-F387
614-F386
200-F28
200-F99
614-F96
205-F222 BK- 16 KEYSW ON 8 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
200-P9 BK- 16 205-F168 BK- 18 R-TERM 9 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-P11 BK- 16 614-F245 PU- 18 614-F19 PU- 18 CDL + 10 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
614-F13 PU- 18 614-F64 PU- 18 CDL - 11 BR - 18
X753-F376 YL - 18 116-F310 BR- 16 501-F92 GN- 16 614-F328 PU- 18 GPS VHF
608-P5 GN- 16 614-F94 PU- 18 614-F327 PU- 18 CAN LOW 12 Y795-PL10 GN- 18 403-PL4 GN- 18
794-F280 YL - 18 118-F87 GY- 16 504-F51 YL - 16 614-F96 PU- 18 207-6798
615-P7 YL - 16 614-F23 PU- 18 614-F63 PU- 18 CAN HIGH 13 Y794-PL15 OR - 18 945-PL12 BR- 18
X753-F377 YL - 18 150-F381 RD- 16 118-F88 GY- 16 507-F56 WH- 18 614-F327 PU- 18
614-F386 PU- 18 CAN SHIELD 14 944-PL11 OR- 18
150-F303 RD- 14 114-F251 RD- 16 524-F53 BU- 16 614-F382 PU- 18
FRAME LVL INTLK AUX DIV GND AUX DIV PWR 614-F24 PU- 18 RS-232 PORT 3-GND 15 Y795-PL10 GN- 18
529-F55 WH- 18 614-F386 PU- 18
608-P1 GN- 16 608-P5 GN- 16 200-P10 BK- 16 140-9378 140-9378 140-9378 614-F178 PU- 18 F-C41 RS-232 PORT 3-TXD 16
C903-F169 BU- 16 124-F284 GN- 14 614-F13 PU- 18 J759-F250 GN- 18
608-P6 GN- 16 608-P6 GN- 16 614-F382 PU- 18 1552269 RS-232 PORT 3-RXD 17
147-F278 PU- 16 F-C17 127-F70 OR- 16 614-F14 PU- 18 J759-F261 GN- 18
614-F93 PU- 18 614-F328 PU- 18 MSS TIRIS ANTENNA ANTENNA RADIO 18
3E3364 128-F414 PK - 12 614-F18 PU- 18 J757-F359 PU- 18 605-F136 YL - 16 T901-F165 YL - 18
614-F157 PU- 18
2285856
615-P3 YL - 16 615-P7 YL - 16 205-8257 8E-1118 19
321-F146 BR- 18 128-F415 PK - 12 614-F21 PU- 18 J757-F361 PU- 18 606-F140 GY- 16 T902-F166 PK - 18
BK-18 614-F153 PU- 18
F-C64
615-P8 YL - 16 308-F141 YL - 16 20
987-F281 WH- 16 130-F59 GN- 16 614-F22 PU- 18 J764-F390 BR- 18
RH REAR FLOOD C905-F229 OR- 16 200-F286 BK- 16 BK-18 614-F96 PU- 18 21
990-F300 GN- 16 131-F61 BR- 16 614-F23 PU- 18 870-F117 OR- 16
200-P2 BK- 16 200-P9 BK- 16 212-9347 P-C3 614-F14 PU- 18 614-F65 PU- 18 F-C78 22
200-F282 BK- 16 200-F276 BK- 16 614-F93 PU- 18 308-F126 YL - 18
200-P10 BK- 16 1552269 112-F351 PU- 10 109-F323 RD- 2 614-F21 PU- 18 614-F95 PU- 18 1552272 23
116-F293 BR- 16 200-F282 BK- 16 614-F94 PU- 18 308-F127 YL - 18
WH-18 608-P6 GN- 16 112-F350 PU- 10 109-F372 RD- 10 614-F18 PU- 18 614-F62 PU- 18 24
870-F117 OR- 16 A309-F374 GY- 16 799-F25 WH- 18 799-F25 WH- 18 TURN SIGNAL 308-F141 YL - 16 308-F125 YL - 16 YL-16 KEY SWITCH
200-P4 BK- 16 200-P12 BK- 16 BK-18 200-P10 BK- 16 112-F352 PU- 10 109-F324 RD- 10 614-F22 PU- 18 614-F32 PU- 18 COAX CABLE GPS ANTENNA
C905-F229 OR- 16 612-F288 GY- 18 799-F176 WH- 18 J764-F39 BR- 18 202-2281 308-F399 YL - 18 PU-16 295-3351
200-P11 BK- 16 109-F325 RD- 10 OR-16 199-3387 VHF ANTENNA
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
F710-F369 BR- 18 783-F295 OR- 18 MAIN PWR RLY 200-F313 BK- 16 863-F33 BU- 18 J759-F261 GN- 18 307-F320 OR- 16 105-F172 RD- 16 BR-16
150-F381 RD- 16 241-8367 200-F286 BK- 16 308-F126 YL - 18
615-P8 YL - 16 109-F325 RD- 10 614-F245 PU- 18 J757-F359 PU- 18
42 Page
794-F283 YL - 16 521-F11 YL - 14 308-F127 YL - 18

109-F324 RD- 10 J757-F171 PU- 16 J757-F361 PU- 18
522-F103 WH- 16 123-F253 WH- 18 308-F141 YL - 16
G 200-P12 BK- 16
STAB RLY 2 LIFT PUMP 140-9378
794-F280
794-F279
YL - 18
YL - 18
109-F372 RD- 10 616-F60
750-F34
BU- 16
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 G
140-9378 140-9378 NOTE D 241-4938
F-C88 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
3E3364 BK-18 ACCELERATOR
200-F286 BK- 16 774-F38 YL - 18 J764-F367 BR- 18 J764-F113 BR- 18 993-F357 BR- 18
993-F357 BR- 18 160-2443
521-F11 YL - 14 K791-F416 OR- 16 K791-RF416 OR- 16 780-F258 PU- 18 J764-F83 BR- 18 F702-F358 GN- 18 YL-18 F-C42
795-F162 YL - 16 522-F103 WH- 16 781-F259 PK - 18 1552264
795-F274 YL - 18 616-F60 BU- 16 782-F260 GY- 18 509-F181 WH- 18 BLACK
117-F380 RD- 16 795-F161 YL - 18 750-F34 GN- 18 200-F286 BK- 16 SEAT PUMP J764-F335 BR- 16 T901-F165 YL - 18 508-F180 PU- 18 BLUE
A309-F374 GY- 16 753-F35 GY- 18 792-F36 OR- 18 780-F258 PU- 18 213-4579 J764-F41 BR- 18 J764-F390 BR- 18 T902-F166 PK - 18 200-F238 BK- 18 BLACK
200-F313 BK- 16 774-F38 YL - 18 308-F141 YL - 16 793-F37 YL - 18 H14 J764-F269 BR- 18 J764-F360 BR- 18
RADIO 136-CC116 GN- 16
H3 J757-F171 PU- 16 780-F258 PU- 18 781-F259 PK - 18 J764-F84 BR- 18 108-F239 RD- 18 108-F239 RD- 18 RED
799-F290 WH- 18 AFTERMARKET
F-C3
1129609 799-F210 WH- 18
781-F259
782-F260
PK - 18
GY- 18
CONN 12 856-F405 GN- 18
782-F260 GY- 18
F-C37
J764-F145
J764-F107
BR- 18
BR- 16
135-F240
200-F238
BU- 18
BK- 18
135-F240 BU- 18
J764-CC245 BR- 16
200-CC227 BK- 16
M 512-F182 GN- 18 BLACK
RELAY BLOCK 799-F385 WH- 18
799-F25 WH- 18 792-F36 OR- 18
F-C32
1779641
CC-C40
1779646
863-F33 BU- 18
867-F404 PU- 18
792-F36 OR- 18
BR-16
1552269
141-F109 PK - 18 141-F109 PK - 18
508-F180
509-F181
PU- 18
WH- 18
511-F179 BR- 18 GREEN
200-CC237
200-CC238
BK- 16
BK- 16
H15 OR-16 111-CC96 RD- 12
799-F176 WH- 18 793-F37 YL - 18 T941-F235 BR- 16 799-F176 WH- 18 200-F296 BK- 18 200-F296 BK- 18 511-F179 BR- 18
111-F209 RD- 12 111-CC96 RD- 12
T942-F314 PK - 16 J764-F269 BR- 18 512-F182 GN- 18
KEYSW HAZARD HEADLAMP 2 HEADLAMP 1 F710-F369
H764-F163
BR- 18
GY- 18 856-F405 GN- 18 CONN 11 T943-F234
T944-F329
GY- 16
GN- 16
J764-F366
J764-F367
BR- 18
BR- 18
DASH PHS JOYSTICK
111-CC92 RD- 14
111-CC93 RD- 14
324-CC49 BU- 16
F-C35 CC-C5 230-5591 111-CC94 RD- 14
H765-F164 WH- 18 863-F33 BU- 18 856-F405 GN- 18 403-CC290 GN- 18
1673693 1673692 ITT GRIP
102-F213 RD- 16 867-F404 PU- 18 867-F404 PU- 18
BASE 221-3064 111-CC274 RD- 14
PU- 18
BR - 16
109-F324 RD- 10 X753-F378 YL - 18 T944-F329 GN- 16 403-CC279 GN- 18
PU- 18
BK - 18
205-F228 BK - 16 205-CC144 BK- 16
PK - 16
GY- 16
BR - 16
GN- 16
PK - 16
PU- 14
103-F78 RD- 16 T942-F314 PK - 16 109-F323 RD- 2 136-CC116 GN- 16
BK - 18
PU- 14
307-F320 OR- 16 307-CC10 OR- 16
BU- 14
161-F104 RD- 16 X753-F376 YL - 18 T943-F234 GY- 16 200-CC237 BK- 16 F711-CC267 GN- 16
WH- 18
BU- 18
OR- 16
YL - 14
308-F126 YL - 18 308-CC263 YL - 18 MACHINE SECURITY SYS
BU- 16
GN- 16
F-C80
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 R-C1
YL - 16
324-F218 BU - 16 324-CC49 BU- 16 156-6155
E528-F291
BASE CONN
A515-F285
X753-F377 YL - 18 1552273 F712-CC268 GY- 16 1506766
E528-F208
200-F294
A516-F287
403-F401 GN- 18 403-CC279 GN- 18 205-CC239 BK- 14
T943-F234
T941-F235
T944-F329
T942-F314
E528-F265
123-F253 WH- 18
200-F227
123-CC258 WH- 18 1 BAT 111-R11 RD- 14 1 +BATTERY
E528-F266
517-F8
604-F215 OR- 16 604-CC63 OR- 16 205-F267 BK- 18
BEACON FUSE ACC SOCKET 1 SEAT RADIO SW 403-F401 GN- 18 2 GND J764-CC148 BR- 18 205-R3 BK- 16
123-F205
913-F102
502-F101
521-F11
3 GROUND
616-F60
608-F45
753-F35
750-F34
774-F38
793-F37
503-F49
119-F48
119-F43
523-F52
119-F50
119-F46
506-F91
500-F90
605-F225 YL - 16 605-CC114 YL - 16
2285856
2285856
2285856
2285856
2285856
2285856
2285856
2285856
2285856
2285856
782-F260 GY- 18
615-F2
C743-F143 PK - 18 3 PWM X-AXIS 205-CC241 BK- 16 J764-CC230 BR- 16 5 DRIVER #2 OUTPUT
606-F147 GY - 16 606-CC111 GY- 16
F-C30
F-C26
F-C29
F-C24
F-C53
F-C28
F-C27
F-C46
F-C45
F-C21
J811-F270 BK- 18 150-CC253 RD- 14 200-F28 BK- 16 4 CAL 205-CC242 BK- 16 T901-R8 YL - 16 7 EXCITER COIL SIG
611-F80 PU - 16 611-CC59 PU- 16 781-F259 PK - 18 PWM Y-AXIS
135-F240 BU- 18 J811-F159 BK- 18 C744-F144 PU- 18 308-CC264 YL - 18 200-F183 BK- 14 5 205-CC243 YL - 16
MOM
9 DRIVER #1 INPUT
MOM
LH STOP TURN TAIL FOG
MOM
H17 617-F242 BR - 16 617-CC126 BR- 16 J764-CC247 BR- 16
MOM
BOOM FLOOD SW
CAB PLATFORM SEL
112-F354 PU- 10 J811-F160 BK- 18 200-F184 BK- 16 6 CAL 11 DRIVER #1 OUTPUT
FRONT WIPER SW
195-0194
F
ROOF WIPER SW
HVAC BLOWER
REAR WIPER SW
619-CC62 GN- 16
619-F349 GN- 16
F
CAB FLOOD
HEAT AC SW
FR WASHER
TOW HITCH
141-F109 PK - 18 J811-F272 BK- 18 200-F186 BK- 18 J764-CC78 BR- 16
IMP DISABLE
13 NOT USED
2285856
202-2277
190-8217
206-2607
202-2282
190-8216
190-8227
190-8218
190-8222
190-8223
246-3460
246-3461
757-F74 PU - 18 757-CC5 PU- 18 F-C69 307-CC10 OR- 16
121-F249 YL - 14 J811-F273 BK- 18 F711-F230 GN- 16 200-F187 BK- 18 J764-CC226 BR- 18 18 DRIVER #2 INPUT
F-C62
STOP 759-F110 OR- 18 759-CC11 OR- 18 1552252 GRIP CONN 308-CC265 YL - 18
144-F319 GN- 16 J811-F375 BK- 18 200-F188 BK- 18 J764-CC245 BR- 16 J843-R14 BK- 18 19 LED GROUND
760-F111 PK - 18 760-CC12 PK- 18 799-F176 WH- 18 324-CC49 BU- 16
A309-CC266 GY- 16 200-F189 BK- 18 1 PWR-PWM 308-R5 YL - 16 24 KEYSW ON
MOM
761-F112 GY - 18 761-CC13 GY- 18 J764-F269 BR- 18
LH TAIL LAMP RH TAIL LAMP ENG RUN 958-F301 YL - 16 123-F371 WH- 18 521-CC118 YL - 16 200-F196 BK- 14 2 GND-PWM 403-CC290 GN- 18 403-R7 GN- 18 26 ALT R TERM
TAIL 763-F115 BU - 18 763-CC22 BU- 18 780-F258 PU- 18
959-F302 WH- 16 205-F228 BK- 16 3 PWM1-SIG 403-CC279 GN- 18 29 SWITCH INPUT #1
764-F114 PU - 18 764-CC23 PU- 18 H14
987-F281 WH- 16 307-F320 OR- 16 522-CC119 WH- 16 200-F199 BK- 16 NOTE D E529-F252 YL - 14 4 447-CC189 PK- 18 J811-CC228 BK- 18 308-R6 YL - 16 31 KEYSW START
GN- 14
MATE TO 765-F116 OR- 18 765-CC24 OR- 18
990-F300 GN- 16 A700-CC249 OR- 18 200-F201 BK- 12 J764-F366 BR- 18 5 SW RTN 757-CC5 PU- 18 40 NOT USED
PU- 14
BR - 18
GN- 14
CC-C22
BR - 18
BR - 16
BK - 16
BK - 16
TURN 766-F154 GN- 16 766-CC67 GN- 16 F711-CC267 GN- 16
BK - 18
PU- 18
CC-C13
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 F702-CC251 GN- 18 200-F307 BK- 14 6 SW1-NO 759-CC11 OR- 18 Y787-CC152 WH- 16 H5 893-R1 GN- 16 42 CAT DATALINK+
769-F72 BU - 18 769-CC275 BU- 18 J764-F367 BR- 18 F711-CC99 GN- 16 1552267
117-F380 RD- 16 308-F141 YL - 16 F710-CC255 BR- 18 200-F276 BK- 16 7 TRIG SW RTN 760-CC12 PK- 18 892-R2 BR- 16 45 CAT DATALINK-
892-F174 BR - 16 892-CC102 BR- 16
618-F243 YL - 16 F711-CC103 GN- 16 200-F282 BK- 16 8 SW2-NO 761-CC13 GY- 18 Y788-CC153 GY- 16 F711-CC97 GN- 16
124-F244
A 47 GROUND
FOG 893-F173 GN- 16 893-CC121 GN- 16 867-F408 PU- 18 TERMINATING RES 2B
125-F384 OR- 16 324-F218 BU- 16 F712-CC104 GY- 16 200-F248 BK- 14 9 SW1 & 2 PAR 763-CC22 BU- 18 F712-CC98 GY- 16
124-F284
200-F26
52 DRIVER #2 RETURN
E528-F264
116-F310
200-F309
B
J764-F39
J764-F41
G757-CC1
- OR 18 G757-CC1 OR- 18 134-2540
130-F59
200-F289
614-F245
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- 16 892-CC273 BR- 16 200-F309 BK- 16 792-F36 OR- 18 10 TRIG SW NO 764-CC23 PU- 18 C T902-R15 PK - 16 53 EXCITER COIL RTN
J755-F118 BU - 16 J755-CC53 BU- 16 856-F405 GN- 18 F712-CC100 GY- 16
649-F82 YL - 16 J764-F191 BR- 18 605-F225 YL - 16 893-CC271 GN- 16 11 TRIG SW PAR 765-CC24 OR- 18 58 DRIVER #1 RTN
J756-F119 BR - 16 J756-CC52 BR- 16 867-F407 PU- 18 F712-CC268 GY- 16
606-F147 GY- 16 993-CC250 BR- 18 12 PWM2-SIG 766-CC67 GN- 16 F846-R12 PU- 18 60 RED LED SIG
J758-F121 PK - 16 J758-CC51 PK- 16 CC-C12
RADIO UNSW HORN FUSE A4E1 ECM A4M1 ECM 611-F80 PU- 16 769-CC275 BU- 18 G848-R13 GN- 18 62 GREEN LED SIG
J760-F120 YL - 16 J760-CC50 YL - 16 1552267
617-F242 BR- 16 774-CC35 YL - 18 A4M1 MACHINE CONTROL 64 DRIVER #2 ENABLE
J764-F107 BR - 16 J764-CC78 BR- 16
619-F349 GN- 16 780-CC84 PU- 18 295-3460 136-CC116 GN- 16 A RD-18 +V 66 SWITCH INPUT #2
P909-F71 PK - 18 P909-CC6 PK- 18 867-F404 PU- 18 CC-C3 FRONT AXLE CENTER
627-F395 YL - 16 781-CC85 PK- 18 200-CC238 BK- 16 B BK-18 GROUND 68 NOT USED
J811-F270 BK - 18 J811-CC128 BK- 18 199-0704
LH STOP TAIL TURN REV
295-3381
757-F74 PU- 18 RH CONSOLE 782-CC86 GY- 18 1471445 H750-CC205 BR- 18 C YL-18 SIGNAL 308-R4 YL - 16 70 NOT USED
111-F318
109-F325
RD- 12
RD- 10
759-F110 OR- 18
760-F111 PK - 18
CONN 10 111-CC96 RD- 12
111-CC274 RD- 14
783-CC83 OR- 18 308-CC265
E900-CC32
YL - 18
WH- 18
1
2
KEYSWITCH ON
TRANSMISSION OUTPUT SP+
STOP 150-F303 RD- 14 761-F112 GY- 18 F-C36 CC-C6 136-CC116 GN- 16 792-CC36 OR- 18 E901-CC31 GN- 18 3 TRANSMISSION OUTPUT SP-
CC-C22 2253861 2253854
1552273 114-F251 RD- 16 763-F115 BU- 18 200-CC237 BK- 16 793-CC43 YL - 18 4 DIFF SPEED 2+ - NOT USED 308-R4 YL - 16
F-C4 108-F406 RD- 18 764-F114 PU- 18 205-CC239 BK- 14 794-CC88 YL - 16 5 DIFF SPEED 2- - NOT USED 308-R5 YL - 16
TAIL 604-CC172 OR- 16 H24
765-F116 OR- 18 307-CC10 OR- 16 795-CC69 YL - 16 E902-CC2 PU- 18 CC-C37 R-C2 308-R6 YL - 16
617-CC131 BR- 16 1249636
FUSE BLOCK F-C76 766-F154 GN- 16 321-F146 BR- 18 321-CC124 BR- 18 308-CC265 YL - 18 109-FR323 RD- 2 E903-CC3 YL - 18
6
7
#1 INTERMEDIATE XMSN SP+
#1 INTERMEDIATE XMSN SP- CONN 32 3E5179 1552252
605-CC115 YL - 16 1552269 521-F11 YL - 14 521-CC118 YL - 16
769-F72 BU- 18 324-CC49 BU- 16 C743-CC82 PK- 18 8 DIFF SPEED 4+ - NOT USED 893-CC272 GN- 16 1 893-R1 GN- 16
627-CC277 YL - 16 522-F103 WH- 16 522-CC119 WH- 16
TURN J764-F191 BR- 18 775-F341 BR- 18 X-C9 C744-CC81 PU- 18 9 DIFF SPEED 4- - NOT USED 892-CC270 BR- 16 2 892-R2 BR- 16
612-CC176 GY- 16 612-F288 GY- 18 612-CC174 GY- 16
200-CC137 BK- 16
200-CC137
200-CC234
BK- 16
BK- 16
447-F271 PK - 18 776-F347 YL - 18
C919-F346 PU- 18 616-F60 BU- 16 616-CC145 BU- 16
403-CC290 GN- 18
403-CC279 GN- 18
Y793-X54 YL - 18
XXX-XXXX
A/C COMPRESSOR 893-CC122 GN- 16 10
11
CAT DATALINK+
5V SENSOR SUPPLY - NOT USED
111-CC274 RD- 14
308-CC269
205-CC201
YL - 16
BK- 16
3
4
308-R4
205-R3
YL - 16
BK- 16
REV 604-CC172 OR- 16 618-F243 YL - 16 618-CC127 YL - 16 447-CC189 PK- 18
1 CAN-
G757-CC1 OR- 18 321-CC107 BR- 18 205-CC201 BK- 16 111-CC274 RD- 14
778-F344 BR- 18
E 605-CC115 YL - 16 C917-F345 YL - 18 627-F395 YL - 16
750-F34 GN- 18
627-CC248 YL - 16 757-CC5 PU- 18 CONN 19 Y792-X45 PK - 18 2
3
CAN+
UNUSED
205-CC241 BK- 16
12
13
BACKUP ALARM & RELAY
MACHINE GROUND
308-CC269
403-CC290
YL - 16
GN- 18
5
6
111-R11 RD- 14
E
612-CC176 GY- 16 759-CC11 OR- 18 W-C16 W-C28 CC-C9 BLOWER ON REPLACES HEAT A/C SW (F-6) F799-CC44 BU- 16 14 FRAME LEVEL ACTIVATED INPUT 7
753-F35 GY- 18 4 UNUSED FUEL INJ PUMP 892-CC270 BR- 16
617-CC131 BR- 16 760-CC12 PK- 18 1552269 1673692 1673693 247-5539 WHEN A/C IS NOT INSTALLED F799-CC44 BU- 16 E908-CC21 BR- 18 15 CONVERTER OUTPUT SPEED SENSOR+ 8
774-F38 YL - 18 774-CC35 YL - 18 F770-X1 BR- 18 5 FUEL SHUT OFF 225-5173 893-CC272 GN- 16
617-CC156 BR- 16 761-CC13 GY- 18 H764-CC46 GY- 18 E909-CC20 WH- 18 16 CONVERTER OUTPUT SPEED SENSOR- 9
CONN 5 627-CC277 YL - 16
SENDER FUEL
295-3421
H18
780-F258 PU- 18 780-CC84 PU- 18 763-CC22 BU- 18
XMSN INTMED SP SNSR 1
189-9801
BK-18 E903-W32 YL - 18 E908-W59 BR- 18 E908-CC21 BR- 18 A278-X89 BK- 14 6 GND
H765-CC47 WH- 18 17 DIFF SPEED 6+ - NOT USED 10
CL-C1 CL-C3 CC-C23 781-F259 PK - 18 781-CC85 PK- 18 BK-18 E902-W33 PU- 18 P916-W45 OR- 18 P916-CC9 OR- 18 329-X90 YL - 14 7 B+ 200-E72 BK- 14
764-CC23 PU- 18 J764-CC78 BR- 16 18 DIFF SPEED 6- - NOT USED 403-CC290 GN- 18 11 403-R7 GN- 18
1552269 3E3364 1552269 782-F260 GY- 18 782-CC86 GY- 18 991-W3 WH- 18 991-CC4 WH- 18 999-X55 WH- 18 8 ENG POS 521-E6 YL - 16
779-F340 WH- 18 765-CC24 OR- 18 SECONDARY BUCKET LOWER X753-CC48 YL - 18 19 NOT USED 12
783-F295 OR- 18 783-CC83 OR- 18 C993-W4 WH- 18 C993-CC8 WH- 18 522-E7 WH- 16 R-C4
REG PLATE LAMP 1 BK-18 617-CL3 BR- 16 617-CL1 BR- 16 617-CC156 BR- 16 784-F262 YL - 18 766-CC67 GN- 16 A/C MOD AF-C3 852-CC282 GN- 18 892-CC120 BR- 16 20 CAT DATALINK-
W-C17 T800-W19 OR- 18 T800-CC225 OR- 18 X-C10 1552269
295-3382 BK-18 200-CL4 BK- 16 200-CL2 BK- 16 200-CC234 BK- 16 CONN 6 785-F263 PK - 18 784-F262 YL - 18
785-F263 PK - 18
769-CC275 BU- 18 1552269 755-W7 OR- 18 755-CC15 OR- 18 1779654 AF-C5 212-2204 3E3376 856-CC283 GN- 18 L740-CC75 BR- 18 21 5V SENSOR RETURN
WH-18 1 T901-R8 YL - 16
CC-C14 HA-C1 A700-F356 OR- 18 1684999 867-CC284 PU- 18 443-CC235 YL - 18 22 TORQUE CONVERTER TEMP SNSR
792-F36 OR- 18 792-CC36 OR- 18 TC SP SNSR BK-18 E909-W51 WH- 18 975-W12 WH- 18 975-CC66 WH- 18 323-X68 WH- 14 1 RD-14 +BAT IN SIG GN 1 513-AF4 OR- 16 BK-18 2 T902-R15 PK - 16
CC-C21 1552272 3E3376 F702-F358 GN- 18 774-CC35 YL - 18 123-CC258 WH- 18 869-CC281 PU- 18 23 - BATTERY 2 - NOT USED
793-F37 YL - 18 793-CC43 YL - 18 WIRE4252 BK- 00 191-8305 BK-18 E908-W59 BR- 18 443-W38 YL - 18 443-CC235 YL - 18 329-X90 YL - 14 2 OR-14 +BAT OUT VLPM 513-AF4 OR- 16 A 12VDC SW RD 521-AF3 YL - 16 FERRITE COIL R-C3
3E3376 780-CC84 PU- 18 892-CC120 BR- 16 24 SWB 2 - NOT USED
1552269
958-CC167 YL - 16 YL - 16 863-F33 BU- 18 WIRE4251 RD- 00 E909-W51 WH- 18 E909-CC20 WH- 18 A278-X89 BK- 14 3 BR-14 -BAT OUT 216-2621 522-AF1 WH- 16 B GND BK 2 200-AF5 BK- 14 222-3870
F712-F231 GY- 16 781-CC85 PK- 18 AIR RESTRICTION IND 893-CC122 GN- 16 25 SWB 3 - NOT USED
T800-CC146 OR- 18 959-CC165 WH- 16 BU - 16 H5 987-F281 WH- 16 987-CC164 WH- 16 E901-W34 GN- 18 E901-CC31 GN- 18 200-X67 BK- 14 4 BK-14 -BAT IN E-C5 CLUTCH BU 3 E554-AF7 PK - 14 BK-18 2 T902-R10 PK - 16
782-CC86 GY- 18 151-8367 150-CC253 RD- 14 P909-CC6 PK- 18 26 BOOM LOWERED SW PARITY
LSI STRAIN SNSR J764-CC148 BR- 18 987-CC164 WH- 16 WH- 16 990-F300 GN- 16 990-CC159 GN- 16 428-W39 OR- 18 428-CC72 OR- 18 1166158 WH-18 1 T901-R9 YL - 16
227-4455 874-CC288 GY- 18 990-CC159 GN- 16 GN- 16 F710-F369 BR- 18 F710-CC255 BR- 18
783-CC83 OR- 18 CONN 16 752-W15 YL - 18 752-CC41 YL - 18 BK-18 1 A710-E48 GY- 18
A/C HIGH PRESS SW 308-CC264 YL - 18 P909-CC6 PK- 18
769-CC275 BU- 18
27
28
AUTO/MANUAL SW - MANUAL
AUTO/MANUAL SW - VSC
F711-F230 GN- 16 F711-CC103 GN- 16 EL-C2 EJ-C1 751-W1 GN- 18 751-CC42 GN- 18 X-C1 BK-18 236-6923 AF-C2
792-CC36 OR- 18 2 F729-E60 GN- 18 29 ANALOG PASSIVE 2 - NOT USED
F712-CC104 GY- 16 3E3364 1552269 754-W6 BU- 18 754-CC14 BU- 18 1696870 1552269
CL-C2 F712-F231 GY- 16 793-CC43 YL - 18 447-CC189 PK- 18 30 FUEL LEVEL SENSOR
H764-F163 GY- 18 H764-CC46 GY- 18 1 901-W9 WH- 18 901-CC17 WH- 18 L730-X84 OR- 18 A RD-18 +V A/C COMPRESSOR GP GN-14 1 E554-AF7 PK - 14 LEDS IN CAB H23
1552269 J755-F118 BU- 16 794-CC88 YL - 16 2 31 + BATTERY 1 - NOT USED
T943-F234 GY- 16 T943-CC55 GY- 16 J764-W55 BR- 18 J764-CC226 BR- 18 L731-X81 BR- 18 B BK-18 GROUND 178-9570 GN-14 2 200-AF6 BK- 14 R-C6
REG PLATE LAMP 2 BK-18 617-CL5 BR- 16 J756-F119 BR- 16 795-CC69 YL - 16 W-C19 A309-CC266 GY- 16 32 LOCATION CODE ENABLE - NOT USED 1552267
T941-F235 BR- 16 T941-CC56 BR- 16 E900-W35 WH- 18 E900-CC32 WH- 18 X731-X13 BU- 18 C YL-18 SIGNAL
295-3382 BK-18 200-CL6 BK- 16 J758-F121 PK - 16 1552269 757-CC5 PU- 18 33 XMSN NEUTRALIZER DISABLE SW RED
T944-F329 GN- 16 T944-CC57 GN- 16 C743-CC82 PK- 18 521-CC118 YL - 16 H16 F846-R12 PU- 18 A RD
J760-F120 YL - 16 INTAKE MANIFOLD PRESS SNSR OIL FILTER BYPASS SW E-C6 34 BOOM RETRACTED SW PARITY - NOT USED
T942-F314 PK - 16 T942-CC58 PK- 16 WIRE4249 BK- 00 XMSN OUT SP SNSR BK-18 E901-W34 GN- 18 324-W53 BU- 16 324-CC49 BU- 16 J843-R14 BK- 18 B GN
J764-F107 BR- 16 C744-CC81 PU- 18 203-4344 203-7984 522-CC119 WH- 16 E450-CC191 GN- 18 35 XMSN OIL FILTER BYPASS
K791-F416 OR- 16 189-5746 BK-18 E900-W35 WH- 18 200-W54 BK- 16 200-CC227 BK- 16 X-C2 1552269
CONN 24 A700-CC249 OR- 18 36 ANALOG ACTIVE 1 - NOT USED
G848-R13 GN- 18 C BK
GREEN
CC-C34
1552267
J811-CC128 BK- 18 852-F388 GN- 18 CONN 9 756-W52 WH- 18 756-CC141 WH- 18
H802-CC73 GY- 18
1552269
INTAKE MANIFOLD TEMP SNSR
BK-18 1 E450-E9 GN- 18 E-C7 AF-C1 F702-CC251 GN- 18 321-CC107 BR- 18 37 ANALOG ACTIVE 2 - NOT USED
F-C33 CC-C7 G757-CC1 OR- 18 MOTOR PUMP ASSY H802-W29 GY- 18 C967-X29 BU- 18 1 BK-18 2 J764-E33 BR- 16 1552272 3E3376 F710-CC255 BR- 18 352-CC136 BU- 18 111-CC92 RD- 14
799-CC89 WH- 18 869-F389 PU- 18 38 UNSWITCHED BATTERY
Y787-CC157 WH- 16 1673692 1673693 L731-X82 BR- 18 2 191-6563
RD- 2
TERMINATING RES 1A 958-CC167 YL - 16 892-F174 BR- 16 522-E7 WH- 16 1 F711-CC103 GN- 16 799-CC90 WH- 16 111-CC93 RD- 14 39 UNSWITCHED BATTERY
Y788-CC158 GY- 16 959-CC165 WH- 16 123-F371 WH- 18 123-CC258 WH- 18 F799-CC44 BU- 16 W-C20 F712-CC104 GY- 16
134-2540 893-F173 GN- 16 T° 200-E72 BK- 14 2 200-AF2 BK- 14 200-AF6 BK- 14 H751-CC204 OR- 18 40 LEFT STAB RAISE
133-F355 OR- 14 133-CC108 OR- 14 WIRE4250 RD- 00 1552269 E903-W32 YL - 18 E903-CC3 YL - 18
799-CC90 WH- 16 H764-CC46 GY- 18 3 200-AF5 BK- 14 892-CC273 BR- 16 J764-CC148 BR- 18 41 SWG 9 - NOT USED
136-F246 GN- 16 136-CC117 GN- 16 E902-W33 PU- 18 E902-CC2 PU- 18
799-CC91 WH- 18 987-CC164 WH- 16 H765-CC47 WH- 18 XMSN OIL TEMP 428-W39 OR- 18 521-E6 YL - 16 4 521-AF3 YL - 16 893-CC271 GN- 16 Y758-CC194 PK- 18 42 LEFT STAB LOWER
109-F323
150-F306 RD- 14 150-CC253 RD- 14 L740-W27 BR- 18 L740-CC75 BR- 18
799-CC183 WH- 18 990-CC159 GN- 16 J764-CC78 BR- 16 130-9811 L740-W27 BR- 18 993-CC250 BR- 18 Y761-CC198 OR- 18 43 BOOM RETRACTED SW
D 993-F357 BR- 18 447-F271 PK - 18 447-CC189 PK- 18 X753-CC48 YL - 18 X750-W16 OR- 18 X750-CC65 OR- 18 X-C3
T800-CC213 OR- 18 44 8V SENSOR POWER MACHINE SECURITY SYS-ATCH
133-CC108 OR- 14
136-CC95 GN- 16
P909-F71 PK - 18 775-F341 BR- 18 852-CC282 GN- 18 902-W25 BR- 18
900-W8 PU- 18
902-CC18
900-CC16
BR- 18
PU- 18 995-X14 BU- 18
1552269
1 COOLANT TEMP SNSR
Y787-CC152 WH- 16 J764-CC245 BR- 16 45 8V SENSOR RETURN
J758-CC37 PK- 16
D
133-CC147 OR- 14 133-CC108 OR- 14 776-F347 YL - 18 856-CC283 GN- 18 Y788-CC153 GY- 16 46 + BATTERY 5 - NOT USED
133-CC182 OR- 14 C919-F346 PU- 18 867-CC284 PU- 18 L731-X80 BR- 18 2 191-6563 NOTE C 874-CC288 GY- 18 111-CC94 RD- 14 47 UNSWITCHED BATTERY J758-CC311 PK- 16 CC-C43
200-CC133 BK- 16
205-CC154 BK- 14 133-CC147 OR- 14 200-CC139 BK- 16 111-F209 RD- 12 778-F344 BR- 18 869-CC281 PU- 18 T° J811-CC132 BK- 18 754-CC14 BU- 18 48 XMSN SPEED CLUTCH 1 1552269
205-CC184 BK- 14 133-CC182 OR- 14 C917-F345 YL - 18 892-CC120 BR- 16 J811-CC228 BK- 18 755-CC15 OR- 18 49 XMSN SPEED CLUTCH 2 J756-CC310 BR- 16 2 FRAME LVL SUPPR 1
CC-C16 779-F340 WH- 18 W-C23
Y758-CC194 PK- 18 200-CC232 BK- 14 133-F355 OR- 14 893-CC122 GN- 16 G962-CC140 OR- 18 975-CC66 WH- 18 50 XMSN SPEED CLUTCH 1-4 RETURNS J758-CC311 PK- 16 1 106-8704
2312295 794-F283 YL - 16 794-CC88 YL - 16 1552269 X-C5 200-E72 BK- 14
136-CC95 GN- 16 136-F246 GN- 16 P909-CC6 PK- 18 900-CC16 PU- 18 51 XMSN SPEED CLUTCH 3
Y761-CC198 OR- 18
Y759-CC199 YL - 18 200-CC133 BK- 16
200-CC137 BK- 16
795-F162 YL - 16 795-CC69 YL - 16 SHUTTLE XMSN-ATCH DIFF LOCK SOL
195-9700
BK-18
BK-18
324-W53 BU- 16
200-W54 BK- 16
200-X67 BK- 14
E966-X38
1552269
YL - 18 1 BK-18 ENGINE SPEED SNSR 200-E74 BK- 14 T800-CC213 OR- 18
901-CC17 WH- 18 52 XMSN SPEED CLUTCH 4 CC-C30
FRAME LVL SOL1
201-0315
200-CC137 BK- 16 150-F306 RD- 14 799-F290 WH- 18 799-CC91 WH- 18 RF-C89 428-CC72 OR- 18 53 XMSN OIL TEMP SENSOR 1552269
Y787-CC150 WH- 16 Y761-CC198 OR- 18 200-CC138 BK- 16 852-F388 GN- 18 852-CC282 GN- 18 323-X68 WH- 14 E965-X46 BU- 18 2 BK-18 192-7359 1552269
200-CC139 BK- 16 X750-CC65 OR- 18 PWM DRIVER 2W RETURN 11-12 CC-C46
799-CC89 WH- 18 Y787-CC157 WH- 16 200-CC234 BK- 16 321-F146 BR- 18 856-F405 GN- 18 856-CC283 GN- 18
W-C25
CONN 25 K791-RF416 OR- 16
229-E21 BK- 14 T800-CC146 OR- 18 X753-CC48 YL - 18
54
55 PWM DRIVER 9-12 RETURN
J758-CC51
J756-CC52
PK- 16
BR- 16
J758-CC308
J756-CC309
PK- 16
BR- 16
1
2
BK-18
BK-18 1552269
205-CC154 BK- 14 205-CC154 BK- 14 200-CC170 BK- 14 867-F404 PU- 18 867-CC284 PU- 18 329-X90 YL - 14 TO REV FAN ATCH 403-CC278 GN- 18
1552272 200-RF2 BK- 16 BUS BAR 1 56 - BATTERY 5 - NOT USED J758-CC37 PK- 16 2 FRAME LVL DUMP POS 1
Y788-CC151 GY- 16 Y787-CC150 WH- 16 869-F389 PU- 18 869-CC281 PU- 18 TH220B ONLY 375-E49 BR- 18
205-CC184 BK- 14 200-CC234 BK- 16 111-CC274 RD- 14 114-4516 306-CC200 GN- 18 T800-CC225 OR- 18 205-CC242 BK- 16 57 MACHINE GROUND F799-CC38 BU- 16 1 106-8704
Y759-CC199 YL - 18 958-F301 YL - 16 958-CC167 YL - 16 W BK-18 T800-W56 OR- 18 A278-X89 BK- 14 X-C6
352-CC136 BU- 18 200-CC142 BK- 14 C903-F169 BU- 16 200-CC227 BK- 16 902-CC18 BR- 18 58 XMSN SPEED CLUTCH 5
133-CC147 OR- 14 Y787-CC187 WH- 16 959-F302 WH- 16 959-CC165 WH- 16 BK-18 J764-W48 BR- 18 1552267 A710-E48 GY- 18
604-CC172 OR- 16 C905-F229 OR- 16 200-CC236 BK- 16 324-CC49 BU- 16 756-CC141 WH- 18 59 XMSN SYNC MOD VALVE
993-F357 BR- 18 993-CC250 BR- 18 BK-18 991-W3 WH- 18 L730-X84 OR- 18 L730-X85 OR- 18 A RD-18 +V J756-CC310 BR- 16
PHS VALVE SSV4 605-CC115 YL - 16 200-CC171 BK- 14 205-CC201 BK- 16 OIL PRESSURE SNSR E450-CC191 GN- 18 428-CC72 OR- 18 H802-CC508 GY- 18 60 PWM DRIVERS 5-8 RETURN CC-C47
CC-C19 A309-F374 GY- 16 A309-CC266 GY- 16 BK-18 L731-X83 BR- 18 B BK-18 GROUND F729-E60 GN- 18 H22
295-3450 Y787-CC188 WH- 16 612-CC176 GY- 16 A309-F374 GY- 16 308-CC269 YL - 16 190-0809 443-CC235 YL - 18 P936-CC506 GY- 16 61 FRAME LVL LOAD SENSE SOL - STABILIZER 1552269
2312295 A700-CC249 OR- 18 L730-X85 OR- 18 994-X23 GY- 18 C YL-18 SIGNAL 109-E25 RD- 2
616-CC145 BU- 16 447-F271 PK - 18 A700-F356 OR- 18 SHIFT RAIL SNSR 1 443-W38 YL - 18 F711-CC267 GN- 16 751-CC42 GN- 18 62 PWM DRIVER 8 - NOT USED J760-CC39 YL - 16 2 FRAME LVL DUMP POS 2
617-CC131 BR- 16 205-CC154 BK- 14 612-F288 GY- 18 C743-F143 PK - 18 C743-CC82 PK- 18 403-CC290 GN- 18 214-8970 150-E43 RD- 14 F712-CC268 GY- 16 752-CC41 YL - 18 793-CC43 YL - 18 63 IMPLEMENT DISABLE SW - ENABLE F799-CC40 BU- 16 1 106-8704
Y759-CC199 YL - 18 Y787-CC152 WH- 16 W-C26 751-W1 GN- 18 L731-X80 BR- 18 123-E51 WH- 18
205-CC184 BK- 14 618-F243 YL - 16 C744-F144 PU- 18 C744-CC81 PU- 18 606-CC109 GY- 16 752-W15 YL - 18 754-CC14 BU- 18 774-CC35 YL - 18 64 IMPLEMENT DISABLE SW - DISABLE F799-CC38 BU- 16
Y787-CC188 WH- 16 1552272 150-E55 RD- 14
617-CC156 BR- 16 783-F295 OR- 18 F702-F358 GN- 18 F702-CC251 GN- 18 611-CC59 PU- 16 150-E56 RD- 16 J764-CC230 BR- 16 755-CC15 OR- 18 65 FLOW CTRL VALVE SOL - STABILIZER F799-CC44 BU- 16 F799-CC40 BU- 16
799-CC183 WH- 18 Y788-CC158
Y788-CC151
GY- 16
GY- 16
627-CC277 YL - 16
321-CC124 BR- 18
794-F283 YL - 16 H765-F164 WH- 18 H765-CC47 WH- 18 618-CC129 YL - 16 W BK-18 T800-W42 OR- 18 754-W6 BU- 18
755-W7 OR- 18
L731-X82 BR- 18 CONN 23 150-E55 RD- 14
150-E56 RD- 16 J811-CC228 BK- 18 756-CC141 WH- 18 794-CC88 YL - 16 66 AUX DIVERTER VALVE
205-CC184 BK- 14 799-CC90 WH- 16 604-CC63 OR- 16 C903-F169 BU- 16 619-CC62 GN- 16 BK-18 J764-W49 BR- 18 X-C7 E-C9 308-E40 YL - 18 751-CC42 GN- 18 J760-CC39 YL - 16
795-F162 YL - 16 756-W52 WH- 18 67 XMSN FORWARD CLUTCH
Y788-CC186 GY- 16 799-CC91 WH- 18 C905-F229 OR- 16 J755-CC53 BU- 16 BK-18 C993-W4 WH- 18 L731-X83 BR- 18 1673692 1673693 308-E69 YL - 18 J764-CC226 BR- 18 752-CC41 YL - 18
799-F290 WH- 18 X750-W16 OR- 18 68 XMSN REVERSE CLUTCH
Y758-CC194 PK- 18 Y788-CC185 GY- 16 604-CC178 OR- 16 X753-F378 YL - 18 X753-CC48 YL - 18 BK-18 323-E46 WH- 14
H751-CC204 OR- 18 F710-F369 BR- 18 J756-CC52 BR- 16 900-W8 PU- 18 150-X52 RD- 18 1 150-E43 RD- 14 H802-CC73 GY- 18 799-CC90 WH- 16 69 10V PHS VALVE POWER
133-CC182 OR- 14 604-CC172 OR- 16 L731-X81 BR- 18 RESISTOR ALT 325-E47 PK - 18
Y788-CC186 GY- 16 J764-CC148 BR- 18 H20 H764-F163 GY- 18 J758-CC51 PK- 16 SHIFT RAIL SNSR 2 901-W9 WH- 18 229-X64 BK- 18 2 229-E21 BK- 14 X750-CC65 OR- 18 205-CC243 YL - 16 70 MACHINE GROUND
604-CC173 OR- 16 200-E74 BK- 14 134-2540 A309-E52 GY- 16
Y758-CC194 PK- 18 H765-F164 WH- 18 J760-CC50 YL - 16 214-8970 902-W25 BR- 18 325-X39 PK - 18 3 325-E47 PK - 18 900-CC16 PU- 18 CC-C4
F799-CC44 BU- 16 W-C27 308-E69 YL - 18 E450-E9 GN- 18
Y788-CC153 GY- 16 Y761-CC198 OR- 18 X753-F378 YL - 18 892-CC270 BR- 16 991-W3 WH- 18 200-X67 BK- 14 4 200-E74 BK- 14 A 1471446 CC-C31
1552272 229-E21 BK- 14 C444-E67 YL - 18 521-E6 YL - 16
Y787-CC152 WH- 16 893-CC272 GN- 16 308-X66 YL - 18 5 308-E68 YL - 18 B 901-CC17 WH- 18 307-CC10 OR- 16 1 KEYSWITCH START 1552269
Y788-CC153 GY- 16 F799-CC44 BU- 16 W BK-18 T800-W41 OR- 18 150-X52 RD- 18 C 522-E7 WH- 16 902-CC18 BR- 18 G962-CC140 OR- 18
605-CC113 YL - 16 J811-F270 BK- 18 C993-W4 WH- 18 A4E1 ENGINE CONTROL X-C8 F710-X28 BR- 18 6 F710-E59 BR- 18 2 IMPL DISABLE SOL
J760-CC50 YL - 16 J760-CC312 YL - 16 1 BK-18 FRAME LVL SOL2
874-CC288 GY- 18 BK-18 J764-W50 BR- 18 200-X67 BK- 14 E-C4 A700-E58 OR- 18 975-CC66 WH- 18 795-CC69 YL - 16
605-CC115 YL - 16 958-F301 YL - 16 136-CC95 GN- 16 P916-W45 OR- 18 190-0416 1471445 375-X40 BR- 18 7 375-E49 BR- 18 3 QUICK CPLR RLY
J755-CC53 BU- 16 J755-CC313 BU- 16 2 BK-18 201-0315
BK-18 P916-W45 OR- 18 F702-E57 GN- 18
C T800-CC146 OR- 18
G962-CC140 OR- 18
606-CC110
606-CC112
GY- 16
GY- 16
959-F302
987-F281
WH- 16
WH- 16
136-CC116 GN- 16 BK-18 E DOUT 50Ma 1 F770-X1 BR- 18 229-X64 BK- 18
323-X68 WH- 14
F715-X33 PU- 18
8
9
323-E46 WH- 14 1552267
F710-E59 BR- 18
991-CC4 WH- 18
C993-CC8 WH- 18
352-CC136 BU- 18
H764-CC46 GY- 18
4
5
IMPL DISABLE SOL RETURN
CIRCLE STEER RLY C
136-CC117 GN- 16 SWB 1 2 A709-X77 OR- 18 308-X66 YL - 18 308-E68 YL - 18 F711-E62 GN- 16
990-F300 GN- 16 SHIFT RAIL SNSR 3 F709-X11 BU- 18 10 150-E56 RD- 16 E900-CC32 WH- 18 H765-CC47 WH- 18 6 CRAB STEER RLY
612-CC174 GY- 16 SWB 2 3 D F711-E63 GN- 16
205-CC144 BK- 16 214-8970 F707-X12 WH- 18 11 E901-CC31 GN- 18 306-CC200 GN- 18 7 NEUTRAL START RELAY CC-C44
205-CC149 BK- 14 W-C18 893-X3 GN- 18 323-X68 WH- 14 308-E69 YL - 18 101-EY1 RD- 2 B+ W F712-E65 GY- 16
F708-X22 YL - 18 12 308-E69 YL - 18 E902-CC2 PU- 18 J811-CC132 BK- 18 8 ON/OFF DRIVER 2-5 RETURN 1552269
612-CC175 GY- 16 1552269 892-X4 BR- 18 308-E40 YL - 18 F712-E64 GY- 16 NOTE C
200-F286 BK- 16 205-CC154 BK- 14 A709-X77 OR- 18 13 E903-CC3 YL - 18 869-CC281 PU- 18 9 CONTINUOUS FLOW LED
J755-CC314 BU- 16
612-CC176 GY- 16 TC OIL TEMP 443-W38 YL - 18 WM ALTERNATOR (90A) J764-E33 BR- 16 2 FRAME LVL SUPPR 2
308-F141 YL - 16 205-CC184 BK- 14 J764-W55 BR- 18 A700-E58 OR- 18 14 A700-E58 OR- 18 323-E46 WH- 14 E908-CC21 BR- 18 783-CC83 OR- 18 10 FRAME LEVEL DISABLE RLY
J760-CC315 YL - 16
130-9811 J764-W40 BR- 18 WM 325-X39 PK - 18 323-E46 WH- 14 207-6035 101-E29 RD- 10 1 106-8704
133-CC108 OR- 14 893-X3 GN- 18 15 893-E24 GN- 16 E909-CC20 WH- 18 11 STABILIZER ISOLATION RELAY 1
WM 375-X40 BR- 18 325-E47 PK - 18 ATCH (120A) 892-E53 BR- 16
616-CC145 BU- 16 308-F141 YL - 16 205-CC201 BK- 16 136-CC95 GN- 16 J764-W50 BR- 18 892-X4 BR- 18 16 892-E53 BR- 16 325-E47 PK - 18 P916-CC9 OR- 18 12 STABILIZER ISOLATION RELAY 2
W A711-X8 PU- 18 A700-X16 OR- 18 375-E49 BR- 18 GND 211-6802 893-E24 GN- 16
200-F286 BK- 16 200-CC170 BK- 14 993-X41 BR- 18 993-E34 BR- 18 L740-CC75 BR- 18 Y758-CC194 PK- 18 13 PHS ADDRESS OUT
617-CC131
617-CC156
BR- 16
BR- 16 109-F324 RD- 10 308-CC263 YL - 18 200-CC171 BK- 14
J764-W40
J764-W48
BR- 18
BR- 18
W F720-X9 GN- 18 A701-X62 GY- 18
A746-X17 PK - 18
17
18 A700-E58 OR- 18 993-E34 BR- 18
101-E29 RD- 10 403-CC190 GN- 18 14 ALTERNATOR R TERMINAL CONN 31
F718-X10 BU- 18 A702-X61 PU- 18 120 308-E69 YL - 18
BACKUP ALARM 321-CC107 BR- 18 617-CC179 BR- 16 109-F325 RD- 10
109-F372 RD- 10
308-CC265 YL - 18
308-CC264 YL - 18
200-CC232
205-CC154
BK- 14
BK- 14
J764-W49 BR- 18
W
F709-X11 BU- 18 A703-X60 BR- 18
F703-X78 GY- 18 19 A710-E48 GY- 18
F702-E57 GN- 18 MAIN BKR FUSE FUEL PUMP 403-E3 GN- 18 CONN 26 852-CC282 GN- 18
874-CC288 GY- 18
15
16
CONTINUOUS FLOW
LSI SENSOR
CC-C1
1552273
CF-C1
3E3382
CF-C2
1552273
170-0950 321-CC124 BR- 18 997-X42 OR- 18 20 232-6312 E-C1 CC-C8
112-F350 PU- 10 308-CC269 YL - 16 205-CC184 BK- 14 F707-X12 WH- 18 A704-X59 GN- 18 F710-E59 BR- 18 216-4970 109-E25 RD- 2 17 580 BOOM EXTEND LIMIT PARITY 5 5
618-CC130 YL - 16 T800-W19 OR- 18 F716-X25 WH- 18 21
1673692 1673693
112-F351 PU- 10 321-CC124 BR- 18 X731-X13 BU- 18 A705-X63 BU- 18 F729-E60 GN- 18 18 LH STAB DOWN PRESS SW PARITY 611-CC59 PU- 16 611-CF4 PU- 16 BU-18 RH HEAD TURN POS LAMP
321-CC125 BR- 18 618-CC177 YL - 16 F719-X18 BR- 18 22 20A 122-E45 BU- 12 4 4
CC-C18 604-CC63 OR- 16 995-X14 BU- 18 A706-X51 GY- 18 306-E1 GN- 18 1 306-CC200 GN- 18 619-CC62 GN- 16 619-CF6 GN- 16 RD-18 295-3379 LH DIP
J811-CC135 BK- 18 112-F352 PU- 10 T800-W41 OR- 18 A710-X21 GY- 18 23 A710-E48 GY- 18 E-C14 19 CAB/PLATFORM INDICATOR (SWITCH) 6 6
1552269 605-CC113 YL - 16 WM 16 F702-X15 GN- 18 A707-X58 PU- 18 892-E53 BR- 16 J811-E2 BK - 18 2 J811-CC228 BK- 18 618-CC129 YL - 16 618-CF3 YL - 16 WH-18 295-3377 RH DIP
627-CC248 YL - 16 T800-W56 OR- 18 F718-X10 BU- 18 24 9X1054 20 300 MA SINK 7 - NOT USED 3 3
IMP DISABLE SOL BK-18 G962-CC140 OR- 18 605-CC114 YL - 16 605-CC115 YL - 16 751-W1 GN- 18 m 17 A700-X16 OR- 18 893-E24 GN- 16 30 403-E3 GN- 18 3 403-CC278 GN- 18 306-CC200 GN- 18 21 300 MA SINK 8 - NOT USED 606-CC109 GY- 16 1 606-CF1 GY- 16 1 YL-18
T800-W42 OR- 18 F717-X19 YL - 18 25 1
200-6210 BK-18 352-CC136 BU- 18 605-CC115 YL - 16 606-CC110 GY- 16 752-W15 YL - 18 18 A746-X17 PK - 18 A708-X50 BR- 18 993-E34 BR- 18 86(+) 521-E6 YL - 16 4 521-CC118 YL - 16 E450-CC191 GN- 18 200-CC236 BK- 16 200-CF2 BK- 16 BK-18
1
2
F721-X27 GY- 18 26 5 150-E56 RD- 16 22 DIGITAL RETURN - NOT USED 2 2
627-CC276 YL - 16 605-CC113 YL - 16 606-CC112 GY- 16 W 19 F719-X18 BR- 18 A709-X77 OR- 18 522-E7 WH- 16 5 522-CC119 WH- 16 F711-CC267 GN- 16 792-CC36 OR- 18 23 SWG 14 - JOYSTICK TRIG SW
975-W12 WH- 18 F702-X15 GN- 18 27 F702-E57 GN- 18 CBL-JJ1 E-C15 2 325-E47 PK - 18 NOTE C
627-CC277 YL - 16 612-CC174 GY- 16 754-W6 BU- 18 W 20 F717-X19 YL - 18 A710-X21 GY- 18 85(-) J764-E33 BR - 16 6 J764-CC230 BR- 16 F712-CC268 GY- 16 H751-CC204 OR- 18 24 REAR AXLE ALIGN SW
F729-X34 GN- 18 28 F729-E60 GN- 18 2254950 4 323-E46 WH- 14 H8
CC-C20 616-CC145 BU- 16 755-W7 OR- 18 W 21 F722-X20 OR- 18 A711-X8 PU- 18 F711-E62 GN- 16 87 E450-E9 GN- 18 7 E450-CC191 GN- 18 J764-CC230 BR- 16 759-CC11 OR- 18 25 STEER MODE SELECT - FRONT
799-CC91 WH- 18 975-W22 WH- 18 F727-X26 BU- 18 29
CK-C1
8I5176
CONN 3 OR-18
1552267
958-CC167 YL - 16 RR TT VV 606-CC109 GY- 16 617-CC131 BR- 16 756-W52 WH- 18
900-W8 PU- 18 975-W24 WH- 18
W 22
23
A710-X21
F708-X22
GY- 18
YL - 18
A712-X35 BR- 18
A746-X17 PK - 18
F711-X49 GN- 18 30 F711-E61 GN- 18
F711-E63 GN- 16
101-E41 RD- 12
87A 150-E55 RD- 14 8 150-CC253 RD- 14 J811-CC228 BK- 18 760-CC12 PK- 18 26 STEER MODE SELECT - CIRCLE
CK-C2 CC-C26 136-CC95 GN- 16 959-CC165 WH- 16 606-CC110 GY- 16 617-CC156 BR- 16 F712-X57 GY- 18 F712-E66 GY- 18 FUEL PUMP RL F710-E59 BR- 18 9 F710-CC255 BR- 18 761-CC13 GY- 18 27 STEER MODE SELECT - CRAB
REAR AXLE CENTER 901-W9 WH- 18 975-W23 WH- 18 994-X23 GY- 18 E798-X43 PK - 18
31
3E3382 1552273 BK-18 200-CC139 BK- 16 606-CC111 GY- 16 617-CC179 BR- 16 24
CBL-JJ2 115-1615 A309-E52 GY- 16 10 A309-CC266 GY- 16 403-CC278 GN- 18 H750-CC205 BR- 18 28 FRONT AXLE ALIGN SW
199-0704 987-CC164 WH- 16 975-W21 WH- 18
605-CK1 YL - 16 605-CC113 YL - 16 WH-18 H751-CC204 OR- 18 618-CC130 YL - 16 902-W25 BR- 18 25 F703-X78 GY- 18 F700-X36 BU- 18 F711-E61 GN- 18 105 F702-E57 GN- 18 11 F702-CC251 GN- 18 29 RIGHT STAB RAISE
990-CC159 GN- 16 606-CC112 GY- 16
200-CK2 WH-14 200-CC142 BK- 14 ENGINE ENGINE CHASSIS CAB 618-CC177 YL - 16 X750-W16 OR- 18 m 26 L730-X24 OR- 18 F701-X44 BR- 18 ALT BRKR A700-E58 OR- 18 12 A700-CC249 OR- 18 30 SWG 17 - NOT USED
J811-CC128 BK- 18 H802-W29 GY- 18 F712-E65 GY- 16 CBL-CC2 RD- 2 276-4644 00
606-CK3 GN-16 606-CC112 GY- 16 627-CC248 YL - 16 27 F702-X15 GN- 18 171-2212 NOTE A 993-E34 BR - 18 13 993-CC250 BR- 18 403-CC190 GN- 18 31 RIGHT STAB LOWER
T941-CC56 BR- 16 617-CC126 BR- 16
618-CK4 BR-16 618-CC177 YL - 16 CONN 4 T942-CC58 PK- 16 617-CC131 BR- 16 799-CC91 WH- 18 975-W23 WH- 18
975-W21 WH- 18 H802-W57 GY- 18
W 28 F716-X25
F727-X26
WH- 18
BU- 18
F703-X78 GY- 18
F705-X47 PK - 18
F712-E64 GY- 16 ATCH (135A) 123-E51 WH- 18 14 123-CC258 WH- 18 403-CC279 GN- 18 781-CC85 PK- 18 32 JOYSTICK LONGITUDINAL COMMAND THIS SCHEMATIC IS FOR TH220B TH330B CHASSIS
604-CK5 RD-16 604-CC178 OR- 16 CA-C1 CC-C29 J811-CC128 BK- 18 W 29 171-2213 308-E40 YL - 18 15 308-CC264 YL - 18 403-CC290 GN- 18 780-CC84 PU- 18 33 JOYSTICK LH THUMB SLIDER COMMAND WITH ELECTRIC ENGINE AND EROPS
T943-CC55 GY- 16 617-CC156 BR- 16 H802-W58 GY- 18
617-CK6 BK-16 617-CC179 BR- 16 3E3364 1552269 T944-CC57 GN- 16 MACHINE GROUNDS STRAPS 617-CC179 BR- 16 958-CC167
959-CC165
YL - 16
WH- 16
975-W22 WH- 18
975-W24 WH- 18
W 30
31
F721-X27
F710-X28
GY- 18
BR- 18
F706-X56 PU- 18
F707-X12 WH- 18
F712-E66 GY- 18 60
101-E29 RD- 10
101-E27 RD- 10
F711-E63 GN- 16
F712-E64 GY- 16
16
17
F711-CC267
F712-CC268
GN- 16
GY- 16
34
35
PLATFORM MODE SW - CAB
PLATFORM MODE SW - PLATFORM
H6 616-CA1 BU - 16 616-CC145 BU- 16 CBL-CC2 RD- 2 STARTER BRKR COMPONENTS ARE SHOWN INSTALLED ON A FULL Y HARNESS AS
B 200-CA2 BK 16 200-CC133 BK- 16
618-CC127 YL - 16
987-CC164
990-CC159
WH- 16
GN- 16
H802-W57 GY- 18
H802-W58 GY- 18 WM
32
33
C967-X29 BU- 18 F708-X22 YL - 18
F709-X11 BU- 18
CBL-AA5 RD- 2 171-2208
893-E24 GN- 16
892-E53 BR - 16
18
19
893-CC271
892-CC273
GN- 16
BR- 16
763-CC22
765-CC24
BU- 18
OR- 18
36
37
QUICK COUPLER ENABLE SW - ENGAGE
QUICK COUPLER ENABLE SW - DISENGAGE
OPERABLE MACHINE WITH THE KEY AND ENGINE OF F IDENT PART NO CHG LOC DESCRIPTION B
321-CC107 BR- 18 AND THE TRANSMISSION SHIFTER IN NEUTRAL. A 174-1229 02 H-10 ATCH BLOWER IN CAB
200-CC142 BK- 14 352-CC136 BU- 18 CHASSIS GROUND 618-CC129 YL - 16 T941-CC56 BR- 16 34 L731-X31 BR- 18 F710-X28 BR- 18 STARTER F711-E62 GN- 16 20 F711-CC103 GN- 16 764-CC23 PU- 18 38 QUICK COUPLER ENABLE SW - PARITY
321-CC107
321-CC124
BR- 18
BR- 18
799-CC90 WH- 16
H751-CC204 OR- 18
618-CC130
618-CC177
YL - 16
YL - 16
T942-CC58
T943-CC55
PK- 16
GY- 16 W
35
3 F715-X33 PU- 18
F711-X49 GN- 18
F712-X57 GY- 18 ENGINE 144-9955
304-E30 WH- 10
F712-E65 GY- 16 21
22
F712-CC104 GY- 16 H802-CC73 GY- 18
H802-CC507 GY- 16 782-CC86 GY- 18
39
40
RH STAB DOWN PRESS SW PARITY
JOYSTICK LATERAL COMMAND
LOC NOTE A: ALL TERMINALS INSIDE BOX ARE
E
F
263-9557
263-9519
00
00
B-5
L-14
STD
ATCH
ENGINE - ELECTRIC
CAB - EROPS
GROUND
NOTE A NOTE A G S
604-CC178 OR- 16 T944-CC57 GN- 16 W F729-X34 GN- 18 23 H802-CC508 GY- 18 41 SWG/PWM STD 14 - NOT USED CONNECTED TO A COMMON STUD(S). G 215-1635 01 L-8 ATCH STOP LAMP SWITCH JUMPER
J764-CC148 BR- 18 892-CC120 BR- 16
605-CC113 YL - 16 M10 M10 W A712-X35 BR- 18 E-C2 24 766-CC67 GN- 16 42 SERVICE BRAKE PRESSURE SW B-6 K 201-7940 00 L-15 STD SERVICE PORT
Y758-CC194 PK- 18 892-CC219 BR- 16 MTR BAT 9X1054
606-CC112 GY- 16 F700-X36 BU- 18 F715-X33 PU- 18 200-RF2 BK- 16 25 43 580 BOOM EXTEND LIMIT PARITY B-13 N 199-7922 00 L-19 ATCH SPEAKERS
Y761-CC198 OR- 18 892-CC273 BR- 16 30 P936-CC506 GY- 16
RH STOP TAIL TURN REV 617-CC179 BR- 16 136-CC117 GN- 16 F716-X25 WH- 18 229-E21 BK- 14 304-E30 WH- 10 1 26 44 RIGHT STABILIZER DOWN PRESS SW K-4 P 202-9266 02 M-18 ATCH CAB FLOOD LAMPS
CBL-CC1 RD- 00
86(+) LOAD SENSE CTRL SOL H802-CC507 GY- 16
E966-X38 YL - 18 F717-X19 YL - 18 306-E1 GN- 18
CBL-AA3 RD- 00
295-3381 618-CC177 YL - 16 205-CC144 BK- 16 WM 200-E74 BK- 14 5 27 45 LEFT STABILIZER DOWN PRESS SW R 213-7346 01 M-4 ATCH MACHINE SECURITY SYSTEM
Y787-CC152 WH- 16 892-CC102 BR- 16 MOTOR 295-3459
J811-CC135 BK- 18 205-CC149 BK- 14 325-X39 PK - 18 F718-X10 BU- 18 200-E72 BK- 14 J811-E2 BK- 18 2 28 CC-C49 856-CC283 GN- 18 46 JOYSTICK TRIGGER SW PARITY NOTE B: PINS 1 AND 2 OF THE SERVICE BRAKE SWITC H T 201-0144 01 M-18 STD ROOF
OR- 18
Y788-CC153 GY- 16 892-CC219 BR- 16 85(-)

308-CC263 YL - 18 375-X40 BR- 18 F719-X18 BR- 18 200-E71 BK- 14 101-E27 RD- 10 4 29 1552269 47 BOOM ANGLE SW (40) ARE NORMALLY CLOSED, BUT ARE INSTALLE D W 220-4945 01 D-9 ATCH TRANSMISSION - SYNCHR O
STOP CC-C27 874-CC288 GY- 18 892-CC270 BR- 16 87
605-CC114 YL - 16 M 993-X41 BR- 18 F720-X9 GN- 18 M10 30 BK-18 1 136-CC116 GN- 16 867-CC284 PU- 18 48 JOYSTICK RH AUX PARITY/AUX PWM IN A NORMALLY OPEN POSITION. X 224-8642 03 C-7 STD BASIC ENGINE - ELECTRI C
1552273 T800-CC146 OR- 18 87A
H802-W57 GY- 18
893-CC122 GN- 16 606-CC111 GY- 16 m M 997-X42 OR- 18 F721-X27 GY- 18 BK-18 200-CC238 BK- 16 991-CC4 WH- 18
H802-W58 GY- 18
X750-W44 OR- 18
X750-W43 OR- 18
CBL-GG1 BK- 00 31 2 49 SHIFT RAIL SNSR 1 M-9 AF 265-7690 00 D-6 ATCH HVAC
975-W24 WH- 18
902-W25 BR - 18
756-W52 WH- 18
752-W15 YL - 18
975-W21 WH- 18
975-W22 WH- 18
975-W23 WH- 18
X750-W16
E798-X43 PK - 18 F722-X20 OR- 18 START RELAY

901-W9 WH- 18
604-CC173 OR- 16 m
BK - 00
893-CC222 GN- 16 617-CC126 BR- 16 C993-CC8 WH- 18
751-W1 GN- 18
754-W6 BU- 18
755-W7 OR- 18
900-W8 PU- 18
TAIL J811-CC135 BK- 18 FUEL LIFT PUMP 50 SHIFT RAIL SNSR 2 CA 212-7955 01 B-17 ATCH BOOM FLOOD LAMPS
618-CC130 YL - 16 893-CC271 GN- 16 618-CC127 YL - 16 m F701-X44 BR- 18 F727-X26 BU- 18 E-C8 115-1615 F711-CC99 GN- 16 P916-CC9 OR- 18 51 SHIFT RAIL SNSR 3
J811-CC128 BK- 18 203-7848 NOTE C: THE FOLLOWING WIRE PAIRS MUST BE CC 263-9536 01 B-18 STD CHASSIS
606-CC110 GY- 16 892-CC102 BR- 16 Y792-X45 PK - 18 F729-X34 GN- 18 1552269 F711-CC267 GN- 16 C744-CC81 PU- 18 52 PARK BRAKE SW - ENGAGED
J811-CC132 BK- 18 893-CC121 GN- 16 TWISTED AT LEAST 1 TURN/25 MILLIMTERS: CF 226-1605 00 C-2 ATCH RH FRONT HEADLAMPS
627-CC276 YL - 16 892-CC219 BR- 16 WM E965-X46 BU- 18 2 200-E71 BK- 14 F712-CC100 GY- 16 C743-CC82 PK- 18 53 PARK BRAKE SW - DISENGAGED
CBL-EE1
TURN J811-CC228 BK- 18 893-CC222 GN- 16 B-4 F711-GN, F712-G Y CG 192-1915 02 M-4 ATCH LH FRONT HEADLAMPS
612-CC175 GY- 16 893-CC121 GN- 16 F705-X47 PK - 18 MOTOR 1 A309-E52 GY- 16 F712-CC268 GY- 16 54 BOOM LOWERED SW
200-CC138 BK- 16 200-CC138 BK- 16 893-CC272 GN- 16 L730-X84 OR- 18 D-4 Y787-WH, Y788-G Y CK 224-2533 00 B-18 ATCH TRAILER LIGHTS
893-CC222 GN- 16 H750-CC205 BR- 18 Y761-CC198 OR- 18 55 PHS ADDRESS IN
604-CC173 OR- 16 F711-X49 GN- 18 L730-X24 OR- 18 CAN A + - NOT USED
C-4 E900-WH, E901-GN CL 221-9044 00 E-17 ATCH REGISTRATION PLATE LIGHTS
REV CBL-CC2 RD- 2 CC-C52 56
606-CC110 GY- 16 W-C21 W-C2 W-C1 W-C3 W-C4 W-C5 W-C6 W-C7 A708-X50 BR- 18 L730-X85 OR- 18 C-4 E902-PU, E903-YL F A 192-1908 02 M-12 ATCH WIPER - ROOF
205-CC149 BK- 14 NEG POS 1552267 57 CAN A SHIELD - NOT USED
1552269 1552269 1552269 1552269 1552269 1552269 1552269 1552269 A706-X51 GY- 18 C-4 E908-BR, E909-WH FC 228-9768 00 L-8 ATCH DIFFERENTIAL LOCK SWITCH JUMPE R
G962-CC140 OR- 18 205-CC239 BK- 14 136-CC117 GN- 16 E-C3 DISC SW G757-CC1 OR- 18 58 SWG 31 - NOT USED
612-CC175 GY- 16 L731-X80 BR- 18 A HA 201-3188 03 E-15 ATCH WIRING GP - BOOM (QC AUX DIV)
205-CC144 BK- 16 9X1054 7N-0718 TERM RES STD Y788-CC153 GY- 16 59 SWG 32 - NOT USED
RD- 00
CC-C24 618-CC130 YL - 16 150-X52 RD- 18 L731-X81 BR- 18 30 BATTERY 1 B
NOTE D: CAB HARNESSES ACCOMMODATES VARIOU S HG 233-5449 00 I-2 ATCH QUICK COUPLER AUXILIAR Y
BK - 00
205-CC149 BK- 14 1 134-2540 Y788-CC168 GY- 16 60 SWG 33 - NOT USED
1552269 627-CC276 YL - 16 200-CC232 BK- 14 L731-X31 BR- 18 86(+)
3T-5760 C
893-CC121 GN- 16 5 123-E51 WH- 18 61 BOOM ANGLE SW (40) PARITY MODELS. SEVERAL CONNECTION S PL 221-6889 00 L-13 ATCH PRODUCT LIN K
TRAILER DOWN SOL BK-18 T943-CC55 GY- 16 T941-CC56 BR- 16 200-CC244 BK- 14 617-CC126 BR- 16 Y793-X54 YL - 18 L731-X82 BR- 18 2 375-E49 BR- 18 Y788-CC256 GY- 16 62 SWG 35 - NOT USED DO NOT APPLY TO ALL MODELS. RF 259-3013 00 G-13 ATCH REVERSABLE FAN
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
BK-18
85(-)
119-1180 BK-18 T944-CC57 GN- 16 T942-CC58 PK- 16 M 999-X55 WH- 18 L731-X83 BR- 18 CBL-FF1 BK- 00
CBL-AA2
RH STOP TURN TAIL FOG 606-CC111 GY- 16 4 101-E29 RD- 10 63 NC - NOT USED
CBL-KK2
87
195-0194 T943-CC55 GY- 16 200-CC236 BK- 16 605-CC114 YL - 16 F706-X56 PU- 18 CBL-KK1 BK- 00 Y787-CC254 WH- 16 Y787-CC166 WH- 16 64 CAN B+ (INSTR) J1939 CABLE AS.
87A
T944-CC57 GN- 16 200-CC237 BK- 16 308-CC263 YL - 18 F712-X57 GY- 18 892-X4 BR- 18 Y788-CC168 GY- 16 65 CAN B- (INSTR) J1939 IDENT PART NO CHG LOC DESCRIPTION
CBL-AA5 RD- 2
TRAILER UP SOL A707-X58 PU- 18 893-X3 GN- 18 COLD START RL E-C13 Y787-CC166 WH- 16
STOP 200-CC170 BK- 14 618-CC127 YL - 16 66 CAN B SHIELD - NOT USED AA 220-4909 01 B-7 ATCH TWO BATTERY OPTION POSITIVE
119-1180 CC-C25 A704-X59 GN- 18 993-X41 BR- 18 115-1615 2219804 Y787-CC152 WH- 16
200-CC171 BK- 14 892-CC102 BR- 16 F711-CC99 GN- 16
CBL-CC2 RD- 2
67 CAN A+ CC 220-4910 01 B-7 ATCH ONE BATTERY OPTION POSITIVE
A 1552269 892-CC219 BR- 16 SOL SYNC MOD SOL 1 REV SOL 2 FWD SOL 3 SP 1 SOL 4 SP 2 SOL 5 SP 3 SOL 6 SP 4 SOL 7 SP 5
A703-X60 BR- 18 997-X42 OR- 18 317-E31 YL - 10 CBL-AA5 RD- 2 F712-CC100 GY- 16 68 CAN A-
EE 191-2802 00 A-6 ATCH ONE BATTERY OPTION NEGATIVE A
1
BK-18 T941-CC56 BR- 16 111-CC274 RD- 14 893-CC222 GN- 16 A702-X61 PU- 18 NEG POS
69 CAN A SHIELD - NOT USED
TAIL 177-7807 177-7807 177-7807 195-9700 195-9700 195-9700 195-9700 195-9700 EY 224-3029 00 A-7 STD ALT B+ TO ALT BREAKER
BK-18 T942-CC58 PK- 16 A701-X62 GY- 18 70 CAN A- - NOT USED
MATE TO A705-X63 BU- 18 FF 208-4511 01 A-6 ATCH ONE BATTERY OPTION NEGATIVE TO DISC SWITC H
BATTERY 2
TURN
CC-C27 403-CC290 GN- 18 SYNCHRO XMSN-ATCH 229-X64 BK- 18
COLD START
232-6661
3T-5760
GG
JJ
207-4110
223-5159
01
00
A-7
B-7
ATCH

TH330B Service Manual

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TH330B Service Manual

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TH220B & TH330B

Telehandler Service Manual

Section Title Manual No.

Service Manual Contents 31200263

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to

Specifications Section Torque-Turn

Metric (ISO) Fasteners

Note: The difference between Caterpillar standard Table 4

Metric (ISO) Machine Screws M36

English (SAE) Fasteners English (SAE) Taperlock Studs

Table 8 Thread Size Torque(1)

Thread Size Inch Nm lb ft

• Tapered Pipe Thread (NPT and NPTF)

1. Clean all surfaces that contact the bolt. Remove

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

Straight Thread O-Ring Fittings

2. Put the fitting assembly in the correct position,

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

Excessive tightening of the connectors can cause

Ferrous Straight Thread O-Ring Fittings Torques for

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

Straight Thread O-Ring Plugs Table 15

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 -

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

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

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

Drain Plugs with Straight Thread

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)

Note: Bulkhead nuts are designed to secure fluid

Air Conditioning Fittings Table 22

Note: Clean the connectors and the seals and

SAE Flareless Fittings

Constant Torque Hose Clamps

Use a torque wrench for proper installation of all

Diameter (B) Standard Torque

The correct torque for the constant torque hose clamp

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to

Battery - Remove and Install

1. Turn the battery disconnect switch to the OFF

Alternator - Remove and Install

2. Install studs (8). With the aid of a second person

3. Remove belt (1) from alternator (2). Refer to

Installation Procedure 2. Disconnect wire clamp(1). Disconnect wire

3. Remove bolts (4). Remove electric starting motor

Electric Starting Motor -Remove

Removal Procedure 2. Install bolts (4) in order to secure electric starting

4. Install wire clamp (1). Tighten center bolt (4) at

Air Cleaner - Remove and Install

Muffler - Remove and Install

Hot oil and components can cause personal injury.

1. 1. Remove bolts (2) and the washers in order to

3. Remove bolts (5) from muffler (6).

1. Drain the coolant from the radiator into a suitable