851FX Manual Case

851FX
851FX Plus
Backhoe Loader
SERVICE MANUAL
Part number 91715732

English
July 2021
© 2021 Case New Holland Construction Equipment (India) Pvt. Ltd. All rights reserved.
SERVICE MANUAL
851FX Plus
851FX
91715732 26/07/2021
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Power coupling........................................................................... 19
[19.100] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Transmission.............................................................................. 21
[21.100] Mechanical transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
Front axle system ....................................................................... 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4
Rear axle system........................................................................ 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
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Brakes and controls .................................................................... 33
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.726] Excavator and backhoe hydraulic controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12
[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13
[35.AAA] Hydraulic systems generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
Frames and ballasting ................................................................. 39

[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
[39.129] Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2
Steering..................................................................................... 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
Wheels ...................................................................................... 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
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[44.AAA] Wheels generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.3
Cab climate control ..................................................................... 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
Electrical systems ....................................................................... 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
Front loader and bucket............................................................... 82

[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
Booms, dippers, and buckets ....................................................... 84

[84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1
[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2
[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3
Platform, cab, bodywork, and decals ............................................. 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.156] Cab windshield and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
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INTRODUCTION
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1
Contents
INTRODUCTION
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules - Ductile iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules - Ductile iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Basic instructions - Fuse and relay locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Basic instructions - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical systems - Basic instructions - Standard torque data for hydraulics . . . . . . . . . . . . . . . . 37
Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Abbreviation - Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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INTRODUCTION
Safety rules
DANGER
Improper operation or service of this machine can result in an accident.
Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have
read and understood the operation, lubrication, maintenance, and repair information.
Failure to comply will result in death or serious injury.
D0010A
WARNING
Maintenance hazard!
Always perform all service procedures punctually at the intervals stated in this manual. This ensures
optimum performance levels and maximum safety during machine operation.
Failure to comply could result in death or serious injury.
W0132A
NOTICE: Extreme working and environmental conditions require shortened service intervals.
Use Case fluids, lubricants, and filters for the best protection and performance of your machine. All fluids, lubricants,
and filters must be disposed of in compliance with environmental standards and regulations. Contact your Dealer with
any questions regarding the service and maintenance of this machine.
Use this manual with the operator's manual to understand and perform the complete service procedures. Read the
safety decals and information decals on the machine. Read the Operator’s Manual and safety manual. Understand
the operation of the machine before you start any service.
Before you service the machine, put a “Do Not Operate” tag on the steering wheel or over the key switch. Ensure the
tag is at a location where everyone who might operate or service the machine may see clearly.
Plastic and resin parts

• Avoid using gasoline, paint thinner, etc. when cleaning plastic parts, console, instrument cluster, etc.
• Use only water, mild soap, and a soft cloth when you clean these parts.
• Using gasoline, thinners, etc. can cause discoloration, cracking, or deformation of the part being cleaned.
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INTRODUCTION
Safety rules - Ductile iron
DANGER
Altering cast ductile iron can cause it to weaken or break.
Before you weld, cut, or drill holes on any part of this machine, make sure that the part is not cast
ductile iron.
D0148A
Altering cast ductile iron can cause it to weaken or break. Unauthorized modifications to cast ductile iron parts can
cause death or serious injury. Do not weld, cut, drill, repair, or attach items to cast ductile iron parts on this machine.
Before you weld, cut, or drill holes on any part of this machine, make sure the part is not cast ductile iron. See your
dealer if you do not know if a part is cast ductile iron.
The following items are examples of cast ductile iron parts. There may also be other parts made of cast ductile
iron that are not on the list below.
• two-wheel drive steering link
• dump links
• front axle
• stabilizers
• extend-a-hoe
• swing tower
• bucket linkage
• Air-Conditioning (A/C) compressor mounting bracket
Do not make any unauthorized modifications. Consult an authorized dealer before making any changes, additions,
or modifications to this machine.
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INTRODUCTION
Safety rules - Ductile iron
DANGER
Improper operation or service of this machine can result in an accident.
Any unauthorized modifications made to this machine can have serious consequences. Consult an
authorized dealer on changes, additions, or modifications that may be required for this machine. Do
not make any unauthorized modifications.
D0030A
Before you weld, cut, or drill holes on any part of this machine, make sure the part is not cast ductile iron. See your
dealer if you do not know if a part is cast ductile iron. The following are cast ductile iron parts:
• two wheel drive steering link
• dump links
• front axle
• stabilizers
• extendahoe
• swing
• bucket linkage
• Air Conditioning (A/C) compressor mounting bracket
Unauthorized modifications to cast ductile iron parts can cause injury or death. Welding, cutting, or drilling can cause
cast ductile iron to break. Do not weld, cut, or drill to repair or to attach items to cast ductile iron parts on this machine.
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INTRODUCTION
Safety rules
Unless otherwise instructed, always perform these steps before you service the machine:
1. Park the machine on a flat, level surface.
2. Place the backhoe in the transport position with the swing lock pin installed for transport.
3. Place the loader bucket on the ground, with the bottom of the loader bucket parallel to the surface.
4. Place the direction control lever and the transmission in neutral.
5. If you need to open the hood to perform service, raise the loader arms and install the support strut.
6. Shut down the engine.
7. Place a 'Do Not Operate' tag on the key switch so that it is visible to other workers or remove the key.
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INTRODUCTION
Personal safety
1. Make sure to arrest all fuel leaks. Any fuel or oil spilled on hot surface or electrical components may cause fire
accidents. Make sure that the machine is sealed from leakage.
2. Do not allow straw, trash, bird nests or flammable material in the machine and remove the same as they can ignite
fire on hot surfaces.
3. Make sure the fire extinguisher installed on or near the machine. If already equipped, the fire extinguisher is
maintained and serviced according to the manufacturer’s instructions.
4. Check and make sure to clean all the trash from the machine especially around hot components such as the
engine, transmission, exhaust, battery, etc. Do these checks and clean the machine at least once a day, probably at
the end of the day. More frequent checks and cleaning of machine may be necessary depending on the operating
environment and conditions.
5. Inspect the electrical system for loose connections and frayed insulation. Repair or replace the loose or damaged
parts.
6. Check and remove the debris accumulation around moving components such as bearings, pulleys, belts, gears,
cleaning fans, etc. More frequent cleaning of the machine may be necessary depending on the operating environment
and conditions.
7. Check all fuses, relay, and MCB’s for correct ratings and validity. Replace the defective or non-complaint parts. Do
not to bypass/override/tamper any safety systems of the machine.
8. Check and remove any oily rags or other flammable material on the machine. Do not to store such material around
or on the machine.
9. Make sure that do not weld or flame cut any items that contain flammable material. Clean the items thoroughly
with non-flammable solvents before welding or flame-cutting.
10. Immediately investigate any unusual smells or odors that may emerge during operation of the machine. Always
aware of such observations and actions thereof.
11. Make sure that the machine is serviced only by authorized CASE CONSTRUCTION dealer service team and not
by any external parties.
12. Check and remove any non-recommended devices that are fitted on the machine. Do not to use any devices that
are not a standard fitment by the company.
13. The personnel make sure that they do not smoke or use mobiles while refuelling. It is not advisable to park
the machine near a place which poses fire hazard (Workshops where welding, grinding, gas cutting etc is underway,
bonfires etc).
NOTICE: Any damage to the machine due to non-adherence of the above guidelines and instructions may lead the
warranty void for the machine.
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INTRODUCTION
Safety rules - Ecology and the environment

Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be
harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper
way to comply with local legislation and available resources.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not
be allowed to get into the soil, but should be collected and disposed of properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.
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INTRODUCTION
Basic instructions - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional,
or local CASE Dealers, reject any responsibility for damages caused by parts and/or components not approved by
the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the
manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your Case New Holland Construction Equipments Sales and Service Networks.
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INTRODUCTION
Basic instructions
WARNING
Explosive gas!
Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen
battery.
W0005A
WARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash
hands after handling.
W0006A
• Do not run the engine with the alternator wires disconnected.

• Before using an electric welder, disconnect the alternator wires, instrument cluster and batteries.
• Do not use a steam cleaner or a cleaning solvent to clean the alternator.
• Keep the battery vents clean. Ensure the battery vents are not restricted.
Disconnect battery
1. Open the battery compartment cover on the right hand
side step of the vehicle, using the key.
2. Disconnect the negative battery cable (1) from the
negative battery terminal.
PTIL21TLB0192AB 1
Connect the battery

1. Connect the negative battery cable (1) to the negative
battery terminal.
2. Close the battery compartment cover on the right hand
side step of the vehicle, using the key.
PTIL21TLB0192AB 2
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INTRODUCTION
Basic instructions - Fuse and relay locations

NOTICE: The fuse and relay boxes are designed to be sealed against moisture and contamination. Always replace
the fuse & relay covers, and make sure the covers are securely latched, after servicing.
The machine is equipped with five fuse box locations. Two locations in the front console, two locations in the side
console, and one location on the master disconnect switch.
Front console box

1. Remove the panel cover (1) from the front console
box.
PTIL21TLB0369AB 1
2. Pull the two yellow tabs (1) outward to unlock the fuse
and relay cover.
3. Squeeze the tabs underneath the yellow tabs and re-
move the fuse and relay cover.
PTIL21TLB0372AB 2
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INTRODUCTION
4. Replace fuse and relay with the same type and am-
perage.
5. Install the cover and secure the position with the yellow
tabs.
NOTE: The fuse and relay decal is on the rear side of
the cover.
PTIL21TLB0371AB 3
The fuse and relay designations are as shown in the im-

age.
PTIL21TLB0571AB 4
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INTRODUCTION
Side console box

1. Turn the two knob screws (1) to loosen the panel cover
(2) for the fuse box.
2. Remove the panel cover from the side console box.
PTIL21TLB0368AB 5
3. Squeeze the tabs underneath the yellow tabs and re-

move the fuse and relay cover.
PTIL21TLB0367AB 6
3. Refer to the decal on the interior side of the panel cover

for fuse, relay, and/or diode functions.
PTIL21TLB0370AB 7
The fuse and relay designations are as shown in the im-

age.
PTIL21TLB0569AB 8
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INTRODUCTION
Glow-plug Control Unit (GCU) fuse

1. Raise the loader arm and engage the safety support.
2. Lift the engine hood.
3. Squeeze the two locking tabs (1) on the fuse box
cover.
4. Remove the fuse box cover.
5. Locate the 60 A GCU fuse (2) on the jumpstart mount-
ing bracket.
6. Locate the 20 A starter fuse (3) on the jumpstart
mounting bracket.
7. Only replace fuse and relay with the same type and
amperage. PTIL21TLB0378AB 9
8. Install the cover until the two locking tabs lock into
position.
PTIL21TLB0377AB 10
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INTRODUCTION
Fuse, relay, and diode icon definitions
Right-hand side console panel
PTIL21TLB0570FB 11
Fuse icon definitions

Icon Function Fuse ID (AMP)
Low beam F-001 ( 15 A)
High beam F-002 ( 15 A)
Hazard switch F-003 ( 15 A)
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INTRODUCTION

Brake switch F-004 ( 10 A)
Flasher switch F-005 ( 10 A)
Diagnostic port F-006 ( 5 A)
Charger socket F-007 ( 10 A)
Speedometer F-008 ( 5 A)
Transmission cut-off F-009 ( 10 A)
Right-hand-side combination switch F-010 ( 15 A)
Rear wiper and washer F-011 ( 15 A)
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INTRODUCTION

Ignition switch F-012 ( 5 A)
License plate lamp F-013 ( 5 A)
Customer Option B+ F-014 ( 20 A)
Customer Option SW B+ F-015 ( 20 A)
USB port F-016 ( 5 A)
Front work lights F-025 ( 15 A)
Rear Work Lights F-026 ( 15 A)
Rear Work Lights F-027 ( 15 A)
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INTRODUCTION

4WD switch F-028 ( 10 A)
Side shift lock switch F-029 ( 10 A)
Foot switch F-030 ( 10 A)
Up/down control switch F-031 ( 5 A)
Dome light F-032 ( 5 A)
Air-conditioning compressor F-033 ( 20 A)
Auto-idle switch F-034 ( 5 A)
Return to dig F-035 ( 10 A)
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INTRODUCTION

Cab fan switch F-036 ( 10 A)
Ignition key F-037 ( 15 A)
Telematics B+ F-038 ( 5 A)
NOTE: Icon image intentionally not shown.
Horn F-039 ( 5 A)
Parking brake switch F-041 ( 5 A)
Auto shutdown F-042 ( 5 A)
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INTRODUCTION
Relay icon definitions

Icon Function Relay ID
Low beam relay K-001
High beam relay K-002
Forward relay K-003
Reverse relay K-004
Transmission cutout relay K-005
Neutral relay K-006
Front work lights relay K-010
Rear work lights relay K-011
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INTRODUCTION

Parking brake relay K-012
Rear Work Lights relay K-013
Return to dig relay K-014
Auto shutdown relay K-015
Shutdown power relay 1 K-025
Shutdown power relay 2 K-026
Flasher relay K-030
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INTRODUCTION
Diode icon definitions

Icon Function Diode ID
Forward diode V-019
Reverse diode V-020
Low beam diode V-022
Front work lights diode V-023
Rear work lights diode V-024
Forward diode V-046
Reverse diode V-047
Auto shutdown diode V-048
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INTRODUCTION
Left-hand side steering column console panel
PTIL21TLB0572FB 12
Fuse icon definitions

Ignition switch F-101 ( 7.5 A)
Waste gate pressure moderator valve F-102 ( 7.5 A)
ECU fuse 1 F-103 ( 7.5 A)
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INTRODUCTION

ECU fuse 2 F-104 ( 20 A)
DEF tank level F-105 ( 10 A)
DEF tank F-106 ( 10 A)
Telematics F-107( 5 A)
NOTE: Icon image intentionally not shown.
Auxiliary ignition switch F-112 ( 25 A)
Relay icon definitions

ECU start interlock relay K-101
Neutral start interlock relay K-102
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INTRODUCTION

ECU start interlock relay K-103
Neutral start interlock relay K-104
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INTRODUCTION
Basic instructions
WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
Raise and support loader lift arms:

1. Empty the loader bucket.
2. Raise the loader lift arms to the maximum height.
RCPH10TLB230AAF 1
4. Remove the retaining pin.

5. Lower the support strut onto the cylinder rod.
6. Install the retaining pin.
RCPH10TLB221AAF 2
7. Start the engine.

8. Slowly lower the lift arms so that the end of the support
strut rests on the cylinder.
RCPH10TLB227AAF 3
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INTRODUCTION
Lower supported loader lift arms:

1. Raise the lift arms so that the end of the support strut
no longer rests on the cylinder.
RCPH10TLB227AAF 4
3. Remove the retaining pin from the support strut.

4. Raise the support strut up to the storage position and
secure with the retaining pin, as shown.
RCPH10TLB231AAF 5

6. Lower the loader to the ground.
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INTRODUCTION
Basic instructions
Open the hood:
2. Turn the handle (1) counter-clockwise to release the
hood latch.
PTIL13TLB1558AB 1
3. Lift the hood and rotate forward.
PTIL12TLB0559AB 2
NOTICE: To avoid damage to the hood parts, always close the hood before moving the loader.
Close the hood:
1. Lower the hood.
2. Turn the handle (1) clockwise to lock the hood latch.
PTIL13TLB1558AB 3
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INTRODUCTION
Basic instructions - Shop and assembly

Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals

For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CASE CONSTRUCTION Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts or CASE CONSTRUCTION Original
Parts can offer this guarantee.
When ordering spare parts, always provide the following information:

• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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INTRODUCTION
Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine
attachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
Special tools
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
W0111A
The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re-
searched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable
repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting oper-
ation.
By using these tools, repair personnel will benefit from:

• Operating in optimal technical conditions
• Obtaining the best results
• Saving time and effort
• Working in safe conditions
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INTRODUCTION
Basic instructions - Minimum tightening torques for normal

assembly
METRIC NON-FLANGED HARDWARE
NOM. LOCKNUT LOCKNUT
SIZE CL.8 CL.10
CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9
CLASS 8 NUT CLASS 10 NUT BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.2 N·m (19 lb 2.9 N·m (26 lb 3.2 N·m (28 lb 4.2 N·m (37 lb 2.9 N·m (26 lb
M4 2 N·m (18 lb in)
in) in) in) in) in)
4.5 N·m (40 lb 5.9 N·m (52 lb 6.4 N·m (57 lb 8.5 N·m (75 lb 5.8 N·m (51 lb
M5 4 N·m (36 lb in)
in) in) in) in) in)
7.5 N·m (66 lb 10 N·m (89 lb 11 N·m (96 lb 15 N·m (128 lb 6.8 N·m (60 lb 10 N·m (89 lb
M6
in) in) in) in) in) in)
18 N·m (163 lb 25 N·m (217 lb 26 N·m (234 lb 35 N·m (311 lb 17 N·m (151 lb 24 N·m (212 lb
M8
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m 225 N·m (166 lb 301 N·m (222 lb 143 N·m (106 lb 205 N·m (151 lb
M16
ft) (155 lb ft) ft) ft) ft) ft)
319 N·m (235 lb 425 N·m 440 N·m (325 lb 587 N·m (433 lb 290 N·m (214 lb 400 N·m (295 lb
M20
ft) (313 lb ft) ft) ft) ft) ft)
551 N·m (410 lb 735 N·m 762 N·m (560 lb 1016 N·m 501 N·m (370 lb 693 N·m (510 lb
M24
ft) (500 lb ft) ft) (750 lb ft) ft) ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
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INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
ft) ft) ft) ft) ft) ft)
M20
ft) ft) ft) ft) ft) ft)
607 N·m (447 lb 809 N·m (597 lb 838 N·m (618 lb 1118 N·m 552 N·m (407 lb
M24
ft) ft) ft) (824 lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
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INTRODUCTION
1. Manufacturer's Identification
2. Property Class
3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60° apart indicate Class
10 properties, and marks 120° apart indicate Class 8.
INCH NON-FLANGED HARDWARE

LOCKNUT LOCKNUT
NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT
GrB W/ Gr5 GrC W/ Gr8
SIZE and NUT and NUT
BOLT BOLT
UN-
UN-
PLATED PLATED PLATED
PLATED
or W/ZnCr W/ZnCr
or PLATED
PLATED GOLD GOLD
SILVER
SILVER
8 N·m (71 lb 11 N·m (97 lb 12 N·m 16 N·m 12.2 N·m (109 lb
1/4 8.5 N·m (75 lb in)
in) in) (106 lb in) (142 lb in) in)
17 N·m 23 N·m 24 N·m 32 N·m 17.5 N·m (155 lb 25 N·m (220 lb
5/16
(150 lb in) (204 lb in) (212 lb in) (283 lb in) in) in)
30 N·m (22 lb 40 N·m 43 N·m (31 lb 57 N·m (42 lb
3/8 31 N·m (23 lb ft) 44 N·m (33 lb ft)
ft) (30 lb ft) ft) ft)
48 N·m (36 lb 65 N·m 68 N·m (50 lb 91 N·m (67 lb
7/16 50 N·m (37 lb ft) 71 N·m (53 lb ft)
ft) (48 lb ft) ft) ft)
74 N·m (54 lb 98 N·m 104 N·m 139 N·m 108 N·m (80 lb
1/2 76 N·m (56 lb ft)
ft) (73 lb ft) (77 lb ft) (103 lb ft) ft)
107 N·m 142 N·m 150 N·m 201 N·m 156 N·m (115 lb
9/16 111 N·m (82 lb ft)
(79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) ft)
147 N·m 196 N·m 208 N·m 277 N·m 153 N·m (113 lb 215 N·m (159 lb
5/8
(108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) ft) ft)
3/4
7/8
1
NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in
through 1 in hardware torque specifications are shown in pound-feet.
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INTRODUCTION
INCH FLANGED HARDWARE

NOM- LOCKNUT LOCKNUT
SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL GrF W/ Gr5 GrG W/ Gr8
NUT NUT
SIZE BOLT BOLT
UNPLATED PLATED UNPLATED PLATED
or PLATED W/ZnCr or PLATED W/ZnCr
SILVER GOLD SILVER GOLD
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
5/16
3/8 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft) ft)
7/16 48 N·m (35 lb ft) 68 N·m (50 lb ft)
ft) ft) ft) ft)
81 N·m (60 lb 108 N·m (80 lb 115 N·m (85 lb 153 N·m 104 N·m (77 lb
1/2 74 N·m (55 lb ft)
ft) ft) ft) (113 lb ft) ft)
117 N·m (86 lb 156 N·m 165 N·m 221 N·m 157 N·m (116 lb
9/16 106 N·m (78 lb ft)
ft) (115 lb ft) (122 lb ft) (163 lb ft) ft)
162 N·m (119 lb 216 N·m 228 N·m 304 N·m 147 N·m (108 lb 207 N·m (153 lb
5/8
ft) (159 lb ft) (168 lb ft) (225 lb ft) ft) ft)
3/4
7/8
1
IDENTIFICATION
Inch Bolts and free-spinning nuts
20083682 3
Grade Marking Examples
SAE Grade Identification

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120° Apart
3 Grade 8 - Five Marks 6 Grade 8 Nut - Marks 60° Apart
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INTRODUCTION
Inch Lock Nuts, All Metal (Three optional methods)
20090268 4
Grade Identification
Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
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INTRODUCTION
Electrical systems - Basic instructions - Standard torque data for

hydraulics
INSTALLATION OF ADJUSTABLE FITTINGS
IN STRAIGHT THREAD O RING BOSSES
1. Lubricate the O-ring by coating it with a light oil or

petroleum. Install the O-ring in the groove adjacent
to the metal backup washer which is assembled at the
extreme end of the groove (4).
2. Install the fitting into the SAE straight thread boss until
the metal backup washer contacts the face of the boss
(5).
NOTE: Do not over tighten and distort the metal
backup washer. 23085659 1
3. Position the fitting by turning out (counterclockwise)
up to a maximum of one turn. Holding the pad of the
fitting with a wrench, tighten the locknut and washer
against the face of the boss (6).
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS

TUBE NUTS FOR 37° FLARED FITTINGS O-RING BOSS PLUGS
ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC- 37° SEATS
SIZE TUBING OD THREAD TORQUE TORQUE
SIZE
4 6.4 mm (1/4 in) 7/16-20 12 – 16 N·m (9 – 12 lb ft) 8 – 14 N·m (6 – 10 lb ft)
12 19.1 mm (3/4 in) 1-1/16-12 104 – 111 N·m (77 – 82 lb ft) 81 – 95 N·m (60 – 70 lb ft)
16 25.4 mm (1 in) 1-5/16-12 149 – 163 N·m (110 – 120 lb ft) 108 – 122 N·m (80 – 90 lb ft)
20 31.8 mm (1-1/4 in) 1-5/8-12 190 – 204 N·m (140 – 150 lb ft) 129 – 158 N·m (95 – 115 lb ft)
These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm
(0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.
Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite
cleaner and apply hydraulic sealant to the 37° flare and the threads.
Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
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INTRODUCTION
PIPE THREAD FITTING TORQUE PIPE THREAD FITTING

Thread Size Torque (Maximum)
Before installing and tightening pipe fittings, clean the
threads with a clean solvent or Loctite cleaner and ap- 1/8-27 13 N·m (10 lb ft)
ply sealant for all fittings including stainless steel or for 1/4-18 16 N·m (12 lb ft)
most metal fittings. For high filtration/zero contamination 3/8-18 22 N·m (16 lb ft)
systems use . 1/2-14 41 N·m (30 lb ft)
3/4-14 54 N·m (40 lb ft)
INSTALLATION OF ORFS (O-RING FLAT

FACED) FITTINGS
When installing ORFS fittings thoroughly clean both flat
surfaces of the fittings (1) and lubricate the O-ring (2) with
light oil. Make sure both surfaces are aligned properly.
Torque the fitting to specified torque listed throughout the
repair manual.
NOTICE: If the fitting surfaces are not properly cleaned,
the O-ring will not seal properly. If the fitting surfaces are
not properly aligned, the fittings may be damaged and will
not seal properly.
NOTICE: Always use genuine factory replacement oils
50011183 2
and filters to ensure proper lubrication and filtration of en-
gine and hydraulic system oils.
The use of proper oils, grease, and keeping the hydraulic

system clean will extend machine and component life.
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INTRODUCTION
Torque - Standard torque data for hydraulics

INSTALLATION OF ADJUSTABLE FITTINGS
IN STRAIGHT THREAD O RING BOSSES
1. Lubricate the O-ring by coating it with a light oil or

petroleum. Install the O-ring in the groove adjacent
to the metal backup washer which is assembled at the
extreme end of the groove (4).
2. Install the fitting into the SAE straight thread boss until
the metal backup washer contacts the face of the boss
(5).
NOTE: Do not over tighten and distort the metal
backup washer. 23085659 1
3. Position the fitting by turning out (counterclockwise)
up to a maximum of one turn. Holding the pad of the
fitting with a wrench, tighten the locknut and washer
against the face of the boss (6).
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS

TUBE NUTS FOR 37° FLARED FITTINGS O-RING BOSS PLUGS
ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC- 37° SEATS
SIZE TUBING OD THREAD TORQUE TORQUE
SIZE
These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm
(0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.
Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite
cleaner and apply hydraulic sealant to the 37° flare and the threads.
Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
91715732 26/07/2021
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INTRODUCTION
PIPE THREAD FITTING TORQUE PIPE THREAD FITTING

Thread Size Torque (Maximum)
Before installing and tightening pipe fittings, clean the
threads with a clean solvent or Loctite cleaner and ap- 1/8-27 13 N·m (10 lb ft)
ply sealant for all fittings including stainless steel or for 1/4-18 16 N·m (12 lb ft)
most metal fittings. For high filtration/zero contamination 3/8-18 22 N·m (16 lb ft)
systems use . 1/2-14 41 N·m (30 lb ft)
3/4-14 54 N·m (40 lb ft)
INSTALLATION OF ORFS (O-RING FLAT

FACED) FITTINGS
When installing ORFS fittings thoroughly clean both flat
surfaces of the fittings (1) and lubricate the O-ring (2) with
light oil. Make sure both surfaces are aligned properly.
Torque the fitting to specified torque listed throughout the
repair manual.
NOTICE: If the fitting surfaces are not properly cleaned,
the O-ring will not seal properly. If the fitting surfaces are
not properly aligned, the fittings may be damaged and will
not seal properly.
NOTICE: Always use genuine factory replacement oils
50011183 2
and filters to ensure proper lubrication and filtration of en-
gine and hydraulic system oils.
The use of proper oils, grease, and keeping the hydraulic

system clean will extend machine and component life.
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40
INTRODUCTION
Abbreviation - Measurements
Typical applications Metric unit Imperial unit
Name Symbol Name Symbol
Area (Land area)

hectare ha acre ac
square meter m² square foot ft²
square inch in²
square millimeter mm² square inch in²
Electricity
ampere A ampere A
volt V volt V
microfarad µF microfarad µF
ohm Ω ohm Ω
Force
kilonewton kN pound lb
newton N pound lb
Force per length
newton per meter N/m pound per foot lb/ft
pound per inch lb/in
Frequency
megahertz MHz megahertz MHz
kilohertz kHz kilohertz kHz
hertz Hz hertz Hz
Frequency − Rotational
revolution per minute r/min revolution per minute r/min ª
rpm rpm
Length
kilometer km mile mi
meter m foot ft
centimeter cm inch in
millimeter mm inch in
micrometer µm
Mass
kilogram kg pound lb
gram g ounce oz
milligram mg
Power
kilowatt kW horsepower Hp
watt W Btu per hour Btu/hr
Btu per minute Btu/min
Pressure or stress (Force per area)
kilopascal kPa pound per square inch psi
inch of mercury inHg
pascal Pa inch of water inH2O
megapascal MPa pound per square inch psi
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INTRODUCTION
Typical applications Metric unit Imperial unit

Name Symbol Name Symbol
Temperature (other than Thermodynamic)

degrees Celsius °C degrees Fahrenheit °F
Time
hour h hour h
minute min minute min
second s second s
Torque (includes Bending moment, Moment of force, and Moment of a couple)
newton meter Nm pound foot lb ft
pound foot lb in
Velocity
kilometer per hour km/h mile per hour mph
meter per second m/s foot per second ft/s
millimeter per second mm/s inch per second in/s
meter per minute m/min foot per minute ft/min
Volume (includes Capacity)
cubic meter m³ cubic yard yd³
cu yd
liter l cubic inch in³
liter l US gallon US gal
UK gallon UK gal
US quart US qt
UK quart UK qt
milliliter ml fluid ounce fl oz
Volume per time (includes Discharge and Flow rate)
cubic meter per m³/min cubic foot per minute ft³/min
minute
liter per minute l/min US gallon per minute US gal/min
milliliter per minute ml/min UK gallon per minute UK gal/min
Sound power level and Sound pressure level
decibel dB decibel dB
91715732 26/07/2021
42
INTRODUCTION
Consumables
S.No. Application Recommended oil International specification Quantity
System capacity -
SAE 10W-30, API GL 4, ISO
Hydraulic oil Multi grade, UTTO 107 L
VG 32/46 (UTTO)
Tank capacity - 50 L
Additional hydraulic oil
3.75 L
1 for Bottom Dump Bucket
Additional hydraulic oil 3.75 L
Same as machine Same as machine
for extendahoe
Additional hydraulic oil 1.5 L
for hammer
SAE 10W-30, API GL 4, ISO
Transmission oil - 2WD Multi grade, UTTO 18 L
VG 32/46 (UTTO)
2
SAE 10W-30, API GL 4, ISO 20 L
Transmission oil - 4WD Multi grade, UTTO
VG 32/46 (UTTO)
3 Rear axle oil SAE 20W-40; API GL 4 SAE 20W-40; API GL 4 * 17.1 L
4WD - Front axle oil
4 SAE 20W-40; API GL 4 SAE 20W-40; API GL 4 ** 8.9 L
(If equipped)
5 Fuel tank Diesel (-) 129 L
FUEL ADDITIVE FOR FPT Fuel additive for FPT
6 Fuel additive 250 mL
ENGINES engines
SAE 15W-40; API CI-4; SAE 15W-40; API CI-4;
7 Engine oil # 8.6 L
ACEA E7 ACEA E7
OAT EXTENDED LIFE
8 Engine coolant COOLANT ASTM D 3306 OAT EG2, 50-50 Premix 20 L
TYPE 1
9 Brake fluid ISO 7308 ISO 7308 0.67 L
Grease – 2WD NLGI 2, LITHIUM SOAP 2 kg
9 GREASE, EXTREME PRESSURE NLGI 2
Grease – 4WD 2.25 kg
(EP), ANTI-WEAR
10 Refrigerant R134A R134a 1.2 kg (2.6 lb)
11 Compressor oil SP-15, VG 68 PAG 46 270 – 300 mL
12 Battery terminals PETROLEUM JELLY Petroleum jelly 0.01 kg
NOTE: * Out of 17.1 L oil, 14.5 L is used in differential and 1.3 L is used in each hub.
NOTE: ** Out of 8.9 L oil, 7.5 L is used in differential and 0.7 L is used in each hub.
NOTE: # 8.6 L is consumed when engine oil filter is not changed. If engine oil filter is also changed, additional 0.5 L
oil is required.
NOTE: Diesel antifreeze should be added in the mentioned quantity in machines with cold start feature.
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INTRODUCTION
91715732 26/07/2021
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SERVICE MANUAL
Engine
851FX Plus
851FX
91715732 26/07/2021
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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
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Engine - 10
Engine and crankcase - 001
851FX Plus
851FX
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Contents
Engine - 10
TECHNICAL DATA
Engine
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTIC
Engine
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Engine - Engine and crankcase
Engine - Weight
Sl.No. Description Weight
1. Engine 330 kg (728 lb)
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Engine - Remove
WARNING
Burn hazard!
The engine and exhaust system become hot during operation. To prevent burns, open the engine
compartment and allow the components to cool to a comfortable touch temperature before you work
inside the engine compartment.
W1406A
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
W0208A
WARNING
Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine.
1. Disengage all drives.
2. Engage parking brake.
3. Lower all attachments to the ground, or raise and engage all safety locks.
4. Shut off engine.
5. Remove key from key switch.
6. Switch off battery.
7. Wait for all machine movement to stop.
W1023A
NOTE: Put identification tags on all disconnected hoses and wires. Close all disconnected hoses and fittings with
caps and plugs immediately.
Prior operation:
Disconnect the battery negative terminal, see Basic instructions () .
Prior operation:
Remove the engine hood, see Hood - Remove (90.100).
Prior operation:
Remove the air cleaner assembly, see Air cleaner - Remove (10.202).
Prior operation:
Drain the engine cooling system and disconnect the radiator hoses from the engine, see Radiator - Remove (10.400).
Prior operation:
Remove the SCR catalyst and its mounting bracket, see Selective Catalytic Reduction (SCR) muffler and catalyst
- Remove - SCR outlet pipe (10.500).
Prior operation:
Remove the air-conditioning compressor and its mounting bracket, see Air-conditioning compressor - Remove
(50.200).
Prior operation:
Remove the alternator and drive belt, see Alternator - Remove (55.301).
Prior operation:
Remove the engine starter, see Engine starter - Remove (55.201).
Prior operation:
Evacuate the air-conditioning system, see Air conditioning - Charging - Evacuation and recharging (50.200).
1. Drain engine oil by loosening the drain nut. Collect the

oil in a clean container, cap it and keep it aside in a
clean place.
2. Disconnect all electrical connections from the engine.
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3. Disconnect the fuel return and inlet lines (1) from the
fuel mud filter (2) and cap them immediately.
PTIL21TLB0273AA 1
4. Loosen and remove the mounting bolts (3) and remove

the fuel mud filter (2) from the engine.
PTIL21TLB0274AA 2
5. Disconnect the cab heater hose (1) from the engine.
PTIL21TLB0275AA 3
6. Loosen and remove the bolt (1) along with washer from
the oil dipstick bracket (2).
7. Remove the oil dipstick bracket (2) from the engine.
PTIL21TLB0276AA 4
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8. Remove the access cover from the flywheel housing

(1).
9. Turn the flywheel for access to the cap screws.
10. Remove the cap screws to disconnect the torque con-
verter from the engine.
11. Connect the lifting equipment to the lifting eyes on the
engine to hold the engine in place.
PTIL13TLB1470AA 5
12. Loosen and remove all the bolts (1) and washers that
fasten the transmission (2) to the flywheel housing (3).
PTIL21TLB0278AA 6
13. Loosen and remove the bolts (1), flat washers, isola-
tors, and nuts (2) from the front engine mount (3).
PTIL21TLB0279AA 7
14. Raise and remove the engine from the machine.

NOTICE: Make sure that the flex plate/converter assembly
stays in place on the transmission. If the engine will be
separated from the transmission for an extended period of
time fasten the flex plate/converter assembly in place on
the transmission.
PTIL14TLB0126AA 8
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Engine - Install
WARNING
Burn hazard!
The engine and exhaust system become hot during operation. To prevent burns, open the engine
compartment and allow the components to cool to a comfortable touch temperature before you work
inside the engine compartment.
W1406A
WARNING
Avoid injury!
Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protec-
tive Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety
footwear.
W0208A
WARNING
Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine.
1. Disengage all drives.
2. Engage parking brake.
3. Lower all attachments to the ground, or raise and engage all safety locks.
4. Shut off engine.
5. Remove key from key switch.
6. Switch off battery.
7. Wait for all machine movement to stop.
W1023A
NOTICE: Make sure that the caps and plugs are removed from the previously disconnected hoses and fittings. re-
move the identification tags after making the hose and wire connections.
1. Position the engine in the machine.

NOTICE: Make sure that the flex plate/converter assembly
stays in place on the transmission.
PTIL14TLB0126AA 1
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2. Install and tighten the bolts (1), flat washers, isolators,

and nuts (2) to the front engine mount (3).
3. Tighten the nuts (2) to a torque of 178 – 240 N·m (132
– 178 lb ft).
4. Disconnect the lifting equipment from the lifting eyes on
the engine.
PTIL21TLB0279AA 2
5. Install and tighten all the bolts (1) and washers that
fasten the transmission (2) to the flywheel housing (3).
6. Tighten bolts (1) to a torque of 52 – 57 N·m (38 – 42 lb
ft) when fixing the torque converter.
PTIL21TLB0278AA 3
7. Install the access cover to the flywheel housing (1) and

fasten the flywheel to the flex plate.
8. Tighten the screws to a torque value of 52 – 57 N·m (38
– 42 lb ft).
PTIL13TLB1470AA 4
9. Position the oil dipstick bracket (2) to the engine.

10. Install and tighten the bolt (1) along with washer to the
oil dipstick bracket (2).
PTIL21TLB0276AA 5
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11. Connect the cab heater hose (1) to the engine.
PTIL21TLB0275AA 6
12. Position the fuel mud filter (2) to the engine and secure
with bolts (3).
PTIL21TLB0274AA 7
13. Connect the fuel return and inlet lines (1) to the fuel
mud filter (2).
14. Connect all electrical connections to the engine.
PTIL21TLB0273AA 8
Next operation:
Recharge the air-conditioning system, see Air conditioning - Charging - Evacuation and recharging (50.200).
Next operation:
Install the engine starter, see Engine starter - Install (55.201).
Next operation:
Install the alternator and drive belt, see Alternator - Install (55.301).
Next operation:
Install the air-conditioning compressor and its mounting bracket, see Air-conditioning compressor - Install (50.200).
Next operation:
Install the SCR catalyst and its mounting bracket, see Selective Catalytic Reduction (SCR) muffler and catalyst -
Install - SCR outlet pipe (10.500).
Next operation:
Connect the radiator hoses to the engine, see Radiator - Install (10.400).
Next operation:
Install the air cleaner assembly, see Air cleaner - Install (10.202).
Next operation:
Fill the engine oil and cooling system up to the prescribed level, see Consumables () for specifications.
Next operation:
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Install the engine hood, see Hood - Install (90.100).

Next operation:
Connect the battery negative terminal, see Basic instructions () .
Next operation:
Start the engine and keep it in idling.
Next operation:
Unlock the support strut lock and lower the loader arm.
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Engine - Troubleshooting
NOTE: The following table lists problems and their possible causes with recommended remedial action.
ATTENTION: When attending a repair the cause of the problem must also be investigated and corrected to avoid
repeat failures.
Problem Possible Cause Correction
Engine does not develop Clogged air cleaner Clean or renew element
full power
Fuel line obstructed Clean
Faulty injectors Clean and reset
Incorrect valve clearance adjustment Clean and reset
Burnt, worn or sticking valves Replace valves with new or oversize,
and/or machine the valve guide bores
Blown head gasket Check head flatness and fit new gasket
Incorrect fuel delivery Check injectors and pump
Low cylinder compression Renew piston rings or re-bore/re-sleeve as
necessary
Oil pressure warning light Bulb burnt out Renew bulb
fails to operate
Warning Light pressure switch faulty Renew pressure switch
Warning light circuit faulty Check and renew wiring
Excessive exhaust smoke Exhaust leak on exhaust manifold Fit new gasket
Air cleaner dirty or restricted Clean
Excessive fuel delivery Overall injection pump and injectors
Engine knocks Diluted or thin oil Check crankshaft bearings for damage,
change as required. Drain and refill with
specified oil and renew filter. Ascertain
cause of dilution
Insufficient oil supply Check oil level and top up as necessary.
Overhaul or renew pump as necessary.
Check oil filter is not clogged
Low oil pressure Overhaul pump or relief valve as necessary
Excessive crankshaft end play Replace thrust washer
Excessive connecting rod or main Install new bearing inserts and/or bearing
clearance re-grind crankshaft
Bent or twisted connecting rods Renew connecting rods
Crankshaft journals out of round Re-grind crankshaft and fit undersize bear-
ing inserts
Excessive piston to cylinder Re-bore/re-sleeve block and fit i bore clear-
ance new pistons
Excessive piston ring clearance Fit new pistons and rings
Broken rings Fit new rings, check bore and pistons for
damage
Excessive piston pin clearance Fit new piston or pin
Piston pin retainer loose or missing Install new retainer, and check bore/pistons
for damage
Excessive camshaft play Install new thrust plate
Imperfections on timing gear teeth Renew timing gear
Excessive timing gear backlash Check and adjust backlash /renew, timing
gear
Engine overheats Coolant hose connection leaking or col- Tighten hose connection, renew hose if
lapsed damaged
Radiator cap defective or not sealing Renew radiator cap
Radiator leakage Repair/renew radiator
Improper fan belt adjustment Re-adjust fan belt
Radiator fins restricted Clean with compressed air
Faulty thermostat Renew thermostat
Internal engine leakage Check for source of leakage. Renew gas-
ket or defective parts
Water pump faulty Overhaul water pump
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Exhaust gas leakage into cooling Renew cylinder head gasket
Coolant aeration Tighten all connections and check coolant
level is correct. Ensure cylinder head gas-
ket has not blown
Cylinder head gasket improperly installed Renew cylinder head gasket installed
Hot spot due to rust and scale or clogged Reverse flush entire clogged water
water jackets
Obstruction to radiator air flow Remove the obstruction
Extended engine idling Do not allow engine to idle for long periods
Oil cooler tube blocked Clean
Radiator core tubes blocked Check free flow
Water temperature gauge Faulty temperature sender Renew sender switch
fails to reach normal
operating temperature
Incorrect or faulty thermostat Renew thermostat
Faulty water temperature gauge Renew temperature gauge
Low oil pressure Engine oil level low Top up, as necessary
Wrong grade of oil Drain and refill with correct grade of oil
Blocked oil pump sump screen Clean pump screen
Oil pressure relief valve faulty Fit new relief valve
Oil pump worn Renew oil pump
Excessive oil pump rotor and shaft assem- Overhaul pump
bly clearance
Excessive main or connecting rod bearing Install new bearings inserts and bearing
clearance clearance or re-grind crankshaft if neces-
sary
Excessive oil Engine oil level too high Reduce oil level
consumption
External oil leaks Renew gaskets and seals, where neces-
sary. Check mating surfaces for damage
or distortion
Worn valves, valve guides or bores Renew
Cylinder head gasket leaking Renew gasket. Check head for damage or
distortion
Oil loss past the pistons and rings Renew rings and/or re-bore/re-sleeve block
as necessary
Oil cooler leak Repair/renew oil cooler assembly
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Index
Engine - 10

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Pump drives - 114
851FX Plus
851FX
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Contents
Engine - 10
Pump drives - 114
SERVICE
Pump drive belts

Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(*) See content for specific models
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Engine - Pump drives
Pump drive belts - Adjust

851FX
1. Move the machine to a level and firm ground.

2. Raise the loader arm and put the safety strut.
3. Place the backhoe attachment in the road travel posi-
tion.
4. Make sure the direction-of-travel lever and gearshift
lever are in neutral position.
5. Engage the parking brake.
6. Stop the engine and remove the key.
7. Wait until the engine reaches ambient temperature be-
fore performing any maintenance activity.
PTIL21TLB0164AA 1
8. Open and raise the engine hood.

9. Inspect the V-belt over the whole length for damage or
cracks. Replace damaged or cracked V-belt.
NOTE: Wherever two belts are applicable, change the
belts in pair only.
10. Check by pressing midway between the pulleys (A)
(span between alternator and fan pulley) and measure
the fan belt deflection inwards. The fan belt deflection
should be 10.0 – 15.0 mm (0.4 – 0.6 in).
11. To adjust the belt (1), loosen the alternator mounting
bolts (3).
12. Slide the alternator (2) away from the engine to tighten
PTIL21TLB0212AA 2
the belt.
13. Torque the bolts (3) to 85 – 115 N·m (63 – 85 lb ft).
14. Lower and lock the engine hood.
15. Release the safety strut and lower the loader attach-
ment.
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Index
Engine - 10
Pump drives - 114

Pump drive belts - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Air cleaners and lines - 202
851FX Plus
851FX
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Contents
Engine - 10
SERVICE
Air cleaner
Service instruction - Primary element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replace - Safety element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Engine - Air cleaners and lines
Air cleaner - Service instruction - Primary element

Cleaning the filter
2. Remove the three clips (1) around perimeter of filter
cover.
3. Remove the cover (2) by rotating in counter clockwise
direction.
PTIL12TLB0239AB 1
4. Remove primary air filter element (3) by rotating in

counter clockwise direction.
PTIL12TLB0240AB 2
5. Clean the filter with controlled air pressure not exceed-

ing 2 bar (29 psi).
6. Visually check air filter element for any filter media dam-
age. If found damaged, replace the air filter element.
NOTICE: The direction of air flow shall be from inside to
outside. Never blow air from outside to inside as this will
cause dust to enter inside the element.
PTIL19TLB0006AA 3
7. Clean the air filter housing and cover with clean cloth.
8. Hold the primary air element horizontally and support
the base with other end.
9. Fix the primary air element in housing by gently press-
ing the filter into the inlet port.
NOTICE: Please make sure that element is not touching
the filter housing wall.
PTIL19TLB0008AA 4
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10. Close the cover (2) and secure it with the three clamps
(1).
PTIL12TLB0239AB 5
Replacing the filter

11. See instructions 1 to 4 and 7 to 10 to replace the pri-
mary element.
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Air cleaner - Replace - Safety element - Replace

NOTICE: Do not clean safety element. It shall be replaced with new element or at recommended intervals.
2. Remove the three clips (1) around perimeter of filter
cover.
3. Remove the cover (2) by rotating in counter clockwise
direction.
PTIL12TLB0239AB 1
4. Remove primary air filter element (3) by rotating in

counter clockwise direction.
PTIL12TLB0240AB 2
5. Remove safety element (4) by rotating it in counter

clockwise direction.
6. Clean the air filter housing and cover with clean cloth.
7. Pick a new safety element.
8. Install the new safety element inside filter housing by
rotating in clockwise direction.
PTIL12TLB0241AB 3
9. Hold the primary air element horizontally and support

the base with other end.
10. Fix the primary air element in housing by gently press-
ing the filter into the inlet port.
NOTICE: Please make sure that element is not touching
the filter housing wall.
PTIL19TLB0008AA 4
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11. Close the cover (2) and secure it with the three clamps
(1).
PTIL12TLB0239AB 5
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Air cleaner - Remove

Prior operation:
1. Disengage the hose clamp on the air cleaner outlet

hose and disconnect the hose (1).
2. Disengage the hose clamp on the Closed Crankcase
Ventilation (CCV) hose (2). Remove any tie wraps at-
tached the CCV hose.
PTIL21TLB0224AA 1
3. Disengage the hose clamp on the air intake hose (1)

and disconnect the hose.
RAIL14TLB1151AA 2
4. Disconnect the air restriction sensor (1).
RAIL14TLB1152AA 3
5. Disconnect the humidity sensor (1).
RAIL14TLB1153AA 4
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6. Loosen and remove the four mounting bolts (1) along

with washers from the air cleaner (2).
PTIL21TLB0193AA 5
7. Remove the air cleaner.
RAIL14TLB1155AA 6
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Air cleaner - Install

1. Install the air cleaner (2) and secure with the bolts (1)
along with washers.
PTIL21TLB0193AA 1
2. Connect the humidity sensor (1) and tighten it to a

torque of 5.6 – 9.0 N·m.
RAIL14TLB1153AA 2
3. Connect the air restriction sensor (1).
RAIL14TLB1152AA 3
4. Connect the air intake hose (1) and secure the hose
clamp. Tighten the hose clamp to a torque of 3.4 –
4.5 N·m.
RAIL14TLB1151AA 4
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5. Connect the outlet hose (1) and secure the hose clamp.
6. Connect the hose clamp on the Closed Crankcase Ven-
tilation (CCV) hose (2).
7. Tighten the both hose clamps to a torque of 3.4 –
4.5 N·m.
8. Secure the CCV hose to the charge air cooler hose with
tie wraps.
PTIL21TLB0224AA 5
Next operation:
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Index
Engine - 10

Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air cleaner - Replace - Safety element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air cleaner - Service instruction - Primary element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Intake and exhaust manifolds and muffler - 254
851FX Plus
851FX
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Contents
Engine - 10
FUNCTIONAL DATA
Intake and exhaust manifolds and muffler

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Intake and exhaust manifolds and muffler

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Overview
PTIL13TLB1200FB 1
1. Muffler 6. Bolt
2. Bracket with muffler 7. Washer
3. Screw 8. Muffler gasket
4. Washer 9. Muffler brace
5. Nylock nut 10. Nut
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PTIL13TLB1201FB 2
1. Exhaust stack 4. Washer

2. Clamp 5. Nylock nut
3. Bolt
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Intake and exhaust manifolds and muffler - Remove

Put identification tags on all disconnected hoses and
wires. Be prepared to cap or plug disconnected hoses
and fittings.
NOTE: The images in this procedure may be different from
your machine and are for reference only.
1. Park the machine on a level surface. Raise the loader
and lock the support strut (1) to hold the loader.
Remove the battery cover and disconnect the negative
battery cable from the battery and move it away from
the battery terminal.
See Basic instructions () .
PTIL13TLB0935AB 1
2. Loosen the air cleaner hose clamp (1) on the tur-

bocharger (2) and detach the hose (3).
PTIL13TLB0950AB 2
3. Loosen the air cleaner inlet hose clamp (1) on the air
cleaner (2). Detach the inlet hose (3) form the air
cleaner.
Disconnect crank case ventilation hose and the aspira-
tion hose.
PTIL13TLB1202AB 3
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4. Remove the cap screws (1) and flat washers that fasten
the fixed hood to the uprights. Remove the fixed hood
and air cleaner as one assembly.
PTIL13TLB0949AB 4
5. Loosen the bolts (1) and disconnect the muffler flange

(2) from the turbo.
PTIL13TLB0193AB 5
6. Remove the mounting hardware that secures the upper

(1) and lower (2) of the muffler to the engine block.
PTIL13TLB0958AB 6
PTIL13TLB0957AB 7
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7. Remove the muffler assembly (1).
PTIL13TLB1204AB 8
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Intake and exhaust manifolds and muffler - Install

NOTICE: Prevent damage to the exhaust system do the following procedures in sequence. All gaps between mount-
ing surfaces should be eliminated before torque sequence is started.
1. Install the muffler assembly.
Torque tighten the assembly bolts (1) to the engine
bracket to 32 – 38 N·m (24 – 28 lb ft).
PTIL13TLB1204AB 1
2. Install the mounting hardware that secures the upper

(1) and lower (2) of the muffler to the engine block.
Torque tighten the bolts to 32 – 38 N·m (24 – 28 lb ft).
PTIL13TLB0958AB 2
PTIL13TLB0957AB 3
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3. Align and secure the muffler flange (2) with turbo and
tighten bolts (1) to 6.5 – 7.5 N·m (4.8 – 5.5 lb ft).
PTIL13TLB0193AB 4
4. Install the fixed hood and air cleaner as one assembly.

Install the cap screws (1) and flat washers that fasten
the fixed hood to the uprights. Connect crank case ven-
tilation hose and the aspiration hose.
PTIL13TLB0949AB 5
5. Attach the inlet hose (3) form the air cleaner. Tighten
the air cleaner inlet hose clamp (1) on the air cleaner
(2).
PTIL13TLB1202AB 6
6. Attach the hose (3) and tighten the air cleaner hose
clamp (1) on the turbocharger (2) end.
7. Install the battery cover and connect battery.
See Basic instructions () .
PTIL13TLB0950AB 7
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8. Start the machine.

Unlock the support strut (1) and lower the loader.
PTIL13TLB0935AB 8
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Index
Engine - 10

Intake and exhaust manifolds and muffler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake and exhaust manifolds and muffler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Selective Catalytic Reduction (SCR) exhaust treatment - 500
851FX Plus
851FX
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10.5 [10.500] / 1
Contents
Engine - 10
SERVICE
Selective Catalytic Reduction (SCR) muffler and catalyst

Remove - SCR outlet pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - SCR outlet pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove - SCR tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - SCR tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Selective Catalytic Reduction (SCR) exhaust treatment
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove -

SCR outlet pipe
1. Loosen and remove the six bolts (1) from the exhaust
mounting bracket (2).
2. Remove the exhaust heat shield (3) from the machine.
PTIL21TLB0179AA 1
3. Loosen and remove the two bolts (4) along with wash-
ers from the exhaust heat shield (3).
4. Remove the exhaust heat shield (3).
PTIL21TLB0180AA 2
5. Remove the electric connectors (5) from the SCR outlet

pipe (6).
6. Remove the hose clamp (7) and disconnect one end of
the SCR outlet pipe (6).
PTIL21TLB0181AA 3
7. Loosen and remove the four bolts (8) along with wash-
ers from the cabin frame (9).
8. Remove one end of the SCR outlet pipe (6) from the
machine.
PTIL21TLB0182AA 4
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9. Disconnect the electric connectors (10) from the SCR

outlet pipe (11).
PTIL21TLB0183AA 5
10. Remove the two hose clamps (12) and disconnect the
SCR outlet pipe (11) from the machine.
11. Loosen and remove the bolt (13) along with washer
from the mounting bracket (14).
12. Remove one end of SCR out pipe (11) from the ma-
chine.
PTIL21TLB0184AA 6
13. Remove the other of the SCR outlet pipe (11), see
Selective Catalytic Reduction (SCR) muffler and
catalyst - Remove - SCR tank (10.500).
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Selective Catalytic Reduction (SCR) muffler and catalyst - Install -

SCR outlet pipe
1. Position the SCR out pipe (1) to the machine.
3. Install the two hose clamps (4) to the SCR outlet pipe
(1).
PTIL21TLB0184AA 1
4. Connect the electric connectors (6) to the SCR outlet

pipe (5).
PTIL21TLB0183AA 2
5. Connect other end of the SCR outlet pipe (5), see Se-
lective Catalytic Reduction (SCR) muffler and cata-
lyst - Install - SCR tank (10.500).
6. Position the SCR outlet pipe (6) along the cabin frame
(7).
7. Install and tighten the four bolts (8) along with washers
to the cabin frame (7).
PTIL21TLB0182AA 3
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8. Connect one end of the SCR outlet pipe (6) and install
the hose clamp (10).
9. Install the electric connectors (11) to the SCR outlet
pipe (6).
PTIL21TLB0181AA 4
10. Position and install the exhaust heat shield (12).

11. Install and tighten the two bolts (13) along with wash-
ers to the exhaust heat shield (12).
PTIL21TLB0180AA 5
12. Install the exhaust heat shield (12) to the machine.

13. Install and tighten the six bolts (14) to the exhaust
PTIL21TLB0179AA 6
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Selective Catalytic Reduction (SCR) muffler and catalyst - Remove

- SCR tank
Prior operation:
Remove the one end of the SCR pipe, see Selective Catalytic Reduction (SCR) muffler and catalyst - Remove -
SCR outlet pipe (10.500).
1. Loosen and remove the six bolts (1) along with washers
from the top plate SCR wrapper (2) and remove the
SCR plate (3).
PTIL21TLB0189AA 1
2. Loosen and remove the two bolts (4) along with wash-
ers and remove the two nuts from the bracket.
3. Remove the hose clamp (5) and disconnect other end
of the SCR outlet pipe (6).
PTIL21TLB0191AA 2
4. Loosen and remove the four bolts (7) along with wash-
ers from the bottom plate SCR wrapper (8).
5. Remove the SCR tank (9) from the machine.
PTIL21TLB0190AA 3
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Selective Catalytic Reduction (SCR) muffler and catalyst - Install

- SCR tank
1. Position the SCR tank (1) to the machine.
2. Install and tighten the four bolts (2) along with washers
to the bottom plate SCR wrapper (3).
PTIL21TLB0190AA 1
3. Install the hose clamp (4) and connect other end of the
SCR outlet pipe (5).
4. Install and tighten the two bolts (6) along with washers
and remove the two nuts to the bracket.
PTIL21TLB0191AA 2
5. Install and tighten the six bolts (7) along with washers
to the top plate SCR wrapper (8) and remove the SCR
plate (9).
PTIL21TLB0189AA 3
Next operation:
Install one end of the SCR pipe, see Selective Catalytic Reduction (SCR) muffler and catalyst - Install - SCR tank
(10.500).
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Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Remove

1. Loosen and remove the six bolts (1) along with washers
from the DEF tank wrapper (2) from the machine.
PTIL21TLB0185AA 1
2. Disconnect the electric connectors (3) from the DEF

tank sensor (4).
PTIL21TLB0186AA 2
3. Remove the DEF tank sensor (4) from the DEF tank
(5).
PTIL21TLB0187AA 3
4. Remove the DEF tank (5) from the plastic fuel tank (6)
in the machine.
PTIL21TLB0188AA 4
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Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Install

1. Position and install the DEF tank (1) to the plastic fuel
tank (2) in the machine.
PTIL21TLB0188AA 1
2. Install the DEF tank sensor (3) to the DEF tank (1).
PTIL21TLB0187AA 2
3. Connect the electric connectors (4) from the DEF tank

sensor (3).
PTIL21TLB0186AA 3
4. Install and tighten the six bolts (5) along with washers
from the DEF tank wrapper (6) from the machine.
PTIL21TLB0185AA 4
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Index
Engine - 10

Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diesel Exhaust Fluid (DEF)/AdBlue®/ARLA tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Selective Catalytic Reduction (SCR) muffler and catalyst - Install - SCR outlet pipe . . . . . . . . . . . . . 5
Selective Catalytic Reduction (SCR) muffler and catalyst - Install - SCR tank . . . . . . . . . . . . . . . . . . 8
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove - SCR outlet pipe . . . . . . . . . . . 3
Selective Catalytic Reduction (SCR) muffler and catalyst - Remove - SCR tank . . . . . . . . . . . . . . . . 7
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Engine - 10
Engine cooling system - 400
851FX Plus
851FX
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10.6 [10.400] / 1
Contents
Engine - 10
FUNCTIONAL DATA
Radiator
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Radiator
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Deaeration tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - Engine cooling system
Radiator - Exploded view
PTIL21TLB0442FB 1
1. Radiator 10. Right-hand side lower intercooler tube

2. Intercooler 11 Right-hand side cooling pack bracket
3. Left-hand side cooling pack bracket 12. Bolt
4. Washer 13. Washer
5. Jam nut 14. Bolt
6. Lock washer 15. Washer
7. Bolt 16. Right-hand side fan guard
8. Fuel cooler 17. Left-hand side upper intercooler tube
9. Fuel cooler bracket 18. Upper radiator seal
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PTIL21TLB0281FA 2
1. Recovery bottle 6. Left-hand side fan guard

2. Radiator purge hose 7. Deaeration tube
3. Upper radiator hose 8. Left-hand side lower intercooler tube
4. Hose clamps 9. Left hand side upper intercooler tube
5. Lower radiator hose 10. Radiator overflow hose
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Radiator - Drain fluid

WARNING
Hot liquid under pressure!
Service when cool.
W1187A
NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling
system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives
(SCA) should not be used when using OAT EXTENDED LIFE COOLANT ASTM D 3306 TYPE 1 . Change the coolant
solution at the change interval recommended.
Drain, flush, and replace the engine coolant every 4000 h of operation or every year, whichever comes first.
Coolant fluid specifications: OAT EXTENDED LIFE COOLANT ASTM D 3306 TYPE 1.
Coolant capacity: 20.0 L (5.3 US gal).
1. Park the machine on level ground.

2. Raise the loader arm and engage the support strut.
3. Shut down the engine and place a 'Do Not Operate' tag
on the key switch.
4. Allow time for the engine and the coolant to cool.
5. Remove the bolts (1) that secure the radiator bumpers
(2). Remove the bumpers.
RCPH10TLB193AAF 1
6. Tip the grille up from the bottom and lift away from the
machine.
RCPH10TLB150AAF 2
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7. Place a piece of hose onto the radiator drain valve (1)

and drain into a suitable container.
PTIL21TLB0198AA 3
8. WARNING
Service when cool.
Failure to comply could result in death or seri-
ous injury.
W1187A
Slowly turn the de-areation cap (1) counter-clockwise

until it is off. It is not necessary to remove the hoses in
order to remove the cap.
PTIL21TLB0195AA 4
9. Remove the bolts that secure the coolers.

10. Swing the coolers out and clean of dirt and debris.
11. Check the hoses, elbows, and system components for
wear or damage.
12. Swing the coolers back in and secure with bolts.
13. After the coolant drains, close the drain valve.
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Radiator - Remove
WARNING
Pressurized fluid can penetrate the skin and cause severe injuries.
Make sure all hydraulic hoses are properly secured, and not in danger of binding or being pinched.
This could cause a hose to break, allowing pressurized fluid to escape.
W0439A
NOTICE: Make sure that the identification tags are installed on all disconnected hoses and wires. Close the discon-
nected hoses and fittings with caps and plugs.
Prior operation:
Park the machine on a level surface. See “Raise and support loader lift arms” in Basic instructions () . Allow the
engine to cool.
Prior operation:
Disconnect the battery negative terminal, see Basic instructions () .
Prior operation:
Prior operation:
Discharge the air-conditioning system, see Air conditioning - Charging - Evacuation and recharging (50.200).
Prior operation:
Remove the receiver drier from the condenser, see Air conditioning - Remove - Receiver drier (50.200).
Prior operation:
Remove the condenser from the radiator, see Air-conditioning condenser - Remove (50.200).
Prior operation:
Remove the recovery bottle from the radiator, see Deaeration tank - Remove (10.400).
ATTENTION: Hot coolant can escape if the coolant reser-

voir cap is removed while the system is still hot. Allow the
system to cool down completely before removing the cap.
1. Install a hose on the drain valve (1) and drain the radi-
ator into a clean container of suitable capacity.
2. Wait for the coolant to drain out completely. For more
information, see Radiator - Drain fluid (10.400).
PTIL21TLB0198AA 1
3. Loosen the clamp (1) and disconnect the upper radiator

hose (2).
PTIL21TLB0223AA 2
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4. Loosen the clamp (1) and disconnect the lower radiator

hose (2).
PTIL21TLB0203AA 3
5. Disconnect both upper cooler tubes (1) (hydraulic oil

and transmission oil) from the oil cooler.
PTIL21TLB0202AA 4
PTIL21TLB0205AA 5
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6. Disconnect both lower cooler tubes (1) (hydraulic oil

and transmission oil) from the oil cooler.
PTIL21TLB0201AA 6
PTIL21TLB0198AA 7
7. Disconnect the fuel hoses (1) from the fuel cooler (2).
PTIL21TLB0199AA 8
8. Loosen and remove the two bolts (1) from the fuel
cooler (2).
9. Remove the fuel cooler (2) from the two brackets (3).
PTIL21TLB0200AA 9
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10. Loosen and remove the two mounting bolts (1) each
from both sides of the radiator.
11. Attach suitable lifting equipment to the radiator.
12. Raise the cooling pack just enough to move it forward
and clear the fan.
13. Make sure that you have cleared the fan from the
shroud, raise the cooling pack from the machine.
PTIL21TLB0202AA 10
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Radiator - Disassemble
1. Place cooling pack on a clean work bench.
2. Remove the cooler line mounting clamps.
3. Remove the fan shroud mounting bolts, de-aeration
tank, and radiator hoses from the radiator.
4. Replace worn or damaged components.
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Radiator - Assemble
NOTE: See Radiator - Exploded view (10.400).
1. Install fan shroud bolts to the prescribed torque of
7.25 N·m (5.3 lb ft).
2. Install de-aeration tank.
3. Install radiator hoses and clamps to the prescribed
torque of 5.8 – 6.8 N·m (4.3 – 5.0 lb ft).
4. If fittings were removed from the oil cooler, install fit-
tings to the prescribed torque of 270 – 300 N·m (199.1
– 221.3 lb ft).
NOTICE: Use two wrenches to minimize the torque trans-
mitted onto the elbow brazed to the oil cooler.
5. Install the clamps to the prescribed torque of 5.6 –
7.9 N·m (4.1 – 5.8 lb ft).
6. Install the mounting brackets and tighten the mounting
bolts.
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Radiator - Install
WARNING
Pressurized fluid can penetrate the skin and cause severe injuries.
Make sure all hydraulic hoses are properly secured, and not in danger of binding or being pinched.
This could cause a hose to break, allowing pressurized fluid to escape.
W0439A
1. Attach suitable lifting equipment to the cooling pack.

2. Lower the assembly just in front of the fan and slowly
guide the cooling pack backward clearing the fan.
NOTE: Adjust fan shroud to obtain 20 mm (0.787 in) clear-
ance around the fan.
3. Install and tighten the two mounting bolts (1) each on
both sides of the radiator.
PTIL21TLB0202AA 1
4. Position the fuel cooler (2) on the two brackets (3).

5. Install and tighten the two bolts (1) to the fuel cooler (2).
PTIL21TLB0200AA 2
6. Connect the fuel hoses (1) to the fuel cooler (2).
PTIL21TLB0199AA 3
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7. Connect both lower cooler tubes (1) (hydraulic oil and

transmission oil) to the oil cooler.
PTIL21TLB0198AA 4
PTIL21TLB0201AA 5
8. Connect both upper cooler tubes (1) (hydraulic oil and

transmission oil) to the oil cooler.
PTIL21TLB0205AA 6
PTIL21TLB0202AA 7
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9. Connect the lower radiator hose (2) and tighten the

clamp (1) to a torque of 6.3 – 7.7 N·m.
PTIL21TLB0203AA 8
10. Connect the upper radiator hose (2) and tighten the
clamp (1) to a torque of 6.3 – 7.7 N·m.
PTIL21TLB0223AA 9
Next operation:
Install the recovery bottle to the radiator, see Deaeration tank - Install (10.400).
Next operation:
Fill the radiator and deaeration tank to the full line, see Radiator - Filling (10.400) .
Next operation:
Install the condenser to the radiator, see Air-conditioning condenser - Install (50.200).
Next operation:
Install the receiver drier to the condenser, see Air conditioning - Install - Receiver drier (50.200).
Next operation:
Charge the air-conditioning system, see Air conditioning - Charging - Evacuation and recharging (50.200).
Next operation:
Next operation:
Connect the battery negative terminal, see Basic instructions () .
Next operation:
Start the engine and allow the coolant to reach operating temperature. Stop the engine and check for leaks.
Next operation:
After the engine cools, check the level and fill as needed.
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Radiator - Filling
WARNING
Service when cool.
W1187A
NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling
system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives
(SCA) should not be used when using OAT EXTENDED LIFE COOLANT ASTM D 3306 TYPE 1 . Change the coolant
solution at the change interval recommended.
Drain, flush, and replace the engine coolant every 4000 h of operation or every year, whichever comes first.
Coolant fluid specifications: OAT EXTENDED LIFE COOLANT ASTM D 3306 TYPE 1.
Coolant capacity: 20.0 L (5.3 US gal).
1. Close the radiator drain valve.
PTIL21TLB0198AA 1
2. WARNING
Service when cool.
ous injury.
W1187A
Slowly turn the de-areation cap (1) counter-clockwise

until it is off. It is not necessary to remove the hoses in
order to remove the cap.
PTIL21TLB0195AA 2
3. Pour approximately 20.0 L (5.3 US gal) of clean water

into the de-aeration reservoir until full.
NOTE: In some situations air pockets in the coolant system
may prevent you from filling the system to capacity. If this
occurs remove the de-aeration valve cap this allows the air
to escape during the fill procedure. The de-aeration valve
cap is on the top right-hand side of the engine below the
air filter housing.
NOTE: Do not over fill the coolant system.
RAIL14TLB1164AA 3
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4. Secure the filler cap on the de-aeration reservoir. If

applicable attach the de-aeration valve cap.
5. Start the engine and run for at least 30 min.
NOTE: Make sure that you activate the heating system (if
equipped) to circulate fluid through the heater core.
6. Remove the de-aeration filler cap.
7. Drain the water from the system.
8. Repeat Steps 3– 7 for a clean system flush.
9. After the radiator flush, close the radiator drain valve,
and detach the drain hose.
10. Pour coolant into the de-aeration reservoir until the
level reaches between the COLD MIN mark and the
HOT MAX mark on the tank.
11. Install the filler cap.
12. Start up the engine.
13. Run the engine for a few minutes and stop the engine
before it reaches operating temperature.
14. Check the system for leaks.
15. Start up the engine again and allow the engine to
reach operating temperature.
17. Check the fluid level in the de-aeration reservoir.
18. If necessary, allow the components to cool and add
coolant to the reservoir.
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Deaeration tank - Remove

WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
W0367A
Prior operation:
Drain the coolant from the deaeration tank, see Radiator - Drain fluid (10.400) .
1. Loosen the clamp (1) and disconnect the one end of

deaeration tube (2) from the radiator (3) at the bottom.
2. Loosen and remove the bolt (4) along with washer from
the radiator clamp (5) at the bottom.
PTIL21TLB0194AA 1
3. Loosen the two clamps (6) and disconnect the other

end of deaeration tube (2) from the recovery bottle (7).
4. Discard the hose ties (8) from the deaeration tube (2)
and overflow hose (9).
PTIL21TLB0195AA 2
5. Disconnect the overflow hose (9) from the recovery bot-

tle (7).
PTIL21TLB0196AA 3
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6. Loosen the two clamps (10) and disconnect the radiator

purge hose (11) from the recovery bottle (7).
7. Loosen and remove the bolts (12) along with washers
from the two hose clamps (13) of the recovery bottle.
8. Remove the overflow hose (9) and purge hose (11)
along with clamps from the recovery bottle (7).
9. Remove the recovery bottle (7) from the radiator
bracket (14).
PTIL21TLB0197AA 4
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Deaeration tank - Install

WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
W0367A
1. Position the recovery bottle (7) to the radiator bracket

(14).
2. Install the overflow hose (9) and purge hose (11) along
with clamps to the recovery bottle (7).
3. Install and tighten the bolts (12) along with washers to
the two hose clamps (13) of the recovery bottle.
4. Connect the radiator purge hose (11) to the recovery
bottle (7) and tighten the two clamps (10).
PTIL21TLB0197AA 1
5. Connect the overflow hose (9) to the recovery bottle (7).
PTIL21TLB0196AA 2
6. Install the hose ties (8) to the deaeration tube (2) and
overflow hose (9).
7. Connect the one end of deaeration tube (2) to the re-
covery bottle (7) and tighten the two clamps (6).
PTIL21TLB0195AA 3
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10.6 [10.400] / 20
radiator clamp (5) at the bottom.
9. Connect the other end of deaeration tube (2) to the
radiator (3) at the bottom and tighten the clamp (1).
PTIL21TLB0194AA 4
Next operation:
Fill the coolant to the deaeration tank, see Radiator - Drain fluid (10.400) .
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Index
Engine - 10

Deaeration tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Deaeration tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Radiator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Radiator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Radiator - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - 10
Aftercooler - 310
851FX Plus
851FX
91715732 26/07/2021
10.7 [10.310] / 1
Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Aftercooler
Aftercooler - Remove
Prior operation:
Remove the condenser, see Air-conditioning condenser - Remove (50.200).
Prior operation:
Remove the fuel cooler and after cooler hoses, see Radiator - Remove (10.400).
1. Loosen and remove the mounting bolts (1) from both

sides of the aftercooler (2).
PTIL21TLB0225AA 1
2. Separate the aftercooler (2) from the radiator without

damaging the fins.
PTIL21TLB0226AA 2
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Engine - Aftercooler
Aftercooler - Install
1. Install the aftercooler (2) on the radiator.
PTIL21TLB0226AA 1
2. Install and tighten the mounting bolts (1) on both the

sides of the after cooler (2).
PTIL21TLB0225AA 2
Next operation:
Install the fuel cooler and after cooler hoses, see Radiator - Install (10.400) .
Next operation:
Install the condenser, see Air-conditioning condenser - Install (50.200) .
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Index
Engine - 10
Aftercooler - 310
Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
91715732 26/07/2021
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Case New Holland Construction Equipment (India) Private Limited, Plot No. 157, Industrial Area – III Pithampur, Madhya Pradesh, India
SERVICE - Technical Publications & Tools
PRINTED IN INDIA
© 2021 Case New Holland Construction Equipment (India) Private Limited All rights reserved.
No part of the text or illustrations of this publication may be reproduced.
Case New Holland Construction Equipment (India) Private Limited reserves the right to make improvements in
design and changes in specifications at any time without notice and without incurring any obligation to install them
on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the
time of publication, but are subject to change without notice.
Availability of some models and equipment builds varies according to the country in which the equipment is being
used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.
CASE CONSTRUCTION is a trademark registered in the United States and many other countries, owned or
licensed to CNH Industrial N.V., its subsidiaries or affiliates.
Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or
licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.
91715732 26/07/2021
EN
SERVICE MANUAL
Power coupling
851FX Plus
851FX
91715732 26/07/2021
19
Contents
Power coupling - 19
[19.100] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
91715732 26/07/2021
19
Power coupling - 19
Drive shaft - 100
851FX Plus
851FX
91715732 26/07/2021
19.1 [19.100] / 1
Contents
Power coupling - 19
Drive shaft - 100
SERVICE
Drive shaft
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive shaft from transmission to rear axle
Disassemble - Rear propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble - Rear propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive shaft from transmission to front axle
Disassemble - Front propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble - Front propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSTIC
Drive shaft
91715732 26/07/2021
19.1 [19.100] / 2
Power coupling - Drive shaft
Drive shaft - Service instruction

Maintenance
1. Periodically check that, installation of propeller shaft is
as per requirement and propeller shafts are not dam-
aged.
2. Periodically check flange yoke securing bolts and cen-
ter bearing mounting bolt for tightness and if necessary
retighten to recommended torque values.
3. Periodically check bearing race assemblies of univer-
sal joints, ball bearing of center bearing assembly and
spline assembly of slip joint for noise/play or backlash
and if found abnormal or excessive, replace them.
Lubrication
1. Universal joints and slip joints splines to be greased
after installation of shaft on the vehicle.
2. Universal joint to be greased till discharge of grease
takes place from “Rubber Seals” of bearing race as-
semblies as shown in figure 1. Discharge of grease
from all four rubber seals of joint will make sure com-
plete lubrication of joint.
A. Grease discharge from seal
B. Sleeve yoke
PTIL18TLB0359AB 1
3. Slip joint splines to be greased till grease is discharged

from vent hole and continue to grease till discharged
of grease takes place from slip stub shaft cork washer
(see figure 2). This will make sure complete lubrication
of spline assembly.
A. Grease discharge
PTIL18TLB0360AB 2
4. For LFL (Lube for Life) kit (prepacked) there is no need

for further lubrication.
5. In the rare event of wear having taken place in yoke ear
cross holes, the holes will almost certainly be oval and
yoke will have to be replaced.
6. For hostile and adverse operating conditions, the re-lu-
brication period can be shorter duration as per require-
ment.
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Service
1. Original running of propeller shaft will only be assured if
dismantled parts are reassembled in the same position
and place as prior to dismantling. It would be better to
check straightness and balance of propeller shaft, the
parts of which have been replaced.
2. Normally replacement of stub ball yoke and midship
stub shaft assembly of front propeller shaft as well as
slip stub shaft and stub ball yoke of rear propeller shaft
is not recommended. Instead entire tubular shaft as-
sembly is to be replaced.
Do’s
Use only genuine spare parts.
Assemble dismantled parts in the same position and
place as prior to dismantling to get original and desired
functioning of propeller shaft.
All assembly operations to be done in a dust free at-
mosphere and all parts should be clean and free from
dirt and other impurities.
Do not hammer on bearing race while assembling.
Strictly adhere the lubrication procedure as mentioned
in this manual.
After any kind of repairing of propeller shaft, make sure
straightening and balancing before installing on vehicle.
Dont’s
Do not replace only bearing in case of wear or load
marking, as it will cause wear rapidly. Instead of that
replace entire Universal joint cross.
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19.1 [19.100] / 4
Drive shaft from transmission to rear axle - Disassemble - Rear

propeller shaft
1. Place the shaft on V-blocks.
2. Straighten out the prongs of dust cap and pull back
dust cap, steel washer and rubber seal. Sleeve yoke
assembly can now be pulled out from slip stub shaft.
3. Hold the shaft firmly and tap the flange yoke with a
soft hammer. The bearing race assembly will begin to
emerge until finally the shaft can be turned over and the
bearing race assembly removed (see figures 1 and 2).
Make sure that the needle rollers do not accidentally
spill out of the bearing race assembly.
4. For opposite bearing race assembly, hold the shaft
firmly and tap the flange yoke with a soft hammer. The
bearing race assembly will begin to emerge until finally
the shaft can be turned over and the bearing race as-
sembly removed (see figures 1 and 2). Make sure that
the needle rollers do not accidentally spill out of the
bearing race assembly. Now the unretained flanged PTIL18TLB0355AB 1
yoke can be removed from the joint.
emerge until finally the shaft can be turned over and
the bearing race assembly removed (see figures 1 and
2). Make sure that the needle rollers do not acciden-
tally spill out of the bearing race assembly. For oppo-
site bearing race assembly, hold the shaft firmly and tap
the flange yoke with a soft hammer. The bearing race
assembly will begin to emerge until finally the shaft can
be turned over and the bearing race assembly removed
(see figures 1 and 2). Make sure that the needle rollers
do not accidentally spill out of the bearing race assem-
bly. The unretained flanged yoke can now be removed PTIL18TLB0356AB 2
from the joint. Now remove the two remaining bearing

race assemblies.
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19.1 [19.100] / 5
Drive shaft from transmission to rear axle - Assemble - Rear

propeller shaft
1. All assembly operations to be done in a dust free at-
mosphere and all parts used should be clean and free
from dirt and other impurities.
2. If load markings or wear are observed on journal peg
diameter, needle rollers or inner diameter of bearing
races of dismantled universal joint , the entire univer-
sal joint is to be replaced, because new Journal used
with old bearing race assemblies or new bearing as-
semblies used with old journal will wear more rapidly
making another replacement necessary in a short time.
3. All assembly operations to be carried out in a dust free
atmosphere and all parts used should be clean and free
of dirt and other impurities.
4. Insert journal in flange yoke cross holes and using a
soft nosed drift (which is slightly smaller than the out-
side diameter of bearing race assembly), tap the bear-
ing race assembly into position by a soft hammer taking
care to avoid accidental spillage of needle rollers (see
figure 1).
Fit shim if required on top of bearing race assembly and
snap ring in the yoke ear groove.
PTIL18TLB0357AB 1
5. To insert the second bearing race assembly in the other

yoke ear of flange yoke turn the flange yoke by 180°
and insert journal in flange yoke cross holes and using
a soft nosed drift (which is slightly smaller than the out-
figure 1).
6. To insert the remaining two bearing race assemblies in
the other yoke, insert journal in flange yoke cross holes
and using a soft nosed drift (which is slightly smaller
than the outside diameter of bearing race assembly),
tap the bearing race assembly into position by a soft
hammer taking care to avoid accidental spillage of nee-
dle rollers (see figure 1) and
To insert the second bearing race assembly in the other
figure 1).
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19.1 [19.100] / 6
7. The articulation of joint should be smooth and uniform

and in case the articulation is stiff, tap yoke ears with a
soft hammer (see figure 2) to achieve proper articula-
tion of joint.
Sometimes snap ring of graded thickness and/or shim
may be required to get proper articulation of joint.
PTIL18TLB0358AB 2
8. The joint should be lubricated after assembly into pro-

peller shaft. The lubrication should be continued till dis-
charge takes place from one or more rubber seals of
bearing cups.
9. It would be better to check balance of propeller shaft
after assembly of universal joint.
91715732 26/07/2021
19.1 [19.100] / 7
Drive shaft from transmission to front axle - Disassemble - Front

propeller shaft
1. Support shaft on V block and clean enamel and dirt
from snap rings and top of bearing race assemblies.
Pinch the ears of snap ring together by pliers and re-
move all the four snap rings from the joint. If snap ring
does not snap out of groove readily, tap top of bearing
race assembly by a soft hammer to relive the pressure
against the ring.
emerge until finally the shaft can be turned over and the
bearing race assembly removed (see figures 1 and 2).
Make sure that the needle rollers do not accidentally
spill out of the bearing race assembly.
3. For opposite bearing race assembly, hold the shaft
firmly and tap the flange yoke with a soft hammer. The
bearing race assembly will begin to emerge until finally
the shaft can be turned over and the bearing race as-
sembly removed (see figures 1 and 2). Make sure that
the needle rollers do not accidentally spill out of the
bearing race assembly. Now the unretained flanged PTIL18TLB0355AB 1
yoke can be removed from the joint.
emerge until finally the shaft can be turned over and
the bearing race assembly removed (see figures 1 and
2). Make sure that the needle rollers do not acciden-
tally spill out of the bearing race assembly. For oppo-
site bearing race assembly, hold the shaft firmly and tap
the flange yoke with a soft hammer. The bearing race
assembly will begin to emerge until finally the shaft can
be turned over and the bearing race assembly removed
(see figures 1 and 2). Make sure that the needle rollers
do not accidentally spill out of the bearing race assem-
bly. The unretained flanged yoke can now be removed PTIL18TLB0356AB 2
from the joint. Now remove the two remaining bearing

race assemblies.
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Drive shaft from transmission to front axle - Assemble - Front

propeller shaft
1. If load markings or wear are observed on journal peg
diameter, needle rollers or inner diameter of bearing
races of dismantled universal joint , the entire univer-
sal joint is to be replaced, because new Journal used
with old bearing race assemblies or new bearing as-
semblies used with old journal will wear more rapidly
making another replacement necessary in a short time.
2. All assembly operations to be carried out in a dust free
atmosphere and all parts used should be clean and free
of dirt and other impurities.
3. Insert journal in flange yoke cross holes and using a
soft nosed drift (which is slightly smaller than the out-
figure 1).
Fit shim if required on top of bearing race assembly and
snap ring in the yoke ear groove.
PTIL18TLB0357AB 1
4. To insert the second bearing race assembly in the other

figure 1).
5. To insert the remaining two bearing race assemblies in
the other yoke, insert journal in flange yoke cross holes
and using a soft nosed drift (which is slightly smaller
than the outside diameter of bearing race assembly),
tap the bearing race assembly into position by a soft
hammer taking care to avoid accidental spillage of nee-
dle rollers (see figure 1) and
To insert the second bearing race assembly in the other
figure 1).
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6. The articulation of joint should be smooth and uniform

and in case the articulation is stiff, tap yoke ears with a
soft hammer (see figure 2) to achieve proper articula-
tion of joint.
Sometimes snap ring of graded thickness and/or shim
may be required to get proper articulation of joint.
PTIL18TLB0358AB 2
7. The joint should be lubricated after assembly into pro-

peller shaft. The lubrication should be continued till dis-
charge takes place from one or more rubber seals of
bearing cups.
8. It would be better to check balance of propeller shaft
after assembly of universal joint.
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Drive shaft - Troubleshooting

Vibration in the propeller Bent propeller shaft Straighten it
shaft
Broken or worn out universal joint crosses Replace them
and bearing
Loose propeller shaft supporting mounting Tight it
Loose universal joint bolt nut Tighten them
Splines not properly aligned at sliding joint. Align them with the help of Arrows
Intermediate flange not properly aligned Realign them
with forward propeller shaft yoke
Rattle/Abnormal noise Due to lack of lubrication Grease the joint
Worn or broken universal joint cross Joint Replace them
bearing and joint seals
Universal joint bearing not seated properly Adjust them
in yoke or flange
Propeller shaft support mounting cap screw Tighten them
loose
Lubricant loss at joint This may be due to worn out joint seal, worn Replace the joint seal and place bearing
out universal joint cross as well as bearing properly on yoke or flange seat
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Index
Power coupling - 19
Drive shaft - 100

Drive shaft - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive shaft - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive shaft from transmission to front axle - Assemble - Front propeller shaft . . . . . . . . . . . . . . . . . . . 9
Drive shaft from transmission to front axle - Disassemble - Front propeller shaft . . . . . . . . . . . . . . . . 8
Drive shaft from transmission to rear axle - Assemble - Rear propeller shaft . . . . . . . . . . . . . . . . . . . 6
Drive shaft from transmission to rear axle - Disassemble - Rear propeller shaft . . . . . . . . . . . . . . . . . 5
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Transmission
851FX Plus
851FX
91715732 26/07/2021
21
Contents
Transmission - 21
[21.100] Mechanical transmission hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2
[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
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Transmission - 21
Mechanical transmission hydraulic components - 100
851FX Plus
851FX
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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission oil filter

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - Mechanical transmission hydraulic components
Transmission oil filter - Exploded view
PTIL13TLB1552FB 1
1. Oil filter 4. Cover

2. Screen 5. Bolts
3. O-ring 6. Transmission assembly.
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Index
Transmission - 21

Transmission oil filter - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - 21
Power shuttle transmission - 112
851FX Plus
851FX
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Contents
Transmission - 21
TECHNICAL DATA
Power shuttle transmission

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speeds - Stall test check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Speeds - Stall test check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUNCTIONAL DATA

Exploded view - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view - Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission housing
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassemble - Plugs and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble - Plugs and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassemble - Oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assemble - Oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pressure test - 4 wheel drive, test one - Engine at idle 900 to 1100 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pressure test - 4 wheel drive, test two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure test - 2 wheel drive, test one - Engine at Idle 900 to 1100 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pressure test - 2 wheel drive, test two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check - Checking supply pump pressure (4WD only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Test - Checking converter in pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test - Checking regulated clutch pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Test - Checking supply pump flow and relief pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test - Checking converter out pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Inspect - Checking lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Check - Pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Test - Stall test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check - Mechanical problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check - Hydraulic problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tool connection - Four wheel drive port identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Check - Electrical problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Tool connection - Two wheel drive port identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Transmission housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Oil drain plug
Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
DIAGNOSTIC

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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Transmission - Power shuttle transmission
Power shuttle transmission - General specification

570ST
Type of transmission oil MS-1209, Hy-Tran™ Ultra
Clutch disc clearance 2.3 – 4.3 mm (0.1 – 0.2 in)
Oil capacity - 2WD/2WS 16.00 l (4.23 US gal)
Oil capacity - 4WD/2WS 18.50 l (4.89 US gal)
Specifications 570ST ( 63 kW (86 Hp))

2WD/2WS
Model CARRARO 2WD TLB1
Type 4 forward and 4 reverse travel gears
Weight 105 kg (231 lb)
Torque converter ratio 3.01:1
1st gear forward travel 1:5.603 - 1st gear forward travel 6.2 km/h -
reverse travel 1:4.643 reverse travel 7.4 km/h
2nd gear forward travel 1:3.481 - 2nd gear forward travel 10 km/h -
reverse travel 1:2.884 reverse travel 12 km/h
Transmission ratios:
3rd gear forward travel 1:1.585 - 3rd gear forward travel 20.7 km/h -
reverse travel 1:1.313 reverse travel NR
4th gear forward travel 1:0.793 - 4th gear forward travel 39.2 km/h -
reverse travel 1:0.657 reverse travel NR
Suction strainer 250 µm
Filter capacity 10 µm
Filter type Spin-on
Oil capacity (System) 16 Liters (PSB-202)
Oil change period Every 1000 h
Filter Every 1000 h
4WD/2WS
Model CARRARO 4WD TLB1
Type 4 forward and 4 reverse travel gears
Torque converter ratio 3.01:1
1st gear forward travel 1:5.603 - reverse travel 1:4.643
2nd gear forward travel 1:3.481 - reverse travel 1:2.884
Transmission ratios:
3rd gear forward travel 1:1.585 - reverse travel 1:1.313
4rd gear forward travel 1:0.793 - reverse travel 1:0.657
Rear axle model Carraro 28.3 M

Bevel gear ratio 2.467:1
Epycylic gear ratio 6.923:1
Total gear ratio 17.077:1
Front axle
2WD CNH PS 1300
4WD Carraro 26.17
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 h. Your
figures may differ slightly depending upon the temperature, instrument variables, engine hours, etc.
570ST
Parameter Operating pressure/temperature
Output of pump supply 32 – 68 l/min (8.5 – 18.0 US gpm) at 900 – 2200 RPM
Pump supply pressure (4WD) 1248 – 1551 kPa (181 – 225 psi) at 900 – 2200 RPM
Regulated clutch pressure 1103 – 1303 kPa (160 – 189 psi) at 900 – 2200 RPM
Torque pressure IN pressure 48 – 903 kPa (7 – 131 psi) at 900 – 2200 RPM
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Parameter Operating pressure/temperature

Torque converter OUT pressure 0 – 427 kPa (0 – 62 psi) at 900 – 2200 RPM
Lubrication pressure 40 – 303 kPa (6 – 44 psi)at 900 – 2200 RPM
Transmission oil operating temperature (normal) 78 – 82 °C (172 – 180 °F)
Flow rating 60 L/min

Element rating (capacity) 10 µm
By pass setting minimum 2.5±0.03 bar
Service cycle every 1000 h (both oil and filter)
Power shuttle transmission - Special tools

ATTENTION: Operations described in this section of the manual must be performed using the following tools to work
safely and achieve the best technical results.
380040161 Teflon seal installation
RCPH10TLB828AAL 1
380002211 Handle
PTIL13TLB0431AA 2
380200403 Driver
PTIL13TLB0432AA 3
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380200404 Driver
PTIL13TLB0433AA 4
380200405 Driver
PTIL13TLB0434AA 5
380200406 Gauger
PTIL13TLB0435AA 6
380200414 Clutch assembly/disassembly
PTIL13TLB0436AA 7
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380200407 Driver
PTIL13TLB0437AA 8
380200408 Protection shims
PTIL13TLB0438AA 9
380200409 Pusher
PTIL13TLB0439AA 10
380001926 Protection
PTIL13TLB0440AA 11
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380200410 Driver
PTIL13TLB0441AA 12
380200411 Driver
PTIL13TLB0442AA 13
380001933 Protection shims
PTIL13TLB0443AA 14
380001927 Gauger
PTIL13TLB0444AA 15
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380001928 Pusher
PTIL13TLB0445AA 16
380200412 C shaft hook
PTIL13TLB0446AA 17
380200413 Protection
PTIL14TLB0100AA 18
Power shuttle transmission - Speeds - Stall test check sheet

Check sheet
Results from stall test procedure (fill in the values accordingly)
ID RPM Test Value Stall test component (specified value)
1 Loader hydraulic stall speed ( 2200 – 2325 RPM)
2 Backhoe hydraulic stall speed ( 2200 – 2325 RPM)
3 Torque converter stall speed ( 2000 – 2150 RPM)
Combined - loader hydraulic and torque converter - stall speed ( 1680 –
4
1850 RPM)
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Power shuttle transmission - Speeds - Stall test check sheet

Check sheet
Results from stall test procedure (fill in the values accordingly)
ID RPM Test Value Stall test component (specified value)
1 Loader hydraulic stall speed ( 2225 – 2325 RPM)
2 Backhoe hydraulic stall speed ( 1290 – 1360 RPM)
3 Torque converter stall speed ( 2000 – 2150 RPM)
Combined - loader hydraulic and torque converter - stall speed ( 1350 –
4
1550 RPM)
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Power shuttle transmission - Exploded view - Oil pump
PTIL13TLB0211FB 1
1. Screw 3. O-ring
2. Oil pump 4. Seal ring
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Power shuttle transmission - Exploded view - Pipes
PTIL13TLB0223FB 1
1. Screw 3. Pipe
2. Screw 4. Gasket
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Transmission housing - Exploded view
PTIL13TLB0255FB 1
NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Snap ring 18. Ball

2. Flange retaining screw 19. Bolt
4. Flange 21. Spring
5. O-ring 22. Ball
6. Cap screw 23. Snap ring
7. Shift tower assy 24. Shaft
8. O-ring 25. Snap ring
9. Cap screw 26. Snap ring
10. Rear cover 27. Bearing
11. Cap screw 28. Bolt
12. O-ring 30. Front housing
13. Seal 31. Bearing
14. Pin 32. Bearing
15. Detent 33. Dowel
16. Screw 34. Centering pins
17. Bracket
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Power shuttle transmission - Remove

Prior operation:
Basic instructions
Prior operation:
Rear wheels - Remove (44.520)
Prior operation:
Fuel tank - Remove (10.216)
Prior operation:
Pump - Remove (35.104)
1. Position machine on a flat surface high enough to allow

transmission removal.
2. Remove front drive shaft guard. (Applicable for 4WD
only).
RCPH11TLB001AAL 1
RCPH11TLB002AAL 2
3. Remove front drive shaft hardware.
RCPH11TLB003AAL 3
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4. Remove shaft from yoke.
RCPH11TLB004AAL 4
5. Remove front drive shaft.
RCPH11TLB005AAL 5
6. Remove plug and drain transmission oil. Install plug

into transmission after all of the oil has drained.
RCPH11TLB006AAL 6
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7. Identify, tag and disconnect the transmission cooler

lines.
RCPH11TLB007AAL 7
RCPH11TLB008AAL 8
8. Disconnect the transmission control valve connection.
RCPH11TLB009AAL 9
9. Remove control valve connection bracket.
RCPH11TLB010AAL 10
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10. Remove oil level tube.
RCPH11TLB013AAL 11
11. Disconnect oil the temperature sensor.
RCPH11TLB014AAL 12
12. Disconnect blue wire at switch (left hand rear of trans-

mission).
RCPH11TLB015AAL 13
13. Disconnect black and white wire at switch (left hand

rear top of transmission).
RCPH11TLB016AAL 14
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14. Plug and cap all open ports.
RCPH11TLB018AAL 15
15. Disconnect starter ground and positive battery con-

nections.
RCPH11TLB051AAM 16
16. Remove the starter.

17. Disconnect the ignition connection.
RCPH11TLB052AAM 17
18. Remove the access cover.
RCPH11TLB019AAL 18
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19. Rotate engine to access flywheel hardware.
RCPH11TLB062AAM 19
20. Rotate the engine to remove the flywheel to flex plate

hardware.
RCPH11TLB055AAM 20
21. Use an appropriate lifting device to support engine.
PTIL12TLB0558AB 21
22. Support the transmission.
PTIL13TLB1556AB 22
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23. Remove the engine to transmission hardware.
RCPH11TLB058AAM 23
24. Remove the right hand and left hand transmission

mount hardware.
RCPH11TLB022AAL 24
25. Disconnect hydraulic reservoir hoses.
RCPH11TLB023AAL 25
26. Carefully remove the transmission.
PTIL13TLB1557AB 26
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Power shuttle transmission - Install

1. Move the transmission under the machine and raise it
into place.
PTIL13TLB1557AB 1
2. Connect the hydraulic reservoir hoses.
RCPH11TLB023AAL 2
3. Install the right hand and left hand transmission mount

hardware.
RCPH11TLB022AAL 3
4. Remove the transmission support.
PTIL13TLB1556AB 4
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5. Remove engine supports.
PTIL12TLB0558AB 5
6. Remove the access cover.
RCPH11TLB019AAL 6
7. Rotate the engine to access the flywheel mounting

holes.
RCPH11TLB062AAM 7
8. Install the flywheel flex plate hardware.

9. Reconnect the ignition connection on the starter.
RCPH11TLB055AAM 8
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10. Reinstall starter.
RCPH11TLB052AAM 9
11. Connect the starter ground and positive battery con-

nections.
RCPH11TLB051AAM 10
12. Connect the black and white wire at the switch (left
hand rear top of transmission).
RCPH11TLB016AAL 11
13. Connect the blue wire at the switch (left hand rear of
transmission).
RCPH11TLB015AAL 12
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14. Connect the oil temperature sensor.
RCPH11TLB014AAL 13
15. Install the oil level tube.
RCPH11TLB013AAL 14
16. Install control valve connection bracket.
RCPH11TLB010AAL 15
17. Reconnect the transmission control valve connection.
RCPH11TLB009AAL 16
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18. Reconnect the transmission cooler lines.
RCPH11TLB007AAL 17
RCPH11TLB008AAL 18
19. Install front drive shaft.
RCPH11TLB005AAL 19
20. Install shaft to the yoke.
RCPH11TLB004AAL 20
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21. Install front drive shaft hardware.
RCPH11TLB003AAL 21
22. Install front drive shaft guard.

23. Install wheels. Remove supports and lower machine.
NOTICE: Before staring the engine do the following.
24. Make sure the transmission drain plug has been in-
stalled and tightened.
25. Fill the transmission oil, see Power shuttle transmis-
sion - General specification (21.112).
NOTE: If removed, install the rear wheels.
26. Remove the stands from under the machine and lower
the machine to the floor. RCPH11TLB001AAL 22
27. With the machine parked on level ground and the en-
gine running at low idle, check the transmission oil
level. The oil level must be between the ADD and the
FULL marks on the dipstick. If the oil level is at the
ADD mark, add oil as required until the oil level is at
the FULL mark.
RCPH11TLB002AAL 23
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Power shuttle transmission - Disassemble - Plugs and filters

1. Remove screws (1).
NOTICE: Mark the pump position with respect to the bell
housing before untightening the screws.
PTIL13TLB0212AB 1
2. Remove the pump by means of two levers.
PTIL13TLB0213AA 2
3. Remove the oil pump (2).

NOTICE: Oil pump seal ring can be damaged during this
operation.
PTIL13TLB0214AB 3
4. If replacement is necessary, remove O-ring (3).

NOTICE: Do not open/disassemble the pump or its oper-
ation may be compromised. Special tools from the manu-
facturer are required for reassembly.
PTIL13TLB0215AB 4
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5. If replacement is necessary, remove seal ring (4).
PTIL13TLB0216AB 5
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Power shuttle transmission - Assemble - Plugs and filters

1. Assemble seal ring (4) on oil pump (2).
PTIL13TLB0217AB 1
2. Fit O-ring (3). Inspect the O-ring before assembly.

NOTICE: Before oil pump assembly (if new), check that oil
passage holes between pump and half-case or the visual
marks coincide.
PTIL13TLB0218AB 2
PTIL13TLB0219AB 3
3. Grease the ring to keep it centred/coaxial with respect

to the shaft slot centre line and to make the introduction
onto the pump easier.
PTIL13TLB0220AA 4
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4. Apply a thin film of grease on the coupling seat with the

front half-case.
Assemble the oil pump (2).
PTIL13TLB0221AB 5
5. Fit screws (1).

NOTICE: Carefully check that marks on the oil pump and
on the bell housing coincide.
PTIL13TLB0222AB 6
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Power shuttle transmission - Disassemble - Oil lines

1. Drain oil from transmission hydraulic circuit, and re-
move screws (1) and (2). Remove pipe (3). Collect
gaskets (4).
PTIL13TLB0224AB 1
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Power shuttle transmission - Assemble - Oil lines

Assemble pipe (3), bolts (1) and (2).
ATTENTION: Replace gaskets (4).
PTIL13TLB0224AB 1
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Power shuttle transmission - Pressure test - 4 wheel drive, test one

- Engine at idle 900 to 1100 rpm
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 h of engine,
your figures may differ slightly.
Test port Item Specifications - 4 wheel drive Actual

27 – 28 l/min (7.13 – 7.40 US gpm) at 1379 kPa
1 and 2 Supply pump flow (200 psi)
14 bar (203 psi) at 49 °C (120 °F)
2875 – 3137 kPa (417 – 455 psi)
1 and 2 Cold oil bypass
29.3 – 32 bar (425 – 464 psi) at 49 °C (120 °F)
Forward
1393 – 1427 kPa (202 – 207 psi)
9 Pump supply pressure
14.2 – 14.6 bar (206 – 212 psi)
1276 – 1317 kPa (185 – 191 psi)
4 Regulated clutch pressure
13 – 13.4 bar (188 – 194 psi)
545 – 607 kPa (79 – 88 psi)
6 Torque converter IN
5.6 – 6.2 bar (81 – 90 psi)
393 – 414 kPa (57 – 60 psi)
7 Torque converter OUT
4 – 4.2 bar (58 – 61 psi)
269 – 283 kPa (39 – 41 psi)
8 Lubrication pressure
2.7 – 2.9 bar (39 – 42 psi)
Neutral
690 – 758 kPa (100 – 110 psi)
7 – 17.7 bar (102 – 257 psi)
517 – 579 kPa (75 – 84 psi)
5.3 – 5.9 bar (77 – 86 psi)
414 – 427 kPa (60 – 62 psi)
4.2 – 4.4 bar (61 – 64 psi)
352 – 365 kPa (51 – 53 psi)
3.4 – 3.7 bar (49 – 54 psi)
Reverse
1400 – 1434 kPa (203 – 208 psi)
14.2 – 14.6 bar (206 – 212 psi)
1276 – 1317 kPa (185 – 191 psi)
13 – 13.4 bar (188 – 194 psi)
517 – 565 kPa (75 – 82 psi)
6 Torque converted IN
5.3 – 5.8 bar (77 – 84 psi)
331 – 345 kPa (48 – 50 psi)
3.4 – 3.5 bar (50 – 51 psi)
214 – 228 kPa (31 – 33 psi)
2.2 – 2.3 bar (32 – 33 psi)
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Power shuttle transmission - Pressure test - 4 wheel drive, test

two - Engine at 2200 rpm
62 – 70 l/min (16.4 – 18 US gpm) at 1379 kPa
14 bar (203 psi) at 49 °C (120 °F)
3034 – 3310 kPa (440 – 480 psi)
30.9 – 33.7 bar (448 – 489 psi) at 49 °C (120 °F)
Forward
1586 – 1655 kPa (230 – 240 psi)
16.2 – 16.9 bar (235 – 245 psi)
1276 – 1317 kPa (185 – 191 psi)
13 – 14.1 bar (188 – 204 psi)
827 – 965 kPa (120 – 140 psi)
8.4 – 9.8 bar (122 – 142 psi)
434 – 455 kPa (63 – 66 psi)
4.4 – 4.6 bar (64 – 67 psi)
290 – 303 kPa (42 – 44 psi)
3 – 3.1 bar (44 – 45 psi)
Neutral
1407 – 1462 kPa (204 – 212 psi)
14.4 – 14.9 bar (209 – 216 psi)
724 – 862 kPa (105 – 125 psi)
7.4 – 8.8 bar (107 – 128 psi)
483 – 503 kPa (70 – 73 psi)
4.9 – 5.3 bar (71 – 77 psi)
414 – 434 kPa (60 – 63 psi)
4.2 – 4.4 bar (61 – 64 psi)
Reverse
1585 – 1627 kPa (230 – 236 psi)
15.9 – 16.6 bar (231 – 241 psi)
1276 – 1379 kPa (185 – 200 psi)
13 – 14.1 bar (188 – 204 psi)
827 – 965 kPa (120 – 140 psi)
8.4 – 9.8 bar (122 – 142 psi)
339 – 414 kPa (49 – 60 psi)
4 – 4.2 bar (58 – 61 psi)
241 – 255 kPa (35 – 37 psi)
2.5 – 2.6 bar (36 – 38 psi)
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Power shuttle transmission - Pressure test - 2 wheel drive, test one

- Engine at Idle 900 to 1100 rpm
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 h of engine,
your figures may differ slightly.

27 – 28 l/min (7.13 – 7.40 US gpm) at 1379 kPa
14 bar (203 psi) at 49 °C (120 °F)
2875 – 3137 kPa (417 – 455 psi)
29.3 – 32 bar (425 – 464 psi) at 49 °C (120 °F)
Forward
1393 – 1427 kPa (202 – 207 psi)
14.2 – 14.6 bar (206 – 212 psi)
1276 – 1317 kPa (185 – 191 psi)
13 – 13.4 bar (188 – 194 psi)
545 – 607 kPa (79 – 88 psi)
5.6 – 6.2 bar (81 – 90 psi)
393 – 414 kPa (57 – 60 psi)
4 – 4.2 bar (58 – 61 psi)
269 – 283 kPa (39 – 41 psi)
2.7 – 2.9 bar (39 – 42 psi)
Neutral
690 – 758 kPa (100 – 110 psi)
7 – 17.7 bar (102 – 257 psi)
517 – 579 kPa (75 – 84 psi)
5.3 – 5.9 bar (77 – 86 psi)
414 – 427 kPa (60 – 62 psi)
4.2 – 4.4 bar (61 – 64 psi)
352 – 365 kPa (51 – 53 psi)
3.4 – 3.7 bar (49 – 54 psi)
Reverse
1400 – 1434 kPa (203 – 208 psi)
14.2 – 14.6 bar (206 – 212 psi)
1276 – 1317 kPa (185 – 191 psi)
13 – 13.4 bar (188 – 194 psi)
517 – 565 kPa (75 – 82 psi)
5.3 – 5.8 bar (77 – 84 psi)
331 – 345 kPa (48 – 50 psi)
3.4 – 3.5 bar (50 – 51 psi)
214 – 228 kPa (31 – 33 psi)
2.2 – 2.3 bar (32 – 33 psi)
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Power shuttle transmission - Pressure test - 2 wheel drive, test

two - Engine at 2200 rpm
62 – 70 l/min (16.4 – 18 US gpm) at 1379 kPa
14 bar (203 psi) at 49 °C (120 °F)
3034 – 3310 kPa (440 – 480 psi)
30.9 – 33.7 bar (448 – 489 psi) at 49 °C (120 °F)
Forward
1586 – 1655 kPa (230 – 240 psi)
16.2 – 16.9 bar (235 – 245 psi)
1276 – 1317 kPa (185 – 191 psi)
13 – 14.1 bar (188 – 204 psi)
827 – 965 kPa (120 – 140 psi)
8.4 – 9.8 bar (122 – 142 psi)
434 – 455 kPa (63 – 66 psi)
4.4 – 4.6 bar (64 – 67 psi)
290 – 303 kPa (42 – 44 psi)
3 – 3.1 bar (44 – 45 psi)
Neutral
862 – 965 kPa (125 – 140 psi)
8.8 – 9.8 bar (128 – 142 psi)
724 – 862 kPa (105 – 125 psi)
7.4 – 8.8 bar (107 – 128 psi)
483 – 503 kPa (70 – 73 psi)
4.9 – 5.3 bar (71 – 77 psi)
414 – 434 kPa (60 – 63 psi)
4.2 – 4.4 bar (61 – 64 psi)
Reverse
1585 – 1627 kPa (230 – 236 psi)
15.9 – 16.6 bar (231 – 241 psi)
1276 – 1379 kPa (185 – 200 psi)
13 – 14.1 bar (188 – 204 psi)
827 – 965 kPa (120 – 140 psi)
8.4 – 9.8 bar (122 – 142 psi)
339 – 414 kPa (49 – 60 psi)
4 – 4.2 bar (58 – 61 psi)
241 – 255 kPa (35 – 37 psi)
2.5 – 2.6 bar (36 – 38 psi)
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Power shuttle transmission - Check - Checking supply pump

pressure (4WD only)
NOTE: See Power shuttle transmission - Tool connec-
tion - Two wheel drive port identification (21.112) for
port identification.
NOTE: Two wheel drive machines can only be tested by
performing a flow meter test.
2. Start the engine. The oil should be at normal operating
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 10 (A),
see Power shuttle transmission - Tool connection -
Four wheel drive port identification (21.112).
4. Monitor the gauge and record the values for low idle,
see Power shuttle transmission - Pressure test - 4
wheel drive, test one - Engine at idle 900 to 1100
rpm (21.112).
5. Monitor the gauge and record the values for full throttle,
RCPH11TLB014BAL 1
wheel drive, test two - Engine at 2200 rpm (21.112).
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Power shuttle transmission - Test - Checking converter in pressure

tion - Two wheel drive port identification (21.112) or
Power shuttle transmission - Tool connection - Two
wheel drive port identification (21.112) for test port lo-
cations.
temperatures.
3. Connect a 14 bar (200 psi) to test port 6 (A) for 2WD
or 4WD machines.
4. Place transmission controls in neutral.
wheel drive, test one - Engine at Idle 900 to 1100
rpm (21.112) or Power shuttle transmission - Pres-
sure test - 4 wheel drive, test one - Engine at idle
900 to 1100 rpm (21.112). RCPH11TLB015BAL 1
wheel drive, test two - Engine at 2200 rpm (21.112)
or Power shuttle transmission - Pressure test - 4
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Power shuttle transmission - Test - Checking regulated clutch

pressure
cations.
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 3 (A).
4. Move the direction control lever to forward.
900 to 1100 rpm (21.112).
1
6. Monitor the gauge and record the values for full throttle, RCPH11TLB016BAL

7. Repeat Steps 5 and 6 with the control lever in reverse.
NOTE: Forward and reverse clutch pressure can be
recorded separately using test port 5 (C) for Forward and
test port 4 (B) for Reverse.
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Power shuttle transmission - Test - Checking supply pump flow

and relief pressure
cations.
1. Verify that all test equipment is clean.
temperatures.
4. Connect flowmeter and adapter to the transmission fil-
ter base at test port 1 (A) and test port 2 (B). Open the
load valve on the flowmeter.
5. Move the transmission control into neutral.
RCPH11TLB017BAL 1
900 to 1100 rpm (21.112).
8. At full throttle, close the load valve until the flow
drops. Read and record the pressure at which the flow
dropped.
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Power shuttle transmission - Test - Checking converter out

pressure
cations.
temperatures.
3. Connect a 20 bar (200 psi) to the service tee on test
port 8 (A).
4. Place the transmission in the neutral position.
900 to 1100 rpm (21.112). RCPH11TLB018BAL 1
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Power shuttle transmission - Inspect - Checking lubrication

pressure
cations.
temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 9 (A).
4. Place the transmission in neutral.
900 to 1100 rpm (21.112).
1
6. Monitor the gauge and record the values for full throttle, RCPH11TLB019BAL

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Power shuttle transmission - Service instruction

1. This list of possible failures and remedies provides no
more than an indication of what the problem might be
and how to fix it.
2. It should be remembered that problems are not caused
by just one part, but by that part’s interaction with other
elements accordingly, additional action over and above
the steps described is frequently required.
3. This list may not cover all possible problems and reme-
dies.
4. Specialist personnel must identify the problem and its
cause and then proceed with the necessary repairs.
NOTICE: All checks and tests must be performed with the
oil at working temperature: 78 – 82 °C (172 – 180 °F).
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Power shuttle transmission - Check

Always check the correct oil level and correct oil speci-
fications.
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Power shuttle transmission - Check - Pressure check

Several transmission breakdowns can be identified
by running pressure checks. Irregular measurements
might indicate that there is a problem, which specialist
personnel must identify.
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Power shuttle transmission - Test - Stall test

Do the stall test to find the cause of poor performance.
The main relief valve must be set within specifications
to achieve accurate readings when performing the fol-
lowing stall tests.
The engine is run at full throttle and the transmission
and hydraulic systems are engaged separately, and
then together.
Comparing the engine speeds from the stall test with
the check sheet will help to find the cause of the prob-
lem. (Refer to Power shuttle transmission - Speeds
- Stall test check sheet (21.112)). It can be necessary
to check a separate system to find the exact cause of
the problem.
Use a photo tachometer or other tachometer of equal
accuracy to get accurate results from the stall test.
The engine, transmission and hydraulic system must
be at operating temperature before doing the stall test.
Heat the oil according to instructions in this section.
Preparation for stall test

1. Apply the parking brake.
2. Move the transmission gear selector into fourth gear.
3. Lock the brake pedals together. Put your foot on the
service brakes and hold the machine with service
brakes.
4. Release the parking brake.
5. With the engine running at low idle, move the direction
control lever forward.
6. Slowly increase the engine speed to full throttle.
7. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine.
Procedure to heat torque converter and hydraulic oil

2. Start and run the engine at low idle.
3. Run the engine at full throttle, hold the loader control
lever in the rollback position for 15 s.
4. Return the loader control lever to neutral for 15 s.
5. Return the boom control lever to neutral for 15 s.
6. Repeat steps 4 and 5 until the temperature of the oil
is 52 °C (126 °F). The side of the reservoir will be very
warm at this temperature.
7. With the engine running at low idle, move the trans-
mission control to fourth gear and the direction control
lever to forward.
8. Run the engine at full throttle for 15 s.
9. Decrease the engine speed to low idle and move the
direction control lever to neutral for 15 s.
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10. Repeat steps 6 through 8 until the pointer in the gauge

for transmission oil temperature is in the center of the
green zone of the gauge for transmission oil temper-
ature.
Stall test procedure

1. Prepare the machine for the stall test according to in-
structions in this section.
2. Heat the oil according to instructions in this section.
3. Apply the parking brake and start the engine.
4. With the engine running at full throttle, hold the loader
control lever in the lift position and read the tachometer.
Record the reading on line 1 of the check sheet. (Refer
to Power shuttle transmission - Speeds - Stall test
check sheet (21.112)).
5. With the engine running at full throttle and boom in
travel lock, hold the dipper lever in the in position and
read the tachometer. Record the reading on line 2 of
the check sheet. (Refer to Power shuttle transmis-
sion - Speeds - Stall test check sheet (21.112)).
6. Decrease the engine speed to low idle.
7. Move the transmission control lever to fourth gear.
8. Lock the brake pedals together. Put your foot on the
service brakes and hold the machine with service
brakes.
9. Release the parking brake.
10. Move the direction control lever to forward.
11. Slowly increase the engine speed to full throttle and
read the tachometer. Record the reading on line 3 on
the check sheet. (Refer to Power shuttle transmis-
sion - Speeds - Stall test check sheet (21.112)).
12. With the transmission control lever in fourth gear, the
direction control lever in forward, and the engine run-
ning at full throttle, hold the loader control lever in the
lift position and read the tachometer. Record the read-
ing on line 4 on the check sheet. (Refer to Power
shuttle transmission - Speeds - Stall test check
sheet (21.112)).
13. Decrease the engine speed to low idle, move the di-
rectional control lever to neutral.
14. Run the engine at low idle for 2 min and then stop the
engine.
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Power shuttle transmission - Check - Mechanical problems

1. Check that all of the transmission’s internal and exter-
nal mechanical parts are correctly fitted (see Power
shuttle transmission - Install (21.112) and Power
shuttle transmission - Remove (21.112)).
2. Check that the cooling system is in good operating con-
dition.
3. Check the efficiency of the engine. Make sure that
the engine’s idling speed is set correctly and that it
complies with the maximum speed specifications un-
der load less conditions.
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Power shuttle transmission - Check - Hydraulic problems

1. Check the transmission oil level.
2. Use the specified oils.
3. Check that the hydraulic system is correctly filled.
4. Check the efficiency of the hydraulic system. Check for
oil leaks.
5. Check the efficiency of the transmission’s hydraulic
components (converter, oil pump, filter, connections,
hoses).
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Power shuttle transmission - Tool connection - Four wheel drive

port identification
PTPH12TLB0507GB 1
1 Flow meter adapter from charge pump to flow meter. Connect the flow meter.
2 Return from flow meter to transmission
3 Regulated clutch pressure, common to forward and reverse.
4 Regulated reverse clutch pressure.
5 Regulated forward clutch pressure.
6 Torque Converter IN pressure.
7 Converter out to cooler.
8 Lubrication pressure, common to converter return.
9 Pump supply pressure, 4 wheel drive only.
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Power shuttle transmission - Check - Electrical problems

1. Check the efficiency and correct installation of the ve-
hicle battery.
2. Check the efficiency and correct installation of all elec-
trical components outside the transmission (wiring, ca-
bles, alternator, battery, etc.).
3. Check the efficiency and correct installation of all trans-
mission electrical components (wiring, sensors, sole-
noid valves, etc.).
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Power shuttle transmission - Tool connection - Two wheel drive

port identification
PTPH12TLB0506AB 1
Flow meter adapter from charge pump to flow meter. Connect the flow meter. Pump supply pressure on 2
1
wheel drive units can only be taken with a flow meter connected to ports 1 and 2
2 Return from flow meter to transmission
3 Regulated clutch pressure, common to forward and reverse.
4 Regulated reverse clutch pressure.
5 Regulated forward clutch pressure.
6 Torque Converter IN pressure.
7 Converter out to cooler.
8 Lubrication pressure, common to converter return.
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Transmission housing - Disassemble

1. Remove bearing snap ring (1).
PTIL13TLB0256AB 1
2. Untighten and remove flange retaining screw (2). Use

a screwdriver and two screws to avoid flange rotation.
PTIL13TLB0257AB 2
3. Remove washer (3).
PTIL13TLB0258AB 3
4. Remove flange (4) and O-ring (5).
PTIL13TLB0259AB 4
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5. Remove the three cap screws (6).
PTIL13TLB0260AB 5
6. Remove the shift tower assembly (7) and the O-ring (8).
PTIL13TLB0261AB 6
7. Remove the O-ring (12).

Remove the six cap screws (9) and the two capscrews
(11) which fasten the rear cover (10) to the rear half
housing.
PTIL13TLB0262AB 7
8. Use a pry bar to loosen the rear cover from the housing.
Remove the rear cover (10).
PTIL13TLB0263AB 8
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9. Remove the seal (13) from the rear cover.
PTIL13TLB0264AB 9
10. Use a punch to remove the pins (14) which fasten the
shift collars to the shift rods and centering pins (34).
NOTE: If the bearing is not very tight on the secondary
shaft, part could fall from the shaft when its is removed
from the rear housing. To prevent this a hose clamp can
be installed on the output end of the secondary shaft. This
will keep the bearing in position during remove of the shaft.
PTIL13TLB0265AB 10
11. Remove all of the housing bolts that are fastened from
the rear housing to the front housing. There are 13
of these bolts on the four-wheel drive and 14 on the
two-wheel drive. On the two-wheel drive, two of the
bolts are longer than the others. Record the locations
of these two.
RCPH10TLB704AAL 11
12. Rotate the transmission so that the front housing is

up. On four-wheel drive transmissions only, there are
three bolts fastened from the front housing to the rear
housing. Remove these bolts.
NOTE: Steps 13 through 20 are for four-wheel drive trans-
missions only. If you are working on a two-wheel drive
transmission, go to Step 21.
RCPH10TLB717AAL 12
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13. Install two bolts in the four-wheel drive flange as

shown. Use a pry bar between the two bolts to hold
the four-wheel drive flange while you remove the bolt
from the four-wheel drive shaft.
RCPH10TLB906AAL 13
14. Remove the washer.
RCPH10TLB705AAL 14
15. Remove the four-wheel drive flange.
RCPH10TLB706AAL 15
16. Remove the O-ring from the four-wheel drive flange.
RCPH10TLB707AAL 16
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17. Remove the three bolts that fasten the cover to the
front housing.
RCPH10TLB708AAL 17
18. Remove the cover.
RCPH10TLB710AAL 18
19. Remove the O-ring from the cover.
RCPH10TLB711AAL 19
20. Remove the seal from the cover.
RCPH10TLB020ABL 20
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21. Make a mark across the joint between the oil pump
and the torque converter housing so that the oil pump
can be aligned the same way during installation.
RCPH10TLB866AAL 21
22. Remove the six bolts that fasten the oil pump in posi-
tion.
RCPH10TLB867AAL 22
23. Use two pry bars to lift the oil pump evenly until the oil
pump can be removed.
RCPH10TLB713AAL 23
24. Remove the oil pump.
RCPH10TLB714AAL 24
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25. Pull up the input shaft to get clearance as you release

the snap ring.
RCPH10TLB715AAL 25
26. Remove the snap ring.
RCPH10TLB716AAL 26
27. Fasten acceptable lifting equipment to the front hous-

ing as shown. Use pry bars at both ends of the hous-
ings to separate the front housing from the rear hous-
ing.
RCPH10TLB718AAL 27
28. As you lift the front housing, continue to use the pry bar
to make sure that the front housing comes up evenly.
Also, it will probably be necessary to hit the end of
the four-wheel drive shaft, if so equipped, and the end
of the input shaft with a soft hammer so that the two
shafts come down out of the front housing and stay
with the rear housing.
NOTE: The bearings in Steps 29 and 36 are a close slip fit.
If a bearing is difficult to remove, the bearing is probably
not straight in the bore or on the shaft. Push the bearing
back into the installed position and try again.
RCPH10TLB910AAL 28
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29. The bearing for the primary shaft and the bearing for
the secondary shaft can stay with either the shafts or
the front housing. Remove the two bearings.
RCPH10TLB720AAL 29
30. On machines with four-wheel drive, remove the four-

wheel drive shaft bearing from the front housing.
RCPH10TLB911AAL 30
31. Remove the tube from the front housing only if the
tube is damaged or leaking.
RCPH10TLB027ABL 31

wheel drive shaft.
RCPH10TLB720AAL 32
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33. Remove the input shaft and the reverse shaft together.
NOTE: Make a mark on the top end of the reverse shaft so
that you can install the reverse shaft with the same end up
during assembly.
RCPH10TLB921AAL 33
34. Rotate the rear housing so that the open side is up.
Connect acceptable lifting equipment to the top gear
on the secondary shaft.
RCPH10TLB912AAL 34
35. Use a puller to begin lifting the secondary shaft while

you use your hands to lift the primary shaft. At the
same time, move the primary shaft back and forth to
keep the primary shaft moving freely. It may be nec-
essary to tap the ends of the shift rods (from below the
rear housing) so that the shift rod and fork assemblies
continue to move freely.
When the primary shaft is free of the rear housing and
the secondary shaft, remove the primary shaft.
RCPH10TLB913AAL 35
36. Continue to lift the secondary shaft until you can move
the secondary shaft out of the shift forks. Then re-
move the secondary shaft.
RCPH10TLB914AAL 36
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37. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
RCPH10TLB915AAL 37
38. Remove the shift rod and fork assembly for third and
fourth gear from the rear housing. Remember that this
assembly was installed in the bore nearer the top of
the rear housing.
NOTE: Steps 39 and 40 are for four-wheel drive transmis-
sions only. If you are working on a two-wheel drive trans-
mission, go to Step 41.
RCPH10TLB916AAL 38
39. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 39
40. Remove the bearing.
RCPH10TLB917AAL 40
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41. It is not necessary to remove the test port plugs (1), the
breather (2), or the temperature sender (3) from the
rear housing unless these parts are leaking or dam-
aged.
RCPH10TLB918AAL 41
42. Inspect the input shaft bore in the rear housing. If

there are grooves from the sealing rings, you must use
new rear housing. Remove any sharp edges at the
ends of the input shaft bore and at the oil distribution
holes.
Remove the four-wheel drive clutch tube (four-wheel
drive machines only) from the front housing only if the
front housing must be replaced or if the tube is leaking
or damaged.
RCPH10TLB023ABL 42
43. Remove the three Allen head bolts that fasten the
valve plate to the front housing.
RCPH10TLB025ABL 43
44. Remove the valve plate from the front housing.
RCPH10TLB024ABL 44
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45. Remove the gasket.
RCPH10TLB026ABL 45
46. Remove snap ring (26).
PTIL13TLB0276AB 46
47. Extract bearing (27) with tool.
PTIL13TLB0277AB 47
48. Remove all of the housing bolts that are fastened from
the rear housing to the front housing. There are 13
of these bolts on the four-wheel drive and 14 on the
two-wheel drive. On the two-wheel drive, two of the
bolts are longer than the others. Record the locations
of these two.
RCPH10TLB704AAL 48
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49. Rotate the transmission so that the front housing is

up. On four-wheel drive transmissions only, there are
three bolts fastened from the front housing to the rear
housing. Remove these bolts.
RCPH10TLB717AAL 49
50. Install two bolts in the four-wheel drive flange as

shown. Use a pry bar between the two bolts to hold
the four-wheel drive flange while you remove the bolt
from the four-wheel drive shaft.
RCPH10TLB906AAL 50
51. Remove the washer.
RCPH10TLB705AAL 51
52. Remove the four-wheel drive flange.
RCPH10TLB706AAL 52
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53. Remove the O-ring from the four-wheel drive flange.
RCPH10TLB707AAL 53
54. Remove the three bolts that fasten the cover to the
front housing.
RCPH10TLB708AAL 54
55. Remove the cover.
RCPH10TLB710AAL 55
56. Remove the O-ring from the cover.
RCPH10TLB711AAL 56
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57. Remove the seal from the cover.
RCPH10TLB020ABL 57
58. Make a mark across the joint between the oil pump
and the torque converter housing so that the oil pump
can be aligned the same way during installation.
RCPH10TLB866AAL 58
59. Remove the six bolts that fasten the oil pump in posi-
tion.
RCPH10TLB867AAL 59
60. Use two pry bars to lift the oil pump evenly until the oil
pump can be removed.
RCPH10TLB713AAL 60
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61. Remove the oil pump.
RCPH10TLB714AAL 61
62. Pull up the input shaft to get clearance as you release

the snap ring.
RCPH10TLB715AAL 62
RCPH10TLB716AAL 63
64. Fasten acceptable lifting equipment to the front hous-

ing as shown. Use pry bars at both ends of the hous-
ings to separate the front housing from the rear hous-
ing
RCPH10TLB718AAL 64
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65. As you lift the front housing, continue to use the pry bar
to make sure that the front housing comes up evenly.
Also, it will probably be necessary to hit the end of
the four-wheel drive shaft, if so equipped, and the end
of the input shaft with a soft hammer so that the two
shafts come down out of the front housing and stay
with the rear housing.
NOTE: The bearings in Steps 66 and 67 are a close slip fit.
If a bearing is difficult to remove, the bearing is probably
not straight in the bore or on the shaft. Push the bearing
back into the installed position and try again.
RCPH10TLB910AAL 65
66. The bearing for the primary shaft and the bearing for
the secondary shaft can stay with either the shafts or
the front housing. Remove the two bearings.
RCPH10TLB720AAL 66

wheel drive shaft bearing from the front housing.
RCPH10TLB911AAL 67
68. Remove the tube from the front housing only if the
tube is damaged or leaking.
RCPH10TLB027ABL 68
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69. Remove the three O-rings from the flange of the rear
housing.
RCPH10TLB920AAL 69

wheel drive shaft.
RCPH10TLB720AAL 70
71. Remove the input shaft and the reverse shaft together.
NOTE: Make a mark on the top end of the reverse shaft so
that you can install the reverse shaft with the same end up
during assembly.
RCPH10TLB921AAL 71
72. Rotate the rear housing so that the open side is up.
Connect acceptable lifting equipment to the top gear
on the secondary shaft.
RCPH10TLB912AAL 72
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73. Use the lifting equipment to begin lifting the secondary

shaft while you use your hands to lift the primary shaft.
At the same time, move the primary shaft back and
forth to keep the primary shaft moving freely. It can be
necessary to tap the ends of the shift rods (from below
the rear housing) so that the shift rod and fork assem-
blies continue to move freely. When the primary shaft
is free of the rear housing and the secondary shaft,
remove the primary shaft.
RCPH10TLB913AAL 73
74. Continue to lift the secondary shaft until you can move
the secondary shaft out of the shift forks. Then re-
move the secondary shaft.
RCPH10TLB914AAL 74
75. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
RCPH10TLB915AAL 75
76. Remove the shift rod and fork assembly for third and
fourth gear from the rear housing. Remember that this
assembly was installed in the bore nearer the top of
the rear housing.
RCPH10TLB916AAL 76
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Transmission housing - Disassemble - Shifter housing

1. Use side cutters as shown to release the catch on the
band that fastens the boot to the shifter housing. Re-
move the band.
RCPH10TLB012ABL 1
2. Remove the boot from the shifter housing.
RCPH10TLB013ABL 2
3. Remove the two pins (one on either side of the shifter

housing). Use a screwdriver to lift each pin as shown
until you can reach the pin with your fingers. Then pull
the pin out.
RCPH10TLB013ABL 3
4. Remove the snap ring from the shift lever.
RCPH10TLB016ABL 4
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5. Remove the bushing from the shift lever.
RCPH10TLB019ABL 5
6. Remove the spring.
RCPH10TLB018ABL 6
7. Remove the shift lever from the shifter housing.
RCPH10TLB017ABL 7
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Transmission housing - Disassemble - Shift rods and shift forks

If disassembly is required, remove the roll pins and sep-
arate the shift forks from the shift rods. Make sure that
you remember how the parts are assembled and which
parts go together. The forks are the only parts that are
not interchangeable. Inspect all parts for burrs and ex-
cessive wear. Assembly is the reverse of disassembly.
RCPH10TLB944AAL 1
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Transmission housing - Assemble - Shifter housing

1. Apply lithium grease to the ball of the shift lever. Install
the shift lever in the shifter housing.
RCPH10TLB017ABL 1
2. The correct alignment of the shift lever and the shifter

housing is shown above. The slot (1) in the shift lever
must be toward the flat side (2) of the flange on the
shifter housing. The slots (3) on each side of the shift
lever must be aligned with the holes (4) in each side of
the shifter housing.
RCPH10TLB021ABL 2
3. Install the spring.
RCPH10TLB018ABL 3
4. Install the bushing.
RCPH10TLB019ABL 4
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5. Put the snap ring on the shift lever. Use a deep well
socket to push the snap ring into the snap ring groove.
RCPH10TLB015ABL 5
6. Install the pins through the holes in the shifter housing

so that the pins engage the slots in the shift lever.
RCPH10TLB013ABL 6
7. Install the boot so that the end of the boot fits over the
ends of the pins. Be careful so that the pins do not fall
out during this step.
RCPH10TLB013ABL 7
8. Install the band or clamp on the boot. Use the side

cutters to engage the catch on the band.
RCPH10TLB012ABL 8
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Transmission housing - Assemble

1. If the four-wheel drive clutch tube (four-wheel drive ma-
chine only) was removed from the front housing, install
the four-wheel drive clutch tube. Tighten the fittings to
a torque of 40 N·m (354 lb in).
RCPH10TLB023ABL 1
2. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the rear housing. Scrape all
sealing material from the sealing surface of the rear
housing. Prepare the sealing surface by rubbing with a
3M Scotch-Brite fiber pad or equivalent. DO NOT use
steel wool or anything that can leave material on the
sealing surface. Flush the rear housing with solvent.
RCPH10TLB028ABL 2
3. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the front housing. (The plugs
have not been installed in the picture above.) Scrape
all sealing material from the sealing surface of the front
housing. Prepare the sealing surface by rubbing with a
3M Scotch-Brite fiber pad or equivalent. DO NOT use
steel wool or anything that can leave material on the
sealing surface. Flush the front housing with solvent.
RCPH10TLB023ABL 3
4. Install the gasket for the valve plate on the front hous-
ing.
RCPH10TLB026ABL 4
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5. Put the valve plate into position.
RCPH10TLB024ABL 5
6. Install the three Allen head bolts to fasten the valve

plate to the front housing. Tighten the Allen head bolts
to a torque of 23 N·m (204 lb in).
RCPH10TLB025ABL 6
7. If the test port plugs (1), the breather (2), and the tem-
perature sender (3) were removed from the rear hous-
ing, install these parts. Tighten the test port plugs (1)
to a torque of 23 N·m (204 lb in).
NOTE: Steps 8 through 9 are for four-wheel drive transmis-
sions only. If you are working on a two-wheel drive trans-
mission, go to Step 10.
RCPH10TLB918AAL 7
8. Put the bearing for the four-wheel drive shaft into posi-
tion in the rear housing.
RCPH10TLB917AAL 8
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9. Install the four-wheel drive clutch gear so that the side

with the lugs is up.
RCPH10TLB733AAL 9
10. Connect acceptable lifting equipment to the top gear

on the secondary shaft. Lift the secondary shaft over
the rear housing. Engage the shift forks with the syn-
chronizers as shown. Begin to lower the assembly
into the rear housing.
RCPH10TLB029ABL 10
11. As you lower the assembly into the rear housing, also
begin to install the primary shaft so that the gears on
the primary shaft go into mesh with the gears on the
secondary shaft. Continue to lower the parts, making
sure that each part goes into the correct bore in the
rear housing. (Remember that the shift rod and fork
assembly for third and fourth gear goes into the bore
nearer the top of the rear housing). When all of the
parts are in position, disconnect the lifting equipment.
RCPH10TLB913AAL 11
12. Push the secondary shaft toward the rear of the rear
housing so that there is clearance between the snap
ring groove and the rear housing. Install the snap ring.
NOTE: In Steps 13 through 16, the photos show the upper
detent parts already installed. It is necessary for you to
install both the upper and lower detent parts according to
the instructions in the procedure. Make sure that you start
with both shift rods in the NEUTRAL position.
RCPH10TLB732AAL 12
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13. Install the lower detent ball.
RCPH10TLB049ABL 13
14. Install the lower detent spring.
RCPH10TLB731AAL 14
15. Install the copper washer on the detent plug. Install

the lower detent plug. Tighten the lower detent plug
to a torque of 80 N·m (59 lb ft).
16. Repeat Steps 13 through 15 to install the upper detent
ball, spring, copper washer, and plug.
RCPH10TLB730AAL 15
17. Install the two detent balls in the groove between the
two shift rods.
RCPH10TLB729AAL 16
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18. Install the plate over the two detent balls.
RCPH10TLB728AAL 17
19. Apply LOCTITE® 542™ or Super bond 321 to the

threads of the two Allen head bolts. Install the two
Allen head bolts to fasten the plate in position. Tighten
the two Allen head bolts to a torque of 50 N·m (37 lb
ft).
RCPH10TLB727AAL 18
20. Install the shift collars on the shift rods.
RCPH10TLB725AAL 19
21. Install the pins to fasten the shift collars to the shift
rods.
22. Scrape all sealing material from the sealing surface of
the rear cover. Prepare the sealing surface by rubbing
with a 3M Scotch-Brite fiber pad or equivalent. DO
NOT use steel wool or anything that can leave material
on the sealing surface. Wipe the sealing surface with
Loctite Safety Solvent or equivalent. Apply a layer
of LOCTITE® 518™ or Super bond 539 to the sealing
surface.
RCPH10TLB724AAL 20
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23. Put the rear cover in position. Make sure that the
dowel is installed in the rear housing and through the
hole in the rear cover. Install the seven bolts to fas-
ten the rear cover to the rear housing. If necessary,
tap the rear cover with a soft faced hammer to close
the gap between the rear housing and the rear cover
before you tighten the bolts. Tighten the seven bolts
sequentially to a torque of 50 N·m (37 lb ft).
NOTE: The above photo shows the shifter installed, the
shifter should not be installed at this time.
RCPH10TLB861AAL 21
24. Install a new O-ring on the shifter assembly. Use clean

oil to lubricate the O-ring. Put the shifter assembly into
position on the rear cover.
RCPH10TLB722AAL 22
25. Install the three Allen head bolts to fasten the shifter
assembly to the rear cover. Tighten the three Allen
head bolts to a torque of 23 N·m (204 lb in).
RCPH10TLB721AAL 23
26. If the tube was removed from the front housing, install
the tube now. Tighten the hollow bolts to a torque of
40 N·m (354 lb in).
RCPH10TLB027ABL 24
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27. Install the input shaft and the reverse shaft together
as shown. If you are using the same reverse shaft,
make sure that you install it with the same end up as
when it was removed.
RCPH10TLB921AAL 25
28. On machines with four-wheel drive, install the four-

wheel drive shaft. Use clean transmission oil to lu-
bricate the bearing surfaces on the four-wheel drive
shaft. Make sure that the four-wheel drive shaft goes
through the four-wheel drive clutch gear, the thrust
washer, and the bearing.
RCPH10TLB719AAL 26
29. Wipe the sealing surface of the rear housing and the
front housing with LOCTITE® Safety Solvent or equiv-
alent. Apply a layer of LOCTITE® 518™ or Super bond
529 to the sealing surface of the rear housing.
RCPH10TLB030ABL 27
30. Remove the three plugs from the oil passages in the
rear housing (see arrows). Install three new O-rings
for the oil passages. Remove the three plugs from the
oil passages in the front housing.
RCPH10TLB920AAL 28
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31. Use clean transmission oil to lubricate the bearing for

the primary shaft and the bearing for the secondary
shaft. Install the bearings.
RCPH10TLB720AAL 29
32. Install the front housing on the rear housing. Make

sure that the bearings on the shafts go straight into
the bores in the front housing. Push the front housing
all the way down on the rear housing.
RCPH10TLB718AAL 30
33. Install all of the housing bolts that fasten the rear hous-
ing to the front housing. There are 13 of these bolts on
four-wheel drive transmissions and 14 on two-wheel
drive transmissions. Tighten the bolts evenly until
the front housing and rear housing are together, then
tighten the bolts to a torque of 50 N·m (37 lb ft).
RCPH10TLB704AAL 31
34. Install the three bolts that fasten from the front housing
to the rear housing. Tighten the bolts to a torque of
50 N·m (37 lb ft).
RCPH10TLB033ABL 32
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35. Use clean transmission oil to lubricate the bearing for

the four-wheel drive shaft. Install the bearing on the
four-wheel drive shaft.
RCPH10TLB034ABL 33
36. Use the special tool 380200410 to install a new seal

in the cover. Push just until the seal stops moving.
DO NOT use excessive force. Fill the cavity under
the lip of the seal with high temperature wheel bearing
grease.
RCPH10TLB022ABL 34
37. Install a new O-ring on the cover. Use clean transmis-

sion oil to lubricate the O-ring.
RCPH10TLB711AAL 35
38. Install the cover in the front housing.
RCPH10TLB710AAL 36
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39. Install the three bolts that fasten the cover to the
front housing. Tighten the bolts to a torque of 23 N·m
(204 lb in).
RCPH10TLB709AAL 37
40. Install a new O-ring in the four-wheel drive flange. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB707AAL 38
41. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB706AAL 39
42. Install the washer.
RCPH10TLB705AAL 40
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43. Install and tighten the cap screw in the four-wheel

drive shaft to a torque of 139 N·m (103 lb ft).
RCPH10TLB906AAL 41
44. Pull the input shaft toward the front of the transmission
to get clearance for the snap ring.
RCPH10TLB031ABL 42
45. Install the snap ring on the bearing.
RCPH10TLB032ABL 43
46. It will be easier to install the oil pump if you use a guide
stud as shown above. You can make a guide stud by
cutting the head from an M8 bolt.
RCPH10TLB036ABL 44
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47. Use clean transmission oil to lubricate the O-ring on

the oil pump. Install the oil pump. Make sure that the
alignment marks that you made during disassembly
are aligned.
RCPH10TLB035ABL 45
48. If you used a guide stud, remove the guide stud. In-
stall the six bolts that fasten the oil pump in position.
Tighten the bolts to a torque of 23 N·m (204 lb in).
RCPH10TLB712AAL 46
49. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 47
50. Install a reaction plate first.
RCPH10TLB876AAL 48
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51. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 49
52. Install the back plate as shown.
RCPH10TLB874AAL 50
53. Install a new O-ring.
RCPH10TLB873AAL 51
54. Install the brake housing.
RCPH10TLB872AAL 52
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55. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 N·m (37 lb ft).
RCPH10TLB871AAL 53
56. Install the flange and a new O-ring.
RCPH10TLB869AAL 54
57. Install the bolt and washer.
RCPH10TLB868AAL 55
58. Torque bolt to 139 N·m (103 lb ft).
RCPH10TLB870AAL 56
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59. Make sure the orifice is in the brake housing, install

new O-rings.
RCPH10TLB855AAL 57
60. Install the pressure sensor switch into the brake hous-
ing.
RCPH10TLB853AAL 58
61. Slide the expander/protector onto the pump drive

shaft.
RCPH10TLB842AAL 59
62. Heat the Teflon sealing ring to 80 – 100 °C (176 –

212 °F). Install the Teflon sealing ring onto the ex-
pander/protector.
RCPH10TLB843AAL 60
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63. Install the pusher over the expander/protector and

slide the sealing ring until it reaches the groove in the
shaft. Remove the pusher and expander/protector
from the shaft.
RCPH10TLB844AAL 61
64. Install the end of the seal compressor with the deep
chamfer onto the shaft and over the sealing ring. Use
a back and forth twisting motion to allow the seal com-
pressor to slip over the top of the sealing ring and seat
the sealing ring into the groove. Be careful not to dam-
age the sealing ring. After the sealing ring is seated
in the groove, remove the seal compressor from the
shaft.
RCPH10TLB845AAL 62
65. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over the
sealing ring. Leave the seal compressor in place for
15 min until the sealing ring has cooled and is prop-
erly sized and seated in the groove. After the sealing
ring has cooled, remove the seal compressor from the
shaft.
66. Install the bearing and snap ring on the pump drive
shaft, install the shaft in the rear housing.
RCPH10TLB846AAL 63
67. Install the PTO shaft into the transmission.

68. Scrape all sealing material from the sealing surface of
the pump mount and rear cover. Prepare the sea ling
surface by rubbing with a 3M Scotch-Brite fiber pad or
equivalent. DO NOT use steel wool or anything that
can leave material on the sealing surface. Wipe the
sealing surface with Loctite Safety Solvent or equiva-
lent. Apply a layer of LOCTITE® 518™ or Super bond
539 to the sealing surface.
RCPH10TLB850AAL 64
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69. Install the pump mount on the rear housing, torque

bolts to 50 N·m (37 lb ft).
RCPH10TLB849AAL 65
70. Install the fitting for the dipstick tube.
RCPH10TLB808AAL 66
71. Install the dipstick tube.
RCPH10TLB909AAL 67
72. Install the dipstick.

NOTE: The following photo shows the four-wheel drive pri-
ority valve installed and is for reference for the plug only.
RCPH10TLB908AAL 68
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73. If the plug was removed, make sure that the threads
are clean and apply Loctite 543 or LOCTITE® 262™
(red) to the threads before installation. Tighten the
plug to a torque of 40 N·m (354 lb in).
RCPH10TLB703AAL 69
74. Install the four-wheel drive priority valve in the oil filter
bore.
RCPH10TLB037ABL 70
RCPH10TLB702AAL 71
76. Install the spool.
RCPH10TLB701AAL 72
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77. Install the fitting for the oil filter. Tighten the fitting to a
torque of 50 N·m (37 lb ft).
RCPH10TLB700AAL 73
78. Use clean transmission oil to lubricate the gasket on

the oil filter. Install the oil filter.
RCPH10TLB698AAL 74
79. Install the gasket for the four-wheel drive valve.
RCPH10TLB905AAL 75
80. Put the four-wheel drive valve in position on the gas-

ket.
RCPH10TLB697AAL 76
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81. Install the three bolts that fasten the four-wheel drive
valve to the front housing. Tighten the bolts to a torque
of 23 N·m (204 lb in).
RCPH10TLB696AAL 77
82. Install a new O-ring on the oil screen. Use clean trans-
mission oil to lubricate the O-ring. Install the oil screen
and O-ring.
RCPH10TLB695AAL 78
83. Install the cover for the oil screen. Install the two bolts
that fasten the cover for the oil screen. Tighten the
bolts to a torque of 23 N·m (204 lb in).
RCPH10TLB694AAL 79
84. Install the gasket for the transmission control valve.

Put the transmission control valve in position on the
gasket.
RCPH10TLB692AAL 80
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85. Install the bolts that fasten the transmission control

valve to the front housing. Tighten the bolts in a pat-
tern alternating from front to back and side to side until
all the bolts are at a torque of 23 N·m (204 lb in).
RCPH10TLB691AAL 81
NOTE: The following photo shows the drain plug for four wheel drive machines.
86. Install a new O-ring on the drain plug. Lubricate the
O-ring with clean transmission oil. Install the drain
plug. Tighten the drain plug to a torque of 80 N·m
(59 lb ft).
RCPH10TLB690AAL 82
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Oil drain plug - Disassemble

851FX
1. Remove the drain plug (1) and drain the oil from the
transmission.
PTIL13TLB0201AB 1
2. Remove the two cap screws (2) which fasten the cover
for the oil screen.
Remove the cover (3).
PTIL13TLB0202AB 2
3. Remove the oil screen (4) and the O-ring (5).

Filter handling and wash according to the rules in force.
In case of replacement, use only authorized disposal
procedures and, incase of doubt, refers to the autho-
rized bodies.
PTIL13TLB0203AB 3
4. Remove the mouting bolt (1) and remove the filter as-
sembly.
PTIL13TLB0204AB 4
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5. Remove O-ring (10) from assembly (9).
PTIL13TLB0205AB 5
6. Remove the spool (11).
PTIL13TLB0207AB 6
7. Remove the spring (12).
PTIL13TLB0208AB 7
8. Use a puller to remove the four-wheel drive priority

valve (13) (if applicable.)
NOTE: The four-wheel drive priority valve is adjusted at
the factory. DO NOT try to disassemble or adjust the four-
wheel drive priority valve. If any of the parts are damaged,
use a new four-wheel drive priority valve.
PTIL13TLB0209AB 8
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9. It is not necessary to remove the port plugs (14), the

breather (15), or the oil temperature sensor (16) unless
these parts are leaking or damaged.
PTIL13TLB0210AB 9
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Oil drain plug - Assemble

851FX
1. Assemble the port plugs (14), the breather (15) and the
oil temperature sensor (16).
PTIL13TLB0210AB 1
2. Assemble valve (13).
PTIL13TLB0209AB 2
3. Assemble spring (12).
PTIL13TLB0208AB 3
4. Assemble spool (11).
PTIL13TLB0207AB 4
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5. Assemble the O-ring (10) on filter assembly (9).
PTIL13TLB0205AB 5
6. Install and tighten the mounting bolt (1).
PTIL13TLB0204AB 6
7. Assemble filter (4) and O-ring (5) after having washed

or replaced it.
PTIL13TLB0203AB 7
8. Assemble cover (3) and screws (2).
PTIL13TLB0202AB 8
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9. Assemble plug (1).
PTIL13TLB0201AB 9
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Power shuttle transmission - Troubleshooting

Vehicle does not move in Faulty supply to solenoid valves Check/Replace
either direction/s
Damaged/faulty solenoids Replace
Jammed/broken distributor spool/springs Check/Replace
Low transmission pressure Check and correct
Worn clutch discs Replace
Damaged synchronisers Replace
No drive in transmission (broken gears, Check/Repair/Replace
shafts, bearings, etc.)
Vehicle has reduced Incorrect oil level Top up
power transmission
Incorrect oil temperature Wait for oil to reach working temperature
(stall test)
Transmission oil overheating Restore acceptable temperature values
Incorrect operating pressure Check hydraulic circuit and replace (oil
pump, filters, control valve)
Damaged converter Replace
4WD clutch failure (if applicable) Repair/Replace
Overheating solenoids Replace
Overheating Incorrect oil level/specification Top up/Replace
Damaged heat exchanger Replace
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Seizing (broken gears, shafts, bearings, Check/Repair/Replace
etc.)
Braking force outside transmission: irregu- Check/Repair axle
lar axle operation
Worn oil pump Replace
Wheels rotate when Faulty reverser locking Repair/Replace
vehicle is raised
Distributor spool jam Check and clean
Gear seized in engaged condition Check and correct
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature
(stall test)
Noise Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level / Check oil specifications
Seizing (broken gears, shafts, bearings, Check/Repair/Replace
etc.)
Worn clutch plates Replace
Worn synchronizer actuation unit Replace
Worn 4WD clutch Replace
Irregular actuation of FNR Electrical system fault Repair/Replace
function
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature
(stall test)
Overheating See "overheating"
No 4WD power Electrical system fault Repair/Replace
transmission
Damaged/faulty solenoids Replace
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Hydraulic system fault Repair/Replace
Damaged 4WD clutch Replace
Gear shift won’t engage Damaged shifter Replace
Damaged synchronizers Replace
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Index
Transmission - 21

Oil drain plug - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Oil drain plug - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Power shuttle transmission - Assemble - Oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power shuttle transmission - Assemble - Plugs and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power shuttle transmission - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power shuttle transmission - Check - Checking supply pump pressure (4WD only) . . . . . . . . . . . . . 37
Power shuttle transmission - Check - Electrical problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Power shuttle transmission - Check - Hydraulic problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Power shuttle transmission - Check - Mechanical problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power shuttle transmission - Check - Pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power shuttle transmission - Disassemble - Oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power shuttle transmission - Disassemble - Plugs and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power shuttle transmission - Exploded view - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power shuttle transmission - Exploded view - Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power shuttle transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power shuttle transmission - Inspect - Checking lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power shuttle transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power shuttle transmission - Pressure test - 2 wheel drive, test one - Engine at Idle 900 to 1100 rpm 35
Power shuttle transmission - Pressure test - 2 wheel drive, test two - Engine at 2200 rpm . . . . . . . 36
Power shuttle transmission - Pressure test - 4 wheel drive, test one - Engine at idle 900 to 1100 rpm 33
Power shuttle transmission - Pressure test - 4 wheel drive, test two - Engine at 2200 rpm . . . . . . . 34
Power shuttle transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power shuttle transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power shuttle transmission - Speeds - Stall test check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power shuttle transmission - Speeds - Stall test check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power shuttle transmission - Test - Checking converter in pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Power shuttle transmission - Test - Checking converter out pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power shuttle transmission - Test - Checking regulated clutch pressure . . . . . . . . . . . . . . . . . . . . . . . 39
Power shuttle transmission - Test - Checking supply pump flow and relief pressure . . . . . . . . . . . . . 40
Power shuttle transmission - Test - Stall test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power shuttle transmission - Tool connection - Four wheel drive port identification . . . . . . . . . . . . . . 50
Power shuttle transmission - Tool connection - Two wheel drive port identification . . . . . . . . . . . . . . 52
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Power shuttle transmission - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Transmission housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Transmission housing - Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Transmission housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Transmission housing - Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Transmission housing - Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Transmission housing - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Transmission - 21
Power shuttle transmission external controls - 134
851FX Plus
851FX
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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission control valve

Exploded view - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Transmission control valve

Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Transmission - Power shuttle transmission external controls
Transmission control valve - Exploded view - Hydraulic control

valve
PTIL13TLB0225FB 1
1. Plug 29. O-ring

2. O-ring 30. Solenoid
3. Snap ring 31. O-ring
4. Piston 32. Plug
5. Spring 33. Screw
6. Plug 34. Valve cover
7. O-ring 35. Plate gasket
8. Piston 36. Plate
9. Spring 37. Plate gasket
10. Thrust washer 38. Outward piston
13. Screws 39. Spring
14. Plug 40. Spring
15. Washer 41. Spring
16. Plug 42. Pin
21. Spool 47. Control valve
24. Solenoid tube 48. Screw
25. Spring 49. Gasket
26. Ball 50. Plate
27. O-ring 51. Gasket
28. Solenoid 53. Control valve
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Transmission control valve - Disassemble - Four wheel drive valve

(if equipped)
1. Remove the nut.
RCPH10TLB734AAL 1
2. Remove the solenoid coil.
RCPH10TLB737AAL 2
3. Remove the solenoid valve.
RCPH10TLB738AAL 3
4. Remove the check valve from the solenoid valve body.

DO NOT try to disassemble the check valve. There are
no serviceable parts. If there is a problem, use a new
check valve.
RCPH10TLB740AAL 4
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5. Remove the three O-rings from the solenoid valve.
RCPH10TLB741AAL 5
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Transmission control valve - Assemble - Assembly

1. Install the three new O-rings on the solenoid valve. Use
clean transmission oil to lubricate the O-rings.
RCPH10TLB741AAL 1
2. Install the check valve in the valve body as shown.
RCPH10TLB740AAL 2
3. Install the solenoid valve in the solenoid valve body.

Tighten the solenoid valve to a torque of 22 N·m (195 lb
in).
RCPH10TLB739AAL 3
4. Install the solenoid coil on the solenoid valve.
RCPH10TLB737AAL 4
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5. Install the nut.
RCPH10TLB736AAL 5
6. Tighten the nut to a torque of 8 N·m (71 lb in).
RCPH10TLB735AAL 6
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Transmission control valve - Disassemble

1. Before removing hydraulic control valve disconnect
all electrical wires and drain the hydraulic oil from the
transmission.
Remove the screws (13) and remove the control valve
(53).
PTIL13TLB0226AB 1
2. Remove the gasket (49).
PTIL13TLB1535AB 2
3. Remove the screws (48) and the plate (50).
PTIL13TLB0228AB 3
4. Remove the gasket (51).
PTIL13TLB1536AB 4
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5. Lock the control valve with a clamp.

Remove the plug (1).
Remove the O-ring (2).
PTIL13TLB0230AB 5
6. Push down the piston (4) then remove the snap ring (3).
PTIL13TLB0231AB 6
7. Remove the piston (4) and the spring (5).
PTIL13TLB0232AB 7
8. Check the wear conditions of removed parts.
PTIL13TLB0233AA 8
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NOTICE: Do not remove the piston (8) from the control

valve (47). If removed then the control valve (47) has to
be replaced.
PTIL13TLB0234AB 9
9. Remove the plug (6).

PTIL13TLB0235AA 10
PTIL13TLB1540AB 11
11. Remove the thrust washer (10).
PTIL13TLB1541AB 12
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12. Turn the control valve (47).

Remove the screws (33).
PTIL13TLB1542AB 13
13. Remove the valve cover (34).
PTIL13TLB1543AB 14
14. Remove the plate gasket (35).
PTIL13TLB1544AB 15
15. Remove the plate (36).
PTIL13TLB1545AB 16
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16. Remove the outward piston (38), the springs (39),

(40), (41), the pin (42) and the inward piston (43).
PTIL13TLB0242AB 17
17. Check the wear conditions of removed parts.
PTIL13TLB0243AB 18
18. Remove the plate gasket (37).
PTIL13TLB1546AB 19
19. Remove the ball (26).
PTIL13TLB1547AB 20
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PTIL13TLB1537AB 21
21. Remove the plug (32).

Remove the O-ring.
PTIL13TLB1538AB 22
22. Remove the solenoid (30).

PTIL13TLB0248AB 23
23. Remove the solenoid (28).

PTIL13TLB0249AB 24
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24. Unscrew the solenoid tube (24).
PTIL13TLB1539AB 25
25. Remove the solenoid tube (24) with spool (21).
PTIL13TLB0251AB 26
26. Disassemble the spool (21) from the solenoid tube

(24) by removing the spring (23) and thrust washer
(22).
PTIL13TLB0252AB 27
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Transmission control valve - Inspect - Transmission control valve

1. Use cleaning solvent to clean all metal parts.
2. Check the springs for wear, cracks, heat distortion, and
other damage. Replace as necessary.
3. Inspect the spool and the pistons for damage or wear.
Make sure that the orifice in the outer modulation piston
is open. Use new parts as necessary.
4. Inspect the control valve body for cracks, corrosion,
and wear. Inspect the bores for wear. Find the bore
from which the ball was removed. There is a very small
orifice in one side of this bore. Make sure that this
orifice is open. If the control valve body is bad, you
must use a new transmission control valve.
5. Find the plate that held the ball in position. Put the ball
on the hole in the plate so that the ball is in contact with
the edge that has the radius. Hold the plate and the
ball up to a bright light and look at the bottom side of
the plate and the ball. There must be no light visible
between the plate and the ball. If light is visible, use a
new plate.
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Transmission control valve - Assemble

1. Assemble the solenoid tube (24) and spring (23) at the
spool (21) and thrust washer (22).
PTIL13TLB0252AB 1
2. Assemble the solenoid tube (24) with spool (21) to the

control valve.
PTIL13TLB0251AB 2
3. Screw the solenoid tube (24).
PTIL13TLB1539AB 3
4. Assemble the O-ring (27).

5. Assemble the solenoid (28).
PTIL13TLB0249AB 4
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6. Assemble the O-ring (29).

7. Assemble the solenoid (30).
PTIL13TLB0248AB 5
8. Assemble the O-ring on the plug.

9. Assemble the plug (32).
PTIL13TLB1538AB 6
10. Assemble the spring (25).
PTIL13TLB1537AB 7
11. Position the ball (26).
PTIL13TLB1547AB 8
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12. Assemble the plate gasket (37).
PTIL13TLB1546AB 9
13. Preassemble the components.
PTIL13TLB0243AB 10
14. Assemble the outward piston (38), the springs (39),

(40) and (41), the pin (42) and the inward piston (43).
PTIL13TLB0242AB 11
15. Assemble the plate (36).
PTIL13TLB1545AB 12
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16. Assemble the plate gasket (35).
PTIL13TLB1544AB 13
17. Assemble the valve cover (34).
PTIL13TLB1543AB 14
18. Turn the control valve (47) and assemble the screws
(33).
PTIL13TLB1542AB 15
19. Turn the control valve and assemble the thrust washer
(10).
PTIL13TLB1541AB 16
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20. Assemble the spring (9).
PTIL13TLB1540AB 17
21. Assemble the O-ring (7) on the plug.

PTIL13TLB0235AA 18
23. Assemble the piston (4) and the spring (5).
PTIL13TLB0232AB 19
24. Push down the piston (4) then assemble the snap ring
(3) in its seat.
PTIL13TLB0231AB 20
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25. Assemble the O-ring (2) on the plug.

PTIL13TLB0230AB 21
27. Assemble the gasket (51) on the transmission.
PTIL13TLB1536AB 22
28. Assemble the plate (50) and the screws (48).
PTIL13TLB0228AB 23
29. Assemble the gasket (49).
PTIL13TLB1535AB 24
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30. Assemble the control valve and the screws (13).
PTIL13TLB0226AB 25
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Index
Transmission - 21

Transmission control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transmission control valve - Assemble - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission control valve - Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . 4
Transmission control valve - Exploded view - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission control valve - Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Transmission - 21
Power shuttle transmission internal components - 154
851FX Plus
851FX
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Contents
Transmission - 21
SERVICE
Transmission drive and driven shafts

Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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Transmission - Power shuttle transmission internal components
Transmission drive and driven shafts - Disassemble - Input shaft

NOTE: Do Steps 1 and 2 before you disassemble the input
shaft. This will help to locate any problems. After you as-
semble the input shaft, the tests will be done again to make
sure that the input shaft is working correctly.
1. Apply compressed air of approximately 620 kPa
(90 psi) to the forward clutch passage. Listen to hear
the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward
gear must not turn on the input shaft. Try to move the
reverse gear. The reverse gear must turn freely on
the input shaft. If the clutches do not work correctly,
inspect the parts closely during disassembly so that
you can find and correct the problem.
(90 psi) to the reverse clutch passage. Listen to hear
the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The reverse
forward gear. The forward gear must turn freely on
inspect the parts closely during disassembly so that
you can find and correct the problem.
3. Use the bottom piece of special tool 380200414 as
shown to fasten the input shaft in the vise so that the
reverse clutch is up.
RCPH10TLB786AAL 1
4. Remove the sealing ring.
RCPH10TLB788AAL 2
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5. Remove the snap ring above the bearing.
RCPH10TLB787AAL 3
6. Install a bearing separator under the gear as shown.

DO NOT install the bearing separator between the gear
and the bearing. Install a puller on the bearing sep-
arator. Use a shaft protector between the puller and
the end of the input shaft. Use molydisulfide grease to
lubricate the shaft protector and the end of the puller.
Make sure that you pull only until the bearing is free.
Pulling any farther can damage the parts.
RCPH10TLB789AAL 4
RCPH10TLB790AAL 5
8. Remove the spacer.
RCPH10TLB791AAL 6
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9. Remove the gear.
RCPH10TLB792AAL 7
10. Remove the needle bearing.
RCPH10TLB793AAL 8
11. Remove the thrust washer.
RCPH10TLB794AAL 9
12. Remove the roll pin.
RCPH10TLB795AAL 10
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13. Tap lightly on the thrust plate to move the thrust plate
down so that there is clearance between the snap ring
and the thrust plate.
RCPH10TLB796AAL 11
14. Tap lightly on the thrust plate to move the thrust plate
down so that there is clearance between the snap ring
and the thrust plate. Remove the snap ring.
RCPH10TLB797AAL 12
15. Install the top piece of the special tool 380200414 as

shown. Use the three threaded rods and nuts to fasten
the two pieces together.
RCPH10TLB798AAL 13
16. Tighten the nuts evenly to compress the spring. Com-

press the spring just enough to get access to the snap
ring.
RCPH10TLB800AAL 14
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RCPH10TLB799AAL 15
18. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
special tool 380200414.
RCPH10TLB800AAL 16
19. Use pry bars to lift the thrust plate evenly.
RCPH10TLB922AAL 17
20. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB809AAL 18
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21. Place a mark below the groove on the housing.
RCPH10TLB878AAL 19
22. Place a mark on each steel and friction disc and the
thrust plate. These marks will be used for reference
during the reassembly procedure.
RCPH10TLB879AAL 20
23. Place a mark on top of the thrust plate and each steel
and friction disc as they are removed. These marks
will be used for reference during the reassembly pro-
cedure.
RCPH10TLB880AAL 21
24. Remove the pressure plate and spring.
RCPH10TLB881AAL 22
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25. Remove the sleeve.

NOTICE: Use an air hose with a safety on/off control nozzle
with 2.1 bar (30.5 psi) maximum at the nozzle. Wear face
protection.
RCPH10TLB807AAL 23
26. Use compressed air in the port shown to remove the

piston.
RCPH10TLB801AAL 24
27. Remove the piston.
RCPH10TLB802AAL 25
28. Put the input shaft in the bottom piece of the special
tool 380200414 as shown so that the forward clutch is
up.
RCPH10TLB923AAL 26
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29. Remove the four sealing rings (1).
RCPH10TLB819AAL 27
RCPH10TLB924AAL 28

DO NOT install the bearing separator between the
gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the input shaft. Use moly-
disulfide grease to lubricate the shaft protector and
the end of the puller. Make sure that you pull only un-
til the bearing is free. Pulling any farther can damage
the parts.
RCPH10TLB925AAL 29
RCPH10TLB926AAL 30
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NOTE: It is possible that the gear moved partially out of the
clutch pack when the bearing was removed. If this occurs,
it can be difficult to remove the roll pin. Move the gear as
necessary to remove the roll pin.
RCPH10TLB927AAL 31
34. Remove the gear.
RCPH10TLB928AAL 32
35. Remove the needle bearing.
RCPH10TLB929AAL 33
RCPH10TLB930AAL 34
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37. Tap lightly on the end plate to move the end plate down
so that there is clearance between the snap ring and
the end plate.
RCPH10TLB932AAL 35
RCPH10TLB931AAL 36
39. Use pry bars to lift the end plate evenly. Remove the
end plate.
RCPH10TLB933AAL 37
40. Remove the roll pin.
RCPH10TLB934AAL 38
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41. Install the top piece of the special tool 380200414 as

shown. Use the three threaded rods and nuts to fasten
the two pieces together.
RCPH10TLB935AAL 39
42. Tighten the nuts evenly to compress the spring. Com-

ring.
RCPH10TLB936AAL 40
RCPH10TLB937AAL 41
44. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
RCPH10TLB938AAL 42
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45. Remove the retainer plate.
RCPH10TLB939AAL 43
46. Remove the spring.
RCPH10TLB940AAL 44
47. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
48. Follow the same procedure as Step 21 and Step 22 for
marking the top of the thrust plate and the steel and
friction discs as they are removed from the housing.
RCPH10TLB941AAL 45
49. Remove the sleeve.

NOTICE: Use an air hose with a safety on/off control nozzle
with 2.1 bar (30 psi) maximum at the nozzle. Wear face
protection.
RCPH10TLB806AAL 46
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50. Use compressed air in the port shown to remove the

piston.
RCPH10TLB803AAL 47
51. Remove the piston.
RCPH10TLB802AAL 48
52. Remove the sealing ring from the OD and the ID of

each piston.
RCPH10TLB805AAL 49
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Transmission drive and driven shafts - Inspect - Input shaft

1. Check the springs for broken or cracked coils. Com-
pare the heights of the two springs. If the two springs
are not approximately the same height, use new
springs. The correct spring height is approximately
85.5 mm (3.4 in). Use new parts as required.
2. Check the sealing ring grooves (large and small) for
wear and damage. Use new parts as required.
3. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear. Use
new parts as required.
4. Check the splines on the output shaft for wear and dam-
age. Check the passages in the output shaft to be sure
that the passages are open and free of foreign mate-
rial. Use new parts as required.
5. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
6. If the clutch discs are to be used again, keep the clutch
packs separate and record which clutch pack goes with
each clutch. Use new parts as required.
RCPH10TLB804AAL 1
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7. Use a straight edge to check each steel disc (1) and

each friction disc (2) to be sure each part is flat. If
a steel disc (1) or a friction disc (2) is not flat, a new
part must be installed during assembly. If the friction
discs (2) are smooth or almost smooth, use new parts
during assembly. If the friction material is damaged or
appears burned, use new parts during assembly. Also,
check the splines for wear. Inspect the steel discs (1)
for pitting, scoring, or other damage. If there is any
damage, use new parts during assembly. If you will be
using new friction discs, soak the friction discs in clean
transmission oil for at least an hour before assembly. If
you are using the old friction discs, make sure that the
friction surfaces are coated with transmission oil before RCPH10TLB942AAL 2
assembly.
RCPH10TLB943AAL 3
8. Inspect the bore and the shaft in the input shaft housing
for damage that will cause leakage when the clutch is
assembled. Check the slots in the side of the input shaft
housing for damage from the tangs on the steel discs.
Use new parts as required during assembly.
9. Inspect the end of the clutch pack housing line bore
holes, if a rivet is coming out of the housing (arrow),
replace the rivet.
RCPH10TLB818AAL 4
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Transmission drive and driven shafts - Assemble

1. Use clean transmission oil to lubricate the sealing rings.
Install new sealing rings in each piston.
RCPH10TLB805AAL 1
2. Slide the special tool 380001926 on the input shaft.
RCPH10TLB820AAL 2
3. Use clean transmission oil to lubricate the edge and

the bore of the piston. Install the piston. Remove the
special tool 380001926 from the input shaft.
RCPH10TLB806AAL 3
RCPH10TLB940AAL 4
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5. Install the retainer plate. The side that has a raised

area around the bore goes down.
RCPH10TLB939AAL 5
6. Install the top piece of the special tool 380200414. Use

the three threaded rods and nuts to fasten the two
pieces together. Tighten the nuts evenly to compress
the spring just enough to get access to the snap ring
groove in the input shaft. Install the snap ring. Loosen
the nuts to relieve the spring tension and remove the
special tool 380200414. Make sure that the outer edge
of the snap ring is seated in the groove in the retainer
plate.
RCPH10TLB961AAL 6
7. Install the pin.
RCPH10TLB962AAL 7
8. Use clean transmission oil to lubricate the thrust

washer. Install the thrust washer so that the notch in
the inner edge fits over the pin. Make sure that the
side with the oil grooves is up.
RCPH10TLB963AAL 8
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9. Use clean transmission oil to lubricate the needle bear-

ings. Install the needle bearing.
RCPH10TLB964AAL 9
10. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the reference
mark on top of the plate made during disassembly is
facing towards the gear.
RCPH10TLB971AAL 10
11. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one friction
disc with the reference mark on top towards the gear.
RCPH10TLB972AAL 11
NOTE: If you will be using new friction discs, soak the fric-
tion discs in clean transmission oil for at least an hour be-
fore assembly. If you are using the old friction discs, make
sure that the friction surfaces are coated with transmission
oil before assembly.
12. Install one steel disc with reference mark on top of the
steel disc towards the gear.
13. Repeat steps 11 and 12 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
RCPH10TLB048ABL 12
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14. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs are
down. Put the clutch pack on the clutch housing as
shown so that the tabs with the reference marks on
the steel discs are almost ready to start into the slot in
the clutch housing with the reference mark.
RCPH10TLB965AAL 13
15. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all the
tabs are going into the slots. Make sure all of the
tabs with reference marks are aligned in the slot in
the housing with the reference mark. Also make sure
that the gear moves down with the clutch pack.
RCPH10TLB966AAL 14
16. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move the
thrust plate down evenly just far enough to get access
to the snap ring groove in the clutch housing.
RCPH10TLB967AAL 15
17. Install the snap ring.
RCPH10TLB968AAL 16
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18. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When the
thrust plate is up all the way, the inner edge of the snap
ring will fit in this recess.
RCPH10TLB969AAL 17

side with the oil grooves is down.
RCPH10TLB927AAL 18
20. Use an acceptable driver to drive the bearing onto the

input shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB970AAL 19
RCPH10TLB924AAL 20
NOTE: For clarity of the Teflon sealing ring installation pro-

cedure the following photos do not show the clutch pack,
gear, spacer, bearing, and snap ring installed on the input
shaft. Steps 1 through 21 must be performed before in-
stalling the Teflon sealing ring on the input shaft.
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22. Place the special tool 380001929 into the special tool
380001933.
RCPH10TLB821AAL 21
23. Slide the special tool 380001933 and the spacer onto
the shaft. Heat the Teflon sealing ring to 80 – 100 °C
(176 – 212 °F). Install the Teflon sealing ring onto the
expander/protector.
RCPH10TLB831AAL 22
24. Install the special tool 380001928 over the expander/

protector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher, protector,
and spacer from the shaft.
RCPH10TLB838AAL 23
25. Install the end of the special tool 380001927 with the
deep chamfer onto the shaft and over the sealing ring.
Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the sealing ring and
seat the sealing ring into the groove. Be careful not
to damage the sealing ring. After the sealing ring is
seated in the groove, remove the seal compressor
from the shaft.
RCPH10TLB839AAL 24
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shaft.
RCPH10TLB840AAL 25
380001933.
RCPH10TLB822AAL 26
28. Slide the expander/protector and the spacer onto the

shaft. Heat the Teflon sealing ring to 80 – 100 °C
expander/protector.
RCPH10TLB832AAL 27

groove in the shaft. Remove the pusher, expander/
protector, and spacer from the shaft.
RCPH10TLB837AAL 28
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from the shaft.
RCPH10TLB839AAL 29
shaft.
RCPH10TLB840AAL 30
380001933.
RCPH10TLB823AAL 31

expander/protector.
RCPH10TLB833AAL 32
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RCPH10TLB836AAL 33
from the shaft.
RCPH10TLB839AAL 34
shaft.
RCPH10TLB840AAL 35
380001933.
RCPH10TLB824AAL 36
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expander/protector.
RCPH10TLB834AAL 37

RCPH10TLB835AAL 38
from the shaft.
RCPH10TLB839AAL 39
shaft.
RCPH10TLB840AAL 40
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42. Put the input shaft in the bottom piece of the spe-
cial tool 380200414 so that the reverse clutch housing
is up. Slide the special tool 380001926 on the input
shaft.
43. Use clean transmission oil to lubricate the edge and
the bore of the piston. Install the piston. Remove the
piston installation tool.
RCPH10TLB825AAL 41
44. Install the sleeve.
RCPH10TLB882AAL 42
45. Install the pressure plate and the spring. The raised
area around the bore of the pressure plate must go
down. The side that has the groove around the bore
should face up. The outer edge of the snap ring must
fit in the groove after the parts are assembled.
RCPH10TLB881AAL 43
46. Install the top piece of the special tool 380200414.

Use the three threaded rods and nuts to fasten the
two pieces together. Tighten the nuts evenly to com-
ring groove in the input shaft. Install the snap ring.
Loosen the nuts to relieve the spring tension and re-
move the special tool 380200414. Make sure that the
outer edge of the snap ring is seated in the groove in
the retainer plate.
RCPH10TLB973AAL 44
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47. Install the pin.
RCPH10TLB974AAL 45

side with the oil grooves is up.
RCPH10TLB975AAL 46
49. Use clean transmission oil to lubricate the needle

bearing. Install the needle bearing.
RCPH10TLB793AAL 47
50. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the reference
mark on top of the plate made during disassembly is
facing towards the gear.
RCPH10TLB971AAL 48
NOTE: If you will be using new friction discs, soak the fric-
tion discs in clean transmission oil for at least an hour be-
fore assembly. If you are using the old friction discs, make
sure that the friction surfaces are coated with transmission
oil before assembly.
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51. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one friction
disc with the reference mark on top towards the gear.
RCPH10TLB972AAL 49
52. Install one steel disc with reference mark on top of the
steel disc towards the gear.
53. Repeat Steps 51 and 52 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
RCPH10TLB048ABL 50
54. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs are
down. Put the clutch pack on the clutch housing as
shown so that the tabs with the reference marks on
the steel discs are almost ready to start into the slot in
the clutch housing with the reference mark.
RCPH10TLB976AAL 51
55. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all the
tabs are going into the slots. Make sure all of the
tabs with reference marks are aligned in the slot in
the housing with the reference mark. Also make sure
that the gear moves down with the clutch pack.
RCPH10TLB977AAL 52
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56. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move the
thrust plate down evenly just far enough to get access
to the snap ring groove in the clutch housing.
RCPH10TLB978AAL 53
RCPH10TLB979AAL 54
58. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When the
thrust plate is up all the way, the inner edge of the snap
ring will fit in this recess.
RCPH10TLB980AAL 55
59. Use clean transmission oil to lubricate the spacer (1)

and install the spacer (1) on the input shaft. Install the
bearing (2) onto the input shaft. Use an acceptable
driver (3) to drive the bearing onto the input shaft until
the bearing (2) makes contact with the spacer (1)
RCPH10TLB981AAL 56
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RCPH10TLB919AAL 57
NOTE: For clarity of the Teflon sealing ring installation pro-

cedure the following photos do not show the clutch pack,
gear, spacer, bearing, and snap ring installed on the input
shaft. Steps 42 through 60 must be performed before in-
stalling the Teflon sealing ring on the input shaft.
380001428.
RCPH10TLB826AAL 58
62. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80 – 100 °C
RCPH10TLB829AAL 59

RCPH10TLB830AAL 60
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from the shaft.
RCPH10TLB841AAL 61
shaft.
RCPH10TLB827AAL 62
66. Measure the clutch disc clearance for each clutch as-
sembly. The end cover must be all the way up against
the snap ring. Use a feeler gauge to measure the dis-
tance between the end cover and the first metal disc.
The distance must be 2.3 – 4.3 mm (0.09 – 0.17 in).
If the distance is not within specification, the clutch is
probably assembled wrong. Clutch plate wear will not
cause the distance to be outside the specification.
RCPH10TLB982AAL 63
NOTE: The art shows a clutch pack without the PTO

through shaft, the procedures for Steps 67 and 68 are the
same.
(90 psi) to the forward clutch passage. Listen to hear
the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward
reverse gear. The reverse gear must turn freely on
the input shaft . If the clutches do not work correctly,
disassemble the clutches to find the problem.
RCPH10TLB054GAL 64
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Clutch pack
1 Forward clutch passage 5 Reverse clutch pack
2 Reverse clutch passage 6 Reverse gear
3 Forward gear 7 Input shaft
4 Forward clutch pack

(90 psi) to the reverse clutch passage. Listen to hear
the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The reverse
forward gear. The forward gear must turn freely on
disassemble the clutches to find the problem.
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Transmission drive and driven shafts - Disassemble - Secondary

shaft
1. Support the secondary shaft on blocks on the bench as
shown.
RCPH10TLB765AAL 1

and the bearing. If the bearing separator has a beveled
edge, the beveled edge must be down. Do not tighten
the bearing separator so much that the bearing sepa-
rator pushes the synchronizer down. Install an accept-
able puller on the bearing separator. Use a shaft pro-
tector between the puller and the end of the secondary
shaft. Use molydisulfide grease to lubricate the shaft
protector and the end of the puller. Make sure that you
pull only until the bearing is free. Pulling any farther
can damage the parts .
RCPH10TLB766AAL 2
RCPH10TLB767AAL 3
RCPH10TLB768AAL 4
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5. Remove the third gear from the shaft.
RCPH10TLB769AAL 5
6. Remove the synchronizer assembly.
RCPH10TLB770AAL 6
7. Use a feeler gauge to measure the clearance between

the clutch ring (1) and the edge of the tapered friction
ring (2). This clearance (3) should be approximately
1 mm (0.04 in) with used parts in good condition. If the
clearance is 0.5 mm (0.02 in) or less, use new parts
as required. Repeat the measurement for the opposite
side of the synchronizer assembly before disassembly.
RCPH10TLB810AAL 7
8. Remove the clutch ring from each side of the synchro-

nizer assembly.
RCPH10TLB817AAL 8
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9. Remove the tapered friction ring from each side of the

synchronizer assembly.
RCPH10TLB816AAL 9
10. Inspect the clutch ring teeth for wear, wear in excess
of 0.5 mm (0.02 in) the ring must be replaced.
RCPH10TLB815AAL 10
NOTE: The parts may fly out of the hub when you do the fol-
lowing step. Putting the synchronizer assembly in a card-
board box during this step can prevent loss of parts.
11. Remove the sleeve from the synchronizer hub. When
the sleeve is removed from the synchronizer hub the
spring plates, hub pins and hub springs will be re-
leased from the synchronizer hub. Be careful not to
lose any of these parts.
RCPH10TLB893AAL 11
12. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 12
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13. Remove fourth gear.
RCPH10TLB771AAL 13
14. Turn the secondary shaft over so that second gear is

at the top. You can use a vise with soft jaws to hold
the secondary shaft in position.
RCPH10TLB772AAL 14
15. Install a bearing separator under the bearing race as

shown. If the bearing separator has a beveled edge,
the beveled edge must be down. Do not tighten the
bearing separator so much that the bearing separator
pushes the synchronizer down. Install an acceptable
puller on the bearing separator. Use a shaft protector
between the puller and the end of the secondary shaft
. Use molydisulfide grease to lubricate the shaft pro-
tector and the end of the puller. Make sure that you
pull only until the bearing race is free. Pulling any far-
ther can damage the parts.
RCPH10TLB773AAL 15
16. Remove the bearing race from the shaft.
RCPH10TLB774AAL 16
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17. Remove the snap ring from the shaft.
RCPH10TLB775AAL 17
18. Remove the shim(s) and the thrust washer.
RCPH10TLB776AAL 18
19. Remove the pin.
RCPH10TLB777AAL 19
20. Remove second gear.
RCPH10TLB778AAL 20
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21. Remove the spacer.
RCPH10TLB779AAL 21
22. Remove the synchronizer ring and the first-second

synchronizer as an assembly.
23. Use a feeler gauge to measure the clearance between
the bottom of the teeth on the synchronizer ring and
the edge of the sleeve on the outside of the synchro-
nizer assembly. This clearance should be approxi-
mately 1 mm (0.04 in) with used parts in good condi-
tion. If the clearance is 0.5 mm (0.02 in) or less, use
new parts as required. Repeat the measurement for
the opposite side of the synchronizer assembly before
disassembly.
RCPH10TLB780AAL 22
24. Remove the steel ring (1) and the bronze ring (2) to-
gether.
RCPH10TLB946AAL 23
25. Remove the tapered friction ring.
RCPH10TLB947AAL 24
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26. Turn the synchronizer assembly over and remove the

synchronizer ring from the other side.
RCPH10TLB945AAL 25
27. Remove the steel ring (1) and the bronze ring (2) to-
gether.
RCPH10TLB946AAL 26
28. Remove the tapered friction ring.
RCPH10TLB947AAL 27
NOTE: The parts will fly out of the hub when you do the fol-
lowing step. Putting the synchronizer assembly in a card-
board box during this step can prevent loss of parts.
29. Support the sleeve on blocks. Push down on the hub
while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB948AAL 28
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30. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 29
31. Remove first gear.
RCPH10TLB781AAL 30
32. If equipped with four wheel drive, remove the snap

ring from the four wheel drive gear.
RCPH10TLB782AAL 31
33. Remove the four wheel drive gear, if equipped. On

two-wheel drive transmissions, there is a raised area
on the shaft.
RCPH10TLB783AAL 32
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34. If equipped with four wheel drive, do not remove the

snap ring for the four wheel drive gear unless the snap
ring is damaged.
RCPH10TLB784AAL 33
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Transmission drive and driven shafts - Inspect - Secondary shaft

or spline that is in mesh with the damaged gear.
2. Check the splines on the secondary shaft for wear and
damage. Check the passages in the secondary shaft to
be sure that the passages are open and free of foreign
material.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
4. Check the teeth in the synchronizer assemblies for
wear and damage. Replace as necessary.
5. Check for wear or damage to the steel rings and the
bronze rings from the synchronizer assemblies. Check
the springs in the synchronizer assemblies for wear,
cracks, heat distortion, and other damage. Replace as
necessary.
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Transmission drive and driven shafts - Assemble - Secondary shaft

NOTE: Before each gear is installed on the secondary shaft, make sure that the bore of the gear and the outside
diameter of the secondary shaft are completely lubricated with clean transmission oil.
NOTE: When you install snap rings on the secondary shaft, make sure that the ends of each snap ring are seated in
the snap ring groove. Do not install a snap ring so that the ends extend into an axial slot on the secondary shaft.
1. If equipped with four wheel drive, if the snap ring was
removed from the shaft, install the snap ring as shown.
RCPH10TLB784AAL 1
2. Put the secondary shaft on the bench so that the first-

second gear end is up. You can use a vise with soft
jaws to hold the secondary shaft in position. Install the
four-wheel drive gear, if equipped.
RCPH10TLB783AAL 2
3. If equipped with four wheel drive, install the snap ring

for the four wheel drive gear.
RCPH10TLB782AAL 3
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4. Install first gear.
RCPH10TLB781AAL 4
5. This photo shows the correct relationship between the

hub and the sleeve for assembly of the first-second
synchronizer. The tabs (1) in the inside diameter of
the sleeve fit into the small recesses (2) in the outside
diameter of the hub. The large recesses (3) in the hub
are for the detent assemblies, that are not yet installed.
RCPH10TLB950AAL 5
6. This photo shows the correct positions of the hub, the

sleeve, the springs, the blocks, and the balls prior to
final assembly. The springs are installed in the hub,
and the blocks are on the springs. The blocks are not
yet pushed down into the sleeve and are holding the
hub up out of the sleeve. The balls are loose in the
recesses of the blocks.
RCPH10TLB951AAL 6
7. Use a punch or screwdriver to push the balls into the

blocks and to push the blocks down so that the balls
are on the flat faces of the teeth, but not into the detent
grooves. When all the balls are in position, push the
hub and the blocks down until the balls move into the
detent groove.
RCPH10TLB952AAL 7
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8. Install the tapered friction ring on the synchronizer as-

sembly.
RCPH10TLB947AAL 8
9. Use clean transmission oil to lubricate the bronze ring

(1) and the steel ring (2). Install the bronze ring (1) and
the steel ring (2) as shown.
RCPH10TLB946AAL 9
10. Install the synchronizer ring as shown. The flat sides

of the teeth must be up.
RCPH10TLB945AAL 10
11. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 11
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12. Use clean transmission oil to lubricate the bronze ring

(1) and the steel ring (2). Install the bronze ring (1)
and the steel ring (2) as shown.
RCPH10TLB946AAL 12
13. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top synchronizer ring. To
do this, you must use enough force to overcome the
strength of the detent springs and balls. When the
synchronizer ring and the sleeve are completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or does
not stay in position when moved to any of the three
positions, the synchronizer assembly has damaged
parts or was not assembled correctly. Disassemble
the synchronizer assembly to find the problem.
14. Install the synchronizer ring and the first-second syn-
chronizer as an assembly. Make sure the top synchro-
nizer ring is installed so that the flat sides of the teeth
are up.
NOTE: There is a groove in the bore at one end of the
synchronizer hub. The synchronizer assembly must be in-
stalled so that the groove is down.
RCPH10TLB780AAL 13
15. Install the spacer.
RCPH10TLB779AAL 14
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16. Install and second gear. The teeth in the inside diame-
ter of the spacer must engage the teeth on the bottom
of second gear before second gear is installed.
RCPH10TLB778AAL 15
17. Install the pin.
RCPH10TLB777AAL 16
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Transmission drive and driven shafts - Adjust - Backlash

adjustment
1. Install the thrust washer and snap ring.
RCPH10TLB775AAL 1
2. Use a feeler gauge and measure the backlash between

the gear and the thrust washer. Record this measure-
ment (a). Subtract the recorded measurement (a) from
0.2 – 0.42 mm (0.0079 – 0.0165 in) (b). Select the
shim(s) required (c). Example: Use 0.72 – 0.94 mm
(0.0283 – 0.0370 in) shim(s).
a. 1.14 mm (0.0449 in)

b. -0.31 mm (-0.0122 in)
c. 0.83 mm (0.0327 in)
3. Remove the snap ring and thrust washer.
RCPH10TLB775AAL 2
4. Use clean transmission oil to lubricate the shim(s) and

the thrust washer. Install the shim(s). Install the thrust
washer on top of the shim(s). Make sure that the side
with the oil grooves is down.
RCPH10TLB776AAL 3
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5. Put the bearing race on the shaft.
RCPH10TLB774AAL 4
6. Use an acceptable driver to drive the bearing race onto

the secondary shaft until bearing race makes contact
with the snap ring.
RCPH10TLB785AAL 5
7. Turn the secondary shaft over so that second gear is at

the bottom. Use blocks to support the secondary shaft.
Install the fourth gear on the secondary shaft.
RCPH10TLB771AAL 6
8. This photo shows the correct relationship between the

hub and the sleeve for assembly of the third-fourth syn-
chronizer. The tabs (1) in the inside diameter of the
sleeve fit into the small recesses (2) in the outside di-
ameter of the hub. The large recesses (3) in the hub
are for the detent assemblies, shown installed.
RCPH10TLB811AAL 7
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9. Install the 3 sets of hub springs, hub pins, and spring

plates into the synchronizer hub. Use a punch or
screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that
the spring plates are aligned with the grooves in the
sleeve.
RCPH10TLB952AAL 8
10. Install the friction ring on each side the synchronizer

assembly.
RCPH10TLB892AAL 9
11. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assembly.
RCPH10TLB891AAL 10
12. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top synchronizer ring. To
do this, you must use enough force to overcome the
strength of the detent springs and balls. When the
synchronizer ring and the sleeve are completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or does
not stay in position when moved to any of the three RCPH10TLB810AAL 11
positions, the synchronizer assembly has damaged

parts or was not assembled correctly. Disassemble
the synchronizer assembly to find the problem.
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13. Install the synchronizer assembly onto the shaft.
RCPH10TLB770AAL 12
14. Install the third gear on the shaft.
RCPH10TLB769AAL 13

washer. Install the thrust washer onto the shaft.
RCPH10TLB768AAL 14
16. Put the bearing in position on the secondary shaft.

Make sure that the snap ring groove is at the top.
RCPH10TLB767AAL 15
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secondary shaft until the bearing makes contact with
the thrust washer.
NOTE: If the bearing is not very tight on the secondary
shaft, parts could fall from the secondary shaft when you
install the secondary shaft in the rear housing. To prevent
this, you can install a hose clamp on the output end of
the secondary shaft. This will keep the bearing in position
during installation of the secondary shaft.
18. Check for correct operation of both synchronizer as-
semblies. If they do not shift smoothly, with the teeth
on the synchronizer ring aligned with the splines on
RCPH10TLB953AAL 16
the sleeve, the re is a problem. Disassemble as nec-
essary, and correct the problem.
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Transmission drive and driven shafts - Disassemble - Primary shaft

1. Put the primary shaft on the bench so that the end with
the bearing attached is up. Remove the snap ring.
RCPH10TLB954AAL 1

and the bearing. Install an acceptable puller on the
bearing separator. Use a shaft protector between the
puller and the end of the primary shaft. Use molydisul-
fide grease to lubricate the shaft protector and the end
of the puller. Pull the bearing from the primary shaft.
RCPH10TLB955AAL 2
RCPH10TLB956AAL 3
RCPH10TLB957AAL 4
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5. Install a bearing separator under the lip of the bearing

race as shown. Install an acceptable puller on the bear-
ing separator. Use a shaft protector between the puller
and the end of the primary shaft. Use molydisulfide
grease to lubricate the shaft protector and the end of
the puller. Pull the bearing race from the primary shaft.
RCPH10TLB958AAL 5
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Transmission drive and driven shafts - Inspect - Primary shaft

or spline that is in mesh with the damaged gear.
2. Check the splines on the primary shaft for wear and
damage.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
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Transmission drive and driven shafts - Assemble - Primary shaft

1. Use an acceptable driver to drive the bearing race all
the way onto the primary shaft.
RCPH10TLB959AAL 1

washer. Install the thrust washer so that the side with
the oil grooves is down.
RCPH10TLB957AAL 2
3. Put the bearing into position so that the snap ring

groove on the outside diameter of the bearing is at the
top.
RCPH10TLB956AAL 3

primary shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB960AAL 4
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RCPH10TLB954AAL 5
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Transmission drive and driven shafts - Disassemble - Reverse shaft

The bearings are the only serviceable parts on the re-
verse shaft. If you remove the bearings, use a shaft
protector between the puller and the end of the reverse
shaft. Use molydisulfide grease to lubricate the shaft
protector and the end of the puller.
1. Bearing
2. Reverse shaft
RCPH10TLB050ABL 1
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Transmission drive and driven shafts - Inspect - Reverse shaft

Check the teeth on the gears for wear and damage. If a
tooth is badly damaged, be sure to inspect the gear that
is in mesh with the damaged gear. Check the bearings
for flat areas, pitting, and other damage. Replace as
necessary.
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Transmission drive and driven shafts - Assemble - Reverse shaft

Use an acceptable driver to drive each bearing onto the
reverse shaft until the bearing makes contact with the
shoulder on the reverse shaft.
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Index
Transmission - 21

Transmission drive and driven shafts - Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Transmission drive and driven shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transmission drive and driven shafts - Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Transmission drive and driven shafts - Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Transmission drive and driven shafts - Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Transmission drive and driven shafts - Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission drive and driven shafts - Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Transmission drive and driven shafts - Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Transmission drive and driven shafts - Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . 35
Transmission drive and driven shafts - Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transmission drive and driven shafts - Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Transmission drive and driven shafts - Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Transmission drive and driven shafts - Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Transmission - 21
Torque converter - 700
851FX Plus
851FX
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21.5 [21.700] / 1
Contents
Transmission - 21
FUNCTIONAL DATA
Torque converter
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Transmission - Torque converter
Torque converter - Exploded view
PTIL13TLB1551FB 1
1. Bolt 4. Converter
2. Washer 5. Oil pump
3. Flywheel towing plate 6. Transmission
NOTICE: The torque converter is a non - serviceable item and should never be opened.
NOTICE: Handle the torque converter carefully. Always plug the open ports to prevent dust.
NOTE: Make sure the bolts (1) are torqued to 52 – 57 N·m (38 – 42 lb ft).
91715732 26/07/2021
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Index
Transmission - 21

Torque converter - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Front axle system
851FX Plus
851FX
91715732 26/07/2021
25
Contents
Front axle system - 25
[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2
[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4
91715732 26/07/2021
25
Powered front axle - 100
851FX Plus
851FX
91715732 26/07/2021
25.1 [25.100] / 1
Contents
TECHNICAL DATA
Powered front axle

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Powered front axle

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Powered front axle

Remove - (2WD and 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install - (2WD and 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Front axle system - Powered front axle
Powered front axle - General specification

Description Values
Weight(2WD) 290 kg (639.34 lb)
Weight(4WD) 314 kg (692.25 lb)
Maximum steering angle 56 ± 1°
Toe-in A = -1 ± 1 mm
Bevel gear ratio 2.000/1
Epicyclic reduction gear ratio 6.000/1
Total ratio 12.000/1
Oil specification: Use recommended oil enriched in additives SAE 30
Differential oil capacity 7.50 l (1.98 US gal)
Epicyclic reduction gear oil capacity each side 1.30 l (0.34 US gal)
Assembly main data

Bevel gear set backlash 0.15 mm (0.006 in) ÷ 0.30 mm (0.012 in)
Pinion bearings preloading
P = 91.8 N (20.64 lb) ÷ 137.6 N (30.93 lb)
(measured on D = 34.87 mm (1.37 in) without seals)
Total pinion-ring gear bearing preloading
T = (P + 45.9 N (10.32 lb)) ÷ (P + 68.8 N (15.47 lb)) N
(measured on D = 34.87 mm (1.37 in) without seals)
Pinion bearings rolling torque measured without seal TP = 1.6 N·m (1.18 lb ft) ÷ 2.4 N·m (1.77 lb ft)
Total pinion-ring gear bearing rolling torque measured TT = (TP + 0.80 N·m (0.59 lb ft)) ÷ (TP + 1.20 N·m
without seal (0.89 lb ft))
Powered front axle - Special tools

The special drifts/pad used to assembly the seals, bearings and bushes should always be used with the interchange-
able handle, its use is recommended together with a suitable safety handle in order to protect the hands.
380000406 Wrench
PTIL13TLB0670AA 1
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380200186 Driver
PTIL13TLB0678AA 2
380200455 False differential box disc
PTIL13TLB0675AA 3
380002214 False differential box pin
PTIL13TLB0679AA 4
380200456 Driver
PTIL13TLB0672AA 5
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380002215 Driver
PTIL13TLB0676AA 6
380002216 Driver
PTIL13TLB0680AA 7
380002219 False pinion
PTIL13TLB0673AA 8
380200457 Driver
PTIL13TLB0681AA 9
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380200458 Driver
PTIL13TLB0682AA 10
380002223 Driver
PTIL13TLB0687AA 11
380200459 Driver
PTIL13TLB0692AA 12
380200460 Driver
PTIL13TLB0683AA 13
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380200461 Wrench
PTIL13TLB0688AA 14
380002224 Driver
PTIL13TLB0693AA 15
380200462 Driver
PTIL13TLB0684AA 16
380200221 Driver
PTIL13TLB0689AA 17
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380200463 Driver
PTIL13TLB0694AA 18
380002229 Driver
PTIL13TLB0685AA 19
380200023 Driver
PTIL13TLB0690AA 20
380200464 Driver
PTIL13TLB0695AA 21
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380200465 Driver
PTIL13TLB0686AA 22
380200026 Driver
PTIL13TLB0691AA 23
380200466 Tool for preload measure
PTIL13TLB0696AA 24
380200467 Driver
PTIL13TLB0697AA 25
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380200468 Driver
PTIL13TLB0698AA 26
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Powered front axle - Exploded view

Axle beam group
PTIL13TLB0558FB 1
1. Axle beam 5. Seal rings

2. Upper bush 6. U-joints
3. Ball bearing cup 7. Seal rings
4. Bush 8. Bush
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Powered front axle - Remove - (2WD and 4WD)

1. Park the machine on a level surface. Stop the engine
and apply the parking brake.
PTIL14TLB0009AA 1
2. Loosen the front wheel lug nuts (1) on both sides.
PTIL12TLB0190AB 2
3. Lower the loader and lift the machine.
PTIL14TLB0131AA 3
4. Support the machine as shown.
PTIL13TLB1218AA 4
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5. After supporting the machine firmly, lift the loader com-

pletely and engage the support strut (3) and the lock
pin (2) and (1).
6. Switch Off the engine and disconnect the negative ter-
minal of the battery. See Basic instructions () .
PTIL13TLB1190AB 5
7. Remove the front wheels from the machine.
PTIL13TLB0732AA 6
8. Identify tag and disconnect the steering hoses (1). Plug

the hoses and install caps on the steering cylinder fit-
tings.
PTIL13TLB0733AB 7
9. Disconnect the drive shaft (1) from the front axle end (if
4WD).
10. Support the drive shaft suitably.
PTIL13TLB1217AB 8
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11. Place a trolley jack of suitable capacity under the front

axle to hold the axle in position.
PTIL13TLB0734AA 9
12. Remove the circlip (1).
PTIL13TLB1191AB 10
13. Tap and remove the pivot pin (1) from the front axle
using a mallet.
PTIL13TLB1192AB 11
14. Carefully lower and remove the front axle from the
machine.
PTIL13TLB0731AA 12
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Powered front axle - Install - (2WD and 4WD)

1. Carefully slide and position the front axle under the ma-
chine using a trolley.
2. Using a mallet drive in the pivot pin (1) to the front axle.
PTIL13TLB1192AB 1
3. Install the circlip (1).
PTIL13TLB1191AB 2
4. Raise the trolley jack to position the front axle in the

machine.
PTIL13TLB0734AA 3
5. Free the drive shaft (1) from the support and connect it
to the front axle end (if 4WD).
PTIL13TLB1217AB 4
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6. Remove the caps and plugs from the steering cylinder

fittings and hoses (1). Connect the steering hoses.
PTIL13TLB0733AB 5
7. Install the front wheels to the machine and tighten the

wheel nuts.
Connect the negative terminal of the battery Basic in-
structions.
Switch “On” the engine.
PTIL13TLB0732AA 6
8. Lower the loader to lift the machine slightly.

Remove the support planks from chassis and rest the
machine on wheels. Remove the trolley jack from the
machine.
PTIL14TLB0131AA 7
9. Switch “Off” the engine and tighten the front wheel lug
nuts to a torque of 196.13 N·m (144.66 lb ft).
PTIL12TLB0190AB 8
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Powered front axle - Disassemble

1. Remove the two double U-joints (6) from the axle beam
(1).
PTIL13TLB0559AB 1
2. Remove the seal rings (5) from the axle beam (1).
NOTE: Destructive operation for the seal rings (5), the seal
rings must be replaced.
3. Remove the bush (4) from the axle beam (1) only if the
wear conditions require this.
ATTENTION: Be careful not to damage the bush seat.
PTIL13TLB0560AB 2
4. Remove the upper king pin bush (2) and the ball bear-
ing cup (3) from the king pin seats using a suitable
puller only if the wear conditions require this.
PTIL13TLB0561AB 3
5. Remove the seal rings (7) from the axle beam (1).
NOTE: Destructive operation for the seal rings (7), the seal
rings must be replaced.
6. Remove the bushes (8) from the axle beam (1) only if
the wear conditions require this.
ATTENTION: Be careful not to damage the bush seats.
PTIL13TLB0562AB 4
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Powered front axle - Assemble

1. Cool the upper king pin bush (2) and the ball bearing
cup (3) at a temperature lower than -100 °C (-148 °F)
with liquid nitrogen.
ATTENTION: Wear safety gloves.
2. Assemble the upper bush (2) on the upper king pin seat
with the indicated special tool and a hammer.
3. Assemble the ball bearing cup (3) on the lower king pin
seat with the indicated special tool and a hammer.
PTIL13TLB0563AB 1
4. Assemble the bush (4) on the axle beam (1) with the
indicated special tool and a hammer.
5. Assemble the seal ring (5) on the axle beam with the
indicated special tool and a hammer.
NOTE: Grease carefully the seal rings.
ATTENTION: Assemble the seal ring (5) as in figure in de-
pending of the axle type.
PTIL13TLB0564AB 2
PTIL13TLB0565AB 3
6. Insert the double U-Joint (6) inside the axle beam (1).
ATTENTION: Be careful not to damage the seal ring (5).
PTIL13TLB0566AB 4
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7. Assemble the bushes (8) on the axle beam (1) with the
special tool and a hammer.
8. Assemble two new seal rings (7) on the axle beam with
the special tool and a hammer.
PTIL13TLB0567AB 5
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Powered front axle - Toe in adjust

Toe-in adjustment
1. Put two equal 1 m (39.37 in) bars on the wheel sides
and lock them with two nuts on the wheel hub stud bolt.
ATTENTION: The two bars should be fixed on their middle
so that they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two bars.
RCPH10TLB618ABL 1
2. Measure “A” and “B” at ends of the bar.
RCPH10TLB619ABL 2
3. Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the re-
quested tolerance range. Refer to Powered front axle
- General specification (25.100).
RCPH10TLB718ABL 3
4. If toe-in is incorrect, operate with two wrenches on the

guide rods (1) screwing in and out the two joint tie rods
(3) equally till the toe-in is within the requested toler-
ance.
RCPH10TLB620ABL 4
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5. After adjusting, screw in the lock nuts (2) of the guide

rods (1) to 120 N·m (88.5 lb ft).
RCPH10TLB621ABL 5
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Powered front axle - Test

1. With engine “Off”, lift the axle so that the tires get away
from the ground.
2. Engage the gear so that the pinion gets locked.
3. With the help of another person standing on the op-
posite side, begin the assembly testing by rotating as
much as possible both the wheels forward. (Both the
wheels should get blocked after a while).
4. Keeping the pinion locked, free the right wheel and ro-
tate the left one in the line of march. Rotate the right
wheels in the opposite direction.
The wheel will move freely without difficulty and the right
wheel will move in the opposite direction if the assembly
has been carried out correctly.
Repeat the same operation in the opposite direction (re-
verse gear).
If one wheel does not rotate freely in both directions,
then check step by step all assembly operations.
Check and see that the brakes are regulated correctly
and functioning properly.
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Index

Powered front axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Powered front axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Powered front axle - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Install - (2WD and 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Powered front axle - Remove - (2WD and 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered front axle - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Powered front axle - Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Front bevel gear set and differential - 102
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Differential
Exploded view - Differential support group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Axle pinion
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Bevel gear set and differential carrier

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Axle pinion
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Front axle system - Front bevel gear set and differential
Differential - Exploded view - Differential support group
PTIL13TLB0568FB 1
1. Differential support 8. Ring nut retainer

2. Screw 9. Bolt
3. Ring nuts 10. Bush
4. Bearing cups 11. Half-collars
5. Differential housing 12. Screw
6. Bearing cups 13. Sleeve
7. Ring nuts 14. Axle housing
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Differential - Exploded view
PTIL13TLB0158FB 1
1. Bush 13. Washer

2. Half boxes 14. Sun gear
3. Half boxes 15. Trunion
4. Dowel pin 16. Planetary gear
5. Bevel gear 17. Washer
6. Bush 18. Pin
7. Screws 19. Planetary gear
8. Bearing cone 20. Washer
9. Lock ring 21. Sun gear
10. Sleeve 22. Washer
11. Pin 23. Bearing cone
12. Differential housing
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Axle pinion - Exploded view
PTIL13TLB0171FB 1
1. Bevel pinion 6. Washer

2. Shim 7. Central body
3. Bearing cone 8. Bearing cone
4. Washer 9. Washer
5. Collapsible spacer 10. Lock nut
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Bevel gear set and differential carrier - Test

To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
PTIL13TLB0597AA 1
“OK” -> Correct contact:

If the bevel gear is well adjusted, the mark on the teeth
surfaces will be regular.
“Z” -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in order
to adjust the backlash.
“X” -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and then
approach the ring bevel gear to the pinion in order to
adjust the backlash.
PTIL13TLB0598AA 2
Movements to correct:
1. Move the pinion for type ”X” contact adjustment.
2. Move the pinion for type “Z” contact adjustment.
PTIL13TLB0599AB 3
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Differential - Remove
Refer Differential - Exploded view - Differential sup-
port group (25.102)
1. Drain the oil completely from the differential.
2. Disassemble the wheel/double U-joint group from the
axle beam.
NOTICE: Remove the double U-joint from the differential
before disassembling the differential support group.
PTIL13TLB0569AA 1
3. Loosen and remove the screws (2) on the differential

support (1).
4. Remove the differential support (1) from the axle hous-
ing (14).
NOTICE: Support the differential support with a rope or
other appropriate means.
PTIL13TLB0570AB 2
5. Measure the starting total pre-loading To of the bear-

ings (pinion crown gear system), using a dynamometer
whose cord is wound on the pinion splined end.
6. Note the value To that is necessary in the bearings
reassembly.
PTIL13TLB0571AB 3
7. Loosen and remove the screws (9) to take out the two
ring nut retainers (8).
PTIL13TLB0572AB 4
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8. Before removing the bolts, mark both half-collars (11)

and the differential support with permanent reference
marks to avoid inverting them during re-assembly.
Mark the area between the ring nuts (3) and (7) and
the differential support (1) as well.
PTIL13TLB0573AB 5
9. Unscrew the adjuster ring nuts (3) and (7) using the
special tool 380000406 and a wrench.
PTIL13TLB0574AB 6
10. Remove the 4 screws (12) and remove both half-col-

lars (11).
NOTE: Check that the bushes (10) remains in their hous-
ings.
PTIL13TLB0575AB 7
11. Remove the differential housing (5).

12. The bearing cups (4) and (6) are removed together
with the differential housing.
NOTICE: Do not invert the bearing cups if the bearings are
not replaced.
PTIL13TLB0576AB 8
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Differential - Assemble
See Differential - Exploded view (25.102).
1. Assemble the bearings cups (4) and (6) on the differ-
ential housing (5).
NOTICE: Do not invert the bearing cups if the bearings are
not replaced.
PTIL13TLB0577AB 1
2. Position the complete differential box with bearings on

the differential carrier (1) and assemble the fork to the
differential sleeve.
NOTICE: Check the right side of the bevel crown assembly.
PTIL13TLB0578AB 2
3. Move the differential group so to place the bevel crown

gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using the
previously traced reference marks.
Lock both collars with their fastening bolts (12).
PTIL13TLB0579AB 3
4. Assemble the adjusting ring nuts (3) and (7) to the dif-
ferential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly pre-loaded.
Check that the differential bearings are well settled, if
necessary, knock slightly with a plastic mallet, in order
to properly set the bearings in position.
PTIL13TLB0580AB 4
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5. Position a magnetic-base dial gauge on the differential

support, so that the feeler stylus touches the surface of
one tooth of the crown gear with a 90° angle.
PTIL13TLB0581AA 5
6. Lock the pinion and move the crown gear alternatively

and note the pinion-ring gear backlash, measured with
the comparator.
Repeat the operation on 2 or more points (teeth), rotat-
ing the crown gear, so that to obtain an average value.
Check if the measured backlash value is within the
requested range of 0.150 – 0.300 mm (0.006 –
0.012 in).
Set the backlash by turning the adjusting ring nuts (3)
and (7) with the special tool 380000406.
PTIL13TLB0582AB 6
7. Adjust the ring nuts (3) and (7), remembering that:

A. If the measured backlash is greater than the given
tolerance range, unscrew the adjuster ring nut (3)
and screw in the adjuster ring nut (7) by the same
measure.
B. If the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut (7)
and screw in the adjuster ring nut (3) by the same
measure.
PTIL13TLB0583AB 7
8. Once the adjustment of the pinion-ring gear backlash

has been carried out, check also that there is a mini-
mum pre-loading on the differential box bearings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
PTIL13TLB0584AA 8
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9. Once the pinion-ring gear backlash has been estab-

lished, if the bearings have been not replaced, measure
the total pre-loading Tm of the bearings (pinion-crown
bevel gear system), using a dynamometer whose cord
is wound on the pinion splined end.
NOTICE: Do not use this method with new bearings, if the
bearings have been replaced see next step.
The measured value should must be the starting value:
Tm = T0
follow the operating procedures in Step 8.
PTIL13TLB0585AB 9
10. If the bearings have been replaced, measure the total

pre-loading Tm of the bearings (pinion-crown bevel
gear system), using a dynamometer whose cord is
wound on the special tool 380200466 inserted on the
pinion splined end.
PTIL13TLB0586AB 10
11. The total pre-loading Tm is measured on the special

tool 380200466.
The measured value should be within the following
range:
Tm = (Pm + 16.9 N (3.80 lb)) ÷ (Pm + 25.3 N
(5.69 lb))
Tm = (Pm + 14.6 N (3.28 lb)) ÷ (Pm + 21.9 N
(4.92 lb))
Tm = (Pm + 14.7 N (3.30 lb)) ÷ (Pm + 21.7 N
(4.88 lb))
where Pm is the effectively pre-loading measured on
the special tool 380200466 (gauge diameter Dm = PTIL13TLB0587AB 11
104.7 mm (4.122 in)).
lished, instead proceeding with Step 10 and 11 mea-
sure the total rolling torque (TT) of the bearings (pin-
ion-crown bevel gear system) with a torque meter and
the special wrench.
NOTICE: All the pre-loads must be measured without the
seal installed.
PTIL13TLB0587AB 12
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13. The total rolling torque TT must be within the following

range:
TT = (TP + 15.3 N·m (11.28 lb ft)) ÷ (TP +
22.9 N·m (16.89 lb ft))
TT = (TP + 13.3 N·m (9.81 lb ft)) ÷ (TP + 19.6 N·m
(14.46 lb ft))
where TP is the pinion bearings pre-loading.
PTIL13TLB0589AB 13
14. If the measurement is not within the requested range,

check well the assembly of each component and op-
erate on the adjuster ring nuts (3) and (7) of the dif-
ferential support:
A. If the total pre-loading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion ring
gear backlash value unchanged.
B. If the total pre-loading is greater than the given
range, unscrew both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-ring
gear backlash value unchanged.
PTIL13TLB0590AB 14
15. Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws
(9), tightening them to the requested torque.
PTIL13TLB0591AB 15
16. Tighten the bolts (12) of both half collars (11) to the
requested torque.
PTIL13TLB0592AA 16
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17. Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with appro-
priate detergents.
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier (1).
NOTE: Check that two dowel pins (13) are in their housing.
PTIL13TLB0593AB 17
18. Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.
PTIL13TLB0594AB 18
19. Check the wear conditions and the correct position of

the seal ring (s) and bushing (b) in the axle beam (14).
If necessary replace the damaged parts.
PTIL13TLB0595AB 19
20. Assemble the wheel/double U-joint group to the axle

beam.
PTIL13TLB0596AA 20
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Differential - Disassemble
See Differential - Exploded view (25.102)
1. Remove the differential support group before disas-
sembling the differential group.
See Differential - Exploded view (25.102).
2. Remove the lock ring (9).
3. Remove the sleeve (10) and pins (11) from the differ-
ential housing (12).
PTIL13TLB0159AA 1
4. Lock the differential with a clamp.

5. Unscrew the fastening screws (7) and remove the bevel
gear (5).
ATTENTION: This will make both differential half boxes (2)
and (3) free, so take care not to drop the internal compo-
nents.
PTIL13TLB0160AA 2
6. Make alignment marks on the half boxes before split-

ting them.
7. Disassemble the differential half boxes (2) and (3) with
the relative components.
8. Disassemble all the components.
9. Check the operating and wear conditions of the com-
ponents.
PTIL13TLB0161AB 3
10. Remove the bearings cones (8) and (23) of the half
boxes (2) and (3), using two levers or a three-hold
extractor.
PTIL13TLB0162AB 4
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11. Remove the bush (1) and (6) from the half boxes (2)
and (3) only if the wear conditions require this.
NOTE: This is a destructive operation for the bushes.
ATTENTION: Be careful not to damage the bush seat.
PTIL13TLB0163AB 5
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See Differential - Exploded view (25.102)
1. Assemble the bushes (1) and (6) to the half housings
(2) and (3) with a driver and a hammer.
PTIL13TLB0164AB 1
2. Assemble the bearing cones (8) and (23) on the half

housings (2) and (3), using the special tool 380002216
and a hammer.
PTIL13TLB0165AB 2
3. Position the half housing (2) on a work bench and as-

semble all inner components as shown in Fig. 3.
4. Join the two half boxes, aligning the reference marks
made in disassembly.
PTIL13TLB0166AB 3
5. Before matching surfaces, make sure that they are per-

fectly clean, degrease and clean them with appropriate
detergents.
6. Position the bevel crown gear (5) on the half box (3).
NOTE: Check dowel pin (4) position.
7. Apply LOCTITE® 270 / Superbond® 331 sealant on the
thread and tighten the bolts (7) to the requested torque.
PTIL13TLB0167AA 4
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8. Assemble the sleeve (10) on the differential housing

(2).
ATTENTION: Take care to assemble it in the correct posi-
tion.
9. Assemble the lock ring (9) to the differential housing
(2).
PTIL13TLB0170AA 5
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Axle pinion - Disassemble

Refer Axle pinion - Exploded view (25.102)
1. Unscrew the lock nut using special tools 380000021
and 380200461.
NOTE: This operation damages the ring nut, the ring nut
must be replaced when assembling the group.
PTIL13TLB0172AA 1
2. Tap the end shaft with a soft hammer to remove the

bevel pinion.
3. Collect the washer and the bearing cone.
PTIL13TLB0173AA 2
4. Once the bevel pinion has been removed, collect the

washer, the collapsible spacer and the washer.
NOTE: The collapsible spacer must be replaced when as-
sembling the group.
PTIL13TLB0174AA 3
5. Check the bearing cups wear condition.

6. If bearings replacement is necessary, remove bearing
cups from central body with a drift and a hammer.
PTIL13TLB0175AA 4
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7. Remove the bearing cone (3) of the bevel pinion (1)

with a standard extractor.
Collect the shim (2).
PTIL13TLB0176AB 5
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Axle pinion - Assemble

See Axle pinion - Exploded view (25.102).
1. Position the central body (6) on a workbench.
2. Fit the bearing cups (3) and (8) into their seats using
the special tool 380002215.
PTIL13TLB0177AA 1
3. Use the special tools false pinion and false differential

box ( 380002214 and 380200455) to measure the conic
distance.
4. Insert into the seats the bearing cups (3) and (8) and
the false pinion. Tighten the ring nut (10) to eliminate
the backlash.
PTIL13TLB0178AA 2
5. Check the correct positioning of the right and left brake

cylinder and differential housing supports, using the ref-
erence marks on them and on the central body (6).
6. Assemble the two brake cylinders with their fastening
bolts.
PTIL13TLB0179AA 3
7. Insert the false differential box into the central body (6).
8. Check that the false differential box is inserted in both
differential support housings.
PTIL13TLB0180AA 4
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9. To adjust bevel gear/pinion measure the distance “A”

with a depth gauge.
Calculate the value “X” as follows:
X=(A+C)-B mm
where “B” and “C” are known.
PTIL13TLB0181AA 5
10. From the value “X” deduct the value “V” (stamped on
the pinion head) to get the value “S”.
S=X-V mm
PTIL13TLB0182AB 6
11. Choose the shim (2) with thickness value (S) among
the available shims range.
PTIL13TLB0183AA 7
Shims range
Thick- 2.5 mm 2.6 mm 2.7 mm 2.8 mm 2.9 mm 3.0 mm 3.1 mm 3.2 mm 3.3 mm 3.4 mm
ness (0.1 in) (0.10 in) (0.11 in) (0.11 in) (0.11 in) (0.12 in) (0.12 in) (0.13 in) (0.13 in) (0.13 in)
Qty. - - - - - - - - - -
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12. Loosen and remove the ring nut (10).

13. Remove the false pinion and the bearing cones (3)
and (8) from the central body (7).
14. Disassemble the false differential box from the brake
cylinders and then unscrew the screws to remove the
brake cylinders.
PTIL13TLB0184AB 8
15. Insert the chosen shim (2) with the chamfer against
the gear on the pinion shaft (1).
16. Force the bearing (3) on the pinion shaft (1) with the
special tool 380002224 under a press, making sure
that it is well set.
17. Assemble the shim (4), a new collapsible spacer (5)
and the shim (6) to the pinion shaft.
NOTE: Use always a new collapsible spacer (5).
PTIL13TLB0185AB 9
18. Insert the bevel pinion (1) unit into the central body (7)
and the bearing (8) into the pinion shaft, as shown in
figure.
19. Force the bearing (8) in position with the special tool
380002224 and a hammer.
NOTE: Push the pinion against the central body to perform
this operation.
PTIL13TLB0186AA 10
20. Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
21. Screw the ring nut (10) in, using the wrench for ring
nut 380000021 and for pinion retainer 380200461.
ATTENTION: The torque setting is given by the preloading
measurement on bearings (3) and (8), tighten the ring nut
(10) gradually.
NOTE: If the tightening is excessive, the collapsible spacer
(5) must be replaced and the procedure repeated.
22. When you check the preloading, it is advisable to beat
slightly both pinion ends (1) with a soft hammer, so as
PTIL13TLB0172AA 11
to help setting the bearings (3) and (8).
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23. To measure the preloading “P” of the pinion taper roller

bearings, use a dynamometer whose cord is wound
on the special tool 380200466 inserted on the end of
pinion shaft.
24. The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.
PTIL13TLB0187AA 12
25. The effectively preloading Pm is measured on the spe-

cial tool (gauge diameter Dm = 104.4 mm (4.1 in)).
range:
Pm = 30.7÷45.7 N
PTIL13TLB0188AB 13
26. Once the requested preloading value is achieved,

stake the ring nut (10), using a hammer and a chisel.
PTIL13TLB0189AA 14
27. Assemble the flange group.
PTIL13TLB0190AA 15
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Index

Axle pinion - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Axle pinion - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Axle pinion - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bevel gear set and differential carrier - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Differential - Exploded view - Differential support group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Final drive hub, steering knuckles, and shafts - 108
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Final drive hub, steering knuckles, and shafts

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wheel hub
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Front axle system - Final drive hub, steering knuckles, and shafts
Final drive hub, steering knuckles, and shafts - Exploded view

Epicyclic reduction gear group (applicable for 4WD)
PTIL13TLB0510FB 1
1. Screws 6. Needle bearing

2. Oil plug 7. Planetary gears
3. Planetary carrier 8. Triangular plate
4. O-ring 9. Snap ring
5. Washer
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Final drive hub, steering knuckles, and shafts - Exploded view

Reduction gear for axles
PTIL13TLB0520FB 1
1. Screws 6. Needle bearing

2. Oil plug 7. Washer
3. Planetary carrier 8. Snap ring
4. Needle bearing 9. O-ring
5. Planetary gears 10. Wheel nut stud
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Wheel hub - Exploded view
PTIL13TLB0530FB 1
1. Lock ring 15. Cone

2. Shaft washer 16. Lower king pin
3. Shaft washer 17. Bolt
4. Epicyclic ring gear 18. Upper king pin
5. Bolt 19. Bolt
6. Bush 20. Nut
7. Wheel carrier 21. Screw
8. Steel lock ring 22. Bush
9. Bearing cone 23. Seal ring
10. Wheel nut stud 24. Axle shaft
11. Wheel hub 25. Belleville washers
12. Bearing cone 26. Axle housing
13. Seal ring 27. Belleville washers
14. Swivel housing
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Final drive hub, steering knuckles, and shafts - Disassemble

Refer Final drive hub, steering knuckles, and shafts
- Exploded view (25.108)
1. Drain the oil completely from the planetary carrier.
PTIL13TLB0511AA 1
2. Unscrew and remove both fastening screws (1) of the

planetary carrier (3) with a wrench.
PTIL13TLB0512AB 2
3. Remove the planetary carrier (3) from the wheel hub

and collect the relative O-ring (4).
NOTE: Destructive operation for the O-ring (4), the O-ring
must be replaced.
Position the planetary carrier (3) on a workbench and
check its wear conditions.
PTIL13TLB0513AA 3
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4. If required replace the planetary gears as follows:

• Remove the Seeger rings (9) on every pin.
• Remove the triangular plate (8).
• Remove the planetary gears (7) from the pins.
• Collect the needle bearings (6), checking their con-
ditions.
• Collect the washer (5).
PTIL13TLB0514AB 4
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Final drive hub, steering knuckles, and shafts - Assemble

1. Collect all epicyclic reduction gear parts: The planetary
carrier (3), the thrust washers (5), the needle bearings
(6), the planetary gears (7), the triangular plate (8) and
the snap rings (9) of every pin.
NOTE: With new planetary gears is advisable to assembly
new roller bearings.
PTIL13TLB0514AB 1
2. Position the planetary carrier on a workbench.

Insert the thrust washers (5) and the epicyclic gears (7)
in the planetary carrier pins.
Insert the needle bearings (6) in the epicyclic gears (7).
NOTE: Grease well the needles.
Assemble the triangular plate (8) and the related snap
rings (9).
PTIL13TLB0516AB 2
3. Assemble a new O-ring (4) on the planetary carrier (3).

Assemble the epicyclic reduction gear on the wheel
hub.
PTIL13TLB0517AB 3
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4. Assemble the screws (1) and tighten them to the pre-

scribed torque.
PTIL13TLB0512AB 4
5. Top up the oil on the wheel hub.

Fit the filling/drain and level oil plug (2) on the planetary
carrier (3) and tighten to the prescribed torque.
PTIL13TLB0519AB 5
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Reduction gear
1. Drain the oil completely from the epicyclic reduction
gear.
PTIL13TLB0521AA 1
2. Unscrew and remove the two fastening screws (1) of

the planetary carrier (3) with a wrench.
PTIL13TLB0522AB 2

and remove the relative O-ring (9).
NOTE: Destructive operation for the O-ring (9), the O-ring
must be replaced.
Position the planetary carrier (3) on a workbench and
PTIL13TLB0523AB 3
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4. If required replace the planetary gears as follows:

• Remove the snap rings (8) on every pin.
• Remove the planetary gears (5) from the pins.
• Collect the needle bearings (6) and (4), checking
their conditions.
• Collect the washer (7).
PTIL13TLB0524AB 4
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Final drive hub, steering knuckles, and shafts - Assemble

Reduction gear
- Exploded view (25.108).
1. Collect all epicyclic reduction gear parts, the planetary
gears carrier (3), the planetary gears (5), the needle
bearings (4) and (6), the washer (7) and the snap rings
(8) of every pin.
NOTE: With new planetary gears it is advisable to assem-
bly new needle bearings.
PTIL13TLB0525AB 1
2. Insert the needles (4) and (6) into the gears (5).
NOTE: Grease well the needles (4) and (6).
Insert the gears (5) with assembled needles in the plan-
etary carrier pins.
PTIL13TLB0526AA 2
3. Assemble the washer (7) and snap ring (8) on every

pin.
PTIL13TLB0527AB 3
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4. Assemble a new O-ring (9).

Fit the epicyclic reduction gear assembly (3) to the
wheel hub.
Assemble the screws (1) and tighten them to the pre-
scribed torque.
PTIL13TLB0528AB 4
5. Load the specified oil in the epicyclic reduction gear.

Fit the plug (2) on the epicyclic reduction gear (3) and
tighten to the prescribed torque.
PTIL13TLB0529AA 5
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Wheel hub - Disassemble

Refer to Steering cylinder - Exploded view (41.216)
and Final drive hub, steering knuckles, and shafts -
Exploded view (25.108) before disassemble the wheel
hub group.
1. Insert a lever between the swivel housing (14) and the
axle beam and fit it into the double U-joint. With the
lever push the double U-joint in the direction of the
wheel hub to allow the lock ring (1) removal.
ATTENTION: Do not damage the double U-joint.
PTIL13TLB0531AA 1
2. Remove the lock ring (1) from the double U-joint shaft.
3. Collect the double U-joint shaft washers (2) and (3).
NOTE: The shape of the washers (2) and (3) is different in
depending of the axle on which the operation is carried out.
PTIL13TLB0532AA 2
4. Unscrew and remove the fastening bolts (5) from the

wheel carrier (7).
PTIL13TLB0533AA 3
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5. To extract the wheel carrier screw two of the just re-

moved bolts (5) in the threaded holes. Remove the
wheel carrier (7) with the epicyclic ring gear (4).
PTIL13TLB0534AB 4
6. Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). Only if nec-
essary, remove the centering bushes (6) from the wheel
carrier with a hammer and the indicated special tool.
PTIL13TLB0535AB 5
7. Remove the wheel hub (11) using levers and a hammer

to facilitate the operation.
NOTE: Collect the bearing cone (9).
PTIL13TLB0536AA 6
8. Position the wheel hub (11) on a flat surface and re-

move the seal ring (13) with a puller.
NOTE: Destructive operation for the seal ring (13), the seal
ring must be replaced.
9. Remove the bearing cups (9) and (12) using a hammer
and a suitable drift.
10. Remove the bearing cone (12) from the swivel hous-
ing end (14), using a suitable puller.
PTIL13TLB0537AB 7
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25.3 [25.108] / 15
11. Unscrew and remove the fastening bolts (19) and (17)
from the upper (18) and lower (16) king pin.
ATTENTION: Before removing the king pins (16) and (18),
secure the swivel housing (14) with a belt or a rope to a
hoist or any other supporting device, observe all current
safety regulations to guarantee operator’s safety.
12. Remove the kingpins (16) and (18).
PTIL13TLB0538AA 8
13. Remove the kingpins (16) and (18).

NOTE: In axles the kingpins are in quadrangular shape
and the relative fixing screws are four (A), while in axles
the kingpins are in triangular shape and the relative fixing
screws are three (B).
PTIL13TLB0539AB 9
14. Remove the swivel housing (14) from the axle beam
and from the short shaft of the double U-joint.
15. Collect the belleville washers (25) and (27).
PTIL13TLB0540AA 10
16. Position the swivel housing (14) on a flat surface and

take the seal ring (23) out with a puller.
NOTE: This is a destructive operation for the seal ring (23),
the seal ring must be replaced. Overturn the swivel hous-
ing and take the bush (22) out, using a suitable drift and a
hammer.
PTIL13TLB0541AB 11
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Wheel hub - Assemble

See Steering cylinder - Exploded view (41.216) and
Final drive hub, steering knuckles, and shafts - Ex-
ploded view (25.108) before disassemble the wheel
hub group.
1. If it has been previously removed, reassemble the
steering stop composed by the screw (21) and nut
(20).
NOTE: Do not tighten the nut (20) until the steering angle
adjustment has been done.
PTIL13TLB0542AB 1
2. Force the bush into the swivel housing (14) with the
special tool 380200186 and a hammer or a press.
3. Assemble a new seal ring on the swivel housing (14)
with the special tool 380200462 and a hammer.
4. Grease carefully the seal ring.
PTIL13TLB0543AB 2
5. If the cone (15) of the spherical joint has been pre-

viously removed, reassemble it to the lower king pin
(16) using the indicated special tool 380200221 under
a press.
6. Grease carefully the seats of king pin (16) with specific
grease.
7. Position the belleville washers on the king pin (16) and
housings.
ATTENTION: Secure the swivel housing (14) with a belt or
a rope to a hoist or any other supporting device.
PTIL13TLB0544AB 3
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25.3 [25.108] / 17
8. Protect the splined end of the axle shaft by winding it

with an adhesive tape to avoid damage to the seal ring.
9. Assemble the swivel housing (14) on the axle beam and
after assembly, remove completely the adhesive tape.
PTIL13TLB0545AA 4
10. Assemble the king pins, the lower (16) and the upper
(18), and tighten the retaining screws (17) and (19) to
the requested torque.
NOTE: Make sure that the belleville washers (25) and (27)
remain in their position.
PTIL13TLB0546AA 5
11. The special operation “Set Right” of the bearings (9)

and (12) does not require preload or backlash adjust-
ment. Anyway, before assembling new components
check the indicated dimensions.
A = 0.999 mm (0.039 in)
B = 0.999 mm (0.039 in)
C = 0.995 mm (0.039 in)
PTIL13TLB0547AB 6
12. Force both bearing cups (9) and (12) to their wheel
hub (11) housings using the special tool 380002222
under a press or with a hammer.
13. Insert a new seal ring into the wheel hub (11) with the
special tool 380002229 and a hammer.
NOTE: Do not lubricate the seal ring.
PTIL13TLB0548AB 7
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14. Assemble the bearing cone (12) on the swivel housing

(14) end.
15. Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing cone (9).
PTIL13TLB0549AB 8
16. Position the wheel carrier (7) on a workbench and, if

previously removed, force the bushes (6) to the carrier
surface level with the special tool 380002223.
NOTE: At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to be
used as dowel pins.
PTIL13TLB0550AB 9
17. Preassemble the wheel carrier (7) and the epicyclic

ring gear (4) with the lock ring (8) shown in figure.
PTIL13TLB0551AB 10
18. Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact the
ring bevel gear with the wheel hub.
PTIL13TLB0552AA 11
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19. Force all the hub dowel bushes (6) completely with the
20. Assemble to the wheel carrier (7) the fastening bolts
(5).
NOTE: Tighten the bolts (5) to a torque of 95 N·m.
NOTE: Only for axles, before assembly the bolts (5) apply
the prescribed sealant on the thread.
PTIL13TLB0553AB 12
21. Insert a lever between the swivel housing and the axle
beam and fit it into the double U-joint. With the lever
push the double U-joint in the direction of the wheel
hub to make easier the lock ring insertion.
PTIL13TLB0554AA 13
22. Slide the thrust washers (2) and (3) onto the double
U-joint shaft end (24).
NOTE: The correct shape of the thrust washers for each
axle is shown at next point.
PTIL13TLB0555AB 14
23. Assemble the washers with the correct shape in de-

pending of the axle on which the operation is carried
out.
PTIL13TLB0556AB 15
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24. Insert the lock ring at the end of the splined hub and
push it into its seat.
NOTE: Check that the lock ring is correctly fitted in its seat.
25. Push the double U-joint thoroughly.
PTIL13TLB0557AA 16
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Index

Final drive hub, steering knuckles, and shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Final drive hub, steering knuckles, and shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Final drive hub, steering knuckles, and shafts - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final drive hub, steering knuckles, and shafts - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final drive hub, steering knuckles, and shafts - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wheel hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheel hub - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Non-powered front axle - 400
851FX Plus
851FX
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Contents
TECHNICAL DATA
Non-powered front axle

FUNCTIONAL DATA
Front axle
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Front axle
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSTIC
Front axle
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Front axle system - Non-powered front axle
Non-powered front axle - General specification

Description Values
Toe-in B - A = 1 ± 1 mm
Maximum steering angle 49° ± 1°
Stop length 30.300 mm (1.193 in)
Hub greasing interval 1000 h or 6 months which ever is early
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Front axle - Exploded view

Axle beam group
PTIL13TLB1526FB 1
1. Swivel housing 6. Mounting bolts

2. Axle beam 7. Washer
3. Tie rod end nut 8. Right-hand side tie rod
4. Left-hand side tie rod 9. Jam nut
5. Steering cylinder 10. Spacer
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Front axle - Disassemble

1. Loosen and Remove the grease nipples (19).
PTIL13TLB1518AB 1
2. Loosen and remove the king pin bolts. Retain the bel-
liville washers (17), (18).
PTIL13TLB1517AB 2
3. Remove the bearing cone from the king pin (16).
PTIL13TLB1516AB 3
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4. Remove the upper bush (14) and lower bush (15) from
the axle beam only if necessary.
PTIL13TLB1514AB 4
PTIL13TLB1515AB 5
5. Remove the end cap (12) and separate the O ring (11).
PTIL13TLB1512AB 6
6. Loosen and remove the hub (9) thrust washer (8) and
bolts (7).
PTIL13TLB1510AB 7
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7. Pull out the bearing cone (6).
PTIL13TLB1507AB 8
8. Using a suitable puller, pull out the hub (5).
PTIL13TLB1506AB 9
9. Separate the Inner bearing (3) and outer bearing cups

(2).
PTIL13TLB1503AB 10
PTIL13TLB1504AB 11
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10. Remove the inner wheel bearing cone (1).
PTIL13TLB1501AB 12
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Front axle - Assemble

1. Install inner wheel bearing cone.
A. Pack inner bearing (1) rollers lightly with #2 Moly
Disulfide grease before assembly.
PTIL13TLB1501AB 1
B. Press bearing cone onto knuckle until fully seated.

Pressing force: 3202 – 8111 N (720 – 1823 lb).
NOTE: Note: Use 0.076 mm (0.003 in) feeler gauge to ver-
ify cone is fully seated.
PTIL13TLB1502AA 2
2. Install outer wheel bearing cup.

A. Press outer bearing cup (2) into wheel hub until
fully seated.
NOTE: Note: Use 0.076 mm (0.003 in)feeler gauge to ver-
ify cup is fully seated.
PTIL13TLB1503AB 3
3. Install inner wheel bearing cup.

A. Press inner bearing cup (3) into wheel hub until
fully seated.
NOTE: Use 0.076 mm (0.003 in) feeler gauge to verify cup
is fully seated.
PTIL13TLB1504AB 4
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4. Install wheel cartridge seal.

A. Coat outer and inner surface of the seal (4) with
grease Kluberplus S 06-100.
B. Press inner wheel seal into wheel hub until proper
seated.
C. Verify seal is proper seated
PTIL13TLB1505AB 5
5. Install wheel hub onto knuckle.

A. Press wheel hub (5) onto knuckle.
NOTE: Alignment of hub to knuckle to be controlled to en-
sure seal is installed properly.
PTIL13TLB1506AB 6
6. Install outer bearing cone.

A. Pack inner bearing rollers lightly with #2 Moly
Disulfide grease.
B. Press the bearing cone (6) to flush or 0.250 mm
(0.010 in) above the end of knuckle shaft while ro-
tating the hub to allow bearings to roll. This will en-
sure the bearing does not get damaged and sets
correctly.
NOTE: Keep cup and cone matched.
PTIL13TLB1507AB 7
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7. Install thrust washer and bolts.

A. Install the thrust washer with the flat surface facing
the bearing.
NOTE: Ensure the mating surface (8) are free of dirt and
debris before installing washer.
B. Install and tighten the 3 bolts (7) to 96 – 118 N·m
(71 – 87 lb ft) while rotating the wheel hub (9) at
10 RPM at the same time.
C. Mark each bolt after the tightening them and apply-
ing the torque.
D. Check if the total rolling torque is in the range of 8
PTIL13TLB1510AB 8
– 25 N·m (6 – 18 lb ft).
E. If roll torque is larger than the maximum specified
torque, reinstall the washer and recheck total roll
torque.
F. If the roll torque is still out of range, repeat steps A
to C with new washer
8. Fill grease into cavity.
A. Fill approximately 168.30 ml (5.69 US fl oz) of #2
Moly Disulfide grease into the cavity through the
hole (10) until grease purges from bearing rollers.
PTIL13TLB1511AB 9
9. Install O-ring onto end cover

A. Lubricate O-ring with oil before installation.
B. Install O-ring (11) onto end cover (12).
C. Pack 81.62 ml (2.76 US fl oz) of #2 Moly Disulfide
grease along the inner edge of the cover.
PTIL13TLB1512AB 10
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10. Install cover and plug.

A. Press cover (13) into wheel hub until fully seated.
Press force: 2982 – 5275 N (670 – 1186 lb).
NOTE: Use 0.076 mm (0.003 in) feeler gauge to verify
cover is fully seated.
B. Apply Loctite 592 on plug.
C. Install and torque plug to 20 – 30 N·m (15 – 22 lb
ft).
D. Mark after torque is applied.
PTIL13TLB1513AB 11
11. Install king pin bush into beam.

A. Press bush (14) into beam until fully seated.
Press force: 1463 – 9328 N (329 – 2097 lb).
bushing is fully seated.
PTIL13TLB1514AB 12
12. Install king pin bearing outer ring into beam

A. Press the bearing outer ring (15) into beam end
until fully seated.
Press force: 1209 – 7705 N (272 – 1732 lb).
outer ring is fully seated.
PTIL13TLB1515AB 13
13. Install king pin bearing inner ring onto king pin.
A. Press spherical bearing inner ring (16) onto king
pin until fully seated.
Press force: 4003 – 10407 N (900 – 2340 lb).
NOTE: Use 0.076 mm (0.003 in) feeler gauge to verify in-
ner ring is fully seated.
PTIL13TLB1516AB 14
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14. Install steering knuckle to beam.

A. Pre-grease bearings (16) with #2 Moly Disulfide
grease.
B. Install thick belleville washer (17) on top and thin
belleville washer (18) in the bottom.
C. Ensure proper orientation of the washers and in-
stall the knuckle assembly into the beam.
D. Install and tighten the bolts to a torque of 96 –
118 N·m (71 – 87 lb ft).
NOTE: Use LOCTITE® 242® or LOCTITE® 243™ for the
bolts.
PTIL13TLB1517AB 15
15. Install grease nipples.

A. Apply Loctite 592 and install the nipples (19).
B. Tighten the plug to a torque of 20 – 30 N·m (15 –
22 lb ft).
PTIL13TLB1518AB 16
16. Pre-assemble tie-rods to steer cylinder.

A. Install and tighten the ball joints to a torque of 225
– 315 N·m (166 – 232 lb ft).
PTIL13TLB1519AA 17
17. Assemble steer cylinder group to beam.

A. Mount the steer cylinder on the axle and install
the bolts.
B. Install the tie rod ends tighten to a torque of 129
– 160 N·m (95 – 118 lb ft).
C. Tighten the mounting bolts to a torque of 414 –
560 N·m (305 – 413 lb ft).
PTIL13TLB1520AA 18
18. Adjust toe-in. Refer to Front axle - Toe in adjust

(25.400)).
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19. Install steering stop bolts and set steering angle.

A. Mount the stop bolts and adjust the stop length to
30.30 mm (1.19 in).
PTIL13TLB1522AA 19
B. Repeat procedure on the other side and ensure the

inner wheel steering angle holds at 48 – 50 °C (118
– 122 °F).
C. Tighten the stop bolt locking nut to a torque of 162
– 198 N·m (119 – 146 lb ft).
PTIL13TLB1524AA 20
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Front axle - Toe in adjust

Refer Front axle - Exploded view (25.400) .
1. Remove both front wheels. Refer Front wheels - Re-
move (44.511)
2. Raise the loader completely and lock by engaging the
support strut.
3. Switch off the engine and disconnect the battery.
4. Put two equal 1 m (39.37 in) bars on the wheel sides
and lock them with two nuts on the wheel hub stud bolt.
ATTENTION: The two bars should be fixed on their middle
so that they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two bars.
5. Measure “A” and “B” at ends of the bar.
PTIL13TLB1521AB 1
6. Check that the difference of the measurements is

B-A=1±1 mm.
7. If the toe-in is incorrect operate with two wrenches on
the guide rods (4,8) screwing in and out of two joint
tie rods equally till the toe-in is within the requested
tolerance.
8. After adjusting screw in the lock rods tighten the jam
nuts (9). to a torque of 255 – 315 N•m (66.38 – 73.76 lb
ft).
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Front axle - Troubleshooting

Wheel vibration, front Incorrect installation/defective axle Correct installation or repair or replace the
tyre resistance, half shaft differential in case it does not survive any
breakage one of the test phases
Overloading/incorrect weight distribution Remove excessive weight and redistribute
load, following instructions related to the
vehicle
Different rotation radius of the tires If one tyre has a smaller radius, it will cause
partial wheel slipping when force is applied.
The other tyre with bigger radius will have
to support all the work. Replace the tire
or adjust pressure to have same radius on
both tire
Bent half shaft Replace half shaft
Incorrect use of the product Refer Operators Manual
Steering is difficult; Incorrect installation/defective axle Correct installation or repair or replace the
vehicle goes straight differential in case it does not survive any
while it’s turning one of the test phases
vehicle
Different rotation radius of the tires If one tire has a smaller radius, it will cause
The other tire with bigger radius will have
both tire
Broken half shaft It is not advisable to operate the vehicle
with a broken half shaft. It is acceptable to
move the vehicle (engine “Off” unloaded) a
few meters away only
Incorrect use of the product Refer to Operator Manual for correct usage
of the machine
No differential action, Incorrect installation/defective axle Correct installation or repair or replace the
jamming while steering differential in case it does not survive any
one of the test phases
vehicle
both tire
with a broken half shaft. It is acceptable
to move the vehicle (engine Off unloaded)
a few meters away only
Incorrect wheel adjustments Verify group integrity and wheel side bear-
ings. Adjusting according
Contamination in the axle box or incorrect Look for foreign particles. Check assembly
assembly of parts of the various parts of the axle
of the machine
Uneven wear of tire Incorrect installation/defective axle Correct installation or repair or replace the
differential in case it does not survive any
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Remove excessive weight and redistribute
Overloading/incorrect weight distribution
vehicle
both tire
Blocked differential Abnormal functioning of the differential or
breakage/blockage of command device.
Verify assembly and all components. Vehi-
cles with wide steering angle may proceed
with kicks, have steering difficulty or cause
pneumatic wearing at sharp turns. Reduce
the steering angle to minimum and decel-
erate when the vehicle begins to kick
of the machine
Friction noise Incorrect installation/defective axle Correct installation or repair or replace the
Spoiled or worn out axle parts Check the condition of ring gear, pinion
gear, bearings etc. Replace whenever nec-
essary
Incorrect adjustment of bevel gear set: (Transmission gears, U joints, etc.) Re-
Parts of the transmission worn out place or adjust as required
of the machine
Vibration during forward Incorrect installation/defective axle Correct installation or repair or replace the
drive, intermittent noise differential in case it does not survive any
vehicle
both tire
of the machine
Ring gear tooth broken on Excessive gear load compared to the one Replace bevel gear set follow carefully the
the outer side foreseen recommended operations for the adjust-
ment of bevel gear set backlash
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Incorrect gear adjustment (excessive back- Adjust backlash
lash)
Pinion nut loose Tighten pinion nut
Ring gear tooth broken on Load bump Replace bevel gear set
the inner side
Incorrect gear adjustment (insufficient Follow carefully the recommended opera-
backlash) tions for the adjustment of bevel gear set
backlash
Pinion or ring gear teeth Insufficient lubrication Replace bevel gear set
worn
Contaminated oil Drain the oil and replace with new recom-
mended grade of oil
Incorrect lubrication or depleted additives Use correct lubricants, fill up to the right
levels and replace according to the recom-
mended program
Worn out pinion bearings that cause an Replace with new bearings
incorrect pinion axle backlash and wrong
contact between pinion and ring
Overheated ring and Prolonged functioning at high temperatures Replace bevel gear set
pinion teeth. See if gear
teeth have faded
Incorrect lubrication Use proper lubrication, fill up to right level
and replace at recommended program
Low oil level Top up oil
Contaminated oil Replace oil
Pinion teeth pitting Excessive use Replace bevel gear set
Insufficient lubrication Use correct lubrication, fill up to the right
level and substitute at recommended inter-
vals
Axle beam body bent Vehicle over loaded Replace axle beam body
Vehicle's accident Check chassis alignment
Load bump Replace bevel gear set
Worn out or pitted Insufficient lubrication Replace bearings
bearings
Contaminated oil Use correct lubrication fill up, to the right
level and replace at recommended inter-
vals
Excessive use Follow recommended maintenance interval
Normal wear out Replace as required
Oil leakage form gaskets Prolonged functioning at high temperature Replace the gasket or seal and matching
and seals of the oil surface if damaged
Oil gasket assembled incorrectly Use correct lubrication and replace at rec-
ommended intervals
Seal lip damaged Replace seal
Contaminated oil Replace with new oil
Excessive wearing out of Exhaustive use Replace the flange
input flange Spline
Pinion nut loose Check that the pinion spline is not exces-
sively worn out
Pinion axle backlash Replace bevel gear set if required
Fatigue failure of pinion Exhaustive use Replace bevel gear set
teeth See if the fracture
line is well defined (wave
lines, beach lines)
Continuous overload Refer manual for correct loading values
Pinion and ring teeth Crash load of differential components Check and/or replace other differential
breakage components
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Side gear spline worn Excessive use Replace differential gear group. Replace
out. Replace all scratched half shaft if required
washers (excessive
backlash)
Thrust washer surface Insufficient lubrication Use correct lubrication and fill up to right
worn out or scratched level
Incorrect lubrication Replace at intervals recommended
Contaminated oil Replace at intervals recommended. Re-
place all scratched washers and those with
0.100 mm (0.004 in) thickness lower than
the new ones
Inner diameter of tapered Excessive use Replace bearing
roller bearing worn out
Excessive pinion axial backlash Check pinion axial backlash
Insufficient lubrication Use proper lubrication, fill up to right level
and replace at recommended intervals
Bent or broken half shaft Vehicle intensively operated or overloaded Replace
Half shaft broken at wheel Wheel support loose Replace
side
Beam body bent Check that wheel support is not worn out or
wrongly adjusted
Noise while driving Excessive backlash between pinion and Adjust
ring gear
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loose Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loose Adjust
Ring gear out of roundness Replace
Low lubricant level Oil level
Poor or wrong lubricant Replace
Bent half shaft Replace
Noise while driving in Noise coming from axle are usually heard Replace or adjust (see above)
neutral when vehicle moves in neutral gear but are
not loud
Incorrect backlash between pinion and ring Replace
(sound heard while decelerating disap-
pears while increasing the speed)
Pinion or input flange worn out Adjust
Intermittent noise Ring gear damaged Replace bevel gear set
Differential box bolts loose Tighten to torque
Constant noise Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Noise while steering Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
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Index

Front axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front axle - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front axle - Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Non-powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Rear axle system
851FX Plus
851FX
91715732 26/07/2021
27
Contents
Rear axle system - 27
[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2
[27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3
91715732 26/07/2021
27
Powered rear axle - 100
851FX Plus
851FX
91715732 26/07/2021
27.1 [27.100] / 1
Contents
TECHNICAL DATA
Rear axle
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUNCTIONAL DATA
Rear axle
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SERVICE
Rear axle
Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassemble Axle beam trumpet group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble - Axle beam trumpet group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSTIC
Rear axle
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Rear axle system - Powered rear axle
Rear axle - General specification

Technical features
Description Values
Weight 386.4 kg (851.9 lb)
Bevel gear set backlash 0.18 – 0.23 mm
Pinion bearings pre loading (measured on D= 34.87 mm (1.37 in)
P = 9.2 – 13.7 daN
without seals)
Total pinion-ring gear bearing preloading (measured on D=
T = (P+ 3.73 daN)–(P+ 5.55 daN)
34.87 mm (1.37 in) without seals)
Oil specification: Use recommended oil enriched in additives SAE 30
Differential oil capacity 14.5 l (3.83 US gal)
Epicyclic reduction gear oil capacity each side 1.30 l (0.34 US gal)
Type of brake Wet discs brake
Number of brake disks each side 2
Nominal brake disk thickness 4.80 mm (0.19 in)
Maximum brake disk wearing (each disk) 0.72 mm (0.03 in)
Maximum operating pressure 43 bar (624 psi)
Rear axle - Sealing

Grease application in assembly
Tecnolube®
Apply on the indicated surfaces
POLYMER 400
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PTIL13TLB0003GB 1
Adhesives/sealants application
<– – – – Apply on the contact surfaces
<––––––––– Apply on bolts thread/on pins
Thread parts sealant

Adhesive make and Technical
Carraro Ref. Presence Strength
type characteristics
LOCTITE® 270 Locking of threaded
A High
Superbond® 331 parts
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Fixing parts sealant

Adhesive make and Technical
Carraro Ref. Presence Strength
type characteristics
LOCTITE® 638™
B Fixing adhesive Strong bond
Superbond® 433
LOCTITE® 542™
C Fixing adhesive Medium bond
Superbond® 321
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Sealing compounds and adhesives application
PTIL13TLB0004HB 2
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Rear axle - Torque
PTIL13TLB0194HB 1
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PTIL13TLB0196GB 2
Sl.No Torque values

1 70 N·m (51.6 lb ft)
2 79 N·m (58.3 lb ft)
3 230 N·m (170.2 lb ft)
4 60 N·m (44.3 lb ft)
5 25 N·m (18.4 lb ft)
6 25 N·m (18.4 lb ft)
7 13 N·m (9.6 lb ft)
8 79 N·m (58.3 lb ft)
9 176 N·m (129.8 lb ft)
10 155 N·m (114.3 lb ft)
11 15 N·m (11.1 lb ft)
12 10 N·m (7.4 lb ft)
13 10 N·m (7.4 lb ft)
14 10 N·m (7.4 lb ft)
15 27.6 N·m (20.4 lb ft)
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Rear axle - Special tools

The special drifts/pad used to assembly the seals, bearings and bushes should always be used with the interchange-
able handle, its use is recommended together with a suitable safety handle in order to protect the hands.
380000221 Handle
PTIL13TLB0137AA 1
380000021 Wrench
PTIL13TLB0141AA 2
380002213 Driver
PTIL13TLB0145AA 3
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380300157 False differential box
PTIL13TLB0138AA 4
380200397 Driver
PTIL13TLB0142AA 5
380200398 Handle
PTIL13TLB0146AA 6
380200446 Wrench
PTIL13TLB0139AA 7
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380002222 Driver
PTIL13TLB0143AA 8
380002223 Driver
PTIL13TLB0147AA 9
380200426 Driver
PTIL13TLB0140AA 10
380200427 Driver
PTIL13TLB0144AA 11
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380002436 False pinion
PTIL13TLB0148AA 12
380200428 Driver
PTIL13TLB0149AA 13
380200429 Driver
PTIL13TLB0152AA 14
380200430 Wrench
PTIL13TLB0155AA 15
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380200431 Bearing insertion kit
PTIL13TLB0150AA 16
380200432 Driver
PTIL13TLB0153AA 17
380200434 Driver
PTIL13TLB0151AA 18
380200435 Driver
PTIL13TLB0154AA 19
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380300158 Measurement tool
PTIL13TLB0157AA 20
380200433 Measurement tool
PTIL13TLB0156AA 21
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Rear axle - Component identification
PTIL13TLB0006FB 1
Position Description
1 Oil filling and level plug
2 Oil drain plug
3 Oil breather
4 Filling, level and drain plug of epicyclic reduction gear oil
5 Brakes bleeding plug
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Flange group
PTIL13TLB0012FB 1
1. Lock ring
2. Flange
3. Seal ring
4. O-ring
5. Washer
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Axle beam trumpet group
PTIL13TLB0044FB 1
1. Central body 6. Trumpet

2. Long half shaft 7. Screws
3. Snap ring 8. Bush
4. Sleeve 9. Seal ring
5. O-ring
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Rear axle - Change fluid

ATTENTION: To drain and fill the oil and to check the oil
level the axle must be horizontal.
ATTENTION: Risk of violent oil ejection, follow carefully all
the safety procedures indicated in this manual and in the
vehicle manual.
Before draining the oil from axle housing, use the
breather (3) to release possible internal pressure.
PTIL13TLB0007AB 1
To drain the oil remove the level plug (1) and the drain
plug (2).
ATTENTION: Risk of violent oil ejection.
Drain all oil.
Clean the plug (2) and tighten it to the prescribed
torque.
PTIL13TLB0008AB 2
Before draining the oil from the plug (1), always use the
breather (3) to release possible internal pressure.
Fill to the bottom of the fill plug hole with the specified
oil.
Wait to allow the oil to flow through the axle. Check oil
level and fill to the specified level if necessary.
Close the plug (1) to the prescribed torque.
PTIL13TLB0009AB 3
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ATTENTION: To drain and fill the oil and to check the oil
level the axle must be horizontal.
Before draining the oil from wheel end rotate the wheel
end so that the plug (4) is at the highest position [pos.A]
and partially unscrew to release possible pressure.
Rotate the wheel end so that the plug (4) is toward the
ground [pos.B].
Remove the plug and drain the oil.
PTIL13TLB0010AB 4
Rotate the wheel end so that the hole (4) is in the posi-
tion shown in fig. 5.
Fill to the bottom of the fill plug hole with specified oil
(Sec. Rear axle - General specification (27.100)).
Tighten the plug to the prescribed torque.
PTIL13TLB0011AB 5
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Rear axle - Remove

1. Park the equipment in travel position.
2. Lower the loader firmly on the ground.
PTIL14TLB0132AA 1
3. Drain the rear axle oil through the wheel drain plug (1)
on both the sides.
ATTENTION: Perform service or maintenance activities
only when the machine is at normal temperature. Failure
to comply may result in serious burn injuries.
NOTE: Avoid spillage of oil on the tire or floor.
NOTE: Ensure to tighten the drain plug immediately after
draining the oil.
PTIL12TLB0215AB 2
4. Loosen the drain plug (1) to drain and collect the differ-
ential oil in a clean container.
5. Keep all the collected differential oil in a clean and safe
place.
NOTE: Ensure to tighten the drain plug immediately after
draining the oil.
PTIL13TLB1216AB 3
6. Loosen rear wheel bolts (1) on both sides.
PTIL13TLB1219AB 4
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7. Actuate the stabilizer (1) on the ground to free the rear

wheels.
8. Remove both side rear wheels.
9. Switch “OFF” the engine and disconnect the battery
negative terminal.
10. See Basic instructions () .
11. Shift the gear shift lever to neutral position.
PTIL14TLB0133AB 5
12. Disconnect the drive shaft bolts (1) from the rear axle
end and support the shaft suitably.
PTIL13TLB1211AB 6
13. Disconnect the brake shoe assembly from the brake

disc by removing the assembly bolts (1).
14. Slide the brake shoe assembly away from the disc and
tag it properly to the machine.
PTIL13TLB1212AB 7
15. Remove the parking brake disk (1) by removing the

snap ring (2).
PTIL13TLB1215AB 8
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16. Disconnect the brake oil hoses (1) from the rear axle
end.
17. Cap and tag it immediately.
PTIL13TLB1213AB 9
NOTE: Support the rear axle assembly properly by using a

trolley jack.
18. Remove the rear axle mounting bolts (1) from both
sides.
19. Lower and slide the rear axle safely from under the
machine.
PTIL18TLB0026AA 10
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Rear axle - Disassemble

1. Remove the lock ring (1) and remove the flange (2).
Collect the O-ring (4) and the washer (5).
PTIL13TLB0013AB 1
2. Remove the seal ring (3).

NOTE: This is a destructive operation for the seal ring.
PTIL13TLB0014AB 2
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Rear axle - Assemble

1. Insert the seal ring (3) into the central body with a spe-
cial tool 380200435 and a hammer.
PTIL13TLB0015AB 1
2. Insert the washer (5) on the pinion end and a new

O-ring (4).
Assemble the flange (2) to the pinion end.
Lock the whole with a lock ring (1).
PTIL13TLB0016AB 2
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Rear axle - Disassemble Axle beam trumpet group

See Rear axle - Component identification (27.100).
Remove the wheel hub group before disassembling the
axle beam trumpet group.
1. Remove the seal ring (9) from the beam trumpet (6)
with a lever.
NOTE: Destructive operation for the seal ring.
PTIL13TLB0045AB 1
2. Put alignment marks on the beam trumpets, on the

brake cylinders and on the central body, in order to be
absolutely sure to identify the coupled parts.
Position the axle on supports fitted to hold both the cen-
tral body and the two beam trumpets, even after their
disjunction, or secure the disjointed groups to a lifting
device with ropes or belts.
PTIL13TLB0046AB 2
3. Unscrew and remove the fastening screws (7).
PTIL13TLB0047AA 3
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4. Remove the beam trumpet (6) and collect the O-ring

(5).
ATTENTION: Once the beam trumpet has been removed,
the long half shaft (2) is free. Remove the bush (8) from the
beam trumpet (6) only if the wear conditions require this.
Be careful not to damage the bush seat.
PTIL13TLB0048AB 4
5. Remove the shaft (2) and the splined sleeve (4).

6. Only if necessary remove the snap ring (3) from the
splined sleeve.
PTIL13TLB0049AB 5
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Rear axle - Assemble - Axle beam trumpet group

See Rear axle - Component identification (27.100).
Assemble the brake group before assembling the axle
beam trumpets group.
1. Check that the snap ring (3) is already assembled on
the splined sleeve (4). Assemble the splined sleeve (4)
to the shaft (2).
2. Insert the shaft on the central body (1) as in figure.
PTIL13TLB0050AB 1
3. Assemble on the beam trumpet (6) the bush (8) with

the special tool 380200432 and a hammer.
4. Assemble a new O-ring (5) into the beam trumpet.
PTIL13TLB0051AB 2
5. Assemble the beam trumpet on the central body (1) us-

ing the reference marks carried out during disassembly.
ATTENTION: Support the groups properly as already
pointed out for disassembly phase.
PTIL13TLB0052AB 3
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6. Screw in the fastening bolts (7) to the requested torque.
PTIL13TLB0053AA 4
7. Tighten the fastening screws (7) according to the se-

quence shown in figure.
PTIL13TLB0054AB 5
8. Assemble a new seal ring (9) in the beam trumpet (6)

using the special tool 380200434 and a hammer.
PTIL13TLB0055AB 6
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Rear axle - Install

1. Carefully slide the rear axle beneath the machine and
lift the trolley jack to seat the axle in its position.
2. Install the rear axle mounting bolts (1) on both sides.
3. Install & tighten the nuts (2) to a torque of 570 –
630 N·m.
NOTE: Retorque after first 50 hours of operation.
PTIL18TLB0026AA 1
4. Connect the brake oil hoses (1) on the rear axle end.
PTIL13TLB1213AB 2
5. Install the parking brake disk (1) and the snap ring (2).
PTIL13TLB1215AB 3
6. Seat the brake shoe assembly over the disc and con-
nect it by installing the assembly bolts (1).
PTIL13TLB1212AB 4
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7. Install the drive shaft to the brake disk by tightening the

bolts (1) on the rear axle end. Torque the bolt (1) to 33
– 39 N·m.
PTIL13TLB1211AB 5
8. Install rear wheels on both sides. Remove the trolley

jack and release the stabilizer (1) from the ground.
PTIL14TLB0133AB 6
9. Tighten the rear wheel nuts (1) on both sides firmly.
PTIL13TLB1219AB 7
10. Fill the differential oil through the breather plug (1).
PTIL13TLB1464AB 8
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11. Connect the battery negative terminal. Basic instruc-

tions.
12. Perform brake bleeding. Refer to Brakes - Bleed -
Removing air from the brake system (33.202).
13. Switch on the engine and free the machine by raising
the loader attachments.
PTIL14TLB0132AA 9
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Rear axle - Troubleshooting

Wheel vibration, half shaft Incorrect installation/defective axle Correct installation or repair or replace the
breakage differential in case it does not survive any
vehicle
both tire
Incorrect use of the product See the vehicle producer‘s instructions
once again
Steering is difficult vehicle Incorrect installation/defective axle Correct installation or repair or replace the
goes straight while it’s differential in case it does not survive any
turning one of the test phases
vehicle
both tire
to move the vehicle (engine off unloaded)
once again
No differential action, Incorrect installation / defective axle Correct installation or repair or replace the
jamming while steering differential in case it does not survive any
Overloading / incorrect weight distribution Remove excessive weight and redistribute
vehicle
to support all the work. Replace the tyre
both tire
once again
Uneven wear of tire Incorrect installation / defective axle Correct installation or repair or replace the
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vehicle
both tire
Blocked differential Abnormal functioning of the differential or
breakage/blockage of command device.
Verify assembly and all components. Vehi-
cles with wide steering angle may proceed
with kicks, have steering difficulty or cause
pneumatic wearing at sharp turns. Reduce
the steering angle to minimum and decel-
erate when the vehicle begins to kick
ings Adjusting according
Incorrect use of the product See the vehicle producer‘s. instructions
once again
Friction noise Incorrect installation / defective axle Correct installation or repair or replace the
Spoiled or worn out axle parts Check the condition of ring gear, pinion
gear, bearings etc. Replace whenever nec-
essary
Incorrect adjustment of bevel gear set: (transmission gears, U joints, etc.) Replace
Parts of the transmission worn out or adjust as required
once again
Vibration during forward Incorrect installation / defective axle Correct installation or repair or replace the
drive, intermittent noise differential in case it does not survive any
vehicle
to support all the work. Replace the tyre
both tire
once again
Ring gear tooth broken on Excessive gear load compared to the one Replace bevel gear set Follow carefully the
the outer side foreseen recommended operations for the adjust-
ment of bevel gear set backlash
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Incorrect gear adjustment (excessive back- Adjust backlash
lash)
Ring gear tooth broken on Load bump Replace bevel gear set
the inner side
Incorrect gear adjustment (insufficient Follow carefully the recommended opera-
backlash) tions for the adjustment of bevel gear set
backlash
Pinion or ring gear teeth Insufficient lubrication Replace bevel gear set
worn
Contaminated oil Follow carefully the recommended opera-
tions for the adjustment of bevel gear set
backlash
Incorrect lubrication or depleted additives Use correct lubricants, fill up to the right
levels and replace according to the recom-
mended program
Worn out pinion bearings that cause an Replace with new bearings
incorrect pinion axle backlash and wrong
contact between pinion and ring
Overheated ring and Prolonged functioning at high temperatures Replace bevel gear set
pinion teeth. See if gear
teeth have faded
Incorrect lubrication Use proper lubrication, fill up to right level
and replace at recommended program
Low oil level Top up oil
Contaminated oil Replace oil
Pinion teeth pitting Excessive use Replace bevel gear set
Insufficient lubrication Use correct lubrication, fill up to the right
level and substitute at recommended inter-
vals
Axle beam body bent Vehicle over loaded Replace axle beam body
Vehicle's accident Check chassis alignment
Load bump Replace bevel gear set
Worn out or pitted Insufficient lubrication Replace bearings
bearings
Contaminated oil Use correct lubrication fill up to the right
level and replace at recommended inter-
vals
Excessive use Follow recommended maintenance interval
Normal wear out Replace as required
Oil leakage form gaskets Prolonged functioning at high temperature Replace the gasket or seal and matching
and seals of the oil surface if damaged
Oil gasket assembled incorrectly Use correct lubrication and replace at rec-
ommended intervals
Seal lip damaged Replace seal
Excessive wearing out of Exhaustive use Replace the flange
input flange Spline
Pinion nut loose Check that the pinion spline is not exces-
sively worn out
Pinion axle backlash Replace bevel gear set if required
Fatigue failure of pinion Exhaustive use Replace bevel gear set
teeth See if the fracture
line is well defined (wave
lines, beach lines)
Continuous overload Refer manual for correct loading values
Pinion and ring teeth Crash load of differential components Check and/or replace other differential
breakage components
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Side gear spline worn Excessive use Replace differential gear group. Replace
out Replace all scratched half shaft if required
washers
Thrust washer surface Insufficient lubrication Use correct lubrication and fill up to right
worn out or scratched level
Incorrect lubrication Replace at intervals recommended. Re-
place all scratched washers and those with
0.1 mm (0.004 in) thickness lower than the
new ones
Inner diameter of tapered Excessive use Replace bearing
roller bearing worn out
Excessive pinion axial backlash Check pinion axial backlash
Insufficient lubrication Use proper lubrication, fill up to right level
and replace at recommended intervals
Bent or broken half shaft Vehicle intensively operated or overloaded Replace
Half shaft broken at wheel Wheel support loose Replace
side
Beam body bent Check that wheel support is not worn out or
wrongly adjusted
Noise while driving Excessive backlash between pinion and Adjust
ring gear
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loose Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loose Adjust
Ring gear out of roundness Replace
Low lubricant level Oil level
Poor or wrong lubricant Replace
Noise while driving in Noise coming from axle are usually heard Replace or adjust (see above)
neutral when vehicle moves in neutral gear but are
not loud
Incorrect backlash between pinion and ring Replace
(sound heard while decelerating disap-
pears while increasing the speed)
Pinion or input flange worn out Adjust
Intermittent noise Ring gear damaged Replace bevel gear set
Differential box bolts loose Tighten to torque
Constant noise Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Noise while steering Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
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Index

Rear axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rear axle - Assemble - Axle beam trumpet group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear axle - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear axle - Disassemble Axle beam trumpet group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear axle - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Rear bevel gear set and differential - 106
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Bevel pinion
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential
Component identification - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Bevel gear
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bevel pinion
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Differential
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassemble - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Rear axle system - Rear bevel gear set and differential
Bevel pinion - Component identification
PTIL13TLB0117FB 1
1. Bevel pinion 6. Washer

2. shim 7. Central body
3. Bearing cone 8. Bearing cone
4. Washer 9. Washer
5. Collapsible spacer 10. Lock nut
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Differential - Component identification

Disassembly
PTIL13TLB0074FB 1
1. Central body 8. O-ring

2. O-ring 9. Brake cylinder
3. Pipe 10. Adjuster ring nut
4. O-ring 11. Ring nut retainer
5. O-ring 12. Screw
6. Differential housing 13. Screw
7. Bearing cup
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Differential - Component identification - Bush
PTIL13TLB0104FB 1
1. Bush 13. Washer

2. Half boxes 14. Sun gear
3. Half boxes 15. Trunion
4. Dowel pin 16. Planetary gear
5. Bevel gear 17. Washer
6. Bush 18. Pin
7. Screws 19. Planetary gear
8. Bearing cone 20. Washer
9. Lock ring 21. Sun gear
10. Sleeve 22. Washer
11. Pin 23. Bearing cone
12. Differential housing
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Bevel gear - Test

NOTE: To test the marks of the bevel gear teeth, paint the
ring gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
PTIL13TLB0101AA 1
OK →Correct contact:
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z → Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash.
X → Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
order to adjust the backlash.
PTIL13TLB0102AA 2
Movements to correct:
1 →Move the pinion for type X contact adjustment.
2 →Move the pinion for type Z contact adjustment.
PTIL13TLB0103AB 3
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Bevel pinion - Disassemble

Refer: Bevel pinion - Component identification
(27.106) before disassemble the pinion group.
1. Unscrew the lock nut (10) using special tools
380000021 and 380200446.
NOTE: This operation damages the ring nut, the ring nut
(10) must be replaced when assembling the group.
PTIL13TLB0118AA 1
2. Tap the end shaft with a soft hammer to remove the

bevel pinion (1).
3. Collect the washer and the bearing cone.
PTIL13TLB0119AA 2
4. Once the bevel pinion (1) has been removed, collect

the washer the collapsible spacer (5) and the washer
(4).
NOTE: The collapsible spacer (5) must be replaced when
assembling the group.
PTIL13TLB0120AA 3
5. Check the bearing cups wear condition.

6. If bearings replacement is necessary, remove bearing
cups from central body with a drift and a hammer.
PTIL13TLB0121AA 4
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7. Remove the bearing cone (3) of the bevel pinion (1)

with a standard extractor. Collect the shim (2).
PTIL13TLB0122AB 5
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Bevel pinion - Assemble

See Bevel pinion - Component identification
(27.106).
1. Position the central body (7) on a workbench.
2. Fit the bearing cups (3) and (8) into their seats using
the special tool 380200431.
PTIL13TLB0123AA 1
3. Use the special tools false pinion ( 380002436) and

false differential box ( 380300157) to measure the conic
distance.
4. Insert into the seats the bearing cups (3) and (8) and
the false pinion. Tighten the ring nut (10) to eliminate
the backlash.
PTIL13TLB0124AA 2
5. Check the correct positioning of the right and left brake

cylinder and differential housing supports, using the ref-
erence marks on them and on the central body (7).
6. Assemble the two brake cylinders with their fastening
bolts.
PTIL13TLB0125AA 3
7. Insert the false differential box into the central body (7).
8. Check that the false differential box is inserted in both
differential support housings.
PTIL13TLB0126AA 4
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9. To adjust bevel gear/pinion measure the distance “A”

with a depth gauge.
Calculate the value “X” as follows: X=(A+C)-B mm
where “B” and “C” are known.
PTIL13TLB0127AA 5
10. From the value “X” deduct the value “ (V)” (stamped
on the pinion head) to get the value “S”.
S=X-V mm
PTIL13TLB0128AB 6
11. Choose the shim (2) with thickness value (S) among
the available shims range.
PTIL13TLB0129AA 7
Shims range
Spess./
thick - 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm
Qty. - - - - - - - - - -
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12. Loosen and remove the ring nut (10).

13. Remove the false pinion and the bearing cones (3)
and (8) from the central body (7).
14. Disassemble the false differential box from the brake
cylinders and then unscrew the screws to remove the
brake cylinders.
PTIL13TLB0130AB 8
15. Insert the chosen shim (2) with the chamfer against
the gear on the pinion shaft (1).
16. Force the bearing (3) on the pinion shaft (1) with the
special tool 380200428 under a press, making sure
that it is well set.
17. Assemble the shim (4), a new collapsible spacer (5)
and the washer (6) to the pinion shaft.
NOTE: Use always a new collapsible spacer (5).
PTIL13TLB0131AB 9
18. Insert the bevel pinion (1) unit into the central body (7)
and the bearing (8) into the pinion shaft, as shown in
figure.
19. Force the bearing (8) in position with the special tool
380200428 and a hammer.
NOTE: Push the pinion against the central body to perform
this operation.
PTIL13TLB0132AA 10
20. Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
21. Screw the ring nut (10), using the wrench for ring nut
and for pinion retainer.
ATTENTION: The torque setting is given by the preloading
measurement on bearings (3) and (8), tighten the ring nut
(10) gradually.
NOTE: If the tightening is excessive, the collapsible spacer
(5) must be replaced and the procedure repeated.
22. When you check the preloading, it is advisable to beat
slightly both pinion ends (1) with a soft hammer, so as
PTIL13TLB0189AA 11
to help setting the bearings (3) and (8).
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23. To measure the preloading P of the pinion taper roller

bearings, use a dynamometer whose cord is wound
on the special tool 380300158 inserted on the end of
pinion shaft.
24. The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.
PTIL13TLB0133AA 12
25. The effectively preloading Pm is measured on the

special tool 380300158 (gauge diameter Dm =
104.4 mm).
range:
Pm= 30.7/45.7 N.
PTIL13TLB0134AB 13
26. Once the requested preloading value is achieved,

stake the ring nut (10), using a hammer and a chisel.
PTIL13TLB0135AA 14
27. Assemble the flange group.
PTIL13TLB0136AA 15
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Bevel pinion - Test

Testing methods
1. With engine off, lift the axle so that the tires get away
from the ground.
2. Engage the gear so that the pinion gets locked.
3. With the help of another person standing on the op-
posite side, begin the assembly testing by rotating as
much as possible both the wheels forward. (Both the
wheels should get blocked after a while.)
4. Keeping the pinion locked, free the right wheel and ro-
tate the left one in the line of march. Rotate the right
wheels in the opposite direction.
The wheel will move freely without difficulty and the right
wheel will move in the opposite direction if the assembly
has been carried out correctly.
Repeat the same operation in the opposite direction (re-
verse gear).
If one wheel does not rotate freely in both directions,
then check step by step all assembly operations.
Check and see that the brakes are regulated correctly
and functioning properly.
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Differential - Disassemble
Refer Differential - Component identification
(27.106)
1. Remove the brake disks and counter disks.
PTIL13TLB0075AA 1
2. Secure the brake cylinder (9) to a hoist with ropes or

safety belts.
3. Remove the fastening screw (13).
PTIL13TLB0076AB 2
4. Remove the brake cylinder.

ATTENTION: The differential box is free.
5. Remove the O-ring (8) from the brake cylinder (9).
PTIL13TLB0077AB 3
6. Remove differential housing (6).
PTIL13TLB0078AB 4
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7. Unscrew and remove the screw (12) and the ring nut
retainer (11) from the brake cylinder (9).
PTIL13TLB0081AB 5
8. Unscrew and remove the adjuster ring nut (10) from the
brake cylinder (9) with the special tool 380200430.
PTIL13TLB0082AB 6
9. Use a driver and a hammer to remove the bearing cup

(7) from the brake cylinder (9).
ATTENTION: Do not invert the bearing cups if the bearings
are not replaced.
PTIL13TLB0083AB 7
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Refer Differential - Component identification
(27.106)
1. Assemble the pinion group before assemble the differ-
ential support group. See Bevel pinion - Assemble
(27.106).
PTIL13TLB0084AA 1
2. Lubricate and assemble new O-rings (2) and (4) on the

pipe (3).
3. Insert the pipe (3) into the central body (1).
4. Lubricate and assemble new O-ring (5) on every side
of the central body (1).
PTIL13TLB0085AB 2
5. Position the brake cylinder (9) on a flat surface

and force the bearing cup (7) using the special tool
380200397.
ATTENTION: Do not invert the bearing cups if the bearings
are not replaced.
PTIL13TLB0087AB 3
6. Measure the external diameter C of the bevel crown

gear assembled to differential housing.
Calculate the value: R=C/ 2 mm (0.08 in).
NOTE: This value is necessary to measure the backlash
between pinion and crown.
PTIL13TLB0088AA 4
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7. Assemble a new well lubricated O-ring (8) on the brake

cylinder (9) housing.
First assemble the right brake cylinder (Rh) to the cen-
tral body (1) Insert the differential group into the cen-
tral body (1) and assemble the fork (f) to the differential
sleeve.
See: Part (10) in Differential - Component identifica-
tion - Bush (27.106).
ATTENTION: The bevel gear must be placed on the left
side (Lh). Assemble the left brake cylinder (Lh).
NOTE: Check that the reference marks made during the
disassembly between the brake cylinders and the central
body coincides. PTIL13TLB0089AA 5
8. Assemble the fastening screws (13).

9. Tighten the fastening screws to the requested torque.
10. Assemble in the shown position fastening screws M14
x 120 mm to torque of 79 N·m (58.3 lb ft) on both
sides.
PTIL13TLB0090AB 6
11. Screw both adjuster ring nuts (10) using the special
tool 380200430 till the backlash is eliminated and the
differential bearings are slightly loaded.
PTIL13TLB0091AA 7
12. Assemble the special tool 380200433 on the differen-

tial housing hole. Position a comparator with the feeler
in contact with and at 90° respect to the surface of the
special tool bracket, in correspondence with the refer-
ence “R” value.
PTIL13TLB0092AA 8
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13. Move the bracket of the tool installed on the differential

housing hole alternately by and measure the backlash
between pinion and crown. Check if the measured
backlash value is within the prescribed range: 0.180
– 0.230 mm (0.007 – 0.009 in)
14. Set the backlash by turning the adjusting ring nuts (10)
using the special tool 380200430.
PTIL13TLB0093AA 9
15. Adjust the ring nuts (10), remembering that:

• If the measured backlash is less than the given tol-
erance range, screw the ring nut from the side op-
posite to the ring gear and unscrew the opposite
one of the same measure (A).
• If the measured backlash is greater than the given
tolerance range, screw the ring nut from the side of
the ring gear and unscrew the opposite one of the
same measure (B).
PTIL13TLB0094AB 10
16. Once the adjustment of the pinion-bevel gear back-

lash has been carried out, check also that there is a
minimum pre-loading on the differential housing bear-
ings.
17. Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
PTIL13TLB0095AB 11

lished, measure the total pre-loading T of the bear-
ings (pinion-crown bevel gear system). See Powered
front axle - General specification (25.100).
19. Use a dynamometer whose cord is wound on the spe-
cial tool 380300158 inserted on the end of pinion shaft.
ATTENTION: All the pre-loads should be measured with-
out the seal rings.
PTIL13TLB0096AA 12
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20. The total pre-loading Tm is measured on the spe-

cial tool 380300158 (gauge diameter Dm = 104.4 mm
(4.1 in)).
range: Tm= (Pm+12.5) ÷ (Pm+18.5) N
Where Pm is the effectively pre-loading measured on
the special tool 380300158 (gauge diameter Dm =
104.4 mm (4.1 in)). See Differential - Component
identification - Bush (27.106).
PTIL13TLB0097AB 13
21. If the measurement is not within the requested range,

check well the assembly of each component and op-
erate on the adjuster ring nuts (10) of the differential
support:
• If the total pre-loading is less than the given range,
screw in both adjuster ring nuts by the same mea-
sure, keeping the pinion-ring gear backlash value
unchanged (A).
• If the total pre-loading is greater than the given
range, unscrew both adjuster ring nuts by the same
measure, keeping the pinion-ring gear backlash
value unchanged (B).
PTIL13TLB0098AB 14
22. Once all the adjustment operations have been com-

pleted, fit the adjuster ring nut retainers (11) and
their respective screws (12), tightening them to the
requested torque.
ATTENTION: Turn the adjuster ring nuts (10) slightly in or-
der to allow the assembly.
Remove the fastening screws M14 x 120 mm on both
sides. See: previous Step
PTIL13TLB0100AB 15
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Differential - Disassemble - Bush

Refer Differential - Component identification - Bush
(27.106)
1. Remove the differential support group before disas-
sembling the differential group.
Differential - Component identification - Bush
(27.106).
2. Remove the lock ring (9).
3. Remove the sleeve and pins (11) from the differential
housing (12).
PTIL13TLB0105AA 1
4. Lock the differential with a clamp.

5. Unscrew the fastening screws (7) and remove the bevel
gear (5).
NOTICE: This will make both differential half boxes (2) and
(3) free, so take care not to drop the internal components.
6. Make alignment marks on the half boxes before split-
ting them.
PTIL13TLB0106AA 2
7. Disassemble the differential half boxes (2) and (3) with

the relative components.
8. Disassemble all the components.
9. Check the operating and wear conditions of the com-
ponents.
PTIL13TLB0107AB 3
10. Remove the bearings cones (8) and (23) of the half
boxes (2) and (3), using two levers or a three-hold
extractor.
PTIL13TLB0108AB 4
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11. Remove the bush (1) and (6) from the half boxes (2)
and (3) only if the wear conditions require this.
NOTE: This is a destructive operation for the bushes.
NOTICE: Be careful not to damage the bush seat.
PTIL13TLB0109AB 5
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Differential - Assemble - Bush

Refer Differential - Component identification - Bush
(27.106)
1. Assemble the bushes (1) and (6) to the half housings
(2) and (3) with the special tool 380200429 and a ham-
mer.
PTIL13TLB0110AB 1
2. Assemble the bearing cones (8) and (23) on the half

housings (2) and (3), using the special tool 380200398
and a hammer.
PTIL13TLB0111AB 2
3. Position the half housing (2) on a workbench and as-

semble all inner components as shown in figure.
4. Join the two half boxes, aligning the reference marks
made in disassembly.
PTIL13TLB0112AB 3
5. Before matching surfaces, make sure that they are per-

fectly clean, degrease and clean them with appropriate
detergents.
6. Position the bevel crown gear (5) on the half box.
NOTE: Check dowel pin (4) position.
7. Apply the specified sealant on the thread and tighten
the bolts (7) to the requested torque.
PTIL13TLB0113AA 4
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8. Assemble the sleeve on the differential housing (2).

ATTENTION: Take care to assemble it in the correct posi-
tion.
9. Assemble the lock ring (9) to the differential housing
(2).
PTIL13TLB0116AA 5
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Index

Bevel gear - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bevel pinion - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bevel pinion - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bevel pinion - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bevel pinion - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Differential - Assemble - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Differential - Component identification - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential - Disassemble - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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851FX Plus
851FX
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Contents
FUNCTIONAL DATA

SERVICE

Disassemble - Epicyclic reduction gear group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble - Epicyclic reduction gear group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble - Wheel hub group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Rear axle system - Final drive hub, steering knuckles, and shafts
Final drive hub, steering knuckles, and shafts - Component

identification
Epicyclic reduction gear group
PTIL13TLB0017FB 1
1. Plug 8. Pin
2. Planetary carrier 9. Washer
3. Screws 10. Bolt
4. Thrust washer 11. O-ring
5. Needle bearing 12. Shaft
6. Planetary gear 13. Hub
7. Washer
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Final drive hub, steering knuckles, and shafts - Component

identification
PTIL13TLB0031FB 1
1. Bolts 6. Bearing cone and cup

2. Bushes 7. Wheel hub
3. Ring gear 8. Bearing cone and cup
4. Wheel carrier 9. Seal ring
5. Lock ring
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Final drive hub, steering knuckles, and shafts - Disassemble -

- Component identification (27.124)
1. Unscrew the plug (1) and drain the oil completely from
the epicyclic reduction gear.
PTIL13TLB0018AA 1
2. Unscrew the fastening screws (3) of the planetary car-

rier (2).
PTIL13TLB0019AB 2

(13) and collect the relative O-ring (11).
4. Position the planetary carrier (2) on a workbench and
PTIL13TLB0020AB 3
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5. Remove the shaft (12) from the wheel hub (13).
PTIL13TLB0021AB 4
6. To replace the planetary gears (6):

• Remove the fastening bolts (10) on every pin (8),
• Remove the washers (7) and (9),
• Remove the planetary gears (6) from the pins,
• Collect the needle bearing (5) and check their con-
ditions,
• Collect the thrust washer (4).
PTIL13TLB0022AB 5
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Final drive hub, steering knuckles, and shafts - Assemble -

See Final drive hub, steering knuckles, and shafts -
Component identification (27.124).
See Wheel hub - Assemble (25.108) before assemble
the epicyclic reduction gear group.
1. Position the planetary carrier (2) on a workbench.
2. Insert the thrust washer (4) on every pin.
PTIL13TLB0023AB 1
3. Insert the needles (5) into the planetary gears (6).

NOTE: Grease well the needle bearings (5).
4. Insert the gears (6) with assembled needles into the
planetary carrier pins.
PTIL13TLB0024AA 2
5. Fit the thrust washers (7) and (9) to the planetary carrier
(2) pins.
NOTE: The intermediate thrust washers (7) has a hole for
centering with the dowel pin (8) fitted on the planetary car-
rier (2) pins.
6. Assemble the fastening bolts (10) and then tighten
them to the requested torque.
PTIL13TLB0025AB 3
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7. Assemble the shaft (12) to the epicyclic reduction gear

(2).
PTIL13TLB0026AB 4
8. Assemble a new lubricated O-ring (11) on the wheel

hub (13).
PTIL13TLB0027AB 5
9. Align the epicyclic reduction gear group to the wheel

hub (13) using an appropriate lifting device.
ATTENTION: Observe all current safety regulations to
guarantee operator’s safety.
PTIL13TLB0028AA 6
10. Fit the epicyclic reduction gear group to the wheel hub
(13).
11. Assemble the fastening screws (3) and tighten them
to the prescribed torque.
PTIL13TLB0029AB 7
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12. Top up the specified oil into the epicyclic reduction

gear.
13. See Rear axle - Component identification (27.100).
14. Fit the plug (1) on the epicyclic reduction gear (2) and
tighten to the prescribed torque.
PTIL13TLB0030AA 8
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- Component identification (27.124).
Remove the epicyclic reduction gear group before dis-
assembling the wheel hub group.
Slide the half-shaft from the axle beam trumpet.
Unscrew and remove the fastening bolts (1) from the
wheel carrier (4).
PTIL13TLB0032AB 1
To remove the wheel carrier (4), screw two of the just

removed bolts (1) in the threaded holes. Remove the
wheel carrier (4) and the ring gear (3).
PTIL13TLB0033AB 2
Remove the steel lock ring (5) from the epicyclic ring
gear (3).
Check the wear conditions of the components.
Only if necessary, remove the centering bushes (2) of
the wheel carrier (4) with a hammer and the special tool
380002213.
PTIL13TLB0034AB 3
Remove the wheel hub (7) using levers and a hammer

to facilitate the operation.
NOTE: Collect the bearing cone (6).
PTIL13TLB0035AB 4
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Position the wheel hub (7) on a flat surface and remove

the seal ring (9) with a lever.
NOTE: This is a destructive operation for the seal ring (9).
Remove the bearing cups (6) and (8), on both sides of
the wheel hub (7), using a hammer and a suitable drift.
Remove the bearing cone (8) from the axle bean trum-
pet end, using a suitable extractor.
PTIL13TLB0036AB 5
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Final drive hub, steering knuckles, and shafts - Assemble - Wheel

hub group
- Component identification (27.124)
1. Force both bearing cups (6) and (8) to their wheel hub
(7) housings, using the special tool 380002222 under
a press or with a hammer.
2. Insert the seal ring (9) into the wheel hub (7) with the
PTIL13TLB0037AB 1
3. The special operation “Set Right” of the bearings (6)

and (8) does not require preload or backlash adjust-
ment. Anyway, before assembling new components
check the indicated dimensions.
A = 17.950 – 18.000 mm (0.707 – 0.709 in)
B = 64.385 – 64.385 mm (2.535 – 2.535 in)
C = 23.072 – 23.173 mm (0.908 – 0.912 in)
PTIL13TLB0038AA 2
4. Assemble the bearing cone (8) on the axle bean trum-

pet end. Assemble the wheel hub (7) on the axle and
fit the bearing cone (6) in position.
PTIL13TLB0039AB 3
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5. Position the wheel carrier (4) on a workbench and force

the bushes (2) to the carrier surface level with the spe-
cial tool 380002213.
6. At least two bushes (2) (diametrically-opposed) must
be set slightly higher than the carrier surface level to
be used as dowel pins.
PTIL13TLB0040AB 4
7. Preassemble the wheel carrier (4) and the epicyclic ring

gear (3) with the locking ring (5).
PTIL13TLB0041AB 5
8. Assemble the wheel carrier group on the wheel hub (7)

using the two projecting bushes (2) as dowel pins and
screw the relative bolts (1) in order to put in contact the
wheel carrier (4) with the wheel hub (7).
PTIL13TLB0042AB 6
9. Force all the hub dowel bushes (2) completely with the
10. Screw the fastening bolts (1) and tighten them to the
requested torque. Insert the half shaft in the axle
beam.
PTIL13TLB0043AB 7
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Index

Final drive hub, steering knuckles, and shafts - Assemble - Epicyclic reduction gear group . . . . . . . 7
Final drive hub, steering knuckles, and shafts - Assemble - Wheel hub group . . . . . . . . . . . . . . . . . . 12
Final drive hub, steering knuckles, and shafts - Component identification . . . . . . . . . . . . . . . . . . . . . . 3
Final drive hub, steering knuckles, and shafts - Component identification . . . . . . . . . . . . . . . . . . . . . . 4
Final drive hub, steering knuckles, and shafts - Disassemble - Epicyclic reduction gear group . . . . 5
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Brakes and controls
851FX Plus
851FX
91715732 26/07/2021
33
Contents
Brakes and controls - 33
[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
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33
Hydraulic service brakes - 202
851FX Plus
851FX
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33.1 [33.202] / 1
Contents
TECHNICAL DATA
Hydraulic service brakes

Brake discs
FUNCTIONAL DATA
Hydraulic service brakes

Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brakes
Brake master cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Brakes
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bleed - Removing air from the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake pedals
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Brake master cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

Type off fluid ISO 7308
Capacity 0.67 l (0.18 US gal)
Brand Akcela LHM fluid
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Brake discs - General specification
PTIL13TLB0002FB 1
1. New separator plate thickness = 4.95 – 5.05 mm

Worn separator plate minimum thickness = 4.9 mm
2. New friction plate thickness = 4.75 – 4.85 mm
Worn plate minimum thickness = 4.0 mm
3. New separator plate thickness = 8.9 – 9.0 mm
Worn separator plate minimum thickness = 8.8 mm
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Hydraulic service brakes - Exploded view - Brake pedal
PTIL13TLB1479FB 1

2. Mounting bolt 12. Pedal
3. Brake light switch adjusting screw 13. Clevis pin
4. Pedal mounting bolt 14. Circlip
5. Bracket 15. Washer
6. Snap ring 16. Nut
7. Washer 17. Spring
8. Bolt 18. Brake light switch bracket
9. Spacer 19. Bracket
10. Spacer 20. Grease nipple
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Brakes - Component identification
PTIL13TLB1746FB 1
1. Hub 8. O-ring
2. Brake disc plate 9. Half shaft
3. Brake drive plate 10. Bush
4. Brake large plate 11. Snap ring
5. Brake drive plate 12. Self-adjust kit
6. Brake piston 13. Brake mechanism return kit
7. O-ring
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Brake master cylinder - Exploded view
PTIL13TLB1478FB 1
1. Bolt 12. Bolt

2. Washer 13. Brake hose to RH wheel
3. Bracket 14. Banjo bolt
4. Reservoir 15. Washer
5. RH Brake master cylinder hose 16. Tube
6. Master cylinder mounting bolt 17. Washer
7. Washer 18. Banjo bolt
8. Locking pin 19. Master cylinder RH
9. Clevis pin 20. LH Brake master cylinder hose
10. Brake hose to LH wheel 21. Brake fluid reservoir cap
11. Pad 22. Master cylinder LH
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Brakes - Disassemble
1. Remove rear axle. See Rear axle - Remove (27.100).
2. Remove the beam trumpet and half-shaft from the
brake flange (1).
PTIL13TLB0057AB 1
3. Remove the components from the brake flange. Brake

drive plate (5), hub (1), brake plate (4) and (2), brake
drive plate (3).
NOTE: Remember the position of the brake disk carrier, it
must be reassembled in the same position.
PTIL13TLB1757AB 2
4. Remove the brake control group.
PTIL13TLB0059AA 3
5. Unscrew the fastening screws and remove all the parts

of the self-adjust kit (5) and brake mechanism return kit
(6).
PTIL13TLB0060AB 4
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6. Remove the brake piston (4).

NOTE: If necessary, blow in air through the brake oil input
hole to eject the piston, using the minimum pressure.
ATTENTION: Possible swift ejection of the piston.
PTIL13TLB0061AB 5
7. Remove the O-rings (2) and (3) from the brake piston
(4).
PTIL13TLB0062AB 6
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Brakes - Assemble
1. Keep the brake piston (4) with the outer surface facing
upwards.
2. With the special tool 380200426 and a hammer, push
the bushes into the self-adjust housings till they are
aligned with the piston supporting inner surface.
PTIL13TLB0063AB 1
NOTE: The bushes must be aligned with the piston sup-

porting inner surface.
PTIL13TLB0064AA 2
3. Assemble a new O-rings (2) and (3) to the brake piston

(4). Lubricate the O-rings (2).
PTIL13TLB0065AB 3
4. Insert the piston (4) into the brake cylinder (1) and po-
sition the special tool code 380200427 on the piston.
NOTE: Position the brake piston (4) with a slot aligned with
the hydraulic connection or with the inspection hole on the
brake cylinder (5).
ATTENTION: Do not damage the O-rings.
With a lever anchored to an eyebolt, exert a pressure
just enough to insert the piston into the brake flange.
PTIL13TLB0066AB 4
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5. Assemble the spring cover and the screw of the brake

mechanism return kit (6).
PTIL13TLB0191AB 5
6. Assemble the bush, the washer and the screw of the

self-adjust kit (5) and tighten them to prescribed torque.
PTIL13TLB0192AB 6
7. The brake piston must be pushed in the original position

if worn brake disks are replaced by new disks. Remove
straight threads, bleeds or plugs from the service brake
oil port.
ATTENTION: Risk of oil ejection from the axle.
PTIL13TLB0068AA 7
8. Push the brake piston (4) at the end of stroke using the
special pad and the handle with a hammer.
ATTENTION: Position the pad with accuracy to do not
damage the brake piston.
PTIL13TLB0069AB 8
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9. Assemble the brake control group.
PTIL13TLB0059AA 9
10. Check that the brake plate (8) and (11) and the brake
drive plate (7) and (10) do not present any sign of
burning, on the contrary, replace them. Furthermore
check brake plate wear and if necessary replace it.
NOTE: If new brake plates are installed, before assembling
they should be dipped in the prescribed oil.
PTIL13TLB0070AA 10
11. Assemble the components from the brake flange.

Brake drive plate (5), hub (1), brake plate (4) and (2),
brake drive plate (3).
ATTENTION: Place the brake disk carrier as shown in the
next figure, assemble brake disks with holes aligned.
PTIL13TLB1757AB 11
12. This is the correct position of the teeth on the external

surfaces of the brake disk carrier (9).
PTIL13TLB0072AB 12
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13. Assemble the beam trumpet and half-shaft.
PTIL13TLB0073AA 13
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Brakes - Bleed - Removing air from the brake system

NOTE: Two people are required to perform this procedure, one to actuate the master cylinder and the other to open
and close the brake bleeder valve on the rear axle.
NOTE: Make sure that the parking brake is not engaged.
1. Raise the machine up with the stabilizers at full height.
Support back end of machine with appropriate stands.
2. Shut-off the engine.
3. Attach clear brake bleeding hoses to the left-hand and
right-hand bleeding ports. Attach the other ends of the
bleeding hoses to an oil collecting container. Make sure
to keep the container at lower height than the axle.
4. Detach the brake pedal interconnecting pin.
5. Operate the left-hand brake pedal individually 25 times
to full stroke and keep in the pressed condition.
6. Open the brake oil bleeding screw on the left-hand side.
Let the pedal touch the floor and then retighten the
bleeding screw.
7. Repeat the steps 4 to 6 till clear oil without bubbles
starts flowing through the tube.
8. Repeat the steps 4 to 7 for right-hand side brake pedal.
9. Lock the interconnecting pin.
10. Operate both the pedals together to full stroke 25
times and keep the pedal in pressed condition.
11. Open the brake oil bleeding screw on the left-hand
side. Let the pedal touch the floor and then retighten
the bleeding screw.
12. Repeat the steps 9 to 11 till clear oil without bubbles
starts flowing through the tube.
13. Repeat the steps 9 to 12 for right-hand side bleeding
screw.
14. Make sure that the service brakes stop both rear
wheels when applied together and respective wheels
when applied individually with the machine in 2nd
gear at 1500 RPM. If the service brakes do not stop
the wheels as noted above repeat steps 4 to 13 until
columns of oil without air bubbles are observed in the
left-hand and right-hand bleeder hoses. Verify that
the service brakes hold the machine in 2nd gear at
1500 RPM as noted above.
15. Shut-off the engine.
16. Remove the brake bleeding hoses.
17. Replace covers on left-hand and right-hand brake
bleeders.
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Brake pedals - Remove
PTIL18TLB0010GA 1
1. Remove the cover from the steering column.

2. Disconnect the brake master cylinder from the pedals.
See Brake master cylinder - Remove (33.202).
3. Loosen the four mounting bolts (1) and remove the
brake pedal assembly.
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Brake pedals - Disassemble
PTIL18TLB0010GA 1
1. Disconnect the springs (1) from the brake pedals.

2. Loosen and remove the lock nuts (2) and (3).
3. Remove the circlip (4) and remove the brake pedal
shaft (5).
4. Remove the bolts (6) and (7) and remove the left-hand
side brake pedal shaft (8).
5. Remove the bolts (9) and (10) and remove the right-
hand side brake pedal shaft (11).
6. Remove the bolt (12) and remove the switches (13).
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Brake pedals - Assemble
PTIL18TLB0010GA 1
1. Install the left-hand side brake pedal (8) on the brake

pedal mounting bracket and hand tighten the bolts (6)
and (7). Tighten the bolt (6) to 28.80 N·m (254.90 lb
in).
2. Install the right-hand side brake pedal (11) on the brake
pedal mounting bracket and hand tighten the bolts (9)
and (10). Tighten the bolt (10) to 28.80 N·m (254.90 lb
in).
3. Install the brake pedal shaft (5) along with four washers
(12) and needle bearing (13). See image 1.
4. Insert the circlip (4) on the brake pedal shaft (5).
5. Insert the washer (14) and the check nuts (3) and (2).
Torque the check nuts to 134.0 – 156.0 N·m (1186.0 –
1380.7 lb in).
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6. Connect the spring (1) to both the brake pedals (8) and
(11).
7. Install both the switches (15) with the help of bolts (16)
(17) and nut (18). Tighten the bolt (16) to 7.0 N·m
(62.0 lb in).
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Brake pedals - Adjust

1. Adjust the left-hand and right-hand brake pedals to the
height shown in the image 1. The brake pedals should
be rotated in order to achieve the 5 – 10 mm of free
play measured at pads.
PTIL18TLB0015AB 1
2. Tighten the nut on each pedal to lock the clevises. After

proper adjustment, when the pedals are in their rest
position, the clevis pin should be free.
H = 354 +/- 5 mm
3. When both left-hand and right-hand pedal reach at be-
low (H) position, declutching and brake light gets exe-
cuted.
H = 408 +/- 5 mm
4. Adjust brake light switches (1) so that the switches are
depressed enough to get de-activate when the pedals
are in rest position (switches depressed approximately
by 4 – 6 mm). An audible clicking noise can be heard
when the switches are activated. The switches should
not activate until after the pedals are pushed through
their entire free play range.
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Brake pedals - Install
PTIL18TLB0010GA 1
1. Install the brake pedal assembly and tighten the four

mounting bolts (1).
2. Connect the brake master cylinder on the brake pedals.
See Brake master cylinder - Install (33.202).
3. Install the steering column covers.
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Brake master cylinder - Remove

1. Park the machine on a level surface. Stop the engine
and apply the parking brake.
2. Open the hood.
3. Remove exhaust muffler for better accessibility. See
Intake and exhaust manifolds and muffler - Remove
(10.254).
PTIL18TLB0011GA 1
4. Disconnect the right-hand side hose (1) and left-hand

side hose (2) to the master cylinder (8)
5. Disconnect the right-hand side hose (3) and left-hand
side hose (4) from the master cylinder (8).
6.
NOTE: Cap the hoses immediately to prevent dust ingress.
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7. Disconnect the brake pedals by removing the lock (5)

and the pin (6).
8. Remove the mounting bolts (7) and remove the brake
master cylinders (8).
9. Remove the banjo bolts (9) and remove the tube (10).
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Brake master cylinder - Install
PTIL18TLB0011GA 1
1. Mount the master cylinder (8) onto the cabin using bolts
(7).
2. Connect the right-hand side hose (1) and left-hand side
hose (2) to the master cylinder and tighten the banjo
bolt (9) to 25 – 30 N·m.
3. Connect the right-hand side hose (3) and left-hand side
hose (4) to the master cylinder and install the clamp
(11).
NOTE: During insertion of the brake tube (3) and (4) make sure that the mating parts are fully inserted and the clamps
(11) are positioned at a distance of 2 – 3 mm from edge.
NOTE: Heat the ends of tubes (3) and (4) up to a maximum temperature of 80 °C for 5 s for ease of assembly.
4. Install the tube (10) and tighten the banjo bolt (9) to 25
– 30 N·m.
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5. Connect the brake pedals using the pin (5) and lock
them in place with the locking pin (6).
6. If removed, install the exhaust muffler. See Intake and
exhaust manifolds and muffler - Install (10.254).
7. Close the hood.
8. Perform brake bleeding. See Brakes - Bleed - Remov-
ing air from the brake system (33.202).
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Index

Brake discs - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake master cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake master cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake master cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake pedals - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake pedals - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake pedals - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake pedals - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Brake pedals - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brakes - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brakes - Bleed - Removing air from the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brakes - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brakes - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic service brakes - Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Parking brake or parking lock - 110
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Parking brake or parking lock

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Parking brake or parking lock

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Brakes and controls - Parking brake or parking lock
Parking brake or parking lock - Exploded view
PTIL13TLB1221FB 1
1. Parking brake lever 7. Actuation arm

2. Boot 8. Caliper
3. Grommet 9. Brake pads
4. Brake warning light switch 10. Brake disc
5. Cable 11. washer
6. Caliper bracket
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Parking brake or parking lock - Disassemble

1. Park the machine on a level surface, switch Off the
engine.
2. Provide wheel chocks to prevent any movement.
3. Remove the bolts (1) and disconnect the propeller
shaft.
PTIL13TLB1211AB 1
4. Remove the caliper mounting bolts (1) and remove the

caliper.
PTIL13TLB1212AB 2
Refer the Parking brake or parking lock - Exploded

view (33.110) for the below steps:
5. Remove the pads (9) and keep it in a clean place.
6. Remove the washer (11) and pry out the brake disc (10)
from the axle body.
7. Disconnect the parking brake cable (5) at both ends
and remove.
8. Remove the grommet (3) and remove the boot (2).
9. Remove the cotter pin and remove the parking brake
lever (1).
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Parking brake or parking lock - Inspect

1. Inspect the brake disk for pitting, scoring, excessive
surface wear, and other damage.
2. Use new parts as required.
3. Inspect the pads thickness for wear and tear.
4. Use new parts as required.
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Parking brake or parking lock - Assemble

Refer the Parking brake or parking lock - Exploded
view (33.110).
1. Install the parking brake lever (1) using the cotter pin.
2. Route the parking cable (5) and fix it at the lever end.
3. Insert the washer (11) and place the brake disc (10).
4. Mount the propeller shaft and tighten the bolts (1).
PTIL13TLB1211AB 1
5. Mount the caliper and tighten the mounting bolts (1).
PTIL13TLB1212AB 2
6. Connect the cable at wheel end and lock using split pin
(1).
7. Adjust the number of notches in the lever and tighten
the cable.
8. Slide the boot down and fix using grommets.
PTIL13TLB1477FB 3
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Parking brake adjustment

1. The parking brake is adjusted by tightening the inner
adjuster nut (1) until the brake pad contacts the disc
at which point the 2nd outer nut should be tightened to
lock the assembly.
2. The free movement of the parking brake cable can be
adjusted by rotation of the cable knuckle (2) situated at
the base of the parking brake cable where it attaches
to the transmission by the pin locked by cotter pin.
PTIL13TLB1212AB 4
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Index

Parking brake or parking lock - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking brake or parking lock - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking brake or parking lock - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake or parking lock - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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PRINTED IN INDIA
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EN
SERVICE MANUAL
Hydraulic systems
851FX Plus
851FX
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35
Contents
Hydraulic systems - 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
[35.726] Excavator and backhoe hydraulic controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9
[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11
[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12
[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13
[35.AAA] Hydraulic systems generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
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851FX
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Contents
TECHNICAL DATA
Hydraulic systems
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic systems
Component identification - Backhoe control valve hose connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Static description - Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE
Hydraulic systems
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Test - Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSTIC
Hydraulic systems
Testing - Problem in a loader circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing - Noise from the backhoe hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Hydraulic systems - Hydraulic systems
Hydraulic systems - General specification

Make and model of hydraulic main pump Parker 33/23 with priority
56 cm³ (3 in³) (First section: 37 cm³ (2 in³),
Nominal capacity of hydraulic pump
rear section: 33 cm³ (2 in³))
Steering relief pressure 140 bar (2030 psi)
Pressure settings 570ST
Load sense pressure (system relief valve ) 210 bar (3045 psi)
Backhoe bucket A (upper) port 220 bar (3190 psi)
Backhoe bucket B (lower) port 220 bar (3190 psi)
Swing cylinder cushioning circuit relief valve (LH swing - Upper
205 bar (2972 psi)
and RH swing - Lower)
Loader bucket relief valve (Rod end) 230 bar (3335 psi)
Loader bucket relief valve (piston end) 165 bar (2392 psi)
Clamp control for BDB 240 bar (3480 psi)
Boom A (upper) port - Rod end port 315 bar (4568 psi)
Boom B (lower) port - Head end port 205 bar (2972 psi)
Dipper cylinder (piston end) circuit relief valve 240 bar (3480 psi)
Extent able dipper stick cylinder (Piston end circuit relief valve 124 bar (1798 psi) \ 240 bar (3480 psi)
Hydraulic systems - General specification

Working Cush- A/F HEC/
Type Bore (Dia) Rod (Dia) Stroke Torque
pressure ioning Piston Retainer
Loader lift 210 bar 90 mm 50 mm 679 mm 85 – 95 kgm Hook
NC 65
control (3045 psi) (3.51 in) (1.95 in) (26.481 in) (612 – 684 ftlbs) spanner
Loader
210 bar 80 mm 4\5 mm 685 mm 62 – 72 kgm Hook
bucket NC 55
(3045 psi) (3.12 in) (1.755 in) (26.715 in) (446.4 – 518.4 ftlbs) spanner
control
Bottom
210 bar 80 mm 50 mm 245 mm 60 – 70 kgm Hook
dump NC 46
(3045 psi) (3.12 in) (1.95 in) (9.555 in) (432 – 504 ftlbs) spanner
bucket
Boom 210 bar 130 mm 65 mm 863 mm 220 – 240 kgm Hook
CC -
control (3045 psi) (5.07 in) (2.535 in) (33.657 in) (1584 – 1728 ftlbs) spanner
Dipper
arm NC 90
control
Backhoe
bucket NC 75
control
Stabilizer NC 55
Swing CC 75
Hydraulic systems - Special tools

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380200473 Loader Arm cylinder (Wipro & Dantal)
PTIL13TLB1774AA 1
380200474 Swing cylinder (Wipro)
PTIL13TLB1776AA 2
380200472 Lift cylinder (Wipro & Dantal)
PTIL13TLB1777AA 3
380200476 Boom cylinder (Dantal)
PTIL13TLB1778AA 4
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380200477 Boom cylinder (Wipro)
PTIL13TLB1779AA 5
380200478 Dipper cylinder (Dantal)
PTIL13TLB1780AA 6
380200479 Dipper cylinder (Wipro)
PTIL13TLB1781AA 7
380200475 Backhoe bucket cylinder (Wipro & Dantal)
PTIL13TLB1782AA 8
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Hydraulic systems - Component identification - Backhoe control

valve hose connection
PTIL16TLB0038HB 1
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PTIL16TLB0039HB 2
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1. Connector stab swing port 22. Valve

2. Connector bucket dipper 23. Connector
3. Connector bucket dipper 24. Hose
4. Hydraulic connector 25. Elbow
5. Stabilizer tube 26. Left-hand side clip
6. Stabilizer tube 27. Left-hand side holdfast
7. Stabilizer tube 28. Washer
8. Stabilizer tube 29. Bolt
9. Hose assembly bucket head end 30. Nut
10. Hose assembly bucket rod end 31. Holdfast
11. Hose assembly bucket head end 32. Plate clamp
12. Hose assembly bucket rod end 33. Bolt
13. Hydraulic connector 34. Connector
14. Hose power beyond 35. Hydraulic hose assembly
15. Right-hand side clip 36. Hose
16. Pipe 37. Elbow
17. Right-hand side holdfast 38. Hose
18. Pipe 39. Strap nylon tie
19. Bachkhoe swing hose assembly 40. Washer
20. Bachkhoe swing hose assembly 41. Bolt
21. ORFS Tee assembly
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PTIL16TLB0037HB 3
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1. Tube assembly, bucket and lifting control 11. Adaptor

2. Connector-bucket-dipper 12. Plug
3. Hose 13. Hydraulic connector
4. Hydraulic connector 14. Washer
5. Connector long 15. Bolt
6. ORFS Tee 16. Bolt
7. Elbow 17. Nut
8. Connector 18. Spacer
9. Left-hand side pipe rubber 19. Washer
10. Right-hand side pipe rubber 20. Hydraulic hose
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Hydraulic systems - Static description - Cylinders

Do’s
1. Use soft lint-free cloth, never use cotton waste it may contain metal chips which will damage working surface of
the components.
2. Periodically clean the dust/mud accumulated on wiper seals.
3. Use appropriate tools to service hydraulic cylinder.
4. Clean the stabilizer box periodically.
5. Ensure that the oil is in cold condition before opening the cylinder.
6. Ensure that the cylinder is assembled and disassembled in clean dust free atmosphere.
7. Ensure usage proper lifting tackles (rope, belts, etc.) while handling the cylinder.
8. Apply hand brake while excavation.
9. Apply grease on extended piston rod, if any welding is being carried out near the cylinder. This is to avoid welding
spatters from getting stuck on the piston rod surface. Wipe off the grease after welding is completed.
10. Before replacing new rubber components like O-ring and seals, immerse in hydraulic oil and then replace.
11. Use only the specified grade ( ISO VG-46) of oil to avoid malfunctioning of the product and for optimum.
12. Safety and performance.
13. Use Grease gun to ensure proper greasing and apply grease at all the greasing points periodically.
14. Ensure that there are no obstructions at the working area like electrical line, inflammable material, etc.
15. Check and tighten the hydraulic fittings, bolts and nuts periodically.
16. Check the hydraulic oil contamination and change if required. Maximum oil contamination allowed in system is
NAS 11 or ISO 20/17.
17. Check the filter elements and change if necessary.
18. Check the oil level in the hydraulic tank regularly and fill it to the recommended level, if required.
Dont’s
1. Don’t operate the machine beyond the specified load/pressure limit.
2. Don’t use the bucket to push rocks, boulders, etc.
3. Don’t move the machine when the stabilizer cylinders are in extended position.
4. Don’t load the bucket unevenly.
5. Don’t work under an unsupported shovel.
6. Don’t use the hydraulic cylinder as a conductor for welding purpose.
7. If you have to weld on structure connect earth wire to the structure only not on the chassis.
8. Earth must be given close to the point of welding.
9. Don’t paint on the working surface of the piston rods and wiper seal.
10. Don’t change the relief pressure setting on the control valve.
11. Don’t operate on uneven and soft ground.
12. Don’t heat hydraulic cylinder while dismantling.
13. Don’t open hydraulic connections without releasing the system pressure.
14. Don’t carry out welding without removing the battery terminals.
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Preservation of hydraulic cylinders on machine

Sl. Part
Storage Preservation Remarks
no. description
Exposed portion of the piston rod should
be protected with anti rust oil/petroleum
jelly/grease (Castrol make LCG2 grade)
during storage in idle condition. Also the
protection of exposed portion of the piston
It will protect
Cylinder rod becomes all the more important when Grease/jelly should be
the piston rod
1. mounted on the machine is working/stored in corrosive removed once the machine is
from pitting or
machine environment e g. Sea coast/sea water, sand put back into operation
corrosion
bed, chemical environment. In such cases
the rods should be protected even if the
machine is stored in idle condition overnight.
Grease/jelly should be removed once the
machine is put back into operation
Machine should be operated Protection of
Cylinder
at least once in three days and rods and avoid
2. mounted on During long term storage
all cylinders to be operated for pre-setting of
machine
minimum 10 cycles seals
Wiper lip should be cleaned on a regular
Protection of
3. In operational basis to prevent dirt/dust/grease settling on To improve the life of the seals
seals
the wiper lip
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Hydraulic systems - Hydraulic schema

851FX
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PTIL21TLB0552JB 1
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1. Hydraulic tandem pump ( 33 cm³+ 37 cm³)

2. Steering valve ( 125 cm³)
3a. Loader control valve
3b. Loader 3-section hydraulic valve (optional)
4. Loader lift cylinder
5. Tilt cylinder
6. BDB cylinder (optional)
7a. Backhoe valve assembly 6 spool
7b. Backhoe valve assembly 7 spool (optional)
8. Cooling package ( 72 kW)
9. Hydraulic oil filter assembly
10. Air breather (Hydraulic tank)
11. Hydraulic tank ( 72 kW)
12. Side shift lock piston
13a. Extendable dipper cylinder (14 ft) (optional)
13b. Extendable dipper cylinder (15 ft) (optional)
14. Boom cylinder
15. Swing cylinder
16. Bucket cylinder
17. Stabilizer cylinder (left-hand side)
18. Stabilizer cylinder (right-hand side)
19. Backhoe hammer valve (optional)
20. Check valve ( 8 bar) (optional)
21. Dipper cylinder
22. Strainer filter
23. Check valve ( 5 bar)
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Hydraulic systems - Service instruction

Steering relief valve - pressure check
1. Park the machine on a level surface. Put the backhoe
in the transport position and lower the loader bucket to
the floor.
2. The oil must be at operating temperature. To heat the
oil, do the following steps:
A. With the engine running at full throttle, hold the
loader control lever in the ROLLBACK position for
15 seconds.
B. Put the loader control lever in the NEUTRAL posi-
tion for 15 seconds.
C. Repeat Steps A and B until the temperature of the
oil is 50 °C (122.0 °F) or the side of the reservoir is PTIL13TLB1671AB 1
very warm.
3. Install 0 – 200 bar (0 – 2900 psi) pressure gauge in CF
port.
4. Use a pressure gauge with a capacity of at least
250 bar (3625.0 psi). Connect the pressure gauge
(quick coupler can be used) to the pressure checking
port in CF port in pump. This port is meant for checking
the steering hydraulic pressure.
5. With the engine running at 2000 RPM, turn and hold
the steering wheel all the way to the extreme right or to
the extreme left and read the pressure gauge. Make a
record of the reading.
6. Decrease the engine speed and stop the engine.
7. Compare the pressure value recorded is in the range of
140 – 145 bar (2030 – 2102 psi). If it is in range, then
pressure has been set. If not, adjust the relief valve
in steering unit and record the pressure till it is getting
achieved. If not achieved on full adjustment, Reduce
the engine RPM and follow the disassembly procedure
to check the steering unit.
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Hydraulic systems - Test

Output test hose connections – Rear pump
PTIL13TLB1795FB 1
1. Loader control valve 5. Flowmeter inlet hose

2. T fitting 6. T fitting
3. Pump output hose 7. Pump
4. Flowmeter outlet hose
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Output test hose connections — Front pump
PTIL13TLB1793F 2
Hose connection from pump to loader control valve to be plugged
1. Loader control valve 6. Connector

3. Pump output hose 8. Connector
4. Flowmeter outlet hose 9. Pump
5. Flowmeter inlet hose
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PTIL13TLB1794FB 3
Hose connection from pump to loader control valve to be connected
1. Loader control valve 6. Connector

3. Pump output hose 8. Connector
4. Flowmeter outlet hose 9. Pump
5. Flowmeter inlet hose
NOTICE: Remove hydraulic tank filler cap and place flowmeter outlet hose (6) below oil level, SECURE HOSE.
NOTE: Make copies of the Flowmeter Check Sheet in the rear of this section and use it to record the readings.
Machine preparation
A. With the engine running at full throttle, close the
relief valve on the flowmeter to at least 103.40 bar
(1499.30 psi).
B. Ensure no steering force is being applied to the
steering wheel and observe on the pressure
gauge. This pressure gauge should read ap-
proximately 17 bar (246 psi) and this is stand by
pressure.
C. Hold the loader control lever in the ROLLBACK
position for 15 seconds.
D. Put the loader control lever in the NEUTRAL posi-
tion for 15 seconds.
E. Repeat Steps A and B until the temperature of the
oil is 51.00 °C (123.80 °F) or the side of the reser-
voir is very warm.
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the floor.
3. Remove pressure adapter from pump, connect flowme-
ter input hose to the T fitting.
4. Remove screen from reservoir and secure the flowme-
ter return hose below oil level.
Pump efficiency
The following pump performance test must be per-
formed after pressure testing the system and rear
pump relief valves and when the hydraulic oil is at
normal operating temperature of 51 °C (124 °F)..
1. Disconnect inlet and outlet hoses to backhoe
control valve and install 0 – 200.000 L/min (0 –
7.063 cfm) flowmeter
2. Open flowmeter valve
3. Slowly turn flow control valve and increase pres-
sure to 175 bar (2538 psi) Measure pump flow
which should be 69.000 – 81.000 L/min (2.437 –
2.860 cfm)
Test 3a
Holding the loader on demand, fully open the load
valve, adjust engine to 2000 RPM, read the flow gauge
and record the reading. Record this reading on line 3a
on check sheet.
Test 3b
Continue to run the engine at 2000 RPM.
Slowly close the load valve until the pressure is 138 bar
(2001 psi), read the flow gauge and record the reading.
Record this reading on line 3b on heck sheet.
Divide the flow reading at 138 bar (2001 psi) (3b) by
the flow reading 0 bar (0 psi) (3a).
NOTE: This answer multiplied by 100 is the percent effi-
ciency of the rear pump. If the efficiency of the rear pump
is less than 69 percent, repair or replace the pump. If the
efficiency of the pump is more than 70 percent, the pump
is good.
NOTE: If the machine has a history of poor service intervals
replace the hydraulic system filter and clean pump intake
filter in the reservoir.
Test 3c
Open the front pump outlet connection and plug the
hose. Connect flowmeter inlet hose to the front pump
outlet. Do not disturb the flowmeter outlet hose con-
nection. Fully open the load valve at flowmeter, adjust
engine to 2000 RPM. Record this reading of flowmeter
on line 3c on the check sheet.
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Test 3d
Continue to run the engine at 2000 RPM. Slowly close
the load valve until the pressure is 138 bar (2001 psi),
read the flow gauge and record the reading on line 3d
on the check sheet. Divide the flow reading at 138 bar
(2001 psi) 3d by the flow reading at 0 bar (0 psi) i.e.
3c.
NOTE: This answer multiplied by 100 is the percent effi-
ciency of the front pump. If the efficiency of the front pump
is less than 70 percent, repair or replace the pump. If the
efficiency of the pump is more than 70 percent, the pump
is good.
Loader control valve leakage

Continue to run the engine at 2000 RPM and increase
pressure on flowmeter to 138 bar (2001.00 psi).
Test 4a
Hold the loader in the raised position. Record l/min
(gpm) on line 4a on check sheet.
Test 4b
Lower the loader and hold the loader in the lower posi-
tion. Record l/min (gpm) on line 4b on check sheet.
Test 4c
With the loader approximately eighteen inches from the
ground, hold the bucket in the rollback position. Record
l/min (gpm) on line 4c on check sheet.
Test 4d
Hold the bucket in the dump position. Record l/min
(gpm) on line 4d on check sheet.
Test 4e
Hold the clam in the open position. Record l/min (gpm)
on line 4e on check sheet.
Test 4f
Close and hold the clam in the closed position.
Record l/min (gpm) on line 4f on check sheet.
NOTE: If flow reading between test 3b and tests 4athrough
4f varies more that 4.55 L/min (1 US gpm) there is a prob-
lem in that circuit.
Backhoe control valve leakage

Continue to run the engine at 2000 RPM and the
flowmeter at 138 bar (2001.00 psi). Hold each function
on demand at the end of the stroke.
Test 6a
Swing the backhoe to the left. Record l/min (gpm) on
line 6a on the check sheet.
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Test 6b
Swing the backhoe to the right. Record l/min (gpm) on
line 6b on the check sheet.
Test 6c
If equipped, extend and hold the extend-a-hoe out.
Record l/min (gpm) on line 6c on the check sheet.
Test 6d
Retract and hold the extend-a-hoe in. Record l/min
(gpm) on line 6d on the check sheet.
Test 6e
Raise the left stabilizer. Record l/min (gpm) on line 6e
on the check sheet.
Test 6f
Raise the right stabilizer. Record l/min (gpm) on line 6f
on the check sheet.
Test 6g
NOTE: During stabilizer lower test, evenly lower both sta-
bilizers to full stroke and raise the machine. Lower the
left stabilizer. Record l/min (gpm) on line 6g on the check
sheet.
Test 6h
Lower the right stabilizer. Record l/min (gpm) on line 6h
on the check sheet.
Test 6i
Roll the backhoe bucket to the dump position. Record
l/min (gpm) on line 6i on the check sheet.
Test 6j
Roll the backhoe bucket to the dig position. Record
l/min (gpm) on line 6j on the check sheet.
Test 6k
Hold the dipper in the full extended position. Record
l/min (gpm) on line 6k on the check sheet.
Test 6l
Hold the dipper in the full in position. Record l/min
(gpm) online 6l on the check sheet.
Test 6m
Hold the boom in the lower position. Record l/min (gpm)
on line 6m on the check sheet.
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Test 6n
Hold the boom in the raise position. Record l/min (gpm)
on line 6n on the check sheet.
Test 6o
If equipped with bi-directional auxiliary hydraulics, un-
hook hydraulic quick disconnects or cap lines, hold the
lever out. Record l/min (gpm) on line 6o on the check
sheet.
Test 6p
Reverse directions on the bi-directional valve. Record
l/min (gpm) on line 6p on the check sheet.
NOTE: If flow reading between test 5b and tests 6a through
6p varies more that 4.55 L/min (1 US gpm) there is a prob-
lem in that circuit.
Backhoe valve flow regulator test

Connect a gauge capable of 69 bar (1000 psi) to the
attenuator hose test port. Install a shut off valve in the
hose.
Disconnect the LS hose from the pump, install a “T” fit-
ting with a test port connector, connect a gauge capable
of 69 bar (1000 psi) to the load sense test port. Install
a shut off valve in the hose.
Start engine and run at low idle, Do NOT activate any
controls.
Test 9a
Record the pressure at the end of attenuator hose,
record the reading on line 9a.
Test 9b
Record the pressure at the end of load sense port ,
record the reading on line 9a.
The difference in the pressure reading is the backhoe
valve flow regulator setting.
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Flowmeter check sheet template – Rear pump
PTIL13TLB1454HA 4
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Flowmeter check sheet template – Front pump
PTIL13TLB1787HA 5
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Hydraulic systems - Test - Pressure testing

the floor.
loader control lever in the rollback position for 15
seconds.
B. Put the loader control lever in the neutral position
for 15 seconds.
C. Repeat Steps A and B until the temperature of the
oil is 51 °C (124 °F) or the side of the reservoir is
very warm.
3. Install 0 – 300 bar (0 – 4350 psi) pressure gauge into
450 bar (6526 psi). Remove the PLUG 1/4" BSP
(V204029_30377) from 2-spool valve assembly &
assemble the sensor of G1/4" thread to measure the
main system pressure.
5. With the engine running at 2000 RPM, operate & hold
loader lift or stabilizer lever and read the pressure
gauge. Make a record of the reading.
6. Raise loader until bucket is approximately 0.500 m
(19.685 in) from the ground. This ensures that self
levelling device does restrict movement of bucket
during this test. Hold the loader bucket control lever to
the left causing the bucket to roll back.
8. Observe the reading on the upper gauge which will dis-
play the system pressure relief valve setting. Pressure
reading should be 210 bar (3045 psi).
9. Refer Hydraulic systems - General specification
(35.000) for standard values. If value is within the
range then pressure is set. Else refer Hydraulic
systems generic sub-group - Troubleshooting
(35.AAA) for troubleshooting guidelines.
NOTE: If relief valve is away from specification adjust to
Specification.
NOTE: The same procedure to be followed for the swing
valve only.
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Hydraulic systems - Testing - Problem in a loader circuit

Test N°1
Test Point Condition
Check the machine for missing or damaged parts.
Check
Check the operation of the problem circuit, Do the cylinder(s) move in both directions
Expected Result
Result Yes, check the O-ring on the end of the circuit relieve valve or plug
Other Action
Result No, check the operation of the spool in both directions. Is the spool operation correct? If no, remove and
(Possible inspect the spool and loader valve for damage. Repair or replace the spool or valve, as necessary
Cause)
Test N°2
Test Point Check
Is the circuit relief valve or plug O-ring within acceptable limits?
Expected Result
Result Yes, check the setting of the circuit relief valve, if used, for the problem circuit. Is the setting correct?
Other Action
Result No, replace the O-ring
(Possible
Cause)
Test N°3
Test Point Check
Is the circuit relief valve setting correct?
Expected Result
Result Yes, check the cylinder piston packing. Is the cylinder piston packing acceptable?
Other Action
Result No, adjust circuit reliefs and valve settings
(Possible
Cause)
Test N°4
Test Point Check
Is the cylinder piston packing acceptable?
Expected Result
Result Yes, the control valve has internal wear or damage. Repair or replace the individual section or control
valve as necessary
Other Action
Result No, replace or repair the cylinder, as necessary
(Possible
Cause)
Hydraulic systems - Testing - Noise from the backhoe hydraulic

system
Test N°1
Test Point Check
Does the system operate normally without noise
Expected Result
Result Yes, troubleshooting complete
Other Action
Result No, Start the machine and operate the backhoe, fully stroking each function back and forth. Continuously
(Possible operate the systems until the oil is at operating temperature. If noise persists, shut down and allow to
Cause) cool and repeat the procedure
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Index

Hydraulic systems - Component identification - Backhoe control valve hose connection . . . . . . . . . 6
Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic systems - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems - Static description - Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic systems - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic systems - Test - Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic systems - Testing - Noise from the backhoe hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic systems - Testing - Problem in a loader circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Reservoir, cooler, and filters - 300
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Oil filters
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC
Oil reservoir
Testing - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hydraulic systems - Reservoir, cooler, and filters
Oil filters - Sectional view

1. Casting bowl
2. Spring
3. O-ring bowl
4. O-ring
5. Element assembly
6. Bowl
PTIL13TLB0183BB 1
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Hydraulic systems - Reservoir, cooler, and filters
Oil reservoir - Testing - Hydraulic oil reservoir

Test N°1
Test Point Condition
Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any dam-
aged or missing parts
Check
Check the oil level in the hydraulic reservoir. Is the oil level correct?
Expected Result
Result Yes, verify correct movement of the controls. Check the operation of the machine, does the machine
operate correctly
Other Action
Result Fill the hydraulic reservoir with the oil
(Possible
Cause)
Test N°2
Test Point Check
Does the machine operate correctly?
Expected Result
Result Yes, troubleshooting complete
Other Action
Result Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits
(Possible have problems
Cause)
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Index

Oil filters - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil reservoir - Testing - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Fixed displacement pump - 104
851FX Plus
851FX
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35.3 [35.104] / 1
Contents
TECHNICAL DATA
Pump
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Pump
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prepare - Work surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSTIC
Pump
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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Hydraulic systems - Fixed displacement pump
Pump - Weight
1. Pump 28 kg (62 lb)
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Pump - Sectional view
PTIL13TLB1759F 1
1. Drive gear 9. O-Ring

2. Driven gear 10. Coupling
3. Driven gear 11. Drive gear
4. Bush 12. Spacer
5. Seal section 13. Seal lip
6. Balance plate 14. Circlip
7. Seal energ 15. Priority valve assembly
8. Seal element
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Pump - Remove
NOTE: Put identification tags on all disconnected hoses and wires. Close disconnected hoses and fittings with caps
and plugs.
1. Park the machine on a level surface and apply the park-
ing brake.
2. Lower the loader bucket to the floor and stop the en-
gine.
3. Move the loader and backhoe control levers in all direc-
tions to release the pressure from the hydraulic circuits.
4. Remove the cap (2) from the hydraulic reservoir (1).
This will reduce the hydraulic oil loss as the hoses and
tubes are removed from the hydraulic pump. The oil
level can be monitored from the oil level gauge (3).
PTIL12TLB0172AB 1
5. Remove the drive shaft (1) from the transmission to the

rear axle.
PTIL16TLB0040AB 2
6. Remove the Allen head screw (4) and loosen the hose
clamp (5) on the inlet hose to the pump.
RCPH10TLB320ABL 3
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7. Remove the two lower mounting nuts (6).

8. Attach suitable lifting equipment to the pump.
RCPH10TLB323ABL 4
9. Disconnect hoses from fittings (8), (9) and (10).

10. Remove the pipe (7) from the pump.
11. Remove the two upper mounting bolts.
12. Slide the pump to the rear off of the drive splines,
remove the pump from the machine.
PTIL16TLB0041AB 5
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Pump - Install
Prior operation:
Refer to Pump - Remove (35.104).
1. Use a new O-ring on pump mounting flange, slide the

pump onto the drive splines.
2. Install but do not tighten the two upper mounting bolts
(6).
RCPH10TLB325ABL 1
3. Install but do not tighten the lower mounting nuts (6).

Refer Hydraulic systems generic sub-group - Re-
place (35.AAA) for the torque of the nut.
4. Tighten the lower and upper mounting nuts.
RCPH10TLB323ABL 2
5. Remove lifting equipment to the pump.

6. Connect and tighten hoses to fittings (8), (9) and (10).
7. Install the pipe (7).
8. Ensure O-ring is installed in the suction flange.
PTIL16TLB0041AB 3
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NOTE: Make sure that suction hose “END - B” is connected

at pump end (suction flange).
PTIL17TLB0183AB 4
9. Install the Allen screw (4). Tighten all three Allen

screws simultaneously. Refer Hydraulic systems
generic sub-group - Replace (35.AAA) for the torque
of the allen screw.
10. Tighten the hose clamp (5) on the inlet hose to the
pump.
11. Install the drive shaft to the rear axle.
12. Fill the hydraulic reservoir.
13. Verify the oil level in the hydraulic reservoir is correct.
14. Close the hydraulic reservoir cap.
RCPH10TLB320ABL 5
15. Start the engine and operate all hydraulic circuits.
Stop the engine and check for any leaks.
16. Fill the hydraulic reservoir as required.
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Pump - Prepare - Work surface

Hydraulic pumps are precision machined components
and must be handled appropriately. Before beginning
any pump disassembly or repair procedures, clean the
work area thoroughly of all contaminates. It is advised
that clean towels, paper towels or cardboard be placed
on the workbench to provide a clean work surface.
The work area should be free of blowing dust, welding
sparks or anything that could contaminate the pump
components. If any pump component must be cleaned,
use a clean solvent from a can such as brake or carbu-
rettor cleaner. Use of typical shop parts washers is not
advised due to containments in the cleaning fluid.
NOTE: Pump to be dismantled in dust free environment
only to avoid external contamination.
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Pump - Disassemble
NOTE: Clean all the parts with a lint free cloth and a mild solvent as soon as it is removed. Work should be carried
out in a clean and dust free environment.
1. Clean the pump externally and cap all open ports (1).
PTIL13TLB0993AA 1
2. Mark a straight line (2) along the length of the pump.
PTIL13TLB0994AA 2
3. Place the pump on a clean surface in shaft down posi-

tion.
PTIL13TLB0995AA 3
4. Clamp the pump through the flange hole (3) to prevent

rotation.
PTIL13TLB0996AB 4
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5. Remove the LSPV bolts (4) with nut runner and priority
valve.
PTIL13TLB0997AB 5
6. Dismantle the pump sections by removing the nuts &

studs.
PTIL13TLB0998AB 6
7. Remove LSPV O-ring from the cover.
PTIL13TLB0999AA 7
8. Remove the cover (6) and the section O-ring (7).
PTIL13TLB1000AB 8
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9. Remove the balance plate (8) from the body.

10. Check the bushing wear
11. Amount shaved inside diameter of the case is
0.01000 mm (0.00039 in). Check if it is beyond limit
pump need to replaced.
12. Check the wear of sliding portion on the pump hous-
ing on inside of the diameter. Check the abnormal
scratches on inside surface case. If the scratches are
more, pump need to be replaced completely.
PTIL13TLB1001AB 9
PTIL13TLB1002AB 10
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13. Check and replace the seals on the balance plate as

a standard practice.
14. Check the wear plate of wear of inside diameter.
15. Check the sliding face for any scratches of inside di-
ameter of gear case.
PTIL13TLB1003AA 11
PTIL13TLB1004AA 12
PTIL13TLB1005AA 13
16. Remove the first body (10).
PTIL13TLB1006AB 14
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17. Remove the coupler (12) and dowels (11) if required.
PTIL13TLB1007AB 15
18. Remove the O-rings (13) between the gear housings.
PTIL13TLB1009AB 16
19. Remove the gears and balance plate (14) from this
housing.
PTIL13TLB1010AB 17
20. Remove the seals in the balance plates, section seal

and lip seals.
PTIL13TLB1011AA 18
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21. Remove and replace the lip seal (15).
PTIL13TLB1012AB 19
PTIL13TLB1013AB 20
22. Remove the balance plate seals (16), (17) and replace
them.
PTIL13TLB1014AB 21
PTIL13TLB1015AB 22
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23. First the black seal (18) and then the other seal.
PTIL13TLB1016AB 23
24. For section O-ring (19) check for pinching and replace
if damaged.
PTIL13TLB1017AB 24
25. Disassemble the load sensing proportionating valve

(LSPV) with nut runner and remove internal parts.
PTIL13TLB1032AA 25
26. Remove the plug (1) using allen key.
PTIL13TLB1671AB 26
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27. Separate the spool (1) from the priority valve.
PTIL13TLB1672AB 27
PTIL13TLB1673AB 28
NOTE: Do not damage the valve while dismantling.

29. Remove the orifice (1) of the spool carefully and clean
the jet (2).
PTIL13TLB1674AB 29
30. Remove the strainer (1).
PTIL13TLB1675AB 30
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31. Clean the strainer (1) with mild air blow.
PTIL13TLB1676AB 31
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Pump - Assemble
1. Fix the flange (20) and place the section seal (21) on it.
PTIL13TLB1018AB 1
2. Place the balance plate (22) with the small holes to-
wards the outlet and gears.
PTIL13TLB1019AB 2
3. Place the balance plate (24) on the gears (23) as

shown.
PTIL13TLB1020AB 3
PTIL13TLB1021AB 4
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4. Place the pump body (25) with the O-ring groove first.
PTIL13TLB1022AB 5
5. Then place the dowel seal (26).
PTIL13TLB1023AB 6
6. Place the coupler.
PTIL13TLB1024AA 7
7. Place the second body (27).
PTIL13TLB1025AB 8
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8. Place the balance plate (28) then the gears (29).
PTIL13TLB1026AB 9
9. The balance plate (30) should be assembled with the

small holes towards the outlet.
PTIL13TLB1027AB 10
10. Then place the cover.

11. Insert the bolt (31) and washer (32).
PTIL13TLB1028AB 11
12. Tighten it and torque it with 95 N·m (841 lb in) torque.
PTIL13TLB1029AA 12
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13. Install the load sensing proportionating valve (LSPV)

with nut runner and assemble internal parts.
PTIL13TLB1032AA 13
14. Install the strainer (1) into the spool after cleaning.
PTIL13TLB1675AB 14
15. Install the orifice (1) in the spool after cleaning the jet
(2).
NOTE: Do not damage the valve while assembling.
PTIL13TLB1674AB 15
16. Install the spring (1) into the valve.
PTIL13TLB1673AB 16
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17. Install the spool (1) into the priority valve.
PTIL13TLB1672AB 17
18. Tighten the plug (1) using 8.000 mm (0.315 in) allen
key.
PTIL13TLB1671AB 18
19. Place the seal on the cover.

20. Reassemble the LSPV on the pump.
PTIL13TLB1037AA 19
21. Insert the washer and the bolts.

22. Tighten the screws (33) with torque of 45 N·m (398 lb
in).
23. Gradually increase the torque and check the rotation
of shaft.
PTIL13TLB1038AB 20
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24. After assembly confirm that the white marking (2) is in

line.
PTIL13TLB0994AA 21
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Pump - Testing
Test N°1
Test Point Check
Do a pump test. Is the pump good?
Expected Result
Result Yes, do a stall test
Other Action
Result No, Repair or replace the hydraulic pump
(Possible
Cause)
Test N°2
Test Point Check
Do a stall test, Is there still a problem?
Expected Result
Result No, troubleshooting complete
Other Action
Result Yes, clean the system
(Possible Is the oil contaminated?
Cause)
Test N°3
Test Point Check
Is the hydraulic oil contaminated?
Expected Result
Result No, check the remaining circuits
Other Action
Result Yes, clean or replace the hydraulic oil.
(Possible
Cause)
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Index

Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump - Prepare - Work surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Main control valve - 359
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Main control valve

Component identification - Backhoe control valve ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component identification - Loader valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hydraulic systems - Main control valve
Main control valve - Component identification - Backhoe control

valve ports
PTIL13TLB1788FB 1
1. Outlet section - T Port 10. P Port

2. Stabilizer right section 11. T Port
3. Stabilizer left section 12. P-Port to side shift clamp cylinders
4. Dipper section 13. Side shift lock solenoid valve
5. Bucket section 14. Bucket section-circuit relief valve
6. Swing section 15. LS pressure relief valve
7. Boom section 16. Flow control orifice
8. Telescopic section 17. High Pressure Carry Over (HPCO) Port
9. Flow balancing valve 18. Tank line
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Hydraulic systems - Main control valve
Main control valve - Component identification - Loader valve
PTIL13TLB1789FB 1
1. Outlet section 8. Inlet section

2. BDB section 9. Pressure gauge port
3. Tilt section 10. Dump relief valve
4. Lift section 11. Inlet line from pump
5. Line inlet 12. Tank line
6. LS pressure relief plug 13. RTD solenoid (bucket section)
7. Dump valve solenoid valve
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Index

Main control valve - Component identification - Backhoe control valve ports . . . . . . . . . . . . . . . . . . . 3
Main control valve - Component identification - Loader valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Hammer and rotating bucket hydraulic system - 360
851FX Plus
851FX
91715732 26/07/2021
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Contents
SERVICE
Hammer system lines

Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Hydraulic systems - Hammer and rotating bucket hydraulic system
Hammer system lines - Install

851FX
A. Install all straight connector (3) fittings and swivel

elbow (14) to the hammer valve (2).
PTIL17TLB0180AB 1
1. Connect the hose to the fittings on the hammer valve

(2) through elbows (14).
PTIL14II00012AB 2
2. Install the hammer valve (2) onto the chassis of the

machine using bolts (1) and washer (5). Torque the
bolts (1) to 28.8 N·m.
NOTE: Install three washers (5) on each bolt (1) between
the hammer valve (2) and the machine frame. Install one
washer (5) on each bolt (1) between the bolt head and ham-
mer valve (2).
PTIL18TLB0903AA 3
3. Connect the tube flex (6) to the hammer valve (2)

through a connector (3).
PTIL14II00026AB 4
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4. Connect the hammer return hose (10) to the hydraulic

tank through a connector (15).
5. Install the tee (17) to the hydraulic tank.
6. Connect the flex hose (7) to the hydraulic tank through
a tee (17).
PTIL18TLB0009AA 5
7. Install an elbow (48) to the end of the tee (17) and

connect the steering return hose.
PTIL17TLB0182AC 6
8. Connect the hose (16) from the hammer valve (2) to

the back–hoe control valve through an elbow connector
(9).
PTIL14II00015AB 7
9. Using a hose (8) connect hammer valve to loader valve.
PTIL18TLB0905AA 8
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10. Connect the hose (25) from the hydraulic tank to sta-
bilizer unit.
11. Support the hose (25) to the stabilizer frame using
clamp (23), washers (5) and tighten the bolt (21).
NOTE: Route pressure hose through the upper part of sta-
bilizer clamp, second hole from the top.
PTIL18TLB0907AA 9
12. Route the hydraulic tube (4) and (6) using a hydraulic
clamp mounting plate (19).
13. Secure the hydraulic clamp mounting strap (20) using
a bolt (21), conical washer (5) and nut (22).
PTIL18TLB0906AA 10
14. Connect the hose (24) to the hammer valve (2) and
the inside of the swing tower.
15. Connect the hose (25) to the inside of the swing tower.
PTIL14II00018AB 11
16. Connect hammer valve wire harness (18) to the ham-

mer valve (2).
17. Route a hose from the hammer valve wire harness
(18) and connect to the pedal (11) secured through
plate (12), located on left-hand side of backhoe con-
sole, and cylindrical head screw (13).
PTIL14II00029AB 12
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18. Install the bracket (44) on the left-hand side dipper

with the bolt (46) and washer (45).
PTIL16TLB0356AB 13
19. Secure the hydraulic tube (32) with the collar (29) and
bolts (30).
20. Connect the hydraulic hose (33) to the hydraulic tube
(32).
NOTE: Orient the hoses so they do not come in contact
with the boom, dipper or swing tower.
PTIL14II00011AB 14
21. Connect the hydraulic tube (32) to the hydraulic hose

(42) and route the hydraulic hose (42) as shown.
22. Secure the hydraulic tube (32) with the tube (26), plate
(28) and bolt (27).
PTIL14II00009AB 15
23. Install the plug (39) and hydraulic connector (36) on

the block (35).
24. Secure the block (35) using a bolt (41), and washer
(34).
25. Install the check valve (38) on the hydraulic connector
(37) of the block (35).
26. Install the O-ring boss adapter (37) on the block (35).
Connect the hydraulic hose (42) to the O-ring boss
adapter (37) of the block (35).
PTIL14II00007AB 16
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27. Install the bracket (43) on the dipper with the bolt (46)
and washer (45).
PTIL16TLB0357AB 17
28. Connect the hydraulic hose (33) to hydraulic tube (31).

Secure hydraulic tube (31) with the collar (29) and
bolts (30) as shown.
29. Connect the other end of hydraulic hose (33) to its
designated hoses of uni-auxiliary hammer valve.
NOTE: Orient the hoses so they do not come in contact
with the boom, dipper or swing tower.
PTIL14II00005AB 18
30. Connect the hydraulic tube (31) to the hydraulic hose

(42) and route the hydraulic tube (31) as shown.
31. Secure the hydraulic tube (31) with the tube (26), plate
(28) and bolt (27).
32. Install the block assembly (35) on the right-hand side
dipper (A) with the bolts (41) and washers (34).
33. Route the hydraulic hose (42) as shown.
PTIL14II00004AB 19
34. Install the union (40) and plug (39) on the block (35).
35. Install the conical washer spring (47) on the block (35).
36. Install the O-ring boss adapter (37) on the block (35).
37. Connect the hydraulic hose (42) to the O-ring boss
adapter (37) of the block (35).
PTIL17TLB0181AB 20
38. Check and top-up the hydraulic oil.

39. Connect the battery negative cable and turn ON the
engine and keep idle.
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40. Turn OFF the engine and check the hydraulic oil level.
Top-up if required.
41. Check and make sure there is no hydraulic oil leaks.
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Index

Hammer system lines - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front loader hydraulic system control - 724
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Front loader hydraulic system control

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Front loader hydraulic system control

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Hydraulic systems - Front loader hydraulic system control
Front loader hydraulic system control - Overview
PTIL13TLB1372HB 1
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1. Nut 21. Screw

2. Washer 22. Spool
3. Tie rod 23. Fixed cartridge
4. Outlet 24. Spacer
5. Tap 25. Bushing control kit
6. O-ring 26. Spring
7. O-ring 27. Spring bushing cap
8. Washer 28. Pin control
9. Bushing control kit 29. Cap
10. Spring 30. Drain plug
11. Spring cap 31. Socket head screw
12. M8 screw 32. Ring kit
13. End cap 33. Spacer
14. Screw 34. Armature control
15. Block 35. Electro magnetic kit
16. Seal 36. Inlet
17. Flange 37. Plug
18. Screw 38. Plug
19. Fixed cartridge valve 39. Main relief valve
20. Check valve
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Front loader hydraulic system control - Remove

NOTE: Put identification tags on all disconnected hoses and wires. Seal disconnected hoses and fittings with caps
and plugs.
ing brake.
2. Lower the loader bucket to the floor and stop the en-
gine.
3. Move the loader control lever in all directions to release
the pressure from the loader hydraulic circuits.
4. Pull the floor mat away from the loader control cover.
5. Remove the boot retaining grommet.
6. Unscrew (1) and remove the Loader lever console.
PTIL13TLB0195AB 1
7. Remove the loader lever linkages (2), (3), and (4).

8. Remove the bolt (1) and remove the loader control lever
assembly (5).
PTIL18TLB0938AA 2
9. Disconnect the lever linkage rods from the valve.

10. Remove the cap (1) from the hydraulic reservoir. This
will reduce the hydraulic oil loss as the hoses and
tubes are removed from the loader control valve.
PTIL12TLB0457AB 3
11. Disconnect the wiring for the RTD located on the

bucket section of the loader control valve.
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12. Disconnect and remove the tubes (2), and hoses (3),
from the fittings on the loader control valve. Install
caps on the fittings and plugs in the tubes and hoses.
ATTENTION: Put identification tags on all disconnected
hoses.
NOTE: Cab is removed for clarity only.
13. Connect acceptable lifting equipment to the loader
control valve.
14. Loosen and remove the four bolts (1) that fasten the
loader control valve to the chassis.
PTIL13TLB1451AB 4
15. Remove the loader control valve from the machine.
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Front loader hydraulic system control - Disassemble

Bottom dump section disassemble (Optional)
ATTENTION: Switch off the machine completely. Place all the machine’s actuators connected to the control block in
neutral position. Release stored pressure by operating all spools.
1. Place the loader valve (1) on a clean and flat surface
before proceeding the dismantling operation.
PTIL13TLB1684AB 1
2. Remove the tie rod nuts (1).

NOTE: Place all the bolts in a safe location for easy re-
trieval.
PTIL13TLB1686AB 2
3. Separate the outlet section (1) from the valve.
PTIL13TLB1687AB 3
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4. Separate the clam section (1) from the valve and place
in a clean location for dismantling.
PTIL13TLB1689AB 4
5. Unscrew the check valve plug (1) using 8.000 mm

(0.315 in) allen key.
PTIL13TLB1691AB 5
6. Remove the check valve plug (1) on the other side.
PTIL13TLB1692AB 6
7. Dismantle the check valve kit and clean to free from

any dust particle.
PTIL13TLB1693AA 7
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8. Using 8.000 mm (0.315 in) allen key remove the pres-

sure compression kit plug (1).
PTIL13TLB1695AB 8
9. Take the pressure compression kit (1) out of the slot.
PTIL13TLB1696AB 9
10. Dismantle the kit further and clean the components

without damaging the surface.
PTIL13TLB1697AA 10
11. Remove the secondary valve (1).
PTIL13TLB1698AB 11
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12. Check the valve seals and replace if necessary.
PTIL13TLB1699AA 12
Bottom dump bucket spool removal

13. Remove the cover screws (1) using trox screw driver.
PTIL13TLB1700AB 13
14. Remove the cover (2) from the section.
PTIL13TLB1707AC 14
15. Unscrew and remove the bellows kit (1) from the other
end.
PTIL13TLB1702AB 15
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16. Unscrew the adapter (1) using an 8.000 mm

(0.315 in) allen key.
PTIL13TLB1708AB 16
17. Remove the adapter (1), spring retainer (2), spring

(3) after holding it with a spanner on the other end of
spool.
PTIL13TLB1711AB 17
18. Hand remove the plate (1) and lip seal (2).
PTIL13TLB1712AB 18
19. Remove the spool (1) carefully without damaging the

surface.
NOTE: Use the spool clamp and vice to secure the spool.
PTIL13TLB1714AB 19
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20. Hand remove the plate (1) and lip seal (2) from the
opposite end.
PTIL13TLB1716AB 20
Solenoid valve disassemble

1. Remove the solenoid valve section from the working
section.
2. Unscrew the knurled knob (1) and pull the solenoid (2)
from the section.
PTIL13TLB1718AA 21
3. Unscrew and remove the plug (1) and clean it properly.
PTIL13TLB1719AA 22
4. Remove the valve seal (1) and replace if necessary.
PTIL13TLB1722AA 23
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Loader lift section disassemble

1. Follow procedure 1 to 10 of “Bottom dump section dis-
assemble”, before proceeding.
2. Remove the loader lift section from the valve.
3. Loosen and remove the cover (1).
PTIL13TLB1761AA 24
NOTE: Ensure to take care of the spring balls while dis-

mantling. Secure in a safe place for easy retrieval.
4. Remove the detent bush (1), central ball (2), spring (3),
balls (4) and adapter (5).
PTIL13TLB1762AB 25
5. Remove the spacer (1).
PTIL13TLB1725AA 26
6. Remove the lip seal (1). Replace if necessary.
PTIL13TLB1726AA 27
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7. Remove the loader lift section spool carefully without

damaging the spool surface and edges. Refer “Bottom
dump bucket spool removal”.
Loader bucket tilt section disassemble

1. Follow procedure 1 to 10 of “Bottom dump section dis-
assemble”, before proceeding.
2. Remove the loader lift section from the valve.
3. Separate the loader bucket tilt section.
4. Unscrew the pressure relief valve (1) and clean prop-
erly.
PTIL13TLB1729AA 28
5. Unscrew the valve (1) on the other side.
PTIL13TLB1765AB 29
6. Remove the damped pressure compression plug (1)

using 8.000 mm (0.315 in) Allen key.
PTIL13TLB1764AB 30
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7. Take the pressure compression kit out of the chamber.

8. Dismantle the kit further and clean the components
without damaging the surface.
9. Follow the spool removing procedure similar to bottom
dump bucket spool removal.
PTIL13TLB1766AB 31
10. Loosen and remove the solenoid kit (1).
PTIL13TLB1730AA 32
11. Dismantle the electrical detent operating kit (1) by un-

screwing the trox srews (2).
12. Check the armature (3) and adapter (4). Replace if
necessary.
PTIL13TLB1767AB 33
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Front loader hydraulic system control - Assemble

For assembly of individual sections follow the disas-
sembly procedure of respective section of “Front loader
hydraulic system control - Disassemble” in reverse or-
der.
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Front loader hydraulic system control - Install

1. Use acceptable lifting equipment to put the loader con-
trol valve into position in the machine.
2. Install and tighten the four bolts (1) and fasten the
loader control valve to the chassis.
3. Remove the lifting equipment from the loader control
valve.
4. Remove caps from the fittings and plugs from the tubes
and hoses. Connect tubes (2), and hoses (3), install
and connect tubes to the fittings on the loader control
valve.
NOTE: Cab is removed for clarity only.
5. Connect the wiring for the magnetic detent.
PTIL13TLB1451AB 1
6. Install the hydraulic reservoir cap (1).
PTIL12TLB0457AB 2
7. Connect the lever linkage rods to the valves.

8. Mount the loader lever assembly (5) and tighten the bolt
(1).
9. Install the loader control lever linkages (2), (3), and (4).
PTIL18TLB0938AA 3
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10. Install the loader lever console and tighten with screw
(1).
11. Install the boot using grommets.
12. Install floor mats.
PTIL13TLB0195AB 4
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Index

Front loader hydraulic system control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front loader hydraulic system control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front loader hydraulic system control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front loader hydraulic system control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader hydraulic system control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Front loader arm hydraulic system - 701
851FX Plus
851FX
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Contents
SERVICE
Lift arm cylinder

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Front loader arm hydraulic system
Lift arm cylinder - Remove

NOTE: During this procedure hydraulic oil will be released. Keep a container to collect and dispose the fluid properly.
1. Raise and support the loader attachment with a lifting
device.
2. Attach suitable lifting device to loader lift cylinder also.
PTIL13TLB0485AA 1
3. Disconnect the hydraulic lines (1) from the loader lift

cylinder after de-clamping.
4. Cap the oil plugs and lines immediately.
ATTENTION: Ensure not to damage the hydraulic pipes.
Failure to comply may affect oil flow during operations.
PTIL13TLB0486AB 2
5. Attach a suitable lifting device to the lift cylinder.

6. Remove the wear ring (1) and cotter pin from the safety
strut connected link.
PTIL13TLB0487AB 3
NOTE: Tag the safety strut to the loader to avoid injury due
to sudden fall of strut.
7. At the bucket end of the cylinder, tap the pivot pin (1)
from one side using a wooden hammer.
8. Perform the above procedures on both the sides and
place the free end of the cylinder on the ground safely.
PTIL13TLB0488AB 4
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9. At the rear end of the cylinder, remove the snap ring

and shim (1).
10. Perform the same procedure on other side too.
PTIL13TLB0489AB 5
11. Tap the pivot pin (1) from one side using a wooden
hammer to free the loader lift cylinder.
12. Lift both the cylinders and place them aside.
PTIL13TLB0490AB 6
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Lift arm cylinder - Install

1. Lift the cylinders and position them accordingly.
hammer to fix the loader lift cylinder.
PTIL13TLB0490AB 1
3. Perform the same procedure on other side too.

4. Install the shim and snap ring (1) using special tool.
PTIL13TLB0489AB 2
5. At the loader bucket end, place the cylinder and the

safety strut.
hammer.
PTIL13TLB0488AB 3
7. Install the cotter pin and wear ring (1) after attaching
the safety strut connected link.
8. Release the lifting device from the lift cylinder.
PTIL13TLB0487AB 4
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9. Cap the oil plugs and lines to the cylinder plugs and
inlet lines.
10. Connect the hydraulic lines (1) to the loader lift cylin-
der after clamping.
PTIL13TLB0486AB 5
11. Release the lifting devices from the cylinder and

loader attachment.
PTIL13TLB0485AA 6
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Index

Lift arm cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lift arm cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Front loader bucket hydraulic system - 723
851FX Plus
851FX
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Contents
SERVICE
Loader bucket control cylinder

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - Remove

WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under
pressure can penetrate the skin and cause
infection or other injury. To prevent personal
injury: Relieve all pressure before discon-
necting fluid lines or performing work on the
hydraulic system. Before applying pressure,
make sure all connections are tight and all
components are in good condition. Never use
your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood
for this purpose. If injured by leaking fluid, see
your doctor immediately.
ous injury.
W0178A
Move the machine to a level and firm ground, away from

soft ground, excavations or poorly shored cavity.
Raise the loader attachment and place the backhoe at-
tachment in the road travel position.
Ensure the direction-of-travel lever and gearshift lever
are in neutral position.
Engage the parking brake.
Completely raise the stabilizers.
Stop the engine.
Release the hydraulic pressure by operating the control
levers in all directions.
Disconnect the electrical system by disconnecting the
battery.
Place some wedges under the wheels in order to pre-
vent the machine from moving if required.
NOTE: For all service operations which require removal of
hydraulic components from the machine, disconnect the
hydraulic lines from the respective components and cap
the oil plug and the hydraulic lines immediately.
Drain and collect the hydraulic oil from the cylinders and
lines in a suitable container.
ATTENTION: Do not allow any person to stand under the
attachments in raised position. Failure to comply may re-
sult in serious injury or death.
NOTE: During this procedure hydraulic oil will be released.
Keep a container to collect and dispose the fluid properly.
ATTENTION: Keep the work place clean and tidy to avoid
accidents due to slippage.
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1. Raise the loader.

2. Attach a suitable lifting device (1) to the loader cylinder
on both sides.
PTIL13TLB0477AB 1
3. Disconnect the hydraulic lines (1) from the cylinders

and cap them immediately after removing the clamp
(2).
PTIL13TLB0478AB 2
4. Remove the wear ring (1) from both sides.
PTIL13TLB0480AB 3
5. Tap and remove the cotter pin (1) using a wooden ham-
mer.
6. Now tap and remove the pivot pin (2) from the connect-
ing link.
PTIL13TLB0481AB 4
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7. Remove the snap ring (1) and shim from the other end
of the cylinder joint.
PTIL13TLB0482AB 5
8. Remove the pivot pin (1) by taping from one end using
a mandrel and wooden hammer without damaging the
greasing points.
PTIL13TLB0483AB 6
9. Lift the suspending cylinders and place them aside.
PTIL13TLB0484AA 7
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Loader bucket control cylinder - Install

1. Lift the suspending cylinders and position them on the
loader assembly.
PTIL13TLB0484AA 1
2. Install the pivot pin (1) by taping from one end using
a mandrel and wooden hammer without damaging the
greasing points.
PTIL13TLB0483AB 2
3. Install the snap ring (1) and shim from the other side of
the cylinder joint.
PTIL13TLB0482A 3
4. Tap and install the pivot pin (2) from the connecting link.
5. Tap and install the cotter pin (1) using a wooden ham-
mer.
PTIL13TLB0481AB 4
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6. Install the wear ring (1) on both sides.
PTIL13TLB0480AB 5
7. Install the clamp (2) and connect the hydraulic lines (1)
to the cylinder plugs.
PTIL13TLB0478AB 6
8. Release the lifting device (1) from the loader cylinders

on both sides.
PTIL13TLB0477AB 7
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Index

Loader bucket control cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Loader bucket control cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Excavator and backhoe hydraulic controls - 726
851FX Plus
851FX
91715732 26/07/2021
35.9 [35.726] / 1
Contents
FUNCTIONAL DATA
Excavator and backhoe hydraulic controls

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Excavator and backhoe hydraulic controls

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Hydraulic systems - Excavator and backhoe hydraulic controls
Excavator and backhoe hydraulic controls - Exploded view

Overview
PTIL13TLB1401HB 1
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1. Nut 16. Check valve

2. Washer 17. Spool
3. Tie rod 18. O-ring
4. Inlet cover 19. Spacer
5. O-ring 20. Par back
6. FPM plug 21. Flange
7. Poppet kit 22. M8 Screws
8. Anti cavitations plug 23. Bushing control kit
9. Commutative kit 24. Spring
10. O-rings 25. Bushing control kit
11. O-ring 26. Screw
12. Block 27. End cap
13. Fixed cartridge valve 28. M6 screws
14. Block 29. Block
15. Port relief valve 30. Outlet
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Excavator and backhoe hydraulic controls - Remove

NOTE: Put identification tags on all disconnected hoses and tubes. Close disconnected hoses, tubes and fittings with
caps and plugs.
1. Park the machine on a level surface and lower the
loader bucket to the floor.
2. Lower the stabilizers until the stabilizer pads just touch
the floor.
3. Extend the backhoe straight behind the machine with
the backhoe bucket resting on the ground.
4. Stop the engine and apply the parking brake.
5. Move the backhoe control levers in all directions un-
til all hydraulic pressure has been released from the
backhoe hydraulic circuits.
6. Remove the levers boot grommet.
7. Disconnect the levers linkages (2).
8. Disconnect the hoses and tubes (3). Put identification
tags on all disconnected hoses, tubes and cap them.
9. Connect acceptable lifting equipment to the valve as-
sembly.
10. Remove the mounting bolts (1) of the valve assembly
to the chassis.
PTIL13TLB1452BB 1
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Excavator and backhoe hydraulic controls - Disassemble

1. On the inlet element, unscrew the LS pressure relief
valve (1).
PTIL13TLB1734AB 1
2. Remove the valve and clean it properly (1). If neces-

sary fit a new locking cover.
PTIL13TLB1735AB 2
3. Unscrew and remove the flow adaptor (1). Replace the

filter if necessary.
PTIL13TLB1738AB 3
4. Dismantle the flow balancing valve by removing the

plug (1).
PTIL13TLB1740AB 4
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PTIL13TLB1741AB 5
6. Remove the orifice (1) and clean the jet. Ensure the jet
is free from any dust particles.
PTIL13TLB1742AB 6
7. Unscrew the cover (1) to remove the spool from the

swing section.
8. Spool removal is same for all the sections.
NOTE: Handle the spool carefully while removing and in-
stalling into the section. Do not damage its sides and
edges.
PTIL13TLB1744AB 7
9. Slide the swing section spool (1) out of the chamber in

twisting motion. Check the spool and remove dust if
any.
PTIL13TLB1745AB 8
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10. Check the seal lip and replace if necessary.
PTIL13TLB1732AA 9
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Excavator and backhoe hydraulic controls - Assemble

For assembly follow the disassembly procedure of “Ex-
cavator and backhoe hydraulic controls - Disassemble”
in reverse order.
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Excavator and backhoe hydraulic controls - Install

1. Use acceptable lifting equipment to put the control
valve into position in the machine.
2. Install and tighten the mounting bolts (1) that fasten the
control valve to the chassis.
3. Remove the lifting equipment from the loader control
valve.
4. Remove caps from the fittings and plugs from the tubes
and hoses (3) and connect to the fittings on the control
valve.
5. Install the hydraulic reservoir cap.
6. Connect the lever linkage rods (2) to the valves.
7. Install and tighten the loader lever console.
8. Install the boot using grommets.
9. Install floor mats.
PTIL13TLB1452BB 1
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Index

Excavator and backhoe hydraulic controls - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Excavator and backhoe hydraulic controls - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Excavator and backhoe hydraulic controls - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Excavator and backhoe hydraulic controls - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Excavator and backhoe hydraulic controls - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Boom hydraulic system - 736
851FX Plus
851FX
91715732 26/07/2021
35.10 [35.736] / 1
Contents
SERVICE
Boom cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom cylinder line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Hydraulic systems - Boom hydraulic system
Boom cylinder - Remove

ATTENTION: While removing the boom cylinder ensure the safety of the cabin glasses.
1. Lower the backhoe attachment and rest it on the
ground.
PTIL13TLB0453AA 1
2. Attach a suitable lifting device to the boom cylinder (1).
PTIL13TLB0454AB 2
3. Remove the snap ring (1) and shim from the swing
frame end of the boom cylinder.
PTIL13TLB0455AB 3
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4. Tap and remove the pivot pin (1) from one side using
a wooden hammer and let the cylinder rest on the ma-
chine.
PTIL13TLB0456AB 4
5. Disconnect the cylinder from the center pivot point of

the boom.
6. Remove the bracket bolt (1).
7. Tap and remove the pivot pin from the other side to free
the boom cylinder from the machine.
NOTE: Ensure to collect all the shims and keep it aside for
easy retainment while installing.
PTIL13TLB0457AB 5
8. Using the lifting device place the boom cylinder aside

securely.
PTIL13TLB0452AA 6
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Boom cylinder - Install

1. Using the lifting device place the boom cylinder on the
boom.
PTIL13TLB0452AA 1
2. Place the bracket bolt (1) in the retainer bracket and

tap in the pivot pin to install the boom cylinder. Torque:
345 N·m (254 lb ft).
NOTE: Ensure to install all the shims, collected during re-
moval.
PTIL13TLB0457AB 2
3. Tap and install the pivot pin (1) from one side using a
wooden hammer.
PTIL13TLB0456AB 3
4. Install the shim and snap ring (1) on the swing frame
end of the boom cylinder.
PTIL13TLB0455AB 4
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5. Release the lifting device from the boom cylinder (1).
PTIL13TLB0454AB 5
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Boom cylinder line - Remove

1. Place the suitable container below the boom cylinder
to collect the hydraulic oil.
2. Disconnect the boom rod end hose (1) from the one
end of inlet tube (2).
3. Loosen the hose clamp (3) and separate the inlet tube
(2) from the boom cylinder (4).
4. Loosen the orifice connector and disconnect the other
end of inlet tube (2) from the boom cylinder (4).
5. Disconnect the boom head end hose (5) from the one
end of outlet tube (6).
6. Loosen the hose clamp (7) and separate the outlet tube PTIL20TLB0006AB 1
(6) from the boom cylinder (4).
7. Loosen the orifice connector and disconnect the other
end of outlet tube (6) from the boom cylinder (4).
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Boom cylinder line - Install

NOTICE: Make sure that the boom cylinder hoses and tubes are oil free before installation.
1. Connect the one end of outlet tube (1) to the boom
cylinder (2) and tighten the orifice connector.
2. Position the outlet tube (1) on the boom cylinder (2) and
tighten the hose clamp (3).
3. Connect the boom head end hose (4) to the other end
of outlet tube (1).
4. Connect the one end of inlet tube (5) to the boom cylin-
der (2) and tighten the orifice connector.
5. Position the inlet tube (5) on the boom cylinder (2) and
tighten the hose clamp (6).
6. Connect the boom rod end hose (7) to the other end of PTIL20TLB0006AB 1
inlet tube (5).
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Index

Boom cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boom cylinder line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Boom cylinder line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Dipper hydraulic system - 737
851FX Plus
851FX
91715732 26/07/2021
35.11 [35.737] / 1
Contents
SERVICE
Dipper cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Hydraulic systems - Dipper hydraulic system
Dipper cylinder - Remove

1. Lower the backhoe attachment and rest it on the
ground.
PTIL13TLB0453AA 1
2. Before proceeding to remove, attach a suitable lifting

device to the arm cylinder (1).
PTIL13TLB0447AB 2
3. De-clamp and remove the hydraulic lines (1) from the

cylinder and cap them immediately.
NOTE: Store the removed hoses and lines in a secure
place.
PTIL13TLB0448AB 3
4. Remove the retainer bracket bolt (1) and washer.

NOTE: Ensure to collect all the shims for easy retainment
during installation.
PTIL13TLB0449AB 4
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5. Tap and remove the retainer bracket pivot pin (1) using
a wooden hammer from the other side to free the cylin-
der from the boom end.
PTIL13TLB0450AB 5
6. Remove the retainer bracket bolt (1), washer and tap

the pivot pin from the other side using a wooden ham-
mer.
PTIL13TLB0451AB 6
7. Using the lifting device lift the cylinder and place it in a

secure location.
PTIL13TLB0452AA 7
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Dipper cylinder - Install

1. Using the lifting device lift the cylinder and place it on
the boom.
PTIL13TLB0452AA 1
2. Using a wooden hammer install the pivot pin and

tighten the retainer bracket bolt (1) and washer using
LOCTITE® 242®. Torque: 186 N·m (137 lb ft).
moval.
PTIL13TLB0451AB 2
3. Install the retainer bracket bolt (1) and washer us-

ing LOCTITE® 242® on the other end of the cylinder.
Torque: 186 N·m (137 lb ft).
PTIL13TLB0449AB 3
4. Clamp and install the hydraulic lines (1) to the cylinder.

PTIL13TLB0448AB 4
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5. Release the lifting device after installing the dipper

cylinder (1).
PTIL13TLB0447AB 5
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Index

Dipper cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dipper cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Excavator and backhoe bucket hydraulic system - 738
851FX Plus
851FX
91715732 26/07/2021
35.12 [35.738] / 1
Contents
SERVICE
Bucket cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassemble - Bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble - Bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Hydraulic systems - Excavator and backhoe bucket hydraulic system
Bucket cylinder - Remove

1. Lower the backhoe attachment and place the backhoe
bucket parallel to the ground.
PTIL13TLB0491AA 1
2. Attach a suitable lifting device to the bucket cylinder.
PTIL13TLB0492AA 2
3. De-clamp the hydraulic lines (1) from the cylinder ends.

4. Tag and cap the open plugs and hoses immediately.
5. Collect oil flowing from cylinder in a container.
PTIL13TLB0493AB 3
6. Remove the wear ring (1), cotter pin and shims from
the cylinder end on both sides.
PTIL13TLB0494AB 4
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7. Tap the pivot pin (1) from one end using a wooden
hammer and keep it resting on the arm.
PTIL13TLB0495AB 5
8. On the other side remove the pivot pin retainer bolt (1).
PTIL13TLB0496AB 6
9. Tap the pivot pin (1) out from other side to remove the
dipper cylinder completely from the machine.
PTIL13TLB0497AB 7
10. Lift the suspended cylinder from the arm and place it
in a secure location.
PTIL13TLB0452AA 8
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Bucket cylinder - Disassemble - Bucket cylinder
PTIL13TLB1471FB 1
1. Clean the cylinder using good clean cloth. Ensure that

dirt does not go inside through ports.
2. Hold the cylinder on a bench vise firmly with proper
support by using rexin on the outer surface to prevent
any damages on the outer tube.
3. Mark a straight line on tube and HEC before disassem-
bly to make the reassembly easy.
4. Use de-caulking tool / blunt chisel and remove Head
end cover caulking.
5. Unscrew the Head end cover (4) by using adjustable
hoot spanner.
6. Gently pull out the piston rod (2) along with Head end
cover from the tube s/a (1).
7. Hold the piston rod s/a on a bench vise firmly with
proper support by using rexin.
8. Remove the piston seals (11), (12) & (13) and snap ring
(8) gently by using bend screwdriver and unscrew the
grub screw (9) by using Allen key.
9. De-torque the piston (3) by using torque wrench and
remove piston.
10. Remove the piston O-ring (14) from the piston by us-
ing bend screwdriver.
11. Remove the head end cover (4) from the piston rod
gently.
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12. Remove the rod seal (18), (19), wiper (15), O-ring (16)
and backup ring (17) from head end cover (4) by using
bend screwdriver.
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Bucket cylinder - Assemble - Bucket cylinder

1. Assemble the rod seal, wiper, O-ring and backup ring in
the head end cover. Ensure that seal lips face against
pressure side.
2. Smear little hydraulic oil inside the head end cover (rod
seal and wiper area).
3. Gently insert sub-assembled HEC on to the piston rod.
4. Ensure that seal lip is not reversed or twisted during
assembly.
5. Check for smooth movement of head end cover on pis-
ton rod.
6. Assemble the piston O-ring and back up ring in piston
(ID).
7. Gently assemble piston seal and O-ring.
8. Ensure that during assembly seal is not expanded
more.
9. Apply LOCTITE® 262™/ Anabond 115 on piston
threads, engage the piston with piston rod threads
and tighten the same to the specified torque by using
torque wrench.
10. Apply LOCTITE® 242®/ Anabond 118 on grub screw
and tighten the same on piston and assembly the snap
ring by using screwdriver.
11. Assemble the bearing strips.
12. Hold the tube s/a on bench wise, smear little hydraulic
oil inside the tube s/a.
13. Apply hydraulic oil on piston seals and petroleum jelly
on head end cover O-ring and insert the piston rod s/a
into the tube s/a.
14. Tap the head end cover gently during entry into the
tube.
15. Ensure that head end cover O-ring is not cut during
entry.
16. Tighten the head end cover by using adjustable hook
spanner to the previously marked position.
17. Caulk the head end cover effectively.
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Bucket cylinder - Install

1. Lift the dipper bucket and place it on the arm.
PTIL13TLB0452AA 1
2. Tap the pivot pin (1) from outer side to install the dipper
bucket into the machine arm.
moval.
PTIL13TLB0497AB 2
3. Install the retainer bracket bolt (1) and washer using

LOCTITE® 242®. Torque: 186 N·m (137 lb ft)
PTIL13TLB0496AB 3
4. Tap the pivot pin (1) into the bucket control cylinder end
using a wooden hammer.
PTIL13TLB0495AB 4
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5. Install the shims, cotter pin and wear ring (1).
PTIL13TLB0494AB 5
6. Fix the hydraulic hoses to the plugs.

7. Clamp the hydraulic lines (1) to the cylinder.
PTIL13TLB0493AB 6
8. Release the lifting device from the bucket cylinder.
PTIL13TLB0492AA 7
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Index

Bucket cylinder - Assemble - Bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bucket cylinder - Disassemble - Bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Swing arm hydraulic system - 739
851FX Plus
851FX
91715732 26/07/2021
35.13 [35.739] / 1
Contents
SERVICE
Swing arm hydraulic system

Remove - Slide shift lock pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Slide shift lock pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Hydraulic systems - Swing arm hydraulic system
Swing arm hydraulic system - Remove - Slide shift lock pistons

1. Park the vehicle on a flat and firm surface.
2. Stretch the boom and dipper till the bucket is resting on
the ground parallel.
3. Switch Off the engine and engage the parking brake.
4. Remove the key and disconnect the negative terminal
of the battery.
5. Remove the boom. Refer to Boom - Remove (84.910).
6. Disconnect the hydraulic lines (1) to the locking pistons.
PTIL13TLB1532AB 1
7. Support the slide frame with a suitable lifting device.
PTIL13TLB1531AA 2
8. Loosen and remove the slide frame mounting nuts (1).
PTIL13TLB1533AB 3
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9. Remove the piston (2) and keep separately for reuse.

with O-rings from the frame (1).
PTIL13TLB1450AB 4
10. Each piston (2) in the locking barrel (1) has got 2
O-rings (4) and 2 paraback rings (3) and a cap (5) .
PTIL13TLB1555AB 5
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Swing arm hydraulic system - Install - Slide shift lock pistons

1. Clean barrels and pistons and looks for scores, dam-
ages etc. Replace if found scored or damaged.
2. Clean the inner recess (1) of the slider frame where the
piston, O-ring and paraback rings are to be installed.
3. Mount the O-rings onto the piston.
PTIL13TLB1534AB 1
NOTE: Ensure that O-rings are on oil supply or pressure side and paraback rings are behind them.
4. Apply a thin coating of hydraulic oil on the O-rings.
5. Slide the piston assembly (2) into the recess completely
in the frame (1).
PTIL13TLB1450AB 2
6. Support the slide frame with a suitable lifting device.

NOTE: Ensure that all 4 caps of pistons are installed prop-
erly between piston and H-frame.
PTIL13TLB1531AA 3
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7. Install and tighten the slide frame mounting nuts (1).

Torque: 75.0 kgm (542.5 ftlbs.).
NOTE: Install the washer with the bottom surface facing
the frame.
PTIL13TLB1533AB 4
8. Install the hydraulic lines (1) to the locking pistons.
PTIL13TLB1532AB 5
9. Install the boom. Refer to Boom - Install (84.910).

10. Connect the negative terminal of the battery and start
the engine.
11. Operate all the hydraulic controls.
12. Check locking and unlocking operation 2–3 times.
13. Stop the engine and check the hydraulic oil level. Top
up as required.
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Swing cylinder - Remove

1. Park the machine on a flat surface.
2. Position the backhoe in fully stretched position.
3. Turn Off the engine and remove the ignition key.s
4. Disconnect the battery. See Basic instructions () .
5. Carefully remove all hydraulic lines and plug them im-
mediately.
6. Remove the washer, nut and screw (1) from the support
bracket (2).
7. Remove the support bracket from the sliding frame
casting (3).
PTIL13TLB1527AB 1
8. Remove the bush (1) from the top of the swing cylinder
(2).
9. From the bottom of the swing cylinder, remove the cap
screws (5), washer (4), cover plate (3) and gasket (6).
PTIL13TLB1528AB 2
10. Tap the pin-sliding tower (1) from the upper side using
a wooden hammer.
11. Slide both the swing cylinders (4) carefully from the
sliding frame casting (3) and store in secure place.
PTIL13TLB1529AB 3
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Swing cylinder - Install

1. Position both the swing cylinders (4) carefully into the
sliding frame casting (3).
2. Position the piston end of the swing cylinder in the slid-
ing frame casting (3) to insert the pin (1).
PTIL13TLB1529AB 1
3. Tap it from the bottom until it slides in the guide way.

4. Install the gasket (6), cover plate (3), washer (4) and
cap screws (5).
PTIL13TLB1528AB 2
5. Install support bracket (2) on sliding frame casting (3)

and tighten the screws (1) after installing washer and
nut.
6. Remove all dummy plugs from hydraulic lines and con-
nect them to their respective positions carefully without
damaging.
7. Connect the battery. See Basic instructions () .
8. Turn on the engine and retract the backhoe to normal
position.
9. Check the swing cylinder movement for smooth oper-
ation.
PTIL13TLB1527AB 3
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Swing cylinder - Disassemble
PTIL17TLB1010FA 1
1. Clean the cylinder using good clean cloth. Make sure

that the dirt does not go inside through the ports.
2. Hold the cylinder on a bench vice firmly with proper sup-
port by using rexin on the outer surface to prevent any
damage on the outer tube. Mark a straight line on tube
and HEC before disassembly to make the reassembly
easy.
3. Use blunt chisel and remove head end cover caulking.
4. Unscrew the head end cover (4) by using special HEC
hammer.
5. Gently pull out the piston rod (2) along with head end
cover from the tube (1) subassembly.
6. Hold the piston rod subassembly on a bench vice firmly
with proper support using rexin.
7. Remove the piston seals (14), (15), (16), and (17) gen-
tly by using bent screwdriver and unscrew the grub
screw (9) by using allen key.
8. De-torque the piston (3). Remove piston and cushion-
ing cartridge by using torque wrench.
9. Remove the head end cover (4) from piston rod gently.
10. Remove the wiper (26), rod seal (22), (23), O-ring
(21), and backup ring (19) from head end cover (4)
by using bent screw driver.
11. Remove the O-ring (17) and backup ring (20) by using
screw driver.
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Swing cylinder - Inspect

1. Clean all components by using good clean cloth and
hydraulic oil. Any rust on the components should be
removed by smooth emery sheet.
2. Make sure that the head end cover seal grooves, piston
rod end threads and port threads are cleaned properly.
3. Check the piston rod for any dents, scoring lines or any
other abnormalities, if found, piston rod needs to be
replaced.
4. Check for any scoring or damage in tube. If found, tube
needs to be replaced.
5. Check head end cover for damages or dents. Small
dents / damages can be removed by polishing. How-
ever if the damages are heavy, head end cover needs
to be replaced.
6. Check and make sure that port threads and piston rod
threads are not damaged.
7. Once dismantled, seal kit should be replaced with a
new one.
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Swing cylinder - Assemble

1. Assemble the rod seal, wiper, O-ring and backup ring
in the head end cover. Make sure that seal lips face
against pressure side.
seal and wiper area). Gently insert sub-assembled
HEC on to the piston rod. Make sure that seal lip is not
reversed or twisted during assembly. Check for smooth
movement of head end cover on piston rod.
3. Gently insert the cushioning cartridge in to the piston
rod cushioning hole.
4. Apply Loctite 262 / Anabond 115 on piston threads, en-
gage the piston with piston rod threads and tighten the
same to the specified torque by using torque wrench.
5. Assemble piston seal and O-ring gently. Make sure that
during assembly seal is not expanded more.
6. Apply Loctite 242/ Anabond 118 on grub screw and
tighten the same on piston. Assemble the bearing
strips.
7. Apply Loctite 242/ Anabond 118 on grub screw and
tighten the same on piston. Assemble the bearing
strips.
8. Hold the tube subassembly on bench vice, smear little
hydraulic oil inside the tube subassembly.
on head end cover O-ring and insert the piston rod sub-
assembly into the tube subassembly. Tap the head end
cover gently during entry into the tube. Make sure that
head end cover O-ring is not cut during entry.
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Index

Swing arm hydraulic system - Install - Slide shift lock pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing arm hydraulic system - Remove - Slide shift lock pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Swing cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Swing cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Swing cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Swing cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Hydraulic systems generic sub-group - AAA
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Hydraulic systems generic sub-group

Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Static description - Do & Don’t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE

Disassemble - Slew cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspect - Slew cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble - Slew cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble - Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspect - Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble - Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replace - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replace - Piston seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check - Check points for internal leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSTIC

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Hydraulic systems - Hydraulic systems generic sub-group
Hydraulic systems generic sub-group - Component localization
PTIL13TLB1041FB 1
1. End head 11. Back-up ring for gland

2. Piston-rod weldment 12. O-ring for gland
3. Piston 13. O-ring
4. Gland 14. Slid ring for piston
5. Tube weldment 15. Piston seal
6. Piston rod end 16. Back-up ring for piston
7. Wiper seal 17. O-ring for piston
8. Rod seal 18. Steel ball for piston locking
9. Buffer seal 19. Grub screw for piston locking
10. Dew bush 20. Ports
Piston rod weldment
PTIL13TLB1042AA 2
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Piston
PTIL13TLB1043AA 3
Gland
PTIL13TLB1044AA 4
Tube weldment
PTIL13TLB1045AA 5
Gland seals
Wiper seal
PTIL13TLB1046AA 6
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Rod seal
PTIL13TLB1047AA 7
Buffer seal
PTIL13TLB1048AA 8
Dew bush
PTIL13TLB1049AA 9
Backup ring
PTIL13TLB1050AA 10
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O-ring
PTIL13TLB1051AA 11
Moisture O-ring
PTIL13TLB1052AA 12
Piston seals
Slid ring
PTIL13TLB1053AA 13
Piston seal
PTIL13TLB1054AA 14
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Backup ring
PTIL13TLB1055AA 15
O-ring
PTIL13TLB1056AA 16
Steel ball
PTIL13TLB1057AA 17
Grub screw
PTIL13TLB1058AA 18
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Hydraulic systems generic sub-group - Static description - Do

& Don’t
1. Preferably cylinders should be installed in closed condition. If cylinder do not fit in closed condition check structure
alignment.
2. In field Welding should not be done directly on cylinder and precaution should be taken while welding on any part
of machine, earth should be given near to welding point to avoid earth failure of cylinder.
3. Please take adequate care while welding near to cylinder to avoid falling of weld arc, direct heat and spatter etc.
These can damage cylinder parts or sealing system.
4. Care should be taken to avoid external damage on cylinders and especially on plated parts as dents and scratches
on cylinders leads to seal failure and leakages.
5. Ensure cylinder ports should be covered by suitable port plug before commissioning. Ports should not kept open
in any circumstances.
6. Please ensure cleanliness of the cylinder body, local area, mounting zone, ports etc before mounting on machine.
7. Always use recommended oil and inter mixing of two types of oil should not be done.
8. Cleanliness of oil is very important. Filters and oil should be changed as recommended. Contaminated oil leads
to many failures.
9. Always follow instructions for storage of cylinders especially if to be stored for long time.
10. For cleaning of cylinder or cylinder parts only use lint free cloths.
11. Bleed air from the hydraulic cylinder sufficiently before starting the hydraulic cylinder after commissioning.
12. Under “no load” condition loosen the bleed screws or pipe fitting, let the air escape and close the bleed screw or
fittings only when the oil is free of bubbles. Retighten the bleed screw or fittings.
13. While starting the hydraulic cylinder after commissioning, do not operate it quickly to its full stroke. Start slowly
for initial cycles.
14. Pressure and temperature ranges to be maintained as recommended. It should not cross the minimum/maximum
limit recommended in drawing/data sheet for satisfactory working of hydraulic cylinders.
15. Lubrication of swivel eyes or trunions should be done as recommended.
16. In case of any abnormal sound during operation check the related parts/components thoroughly for any abnor-
mality.
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Hydraulic systems generic sub-group - Disassemble - Slew cylinder
PTIL13TLB1472FB 1

4. Use blunt chisel and remove Head end cover caulking.
5. Unscrew the Head end cover (4) by using special HEC
spanner.
6. Gently pull out the piston rod (2) along with head end
8. Remove the piston seals (14), (15), (16) & (17) gently
by using bend screwdriver and unscrew the grub screw
(9) by using Allen key.
9. De-torque the piston (3) by using torque wrench, re-
move piston and cushioning cartridge.
gently.
11. Remove the wiper (26), rod seal (22), (23), O-ring (21)
bend screwdriver.
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12. Remove the O-ring (17) and back up ring (20) by using
the screw driver.
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Hydraulic systems generic sub-group - Inspect - Slew cylinder

Inspection and cleaning
1. Clean all the components by using good clean cloth and
2. Ensure that head end cover seal grooves, piston rod
end threads and port threads are cleaned properly.
3. Check the piston rod for any dents, scoring lines or
any other abnormalities, if found piston rod needs to
be replaced.
4. Check for any scoring lines or damages in tube Id. If
found tube s/a needs to be replaced.
dents/damages can be removed by polishing.
6. However if the damages are heavy, head end cover
7. Check and ensure that port threads and piston rod
8. Once dismantled seal kit should be replaced with a new
one.
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Hydraulic systems generic sub-group - Assemble - Slew cylinder

pressure side.
seal and wiper area). Gently insert sub-assembled
HEC on to the piston rod. Ensure that seal lip is not
reversed or twisted during assembly.
ton rod.
4. Gently insert the cushioning cartridge in to the piston
rod cushioning hole.
torque wrench.
6. Assemble piston seal and O-ring gently. Ensure that
during assembly seal is not expanded more.
and tighten the same on piston. Assemble the bear-
ing strips.
into the tube s/a. Tap the head end cover gently during
entry into the tube. Ensure that head end cover O-ring
is not cut during entry.
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Hydraulic systems generic sub-group - Disassemble - Lift cylinder
PTIL13TLB1471FB 1

4. Use de-caulking tool / blunt chisel and remove Head
end cover caulking.
5. Unscrew the Head end cover (4) by using adjustable
hoot spanner.
6. Gently pull out the piston rod (2) along with Head end
8. Remove the piston seals (11), (12) & (13) and snap ring
(8) gently by using bend screwdriver and unscrew the
grub screw (9) by using Allen key.
9. De-torque the piston (3) by using torque wrench and
remove piston.
10. Remove the piston O-ring (14) from the piston by us-
ing bend screwdriver.
gently.
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12. Remove the rod seal (18), (19), wiper (15), O-ring (16)
bend screwdriver.
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Hydraulic systems generic sub-group - Inspect - Lift cylinder

Inspection and cleaning
1. Clean all the components by using good clean cloth and
2. Ensure that head end cover seal grooves, piston rod
end threads and port threads are cleaned properly.
3. Check the piston rod for any dents, scoring lines or
any other abnormalities, if found piston rod needs to
be replaced.
4. Check for any scoring lines or damages in tube Id. If
found tube s/a needs to be replaced.
dents/damages can be removed by polishing.
6. However if the damages are heavy, head end cover
7. Check and ensure that port threads and piston rod
8. Once dismantled seal kit should be replaced with a new
one.
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Hydraulic systems generic sub-group - Assemble - Lift cylinder

pressure side.
seal and wiper area).
3. Gently insert sub-assembled HEC on to the piston rod.
4. Ensure that seal lip is not reversed or twisted during
assembly.
ton rod.
6. Assemble the piston O-ring and back up ring in piston
(ID).
7. Gently assemble piston seal and O-ring.
8. Ensure that during assembly seal is not expanded
more.
torque wrench.
and tighten the same on piston and assembly the snap
ring by using screwdriver.
11. Assemble the bearing strips.
into the tube s/a.
14. Tap the head end cover gently during entry into the
tube.
15. Ensure that head end cover O-ring is not cut during
entry.
16. Tighten the head end cover by using adjustable hook
spanner to the previously marked position.
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Hydraulic systems generic sub-group - Check

1. Pull the piston rod and push it back to check the
smoothness of assembly.
2. Mount the cylinder on to the equipment and operate at
idle speed, to check for leakages.
3. Ensure that the air is not trapped in the cylinder by
cycling the cylinder at low Idle for 2 min.
NOTE: Dis-assembly, cleaning, inspection, assembly and
cylinder performance check procedures are almost same
for all the other cylinders.
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Hydraulic systems generic sub-group - Disassemble

NOTE: Decide a working order. Make sure the needed
tools shown in Hydraulic systems - Special tools
(35.000) are available. Look for lifting equipment if the
cylinder is heavy.
1. Unlocking the gland (use an appropriate tool for gland).
2. Open the gland (use an appropriate tool for gland).
3. Place the hydraulic cylinder on a bench or hold tightly
in vice taking care not damage machined faces.
1. Using special locking tool at locking area and hit the
tool for unlocking.
2. Ensure tube should not bend inside and any damage
not acceptable during this process.
PTIL13TLB1059AA 1
3. Using special spanner (C Spanner) apply the force to

unthread the gland (1) from the cylinder tube. En-
sure that cylinder tube should not rotate in this process,
tightly hold the cylinder from the rear to prevent it to ro-
tate during this process.
Ensure spanner should not slip and strike on piston rod
to cause any damage during this process.
PTIL13TLB1060AB 2
4. Rotate the gland until it is completely removed from

the cylinder tube, carefully remove the gland from the
cylinder tube with hand, and ensure no damage to the
O-ring in the groove of gland.
PTIL13TLB1061AA 3
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5. Pull the piston rod (1) outside the cylinder manually with
hand while holding the rear end of cylinder tightly, both
the ports should be open before pulling the rod. Hy-
draulic oil may come out from the cylinder while pulling
the rod out so use some bin or container to collect hy-
draulic oil. Ensure no damage to the piston rod and
tube.
NOTE: Do not allow the piston rod to come into contact with
the cylinder bore. The cylinder bore and piston rod may be
damaged by careless dismantling.
PTIL13TLB1062AB 4
6. Pull the rod until piston comes to the end of tube, at

this point carefully hold the rod with upward force and
remove the piston from cylinder tube, ensure no dam-
age to the piston seal.
NOTE: Carefully place the piston rod on a clean and safe
surface by ensuring no damage to the rod and piston sur-
face.
PTIL13TLB1063AA 5
6. Remove the slyd ring (1) from the piston groove with
hand. Show as in figure.
PTIL13TLB1064AB 6
8. After putting the piston rod, hold the piston rod in the
bench vice tightly from the piston rod end, there should
be no damage to the piston rod surface, open the 1 or
2 numbers grub screw (1) with Allen key and remove
the steel ball in piston.
PTIL13TLB1065AB 7
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9. Using torque wrench apply the force to unthread the

piston (1) from the piston rod (2). Ensure that piston
rod should not rotate in this process, tightly hold the
piston rod from the rear to prevent it to rotate during
this process.
NOTE: Torque wrench should not slip and strike on piston
rod to cause any damage during this process.
PTIL13TLB1066AB 8
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Hydraulic systems generic sub-group - Replace - Bush

1. After dismantling the cylinder, dismantle the piston from
the piston rod as per the procedure explained above.
Now remove the gland from the piston rod manually.
2. Pull out old dew bush from the gland (1) with help of the
tool (2), now press the dew bush in the gland groove
with the help of dew bush press machine.
Ensure the following:
A. No chips and no burr on gland seat.
B. Spiral groove is open in rod seal groove.
C. Bush should not damage while pressing.
D. After bush fitting clean the material part.
PTIL13TLB1067AB 1
3. Pull out all the old seals (1) from the gland with help
of some blunt tool, now load the rod seal in the gland
groove with the help of seal loading tool (as shown in
the photograph). Put the seal loading tool on the rod
seal as shown in the photograph.
PTIL13TLB1068AB 2
PTIL13TLB1069AA 3
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4. Rotate the tool handles in such a way to bend the seal

(1) as shown in the photograph. Seal should be bend
carefully its profile should not get damaged during this
process.
PTIL13TLB1070AB 4
5. Pick the seal with seal loading tool in this bend condi-
tion and carefully insert inside the gland groove (1).
B. No chattering mark in rod seal groove.
C. Seal should not be damaged while inserting.
D. Seal must sit inside the grooves properly.
PTIL13TLB1071AB 5
6. Release the seal from the seal loading tool by rotating

the tool handle & bring it to the previous condition. Af-
ter this manually push the seal (1) inside the rod seal
groove carefully.
PTIL13TLB1074AB 6
7. Put the buffer seal (1) in the ID groove of the gland with
hand, Put buffer seal in the groove and make it to sit
uniformly in the gland.
PTIL13TLB1072AB 7
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8. Put the Wiper seal (1) in the groove of the gland and
set it uniformly in the gland id groove.
PTIL13TLB1073AB 8
9. Now after putting all the seals in the inside of the gland,
Put the backup ring (1) in the outer groove of the cylin-
der with hand and set it properly in the outer groove.
D. Back up ring should not get twist in this process.
PTIL13TLB1075AB 9
10. Insert the O-ring (1) in the outer groove of the gland,
Put the O-ring in the same groove in which back up
ring is fitted. Set the O-ring uniformly in the groove.
B. O-ring should be without defect.
C. O-ring should not be damaged while inserting.
D. O-ring must sit inside the grooves properly.
E. O-ring should not get twisted
PTIL13TLB1076AB 10
11. Insert the O-ring (1) in the outer groove of near gland
collar for dust & moisture. Set the O-ring uniform in
the groove.
A. O-ring must sit inside the groove properly.
B. O-ring should not get twisted.
PTIL13TLB1077AB 11
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12. After putting all the seals in the gland it should look like
as shown in the photograph from inside and outside.
1. Wiper seal
2. Buffer seal
3. Road seal
PTIL13TLB1078AB 12
Reverse the procedure of gland seal loading in case of

the unloading of the gland seal.
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Hydraulic systems generic sub-group - Replace - Piston seals

1. Place the piston rod of the cylinder on a clean surface
by ensuring no damage to the piston rod and piston.
2. Remove the slydring (1) from the piston groove with
hand.
PTIL13TLB1079AB 1
3. Remove the piston seal (1) from the piston seal groove
with plastic tie band (2).
PTIL13TLB1080AB 2
4. Use blunt tool to remove the piston seal O-ring (1) from
the piston groove. Ensure that blunt tool should not
damage the piston seal profile and should not twist the
piston seal.
PTIL13TLB1081AB 3
5. Put the back-up ring (1) inside the piston grooves.

A. No chips and no burr on piston groove.
B. Back-up ring should be without defected.
C. Back-up ring should not be damaged while insert-
ing.
D. Back-up ring must sit inside the grooves properly.
PTIL13TLB1082AB 4
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6. Put the O-ring (1) inside the piston groove.

C. O-ring should not be damaged while inserting.
D. O-ring must sit inside the grooves properly.
E. O-ring should not get twisted.
PTIL13TLB1083AB 5
7. For installing a new piston seal (1) on the piston the

above steps should be reversed, ensuring no damage
to the piston seal profile and piston surfaces. Ensure
the use of relevant seals of the cylinder.
A. No chattering and no burr in piston groove.
C. Piston seal should be without defect.
PTIL13TLB1084AB 6
8. Doing the piston seal sizing with sizing tool (1) after
piston seal installing.
A. Sizing tool should be dent and scratch free.
B. During sizing there should be no mark on piston
seal.
PTIL13TLB1085AB 7
9. Hold the piston rod (1) in the bench vice tightly from
the piston rod end, there should be no damage to the
piston rod surface.
A. Piston rod should be dent and scratch free.
B. No sharp edged on piston rod.
C. Check piston rod chamfer.
PTIL13TLB1086AB 8
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10. Insert the seal loaded gland (1) on the rod O-D, sur-
face on which the number is punched should be to-
wards the piston rod end side. Take care while insert-
ing the gland on the piston rod that the rod seal should
not be damaged with the threads.
ATTENTION: Piston seal should not be damage during
gland inserting.
PTIL13TLB1087AB 9
11. Apply only one drop of LOCTITE® 243™ on the pis-

ton rod threads (1) load the piston on the piston rod
threads by rotating it on the threads. Rotate the pis-
ton on the threads until it is free to move.
A. Piston rod thread should be without chips.
B. Piston rod thread should be without dented.
C. Use only one drop LOCTITE® 243™ piston rod
thread.
PTIL13TLB1088AB 10
12. After inserting the gland (1) on the piston rod, load the
piston on the piston rod by rotating on the piston rod
threads. Rotate the piston on the threads completely
until it stop rotating.
A. Piston should be freely inset on rod thread.
B. No sharp edge on piston hex.
PTIL13TLB1089AB 11
13. Tightening of the piston (1) should be done with the

help of the automatic torque machine and torque
wrench.
PTIL13TLB1090AB 12
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Torque table
Thread size Torque value
M55X2 1500 N·m (13276 lb in)
M36X3 1350 N·m (11949 lb in)
M45X2 1400 N·m (12391 lb in)
M48X2 1500 N·m (13276 lb in)
M52X2 1500 N·m (13276 lb in)
M42X2 1400 N·m (12391 lb in)
M45X2 1350 N·m (11949 lb in)
M50X2 1500 N·m (13276 lb in)
M36X3 1000 N·m (8851 lb in)
M42X2 1000 N·m (8851 lb in)
M57X2 1500 N·m (13276 lb in)
M33X2 1000 N·m (8851 lb in)
M60X2 1500 N·m (13276 lb in)
Table for Nylock nut trque Setting

Thread size Torque value
M36 X 3 650 N·m (5753 lb in)
M33 X 2 650 N·m (5753 lb in)
M30 X 2 650 N·m (5753 lb in)
M36 X 3 1000 N·m (8851 lb in)
14. After tightening the piston, insert steel ball (1) in piston
groove for locking.
PTIL13TLB1091AB 13
15. Apply the LOCTITE® 243™ solution on the grub screw

(1). Carefully apply only one drop of the solution on
the grub screw.
PTIL13TLB1094AB 14
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16. Tight the 1 or 2 number grub screw (1) on which

LOCTITE® was applied in the hole which is provided
in the groove of piston with the help of Allen key.
PTIL13TLB1095AB 15
17. After tightening the grub screw in the hole. Take a

punch (1) of 1.5 mm (0.1 in) indentation dia. and
punch it at two positions around the hole at a dis-
tance of 1 mm (0.04 in) from the hole. As shown in
the sketch.
PTIL13TLB1096AB 16
PTIL13TLB1093AA 17
18. Remove any sharp edges or burr around the grub

screw drill with the help of needle file (1). Remove all
the foreign particles from the piston groove with the
help of air pressure gun.
PTIL13TLB1097AB 18
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19. Push the piston rod (1) in to the face of tube, at this
point carefully hold the rod with upward force and push
the piston from cylinder tube.
PTIL13TLB1098AB 19
20. Insert the gland inside the cylinder tube carefully so

that no damage to the gland O-ring from the cylinder
tube threads. After pushing the piston rod in tube then
tight the gland two or three threads manually.
PTIL13TLB1099AA 20
21. After two or three threads tight manually then gland

full tight with assembly machine.
PTIL13TLB1100AA 21
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Check points for outer gland joint leakage
1. Check O-ring condition.
2. Check O-ring size.
3. Check condition of back up ring if any back ring is there.
4. Check tube internal diameter where O-ring rests.
5. Check for metal to metal contact (tube & gland).
6. Check gland groove size (diameter and width).
7. Check gland groove finish.
8. Check tube drill distance.
9. Check tube drill size.
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Check points for inner gland joint leakage
1. Seal condition
2. Check piston rod for dent and scratch.
3. Check piston rod for roundness.
4. Gland groove dimensions.
5. Gland groove finish.
6. Rod size
7. Rod finish
8. Thread machining of tube with respect to tube ID.
9. Thickness of slyd ring.
10. Gap between slyd ring. It should be 2.5 mm (0.10 in).
11. A. Air pocket in the cylinder.
B. Gap between gland and piston rod.
C. High localise pressure near the gland seal.
D. Seal material
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Hydraulic systems generic sub-group - Check - Check points for

internal leakage
1. Piston seal condition.
2. Tube condition (any scratch inside).
3. Tube surface finish.
4. Any side load.
5. Piston O-ring.
6. Tube size.
7. Piston size where seal rests.
8. O-ring seat diameter in piston.
9. If seal got extruded owing to the following reason:
A. Air pocket in the cylinder.
B. Gap between tube and piston major diameter.
C. High localise pressure near the piston seal.
D. Seal material.
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Hydraulic systems generic sub-group - Troubleshooting

Rod seal leakage Excessive Seal wear Check oil contamination and change, if re-
quired
Piston rod scored Apply emery, if scoring is mild. Replace the
piston rod, if the scoring is deep
Weld arcing Replace the piston rod*
Seal assembled wrongly Replace the seal kit and assemble the seal
in right direction*
Piston rod bend Reset the system pressure, if it is malfunc-
tioning and replace the piston rod*
Oil temperature high Air bleed the system properly and change
the oil if contaminated*
Internal leakage Scoring in tube ID Check for side loads on cylinder (Wear on
rod eye/CEC face) and adjust alignment
suitably. Change tube s/a if badly scored*
Tube ID rusting Remove the rust with emery, change tube
s/a, if rust is more
External damage Replace the outer tub
Air in hydraulic circuit Air bleed the hydraulic system
Piston seal damaged Replace the complete seal kit*
Tube ID scored External damage on tube Replace the tube s/a and other damaged
components
Piston rod bend Check the system pressure and replace the
PR s/a*
Foreign particles in the system Check the filter and oil, replace if required
Filter ineffective/clogged Replace the filter
Excessive clearance at mountings Add shims and align the axis suitably
External leakage (Other Seal wrongly assembled Change the seal kit*
than Rod seal)
Weld leakage Rework or replace the component, if it is
not re-workable*
Leakage through casting Change the defective component*
Ineffective sealing due to rust in the cylinder Rework by emery or replace the failure
ID component
Piston rod bend / Break Excessive system pressure Check and reset the system pressure, if
required*
More than recommended load applied Use the system with in recommended load.
Educate the operator
Excessive side loads Check the condition of bushes, pins, shims
and replace if required
External damage Change the piston rod assembly*
Plating defects Rust on rod due to accumulation of mud on Clean the mud periodically from the piston
piston rod rod
Peel off due to piston rod exposure to Protect the piston rods from chemical at-
chemical environment tach. Apply petroleum jelly when the ma-
chine is not in use for more period
Weld arcing Apply grease on piston rod when carry out
welding near rod
Hydraulic operation slow System pressure setting too low Check and reset recommended system
pressure
Auxiliary relief valve pressure setting too Reset the ARV pressure setting
low
MPRV stuck Remove and clean the MPRV then reset
system pressure
Hydraulic oil contamination or incorrect Clean the system properly and change the
grade of oil used hydraulic oil
Hydraulic cylinder internal leakage Check and repair/replace the defective
parts
Hydraulic hose internally collapsed Identify and replace defective hose
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In-sufficient hydraulic oil in tank Top up hydraulic oil
Hydraulic pump internal wear and tear Replace the hydraulic pump and other as-
sociated parts and oil
Hydraulic oil temp. too high Clean the hydraulic oil cooler and check
Engine RPM less than the recommended Reset engine RPM
Control valve malfunctioning or internal Diagnose properly and repair/replace de-
leakage fective parts
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Index

Hydraulic systems generic sub-group - Assemble - Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic systems generic sub-group - Assemble - Slew cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic systems generic sub-group - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic systems generic sub-group - Check - Check points for internal leakage . . . . . . . . . . . . . . 33
Hydraulic systems generic sub-group - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic systems generic sub-group - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic systems generic sub-group - Disassemble - Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic systems generic sub-group - Disassemble - Slew cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic systems generic sub-group - Inspect - Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic systems generic sub-group - Inspect - Slew cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic systems generic sub-group - Replace - Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hydraulic systems generic sub-group - Replace - Piston seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic systems generic sub-group - Static description - Do & Don’t . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic systems generic sub-group - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Frames and ballasting
851FX Plus
851FX
91715732 26/07/2021
39
Contents
Frames and ballasting - 39
[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1
[39.129] Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2
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Frame - 100
851FX Plus
851FX
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39.1 [39.100] / 1
Contents
Frame - 100
TECHNICAL DATA
Frame
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Frames and ballasting - Frame
Frame - Weight
1. Fuel tank 70.7 kg (155.9 lb)
2. Hydraulic tank 82.9 kg (182.8 lb)
3. Cabin 470.0 kg (1036.2 lb)
4. Dipper (14 Feet) 190.0 kg (418.9 lb)
5. Boom (14 Feet) 316.0 kg (696.7 lb)
6. Dipper (15 Feet) 208.0 kg (458.6 lb)
7. Boom (15 Feet) 336.0 kg (740.8 lb)
8. Loader arm 272.0 kg (599.7 lb)
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Index
Frame - 100
Frame - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Stabilizers - 129
851FX Plus
851FX
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Contents
Stabilizers - 129
SERVICE
Stabilizers
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Frames and ballasting - Stabilizers
Stabilizers - Remove
PTIL13TLB1530FB 1
1. Park the machine on a flat surface.

2. Position the backhoe in fully stretched position.
3. Engage the stabilizers with the foot on the ground
firmly.
4. Turn off the engine and remove the ignition key.
5. Disconnect the battery. See Basic instructions () .
6. Release hydraulic pressure from the lines and hoses of
the stabilizers by operating backhoe levers.
7. Remove stabilizer hydraulic connectors and plug them
immediately.
8. Remove the bolt (1), washer (2), hexagonal nut (3) and
mounting plate (4) from the top of the stabilizer to re-
move the light reflectors (5) on both sides.
9. Remove the upper plastic cover (6).
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10. After removing the snap ring (9) and spacer (10) from
both ends remove the head end pin (7) and eye end
pin (8) to free the stabilizer cylinder by tapping with a
wooden hammer.
PTIL13TLB1549AB 2
PTIL13TLB1549AB 3
11. Lift the cylinder using a suitable lifting device and

place it safely aside.
ATTENTION: Before lifting the machine, ensure to check
overhead objects if any and handle the components care-
fully to avoid serious injury. Connect lifting device only at
the lifting eyes (11) provided on the frame.
12. Raise the machine using a suitable lifting device to
slide the sleeve (12) and foot pad (13) out of the sta-
bilizer frame (14).
PTIL14TLB0134AB 4
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Stabilizers - Adjust
Your machine is fitted with stabilizer sleeve locking with
plastic pad arrangement (1) to provide comfort to the
operator during backhoe operation by reducing the play
between the sleeve and the vertical outer.
When machine is in operation there is a defined clear-
ance between the vertical outer and the inner sleeve.
This gap increases as the machine continues to oper-
ate.
This dangling of the machine can be controlled by
plastic pads provided inside the H-frame which pushes
against the inner sleeve to maintain minimum clear-
ance between the vertical outer and the sleeve.
As the inner sleeve comes out of the vertical outer dur-
ing backhoe operation every time it wears out plastic PTIL12TLB0483AB 1
pad resulting in building of clearance and subsequent
dangling of the machine. The pads must be replaced if
found worn out or damaged.
1. Unscrew the four M10 bolts (1) along with the conical
washers (2) and take out cover sleeve locking (3) along
with shims (4).
2. Insert cover sleeve locking (3) along X-direction only
behind the pad (5) from outside and press firmly with
hand.
PTIL12TLB0486AB 2
3. Insert and count the number of shims (4) that fits in the
step created between sleeve locking (3) and welded
boss (6) in pressed condition.
PTIL12TLB0485AB 3
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4. Add one more shim (4) to the number of shims (4) count
in step 3 to front of cover sleeve locking (3).
5. Place the remaining shims (4) on back of cover sleeve
locking (3).
6. Assemble the whole arrangement inside the hole and
tighten the four M10 bolts (1) and conical washers (2).
PTIL12TLB0484AB 4
7. Follow the same procedure for the other pads also.
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Stabilizers - Install
PTIL13TLB1531FB 1
ATTENTION: Before lifting the machine, ensure to check

overhead objects if any and handle the components care-
fully to avoid serious injury. Connect lifting device only at
the lifting eyes (11) provided on the frame.
1. Raise the machine to insert the sleeve (12) and foot
pad (13) inside the stabilizer frame (14) using a lifting
device.
ATTENTION: Before lowering the machine, ensure to
check for any objects underneath and handle the compo-
nents carefully to avoid serious injury.
2. Lower the machine until it rests on the wheels.
PTIL14TLB0134AB 2
3. Insert the stabilizer cylinder from the top using a suit-
able lifting device and align with the eye ends.
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4. Insert the eye end pin (8) to fix the cylinder at the bottom
with the foot pad (13) and sleeve (12) by tapping.
5. Install the spacer (10) and snap ring (9) on the head
end pin (7) and eye end pin (8).
6. Place the upper plastic cover (6).
7. Align the mounting plate (4), hexagonal nut (3),washer
(2) and bolt (1) to install the reflectors (5).
8. Connect stabilizer hydraulic connectors, lines and
hoses.
PTIL13TLB1549AB 3
PTIL13TLB1549AB 4
9. Connect the battery. See Basic instructions () .

10. Turn on the engine and retrieve the backhoe to normal
position.
11. Check the stabilizer operation by engaging and disen-
gaging repeatedly.
12. Check the hydraulic oil level. If found less than the
prescribed level, top up immediately.
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Index
Stabilizers - 129
Stabilizers - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stabilizers - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stabilizers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Steering
851FX Plus
851FX
91715732 26/07/2021
41
Contents
Steering - 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2
[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3
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41
Steering - 41
Steering control - 101
851FX Plus
851FX
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41.1 [41.101] / 1
Contents
Steering - 41
FUNCTIONAL DATA
Steering column
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Steering column
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Steering - Steering control
Steering column - Exploded view
PTIL13TLB1456GB 1
1. Steering nut Cap 8. Orbital block mounting bolt

2. Nut 9. Washer
3. Washer 10. Plate
4. Steering wheel 11. Hose
5. Combination switch 12. Column
6. Column cover 13. Orbitrol block
7. Screw
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Steering column - Remove

ing brake.
2. Lower the bucket to the floor.
NOTE: Refer to Steering column - Exploded view
(41.101) for the following steps.
3. Switch off the engine and disconnect the battery.
4. Remove the steering wheel (4) by removing the nut (2).
5. Remove the front console (1).
6. Disconnect the electrical connections for speedometer
and switches.
7. Unscrew the side cover screws (7) and remove the cov-
ers (6).
8. Disconnect and remove the combinations switches (5).
9. Loosen and remove the steering column (12) mounting
bolts (14).
PTIL13TLB1458AB 1
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Steering column - Install

1. Install the steering column (12), mounting bolts (14)
and tighten.
2. Connect the electrical connections for speedometer
and switches.
3. Install the front console and tighten the screws.
4. Install the combination switches and connect the elec-
trical connections.
5. Install the side covers (6) and tighten the screws (7).
6. Install the steering wheel and tighten the mounting nut.
PTIL13TLB1458AB 1
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Index
Steering - 41

Steering column - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Steering - 41
Hydraulic control components - 200
851FX Plus
851FX
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Contents
Steering - 41
TECHNICAL DATA
Hydraulic steering system

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE

Remove - Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering circuit relief valve
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Steering - Hydraulic control components
Hydraulic steering system - General specification

Type Power steering with gear pump
Model DANFOSS PN 1119195
System working pressure 140 bar (2030 psi)
Displacement 125 cm³
Shock valve adjustment 200 bar (2900 psi)
Pressure relief valve adjustment 140 bar (2030 psi)
Hydraulic steering system - Torque

Maximum tightening torque and hydraulic connections
PTIL13TLB0498FB 1
1. Tank 4. Support port for left turn

2. Pump 5. LS line port
3. Supply port for right turn
Maximum tightening torque

Screwed connection With aluminium
With cutting edge With cooper washer With O-ring
washer
G1/4 35 N·m (310 lb in) 35 N·m (310 lb in) 35 N·m (310 lb in) -
G3/8 70 N·m (620 lb in) 45 N·m (398 lb in) 50 N·m (443 lb in) -
G½ 100 N·m (885 lb in) 55 N·m (487 lb in) 80 N·m (708 lb in) -
7/16 -20UNF - - - 20 N·m (177 lb in)
3/4 -16 UNF - - - 60 N·m (531 lb in)
M12X1.5 30 N·m (266 lb in) 20 N·m (177 lb in) 30 N·m (266 lb in) 25 N·m (221 lb in)
M18X1.5 80 N·m (708 lb in) 55 N·m (487 lb in) 70 N·m (620 lb in) 50 N·m (443 lb in)
M22 X 1.5 100 N·m (885 lb in) 65 N·m (575 lb in) 80 N·m (708 lb in) 60 N·m (531 lb in)
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Hydraulic steering system - Special tools

Holding tool
PTIL13TLB1106AA 1
Guide ring
PTIL13TLB1107AA 2
Assembly tool for O-ring and kin-ring/roto glyd
PTIL13TLB1108AA 3
Assembly tool for lip seal
PTIL13TLB1109AA 4
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Assembly tool for cardan shaft
PTIL13TLB1110AA 5
Assembly tool for dust seal
PTIL13TLB1111AA 6
Torque wrench 0 – 70 N·m
Socket spanner 13 mm
Sockets 6.8 mm and 12 mm
Screwdrivers 12 mm and 2 mm
Ring spanner 13 mm
Socket spanners 6.8 mm and 12 mm
Plastic hammer
Tweezers PTIL13TLB1112AA 7
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Hydraulic steering system - Exploded view
PTIL13TLB1105FB 1
1. Dust seal ring 19. End cover

2. Housing, spool and sleeve. Check valve and the seats
20. Washer
for relief and shock valves are locktited.
3. Ball 8.5 mm (0.33 in) 22. Special screw
4. Thread bushing 23. Screw
5. O-ring used with kin-ring (item 6) 24. Name plate
6. Kin-ring 30. Complete relief valve
7. Bearing assembly 31. Spring wire
10. Ring 32. Complete shock valve
11. Cross pin 33. Ball 3/16 in
12. Set of springs 34. Rolled pin
13. Cardan shaft 35. Bushing
14. Spacer 36. Ball
15. O-ring 38. Spring
16. Distributor plate 39. Kin-ring
17. Gearwheel set 40. O-ring
18. O-ring
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Hydraulic steering system - Remove - Control valve

NOTE: Put identification tags on all disconnected hoses.
Close disconnected hoses and fittings with caps and plugs.
See Cab - Remove (90.150).
1. Disconnect the hoses (1), (2), (3), (4) and (5), identify
and tag them.
2. Cap all the open ports.
PTIL13TLB1457AB 1
3. Unscrew and remove the front console (1).

4. Disconnect the electrical connections for speedometer
and switches.
PTIL13TLB1458AB 2
See Steering column - Exploded view (41.101).

5. Install acceptable lifting equipment to the orbital block.
6. Loosen and remove the mounting bolts (8).
7. Remove the orbital block (13) from the outside of the
cabin.
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Hydraulic steering system - Disassemble

1. Remove the steering column from the steering unit. Put
the steering unit in the holding tool.
2. Remove the screws (23) in the end cover.
PTIL13TLB1113AB 1
3. Remove the end cover (19) through side.
PTIL13TLB1114AB 2
4. Lift the gearwheel (17) set (with the spacer if attached)

off the unit. Remove the two O-rings (18).
PTIL13TLB1115AB 3
5. Remove the cardan shaft (13).
PTIL13TLB1116AB 4
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6. Remove the distributor plate (16).
PTIL13TLB1117AB 5
7. Remove the threaded bush (4) from the check valve.
PTIL13TLB1118AB 6
8. Remove the O-ring (15).
PTIL13TLB1119AB 7
9. Remove the check valve ball (3) and suction valve pins
(34) and balls (35).
10. On some pins (34) there are two springs (38) (not illus-
trated). Replace these pins (34) before the reassem-
bly.
PTIL13TLB1120AB 8
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11. Make sure that you keep the cross pin (11) in the
sleeve and spool (2) horizontal. You can see the pin
(11) through the open end of the spool (2). Press the
spool (2) inwards and the sleeve (2), ring (1), bearing
races (2) and needle bearing (7) will be pushed out of
the housing (2) together. See figures for Steps 12 and
13.
PTIL13TLB1121AB 9
12. Remove the ring (6), the bearing races (7) and the
needle bearing (7) from sleeve and the spool. The
outer (thin) bearing race can be in the housing, exam-
ine its correct position.
PTIL13TLB1122AB 10
13. Push out the cross pin (11). Use the special screw
(22) from the end cover.
PTIL13TLB1123AB 11
14. Carefully push the spool (2) out of the sleeve (2).
PTIL13TLB1125AB 12
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15. Push the neutral position springs (12) out of their slots
in the spool (2).
PTIL13TLB1126AB 13
16. Remove the dust seal (1) and O-ring/Kin-ring/Roto

Glyd (5).
PTIL13TLB1127AB 14
17. Remove plugs from shock valves (32) with a 6 mm

(0.24 in) Allen key (E).
PTIL13TLB1128AB 15
18. Remove the seal washers (32).
PTIL13TLB1129AB 16
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19. Loosen the setting screws (32) with a 6 mm (0.24 in)

Allen key (E).
PTIL13TLB1130AB 17
20. Remove the two springs (32) and two valve balls (32)
into your hand. The valve seats are bonded into the
housing and you cannot remove it.
PTIL13TLB1131AB 18
21. Remove the shock valves (32).
PTIL13TLB1132AB 19
22. Remove the plug (30) with an 8 mm (0.31 in) Allen

key (E). Remove seal washers (30).
PTIL13TLB1133AB 20
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23. Loosen the setting screw (30) with a 6 mm (0.24 in)

Allen key (E).
PTIL13TLB1134AB 21
24. Remove the spring (30) and the piston (30). The valve
seat is bonded into the housing and you cannot re-
move it.
PTIL13TLB1135AB 22
25. The pressure relief valve is removed (30).
PTIL13TLB1136AB 23
26. The steering unit is fully dismantled. Replace these

pins (31) before the assembly.
PTIL13TLB1137AA 24
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Hydraulic steering system - Inspect

1. Clean all the parts carefully using a suitable solvent.
2. Replace all the seals and the washers.
3. Examine all the parts carefully. If necessary, replace
the parts.
4. Before the assembly, lubricate all parts with hydraulic
oil.
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Hydraulic steering system - Assemble

1. Put the two flat neutral position springs (12) in the slot.
2. Put the curved springs (12) between the flat ones. Push
them into its position.
PTIL13TLB1138AB 1
PTIL13TLB1139AA 2
3. Line up the spring set (12).
PTIL13TLB1140AB 3
4. Move the spool (2) into the sleeve (2). Make sure that
the spool (12) and the sleeve (2) are correctly in the
relation with each other.
PTIL13TLB1141AB 4
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Assemble spool and sleeve

NOTE: When assembling spool (2)and sleeve, only one of
two possible positions to set the spring slots. There are
three slots in the spool (2) and three holes in the sleeve; in
the end of the spool/sleeve opposite to the end with spring
slots. Put the slots and holes opposite each other for you
to see the parts of the holes in the sleeve through the slots
in the spool (2).
PTIL13TLB1142AB 5
Assembly pattern for standard bearing

1. Outer bearing race
2. Needle bearing
3. Inner bearing race
4. Spool
5. Sleeve
PTIL13TLB1149AB 6
Assembly pattern for double bearing

1. Washer for axial bearing
2. Outer needle bearing
3. Outer bearing race
4. Spool
5. Sleeve
6. Inner needle bearing
7. Inner bearing race
NOTE: The inner chamfer on the inner bearing race must
point the inner spool.
PTIL13TLB1150AB 7
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Installation instruction for O-ring/Kin-ring/Roto Glyd

1. Turn the steering unit until the bore is horizontal. Move
the outer part of the assembly tool (A) into the bore for
the spool/sleeve (2).
PTIL13TLB1151AB 8
2. Apply grease to the O-ring (5) and king-ring/roto Glyd

(6) with hydraulic oil and put them on the tool (A).
PTIL13TLB1152AB 9
3. Hold the outer part of the assembly tool (A) in the bot-
tom of the steering unit housing and move the inner part
of the tool (A) to the bottom.
PTIL13TLB1153AB 10
4. Push and turn the O-ring/kin-ring (5) to its position in

the housing (2).
PTIL13TLB1154AB 11
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5. Pull the inner and outer parts of the assembly tool (A)
out of the steering unit (2) bore, keeping the guide from
the inner part in the bore.
PTIL13TLB1155AB 12
Installation instruction for lip seal

1. Lubricate the lip seal (1) with hydraulic oil and put it on
the assembly tool (A).
PTIL13TLB1156AB 13
2. Move the assembly tool (A) to the bottom.
PTIL13TLB1157AB 14
3. Push and turn the lip seal (1) in its position in the hous-
ing (2).
PTIL13TLB1158AB 15
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4. With a light turning movement, move the spool (2) and

sleeve (2) into the bore.
NOTE: Install the spool (2) set holding the cross pin hori-
zontal.
PTIL13TLB1159AB 16
5. The spool (2) set will push out the assembly tool (A)
guide. The O-ring (5) and kin-ring/roto Glyd (6) are in
its position.
PTIL13TLB1160AB 17
6. Turn the steering unit until the bore is vertical again.

Put the check valve ball (3) into the hole.
PTIL13TLB1161AB 18
7. Tighten the threaded bush (4) lightly into the check

valve (2) bore. The top of the bush must be below the
surface of the housing.
PTIL13TLB1162AB 19
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8. Put a ball (33) in the two holes.
PTIL13TLB1163AB 20
9. Put a new pin (34) in the same two holes.
PTIL13TLB1164AB 21
10. In some condition a spring (38) must be attached on

the pin (34) before you put it in the housing.
PTIL13TLB1165AB 22
11. Apply grease to the O-ring (15) with mineral oil approx.
viscosity 500 mm²/s [SUS] at 20 °C (68 °F).
PTIL13TLB1166AB 23
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12. Put the distributor plate (16) to align the channel holes
to the holes in the housing (2).
PTIL13TLB1167AB 24
13. Move the cardan shaft (13) into the bore to align the
slot parallel to the connection flange.
PTIL13TLB1168AB 25
14. Put the cardan shaft (13) as shown to hold the mount-
ing fork (B) in its position.
PTIL13TLB1169AB 26
15. Apply grease to the two O-rings (18) with mineral oil
approx. viscosity 500 mm²/s [SUS] at 20 °C (68 °F)
and put them in the two grooves in the gear rim (17).
Attach the gearwheel (17) and rim (17) on the cardan
shaft (13).
PTIL13TLB1170AB 27
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NOTICE: Attach the gearwheel (rotor) (17) and cardan

shaft (13) to align the tooth base in its position in the rotor
(17) to the shaft slot as shown. Turn the gear rim (17) (See
Fig. 29) to align the seven through holes in the housing.
PTIL13TLB1171AB 28
16. Install the spacer (14), if necessary.
PTIL13TLB1172AB 29
17. Put the end cover (19) in its position.
PTIL13TLB1173AB 30
18. Install the special screw (22) with the washer. Put it in
the hole as shown.
PTIL13TLB1174AB 31
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19. Install the six screws (23) with washers. Tighten them.
20. Cross-tighten all the screws (23) and the rolled pin
with a torque of 24 – 36 N·m (212.42 – 318.63 lb in).
PTIL13TLB1175AB 32
Assembly of the pressure relief valve

1. Install the piston (30).
PTIL13TLB1176AB 33
2. Install the spring (31).
PTIL13TLB1177AB 34
3. Tighten the setting screw (30) with an 8 mm (0.31 in)

Allen key (F). Make the pressure setting on a test bench
or the vehicle.
PTIL13TLB1178AB 35
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4. Tighten the plug (30) with the dust seal (1) into the
housing with an 8 mm (0.31 in) Allen key (F).
Tightening torque: 60 – 70 N·m (531.04 –
619.55 lb in).
PTIL13TLB1179AB 36
Assembly of the shock valves

1. Put a ball (32a) in the two holes (A) and (B) shown by
the arrows.
PTIL13TLB1180AB 37
2. Put the springs (32b) and the valve cones above the
two balls.
NOTE: The blue spring (32b) applies to setting range 90
– 180 bar (1305 – 2610 psi). The untreated spring (32b)
applies to setting range 170 – 260 bar (2465 – 3770 psi).
PTIL13TLB1181AB 38
3. Tighten the two setting screws (32c) with a 6 mm

(0.24 in) Allen key (E). Make the pressure setting on
a test bench or the vehicle.
PTIL13TLB1182AB 39
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4. Install the plug with the seal ring (32d) into the two
shock valves and tighten them with a torque of: 20 –
40 N·m (177.01 – 354.03 lb in) with a 6 mm (0.24 in)
Allen key (E).
PTIL13TLB1183AB 40
5. Put the dust seal ring (1) in the housing (2). The dust
seal ring (1) must be set only after the pressure relief
valve (30) and shock valves (32) are installed.
PTIL13TLB1184AB 41
6. Install the dust seal ring (1) in the housing with the
special tool (C) and a plastic hammer (D).
PTIL13TLB1185AB 42
7. Push the plastic plugs (37) into the connection ports.

8. Do not use a hammer.
PTIL13TLB1186AB 43
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Hydraulic steering system - Install

Steering control valve
See Steering column - Exploded view (41.101).
1. Install the orbital block on the cabin using suitable lifting
equipment.
2. Install and tighten the mounting bolts (8).
3. Connect all the hoses (1), (2), (3), (4) and (5) in respec-
tive places.
PTIL13TLB1457AB 1
4. Remove all tags.

5. Connect the electrical connections for the speedometer
and switches.
6. Install the front console (1).
7. Install the steering wheel.
8. Install cabin See Cab - Install (90.150).
9. Check and adjust the hydraulic main pressure relief
valve. (See Hydraulic systems - Service instruction
(35.000)).
10. Stop the engine and check for oil leaks. PTIL13TLB1458AB 2
11. Check the oil level in the hydraulic reservoir. Add oil
as required.
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Steering circuit relief valve - Check

Pressure check procedure as follows:
the floor.
loader control lever in the ROLLBACK position for
15 s.
B. Put the loader control lever in the NEUTRAL posi-
tion for 15 s.
C. Repeat steps A and B until the temperature of the
oil is 50 °C (122 °F) or the side of the reservoir is
very warm.
250 bar (3625 psi). Connect the pressure gauge
(Quick coupler can be used ) to the pressure checking
port in CF port in pump. This port is meant for checking
the steering hydraulic pressure.
4. With the engine running at full throttle, turn and hold
the steering wheel all the way to the extreme right or to
the extreme left and read the pressure gauge. Make a
record of the reading.
6. Compare the Pressure value recorded is in the range
of 140 – 145 bar (2030 – 2102 psi). If it is in range
, then Pressure has been set. If not, adjust the relief
valve in steering unit and record the pressure till it is
getting achieved. If not achieved on full adjustment.
then follow the disassembly Procedure to check the
steering unit.
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Index
Steering - 41

Hydraulic steering system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic steering system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic steering system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic steering system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic steering system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic steering system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic steering system - Remove - Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic steering system - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic steering system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering circuit relief valve - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Steering - 41
Cylinders - 216
851FX Plus
851FX
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Contents
Steering - 41
Cylinders - 216
FUNCTIONAL DATA
Steering cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Steering cylinder
Disassemble - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Steering - Cylinders
Steering cylinder - Exploded view
PTIL13TLB0501AB 1
1. Nut 12. Tie rod end nut

2. Swivel housing 13. O-ring
3. Tie rod 14. O-ring
4. Nut 15. Cylinder head
5. Ball joints 16. O-ring
6. Screw 17. Piston rod
7. Steering cylinder 18. O-ring
8. Swivel housing 19. Cylinder case
9. Nut 20. Cylinder head
10. Tie rod ball joint 21 O-ring
11. Nut 22. O-ring
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Steering cylinder - Disassemble - 4WD

1. Loosen the nut (1) with enough turns till it is protruding
over the threaded pin end of the tie rod (3).
2. Beat on the nut (1) with an appropriate hammer in order
to disjoin the tie rod (3) from the swivel housing (2).
NOTICE: Don’t beat on the threaded pin end of the tie rod
(3).
NOTE: This is a destructive operation for the nut (1).
3. Repeat the whole sequence at the other side.
PTIL13TLB0502AB 1
4. Remove the tie rods (3) and (12) by loosing the nuts
(4) and (12) with a suitable wrench, then check the
conditions.
5. Unscrew the fastening screws (6) and take the steering
cylinder (7) out of its housing, if necessary use a rubber
hammer.
6. Remove only parts that need to be overhauled and/or
replaced.
PTIL13TLB0503AB 2
7. Detach the cylinder head (15) from the cylinder case

(19) and remove it from the rod (17). Remove the rod
(17) from the cylinder case (19).
8. Remove the cylinder head (20) from the cylinder case
(19).
9. Remove all the seals and O-rings (13), (14), (16), (18),
(21) and (22) from the cylinder case (19), the cylinder
heads (15) and (20), and the rod (17).
PTIL13TLB0504AB 3
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Steering cylinder - Assemble - 4WD

1. Assemble new seals and O-rings (13), (14), (16), (18),
(21) and (21) on the cylinder heads (15) and (20), on
the rod piston (17) and on the cylinder body (19).
PTIL13TLB0504AB 1
2. Assemble the cylinder head (20) to the cylinder body

(19).
3. Fit the cylinder head (15) on the rod (17).
4. Slide the pre-assembled rod (17) into the cylinder body
(19).
PTIL13TLB0505AB 2
5. Fit the tie rods (3) and (12), the ball joints (5) and (10),
the nuts (4) and (11) to the ends of the rod (17), then
tighten with a dynamo metric wrench to the requested
torque.
PTIL13TLB0503AB 3
6. Install the steering cylinder (7) already assembled on

the central body.
7. Assemble and tighten the screws (6) with dynamo met-
ric wrench to the prescribed torque.
PTIL13TLB0506AB 4
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8. Align the swivel housing (8) with the axle.

9. Screw the tie rod (12) so that its ball joint can be in-
serted into the swivel housing (8) arm.
NOTE: It is important to unscrew the lock nut (11) to carry
out this operation.
10. Repeat the whole sequence of the mentioned opera-
tions to the other side.
PTIL13TLB0507AB 5
11. Insert the ball joint of the tie rod (3) into its housing on
the swivel housing (2).
12. Assemble and tighten the lock nut (1) with a dynamo
metric wrench to the prescribed torque.
13. Repeat the whole sequence of the mentioned opera-
tions to the other side.
PTIL13TLB0508AB 6
Tightening torques
S No. Description Tightening torque
1 Tie rod end 165 N·m (122 lb ft)
2 Ball joint 300 N·m (221 lb ft)
3 Locking nut 120 N·m (89 lb ft)
4 Screw 120 N·m (89 lb ft)
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Steering cylinder - Disassemble - 2WD

Refer to Front axle - Exploded view (25.400).
1. Park the machine on a level and firm surface and chock
the wheels.
2. Raise the loader arm and lock the safety strut.
3. Switch Off the engine.
5. Relieve the hydraulic pressure by operating all the hy-
draulic controls.
6. Disconnect the steering hydraulic hoses at the cylinder
end and plug the openings.
7. Loosen and remove the tie rod end nuts (3) halfway till
the nut just protrudes out of the last thread of the tie rod
end (4).
8. Tap the nut lightly upwards to free the ends.
9. Repeat the procedure on the other sides.
10. Loosen the jam nuts (9) and remove ball joints (8) on
either side.
11. Loosen and remove the mounting bolts (6) and wash-
ers (7) to remove the steering cylinder (5).
12. Retain the spacer (10).
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Steering cylinder - Assemble - 2WD

Refer to Front axle - Exploded view (25.400).
1. Align the spacer (10) and mount the steering cylinder
(5) with bolts (6) and washer (7).
2. Tighten the bolts evenly to a torque of 414 – 560 N·m
(305 – 413 lb ft).
3. Install the tie rod (4) and hand tighten the same.
4. Install the tie rod end tighten the end nuts (3) to a torque
of 129 – 160 N·m (95 – 118 lb ft).
5. Repeat the procedure on the other side.
6. Check and adjust toe. Refer to Front axle - Toe in
adjust (25.400).
7. Tighten the jam nuts (9) to a torque of 255 – 315 N·m
(188 – 232 lb ft).
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Index
Steering - 41
Cylinders - 216
Steering cylinder - Assemble - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering cylinder - Assemble - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering cylinder - Disassemble - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering cylinder - Disassemble - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Wheels
851FX Plus
851FX
91715732 26/07/2021
44
Contents
Wheels - 44
[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2
[44.AAA] Wheels generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.3
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Wheels - 44
Front wheels - 511
851FX Plus
851FX
91715732 26/07/2021
44.1 [44.511] / 1
Contents
Wheels - 44
Front wheels - 511
SERVICE
Front wheels
Tighten - Front wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Wheels - Front wheels
Front wheels - Tighten - Front wheel mounting nut torque procedure

1. Install all eight (8) mounting nuts. Tighten all mounting
nuts, in the sequence shown, until the wheel is snug
against the axle hub. Torque: 196 N·m (145 lb ft).
2. Tighten the mounting nuts to the specified torque in two
stages.
PTIL13TLB1474AB 1
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Front wheels - Remove

1. Support the machine on the loader and lift the front of
the vehicle till the front wheels are off the ground.
PTIL14TLB0131AA 1
2. Provide support and remove the nuts (1).
PTIL13TLB1473AB 2
3. Remove the front wheel.
PTIL13TLB0732AA 3
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Front wheels - Install

1. Carefully position the front wheel against the hub.
2. Tighten the front wheel nuts. Refer to Front wheels -
Tighten - Front wheel mounting nut torque proce-
dure (44.511).
PTIL13TLB1218AA 1
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Index
Wheels - 44
Front wheels - 511

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tighten - Front wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - 44
Rear wheels - 520
851FX Plus
851FX
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44.2 [44.520] / 1
Contents
Wheels - 44
Rear wheels - 520
SERVICE
Rear wheels
Tighten - Rear wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Wheels - Rear wheels
Rear wheels - Tighten - Rear wheel mounting nut torque procedure

1. Install all ten (10) wheel mounting nuts. Tighten all
mounting nuts, in the sequence shown, until the wheel
is snug against the axle hub. Torque: 490 N·m (361 lb
ft).
2. Tighten the mounting nuts to the specified torque in 3
stages.
PTIL13TLB1476AB 1
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Rear wheels - Remove

1. Lower the stabilizers (1) and raise the rear of the vehi-
cle till the rear wheels are off the ground.
PTIL14TLB0133AB 1
2. Remove the wheel nuts (1) and remove the wheel.
PTIL13TLB1475AB 2
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Rear wheels - Install

1. Carefully position the rear wheel against the hub.
2. Tighten the rear wheel nuts. Refer to Rear wheels -
Tighten - Rear wheel mounting nut torque proce-
dure (44.520).
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Index
Wheels - 44
Rear wheels - 520

Rear wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear wheels - Tighten - Rear wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Wheels - 44
Wheels generic sub-group - AAA
851FX Plus
851FX
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Contents
Wheels - 44
TECHNICAL DATA
Wheels generic sub-group

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Wheels - Wheels generic sub-group
Wheels generic sub-group - General specification

NOTE: When the machine is new or when a wheel is removed for service, check the wheel nut or bolt torques every
10 h of operation until the wheel nuts or bolts remain tight.
NOTE: Use only the mounting nuts shown in the parts catalogue for this machine.
NOTE: Check the torque with a torque wrench. If the nut does not move on the following torques, it is tight and does
not need re-torque.
Tire size details

2WD
Type of rear tire Front tires Rear tires
Standard Rear 9.00-16, 16 PR 16.9-28, 12 PR
Heavy duty rear 9.00-16, 16 PR 14.00-25, 20 PR
4WD
Standard Rear 12.5-18, 12 PR 16.9-28, 12 PR
Heavy duty rear 12.5-18, 12 PR 14.00-25, 20 PR
Inflating pressure details

2WD
Standard Rear 1.79 bar (26 psi)
5.52 bar (80 psi)
Heavyduty rear 2.76 bar (40 psi)
4WD
Standard Rear 1.79 bar (26 psi)
2.41 bar (35 psi)
Heavyduty rear 2.76 bar (40 psi)
Nut torques
Front nuts Rear nuts
196 N·m (145 lb ft) 490 N·m (361 lb ft)
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Index
Wheels - 44

Wheels generic sub-group - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Cab climate control
851FX Plus
851FX
91715732 26/07/2021
50
Contents
Cab climate control - 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
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50
Heating - 100
851FX Plus
851FX
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50.1 [50.100] / 1
Contents
Heating - 100
TECHNICAL DATA
Heating
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Heating
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Heating
Remove - Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove - Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install - Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heater shutoff
Reinforce - Electric heater valve (HVAC option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Cab climate control - Heating
Heating - General specification

Engine radiator coolant
Antifreeze – Ambra Agriflu 12 L (3.2 US gal)
Water 12 L (3.2 US gal)
System type Pressurized full flow by–pass with expansion chamber
Fan belt deflection
Naturally Aspirated 13 – 19 mm (0.51 – 0.75 in)
Turbocharged 10 – 16 mm (0.39 – 0.63 in)
Thermostat
Start to Open at 82 °C (180 °F)
Fully Open at 95 °C (203 °F)
Radiator Cap 0.90 bar (13 psi)
Heating - Torque
Coolant/Hot water hose connections 5 N·m (3.7 lb ft)
Air hose ducting connections 5 N·m (3.7 lb ft)
Heater housing to floor mounting bolts 6.2 N·m (4.6 lb ft)
Heating - Sealing
Code Number Name
82995768 Sealer–Anaerobic Low strength
82995776 Sealer–Silicone
82995774 Sealer–Polyester Urethane
82995773 Sealer–Anaerobic
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Heating - Static description

Cab heating
The cab is heated by a radiator mounted below the cab
seat, which is supplied hot water from the engine coolant
system. A blower motor mounted behind the cab radiator
is used to transfer the heat into the cab.
Heater blower control

The three speed blower is controlled by switch (1)
mounted in the instrument console to the right of the cab
seat. Turn the switch clockwise to the first position for
slow speed. Further rotation of the switch in a clockwise
direction selects medium and fast speeds.
The blower draws outside air from beneath the cab floor
and through a filter medium into the cab.
Heater temperature control

The temperature of the air from the radiator is adjusted
by rotation of the control knob (2) which opens or closes
the radiator valve increasing or decreasing the water flow PTIL14TLB0070AB 1
as required. Turn the control clockwise to increase the
temperature of air from the heater and counter clockwise
to reduce the temperature.
WARNING
The cab air filters are designed to remove dust from the
air but may not exclude chemical vapor. When working in
an enclosed area ensure there is adequate ventilation as
exhaust fumes can suffocate you. Failure to comply could
result in death or serious injury.
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Cab air filter

Before servicing the air filter situated under the drivers
seat, switch off the blower and close all windows and one
door. Forcibly close the other door. The resulting back
pressure will dislodge loose dirt from the underside of the
filters.
To remove the grille (1) release the retaining straps (2)

and remove the filter element (3). Ensure the element,
and sealing faces are not damaged on removal.
NOTICE: In humid conditions, such as occur on most
early mornings, do not switch on the blower prior to ser-
vicing the filters. Damp particles drawn into the filter may
solidify and prove difficult to remove without washing.
PTIL14TLB0063AB 2
The filter elements are made of specially treated paper

with a sealing strip bonded to the outer face.
Clean all of the elements by blowing with compressed air

from the clean side through to the dirty side. The com-
pressed air should not exceed 2 bar (29 psi) and the air
line nozzle should be at least 300 mm (12 in) from the el-
ement.
PTIL14TLB0064AB 3
Heater radiator
The heater radiator (1) is fitted in a housing under the cab
seat for central displacement of warm or cold air flow.
NOTICE: Too ensure a good flow of air through the heater
radiator the filter should be cleaned more frequently when
operating in extremely dusty conditions.
PTIL14TLB0151AB 4
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PTIL14TLB0154FB 5
1. Heater control panel 4. Air ducting to the rear wind screen

2. Air ducting to the front windscreen 5. Air intake to the heater housing from below the
cab floor
3. Air ducting to the B pillar 6. Heater pipes to and from heater taken from cooling
package
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Heating - Remove - Blower motor

1. Remove the bolt (1) and seat from the heater assembly.
2. Remove the bolts (3) and cover (2).
3. Disconnect the blower motor connectors.
PTIL14TLB0153AB 1
4. Remove the mounting hardware and lift the blower mo-

tor (1).
PTIL14TLB0150AB 2
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Heating - Install - Blower motor

1. Install the blower motor (1) and secure it with mounting
hardware.
2. Connect the blower motor connectors.
PTIL14TLB0150AB 1
3. Install the cover (2) with the bolts (3).

4. Install the seat and tighten the bolts (1).
PTIL14TLB0153AB 2
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Heating - Remove - Cab heater

ATTENTION: Remove only when engine is cool.
1. Remove the seat by removing the bolts (1).

2. Remove the bolts (3) and cover (2) from the heater
assembly.
3. Disconnect the heater core connections and cap all
openings.
PTIL14TLB0153AB 1
4. Remove the mounting hardware and lift the heater core

(1).
ATTENTION: Make sure that the heater core fins are not
damaged while removal.
PTIL14TLB0151AB 2
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Heating - Install - Cab heater

1. Install the heater core (1) and secure it with mounting
hardware.
ATTENTION: Make sure that the heater core fins are not
damaged while installing.
2. Remove the caps and connect the heater core connec-
tions.
PTIL14TLB0151AB 1
3. Install the cover (2) with the bolts (3) on the heater
assembly.
PTIL14TLB0153AB 2
5. Refill the coolant.
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Heater shutoff - Reinforce - Electric heater valve (HVAC option)

Electric heater valve
The electric valve is equipped with a software that, each
time the supply of the cock is delayed (therefore also at
backhoe loader start), carries out the momentary posi-
tioning of the cock to “completely closed” and returns
to the position set by the temperature regulation handle
located on the control dashboard.
This enables the software to carry out a self-control on
the cock drive so as to always obtain an optimal regu-
lation of the ball for the water flow.
This is part of the cock normal operation and is not to
be considered as a fault.
Valve release
ATTENTION: The release of the valve has to be performed if this valve remains idle for long periods.
Carry out this operation observing the following proce-
dure:
1. Disconnect the electric connectors (1).
2. Loosen the screws (2) and extract the electric valve (3)
from the evaporator.
3. Loosen and remove the screws (4).
PTIL17TLB0195AB 1
4. Separate the driving unit (5) from the cock (6).

5. By means of a wrench, turn the pin (A) of the cock to
unlock it.
NOTE: Once this operation is complete, reset pin (A) in the
correct start position.
PTIL17TLB0196AB 2
Reinstall the heater valve, repeating the previously car-

ried out operations in reverse order.
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Index
Heating - 100
Heater shutoff - Reinforce - Electric heater valve (HVAC option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heating - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heating - Install - Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heating - Install - Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heating - Remove - Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heating - Remove - Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Heating - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heating - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Heating - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Air conditioning - 200
851FX Plus
851FX
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Contents
TECHNICAL DATA
Air conditioning
Air-conditioning compressor
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Air conditioning
SERVICE
Air conditioning
Remove - Receiver drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install - Receiver drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Charging - Evacuation and recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Recover - Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air-conditioning compressor
Adjust - Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air-conditioning condenser
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air-conditioning evaporator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Cab climate control - Air conditioning
Air conditioning - General specification

Refrigerant specification R134A
Refrigerant charge 1.2 kg (2.6 lb)
Compressor oil specifications PAG SP20
Compressor oil capacity
System (approximately) 135 mL (4.6 US fl oz)
Cooling capacity @ 22 – 49 °C (72 – 120 °F) ambient. 4.5 kW (6.1 Hp), 29,000 BTU/hr Typical (Actual capacity de-
pendent on system control operator settings)
Low pressure cut out switch (Mounted behind the front radiator grille behind the battery and attached to the receiver
drier)
On 1.8 – 2.4 bar (26.1 – 34.8 psi)

Off 1.8 – 2.2 bar (26.1 – 31.9 psi)
Temperature cycling control switch (Mounted under the seat pod in the right hand side)
Switch setting On Off

Minimum cooling 12 – 16 °C (54 – 61 °F) 10 °C (50 °F)
Maximum cooling 3 – 5 °C (37 – 41 °F) 0 – 2 °C (32 – 36 °F)
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Air-conditioning compressor - General specification

Manufacturer and type Sanden SD7H15
Compressor clutch and pulley air gap 0.4 – 0.8 mm (0.016 – 0.031 in)
Drive belt tension (measured at the widest gap) 10 mm (0.4 in) deflection with 1 kg (2.2 lb) force applied
midway between the pulleys
Air-conditioning compressor - Torque

M6 10.8 – 16.6 N·m (8.0 – 12.2 lb ft)
Cylinder head bolts
M8 29.4 – 39.2 N·m (21.7 – 28.9 lb ft)
Clutch front plate retaining bolt M5 x 6 7 – 11 N·m (5.2 – 8.1 lb ft)
Armature retaining nut M8 14.8 – 20.6 N·m (10.9 – 15.2 lb ft)
Compressor mounting bolts 43 N·m (31.7 lb ft)
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Air conditioning - Static description

Safety precautions
WARNING
Before overhauling an air conditioning system read and observe the following Safety Precautions If a repair or re-
placement becomes necessary, ensure that only certified Air Conditioning technicians are employed, using approved
equipment to effect repairs. Do not attempt to disassemble the air conditioning system, It is possible to be severely
frostbitten or injured by escaping refrigerant. Failure to comply could result in death or serious injury.
NOTICE: Do not allow refrigerant to escape into the atmosphere.
Refrigerant must be handled with care in order to AVOID HAZARDS.
Undue direct contact with liquid refrigerant can produce freezing of skin and eyes.
Keep the refrigerant container and air conditioning system away from flame or heat sources, the resulting pressure
increase can cause the container or system to explode.
If in direct contact with open flames or heated metal surfaces, the refrigerant will decompose and produce products
that are toxic and acidic.
Make sure to comply with the following indications and simple precautions to avoid any risk of injury:
• Never discharge refrigerant into the atmosphere. When servicing air conditioning units a certified refrigerant recov-
ery unit operated by a certified technician must be used.
• When discharging the refrigerant in the system make sure you are operating in well–ventilated premises with good
air circulation and far away from open flames.
• When charging and discharging the system always wear goggles and take suitable precautions to protect the face
in general and the eyes in particular, from accidental spillage of the refrigerant fluid.
• The oil and refrigerant mixture inside the air conditioning system is pressurized.
Consequently, never loosen fittings or tamper with lines unless the system has been properly discharged.
• Before loosening any connection, cover the fitting in question with a cloth and wear gloves and goggles in order to
prevent refrigerant from reaching the skin or eyes.
• In the event of an accident, proceed as follows:
If the refrigerant has reached the eyes, wash them immediately with copious amounts of sterilised water or mains
pressure tap water and transfer to hospital for immediate medical help.
If the refrigerant has touched the skin, wash with cold water and transfer to hospital for immediate medical help.
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Description and operation
NOTE: The Air Conditioning compressor will only run
when the cab blower motor is operating.
To operate, turn the switch (1), which will engage the air
conditioning compressor.
NOTE: Once the air conditioning compressor is On, the
indicator (3) illuminates.
A three speed blower is used for the air circulation and

operates by turning the switch (2), mounted to the right of
the operator seat.
1st Position – Low Speed
2nd Position – Medium Speed
3rd Position – Higher Speed PTIL14TLB0175AB 1
The air–conditioner filter is located on the left hand side

of the seat pod.
PTIL14TLB0070AB 2
Refrigerant R–134a
WARNING
R134A can be dangerous if improperly handled. There-
fore it is important the following warning and directions
are adhered to.
R134A has a boiling point of -12 °C (10 °F).
Never expose any part of the air-conditioner system to
flame or excessive heat because of risk of fire or explo-
sion, and the production of phosgene gas.
Never disconnect or disassemble any part of the air-con-
ditioning system as escaping refrigerant can cause frost-
bite.
WARNING
If refrigerant should contact the skin use the same treat-
ment as for frostbite.
Warm the area with your hand or lukewarm water 32 °C
(90 °F), cover the area loosely with a bandage to protect
affected area against infection and consult a doctor im-
mediately.
If refrigerant should contact the eyes wash immediately in
cold clean water for at least 5 min and consult a doctor
immediately.
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Principals of air conditioning
The function of the air conditioning system is to improve
the operator’s comfort by cooling the air temperature in-
side the cab and reducing the humidity level.
In order to achieve this heat transfer the following princi-

pals of heat generation and transfer are applied within the
air conditioning system.
1. When two bodies of different temperature come to-

gether heat is transferred from one to another. On
air conditioning systems an evaporator is used to hold
the low temperature refrigerant which absorbs the heat
from the air within the cab.
PTIL14TLB0156AA 1
2. When a gas is pressurised the temperature of the gas

will rise. In air conditioning systems the increase in
pressure is achieved using a compressor.
PTIL14TLB0157AA 2
3. When a gas is cooled it will condense into a liquid. In

the air conditioning system a condenser is used to cool
the gas and the resulting liquid is stored in a receiver
dryer.
PTIL14TLB0158AA 3
4. When a liquid is atomized through an orifice, the tem-

perature of the resultant vapor will drop. The low tem-
perature of the atomized liquid will then absorb heat
from its surroundings. On air conditioning systems the
refrigerant is atomized using an expansion valve.
PTIL14TLB0159AA 4
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PTIL14TLB0160FA 5
Air conditioning flow diagram
It can now be seen that the principal components of an air conditioning system are:
• Refrigerant
• Evaporator
• Compressor
• Condenser
• Receiver Dryer
• Expansion valve
Refrigerant is drawn into the compressor as a cool, low pressure vapor which is compressed and then pumped out
as a hot, high pressure vapor to the condenser.
As the hot, high pressure vapor passes through the condenser core it gives off heat to the cooler outside air, being
drawn past the fins by the engine cooling fan.
By giving off heat to the outside air, the vapor is condensed to a liquid which moves under high pressure to the receiver
dryer where it is stored until released to the evaporator by the temperature sensing expansion valve.
As liquid refrigerant passes through the metered orifice in the expansion valve the refrigerant changes from a high
pressure liquid to a low pressure atomized liquid with a lower temperature.
This low pressure, low temperature, atomized liquid enters the evaporator coils and absorbs heat from the cab warm
air blown across the coils and fins by the cab blower motor. The refrigerant now changes from a cold low pressure
atomized liquid to a warm low pressure vapor and leaves the evaporator outlet, moving to the suction (low pressure)
side of the compressor to repeat the cycle.
As this heat loss is taking place, moisture (humidity) in the cab air will condense on the outside of the evaporator and
drain off as water through the drain hoses attached to the evaporator drain pan, thereby reducing the humidity level
of the cab.
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System description and operation
Refrigerant
To achieve the absorption and the release of heat which is, in essence, the function of an air conditioning system,
requires the use of a suitable “refrigerant” - a liquid that has a relatively low temperature boiling point, plus certain
desirable safety and stability features.
The refrigerant used in the air conditioning system is refrigerant R134A.

NOTE: To help protect the environment legislation has been introduced in most territories banning the release into
the atmosphere of refrigerants, including R134A. All service procedures contained in this manual can be carried out
without the need to release refrigerant into the atmosphere.
In order to prevent the incorrect type of refrigerant being charged to the system the service valves fitted to the Backhoe
Loader and necessary to connect up refrigerant recovery, evacuation and recycling/recharging equipment will be of
two different sizes as recognized and specified by the air conditioning industry.
WARNING
R134A refrigerant is not compatible with R–12 refrigerant. Do not attempt to replace R134A refrigerant with R–12
refrigerant or test the system using gauges or equipment previously used with R12 as damage to the system will
result.
R134A refrigerant is stable at all operating temperatures and able to absorb great quantities of heat.
The boiling point of R134A is -26.5 °C (-15.7 °F) at atmospheric pressure.
If the pressure is increased, R134A will readily vaporize to absorb heat at temperatures between -11 °C (12 °F) at
1.9 bar (27.5 psi) and 0 °C (32 °F) at -11 °C (12 °F) at 2.9 bar (42 psi) in the evaporator.
At higher pressures, R134A will condense and give off heat at temperatures between 48 °C (118 °F) at 12.4 bar
(179.8 psi) and 58 °C (136 °F) at 15.85 bar (230 psi) in the condenser.
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PTIL14TLB0161FB 1
Air conditioning refrigerant compressor
1. Discharge chamber 6. Wobble plate

2. Pistons 7. Pulley/Electro–magnetic clutch
3. Reed valve plate assembly 8. Pulley bearing
4. Cylinder head 9. Cam plate
5. Static gear
Compressor pump
The air conditioning compressor pump is mounted on the left hand side of the engine and is belt driven from the
crankshaft pulley.
The compressor separates the low and high pressure sides of the system and is basically a pump which has two
functions:
1. To raise the refrigerant temperature by compression to a higher degree of temperature than the ambient (outside
air) temperature.
2. To circulate the required volume of refrigerant through the system.
The refrigerant compressor is a seven cylinder wobble plate unit housed in a die cast aluminium housing.
Drive to the wobble plate is from the pulley, through the electro-magnetic clutch to the main driveshaft. Attached to
the driveshaft is a cam rotor which oscillates the wobble plate. The wobble plate is prevented from rotating by a static
gear engaging with teeth formed in the face of the plate. The seven pistons are connected to the wobble plate by
rods located in ball sockets.
Refrigerant is drawn in on the downward stroke of a piston through the reed valves located either end of the cylin-
der assembly. Refrigerant enters the cylinder assembly through a gallery in the outer circumference of the cylinder
assembly.
The upwards stroke of the piston compresses the refrigerant and expels it through another reed valve into an inner
gallery in the cylinder assembly and out into the refrigerant circuit.
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The compressor is lubricated with a PAG SP20. This oil is miscible with the refrigerant and is carried around the
refrigerant circuit.
The compressor is activated by an electro-magnetic clutch which functions to engage or disengage the compressor
as required in the operation of the air conditioning system.
The clutch is primarily activated by the:

• Temperature control switch
• Low pressure cut–out switch
Temperature control switch

The air conditioner temperature control switch (1) is
mounted beneath the cab seat on the heater cover as-
sembly.
The switch is a device which turns the compressor clutch

on and off to maintain a constant average evaporator tem-
perature and senses the evaporator temperature using a
thermistor attached to the larger evaporator tube.
The temperature control switch compares the voltage of

the thermistor, which is dependent on the temperature of
the evaporator, with the voltage across the potentiometer
of the ‘in cab’ temperature control switch.
PTIL14TLB0170AB 2
The switch upon comparing the two voltages determines
whether the compressor clutch should be switched ‘on’ or
‘off’ in order to maintain the desired in cab temperature
control.
Low pressure cut-out switch

The low pressure switch (1) is mounted on top of the re-
ceiver drier.
The purpose of the switch is to shut off the compressor

pump in the event of low pressure in the refrigerant sys-
tem.
Low refrigerant pressure may occur due to a faulty ex-

pansion valve, icing up of the expansion valve orifice or
refrigerant loss. Low refrigerant pressure may result in
damage to the compressor pump.
The low pressure switch is factory set and cannot be ad-

justed.
PTIL14TLB0169AB 3
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Condenser
The condenser (1) located at the front of the machine in
front of the after cooler consists of a number of turns of
continuous coil mounted in a series of thin cooling fins to
provide a maximum of heat transfer in a minimum amount
of space.
NOTE: The condenser after removal of the attaching bolts
can be slid out for cleaning.
The condenser receives the hot, high pressure refriger-

ant vapor from the compressor. The hot vapor passes
through the condenser coils and outside air is drawn
through the condenser by the engine cooling fan.
4
Heat moves from the hot refrigerant vapor into the cooler PTIL14TLB0065AB
outside air flowing across the condenser coils and fins.
When the refrigerant vapor reaches the pressure and tem-

perature that will induce a change of state, a large quantity
of heat is transferred to the outside air and the refrigerant
changes to a high pressure warm liquid.
The warm liquid refrigerant continues onto the receiver/

drier where it is filtered and desiccated, to remove any
moisture, before passing through an outlet line to the ther-
mostatic expansion valve.
Receiver drier
The receiver/drier (1) situated in front of the condenser
stores the liquid refrigerant to be sure a steady flow to the
thermostatic expansion valve is maintained under widely
different operating conditions.
The drier section contains a desiccant (Molecular sieve)

to absorb any moisture within the system and a filter pre-
vents the entry of foreign particles.
NOTE: Any moisture in the air conditioning system is ex-
tremely harmful. Moisture not absorbed by the dehydra-
tor will circulate with the refrigerant and droplets may col-
lect and freeze in the thermostatic expansion valve orifice.
This action will block the refrigerant flow and stop the cool-
PTIL14TLB0168AB 5
ing action. Moisture will also react with refrigerant R134A
and the lubricant to form a corrosive acid.
The desiccant can only absorb a limited amount of mois-

ture before reaching saturation point. Because of this,
after any system component replacement or repairs re-
quiring entry into the system, the receiver/ drier should be
replaced.
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Expansion valve
The expansion valve (1) is located underneath the evap-
orator in the pressure line leading from the receiver/ drier
and performs the following functions:
1. Metering action
A metered orifice changes the liquid refrigerant from a
high pressure low temperature liquid to a low pressure,
lower temperature atomized liquid.
2. Modulating action
A thermostatically controlled valve within the expan-
sion valve body controls the volume of liquid refriger-
ant passing through the orifice and makes sure the re-
frigerant is fully vaporized within the evaporator. Liquid
refrigerant would damage the compressor reed valves PTIL14TLB0182AB 6
or freeze the pistons.

3. Controlling action
The valve responds to changes in the cooling require-
ments. When increased cooling is required, the valve
opens to increase the refrigerant flow and when less
cooling is required the valve closes and decreases the
refrigerant flow.
Expansion valve - Operation

All of the needed temperature sensing and pressure sens-
ing functions are consolidated into this basic unit and no
external tubes are required for these purposes.
The refrigerant from the condenser and receiver drier en-

ters the thermostatic expansion valve as a high pressure
warm liquid. Upon passing through the ball and spring
controlled metering orifice, the pressure and temperature
of the refrigerant is reduced and the refrigerant leaves the
thermostatic expansion valve as a low pressure, lower
temperature atomized liquid.
The atomized liquid now passes through the evaporator

where it absorbs heat before returning via the expansion PTIL14TLB0162AA 7
valve to the compressor as a warm low pressure vapor.
There are two refrigerant passages in the valve. One pas-

sage is in the refrigerant line from the condenser to the
evaporator and contains the ball and spring type orifice
valve. The other passage is in the refrigerant line from
the evaporator to the compressor and contains the valve’s
temperature sensing element.
Liquid refrigerant flow from the condenser and receiver

drier is controlled by a push-rod forcing the orifice valve
ball off its seat and the spring exerting pressure on the
ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the pres-

sure on the bottom of the expansion valve diaphragm
rises above the pressure on the top of the diaphragm al-
lowing the valve spring to close the orifice.
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When the system is started, the pressure on the bottom of

the diaphragm drops rapidly, allowing the orifice to open
and meter atomized liquid refrigerant to the evaporator
where it begins to vaporize.
Suction from the compressor draws the vaporized refrig-

erant out of the evaporator and back through a gallery in
the top of the valve which passes the temperature sensor.
The temperature sensor reacts to variations in refrigerant

gas pressure returning from the evaporator. When heat
from the passenger compartment is absorbed by the re-
frigerant the pressure of the gas increases causing a dif-
ferential pressure above and below the temperature sen-
sor diaphragm. The diaphragm reacts to this pressure dif-
ferential and a push rod forces the ball in the expansion
valve orifice further off its seat. This reaction allows an
increase in the atomized refrigerant to flow through the
valve, to the evaporator, so that more heat can be ab-
sorbed by the air conditioning system.
Similarly when the temperature of the gas returning from

the evaporator decreases the pressure of the gas de-
creases. This causes the diaphragm to react accordingly
and allow the ball in the orifice to move closer towards its
seat thus reducing the flow of refrigerant through the valve
to the evaporator.
Evaporator
The evaporator (1) is located beneath the cab seat and
consists of a number of turns of continuous coils mounted
in a series of thin cooling fins to provide a maximum of
heat transfer in a minimum amount of space.
Low temperature refrigerant in the evaporator absorbs

heat from the hotter air in the operator’s compartment,
thereby cooling the air.
PTIL14TLB0152AB 8
Air recirculation
An intake grille is located on the left side of the seat base.
A portion of the air flow will recirculate through the evap-
orator.
PTIL14TLB0171AB 9
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Filter general
The blower fan, draws warm air from outside the cab
through the intake filter (1) below the cab floor and al-
ready cooled dehumidified air through the recirculation
grille. The air passes over the evaporator then into the
cab through the six louvered vents.
Two vents are located on the front instrument panel to

direct air onto the windshield. Two are located at the base
of the rear posts to direct air onto the rear window. Two
additional vents are located at the front and rear of the
seat base to direct air at the operators feet.
PTIL14TLB0172AB 10
Blower fan
The blower motor is controlled by a three-speed switch
(1) the switch uses a variable resistor to change the fan
speed.
High blower speed provides the greatest volume of circu-

lated air, however, a slower speed will allow the air to con-
tact the cooling fins and coils of the evaporator for a longer
period resulting in the warm air giving up more heat to the
cooler refrigerant. Therefore, the coldest air temperature
is obtained when the blower fan is operated at the lowest
speed.
PTIL14TLB0173AB 11
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Air conditioning - Remove - Receiver drier

WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -26 °C (-15 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340B
Prior operation:
Open the engine hood, see Hood - Remove (90.100).
1. Evacuate the refrigerant from the system using the rec-

ommended equipment.
2. Fasten identification tags on the hoses and disconnect
the hoses (1) from the receiver drier (3).
3. Install plugs in the hoses and caps on the fittings to
prevent any dirt entering the system.
4. Loosen the support clamps (2) and remove the re-
ceiver-drier (3).
PTIL21TLB0227AA 1
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Air conditioning - Install - Receiver drier

WARNING
Pressurized system!
Refrigerant under pressure. Service, repair, or recharging must be performed only by trained service
technician.
W1180A
1. Install the receiver drier (3) and tighten the support

clamps (2).
2. Remove plugs from the hoses and caps from the fit-
tings.
3. Install new O-rings and connect the hoses (1) to the
fittings.
4. Remove and discard identification tags that were used
during disassemble.
5. Recharge the refrigerant as specified.
PTIL21TLB0227AA 1
Next operation:
Close the engine hood, see Hood - Install (90.100) .
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Air conditioning - Charging - Evacuation and recharging

1. Follow Machine safety position.
PTIL14TLB0038AA 1
NOTICE: Replace the receiver-drier if one or more of the

following conditions occurs before you remove the air and
moisture from the system.
A. The system has been opened for service before.
B. Receiver-drier has operated two or more years.
C. Disassembly of compressor shows of moisture,
dirt particles (gold or brown in color)
D. Large system leak (broken hose, break in line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to be
open (uncapped) longer than 5 min.
2. Removal of air and moisture from the system is nec-
essary after the refrigerant has been removed after the
system has been opened for maintenance.
3. Air enters the system when the system is opened. Air
has moisture that must be removed to prevent damage
to the system components.
NOTE: The pump on the reclamation unit will not pull a
sufficient vacuum to remove air and moisture.
4. Air and moisture are removed from the system by a
vacuum pump. A vacuum pump is the only equipment
made to lower the pressure enough to change the mois-
ture to vapor that can be removed from the system.
NOTE: Refer to the refrigerant reclamation unit manufac-
turer’s user manual for connection of hoses, evacuation
and recharging.
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Air conditioning - Recover - Refrigerant

1. Follow Machine safety position.
PTIL14TLB0038AA 1
2. Recovered refrigerant must preferably be moisture free

before entering the refrigerant tank of the refrigerant
recovery equipment.
3. If possible, run the air conditioning system for 10 min
before starting the recovery process. Turn the sys-
tem off before proceeding with the recovery. Follow
the equipment manufacturer’s recommendations to re-
cover the refrigerant.
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Air-conditioning compressor - Adjust - Drive belt

1. Open the engine hood.
2. Check the compressor belt deflection by pressing the
center of the belt (5) by hand. The deflection should be
8.0 – 12.0 mm (0.3 – 0.5 in).
3. The compressor drive belt (5) tension can be adjusted
by the rotation of the idler arm (4).
4. Loosen the bolts (3) and adjust the idler arm (4) to a
belt deflection of 8.0 – 12.0 mm (0.3 – 0.5 in).
5. Torque the bolts (3) to 57 N·m.
PTIL21TLB0230AA 1
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Air-conditioning compressor - Remove

WARNING
Explosion hazard!
W0340B
Prior operation:

ommended equipment.
2. Disconnect the compressor clutch connector (1).
3. Disconnect the compressor hoses (2) and plug all
openings.
PTIL21TLB0206AA 1
4. Loosen the belt tension adjusting bolt (3) on the idler

arm (4) and remove the belt (5).
PTIL21TLB0230AA 2
5. Loosen and remove the four mounting bolts (6) along

with washers from the compressor (7) and bracket (8).
ATTENTION: Do not drop the compressor or lift it using the
pulley.
6. Remove the air-conditioning compressor (7) from the
PTIL21TLB0207AA 3
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7. Loosen and remove the bolt (10) along with washers

and remove the bracket (8) from the engine.
PTIL21TLB0208AA 4
8. Loosen and remove the three bolts (11) along with

washers from the compressor mounting bracket (9).
9. Remove the compressor mounting bracket (9) from the
engine.
PTIL21TLB0209AA 5
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Air-conditioning compressor - Install

WARNING
Pressurized system!
technician.
W1180A
1. Position the compressor mounting bracket (9) on the

engine.
2. Install and tighten the three bolts (11) along with wash-
ers to the compressor mounting bracket (9).
PTIL21TLB0209AA 1
3. Install the bracket (8) to the engine and secure with the
bolt (10) along with washers.
PTIL21TLB0208AA 2
4. Position the air-conditioning compressor (7) on the

ATTENTION: Do not drop the compressor or lift it using the
pulley.
5. Install and tighten the four mounting bolts (6) along with
washers to the compressor (7) and bracket (8).
PTIL21TLB0207AA 3
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6. Install the belt (5) and install the idler arm (4) with the
belt tension adjusting bolts (3).
PTIL21TLB0230AA 4
7. Remove the plugs and connect the compressor hoses

(2).
8. Connect the compressor clutch connector (1).
9. Adjust the belt tension, see Air-conditioning com-
pressor - Adjust - Drive belt (50.200) .
10. Recharge the refrigerant.
PTIL21TLB0206AA 5
Next operation:
Close the engine hood, see Hood - Install (90.100).
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Air-conditioning condenser - Remove

WARNING
Explosion hazard!
W0340B
Prior operation:
Prior operation:
Remove the fuel cooler, see Radiator - Remove (10.400).

ommended equipment.
2. Remove the receiver drier (1), see Air conditioning -
Remove - Receiver drier (50.200).
3. Install the identification tags on the hoses (2).
4. Disconnect the hoses (2) from the condenser (3).
5. Install plug in the condenser (3) and hoses (2), cap on
the fittings to prevent any dirt entering the system.
PTIL21TLB0229AA 1
6. Remove the bolts (4) that fasten the condenser (3) to

the after cooler and remove the condenser (3).
NOTICE: Keep the condenser in firm and smooth surface.
Because the condenser fins bend easily, be careful when
you clean the condenser.
PTIL21TLB0228AA 2
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Air-conditioning condenser - Install

WARNING
Pressurized system!
technician.
W1180A
1. Install the condenser (3) to the after cooler and secure

with the bolts (4).
PTIL21TLB0228AA 1
2. Remove the plugs from the condenser (3) and hoses

(2), also the caps from the fittings.
3. Install new O-rings and connect the hoses (2) to the
fittings.
4. Remove and discard identification tags that were used
during disassemble.
5. Install the receiver drier (1). see Air conditioning -
Install - Receiver drier (50.200).
6. Recharge the refrigerant as specified.
PTIL21TLB0229AA 2
Next operation:
Install the fuel cooler, see Radiator - Install (10.400).
Next operation:
Close the engine hood, see Hood - Install (90.100).
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Air-conditioning evaporator - Remove

1. Evacuate the refrigerant.
2. Remove the bolt (1) and seat from the heater assembly.
3. Remove the bolts (3) and cover (2).
4. Disconnect the evaporator connections and cap all
openings.
PTIL14TLB0153AB 1
5. Remove the mounting hardware and lift the evaporator

(1).
ATTENTION: Make sure that the evaporator fins are not
damaged while removal.
PTIL14TLB0152AB 2
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Air-conditioning evaporator - Install

1. Install the evaporator (1) and secure it with mounting
hardware.
ATTENTION: Make sure that the evaporator fins are not
damaged while installing.
2. Remove the caps and connect the evaporator connec-
tions.
PTIL14TLB0152AB 1
3. Install the cover (2) with the bolts (3).

PTIL14TLB0153AB 2
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Index

Air conditioning - Charging - Evacuation and recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air conditioning - Install - Receiver drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air conditioning - Recover - Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air conditioning - Remove - Receiver drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air conditioning - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air-conditioning compressor - Adjust - Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air-conditioning compressor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air-conditioning compressor - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Electrical systems
851FX Plus
851FX
91715732 26/07/2021
55
Contents
Electrical systems - 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
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Electrical system - 000
851FX Plus
851FX
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55.1 [55.000] / 1
Contents
FUNCTIONAL DATA
Electrical system
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Electrical systems - Electrical system
Electrical system - Component identification

Engine/chassis & transmission harness
PTIL13TLB0709FB 1
1. Strap cable 12. Screw

2. Connect to transmission high oil temperature switch 13. Washer
3. Washer 14. Connect ground to engine
4. Screw 15. Connect to 4WD solenoid valve
5. Connect to coolant temperature switch 16. Connect to 4WD solenoid valve
6. Screw 17. Connect to reverse solenoid valve
7. Connect to speed sensor 18. Engine harness
8. Connect to fuel sensor 19. Engine harness
9. Connect to low oil pressure switch 20. Engine harness
10. Connect to alternator D+ 21. Jumper horn harness
11. Connect to alternator B+
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Engine/chassis & transmission harness
PTIL13TLB0710FB 2
1. Connect to rear backhoe horn switch 7. Connect to clutch shutoff switch

2. Connect to chassis ground 8. Connect to unloading valve
3. Transmission harness connection to main harness 9. Connect to RTD sensor
4. Transmission harness 10. Connect to clutch shutoff switch
5. Strap cable 11. Connect to side shift solenoid valve
6. Connect to RTD sensor
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Cabin main harness
PTIL13TLB0711FB 3
1. Front right light - harness 6. Front left light horn - harness

2. Front dashboard wire harness 7. De-clutch harness
3. Ring 8. Tapped boss
4. Strap cable 9. Tapped boss
5. Tapped boss 10. Strap cable
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Cabin main harness
PTIL13TLB0712FB 4
1. Tail lamp harness 5. Ring

2. Strap cable 6. Strap cable
3. Hose tie 7. Main harness
4. Cab harness
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Battery install
PTIL13TLB0713FB 5
1. Battery rubber pad 5. Battery

2. Battery negative cable 6. Washer
3. Battery positive cable 7. Nut
4. Battery frame 8. Hexagonal head bolt
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Index

Electrical system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Harnesses and connectors - 100
851FX Plus
851FX
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Contents
FUNCTIONAL DATA
Electrical components
ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sub-Assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Wiring harnesses
Electrical schematic sheet 03 SH03 - POWER DISTRIBUTION / CHARGING SYSTEM . . . . . . . . . . . . 56
Electrical schematic sheet 04 SH04 - STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Electrical schematic sheet 05 SH05 - COLD START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical schematic sheet 06 SH06 - GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Electrical schematic sheet 07 SH07 - ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Electrical schematic sheet 08 SH08 - DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electrical schematic sheet 09 SH09 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical schematic sheet 10 SH10 - FRONT LIGHTING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Electrical schematic sheet 11 SH11 - FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electrical schematic sheet 12 SH12 - REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical schematic sheet 13 SH13 - WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical schematic sheet 14 SH14 - INSTRUMENT CLUSTER / SPEEDOMETER . . . . . . . . . . . . . . . . 78
Electrical schematic sheet 15 SH15 - HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electrical schematic sheet 16 SH16 - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Electrical schematic sheet 17 SH17 - CAB FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Electrical schematic sheet 18 SH18 - AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical schematic sheet 19 SH19 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical schematic sheet 20 SH20 - DOME LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Electrical schematic sheet 21 SH21 - MOBILE CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Electrical schematic sheet 22 SH22 - TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electrical schematic sheet 23 SH23 - TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical schematic sheet 02 SH02 - POWER DISTRIBUTION / CHARGING SYSTEM / STARTING . 98
Electrical schematic sheet 03 SH03 - POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Electrical schematic sheet 04 SH04 - GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electrical schematic sheet 05 SH05 - ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Electrical schematic sheet 08 SH08 - EXAUST SYTEM AND CAN BUS . . . . . . . . . . . . . . . . . . . . . . . . . 110
Electrical schematic sheet 09 SH09 - PRE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electrical schematic sheet 10 SH10 - DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Electrical schematic sheet 11 SH11 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electrical schematic sheet 12 SH12 - FRONT DRIVING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Electrical schematic sheet 13 SH13 - REAR DRIVING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Electrical schematic sheet 14 SH14 - FRONT WORK LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electrical schematic sheet 15 SH15 - REAR WORK LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electrical schematic sheet 16 SH16 - HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Electrical schematic sheet 17 SH17 - DOME LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Electrical schematic sheet 18 SH18 - WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Electrical schematic sheet 19 SH19 - INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Electrical schematic sheet 20 SH20 - PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Electrical schematic sheet 21 SH21 - SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Electrical schematic sheet 22 SH22 - MOBILE CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Electrical schematic sheet 23 SH23 - CAB FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Electrical schematic sheet 24 SH24 - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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Electrical schematic sheet 25 SH25 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Electrical schematic sheet 26 SH26 - AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Electrical schematic sheet 27 SH27 - TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Electrical schematic sheet 28 SH28 - DIAGNOSTIC/CAN BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Wire connectors
Component diagram 00 Connector X-000 to X-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Component diagram 11 Connector X-110 to X-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Component diagram 11 Connector X-110 to X-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
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Electrical systems - Harnesses and connectors
Electrical components - ECU description

A-001 - COLD START MODULE (ECU)
Component Type ECU

Wiring frames SHEET 05 SH05 - COLD START SYSTEM
Connectors X-160 (Plug) - COLD START MODULE [A-001] (Not Serviceable)
X-160A (Receptacle) - COLD START MODULE [A-001] (87705703)
A-002 - INSTRUMENT CLUSTER (ECU)
Component Type ECU

Wiring frames SHEET 14 SH14 - INSTRUMENT CLUSTER / SPEEDOMETER
Connectors X-116 (Receptacle) - INST. CLUSTER [A-002] (84179604)
X-117 (Receptacle) - INST. CLUSTER 2 [A-002] (84479015)
A-003 - TELEMATICS BOX (ECU)
Component Type ECU

Wiring frames SHEET 22 SH22 - TELEMATICS
Connectors X-005A* (Plug) - TELEMATICS BOX [A-003] (Not Serviceable)
A-004 - INSTRUMENT CLUSTER 1A (ECU)
Component Type ECU

Connectors X-001* (Plug) - INSTRUMENT CLUSTER 1A [A-004] (84179604)
A-005 - INSTRUMENT CLUSTER 1B (ECU)
Component Type ECU

Connectors X-002* (Receptacle) - INSTRUMENT CLUSTER 1B [A-005] (84479015)
A-006 - INSTRUMENT CLUSTER 2A (ECU)
Component Type ECU

Connectors X-003* (Receptacle) - INSTRUMENT CLUSTER 2A [A-006] (51493688)
A-007 - INSTRUMENT CLUSTER 2B (ECU)
Component Type ECU

Connectors X-004* (Plug) - INSTRUMENT CLUSTER 2B [A-007] (84478450)
A-053 - SPEAKERS (ECU)
Component Type ECU

Wiring frames SHEET 18 SH18 - AUDIO
Connectors X-063A (Plug) - RH SPEAKER IN [A-053] (84600637)
X-063B (Plug) - RH SPEAKER IN [A-053] (84600636)
X-072B (Plug) - LH SPEAKER [A-053] (84600636)
X-072A (Plug) - LH SPEAKER [A-053] (84600637)
A-111 - A/C KIT POWER (ECU)
Component Type ECU

Wiring frames SHEET 19 SH19 - HVAC
Connectors X-113 (Plug) - A/C KIT [A-111] (47706988)
X-125 (Receptacle) - A/C POWER [A-111] (47415744)
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A-220 - A/C KIT CONTROL (ECU)
Component Type ECU

Connectors X-220 (Receptacle) - A/C CONTROL [A-220] (47373520)
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Electrical components - Sensor description

B-001 - FUEL LEVEL SENDER (Sensor)
Component Type Sensor

Connectors X-147 (Plug) - FUEL LEVEL SENSOR [B-001] (Not Serviceable)
X-146 (Plug) - FUEL LEVEL SENSOR [B-001] (Not Serviceable)
B-003 - RTD SENSOR (Sensor)

Wiring frames SHEET 16 SH16 - ACCESSORIES
Connectors X-050A (Receptacle) - RTD SENSOR [B-003] (84600602)
B-015 - ENG COOLANT TEMP SENDER (Sensor)

Wiring frames SHEET 07 SH07 - ENGINE CONTROL
Connectors X-003 (Receptacle) - ENG. COOLANT TEMP SENDER [B-015] (84491249)
B-019 - PT SPEED SENSOR (Sensor)

Connectors X-115 (Plug) - SPEED SENSOR [B-019] (84062580)
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Electrical components - Lamp description

E-002 - TURN INDICATOR (Lamp)
Component Type Lamp

Wiring frames SHEET 15 SH15 - HAZARD
Connectors X-141 (Receptacle) - TURN SIGNAL GROUND [E-002] (84491249)
X-139 (Receptacle) - RIGHT TURN INDICATOR [E-002] (84491249)
X-140 (Receptacle) - LEFT TURN INDICATOR [E-002] (84491249)
E-003 - SW. LAMP (Lamp)
Component Type Lamp

Wiring frames SHEET 08 SH08 - DRIVES
E-005 - RIGHT FRONT LIGHT (Lamp)
Component Type Lamp

Wiring frames SHEET 11 SH11 - FRONT LIGHTING
Connectors X-059 (Receptacle) - TO RIGHT FRONT LIGHT [E-005] (47511912)
E-007 - LICENSE PLATE LAMP (Lamp)
Component Type Lamp

Wiring frames SHEET 12 SH12 - REAR LIGHTING
Connectors X-163 (Receptacle) - LICENSE PLATE LAMP 3 [E-007] (84182898)
E-008 - LEFT FRONT LIGHT (Lamp)
Component Type Lamp

Connectors X-112 (Receptacle) - TO LEFT FRONT LIGHT [E-008] (47511912)
E-009 - REAR RIGHT LIGHTS (Lamp)
Component Type Lamp

Connectors X-090 (Receptacle) - REAR RIGHT LIGHT [E-009] (47511912)
E-010 - REAR LEFT LIGHTS (Lamp)
Component Type Lamp

Connectors X-089 (Receptacle) - REAR LEFT LIGHT [E-010] (47511912)
E-011 - FRONT WORK LIGHT 2 (Lamp)
Component Type Lamp

Connectors X-058 (Receptacle) - FRONT HEAD LAMP 2 [E-011] (84182898)
E-012 - REAR WORKING LIGHT 1 (Lamp)
Component Type Lamp

Connectors X-068 (Receptacle) - REAR WORKING LAMP 1 [E-012] (84182898)
E-013 - REAR WORK LIGHT 3 (Lamp)
Component Type Lamp

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E-014 - REAR WORKING LIGHT 2 (Lamp)
Component Type Lamp

Component Type Lamp

E-016 - ROOF LIGHT (Lamp)
Component Type Lamp

Wiring frames SHEET 20 SH20 - DOME LIGHT
Connectors X-062A (Receptacle) - ROOF LIGHT [E-016] (84491249)
X-062B (Receptacle) - ROOF LIGHT [E-016] (84491249)
E-017 - SPEEDOMETER (Lamp)
Component Type Lamp

Connectors X-114 (Plug) - SPEEDOMETER [E-017] (87686679)
Component Type Lamp

Connectors X-071 (Receptacle) - FRONT WORK LAMP 1 [E-018] (84182898)
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Electrical components - Fuse description

F-001 - MAXI FUSE ASSY. (Fuse)
Component Type Fuse

Wiring frames SHEET 04 SH04 - STARTING SYSTEM
Connectors X-008 (Plug) - FUSEBOX-O/P [F-001] (65200449)
X-007 (Plug) - FUSE BOX-I/P [F-001] (Not Serviceable)
F-001A - FRONT LIGHT FUSE (Fuse)
Component Type Fuse

F-002 - MOBILE CHARGER (Fuse)
Component Type Fuse

Wiring frames SHEET 21 SH21 - MOBILE CHARGER
F-003 - FRONT WIPER (Fuse)
Component Type Fuse

F-003A - REAR LIGHT FUSE (Fuse)
Component Type Fuse

F-004 - HORN/HAZARD/BATT+ (Fuse)
Component Type Fuse

F-005 - CAB FAN/RADIO (Fuse)
Component Type Fuse

Wiring frames SHEET 17 SH17 - CAB FAN
F-006 - HAMMER VALVE (Fuse)
Component Type Fuse

F-007 - FRONT WIPER (Fuse)
Component Type Fuse

Wiring frames SHEET 13 SH13 - WIPER/WASHER
F-008 - LOW BEAM FUSE (Fuse)
Component Type Fuse

F-008A - LOW BEAM FUSE (Fuse)
Component Type Fuse

Wiring frames SHEET 10 SH10 - FRONT LIGHTING 1
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F-009 - HIGH BEAM FUSE (Fuse)
Component Type Fuse

F-010 - DOME LIGHT BATT+ (Fuse)
Component Type Fuse

F-011 - HVAC KEY ON POWER (Fuse)
Component Type Fuse

F-012 - LOADER SELF LEVELING (Fuse)
Component Type Fuse

F-013 - SIDE SHIFT LOCK FUSE (Fuse)
Component Type Fuse

Wiring frames SHEET 09 SH09 - HYDRAULICS
F-014 - CLUSTER KEY ON POWER (Fuse)
Component Type Fuse

F-015 - SPEEDOMETER FUSE (Fuse)
Component Type Fuse

F-016 - STOP LIGHT (Fuse)
Component Type Fuse

F-017 - HAZARD/LTS/IGN (Fuse)
Component Type Fuse

F-018 - FUEL SHUT OFF (Fuse)
Component Type Fuse

F-019 - 4WD IGN (Fuse)
Component Type Fuse

F-020 - SHUTTLE CONTROL (Fuse)
Component Type Fuse

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F-021 - STARTER FUSE (Fuse)
Component Type Fuse

Connectors X-010 (Plug) - FUSE STARTER [F-021] (87716284)
Component Type Fuse

Connectors X-032 (Plug) - FUSE HOLDER [F-022] (84177914)
Component Type Fuse

Connectors X-024 (Receptacle) - FUSE HOLDER [F-023] (47435876)
F-024 - FRONT WASHER MOTOR FUSE (Fuse)
Component Type Fuse

Connectors X-164 (Receptacle) - FUSE HOLDER-INLINE [F-024] (47435876)
F-025 - COLD START FUSE (Fuse)
Component Type Fuse

Connectors X-021 (Receptacle) - COLD START FUSE [F-025] (47435876)
F-026 - BEACON FUSE (Fuse)
Component Type Fuse

Connectors X-121 (Receptacle) - BEACON FUSE [F-026] (47435876)
F-028 - REAR WORK LAMP (Fuse)
Component Type Fuse

F-029 - HVAC BATT+ POWER (Fuse)
Component Type Fuse

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Electrical components - Voltage source description

G-001 - BATTERY (Voltage source)
Component Type Voltage source

Wiring frames SHEET 03 SH03 - POWER DISTRIBUTION / CHARGING SYSTEM
Connectors X-300 (Plug) - [G-001] (Not Serviceable)
X-502 (Plug) - [G-001] (Not Serviceable)
G-001A - BATTERY (Voltage source)

Connectors X-300A (Plug) - [G-001A] (Not Serviceable)
X-502A (Plug) - [G-001A] (Not Serviceable)
G-067 - ALTERNATOR (Voltage source)

Connectors X-143 (Receptacle) - ALTERNATOR D+ [G-067] (84179570)
X-001A (Plug) - ALTERNATOR B+ [G-067] (Not Serviceable)
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Electrical components - Ground description

GND-001 - (Ground)
Component Type Ground

GND-001A - (Ground)

GND-001B - DECLUTCH GROUND (Ground)

Wiring frames SHEET 06 SH06 - GROUNDING
GND-002 - CABIN GROUND (Ground)

GND-003 - (Ground)

GND-004 - (Ground)

GND-005 - ENGINE GROUND (Ground)

GND-005A - (Ground)

GND-006 - (Ground)

GND-007 - (Ground)

GND-008 - TRANSMISSION GROUND (Ground)

GND-008A - (Ground)

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GND-009 - (Ground)

GND-010 - (Ground)

GND-011 - (Ground)

GND-012 - (Ground)

GND-013 - (Ground)

GND-015 - (Ground)

GND-016 - (Ground)

GND-017 - (Ground)

GND-018 - (Ground)

GND-019 - (Ground)

GND-020 - (Ground)

GND-027 - FRONT PANEL GROUND (Ground)

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GND-1001 - MAIN GROUND (Ground)

GND-2 - MAIN GROUND (Ground)

GND-2A - ENGINE GROUND (Ground)

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Electrical components - Speaker description

H-001 - RIGHT SPEAKER (Speaker)
Component Type Speaker

Connectors X-042 (Receptacle) - RH SPEAKER [H-001] (84182898)
H-002 - LEFT SPEAKER (Speaker)

Connectors X-064A (Receptacle) - LH SPEAKER [H-002] (84182898)
H-003 - HORN (Speaker)

Connectors X-091 (Plug) - TO HORN [H-003] (Not Serviceable)
X-142 (Plug) - TO HORN [H-003] (Not Serviceable)
H-004 - RADIO (Speaker)

Connectors X-061 (Receptacle) - RADIO [H-004] (84179570)
H-005 - BUZZER (Speaker)

Connectors X-144 (Plug) - BUZZER [H-005] (87679493)
H-007 - BACK-UP ALARM (Speaker)

Connectors X-018 (Plug) - TO BACK-UP ALARM [H-007] (87692855)
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Electrical components - Power outlet description

J-001 - CHARGER SOCKET (Power outlet)
Component Type Power outlet

Connectors X-025C (Receptacle) - CHARGER SOCKET [J-001] (84491249)
X-025B (Receptacle) - CHARGER SOCKET [J-001] (84491249)
X-025A (Receptacle) - CHARGER SOCKET [J-001] (84491249)
J-158 - BEACON SOCKET (Power outlet)

Connectors X-158 (Receptacle) - BEACON SOCKET [J-158] (84015523)
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Electrical components - Relay description

K-001 - ENGINE STARTER RELAY (Relay)
Component Type Relay

Connectors X-111 (Receptacle) - ST.RELAY [K-001] (84369037)
K-002 - HAND BRAKEALARM ON/SPEED ALARM RELAY (Relay)

K-003 - NEUTRAL RELAY (Relay)

Connectors X-101 (Receptacle) - RELAY ALARM HAND BRAKE & SPE [K-003] (47781081)
K-004 - LOADER SELF LEVELING RELAY (Relay)

Connectors X-103 (Receptacle) - RELAY LOADER SEF LEVEL / REAR WO [K-004] (47781081)
K-005 - HEAD LAMP HIGH BEAM RELAY (Relay)

Connectors X-100 (Receptacle) - RELAY TRANS. FORW. & REV. / [K-005] (47781081)
K-006 - TRANSMISSION FORWORD/REVERSE RELAY (Relay)

K-008 - FRONT LIGHTS RELAY (Relay)

K-009 - REAR WORK LIGHT RELAY (Relay)

K-010 - SHUTTLE CONTROL REVERSE (Relay)

Connectors X-108 (Receptacle) - RELAY SHUTTLE CONTROL REV. / FOR [K-010] (47781081)
K-011 - SHUTTLE CONTROL FORWARD (Relay)

K-012 - LOW BEAM RELAY (Relay)

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Connectors X-106 (Receptacle) - RELAY LOW BEAM / FRONT WORK LIGH [K-012] (47781081)
K-013 - REAR WORK LAMP (Relay)

Connectors X-166 (Receptacle) - REAR WORK LAMP [K-013] (84369037)
K-030 - FLASHER RELAY (Relay)

Connectors X-030 (Receptacle) - FLASHER [K-030] (84479009)
K-105 - A/C COMPRESSOR RELAY (Relay)

Connectors X-123 (Receptacle) - A/C RELAY [K-105] (84369037)
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LMP-002 - (Lamp)
Component Type Lamp

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Electrical components - Motor description

M-001 - CABIN FAN (Motor)
Component Type Motor

Connectors X-069 (Receptacle) - CABIN FAN [M-001] (84182898)
M-003 - REAR WASHER MOTOR (Motor)

Connectors X-150 (Receptacle) - REAR WASHER MOTOR [M-003] (87693325)
M-004 - STARTER MOTOR (Motor)

Connectors X-005 (Plug) - STARTER MOTOR [M-004] (Not Serviceable)
X-006 (Receptacle) - STARTER SOLENOID [M-004] (84491249)
M-006 - A/C CLUTCH (Motor)

Connectors X-131 (Plug) - A/C CLUTCH [M-006] (87693744)
X-064* (Plug) - [M-006] (2WF 090)
M-009 - FRONT WASHER MOTOR (Motor)

Connectors X-149 (Receptacle) - FRONT WASHER MOTOR [M-009] (87693325)
M-064 - FRONT WIPER MOTOR (Motor)

Connectors X-070 (Receptacle) - WIPER MOTOR [M-064] (84182898)
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Electrical components - Resistor description

R-001 - GLOW PLUG (Resistor)
Component Type Resistor

Connectors X-001 (Plug) - TO GLOW PLUG [R-001] (87745375)
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Electrical components - Switch description

S-002 - BRAKE DECLUTCH (Switch)
Component Type Switch

Connectors X-051 (Receptacle) - DECLUTCH SW [S-002] (87716755)
S-004 - RADIO SW (Switch)

Connectors X-138 (Receptacle) - RADIO SW [S-004] (87716755)
S-006 - HYDRAULIC FILTER RESTRICTION SWITCH (Switch)

Connectors X-009B (Receptacle) - HYDRAULIC FILTER [S-006] (84491249)
X-009A (Receptacle) - HYDRAULIC FILTER [S-006] (84491249)
S-007 - ENG WATER TEMP SWITCH (Switch)

Connectors X-002 (Receptacle) - ENG. COOLANT TEMP SWITCH [S-007] (84491249)
S-008 - ENGINE OIL PRESSURE SW (Switch)

Connectors X-004A (Receptacle) - LOW PRESSURE SWITCH [S-008] (84491249)
S-009 - RHS COMBINATION SW (Switch)

Connectors X-034 (Plug) - RHS COMBINATION SWITCH [S-009] (84600631)
X-037 (Plug) - COMBINATION SWITCH [S-009] (47461910)
S-010 - BUZZER (Switch)

Connectors X-145 (Plug) - BUZZER [S-010] (47415745)
S-011 - FRONT WORK LIGHTS SW (Switch)

Connectors X-074 (Receptacle) - FR WORKING LIGHT SW. [S-011] (87716755)
S-012 - REAR WORK LIGHT SW (Switch)

Connectors X-077 (Receptacle) - REAR WORK LIGHT SW. [S-012] (87716755)
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S-013 - RADIO ANTENNA (Switch)

Connectors X-061A (Receptacle) - RADIO ANTENNA [S-013] (84369030)
X-061B (Plug) - [S-013] (2FT)
S-014 - WIPER MOTOR (Switch)

Connectors X-162 (Receptacle) - REAR WIPER MOTOR [S-014] (87680380)
S-015 - BEACON SWITCH (Switch)

Connectors X-079 (Receptacle) - BEACON SW. [S-015] (87716755)
S-016 - REAR WIPER/WASHER SW (Switch)

Connectors X-161 (Receptacle) - TO REAR WIPER/WASHER SWITCH [S-016] (87632724)
S-017 - IGNITION SWITCH (Switch)

Connectors X-026C (Plug) - [S-017] (3302911)
X-026B (Plug) - [S-017] (3302911)
X-026A (Plug) - [S-017] (3302911)
S-018 - CLUTCH SHUT OFF SW 2 (Switch)

Connectors X-049A (Receptacle) - CLUTCH SHUT OFF SW. [S-018] (84182898)
S-019 - SIDE SHIFT LOCKING SW (Switch)

Connectors X-078 (Receptacle) - SIDE SHIFT LOCK SW. [S-019] (87716755)
S-020 - CAB FAN SW (Switch)

Connectors X-076 (Receptacle) - CAB FAN SW. [S-020] (87716755)
S-021 - BATT. DISCONNECT SWITCH (Switch)

S-022 - (Switch)

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S-023 - (Switch)


S-025 - FOOT SWITCH (Switch)

Connectors X-075 (Plug) - FOOT SWITCH [S-025] (87706470)

Connectors X-044A (Receptacle) - CLUTCH SHUT OFF SW. [S-026] (84182898)
S-027 - PARK BRAKE LIMIT SW (Switch)

Connectors X-027 (Receptacle) - PARK BRAKE LIMIT SW. [S-027] (84606396)
S-028 - (Switch)

S-029 - REAR BACKHOE HORN SWITCH (Switch)

Connectors X-048B (Plug) - TO REAR HORN SWITCH [S-029] (87581782)
X-048A (Plug) - TO REAR HORN SWITCH [S-029] (87581782)
S-030 - TRANSMISSION HIGH OIL TEMP SW (Switch)

Connectors X-011 (Receptacle) - TRANS HIGH OIL TEMP SW. [S-030] (84062580)
S-035 - LHS COMBINATION SW (Switch)

SHEET 10 SH10 - FRONT LIGHTING 1
Connectors X-035 (Receptacle) - LHS COMBINATION SWITCH [S-035] (84600543)
S-037 - HAZARD SWITCH (Switch)

Connectors X-151 (Receptacle) - HAZARD SW. [S-037] (87632725)
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S-038 - BRAKE OIL LEVEL SWITCH (Switch)

Connectors X-038 (Plug) - BRAKE FLUID BOTTLE SW. [S-038] (84417509)
S-043 - 4WD SWITCH (Switch)

Connectors X-043 (Receptacle) - 4WD SW. [S-043] (87716755)
S-069 - A/C PRESSURE SW (Switch)

Connectors X-132 (Receptacle) - A/C PRESSURE SW [S-069] (87679438)
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Electrical components - Solenoid description

Y-001 - REVERSE SPEED SOL VALVE (Solenoid)
Component Type Solenoid

Connectors X-013 (Receptacle) - REV SPEED SOL. VALVE [Y-001] (87695582)
Y-002 - FORWARD SPEED SOL VALVE (Solenoid)

Connectors X-012 (Receptacle) - FOR SPEED SOL. VALVE [Y-002] (87695582)
Y-003 - 4WD SOLENOID VALVE (Solenoid)

Connectors X-014 (Receptacle) - 4WD SOL. VALVE [Y-003] (87695582)
Y-004 - HIGH SPEED SOLENOID (UNLOADING VALVE) (Solenoid)

Connectors X-045A (Receptacle) - UNLOADING VALVE [Y-004] (84607243)
Y-005 - RTD SOLENOID (Solenoid)

Connectors X-046A (Receptacle) - RTD SOLENOID [Y-005] (87695582)
Y-006 - SIDE SHIFT LOCK SOLENOID VALVE (Solenoid)

Connectors X-047 (Receptacle) - SIDE SHIFT LOCK SOL.VALVE [Y-006] (84607243)
Y-007 - FUEL SHUT OFF SOLENOID (Solenoid)

Connectors X-135 (Receptacle) - FUEL SHUT OFF [Y-007] (87687239)
Y-007A - FUEL SHUT OFF SOLENOID (Solenoid)

Connectors X-135B (Plug) - TO FUEL SHUT OFF [Y-007A] (87581782)
Y-008 - HAMMER_VALVE (Solenoid)

Connectors X-073 (Receptacle) - HAMMER_VALVE [Y-008] (84600619)
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Electrical components - ECU description

A-001 - ENGINE CONTROLLER UNIT (ECU)
Component Type ECU

SHEET 06 SH06 - ENGINE CONTROL
SHEET 07 SH07 - ENGINE CONTROL
Connectors X-462 (Receptacle) - ECU [A-001] (84474053)
A-002 - INSTRUMENT CLUSTER (ECU)
Component Type ECU

Wiring frames SHEET 19 SH19 - INSTRUMENT CLUSTER
Connectors X-CN1 (Receptacle) - CLUSTER CN1 [A-002] (82016219)
X-CN2 (Receptacle) - CLUSTER CN2 [A-002] (82028493)
A-003 - TELEMATICS (ECU)
Component Type ECU

Connectors X-005 (Receptacle) - TELEMATICS [A-003] (51452976)
A-004 - SPEEDOMETER (ECU)
Component Type ECU

Wiring frames SHEET 21 SH21 - SPEEDOMETER
Connectors X-114 (Plug) - SPEEDOMETER [A-004] (87686679)
A-005 - DIAGNOSTIC PORT (ECU)
Component Type ECU

Wiring frames SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
Connectors X-031 (Plug) - DIAGNOSTIC PORT [A-005] (87736919)
A-006 - RADIO (ECU)
Component Type ECU

Connectors X-061 (Receptacle) - RADIO [A-006] (84179570)
X-064 (Receptacle) - LH SPEAKER [A-006] (84182898)
X-042 (Receptacle) - RH SPEAKER [A-006] (84182898)
A-008 - HCU (ECU)
Component Type ECU

Wiring frames SHEET 09 SH09 - PRE START
Connectors X-612 (Receptacle) - HEATER CONTROL UNIT [A-008] (47514457)
A-009 - PUMP MODULE (ECU)
Component Type ECU

Connectors X-605 (Receptacle) - DNOX SUPPLY MODULE [A-009] (84152570)
A-010 - GCU (ECU)
Component Type ECU

Connectors X-469 (Receptacle) - GCU [A-010] (84356962)
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A-013 - J-CASE FUSE HOLDER (ECU)
Component Type ECU

Connectors X-P13 (Plug) - [A-013] (Not serviceable)
X-475 (Receptacle) - J-CASE FUSE HOLDER [A-013] (87693326)
A-014 - HAND THROTTLE (ECU)
Component Type ECU

Connectors X-056 (Plug) - HAND THROTTLE [A-014] (47587518)
A-015 - FOOT THROTTLE (ECU)
Component Type ECU

Connectors X-155 (Plug) - FOOT THROTTLE [A-015] (47416268)
A-016 - USB PORT (ECU)
Component Type ECU

Connectors X-009 (Plug) - USB PORT [A-016] (47906572)
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Electrical components - Sensor description

B-001 - SCR TANK HEATING VALVE (Sensor)

Connectors X-130 (Receptacle) - SCR TANK HEATING VALVE [B-001] (84146685)
B-003 - RTD SENSOR (Sensor)

Connectors X-085 (Receptacle) - RTD SENSOR [B-003] (84600602)
B-007 - WIF SWITCH (Sensor)

Connectors X-463 (Receptacle) - WATER IN FUEL SWITCH [B-007] (87709663)
B-009 - CATALYST TEMP (DOWNSTREAM) (Sensor)

Connectors X-618 (Receptacle) - CATALYST TEMP (DOWNSTREAM) [B-009] (84532147)
B-010 - AIR TEMP SENSOR (Sensor)

Connectors X-474 (Receptacle) - AIR TEMP SENSOR [B-010] (84607243)
B-011 - CATALYST TEMP (UPSTREAM) (Sensor)

Connectors X-617 (Receptacle) - CAT TEMP SENSOR UPSTREAM [B-011] (84532147)
B-012 - NOX SENSOR UPSTREAM (Sensor)

Wiring frames SHEET 08 SH08 - EXAUST SYTEM AND CAN BUS
Connectors X-607 (Receptacle) - NOX SENSOR UPSTREAM [B-012] (47514978)
B-013 - UREA SESNOR QUALITY/TEMP/LEVEL (Sensor)

Connectors X-608 (Receptacle) - UREA SENSOR [B-013] (87688719)
B-014 - NOX DOWNSTREAM SENSOR (Sensor)

Connectors X-606 (Receptacle) - NOX SENSOR DOWNSTREAM [B-014] (47514978)
B-015 - NH3 SENSOR (Sensor)

Connectors X-624 (Receptacle) - NH3 SENSOR [B-015] (84146686)
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B-016 - RADIO ANTENNA (Sensor)

Connectors X-061A (Receptacle) - RADIO ANTENNA [B-016] (84369030)
X-061B (Plug) - [B-016] (2FT)
B-019 - PT SPEED SENSOR (Sensor)

Connectors X-115 (Plug) - SPEED SENSOR [B-019] (84062580)
B-9001 - BOOST PRESSURE AND TEMPERATURE SENSOR (Sensor)

Connectors X-9003 (Plug) - BOOST PRESSURE AND TEMPERATURE S [B-9001] (87709809)
B-9002 - FUEL TEMPERATURE SENSOR (T) (Sensor)

Connectors X-9005 (Receptacle) - FUEL TEMPERATURE SENSOR (T) [B-9002] (87709793)
B-9003 - COOLANT TEMPERATURE SENSOR (T) (Sensor)

Connectors X-9006 (Receptacle) - COOLANT TEMPERATURE SENSOR (T) [B-9003]
(87709793)
B-9004 - RAIL PRESSURE SENSOR (P) (Sensor)

Connectors X-9026 (Receptacle) - RAIL PRESSURE SENSOR (P) [B-9004] (84146683)
B-9005 - EXHAUST GAS ABSOLUTE PRESSURE SENSOR (Sensor)

Connectors X-9018 (Plug) - EXHAUST GAS ABSOLUTE PRESSURE SE [B-9005] (84146681)
B-9007 - INCREMENT SPEED SENSOR (CRANKSHAFT) (Sensor)

Connectors X-9021 (Plug) - INCREMENT SPEED SENSOR (CRANKSHA [B-9007] (Not
Serviceable)
B-9017 - SEGMENT SPEED SENSOR (CAMSHAFT) (Sensor)

Connectors X-9008 (Plug) - SEGMENT SPEED SENSOR (CAMSHAFT)â [B-9017] (Not
Serviceable)
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B-9018 - EXHAUST MANIFOLD TEMPERATURE SENSOR (Sensor)

Connectors X-9009 (Plug) - EXHAUST MANIFOLD TEMPERATURE SEN [B-9018] (Not
Serviceable)
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E-001 - LEFT FRONT DRIVING LIGHT (Lamp)
Component Type Lamp

Wiring frames SHEET 12 SH12 - FRONT DRIVING LIGHTS
Connectors X-112 (Receptacle) - TO LEFT FRONT LIGHT [E-001] (47511912)
E-002 - RIGHT DRIVING LIGHT (Lamp)
Component Type Lamp

Connectors X-112A (Receptacle) - TO RIGHT FRONT LIGHT [E-002] (47511912)
E-002A - TURN INDICATOR (Lamp)
Component Type Lamp

Connectors X-141 (Plug) - TURN SIGNAL GROUND [E-002A] (87705140)
X-139 (Plug) - RIGHT TURN INDICATOR [E-002A] (87705140)
X-140 (Plug) - LEFT TURN INDICATOR [E-002A] (87705140)
Component Type Lamp

Wiring frames SHEET 14 SH14 - FRONT WORK LIGHTS
Connectors X-071 (Receptacle) - FRONT WORK LAMP 1 [E-003] (84182898)
Component Type Lamp

Connectors X-058 (Receptacle) - FRONT HEAD LAMP 2 [E-004] (84182898)
Component Type Lamp

Wiring frames SHEET 15 SH15 - REAR WORK LIGHTS
Component Type Lamp

Component Type Lamp

Component Type Lamp

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E-009 - REAR LEFT LIGHTS (Lamp)
Component Type Lamp

Wiring frames SHEET 13 SH13 - REAR DRIVING LIGHTS
Connectors X-089 (Receptacle) - TAIL LIGHTS [E-009] (47511912)
E-010 - REAR RIGHT LIGHTS (Lamp)
Component Type Lamp

Connectors X-090 (Receptacle) - TAIL LIGHTS [E-010] (47511912)
E-011 - LICENSE PLATE LAMP (Lamp)
Component Type Lamp

Connectors X-163 (Receptacle) - LICENSE PLATE LAMP 3 [E-011] (84182898)
E-016 - DOME LIGHT (Lamp)
Component Type Lamp

Connectors X-062A (Receptacle) - ROOF LIGHT [E-016] (84491249)
X-062B (Receptacle) - ROOF LIGHT [E-016] (84491249)
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Electrical components - Fuse description

F-001 - LOW BEAM LIGHTS (Fuse)
Component Type Fuse

F-002 - HIGH BEAM LIGHTS (Fuse)
Component Type Fuse

F-003 - HAZARD LIGHTS / DRIVING LIGHTS (Fuse)
Component Type Fuse

F-004 - BRAKE LIGHTS (Fuse)
Component Type Fuse

F-005 - HAZARD / WORK LIGHT SWITCHES (Fuse)
Component Type Fuse

F-006 - DIAGNOSTIC (Fuse)
Component Type Fuse

Wiring frames SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
F-007 - POWER SOCKET (Fuse)
Component Type Fuse

F-008 - (Fuse)
Component Type Fuse

F-009 - TRANSMISSION (Fuse)
Component Type Fuse

F-010 - FRONT WIPER AND WASHER (Fuse)
Component Type Fuse

F-011 - REAR WASHER AND WIPER (Fuse)
Component Type Fuse

F-012 - CRANK (Fuse)
Component Type Fuse

Wiring frames SHEET 03 SH03 - POWER DISTRIBUTION
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F-013 - SIDE SWITCHES BACKLIGHT (Fuse)
Component Type Fuse

F-014 - B+ (Fuse)
Component Type Fuse

F-015 - IGN (Fuse)
Component Type Fuse

F-016 - (Fuse)
Component Type Fuse

F-025 - FRONT WORK LIGHTS (Fuse)
Component Type Fuse

F-026 - REAR WORKING LIGHTS (Fuse)
Component Type Fuse

F-027 - REAR WORK LIGHTS (Fuse)
Component Type Fuse

F-028 - 4WD (Fuse)
Component Type Fuse

F-029 - SIDE SHIFT LOCK (Fuse)
Component Type Fuse

F-030 - REAR HAMMER (Fuse)
Component Type Fuse

F-031 - CLUSTER ALWAYS-HOT/CLUSTER SWITCHES (Fuse)
Component Type Fuse

F-032 - DOME LIGHT (Fuse)
Component Type Fuse

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F-033 - HVAC (Fuse)
Component Type Fuse

F-034 - CLUSTER IGN (Fuse)
Component Type Fuse

F-035 - RETURN TO DIG (Fuse)
Component Type Fuse

F-036 - CAB FAN/RADIO (Fuse)
Component Type Fuse

F-037 - IGNITION SW (Fuse)
Component Type Fuse

F-038 - TELEMATICS (Fuse)
Component Type Fuse

F-039 - HORN (Fuse)
Component Type Fuse

F-041 - BRAKE SW (Fuse)
Component Type Fuse

Wiring frames SHEET 20 SH20 - PARK BRAKE
F-042 - AUTO SHUTDOWN (Fuse)
Component Type Fuse

F-101 - ENGINE IGNITION (Fuse)
Component Type Fuse

F-102 - EL VALVE / SCR RELAYS B+ (Fuse)
Component Type Fuse

F-103 - ECU B+1 (Fuse)
Component Type Fuse

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F-104 - ECU B+ 2 (Fuse)
Component Type Fuse

F-105 - SCR PUMP MODULE/SCR HEATING VALVE (Fuse)
Component Type Fuse

F-106 - SCR PUMP MODULE (Fuse)
Component Type Fuse

F-107 - TELEMATICS UNSWITCHED (Fuse)
Component Type Fuse

F-112 - AUXULIARY IGNTION (Fuse)
Component Type Fuse

F-200 - (Fuse)
Component Type Fuse

F-201 - MAIN FUSE (Fuse)
Component Type Fuse

Wiring frames SHEET 02 SH02 - POWER DISTRIBUTION / CHARGING SYSTEM / STARTING
Connectors X-P06 (Plug) - [F-201] (Not serviceable)
X-P07 (Plug) - TO MAIN FUSE [F-201] (84176552)
F-202 - BEACON FUSE (Fuse)
Component Type Fuse

Connectors X-121 (Receptacle) - BEACON FUSE [F-202] (47435876)
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Electrical components - Voltage source description

G-001 - BATTERY (Voltage source)

Connectors X-P01 (Plug) - [G-001] (Not serviceable)
X-G02 (Plug) - [G-001] (Not serviceable)
G-002 - ALTERNATOR (Voltage source)

Connectors X-P11 (Plug) - [G-002] (Not serviceable)
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Electrical components - Ground description

GND-001 - (Ground)

GND-002 - (Ground)

SHEET 04 SH04 - GROUNDING
GND-003 - ENGINE HARNESS GROUND - FIREWALL (Ground)

GND-005 - CHASSIS HARNESS GROUND (Ground)

GND-006 - (Ground)

GND-008 - (Ground)

GND-009 - (Ground)

GND-019 - (Ground)

GND-027 - FRONT PANEL GROUND (Ground)

GND-102 - (Ground)

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Electrical components - Speaker description

H-001 - RIGHT SPEAKER (Speaker)

Connectors X-063A (Plug) - RH SPEAKER [H-001] (47763027)
X-063B (Plug) - RH SPEAKER [H-001] (84600636)
H-002 - LEFT SPEAKER (Speaker)

Connectors X-072A (Plug) - LH SPEAKER [H-002] (47763027)
X-072B (Plug) - LH SPEAKER [H-002] (84600636)
H-003 - HORN (Speaker)

Connectors X-142 (Plug) - TO HORN [H-003] (51621244)
X-143 (Plug) - TO HORN [H-003] (51621244)
H-006 - AUDIBLE ALARM (Speaker)

Connectors X-044 (Plug) - AUDIBLE ALARM [H-006] (47415745)
H-007 - BACK-UP ALARM (Speaker)

Connectors X-018 (Plug) - TO BACK-UP ALARM [H-007] (87692855)
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Electrical components - Power outlet description

J-001 - CHARGER SOCKET (Power outlet)

Connectors X-025A (Plug) - CHARGER SOCKET [J-001] (87699736)
X-025B (Plug) - CHARGER SOCKET [J-001] (87705140)
J-002 - JUNCTION BLOCK (Power outlet)

Connectors X-P09 (Plug) - [J-002] (Not serviceable)
X-P10 (Plug) - [J-002] (Not serviceable)
X-P12 (Plug) - [J-002] (Not serviceable)
X-133 (Plug) - TO STARTER [J-002] (47663693)
J-158 - BEACON SOCKET (Power outlet)

Connectors X-158 (Receptacle) - BEACON SOCKET [J-158] (84015523)
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Electrical components - Relay description

K-001 - LOW BEAM RELAY (Relay)

K-002 - HIGH BEAM RELAY (Relay)

K-003 - FORWARD RELAY (Relay)

K-004 - REVERSE RELAY (Relay)

K-005 - TRANSMISSION CUTOUT RELAY (Relay)

K-006 - NEUTRAL RELAY (Relay)

K-010 - FRONT WORK LIGHTS RELAY (Relay)

K-011 - REAR WORKING LIGHTS RELAY (Relay)

K-012 - PARK BRAKE RELAY (Relay)

K-013 - REAR WORKING LIGHTS RELAY (Relay)

K-014 - RETURN TO DIG RELAY (Relay)

K-015 - AUTO SHUTDOWN (Relay)

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K-025 - SHUTDOWN POWER RELAY 1 (Relay)

Connectors X-003 (Receptacle) - SHUTDOWN POWER RELAY 1 [K-025] (84297431)
K-026 - SHUTDOWN POWER RELAY 2 (Relay)

Connectors X-004 (Receptacle) - SHUTDOWN POWER RELAY 2 [K-026] (84297431)
K-030 - FLASHER RELAY (Relay)

Connectors X-030 (Receptacle) - FLASHER [K-030] (84479009)
K-100 - MAIN ECU RELAY (Relay)

Connectors X-108 (Receptacle) - MAIN ECU RELAY [K-100] (84297431)
K-101 - AUXILIARY MAIN RELAY (Relay)

K-102 - SCR MAIN RELAY (Relay)

K-103 - ECU START INTERLOCK RELAY (Relay)

K-104 - NEUTRAL START INTERLOCK RELAY (Relay)

K-125 - STARTER RELAY (Relay)

Connectors X-103 (Receptacle) - STARTER RELAY [K-125] (84297431)
K-200 - A/C COMPRESSOR RELAY (Relay)

Connectors X-123 (Receptacle) - A/C RELAY [K-200] (84297431)
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Electrical components - Motor description

M-001 - STARTER (Motor)

Connectors X-P04 (Plug) - [M-001] (Not serviceable)
X-006 (Plug) - STARTER SOLENOID [M-001] (87679490)
M-003 - REAR WASHER MOTOR (Motor)

Connectors X-150 (Receptacle) - REAR WASHER MOTOR [M-003] (87693325)
M-005 - CABIN FAN (Motor)

Connectors X-069 (Receptacle) - CABIN FAN [M-005] (84182898)
M-006 - A/C CLUTCH (Motor)

Connectors X-131 (Plug) - A/C CLUTCH [M-006] (87687239)
X-064A (Plug) - [M-006] (2WF 090)
M-009 - FRONT WASHER MOTOR (Motor)

Connectors X-149 (Receptacle) - FRONT WASHER MOTOR [M-009] (87693325)
M-064 - FRONT WIPER MOTOR (Motor)

Connectors X-070 (Receptacle) - WIPER MOTOR [M-064] (84182898)
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Electrical components - Resistor description

R-001 - CAN BUS TERMINATING RESISTOR (Resistor)

Connectors X-460 (Plug) - CAN BUS TERMINATING RESISTOR [R-001] (47416266)
R-002 - FUEL LEVEL SENDER (Resistor)

Connectors X-146 (Receptacle) - FUEL LEVEL SENDER [R-002] (84381192)
R-003 - (Resistor)

R-030 - TRANSMISSION OIL TEMPERATURE (Resistor)

Connectors X-011 (Plug) - TRANSMISSION OIL TEMPERATURE [R-030] (84062580)
R-9001 - GLOW PLUG - CYLINDER 1 (Resistor)

Connectors X-9034 (Plug) - GLOW PLUG - CYLINDER 1 [R-9001] (1-928-404-879)



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Electrical components - Switch description

S-001 - IGNITION SWITCH (Switch)

Connectors X-118 (Receptacle) - IGNITION SWITCH [S-001] (84599241)
X-119 (Plug) - IGNITION SWITCH [S-001] (87714250)
S-002 - DISCONNECT SWITCH (Switch)

Connectors X-P02 (Plug) - [S-002] (Not serviceable)
S-004 - RADIO SWITCH (Switch)

Connectors X-138 (Receptacle) - RADIO SWITCH [S-004] (87716755)
S-006 - HYDRAULIC FILTER RESTRICTION SWITCH (Switch)

Connectors X-009A (Receptacle) - HYDRAULIC FILTER [S-006] (87679525)

Connectors X-034 (Plug) - RHS COMBINATION SWITCH [S-009] (84600631)
X-037 (Plug) - COMBINATION SWITCH [S-009] (47461910)
S-010 - BRAKE DECLUTCH SWITCH (Switch)

Connectors X-051 (Receptacle) - BRAKE DECLUTCH SWITCH [S-010] (87716755)
S-011 - FRONT WORK LIGHTS SWITCH (Switch)

Connectors X-074 (Receptacle) - FRONT WORK LIGHTS SWITCH [S-011] (87716755)
S-012 - REAR WORK LIGHTS SWITCH (Switch)

Connectors X-077 (Receptacle) - REAR WORK LIGHTS SWITCH [S-012] (87716755)
S-014 - WIPER MOTOR (Switch)

Connectors X-162 (Receptacle) - REAR WIPER MOTOR [S-014] (87680380)
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S-015 - BEACON SWITCH (Switch)

Connectors X-079 (Receptacle) - BEACON SWITCH [S-015] (87716755)
S-016 - REAR WIPER /WASHER SWITCH (Switch)

Connectors X-161 (Receptacle) - REAR WIPER SWITCH [S-016] (87632724)

Connectors X-083 (Receptacle) - CLUTCH SHUT OFF SW. [S-018] (84182898)
S-019 - SIDE SHIFT LOCK SWITCH (Switch)

Connectors X-078 (Receptacle) - SIDE SHIFT LOCK SWITCH [S-019] (87716755)
S-020 - CAB FAN SWITCH (Switch)

Connectors X-076 (Receptacle) - CAB FAN SWITCH [S-020] (87716755)
S-022 - BRAKE SWITCH (Switch)

S-023 - BRAKE SWITCH (Switch)


S-025 - FOOT SWITCH (Switch)

Connectors X-075 (Plug) - FOOT SWITCH [S-025] (87692877)

Connectors X-082 (Receptacle) - CLUTCH SHUT OFF SW. [S-026] (84182898)
S-027 - PARK BRAKE SWITCH (Switch)

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Connectors X-027 (Plug) - PARK BRAKE SWITCH [S-027] (47587518)
S-029 - REAR BACKHOE HORN SWITCH (Switch)

Connectors X-048 (Receptacle) - TO REAR HORN SWITCH [S-029] (84182898)
S-031 - UP/DOWN CONTROL SW (Switch)

Connectors X-116 (Receptacle) - UP/DOWN SW [S-031] (87716755)
S-032 - DISPLAY/ENTER CONTROL SW (Switch)

Connectors X-117 (Receptacle) - DISPLAY/ENTER CONTROL SW [S-032] (87716755)
S-033 - AIR FILTER SW (Switch)

Connectors X-023A (Plug) - AIR FILTER SW [S-033] (87705127)
X-026 (Plug) - AIR FILTER SW [S-033] (87705127)
S-035 - LHS COMBINATION SW (Switch)

SHEET 12 SH12 - FRONT DRIVING LIGHTS
Connectors X-035 (Receptacle) - LHS COMBINATION SWITCH [S-035] (84600543)
S-037 - HAZARD SWITCH (Switch)

Connectors X-151 (Receptacle) - HAZARD SWITCH [S-037] (87632725)
S-039 - AUTO IDLE SWITCH (Switch)

Connectors X-135 (Receptacle) - AUTO IDLE [S-039] (87716755)
S-040 - ECO MODE SWITCH (Switch)

Connectors X-124 (Receptacle) - ECO MODE SWITCH [S-040] (87716755)
S-041 - BRAKE OIL LEVEL SWITCH (Switch)

Connectors X-038A (Plug) - [S-041] (87581782)
X-038B (Plug) - [S-041] (87581782)
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S-043 - 2WD SWITCH (Switch)

Connectors X-043 (Receptacle) - 2WD SWITCH [S-043] (87716755)
S-044 - SEAT SWITCH (Switch)

Connectors X-046 (Receptacle) - SEAT SWITCH [S-044] (84600602)
S-069 - A/C PRESSURE SW (Switch)

Connectors X-132 (Receptacle) - A/C PRESSURE SW [S-069] (87679438)
S-9016 - OIL PRESSURE SWITCH (Switch)

Connectors X-9016 (Plug) - OIL PRESSURE SWITCH [S-9016] (87687239)
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Electrical components - Solenoid description

Y-001 - REVERSE SPEED SOL VALVE (Solenoid)

Connectors X-013 (Plug) - REVERSE SPEED SOLENOID VALVE (BL [Y-001] (47933788)
Y-002 - FORWARD SPEED SOL VALVE (Solenoid)

Connectors X-012 (Plug) - FORWARD SPEED SOLENOID VALVE (YE [Y-002] (47933796)
Y-003 - 2WD SOLENOID VALVE (Solenoid)

Connectors X-014A (Plug) - 4WD SOLENOID VALVE (BK) [Y-003] (87695900)
Y-004 - HIGH SPEED SOLENOID (UNLOADING VALVE) (Solenoid)

Connectors X-045 (Receptacle) - UNLOADING VALVE [Y-004] (84607243)
Y-005 - RTD SOLENOID (Solenoid)

Connectors X-084 (Plug) - RTD SOLENOID [Y-005] (87695900)
Y-006 - SIDE SHIFT LOCK SOLENOID VALVE (Solenoid)

Connectors X-047 (Receptacle) - SIDE SHIFT LOCK SOL.VALVE [Y-006] (84607243)
Y-008 - HAMMER_VALVE (Solenoid)

Connectors X-073 (Receptacle) - HAMMER_VALVE [Y-008] (84600619)
Y-101 - REDUCTION AGENT DOSING VALVE (Solenoid)

Connectors X-128 (Receptacle) - DOSING VALVE [Y-101] (87709793)
Y-9000 - FUEL METERING UNIT HP FUEL PUMP (Solenoid)

Connectors X-9007 (Plug) - FUEL METERING UNIT HP FUEL PUMP [Y-9000] (87709798)
Y-9001 - INJECTOR 1 (Solenoid)

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Connectors X-9030A (Plug) - INJECTOR 1 [Y-9001] (Not Serviceable)

X-9030 (Plug) - INJECTOR 1 [Y-9001] (Not Serviceable)



Y-9008 - WASTEGATE PRESSURE MODULATOR VALVE (Solenoid)

Connectors X-9038 (Plug) - WASTEGATE PRESSURE MODULATOR VAL [Y-9008] (Not
Serviceable)
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Electrical components - Sub-Assembly description

Z-9000 - EXHAUST GAS RECIRCULATION (EGR) VALVE (Sub-Assembly)
Component Type Sub-Assembly

Connectors X-9010 (Receptacle) - EXHAUST GAS RECIRCULATION (EGR) [Z-9000] (84360293)
Z-9001 - THROTTLE VALVE ACTUATOR (Sub-Assembly)
Component Type Sub-Assembly

Connectors X-9011 (Receptacle) - THROTTLE VALVE ACTUATOR [Z-9001] (84360293)
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Wiring harnesses - Electrical schematic sheet 03 SH03 - POWER

DISTRIBUTION / CHARGING SYSTEM
Type Component Connector / Link
Voltage source G-001 - BATTERY (Voltage source) X-300 - [G-001] (Not Serviceable)
X-502 - [G-001] (Not Serviceable)
Voltage source G-001A - BATTERY (Voltage source) X-300A - [G-001A] (Not Serviceable)
X-502A - [G-001A] (Not Serviceable)
Voltage source G-067 - ALTERNATOR (Voltage source) X-143 - ALTERNATOR D+ [G-067] (84179570)
X-001A - ALTERNATOR B+ [G-067] (Not Serviceable)
Ground GND-001 - (Ground) GND-001
Ground GND-001A - (Ground) GND-001A
Switch S-021 - BATT. DISCONNECT SWITCH (Switch)
Connector X-001A - ALTERNATOR B+ [G-067] (Not Serviceable)
Connector X-017 - TO MAIN HARNESS (84600598)
Connector X-098 - HARNESS ENGINE (84600605)
Connector X-143 - ALTERNATOR D+ [G-067] (84179570)
Connector X-300 - [G-001] (Not Serviceable)
Connector X-300A - [G-001A] (Not Serviceable)
Connector X-301 - (Not Serviceable)
Connector X-301P - (Not Serviceable)
Connector X-502 - [G-001] (Not Serviceable)
Connector X-502A - [G-001A] (Not Serviceable)
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6 5 4 3 2 1
OPTIONAL BATTERY DISCONNECT SWITCH
D D
G-001A S-021
BATTERY BATT. DISCONNECT SWITCH
X-301 X-302
1 1 2 1
P015 RD 70.0 1 1 1 1 P016* RD 70.0 SH4: B-1
NEG POS
X-502A X-300A X-301P X-302P
12.0 Volts
GND-001A
G-001
BATTERY
1 1
C NEG POS
P017* RD 70.0 SH4: C-1 C
X-502 12.0 Volts X-300
GND-001
X-017
G-067
ALTERNATOR 1020 YE 1.0 4 4 1310 YE 1.0 SH14: D-6
CHARGE 2 X-098
INDICATOR D+ P004* RD 10.0 SH4: B-6
X-143
B A
B+
1
P004 RD 25.0 SH4: B-6
B
X-001A X-017
W
1
PHASE 1030 OR 1.0 3 3 1320 OR 1.0 SH14: D-6
X-143 X-098
GND-002
A A
6 5 4 3 2 1
SHT_3 1
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Wiring harnesses - Electrical schematic sheet 04 SH04 - STARTING SYSTEM

Type Component Connector / Link Type Component Connector / Link
Fuse F-001 - MAXI FUSE ASSY. (Fuse) X-008 - FUSEBOX-O/P [F-001] (65200449) Connector X-007 - FUSE BOX-I/P [F-001] (Not Serviceable)
X-007 - FUSE BOX-I/P [F-001] (Not Serviceable) Connector X-008 - FUSEBOX-O/P [F-001] (65200449)
Fuse F-003 - FRONT WIPER (Fuse) Connector X-016 - TO MAIN HARNESS (84600599)
Fuse F-008 - LOW BEAM FUSE (Fuse) Connector X-021 - COLD START FUSE [F-025] (47435876)
Fuse F-022 - STARTER FUSE (Fuse) X-032 - FUSE HOLDER [F-022] (84177914) Connector X-024 - FUSE HOLDER [F-023] (47435876)
Fuse F-023 - STARTER FUSE (Fuse) X-024 - FUSE HOLDER [F-023] (47435876) Connector X-026A - [S-017] (3302911)
Fuse F-025 - COLD START FUSE (Fuse) X-021 - COLD START FUSE [F-025] (47435876) Connector X-026B - [S-017] (3302911)
Ground GND-003 - (Ground) GND-003 Connector X-026C - [S-017] (3302911)
Motor M-004 - STARTER MOTOR (Motor) X-005 - STARTER MOTOR [M-004] (Not Serviceable) Connector X-032 - FUSE HOLDER [F-022] (84177914)
X-006 - STARTER SOLENOID [M-004] (84491249) Connector X-097 - HARNESS ENGINE (84600603)
Switch S-017 - IGNITION SWITCH (Switch) X-026C - [S-017] (3302911) Connector X-118 - IGN. KEY SW. (84599241)
X-026B - [S-017] (3302911) Connector X-118P - (Not Serviceable)
X-026A - [S-017] (3302911)
Connector X-119P - IGN. KEY SW. (87714250)
Switch S-028 - (Switch)
Connector X-119R - (Not Serviceable)
Connector X-004 - STARTER MOTOR B+ (Not Serviceable)
Connector X-120 - UNSWITCHED POWER (Not Serviceable)
Connector X-005 - STARTER MOTOR [M-004] (Not Serviceable)
Connector X-133 - TO STARTER (47663693)
Connector X-005A - (Not Serviceable)
Connector X-006 - STARTER SOLENOID [M-004] (84491249)
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6 5 4 3 2 1
S-017 SH14: D-6

1502 OR 2.5
IGNITION SWITCH
1503 OR 2.5 SH14: B-6
1518 OR 2.5 SH9: D-6
D SH8: C-6
D
1505 OR 2.5
1519 OR 2.5 SH12: C-6
1
1
1506 OR 2.5 SH16: C-6
X-118 TB80 EXPORT
X-026A X-026C 1501* OR 6.0
X-026B
1 1 1 1 X-119R
TB80 DOMESTIC
5 5 1501 OR 2.5 1522 OR 2.5 SH9: B-6
X-118P
X-120 SP-116
SP-008
TB80 DOMESTIC
6 6 1545 OR 2.5 1523 OR 2.5 SH15: C-6
TB80 EXPORT
TB80 EXPORT 1545* OR 6.0
F-022
1504 OR 2.5 SH21: C-6
1 1 2 2
1150** RD 6.0 40.0 A 1151 RD 6.0
1537 OR 2.0 SH13: B-6
X-032 X-032
7 7 1140 YE 1.5 1539 OR 1.5 SH10: B-6
TB80 DOMESTIC
X-119P SH10: A-6
1150* RD 6.0 1540 OR 1.5
SH12: D-6 P013 RD 2.5

SP-115 SH7: D-6
1509 OR 2.5
C SH11: D-6 1153 RD 2.5 P006 RD 10.0 C
TB80 EXPORT
1536 OR 2.5 SH19: C-6

SH15: D-6 P011 RD 2.5
1550 OR 1.0 SH16: B-6
SH17: C-6 P012 RD 2.5 1550* OR 2.5 SH16: B-6

TB80 DOMESTIC
F-023
SH16: D-6 7092 RD 2.5 2 2 1 1
20.0 A
X-024 X-024
SH20: C-6 P007 RD 2.5
SH13: A-6 P018 RD 1.0 P017* RD 70.0 SH3: C-1

X-016
P002 RD 10.0 1 1
P016* RD 70.0 SH3: D-1
X-097
F-001
MAXI FUSE ASSY. M-004
TB80 DOMESTIC STARTER MOTOR
SH5: D-6 P003* RD 2.5 1
F-008
X-303
TB80 EXPORT 1 1 2
1 2 X-005A 1 PWR
SH5: C-6 P003 RD 6.0 P001 RD 10.0 60.0 A 1090 RD 10.0
GND
X-005 1
B SP-112 X-008 X-008
1
M
B
A
1
SH19: C-6 P005 RD 6.0 F-025
X-006
X-133 F-003 1 2 1
1 2
20.0 A 1130 RD 2.5
TB80 EXPORT 1 1 2
SH3: B-1 P004 RD 25.0 60.0 A X-004
X-007 X-021 X-021
SH3: B-1 P004* RD 10.0
1100 WH 4.0
TB80 DOMESTIC
GND-003
1100* WH 2.5 SH5: D-1

TB80 DOMESTIC
SH5: C-1 1135 RD 2.5
TB80 EXPORT
SH5: B-1 1105 WH 2.5 1120 WH 6.0 SH5: C-1
SP-014
1145 YE 1.5 SH5: A-6

TB80 EXPORT
A A
TB80 DOMESTIC
1140* YE 1.5 SH5: B-6
6 5 4 3 2 1
SHT_4 1
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Wiring harnesses - Electrical schematic sheet 05 SH05 - COLD START

SYSTEM
ECU A-001 - COLD START MODULE (ECU) X-160 - COLD START MODULE [A-001] (Not Serviceable)
X-160A - COLD START MODULE [A-001] (87705703)
Fuse F-021 - STARTER FUSE (Fuse) X-010 - FUSE STARTER [F-021] (87716284)
Relay K-001 - ENGINE STARTER RELAY (Relay) X-111 - ST.RELAY [K-001] (84369037)
Relay K-003 - NEUTRAL RELAY (Relay) X-101 - RELAY ALARM HAND BRAKE & SPE [K-003]
(47781081)
Connector X-010 - FUSE STARTER [F-021] (87716284)
Connector X-010A - 12V INPUT TO COLD START MODULE (Not
Serviceable)
Connector X-010AP - (Not Serviceable)
Connector X-010B - 12V OUTPUT TO COLD START MODULE (Not
Serviceable)
Connector X-010BP - (Not Serviceable)
Connector X-101 - RELAY ALARM HAND BRAKE & SPE [K-003]
(47781081)
Connector X-111 - ST.RELAY [K-001] (84369037)
Connector X-160 - COLD START MODULE [A-001] (Not Serviceable)
Connector X-160A - COLD START MODULE [A-001] (87705703)
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6 5 4 3 2 1
D D
TB80 DOMESTIC TB80 DOMESTIC
SH4: B-6 P003* RD 2.5 1100* WH 2.5 SH4: B-1

K-001
F-021 ENGINE STARTER RELAY
TB80 EXPORT
STARTER FUSE
87A
TB80 EXPORT
2 30 D 1120 WH 6.0 SH4: A-1
1 1 2 A
SH4: B-6 P003 RD 6.0 50.0 A P010 RD 6.0 C
87
X-010 X-010 X-017
TB80 EXPORT
E 85 86 B
SH6: D-6 G103 BK 1.5 1110 YE 1.5 1 1
TB80 EXPORT
X-111 X-111 X-098
1110* YE 1.0
SH6: D-6 G103* BK 1.0
TB80 DOMESTIC TB80 DOMESTIC
C C
TB80 EXPORT
A-001
X-017
COLD START MODULE
SH14: C-6 1401 BR 1.0 6 6 1400 BR 1.0 X-010A
85 1
X-098 SH4: A-6
1 1 1135 RD 2.5
30 X-010AP
SH6: D-6 G030 BK 2.5 X-160
86 87A
SH7: B-1 1420 RD 1.0 1105 WH 2.5 SH4: A-6
X-160A X-160A
X-010B
5
X-160
SH7: A-1 1185 YE 2.5 1 1
X-010BP
B B
TB80 DOMESTIC
1180* YE 1.0
TB80 DOMESTIC
K-003
SH4: A-1 1140* YE 1.5 NEUTRAL RELAY
TB80 EXPORT
87A
10 1180 YE 1.5
30
SH4: A-1 1145 YE 1.5 7
87
TB80 EXPORT
8 85 86 6
SH9: C-1 1190 YE 1.0 G146 BK 1.0 SH6: C-6
X-101 X-101
A A
6 5 4 3 2 1
SHT_5 1
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Wiring harnesses - Electrical schematic sheet 06 SH06 - GROUNDING

Ground GND-001B - DECLUTCH GROUND (Ground) GND-001B Ground GND-2A - ENGINE GROUND (Ground) GND-2A
Ground GND-002 - CABIN GROUND (Ground) GND-002 Connector X-016 - TO MAIN HARNESS (84600599)
Ground GND-004 - (Ground) GND-004 Connector X-022A - TO HARNESS MAIN (84600552)
Ground GND-005 - ENGINE GROUND (Ground) GND-005 Connector X-095 - HARNESS TRANSMISSION (84600606)
Ground GND-005A - (Ground) GND-005A Connector X-097 - HARNESS ENGINE (84600603)
Ground GND-006 - (Ground) GND-006 Connector X-134 - TO GROUND (47663137)
Ground GND-007 - (Ground) GND-007 Connector X-198 - BEACON GROUND (Not Serviceable)
Ground GND-008 - TRANSMISSION GROUND (Ground) GND-008 Connector X-200 - GROUND (Not Serviceable)
Ground GND-008A - (Ground) GND-008A Connector X-201 - ENGINE GROUND (Not Serviceable)
Ground GND-010 - (Ground) GND-010 Connector X-202 - GROUND (84182883)
Ground GND-027 - FRONT PANEL GROUND (Ground) GND-027 Connector X-206 - GROUND (Not Serviceable)
Ground GND-1001 - MAIN GROUND (Ground) GND-1001 Connector X-207 - GROUND (Not Serviceable)
Ground GND-2 - MAIN GROUND (Ground) GND-2 Connector X-208 - GROUND (84606401)
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6 5 4 3 2 1
SH14: A-1 G105 BK 1.0
SH5: C-6 G103* BK 1.0 G181 BK 1.0 SH9: A-1

TB80 DOMESTIC
SH5: C-6 G103 BK 1.5 G182 BK 1.0 SH18: B-1

TB80 EXPORT
SP-G10 X-200
SH14: D-1 G102 BK 1.0 G100 BK 2.5 1 G183 BK 1.0 SH16: C-1
D SH5: C-6 G030 BK 2.5

TB80 EXPORT
D
G184 BK 1.0 SH16: C-1
SP-G18 X-095
1 X-204
SH19: D-1 G223 BK 6.0 1 G180 BK 2.5 G185 BK 1.5 10 10 G142 BK 1.5 SH6: C-6
X-134 X-022A
SH19: A-1 G171 BK 2.0 G186 BK 1.0 SH9: B-1

GND-004
ENGINE GROUND
SH9: D-1 G132 BK 1.0
SP-G13
SH14: D-1 G133 BK 1.5 X-201 GND-008A
G130 BK 2.5 1 TRANSMISSION GROUND
SH9: C-6 G135 BK 1.0 G201 BK 1.5 SH12: D-1
G202 BK 1.0 SH12: C-1
SH9: C-6 G136 BK 1.0 G203 BK 1.5 SH12: C-1

SP-G20
GND-005A G200 BK 2.5 G204 BK 1.5 SH12: D-1
ENGINE GROUND
SH14: D-1 G137 BK 1.0 G205 BK 1.5 SH17: B-1
X-016
C G131 BK 2.5 2 2 C
SH6: D-1 G142 BK 1.5
X-097
X-198
SH8: D-6 G143 BK 1.0 G198 BK 1.0 SH13: A-6
1
G141 BK 2.5
SH10: A-6 G144 BK 1.0
G191 BK 2.0 SH13: B-1
SH18: B-1 G145 BK 1.0

G192 BK 1.5 SH11: D-1
SP-G14 X-202 X-206 SP-G19
SH5: A-1 G146 BK 1.0 G140 BK 4.0 1 1 G190 BK 2.5
G193 BK 1.5 SH11: D-1
SH8: B-4 G147 BK 1.0

G194 BK 1.0 SH18: C-2
SH8: C-6 G148 BK 1.0

GND-010 G195 BK 1.0 SH20: B-1
CABIN GROUND
SH11: C-1 G149 BK 1.0
X-207
GND-006 1 G170 BK 1.0 SH8: A-1
MAIN GROUND
SH12: D-1 G023 BK 1.0
G197 BK 1.0 SH15: A-1
B SH15: B-1 G024 BK 1.0 B

G196 BK 1.0 SH18: B-1
SH21: B-1 G025 BK 1.0

G161 BK 1.5 SH11: B-6
SH10: A-6 G166 BK 1.0

GND-011 G162 BK 1.5 SH11: B-6
DECLUTCH GROUND
SH16: C-1 G212 BK 1.0
G163 BK 1.0 SH15: A-1
X-208 SP-G16
1
G160 BK 2.5
G104 BK 1.0 SH14: A-1
SH16: B-1 G224 BK 1.0
TB80 EXPORT
G206 BK 1.0 SH11: C-1
SH19: B-1 G243 BK 2.5
G211 BK 1.0 SH15: D-1
SH17: B-1 G022 BK 1.0

G172 BK 1.0 SH14: C-1
SH9: D-1 G169 BK 1.0
GND-012
SP-329
FRONT PANEL GROUND
SH12: A-1 G152 BK 1.5 G151 BK 1.5 G020 BK 1.0 SH12: D-6
A G153 BK 1.5
A
SH12: A-1 G021 BK 1.0 SH9: A-1
X-203
G150 BK 4.0 1
SH18: A-1 G154 BK 1.0 G066 BK 1.0 SH14: B-1
SP-G15
SH18: D-1 G155 BK 1.0 G187 BK 1.0 SH18: D-1
GND-007
MAIN GROUND
6 5 4 3 2 1
SHT_6 1
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Wiring harnesses - Electrical schematic sheet 07 SH07 - ENGINE

CONTROL
Sensor B-015 - ENG COOLANT TEMP SENDER (Sensor) X-003 - ENG. COOLANT TEMP SENDER [B-015] (84491249)
Fuse F-018 - FUEL SHUT OFF (Fuse)
Resistor R-001 - GLOW PLUG (Resistor) X-001 - TO GLOW PLUG [R-001] (87745375)
Connector X-001 - TO GLOW PLUG [R-001] (87745375)
Connector X-003 - ENG. COOLANT TEMP SENDER [B-015] (84491249)
Connector X-130R - FUSE BOX (Not Serviceable)
Connector X-135 - FUEL SHUT OFF [Y-007] (87687239)
Connector X-135A - FUEL SHUT OFF (87679525)
Connector X-135B - TO FUEL SHUT OFF [Y-007A] (87581782)
Connector X-135P - FUEL SHUT OFF (87687239)
Solenoid Y-007 - FUEL SHUT OFF SOLENOID (Solenoid) X-135 - FUEL SHUT OFF [Y-007] (87687239)
Solenoid Y-007A - FUEL SHUT OFF SOLENOID (Solenoid) X-135B - TO FUEL SHUT OFF [Y-007A] (87581782)
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6 5 4 3 2 1
D D
SH4: C-1 1509 OR 2.5

X-130R
TB80 DOMESTIC
18 18
Y-007A
F-018 FUEL SHUT OFF SOLENOID
X-017 X-135A
1 P N
1 10.0 A 2
28 28 1510 OR 1.0 12 12 1552* OR 1.0 1 1 1426 RD 1.0
X-130P X-098 X-135P X-135B
GND101
C C
Y-007
TB80 EXPORT FUEL SHUT OFF SOLENOID
SP-015
1 P N
1552 RD 1.0 1425 RD 1.0
X-135
GND-017
1420 RD 1.0 SH5: B-6
B B
B-015
ENG COOLANT TEMP SENDER
X-017
N T P 1
5351 YE 1.0 2 2 7060 YE 0.75 SH14: B-6
X-003 X-098
GND-016
R-001
GLOW PLUG
N P 1
1185 YE 2.5 SH5: B-6
X-001
A A
GND-018
6 5 4 3 2 1
SHT_7 1
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Wiring harnesses - Electrical schematic sheet 08 SH08 - DRIVES

Lamp E-003 - SW. LAMP (Lamp)
Fuse F-020 - SHUTTLE CONTROL (Fuse)
Relay K-006 - TRANSMISSION FORWORD/REVERSE RELAY
(Relay)
Relay K-010 - SHUTTLE CONTROL REVERSE (Relay) X-108 - RELAY SHUTTLE CONTROL REV. / FOR [K-010]
(47781081)
Relay K-011 - SHUTTLE CONTROL FORWARD (Relay)
Switch S-002 - BRAKE DECLUTCH (Switch) X-051 - DECLUTCH SW [S-002] (87716755)
Switch S-018 - CLUTCH SHUT OFF SW 2 (Switch) X-049A - CLUTCH SHUT OFF SW. [S-018] (84182898)
Switch S-026 - CLUTCH SHUT OFF SW 1 (Switch) X-044A - CLUTCH SHUT OFF SW. [S-026] (84182898)
Switch S-035 - LHS COMBINATION SW (Switch) X-035 - LHS COMBINATION SWITCH [S-035] (84600543)
Connector X-019 - HARNESS FRONT PANEL (47731489)
Connector X-022A - TO HARNESS MAIN (84600552)
Connector X-035 - LHS COMBINATION SWITCH [S-035] (84600543)
Connector X-036P - BRAKE DECLUTCH (84606400)
Connector X-036R - COMBINATION SWITCH (84606396)
Connector X-044A - CLUTCH SHUT OFF SW. [S-026] (84182898)
Connector X-049A - CLUTCH SHUT OFF SW. [S-018] (84182898)
Connector X-051 - DECLUTCH SW [S-002] (87716755)
Connector X-057 - DIODE [V-018] (84179570)
Connector X-095 - HARNESS TRANSMISSION (84600606)
Connector X-100 - RELAY TRANS. FORW. & REV. / [K-005] (47781081)
Connector X-107 - TO MAIN (47731490)
Connector X-108 - RELAY SHUTTLE CONTROL REV. / FOR [K-010]
(47781081)
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6 5 4 3 2 1
K-006
TRANSMISSION FORWORD/REVERSE RELAY
X-019 87A 2
5 30
15 15 5280 BR 1.0 87
D X-107
4 D
1 85 86 3
SH6: C-6 G143 BK 1.0 1220 YE 1.0
X-100 X-100
S-035
LHS COMBINATION SW
1 4
5220 BR 1.0
3 IN
5240 BR 1.0
2 6
X-035 5230 BR 1.0
X-035
K-011
SHUTTLE CONTROL FORWARD
87A 7
10 30
87 9
1230 VT 1.0 SH9: C-6
X-019
8 85 86 6
SH6: B-6 G148 BK 1.0 5270 BR 1.0 14 14
X-108 X-108 X-107

SH4: D-1 1505 OR 2.5
C C
X-130R
20 20
F-020
SP-121
1 2
10.0 A 30 30 19E1 OR 1.5 19E2 OR 1.0 19E3 OR 1.0
X-095
X-130P
6 6 19E8 OR 1.0
X-022A
K-010
SHUTTLE CONTROL REVERSE
87A
5 30 2
19E4 OR 1.0 87 4
7083 WH 1.0 SH9: C-6
X-019
1 85 86 3
SH6: B-6 G147 BK 1.0 5260 BR 1.0 6 6
X-107
X-108 X-108
S-026
CLUTCH SHUT OFF SW 1
1 2 1 2
SP-204 19E6 OR
19E7 OR 1.0
1.0 2031 YE 1.0
X-095 SP-122
B X-044A X-044A
SP-203 2030 YE 1.0 3 3 1221 YE 1.0
B
S-018
CLUTCH SHUT OFF SW 2 X-022A
X-019 X-036R
1 2 1 2
19E5 OR 1.0 2032 YE 1.0 1222 YE 1.0 1 1 2150 YE 1.0 1 1 2070 YE 1.0
X-049A X-049A X-107 X-036P
SWITCH CLOSES WHEN THE OPERATOR

PRESSES THE DECLUTCH BUTTON
S-002 BRAKE DECLUTCH WILL BE ENABLED WHEN

BRAKE DECLUTCH THE SWITCH IS IN CLOSED POSITION
2 2 1 3
SH12: B-1 4411 VT 1.0 2062 YE 1.0
X-051 X-051
V-018
A DIODE 4 A
7 N P 8 1 2
P N
2061 YE 1.0 2060 YE 1.0
X-051 SP-206 X-057 X-057

X-051
G170 BK 1.0 SH6: B-1
6 5 4 3 2 1
SHT_8 1
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Wiring harnesses - Electrical schematic sheet 09 SH09 - HYDRAULICS

Fuse F-013 - SIDE SHIFT LOCK FUSE (Fuse)
Fuse F-019 - 4WD IGN (Fuse)
Switch S-019 - SIDE SHIFT LOCKING SW (Switch) X-078 - SIDE SHIFT LOCK SW. [S-019] (87716755)
Switch S-043 - 4WD SWITCH (Switch) X-043 - 4WD SW. [S-043] (87716755)
Connector X-012 - FOR SPEED SOL. VALVE [Y-002] (87695582)
Connector X-013 - REV SPEED SOL. VALVE [Y-001] (87695582)
Connector X-014 - 4WD SOL. VALVE [Y-003] (87695582)
Connector X-022A - TO HARNESS MAIN (84600552)
Connector X-031 - DIODE-1 [V-012] (84179574)
Connector X-043 - 4WD SW. [S-043] (87716755)
Connector X-045A - UNLOADING VALVE [Y-004] (84607243)
Connector X-047 - SIDE SHIFT LOCK SOL.VALVE [Y-006] (84607243)
Connector X-078 - SIDE SHIFT LOCK SW. [S-019] (87716755)
Solenoid Y-001 - REVERSE SPEED SOL VALVE (Solenoid) X-013 - REV SPEED SOL. VALVE [Y-001] (87695582)
Solenoid Y-002 - FORWARD SPEED SOL VALVE (Solenoid) X-012 - FOR SPEED SOL. VALVE [Y-002] (87695582)
Solenoid Y-003 - 4WD SOLENOID VALVE (Solenoid) X-014 - 4WD SOL. VALVE [Y-003] (87695582)
Solenoid Y-004 - HIGH SPEED SOLENOID (UNLOADING VALVE) X-045A - UNLOADING VALVE [Y-004] (84607243)
(Solenoid)
Solenoid Y-006 - SIDE SHIFT LOCK SOLENOID VALVE (Solenoid) X-047 - SIDE SHIFT LOCK SOL.VALVE [Y-006] (84607243)
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6 5 4 3 2 1
SH4: D-1 1518 OR 2.5

X-130R
D 19 19 D
S-043
4WD SWITCH Y-003
F-019 4WD SOLENOID VALVE
X-017
1 2 2 IN OUT 1 1 P N 2
10.0 A 29 29 3301 OR 1.5 25E1 YE 1.0 8 8 25E2 YE 1.0 G132 BK 1.0 SH6: D-6
X-130P 8 P N 7 X-098 X-014 X-014

SH10: D-1 4206 VT 0.75
X-043 X-043
G169 BK 1.0 SH6: A-6
SH8: C-1 1230 VT 1.0
Y-002
FORWARD SPEED SOL VALVE
X-017
2 P N 1
SH6: C-6 G135 BK 1.0 2100 VT 1.0 9 9 1232 VT 1.0 SP-123 1191 YE 1.0
V-012 1192 YE 1.0 SH18: A-6
C X-012 X-012 DIODE 1 C
SP-119
3 N
Y-001
1 P1
REVERSE SPEED SOL VALVE 1231 VT 1.0 1190 YE 1.0 SH5: A-6
2 1 SP-708
P N 2 P2
SH6: C-6 G136 BK 1.0 2110 WH 1.0 10 10 7082 WH 1.0 7081 WH 1.0
X-013 X-013 X-098 X-031
SH8: B-1 7083 WH 1.0
SH18: D-6 7080 WH 1.0

2025 YE 1.0
SH12: B-6 7084 WH 1.0
SH12: A-6 7085 WH 1.0
Y-004
HIGH SPEED SOLENOID (UNLOADING VALVE)
X-095
1 P N 2
SH4: D-1 1522 OR 2.5 8 8 2020 YE 1.0 G186 BK 1.0 SH6: D-1
X-130R X-022A X-045A X-045A

B 13 13
B
F-013
1 2
10.0 A 23 23
X-130P
S-019
SIDE SHIFT LOCKING SW
X-095
3 IN OUT 2
1 1 2240 WH 1.0 1559 OR 1.5
X-022A 7 P N 8
3265 VT 1.0 SH10: D-1
X-078 X-078
G021 BK 1.0 SH6: A-1
Y-006
SIDE SHIFT LOCK SOLENOID VALVE
1 2
A 2000 WH 1.0
P N
G181 BK 1.0 SH6: D-1 A
X-047 X-047
6 5 4 3 2 1
SHT_9 1
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Wiring harnesses - Electrical schematic sheet 10 SH10 - FRONT

LIGHTING 1
Fuse F-008A - LOW BEAM FUSE (Fuse)
Fuse F-009 - HIGH BEAM FUSE (Fuse)
Relay K-005 - HEAD LAMP HIGH BEAM RELAY (Relay) X-100 - RELAY TRANS. FORW. & REV. / [K-005] (47781081)
Relay K-012 - LOW BEAM RELAY (Relay) X-106 - RELAY LOW BEAM / FRONT WORK LIGH [K-012]
(47781081)
Connector X-100 - RELAY TRANS. FORW. & REV. / [K-005] (47781081)
Connector X-106 - RELAY LOW BEAM / FRONT WORK LIGH [K-012]
(47781081)
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SH18: B-6
SP-326
3574 VT 1.0 3264 VT 1.0 SH12: D-1
D S-035
LHS COMBINATION SW
D
3265 VT 1.0 SH9: A-1
5 5
5200 YE 1.0
IN
4204 VT 1.0 SH14: C-6
OUT
5195 VT 1.0 SH14: B-6
SP-349 X-019
SP-519
4205 VT 1.5 4202 VT 1.5 16 16 4201 VT 1.5 4206 VT 0.75 SH9: D-6
X-107
3263 VT 1.0 SH17: B-6
3570 VT 1.5 SH12: B-6
1 7 7
SP-420
4200 VT 1.5
1 3562 VT 1.5 SH12: A-6
C SH15: D-1 64B4 RD 1.5
2 2 IN 2 1
5160 OR 1.5 C
3 8 8
X-035 5170 WH 1.0
4203 VT 1.0 SH21: B-6

X-035
SH8:D-5
4210 VT 1.5 SH11: B-6
TB80 EXPORT
4212 VT 1.0 SH13: C-6
4211 VT 1.5 SH11: A-6
4209 VT 1.0 SH14: B-6
4207 VT 1.5 SH18: C-6
B 4208 VT 1.0 SH11: C-6

B
K-005
HEAD LAMP HIGH BEAM RELAY
87A
10 30 7
SH4: C-1 1539 OR 1.5 87 9
3420 OR 1.5
X-020
8 85 86 6
SH6: C-6 G144 BK 1.0 5290 WH 1.0 14 14
X-130R
X-100 X-100 X-099
9 9
F-009
1 2
15.0 A 39 39 3430 OR 1.5 SH11: B-6
K-012
X-130P
LOW BEAM RELAY
A 87A A
5 30 2
SH4: C-1 1540 OR 1.5 87 4
3440 OR 1.5
X-020 X-130R
1 85 86 3
SH6: B-6 G166 BK 1.0 5300 OR 1.0 16 16 8 8
X-106 X-106 X-099

F-008A
1 2
15.0 A 38 38 3450 OR 1.5 SH11: A-6
X-130P
6 5 4 3 2 1
SHT_10 1
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Wiring harnesses - Electrical schematic sheet 11 SH11 - FRONT LIGHTING

Lamp E-005 - RIGHT FRONT LIGHT (Lamp) X-059 - TO RIGHT FRONT LIGHT [E-005] (47511912)
Lamp E-008 - LEFT FRONT LIGHT (Lamp) X-112 - TO LEFT FRONT LIGHT [E-008] (47511912)
Lamp E-011 - FRONT WORK LIGHT 2 (Lamp) X-058 - FRONT HEAD LAMP 2 [E-011] (84182898)
Lamp E-018 - FRONT WORK LIGHT 1 (Lamp) X-071 - FRONT WORK LAMP 1 [E-018] (84182898)
Fuse F-001A - FRONT LIGHT FUSE (Fuse)
Relay K-008 - FRONT LIGHTS RELAY (Relay)
Lamp LMP-002 - (Lamp)
Switch S-011 - FRONT WORK LIGHTS SW (Switch) X-074 - FR WORKING LIGHT SW. [S-011] (87716755)
Connector X-041 - RIGHT FRONT LIGHT (84253886)
Connector X-058 - FRONT HEAD LAMP 2 [E-011] (84182898)
Connector X-059 - TO RIGHT FRONT LIGHT [E-005] (47511912)
Connector X-060 - LEFT FRONT LIGHT (47761028)
Connector X-071 - FRONT WORK LAMP 1 [E-018] (84182898)
Connector X-074 - FR WORKING LIGHT SW. [S-011] (87716755)
Connector X-093 - TO CAB HARNESS (84600543)
Connector X-102 - HARN FRONT RH (84253888)
Connector X-104 - HARN FRONT LH (84600601)
Connector X-106 - RELAY LOW BEAM / FRONT WORK LIGH [K-012]
(47781081)
Connector X-112 - TO LEFT FRONT LIGHT [E-008] (47511912)
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SH4: C-6 1153 RD 2.5
X-130R
D 1 1 D
K-008
FRONT LIGHTS RELAY E-018
F-001A FRONT WORK LIGHT 1
87A
30 7
1 2 10 X-093
15.0 A 31 31 3330 RD 2.0 SP-300
87 9 1 P N 2
3320 VT 2.0 2 2 3000 VT 2.0 3001 VT 1.5 G192 BK 1.5 SH6: C-1
X-130P
8 85 86 6 X-092 X-071
X-071
E-011
X-106 X-106
FRONT WORK LIGHT 2
X-020
1 P N 2
3610 YE 1.0 11 11 3240 YE 1.0 3002 VT 1.5 G193 BK 1.5 SH6: C-1
X-099 X-058 X-058
G149 BK 1.0 SH6: B-6
S-011
FRONT WORK LIGHTS SW
X-020 OUT1
2 2 IN
SH15: C-1 1528 OR 1.5 1 1 1530 OR 1.5 3 3
OUT2
C X-099 C
8 8 P N 7 7
SH10: B-1 4208 VT 1.0 G206 BK 1.0 SH6: A-1
W E-008
X-074 X-074 LEFT FRONT LIGHT
X-104
3
SH14: C-6 3433 OR 1.5 3540 OR 1.5 1 1 3100 OR 1.5
X-020 SP-350
2
SH10: A-1 3430 OR 1.5 3431 OR 1.5 2 2 3502 OR 1.5 3501 OR 1.5 2 2 3110 OR 1.5
SP-004 X-099
1
SH10: C-1 4210 VT 1.5 3 3 3120 VT 1.5
5
SH15: B-1 3521 VT 1.0 8 8 3130 VT 1.0
4
SH6: B-1 G161 BK 1.5 7 7 G164 BK 1.5
B X-060 B
X-112
E-005
RIGHT FRONT LIGHT
X-102
4
SH6: B-1 G162 BK 1.5 4 4 G165 BK 1.5
5
SH15: B-1 3513 WH 1.0 5 5 3180 WH 1.0
X-020 SP-354
3
SH10: A-1 3450 OR 1.5 6 6 3542 OR 1.5 3541 OR 1.5 6 6 3190 OR 1.5
X-099
1
SH10: B-1 4211 VT 1.5 2 2 3200 VT 1.5
2
3503 OR 1.5 1 1 3210 OR 1.5
X-041 X-059
A A
6 5 4 3 2 1
SHT_11 1
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Wiring harnesses - Electrical schematic sheet 12 SH12 - REAR LIGHTING

Lamp E-007 - LICENSE PLATE LAMP (Lamp) X-163 - LICENSE PLATE LAMP 3 [E-007] (84182898) Connector X-055 - (Not Serviceable)
Lamp E-009 - REAR RIGHT LIGHTS (Lamp) X-090 - REAR RIGHT LIGHT [E-009] (47511912) Connector X-055P - W/H MAIN 2 (84606400)
Lamp E-010 - REAR LEFT LIGHTS (Lamp) X-089 - REAR LEFT LIGHT [E-010] (47511912) Connector X-056 - (Not Serviceable)
Lamp E-012 - REAR WORKING LIGHT 1 (Lamp) X-068 - REAR WORKING LAMP 1 [E-012] (84182898) Connector X-056P - W/H MAIN 1 (84606400)
Lamp E-013 - REAR WORK LIGHT 3 (Lamp) X-065 - REAR WORKING LAMP 3 [E-013] (84182898) Connector X-065 - REAR WORKING LAMP 3 [E-013] (84182898)
Lamp E-014 - REAR WORKING LIGHT 2 (Lamp) X-067 - REAR WORKING LAMP 2 [E-014] (84182898) Connector X-066 - REAR WORKING LAMP 4 [E-015] (84182898)
Lamp E-015 - REAR WORK LIGHT 4 (Lamp) X-066 - REAR WORKING LAMP 4 [E-015] (84182898) Connector X-067 - REAR WORKING LAMP 2 [E-014] (84182898)
Fuse F-003A - REAR LIGHT FUSE (Fuse) Connector X-068 - REAR WORKING LAMP 1 [E-012] (84182898)
Fuse F-016 - STOP LIGHT (Fuse) Connector X-077 - REAR WORK LIGHT SW. [S-012] (87716755)
Relay K-009 - REAR WORK LIGHT RELAY (Relay) Connector X-089 - REAR LEFT LIGHT [E-010] (47511912)
Switch S-012 - REAR WORK LIGHT SW (Switch) X-077 - REAR WORK LIGHT SW. [S-012] (87716755) Connector X-090 - REAR RIGHT LIGHT [E-009] (47511912)
Switch S-022 - (Switch) Connector X-092 - TO MAIN (84600597)
Switch S-023 - (Switch) Connector X-093 - TO CAB HARNESS (84600543)
Connector X-019 - HARNESS FRONT PANEL (47731489) Connector X-103 - RELAY LOADER SEF LEVEL / REAR WO [K-004]
Connector X-023 - HARNESS REAR LAMPS (84605163) (47781081)
Connector X-039P - (Not Serviceable) Connector X-107 - TO MAIN (47731490)
Connector X-039R - STOP LIGHT SW.2 (84606396) Connector X-130P - (Not Serviceable)
Connector X-040P - (Not Serviceable) Connector X-130R - FUSE BOX (Not Serviceable)
Connector X-040R - STOP LIGHT SW.1 (84606396) Connector X-136 - (Not Serviceable)
Connector X-052 - TAIL LAMP (47749801) Connector X-136P - (Not Serviceable)
Connector X-053 - L.S. 1 (84606396) Connector X-137 - (Not Serviceable)
Connector X-053P - (Not Serviceable) Connector X-137P - (Not Serviceable)
Connector X-054 - L.S. 2 (84606396) Connector X-163 - LICENSE PLATE LAMP 3 [E-007] (84182898)
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6 5 4 3 2 1
SH4: C-6 P013 RD 2.5

X-130R
3 3 K-009
REAR WORK LIGHT RELAY E-012
F-003A REAR WORKING LIGHT 1
87A
7
1 2 10 30 X-093 SP-301
15.0 A 33 33 P014 RD 2.0 87 9 1 P N 2
D X-130P
42C1 VT 2.0 3 3 42C3 VT 2.0 42C4 VT 1.5 G204 BK 1.5 SH6: C-1 D
8 85 86 6 X-068
X-092 X-068
E-014
X-103 X-103
REAR WORKING LIGHT 2
42C7 YE 1.0
1 P N 2
S-012 42C5 VT 1.5 G201 BK 1.5 SH6: C-1
REAR WORK LIGHT SW
X-067 X-067
G023 BK 1.0 SH6: B-6

7 7 N P 8 8
SH6: A-1 G020 BK 1.0
3264 VT 1.0 SH10: D-1
2 2
SH15: C-1 1529 OR 1.0
7096 OR 1.0 SH15: C-1
3 3
E-013
REAR WORK LIGHT 3
SP-302
1 P N 2
5 5 3021 VT 1.5 G203 BK 1.5 SH6: C-1
SH16: C-6 7095 OR 1.0
X-065 X-065
C E-015 C
6 REAR WORK LIGHT 4
6
1 P N 2
3022 VT 1.5 G202 BK 1.0 SH6: C-1
X-077 X-077
X-066 X-066
SH16: D-1 3023 VT 2.0
X-039R X-055 SP-155 X-053 X-136
1553 OR 1.0 1 1 1 1 1555 OR 1.0 1556 OR 1.0 1 1 1 1

SH4: D-1 1519 OR 2.5
X-130R 2 1
4401 VT 1.0 2 2 2 2 4409 VT 1.0 2 2 2 2
16 16 X-136P
X-039P X-055P X-053P
F-016 X-040R
X-019 X-056 X-054 X-137
1 2
10.0 A 26 26 1520 OR 1.5 13 13 1521 OR 1.5 1554 OR 1.0 1 1 1 1 1557 OR 1.0 1 1 1 1
X-130P X-107 SP-150

SP-441 2 1
SP-440 4402 VT 1.0 2 2 2 2 4408 VT 1.0 4410 VT 1.0 2 2 2 2
X-019 X-040P X-056P X-054P X-137P
4404 VT 1.5 11 11 4403 VT 1.5

4411 VT 1.0 SH8: A-6
X-107
E-010
REAR LEFT LIGHTS
B X-023 B
4
SH18: C-6 45L4 VT 1.0 12 12 G156 BK 1.5 G208 BK 1.5 4
SP-223
1
SP-222 4407 VT 1.5 4 4 4412 VT 1.5 1
SP-224
2
SH10: C-1 3570 VT 1.5 6 6 3575 VT 1.5 7090 VT 1.5 2
3
SH15: B-6 45L3 VT 1.0 45L2 VT 1.0 5 5 45L1 VT 1.0 3
E-007
SP-005
LICENSE PLATE LAMP
6
SH9: C-6 7084 WH 1.0 10 10 7086 WH 1.0 6
X-089 1 P N 2
7091 VT 1.5 G209 BK 1.5
X-163 X-163
E-009
REAR RIGHT LIGHTS
1
4406 VT 1.5 3 3 4413 VT 1.5 1
2
SH10: C-1 3562 VT 1.5 1 1 3563 VT 1.5 2
SP-006
3
A SH15: B-6 45R3 WH 1.0 45R2 WH 1.0 2 2 45R1 WH 1.0 3 A
G152 BK 1.5 SH6: A-6
6
SH18: C-6 45R4 WH 1.0 7085 WH 1.0 9 9 7087 WH 1.0 6
4
SH9: B-6 11 11 G157 BK 1.5 4
X-052 X-090
G153 BK 1.5 SH6: A-6
6 5 4 3 2 1
SHT_12 1
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Wiring harnesses - Electrical schematic sheet 13 SH13 - WIPER/WASHER

Fuse F-007 - FRONT WIPER (Fuse) Connector X-079 - BEACON SW. [S-015] (87716755)
Fuse F-024 - FRONT WASHER MOTOR FUSE (Fuse) X-164 - FUSE HOLDER-INLINE [F-024] (47435876) Connector X-092 - TO MAIN (84600597)
Fuse F-026 - BEACON FUSE (Fuse) X-121 - BEACON FUSE [F-026] (47435876) Connector X-093 - TO CAB HARNESS (84600543)
Power outlet J-158 - BEACON SOCKET (Power outlet) X-158 - BEACON SOCKET [J-158] (84015523) Connector X-099 - TO MAIN (47731489)
Motor M-003 - REAR WASHER MOTOR (Motor) X-150 - REAR WASHER MOTOR [M-003] (87693325) Connector X-107 - TO MAIN (47731490)
Motor M-009 - FRONT WASHER MOTOR (Motor) X-149 - FRONT WASHER MOTOR [M-009] (87693325) Connector X-121 - BEACON FUSE [F-026] (47435876)
Motor M-064 - FRONT WIPER MOTOR (Motor) X-070 - WIPER MOTOR [M-064] (84182898) Connector X-129 - TO WIPER/WASHER (87696073)
Switch S-009 - RHS COMBINATION SW (Switch) X-034 - RHS COMBINATION SWITCH [S-009] (84600631) Connector X-130P - (Not Serviceable)
X-037 - COMBINATION SWITCH [S-009] (47461910) Connector X-130R - FUSE BOX (Not Serviceable)
Switch S-014 - WIPER MOTOR (Switch) X-162 - REAR WIPER MOTOR [S-014] (87680380) Connector X-148 - TO FRONT PANEL HARNESS (87708145)
Switch S-015 - BEACON SWITCH (Switch) X-079 - BEACON SW. [S-015] (87716755) Connector X-149 - FRONT WASHER MOTOR [M-009] (87693325)
Switch S-016 - REAR WIPER/WASHER SW (Switch) X-161 - TO REAR WIPER/WASHER SWITCH [S-016] Connector X-150 - REAR WASHER MOTOR [M-003] (87693325)
(87632724) Connector X-158 - BEACON SOCKET [J-158] (84015523)
Connector X-019 - HARNESS FRONT PANEL (47731489) Connector X-161 - TO REAR WIPER/WASHER SWITCH [S-016]
Connector X-020 - HARNESS FRONT PANEL (47731490) (87632724)
Connector X-034 - RHS COMBINATION SWITCH [S-009] (84600631) Connector X-162 - REAR WIPER MOTOR [S-014] (87680380)
Connector X-037 - COMBINATION SWITCH [S-009] (47461910) Connector X-164 - FUSE HOLDER-INLINE [F-024] (47435876)
Connector X-070 - WIPER MOTOR [M-064] (84182898)
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6 5 4 3 2 1
1035 BR 1.0
S-016
D REAR WIPER/WASHER SW
D
11 11 13 13
1036 BR 1.0
S-014
WIPER MOTOR
2 53 (MOTOR +)
1038 YE 1.0
3 31b
3 3 14 14 SP-021
1037 YE 1.0 M
PARK
1 53a
1032 OR 1.0
31 (GND) 4
15 15 G029 BK 1.0 SH16: A-1
1040 YE 1.0
X-162 X-162
6 6 16 16
1033 OR 1.0 1031 OR 1.0 SH16: A-1
SP-020
C TB80 EXPORT X-129

C
10 10 P N 9 9
SH10: C-1 4212 VT 1.0 2 2 4213 VT 1.0 G027 BK 1.0 SH16: B-1
X-148
X-161 M-003
X-161
REAR WASHER MOTOR
A B
1034 WH 1.0 A M B G028 BK 1.0 SH16: B-1
X-150 X-150
M-009
S-009 TB80 EXPORT
FRONT WASHER MOTOR
RHS COMBINATION SW F-024 X-129
1 1 1 2 A B
1 10.0 A 2 SH16: B-1
1028 GY 1.0 1039 GY 1.0 1 1 1029 GY 1.0 A M B G026 BK 1.0
X-019
2 IN X-037 X-148 X-149
X-164 X-164 X-149
SH4: C-1 1537 OR 2.0 3 3 1538 OR 2.0
2 4 X-020
X-107 X-034
6301 BR 2.0 7 7
X-034 X-099 M-064

FRONT WIPER MOTOR
X-093
1 2
6 6 6304 BR 2.0 A M B G191 BK 2.0 SH6: C-1
B X-092
X-070 X-070 B
X-130R
7 7 6302 BR 2.0
F-007
1023 OR 1.0
1 2
10.0 A 37 37 6303 BR 2.0
X-130P
S-015
BEACON SWITCH
F-026 J-158
BEACON FUSE BEACON SOCKET
OUT1
2 1 2 2 IN
2 1
SH4: C-6 P018 RD 1.0 10.0 A P020 RD 1.0 3
OUT2 3 1 IN OUT 2
1021 OR 1.0 1022 OR 1.0 LOAD
X-121 X-121
SP-16 X-158 X-158
8 8 P N 7 7
G199 BK 1.0
A X-079 X-079
A
SH6: C-1 G198 BK 1.0 G207 BK 1.0
SP-17
6 5 4 3 2 1
SHT_13 1
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Wiring harnesses - Electrical schematic sheet 14 SH14 - INSTRUMENT CLUSTER / SPEEDOMETER

ECU A-002 - INSTRUMENT CLUSTER (ECU) X-116 - INST. CLUSTER [A-002] (84179604) Connector X-011 - TRANS HIGH OIL TEMP SW. [S-030] (84062580)
X-117 - INST. CLUSTER 2 [A-002] (84479015) Connector X-015 - TO MAIN HARNESS (84182907)
Sensor B-001 - FUEL LEVEL SENDER (Sensor) X-147 - FUEL LEVEL SENSOR [B-001] (Not Serviceable) Connector X-017 - TO MAIN HARNESS (84600598)
X-146 - FUEL LEVEL SENSOR [B-001] (Not Serviceable) Connector X-019 - HARNESS FRONT PANEL (47731489)
Sensor B-019 - PT SPEED SENSOR (Sensor) X-115 - SPEED SENSOR [B-019] (84062580) Connector X-020 - HARNESS FRONT PANEL (47731490)
Lamp E-017 - SPEEDOMETER (Lamp) X-114 - SPEEDOMETER [E-017] (87686679) Connector X-038 - BRAKE FLUID BOTTLE SW. [S-038] (84417509)
Fuse F-014 - CLUSTER KEY ON POWER (Fuse) Connector X-096 - HARNESS ENGINE (84182893)
Fuse F-015 - SPEEDOMETER FUSE (Fuse) Connector X-098 - HARNESS ENGINE (84600605)
Ground GND-013 - (Ground) GND-013 Connector X-099 - TO MAIN (47731489)
Ground GND-015 - (Ground) GND-015 Connector X-107 - TO MAIN (47731490)
Switch S-006 - HYDRAULIC FILTER RESTRICTION SWITCH (Switch) X-009B - HYDRAULIC FILTER [S-006] (84491249) Connector X-114 - SPEEDOMETER [E-017] (87686679)
X-009A - HYDRAULIC FILTER [S-006] (84491249) Connector X-115 - SPEED SENSOR [B-019] (84062580)
Switch S-007 - ENG WATER TEMP SWITCH (Switch) X-002 - ENG. COOLANT TEMP SWITCH [S-007] (84491249) Connector X-116 - INST. CLUSTER [A-002] (84179604)
Switch S-008 - ENGINE OIL PRESSURE SW (Switch) X-004A - LOW PRESSURE SWITCH [S-008] (84491249) Connector X-117 - INST. CLUSTER 2 [A-002] (84479015)
Switch S-030 - TRANSMISSION HIGH OIL TEMP SW (Switch) X-011 - TRANS HIGH OIL TEMP SW. [S-030] (84062580) Connector X-130P - (Not Serviceable)
Switch S-038 - BRAKE OIL LEVEL SWITCH (Switch) X-038 - BRAKE FLUID BOTTLE SW. [S-038] (84417509) Connector X-130R - FUSE BOX (Not Serviceable)
Connector X-002 - ENG. COOLANT TEMP SWITCH [S-007] (84491249) Connector X-146 - FUEL LEVEL SENSOR [B-001] (Not Serviceable)
Connector X-004A - LOW PRESSURE SWITCH [S-008] (84491249) Connector X-147 - FUEL LEVEL SENSOR [B-001] (Not Serviceable)
Connector X-009A - HYDRAULIC FILTER [S-006] (84491249)
Connector X-009B - HYDRAULIC FILTER [S-006] (84491249)
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A-002
INSTRUMENT CLUSTER S-006
HYDRAULIC FILTER RESTRICTION SWITCH
SP-012 X-017
4 1 2 1 1
36H4 YE 0.75 36H3 YE 0.75 13 13 36H2 YE 0.75 G102 BK 1.0 SH6: D-6
2
SH3: B-1 1310 YE 1.0
X-116 X-098 X-009A X-009B
X-116
36H5 YE 0.75 SH18: D-6
D B-001 D
FUEL LEVEL SENDER
X-017
1 2 1 SIG GND 1
SH3: B-1 1320 OR 1.0 5362 YE 0.75 7 7 5361 YE 0.75 G133 BK 1.5 SH6: D-6
X-146 X-147
X-117 X-117
SH4: D-1 1502 OR 2.5
S-030
X-130R
TRANSMISSION HIGH OIL TEMP SW
SP-011
14 14 1 15 3 2 2
1
1558 OR 0.75 5376 YE 1.0 5375 YE 1.0 5 5 5371 YE 1.0 G137 BK 1.0 SH6: C-6
F-014 X-116 X-098 X-011 X-011
SP-003
1 2 5
10.0 A 24 24 1549 OR 0.75 1516 OR 0.75
X-130P
4
SH18: C-6 1560 OR 0.75 1517 OR 0.75
X-117
5377 YE 1.0 SH18: D-6
S-008
TB80 EXPORT
ENGINE OIL PRESSURE SW
5
SH5: C-6 1401 BR 1.0 SP-010 X-017
3 1 2 1
1053 WH 1.0 1052 WH 1.0 14 14 1051 WH 1.0
C X-098 X-004A C
14 1054 WH 1.0 SH18: C-6

SH18: A-1 2142 YE 1.0
S-038
BRAKE OIL LEVEL SWITCH
SP-009 X-020
12 16 2 2 1
1
SH11: C-6 3433 OR 1.5 3463 YE 1.0 3462 YE 1.0 10 10 3461 YE 1.0 G172 BK 1.0 SH6: A-1
X-099
X-038 X-038
13 3464 YE 1.0 SH18: D-6

SH10: D-1 4204 VT 1.0
S-007
ENG WATER TEMP SWITCH
SP-013 X-096
10 1 2 1
5353 YE 1.0 5352 YE 1.0 1 1 1070 YE 1.0
11
SH10: D-1 X-116 X-015 X-002
5195 VT 1.0
X-116
3
SH7: B-1 7060 YE 0.75
X-117
B SH4: D-1 1503 OR 2.5 5354 YE 1.0 SH18: D-6

B
X-130R 6
G066 BK 1.0 SH6: A-1
15 15
X-117
F-015
E-017
1 2 SPEEDOMETER
10.0 A 25 25 1511 OR 0.75
X-130P X-019
3
SP-117 1512 OR 0.75 10 10 1546 OR 0.75
X-107 4
SH10: B-1 4209 VT 1.0
1
X-114
1513 OR 0.75
G104 BK 1.0 SH6: B-1
X-019
2702 YE 0.75 7 7
X-107
B-019
A PT SPEED SENSOR A
X-096
3 PWR GND 2
2 2 1514 OR 0.75 G105 BK 1.0 SH6: D-6
X-015 X-115 X-096

OUT 1
2700 YE 0.75 3 3 2701 YE 0.75
X-115 X-015
6 5 4 3 2 1
SHT_14 1
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Wiring harnesses - Electrical schematic sheet 15 SH15 - HAZARD

Lamp E-002 - TURN INDICATOR (Lamp) X-141 - TURN SIGNAL GROUND [E-002] (84491249)
X-139 - RIGHT TURN INDICATOR [E-002] (84491249)
X-140 - LEFT TURN INDICATOR [E-002] (84491249)
Fuse F-004 - HORN/HAZARD/BATT+ (Fuse)
Fuse F-017 - HAZARD/LTS/IGN (Fuse)
Relay K-030 - FLASHER RELAY (Relay) X-030 - FLASHER [K-030] (84479009)
Switch S-024 - RHS COMBINATION SW (Switch)
Switch S-037 - HAZARD SWITCH (Switch) X-151 - HAZARD SW. [S-037] (87632725)
Connector X-030 - FLASHER [K-030] (84479009)
Connector X-034 - RHS COMBINATION SWITCH [S-009] (84600631)
Connector X-139 - RIGHT TURN INDICATOR [E-002] (84491249)
Connector X-140 - LEFT TURN INDICATOR [E-002] (84491249)
Connector X-141 - TURN SIGNAL GROUND [E-002] (84491249)
Connector X-151 - HAZARD SW. [S-037] (87632725)
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SH4: C-6 P011 RD 2.5

X-130R
D 4 4 64B4 RD 1.5 SH10: C-6

D
F-004
X-019
SP-514
1 2
15.0 A 34 34 64B0 RD 1.5 2 2 64B1 RD 1.5 64B3 RD 1.0 SH18: B-6
X-130P S-037
X-107
HAZARD SWITCH
8 10 10
P N G211 BK 1.0 SH6: A-1
P N
3
3
64B2 RD 1.0
2 2
5340 YE 1.0
X-019
1
1
1526 OR 1.0 5 5 1525 OR 1.0
7096 OR 1.0 SH12: C-1
X-107
SH4: D-1 1523 OR 2.5 5 5

5332 BR 1.0
C 1528 OR 1.5 SH11: C-6 C

17 17
X-130R
17 17 18 18
F-017
HAZARD/LTS/IGN
X-151 X-151
1 2
10.0 A 27 27 1524 OR 1.5 1529 OR 1.0 SH12: C-6
X-130P SP-007
K-030
FLASHER RELAY
X-020
2
12 12 3230 YE 1.0 L
1 3
SP-533 5335 BR 1.0 13 13 3220 BR 1.0 B E G024 BK 1.0 SH6: B-6
X-099 X-030
X-030
X-020
B SH12: B-6 45L3 VT 1.0 5 5 3522 VT 1.0
SP-352
3524 VT 1.0 3521 VT 1.0 SH11: B-6
B
X-099
S-024
RHS COMBINATION SW
1 5
3523 VT 1.0
1 IN
5330 BR 1.0
3 2 6
3511 WH 1.0
SP-351
X-034 X-034 3514 WH 1.0 SH11: B-6
3513 WH 1.0
X-019
SH12: A-6 45R3 WH

3512
1.0 WH 1.0 4 4
G197 BK 1.0 SH6: B-1
X-107
E-002
TURN INDICATOR
1 N
X-141
1 P1 P N
3515 WH 1.0
X-139
1 P2 P N
A 3525 VT 1.0 A
X-140
G163 BK 1.0 SH6: B-1
6 5 4 3 2 1
SHT_15 1
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Wiring harnesses - Electrical schematic sheet 16 SH16 - ACCESSORIES

Sensor B-003 - RTD SENSOR (Sensor) X-050A - RTD SENSOR [B-003] (84600602) Connector X-103 - RELAY LOADER SEF LEVEL / REAR WO [K-004]
Fuse F-006 - HAMMER VALVE (Fuse) (47781081)
Fuse F-012 - LOADER SELF LEVELING (Fuse) Connector X-105* - TO WIPER (87696073)
Fuse F-028 - REAR WORK LAMP (Fuse) Connector X-105R - HAMMER VALVE / INSTALLAER POWER
Relay K-004 - LOADER SELF LEVELING RELAY (Relay) X-103 - RELAY LOADER SEF LEVEL / REAR WO [K-004] (87708145)
(47781081) Connector X-126 - TO HAMMER VALVE/CUSTOMER OPTION
Relay K-013 - REAR WORK LAMP (Relay) X-166 - REAR WORK LAMP [K-013] (84369037) (87696073)
Switch S-025 - FOOT SWITCH (Switch) X-075 - FOOT SWITCH [S-025] (87706470) Connector X-127 - TO HAMMER VALVE (87708145)
Connector X-022A - TO HARNESS MAIN (84600552) Connector X-130P - (Not Serviceable)
Connector X-046A - RTD SOLENOID [Y-005] (87695582) Connector X-130R - FUSE BOX (Not Serviceable)
Connector X-050A - RTD SENSOR [B-003] (84600602) Connector X-166 - REAR WORK LAMP [K-013] (84369037)
Connector X-073 - HAMMER_VALVE [Y-008] (84600619) Connector X-167 - FUSE HOLDER (47435876)
Connector X-075 - FOOT SWITCH [S-025] (87706470) Connector X-167P - (Not Serviceable)
Connector X-092 - TO MAIN (84600597) Solenoid Y-005 - RTD SOLENOID (Solenoid) X-046A - RTD SOLENOID [Y-005] (87695582)
Connector X-093 - TO CAB HARNESS (84600543) Solenoid Y-008 - HAMMER_VALVE (Solenoid) X-073 - HAMMER_VALVE [Y-008] (84600619)
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D D
SH4: C-6 7092 RD 2.5
F-028
REAR WORK LAMP
X-167
1 2
15.0 A 2 2
K-013
REAR WORK LAMP
87A D
A 30 X-093
1 1 7093 RD 2.0 87 C
7094 WH 2.0 7 7 3023 VT 2.0 SH12: C-6
X-167P
B 85 86 E X-092
SH12: C-6 7095 OR 1.0 G212 BK 1.0 SH6: B-6
X-166 X-166
SH4: D-1 1506 OR 2.5
C C
K-004 Y-005
X-130R LOADER SELF LEVELING RELAY RTD SOLENOID
X-095
12 12 2 1 2
87A P N
30 1260 WH 1.0 5 5 2010 WH 1.0 G184 BK 1.0 SH6: D-1
5
5302 OR 1.0 87 X-046A X-046A
F-012 4
SP-124 1 85 86 3
1 2
10.0 A 22 22 5301 OR 1.5 5304 OR 1.0 1250 YE 1.0 9 9 2050 YE 1.0
X-130P
X-103 X-103 B-003
TB80 EXPORT RTD SENSOR
5305 OR 1.0
1 PWR GND 2
5305* OR 1.5 2 2 2043 OR 1.0 G183 BK 1.0 SH6: D-1
TB80 DOMSTIC
X-022A X-050A
OUT 3
X-050A
TB80 DOMESTIC
SH4: C-1 1550* OR 2.5 G026 BK 1.0 SH13: B-1
SH4: C-1 1550 OR 1.0

TB80 EXPORT
SP-018 G027 BK 1.0 SH13: C-1
B B
G035 BK 1.0
X-130R Y-008
HAMMER_VALVE
6 6
S-025
F-006 FOOT SWITCH
X-105R SP-016 X-127 X-127 X-105R
1 2 B 2 1 C 1 P N 2
10.0 A 36 36 1551 OR 1.0 1 1 1026 OR 1.0 1027 OR 1.0 1 1 1025 OR 1.0 1024 RD 1.0 G225 BK 1.0 2 2 G226 BK 1.0 G227 BK 1.0 2 2 G224 BK 1.0 SH6: B-6
X-130P SP-017
X-126 X-105* X-075 X-075 X-073 X-073 X-105* X-126
G028 BK 1.0 SH13: C-1
G228 BK 1.0 SP-019
G029 BK 1.0 SH13: D-1
1031 OR 1.0 SH13: C-1

A A
6 5 4 3 2 1
SHT_16 1
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Wiring harnesses - Electrical schematic sheet 17 SH17 - CAB FAN

Fuse F-005 - CAB FAN/RADIO (Fuse)
Motor M-001 - CABIN FAN (Motor) X-069 - CABIN FAN [M-001] (84182898)
Switch S-020 - CAB FAN SW (Switch) X-076 - CAB FAN SW. [S-020] (87716755)
Connector X-069 - CABIN FAN [M-001] (84182898)
Connector X-076 - CAB FAN SW. [S-020] (87716755)
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D D
SH4: C-6 P012 RD 2.5
X-130R
5 5
C F-005 C
CAB FAN/RADIO 3C02 RD 1.5 SH18: C-6
1 2
10.0 A 35 35 3C01 RD 2.5 SP-403
X-130P
3C03 RD 1.5
S-020
CAB FAN SW
X-093 OUT1
3 IN
8 8 4010 BR 1.5 2
OUT2
X-092
8 P N 7
SH10: C-1 3263 VT 1.0 G022 BK 1.0 SH6: A-6
X-076 X-076
B B
M-001
CABIN FAN
1 2
4000 BR 1.5 A M B G205 BK 1.5 SH6: C-1
X-069 X-069
A A
6 5 4 3 2 1
SHT_17 1
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Wiring harnesses - Electrical schematic sheet 18 SH18 - AUDIO

ECU A-053 - SPEAKERS (ECU) X-063A - RH SPEAKER IN [A-053] (84600637) Connector X-042 - RH SPEAKER [H-001] (84182898)
X-063B - RH SPEAKER IN [A-053] (84600636) Connector X-048A - TO REAR HORN SWITCH [S-029] (87581782)
X-072B - LH SPEAKER [A-053] (84600636) Connector X-048B - TO REAR HORN SWITCH [S-029] (87581782)
X-072A - LH SPEAKER [A-053] (84600637) Connector X-060 - LEFT FRONT LIGHT (47761028)
Ground GND-009 - (Ground) GND-009 Connector X-061 - RADIO [H-004] (84179570)
Speaker H-001 - RIGHT SPEAKER (Speaker) X-042 - RH SPEAKER [H-001] (84182898) Connector X-061A - RADIO ANTENNA [S-013] (84369030)
Speaker H-002 - LEFT SPEAKER (Speaker) X-064A - LH SPEAKER [H-002] (84182898) Connector X-061B - [S-013] (2FT)
Speaker H-003 - HORN (Speaker) X-091 - TO HORN [H-003] (Not Serviceable) Connector X-063A - RH SPEAKER IN [A-053] (84600637)
X-142 - TO HORN [H-003] (Not Serviceable)
Connector X-063B - RH SPEAKER IN [A-053] (84600636)
Speaker H-004 - RADIO (Speaker) X-061 - RADIO [H-004] (84179570)
Connector X-064A - LH SPEAKER [H-002] (84182898)
Speaker H-005 - BUZZER (Speaker) X-144 - BUZZER [H-005] (87679493)
Connector X-072A - LH SPEAKER [A-053] (84600637)
Speaker H-007 - BACK-UP ALARM (Speaker) X-018 - TO BACK-UP ALARM [H-007] (87692855)
Connector X-072B - LH SPEAKER [A-053] (84600636)
Relay K-002 - HAND BRAKEALARM ON/SPEED ALARM RELAY
Connector X-091 - TO HORN [H-003] (Not Serviceable)
(Relay)
Switch S-004 - RADIO SW (Switch) X-138 - RADIO SW [S-004] (87716755)
Switch S-010 - BUZZER (Switch) X-145 - BUZZER [S-010] (47415745)
Switch S-013 - RADIO ANTENNA (Switch) X-061A - RADIO ANTENNA [S-013] (84369030)
X-061B - [S-013] (2FT) Connector X-099 - TO MAIN (47731489)
Switch S-027 - PARK BRAKE LIMIT SW (Switch) X-027 - PARK BRAKE LIMIT SW. [S-027] (84606396) Connector X-101 - RELAY ALARM HAND BRAKE & SPE [K-003]
(47781081)
Switch S-029 - REAR BACKHOE HORN SWITCH (Switch) X-048B - TO REAR HORN SWITCH [S-029] (87581782)
X-048A - TO REAR HORN SWITCH [S-029] (87581782) Connector X-104 - HARN FRONT LH (84600601)
Connector X-018 - TO BACK-UP ALARM [H-007] (87692855) Connector X-107 - TO MAIN (47731490)
Connector X-019 - HARNESS FRONT PANEL (47731489) Connector X-138 - RADIO SW [S-004] (87716755)
Connector X-020 - HARNESS FRONT PANEL (47731490) Connector X-142 - TO HORN [H-003] (Not Serviceable)
Connector X-022A - TO HARNESS MAIN (84600552) Connector X-144 - BUZZER [H-005] (87679493)
Connector X-027 - PARK BRAKE LIMIT SW. [S-027] (84606396) Connector X-145 - BUZZER [S-010] (47415745)
Connector X-028 - BACK-UP ALARM (84182898) Connector X-400 - TO HORN JUMPER HARNESS (84182898)
Connector X-029 - TO HARNESS (84477032) Connector X-401 - (84477032)
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H-007
BACK-UP ALARM
X-028
A
SH9: C-6 7080 WH 1.0 1 1 7088 WH 1.0 P
X-029
B
S-010 G158 BK 1.0 N
BUZZER
X-018
X-028
D SH14: C-1
1
SH6: A-6
D
3464 YE 1.0 2 2 G155 BK 1.0
X-029
2
SH14: C-1 5377 YE 1.0
3
SH14: D-1 36H5 YE 0.75
4
SH14: B-1 5354 YE 1.0 9
G187 BK 1.0 SH6: A-1
5 X-145
2143 YE 1.0
6
SH14: C-1 1054 WH 1.0
8
SH14: C-6 1560 OR 0.75
H-005
X-145 BUZZER
1
SH12: A-6 45R4 WH 1.0 P
2
SH12: B-6 45L4 VT 1.0 N
C X-144 C
S-004
RADIO SW H-004
RADIO
X-020 OUT1
2 IN 1
X-020 X-093
SH17: C-1 3C02 RD 1.5 3 3 3C04 RD 1.5 3 7041 YE 1.0 P
OUT2
3C05 YE 1.5 4 4 3C06 YE 1.5 4 4 7040 YE 1.5 SP-303
X-099
2
X-099 X-092
SH6: B-1 G194 BK 1.0 N
8 P N 7 X-061
SH10: B-1 4207 VT 1.5 S-013
RADIO ANTENNA
X-138 X-138
1 2
7042 YE 1.0
X-061A X-061B
GND-009
G196 BK 1.0 SH6: B-1
H-003
TO_HORN HORN
X-104 X-400 JUMPER
SP-520
1
SH10: D-1 5200 YE 1.0 5201 YE 1.0 4 4 3159 YE 1.0 1 1 3160 YE 1.0 P
X-142
B SH15: D-1 5 5 3149 RD 1.0 2 2 3150 RD 1.0

1
N
B
64B3 RD 1.0
X-091
X-401
X-060
FROM_FRONT S-029
LEFT LIGHT REAR BACKHOE HORN SWITCH
5202 YE 1.0
1 2 1 1
7050 YE 1.0 G182 BK 1.0 SH6: D-1
X-095 X-048A X-048B
4 4 5212 YE 1.0
K-002
X-022A HAND BRAKEALARM ON/SPEED ALARM RELAY SH6: C-6
G145 BK 1.0
X-019 87A
30 2 S-027
5
12 12 5210 YE 1.0 5211 YE 1.0 PARK BRAKE LIMIT SW
87 4
X-107 SP-521 1 2 1 2
V-003 2140 YE 1.0 G154 BK 1.0 SH6: A-6
1 85 86 3
DIODE 3 2141 YE 1.0
X-027 X-027
1 2 SP-214
P N
SH9: C-1 1192 YE 1.0 1300 YE 1.0 X-101 X-101
2142 YE 1.0 SH14: C-6
X-033 X-033
H-002
A-053
SPEAKERS LEFT SPEAKER
1 2
L SPEAKER 7010 GY 1.0 P
X-072B
1 1
A L SPEAKER
X-072A
7000 BK 1.0 N A
X-064A
H-001
RIGHT SPEAKER
1 2
R SPEAKER 7030 VT 1.0 P
X-063B
1 1
R SPEAKER 7020 BK 1.0 N
X-063A
X-042
6 5 4 3 2 1
SHT_18 1
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Wiring harnesses - Electrical schematic sheet 19 SH19 - HVAC

ECU A-111 - A/C KIT POWER (ECU) X-113 - A/C KIT [A-111] (47706988)
X-125 - A/C POWER [A-111] (47415744)
ECU A-220 - A/C KIT CONTROL (ECU) X-220 - A/C CONTROL [A-220] (47373520)
Fuse F-011 - HVAC KEY ON POWER (Fuse)
Fuse F-029 - HVAC BATT+ POWER (Fuse)
Relay K-105 - A/C COMPRESSOR RELAY (Relay) X-123 - A/C RELAY [K-105] (84369037)
Motor M-006 - A/C CLUTCH (Motor) X-131 - A/C CLUTCH [M-006] (87693744)
X-064* - [M-006] (2WF 090)
Switch S-069 - A/C PRESSURE SW (Switch) X-132 - A/C PRESSURE SW [S-069] (87679438)
Connector X-064* - [M-006] (2WF 090)
Connector X-080 - TO AC HARNESS ON ENGINE SIDE (47525005)
Connector X-081 - TO CAB (47525012)
Connector X-109 - A/C IGNTION TO MAIN (84179570)
Connector X-110 - TO AC HARNESS (84417509)
Connector X-113 - A/C KIT [A-111] (47706988)
Connector X-122R - 40A FUSE HOLDER (47781606)
Connector X-123 - A/C RELAY [K-105] (84369037)
Connector X-125 - A/C POWER [A-111] (47415744)
Connector X-131 - A/C CLUTCH [M-006] (87693744)
Connector X-132 - A/C PRESSURE SW [S-069] (87679438)
Connector X-220 - A/C CONTROL [A-220] (47373520)
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X-081
G222 BK 6.0 2 2 G223 BK 6.0 SH6: D-6
X-080
A-111 A-220
D A/C KIT POWER A/C KIT CONTROL

D
1 1
A/C 1ST SPEED 4030 YE 1.5 A/C 1ST SPEED
2
GROUND
2 2
A/C 2ND SPEED 4040 YE 1.5 A/C 2ND SPEED
3 3
A/C 3RD SPEED 4050 YE 1.5 A/C 3RD SPEED
5 5
SH4: B-6 P005 RD 6.0 A/C FROM POT 4070 YE 1.0 A/C FROM POT
6 6
X-122R A/C FROM POT
A/C FROM POT 4080 YE 1.0
1 1
F-029 7 7
HVAC BATT+ POWER A/C FROM POT 4090 YE 1.0 A/C FROM POT
X-081
1 2 1
30.0 A 2 2 P017 RD 6.0 1 1 P016 RD 6.0 +30 ELECTRIC FAN 8 8
X-122P A/C FROM POT 4100 YE 1.0 A/C FROM POT
X-080 X-125
9 9
A/C FROM POT 4110 YE 1.0 A/C FROM POT
SP-406
4 4
TB80 EXPORT +15 A/C SUPPLY 6103 OR 2.5 6105 OR 2.5 +15 A/C SUPPLY
C SH4: C-1 1536 OR 2.5 C
X-113
X-130R
11 11
11
F-011 86 A/C RELAY
X-109 1351 YE 1.5
1 2
20.0 A 21 21 6101 OR 2.5 6102 OR 2.5 1 1 10
4064 BK 2.5 GROUND
X-130P X-110
X-220
TB80 EXPORT
X-109
2 2 G243 BK 2.5 SH6: A-6
X-110
6104 OR 2.0
B K-105
B
A/C COMPRESSOR RELAY
M-006
87A A/C CLUTCH
A 30 D
X-081
87 C A 2
60C6 YE 2.0 4 4 60C7 YE 2.0 A M B
E 85 86 B X-131 X-064*
X-123 X-123
S-069
A/C PRESSURE SW
P
A IN OUT B
1330 YE 2.0 3 3 1331 YE 2.0 G171 BK 2.0 SH6: D-6
X-080 X-132 X-132
A A
6 5 4 3 2 1
SHT_19 1
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Wiring harnesses - Electrical schematic sheet 20 SH20 - DOME LIGHT

Lamp E-016 - ROOF LIGHT (Lamp) X-062A - ROOF LIGHT [E-016] (84491249)
X-062B - ROOF LIGHT [E-016] (84491249)
Fuse F-010 - DOME LIGHT BATT+ (Fuse)
Connector X-062A - ROOF LIGHT [E-016] (84491249)
Connector X-062B - ROOF LIGHT [E-016] (84491249)
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6 5 4 3 2 1
D D
C C
SH4: C-6 P007 RD 2.5
X-130R
10 10
E-016
ROOF LIGHT
F-010
X-093
1 2 1 P N 1
10.0 A 40 40 P008 RD 1.0 5 5 P009 RD 1.0 G195 BK 1.0 SH6: B-1
X-130P X-092 X-062A X-062B
B B
A A
6 5 4 3 2 1
SHT_20 1
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Wiring harnesses - Electrical schematic sheet 21 SH21 - MOBILE

CHARGER
Fuse F-002 - MOBILE CHARGER (Fuse)
Power outlet J-001 - CHARGER SOCKET (Power outlet) X-025C - CHARGER SOCKET [J-001] (84491249)
X-025B - CHARGER SOCKET [J-001] (84491249)
X-025A - CHARGER SOCKET [J-001] (84491249)
Connector X-025A - CHARGER SOCKET [J-001] (84491249)
Connector X-025B - CHARGER SOCKET [J-001] (84491249)
Connector X-025C - CHARGER SOCKET [J-001] (84491249)
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D D
C C
SH4: C-1 1504 OR 2.5
X-130R
2 2
J-001
CHARGER SOCKET
F-002
1 2 1 P1 N 1
10.0 A 32 32 1508 OR 1.0 LOAD G025 BK 1.0 SH6: B-6
X-130P X-025C X-025A

1 P2
SH10: C-1 4203 VT 1.0
X-025B
B B
A A
6 5 4 3 2 1
SHT_21 1
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Wiring harnesses - Electrical schematic sheet 22 SH22 - TELEMATICS

ECU A-003 - TELEMATICS BOX (ECU) X-005A* - TELEMATICS BOX [A-003] (Not Serviceable)
Connector X-005A* - TELEMATICS BOX [A-003] (Not Serviceable)
Connector X-006* - GROUND (84488487)
Connector X-007* - UNSWITCHED POWER (87745375)
Connector X-008* - DIODE-5 [V-004] (84179574)
Connector X-010* - DIODE-1 [V-002] (84182904)
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NOTE:
IN TELEMATICS CIRCUIT SHEET NO 22 & 23 * IS ADDED TO AVOID
DUPLICATES IN CONNECTOR , SPLICE & WIRES
A-003
D TELEMATICS BOX
SP-002
D
1
G066C BK 0.75 G066A BK 1.0 SH23: B-5
2
3 SH23: A-5
G066B BK 1.0
4
5
6
7
8
9
10
11
12
13
14
15
16 SP-003*
17
5362C YE 0.75 5362A YE 1.0 SH23: B-5
18
19 SH23: A-5
5362B YE 1.0
20
21
22
23
V-001
24
DIODE-1
25
26 3
3463A YE 1.0 SH23: D-5 1191A YE 1.0
C 27
29
SP-010* 1231A VT 1.0
1
C
3463C YE 0.75 3463B YE 1.0 SH23: B-5
2
7081A WH 1.0
28 SH23: B-5
1320A OR 1.0
X-009
SP-005*
30
1320C OR 0.75 1320B OR 1.0 SH23: A-5
SP-008*
31 V-002
5376C YE 0.75 5376A YE 1.0 SH23: D-5 DIODE-1
32 3
5376B YE 1.0 SH23: B-5
1
SP-1231 1231B VT 1.0
33 SP-007*
34 2
36H4C YE 0.75 36H4A YE 1.0 SH23: D-5 SP-7081 7081B WH 1.0
35
36 SH23: B-5 X-010*
36H4B YE 1.0
V-004
DIODE-5
39 3 N
1001 YE 0.75
1 P1
1231C VT 1.0
40 SH23: B-5
1517A OR 1.0
41 2 P2
42 7081C WH 1.0
1517C OR 0.75 1517B OR 1.0 SH23: A-5
43 X-008*
SP-001
44
45
B 46
1053A WH 1.0 SH23: D-5
B
SP-006*
47
1053C WH 0.75 1053B WH 1.0 SH23: C-5
48 SH23: D-5
5353A YE 1.0
49 SP-009*
50
5353C YE 0.75 5353B YE 1.0 SH23: B-5
51
SP-004*
52
7060C YE 0.75 7060A YE 1.0 SH23: B-5
53
54 SH23: A-5
7060B YE 1.0
55
56 UNSWITCHED POWER
37 1
P018* RD 0.75
X-007*
38
G001 BK 0.75
X-006* 1
X-005A*
GND-020
A A
6 5 4 3 2 1
SHT_22 1
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ECU A-004 - INSTRUMENT CLUSTER 1A (ECU) X-001* - INSTRUMENT CLUSTER 1A [A-004] (84179604)
ECU A-005 - INSTRUMENT CLUSTER 1B (ECU) X-002* - INSTRUMENT CLUSTER 1B [A-005] (84479015)
ECU A-006 - INSTRUMENT CLUSTER 2A (ECU) X-003* - INSTRUMENT CLUSTER 2A [A-006] (51493688)
ECU A-007 - INSTRUMENT CLUSTER 2B (ECU) X-004* - INSTRUMENT CLUSTER 2B [A-007] (84478450)
Connector X-001* - INSTRUMENT CLUSTER 1A [A-004] (84179604)
Connector X-002* - INSTRUMENT CLUSTER 1B [A-005] (84479015)
Connector X-003* - INSTRUMENT CLUSTER 2A [A-006] (51493688)
Connector X-004* - INSTRUMENT CLUSTER 2B [A-007] (84478450)
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A-004
INSTRUMENT CLUSTER 1A
3
SH22: B-3 1053A WH 1.0
4
SH22: C-3 36H4A YE 1.0
16
SH22: C-3 3463A YE 1.0
D 15 D
SH22: C-3 5376A YE 1.0
10
SH22: B-3 5353A YE 1.0
6
7
8
9
14
13
12
11
X-001*
A-006
C 1
C
1558A OR 1.0
2
1310A YE 1.0
5
1401A BR 1.0
11
5195A VT 1.0
12
3433A OR 1.0
6
13
4204A VT 1.0
8
14
2142A YE 1.0
3
SH22: B-3 1053B WH 1.0
4
SH22: C-3 36H4B YE 1.0
7
10
SH22: B-3 5353B YE 1.0
15
SH22: C-3 5376B YE 1.0
16
SH22: C-3 3463B YE 1.0
B X-003* B
A-005
INSTRUMENT CLUSTER 1B
1
SH22: C-3 1320A OR 1.0
2
SH22: C-3 5362A YE 1.0
3
SH22: B-3 7060A YE 1.0
4
SH22: B-3 1517A OR 1.0
6
SH22: D-3 G066A BK 1.0
5
X-002*
A-007
5
1516A OR 1.0
1
SH22: C-3 1320B OR 1.0
A 2 A
SH22: C-3 5362B YE 1.0
3
SH22: B-3 7060B YE 1.0
4
SH22: B-3 1517B OR 1.0
6
SH22: D-3 G066B BK 1.0
X-004*
6 5 4 3 2 1
SHT_23 1
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Wiring harnesses - Electrical schematic sheet 02 SH02 - POWER DISTRIBUTION / CHARGING SYSTEM / STARTING
Fuse F-201 - MAIN FUSE (Fuse) X-P06 - [F-201] (Not serviceable) Connector X-106A - TO FRONT HARNESS (87698254)
X-P07 - TO MAIN FUSE [F-201] (84176552) Connector X-106B - TO ENGINE HARNESS (87698252)
Voltage source G-001 - BATTERY (Voltage source) X-P01 - [G-001] (Not serviceable) Connector X-107A - TO MAIN CAB HARNESS (47696599)
X-G02 - [G-001] (Not serviceable) Connector X-107B - TO FRONT HARNESS (47696620)
Voltage source G-002 - ALTERNATOR (Voltage source) X-P11 - [G-002] (Not serviceable) Connector X-111 - B+ (84364890)
Ground GND-001 - (Ground) GND-001 Connector X-133 - TO STARTER [J-002] (47663693)
Ground GND-002 - (Ground) GND-002 Connector X-G01 - (Not serviceable)
Power outlet J-002 - JUNCTION BLOCK (Power outlet) X-P09 - [J-002] (Not serviceable) Connector X-G02 - [G-001] (Not serviceable)
X-P10 - [J-002] (Not serviceable) Connector X-P01 - [G-001] (Not serviceable)
X-P12 - [J-002] (Not serviceable)
Connector X-P02 - [S-002] (Not serviceable)
X-133 - TO STARTER [J-002] (47663693)
Connector X-P03 - (Not serviceable)
Relay K-103 - ECU START INTERLOCK RELAY (Relay)
Connector X-P04 - [M-001] (Not serviceable)
Relay K-104 - NEUTRAL START INTERLOCK RELAY (Relay)
Connector X-P05 - (Not serviceable)
Relay K-125 - STARTER RELAY (Relay) X-103 - STARTER RELAY [K-125] (84297431)
Connector X-P06 - [F-201] (Not serviceable)
Motor M-001 - STARTER (Motor) X-P04 - [M-001] (Not serviceable)
X-006 - STARTER SOLENOID [M-001] (87679490) Connector X-P07 - TO MAIN FUSE [F-201] (84176552)
Switch S-002 - DISCONNECT SWITCH (Switch) X-P02 - [S-002] (Not serviceable) Connector X-P08 - (Not serviceable)
Connector X-006 - STARTER SOLENOID [M-001] (87679490) Connector X-P09 - [J-002] (Not serviceable)
Connector X-016A - TO MAIN HARNESS (84144194) Connector X-P10 - [J-002] (Not serviceable)
Connector X-016B - HARNESS ENGINE (47955799) Connector X-P11 - [G-002] (Not serviceable)
Connector X-101 - FUSES AND RELAYS BLOCK (47944420) Connector X-P12 - [J-002] (Not serviceable)
Connector X-103 - STARTER RELAY [K-125] (84297431)
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1
SH5: C-6 P201 RD 16.0
X-111
D D
P021 RD 3.0 SH24: C-6
S-002 SP-P02 P023 RD 1.5 SH16: D-6

G-001
DISCONNECT SWITCH BATTERY P020 RD 3.0
X-P03 X-G01 P028 RD 0.75 SH28: D-6
2 1
P001 RD 70.0 G001 BK 70.0
X-P08 X-P02 X-P01 POS NEG X-G02
P013 RD 6.0 SH3: B-6
GND-001
X-P05 F-201
MAIN FUSE P014 RD 6.0 SH3: A-6
SP-P01
1 2 X-016A
P003 RD 25.0 100.0A P011 RD 16.0 1 1 P012 RD 16.0 P031 RD 1.5 SH3: D-6
X-P06 X-P07 X-016B
P033 RD 2.0 SH15: D-6
J-002
P035 RD 2.0 SH15: B-6
JUNCTION BLOCK
SP-P03
P004 RD 62.0 P007 RD 16.0 SH5: A-6 P030 RD 5.0 P037 RD 2.0 SH14: C-6
X-P09 X-P12
P039 RD 1.0 SH17: C-6
P042 RD 0.75 SH19: D-6

G-002 1
ALTERNATOR P005 RD 5.0 SH25: D-6 P047 RD 2.0 SH23: C-6
C D+
X-133 C
X-P10 P052 RD 1.0 SH26: A-6
CHARGEINDICATOR
A K-103
B+ P006 RD 25.0 ECU START INTERLOCK RELAY
X-P11
W 87A
13 30
PHASE
87 21
G440 BK 0.75 SH4: D-6
GND-002
15 86 85 19
SH5: B-6 E530 YE 0.75 E270 YE 0.75 SH5: B-6
X-101 X-101
G441 BK 0.75
K-104
NEUTRAL START INTERLOCK RELAY
87A
16 30
87 24
X-107A X-106A 18 86 85 22
SH10: B-1 1032 YE 0.75 20 20 1033 YE 0.75 F F 103A YE 0.75 G445 BK 0.75 SH4: D-6
X-107B X-106B
X-101 X-101
G442 BK 0.75
K-125
B STARTER RELAY B
5 30 87 3
SH5: A-1 P010 RD 4.0 1100 WH 4.0
1 86 85 2
SH3: D-1 S507 OR 0.75
X-103 X-103
M-001
STARTER
PWR
P002 RD 70.0 GND
X-P04 M
1 A
X-006
GND-002
A A
X-106A X-107A
SH4: D-6 G500 BK 0.75 H H 2401 YE 0.75 33 33 2402 YE 0.75 SH19: A-1
X-106B X-107B
6 5 4 3 2 1
SHT_2 1
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Wiring harnesses - Electrical schematic sheet 03 SH03 - POWER

DISTRIBUTION
Fuse F-012 - CRANK (Fuse)
Fuse F-037 - IGNITION SW (Fuse)
Fuse F-042 - AUTO SHUTDOWN (Fuse)
Relay K-015 - AUTO SHUTDOWN (Relay)
Relay K-025 - SHUTDOWN POWER RELAY 1 (Relay) X-003 - SHUTDOWN POWER RELAY 1 [K-025] (84297431)
Relay K-026 - SHUTDOWN POWER RELAY 2 (Relay) X-004 - SHUTDOWN POWER RELAY 2 [K-026] (84297431)
Switch S-001 - IGNITION SWITCH (Switch) X-118 - IGNITION SWITCH [S-001] (84599241)
X-119 - IGNITION SWITCH [S-001] (87714250)
Connector X-001 - FUSES AND RELAYS BLOCK (47944422)
Connector X-003 - SHUTDOWN POWER RELAY 1 [K-025] (84297431)
Connector X-004 - SHUTDOWN POWER RELAY 2 [K-026] (84297431)
Connector X-106A - TO FRONT HARNESS (87698254)
Connector X-106B - TO ENGINE HARNESS (87698252)
Connector X-107A - TO MAIN CAB HARNESS (47696599)
Connector X-107B - TO FRONT HARNESS (47696620)
Connector X-118 - IGNITION SWITCH [S-001] (84599241)
Connector X-119 - IGNITION SWITCH [S-001] (87714250)
Connector X-120 - UNSWITCHED POWER (87745375)
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SH2: D-1 P031 RD 1.5

S-001
IGNITION SWITCH
55
CRANK 17A
3
F-037
56 1 30A HEAT 17B
1 2 4
15.0 A P032 RD 1.5
RUN
D X-002 X-118 D
OFF
F-012 S502 OR 0.75 SH19: A-6
CRANK
SP-S51 SP-S55
CRANK 50A 7 65 66 X-107A X-106A
1 2 SH5: C-6
S500 OR 1.0 5.0 A S501 OR 1.0 S503 OR 0.75 27 27 S504 OR 0.75 D D S505 OR 0.75 S506 OR 0.75
2 30B HEAT 19A X-107B X-106B
8
SH18: A-6 P300 RD 1.5 X-001 X-001 S507 OR 0.75 SH2: B-6
X-120
RUN 19B 9
X-118
OFF
SP-S01
CRANK 15/54A 5
S001 OR 1.0 S004 OR 0.75 SH19: C-6
HEAT 15/54B 6
RUN
X-119
S002 OR 0.75 SH27: C-6
OFF
F-042
53 1 2 54
S010 OR 0.75 5.0 A S009 OR 0.75 SH3: B-6
C C
X-002 X-002
S142 OR 0.75 SH22: C-6
S109 OR 3.0 SH24: B-6
S110 OR 0.75 SH21: D-6
S120 OR 1.5 SH13: D-6
K-025 S130 OR 1.0 SH16: C-6

SHUTDOWN POWER RELAY 1
5 30 SP-S10 S140 OR 2.0 SH22: B-6

87 3
SH2: D-1 P013 RD 6.0 S100 OR 6.0
1 86 85 S150 OR 2.0 SH18: B-6

2
4002 OR 0.75
X-003 S160 OR 2.0 SH18: D-6

X-003
K-015
B AUTO SHUTDOWN S170 OR 2.0 SH25: D-6

B
87A 35
28 30 4001 OR 0.75 SP-401
SH3: C-1 S009 OR 0.75 G542 BK 0.75 SH4: C-6
87 36
30 86 85 34
2022 YE 0.75 G555 BK 0.75 SH4: C-6
X-002 X-002
S210 OR 2.0 SH12: B-6
V-048
42 S220 OR 2.0 SH12: A-6
41 P N
SH19: A-1 2020 YE 0.75 2021 YE 0.75 2024 YE 0.75
K-026
SP-202
X-002 X-002 SHUTDOWN POWER RELAY 2 S230 OR 1.0 SH11: D-6
30 SP-S20
5 87 3
SH2: D-1 P014 RD 6.0 S200 OR 6.0 S240 OR 1.0 SH11: B-6
1 86 85 2
4003 OR 0.75 S250 OR 1.0 SH24: D-6
X-004 X-004
S260 OR 1.0 SH24: C-6
S270 OR 1.0 SH10: C-6

A A
S280 OR 0.75 SH20: B-6
X-107A X-106A
S290 OR 0.75 26 26 S291 OR 0.75 C C S292 OR 0.75 SH5: C-6
X-107B X-106B
G543 BK 0.75 SH4: C-6
6 5 4 3 2 1
SHT_3 1
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Wiring harnesses - Electrical schematic sheet 04 SH04 - GROUNDING

Ground GND-003 - ENGINE HARNESS GROUND - FIREWALL GND-003
(Ground)
Ground GND-005 - CHASSIS HARNESS GROUND (Ground) GND-005
Ground GND-027 - FRONT PANEL GROUND (Ground) GND-027
Connector X-008 - GROUND (84401295)
Connector X-017C - TO CAB (84600602)
Connector X-134 - TO GROUND (47763001)
Connector X-198 - BEACON GROUND (84398832)
Connector X-207 - RADIO GROUND (84398832)
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SH5: C-6 G400 BK 8.0
SP-G32 G321 BK 1.0 SH11: B-1
SH8: C-1 G410 BK 4.0 G320 BK 2.0
G322 BK 1.0 SH26: A-1
SH9: A-1 G450 BK 2.0
1
SH19: D-1 G430 BK 1.0
SP-G46 SP-G31 SH24: D-1
X-008 G311 BK 1.0
SH2: C-1 G440 BK 0.75 G460 BK 1.0
ENGINE HARNESS GROUND G312 BK 1.0 SH10: B-1
SH2: B-1 CAB FRONT - FIREWALL
G445 BK 0.75
D SH9: B-1 G480 BK 1.5
GND-003
SH21: C-1
D
G310 BK 2.0 G331 BK 0.75
X-200
SH9: B-1 G490 BK 1.5 G332 BK 1.0 SH10: C-1
SP-G33
SH2: A-6 G500 BK 0.75 G330 BK 2.0 G333 BK 1.0 SH10: D-1
G334 BK 1.0 SH11: C-1

GND-005
SH12: A-3 G561 BK 0.75 CHASSIS HARNESS GROUND G336 BK 0.75 SH19: D-1
SH12: B-4 G562 BK 0.75 G337 BK 1.0 SH24: D-1

SP-G56
G338 BK 0.75 SH19: C-1
SH10: C-1 G565 BK 0.75

G201 BK 1.5 SH15: C-1
SH10: B-1 G566 BK 0.75
G202 BK 1.5 SH15: B-1
G203 BK 1.5 SH15: B-1

SP-G20
G560 BK 2.0
SH14: B-1 G551 BK 0.75 G200 BK 2.5 G204 BK 1.5 SH15: D-1
SH15: C-1 G552 BK 0.75 G205 BK 1.0 SH23: C-1
C SH15: A-1 G554 BK 0.75 G550 BK 2.0 C

SP-G55
SH3: B-1 G555 BK 0.75
SH20: B-1 G556 BK 0.75
X-198
SH28: A-1 G541 BK 0.75 G198 BK 1.0 SH18: A-1
SH3: B-1 G542 BK 0.75
SH3: A-1 G543 BK 0.75 G540 BK 4.0 G191 BK 2.0 SH18: B-1
SP-G54
SH19: D-6 G531 BK 0.75
G192 BK 1.5 SH14: C-1
SH19: C-6 G532 BK 0.75 X-206 SP-G19
G190 BK 2.5
SH16: B-1 G533 BK 1.0 CABIN GROUND G193 BK 1.5 SH14: C-1
SH20: C-1 GND-002

G534 BK 0.75
G530 BK 4.0 G195 BK 1.0 SH17: B-1
SH27: C-1 G535 BK 0.75 SP-G53
1
SH23: C-1 G536 BK 0.75 G194 BK 1.0 SH26: C-1
X-207
SH11: D-1 G537 BK 0.75
G222 BK 5.0 SH25: B-1
B SH19: B-4 G538 BK 0.75 1

B
SH19: B-2 G521 BK 0.75 X-134 X-017C
G170 BK 1.0 1 1 G171 BK 1.0 SH25: B-1
SH12: D-1 G522 BK 1.0 X-016
SH26: D-1 G524 BK 1.0 SP-G52

G520 BK 4.0
SH24: C-1 SP-G11 SH14: B-1
G525 BK 1.0 X-017 G111 BK 0.75
G110 BK 2.0
SH19: C-1 G526 BK 0.75 G112 BK 0.75 SH26: D-1
1
SH11: B-1 G527 BK 0.75 G113 BK 1.0 SH16: A-1
SH15: C-1 G528 BK 0.75

X-208
GND-006 SP-G12
SH22: C-1 G529 BK 0.75 G121 BK 1.0 SH16: A-1
MAIN CAB HARNESS GROUND FRONT PANEL GROUND G120 BK 2.0
SH18: C-1 G511 BK 1.5 CAB LEFT - FENDER G122 BK 0.75 SH16: D-1
GND-027
SH22: B-1 G510 BK 3.0 G123 BK 0.75 SH10: A-1
SH19: A-1 G502 BK 1.0

G130 BK 0.75 SH21: C-1
SH13: B-1 G211 BK 1.0 SP-G58
G210 BK 2.0
SH13: A-1 G213 BK 1.0
A A
SP-G57
G571 BK 1.5 SH12: B-1
G570 BK 2.0
G572 BK 1.5 SH12: A-1
6 5 4 3 2 1
SHT_4 1
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Wiring harnesses - Electrical schematic sheet 05 SH05 - ENGINE CONTROL

ECU A-001 - ENGINE CONTROLLER UNIT (ECU) X-462 - ECU [A-001] (84474053) Connector X-108 - MAIN ECU RELAY [K-100] (84297431)
ECU A-010 - GCU (ECU) X-469 - GCU [A-010] (84356962) Connector X-461 - ECU (84474047)
ECU A-013 - J-CASE FUSE HOLDER (ECU) X-P13 - [A-013] (Not serviceable) Connector X-463 - WATER IN FUEL SWITCH [B-007] (87709663)
X-475 - J-CASE FUSE HOLDER [A-013] (87693326) Connector X-469 - GCU [A-010] (84356962)
Sensor B-007 - WIF SWITCH (Sensor) X-463 - WATER IN FUEL SWITCH [B-007] (87709663) Connector X-470 - EINGINE INTERFACE (84154706)
Sensor B-010 - AIR TEMP SENSOR (Sensor) X-474 - AIR TEMP SENSOR [B-010] (84607243) Connector X-474 - AIR TEMP SENSOR [B-010] (84607243)
Sensor B-9005 - EXHAUST GAS ABSOLUTE PRESSURE SENSOR X-9018 - EXHAUST GAS ABSOLUTE PRESSURE SE Connector X-475 - J-CASE FUSE HOLDER [A-013] (87693326)
(Sensor) [B-9005] (84146681) Connector X-9018 - EXHAUST GAS ABSOLUTE PRESSURE SE
Fuse F-101 - ENGINE IGNITION (Fuse) [B-9005] (84146681)
Fuse F-102 - EL VALVE / SCR RELAYS B+ (Fuse) Connector X-9034 - GLOW PLUG - CYLINDER 1 [R-9001] (1-928-404-879)
Fuse F-103 - ECU B+1 (Fuse) Connector X-9035 - GLOW PLUG - CYLINDER 2 [R-9002] (1-928-404-879)
Fuse F-104 - ECU B+ 2 (Fuse) Connector X-9036 - GLOW PLUG - CYLINDER 3 [R-9003] (1-928-404-879)
Relay K-100 - MAIN ECU RELAY (Relay) X-108 - MAIN ECU RELAY [K-100] (84297431) Connector X-9037 - GLOW PLUG - CYLINDER 4 [R-9004] (1-928-404-879)
Resistor R-9001 - GLOW PLUG - CYLINDER 1 (Resistor) X-9034 - GLOW PLUG - CYLINDER 1 [R-9001] (1-928-404-879) Connector X-9040A - (Not Serviceable)
Resistor R-9002 - GLOW PLUG - CYLINDER 2 (Resistor) X-9035 - GLOW PLUG - CYLINDER 2 [R-9002] (1-928-404-879) Connector X-9040B - (Not Serviceable)
Resistor R-9003 - GLOW PLUG - CYLINDER 3 (Resistor) X-9036 - GLOW PLUG - CYLINDER 3 [R-9003] (1-928-404-879) Connector X-9138B - ENGINE SENSOR HARNESS TO VEHICLE
Resistor R-9004 - GLOW PLUG - CYLINDER 4 (Resistor) X-9037 - GLOW PLUG - CYLINDER 4 [R-9004] (1-928-404-879) (84154706)
Connector X-101 - FUSES AND RELAYS BLOCK (47944420) Connector X-P13 - [A-013] (Not serviceable)
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31 A-001
S408 RD 1.0 ENGINE CONTROLLER UNIT
F-102
SP-S42
1 32 5 1-5
2
7.5 A S409 RD 1.0 S404 RD 2.5 BATTERY +C
1-68 68
X-101 3 E680 YE 0.5 SH28: C-1
1-3 ISO K
S405 RD 2.5 BATTERY +B
SH6: D-1 S410 RD 1.0 1 1-1

S407 RD 2.5 BATTERY VOLTAGE
D SH7: B-6 S411 RD 0.75 D
F-103
SH7: A-6 S412 RD 0.75 38 1 2 SP-E72
7.5 A 72
1-72
SH9: A-6 S413 RD 0.75 E720 YE 0.75 E721 YE 1.5 SH9: B-1
SUPPLY MODULE PUMP CONTROL SIG
SP-S43 37
S406 RD 2.5 76
1-76
F-104 SUPPLY MODULE PUMP CONTROL SIG E760 YE 0.75
44 1 2
S403 RD 3.0 20.0 A
SP-S41
43
S402 RD 3.0
25 TP-007 TP-007
1-25
X-101 L007 GN 0.5 SH28: B-1
CAN 1 LO
K-100
MAIN ECU RELAY 1-24 24
H007 YE 0.5 SH28: B-1
CAN 1 HIGH
SP-P20
5 30 87 3
SH2: D-6 P201 RD 16.0 P102 RD 10.0 S401 RD 10.0
2 86 85 1 28 1-28
SH7: B-6 P210 RD 6.0 P103 RD 0.5 E280 BL 0.5 MAIN RELAY
X-108 X-108 SP-G40 2 1-2

SH4: D-6 G400 BK 8.0 G401 BK 2.5 BATTERY MINUS 1 1-20 20
4 1-4 AIR TEMP GND E200 WH 0.5
SH7: B-1 BATTERY MINUS 2 B-010
G405 BK 0.75 G402 BK 2.5
B-007 1-6 AIR TEMP SENSOR
C WIF SWITCH G403 BK 2.5
6
BATTERY MINUS 3 1-19 19 T
C
1 P N 2
AIR TEMP SIGNAL E190 YE 0.5
3 PWR GND 2 X-474 X-474
G404 BK 0.75
SH3: A-1 S292 OR 0.75
X-463 1 30 1-30
OUT
E300 YE 0.75 WIF LEVEL SIGNAL B-9005
25 X-463 EXHAUST GAS ABSOLUTE PRESSURE SENSOR
F-101 S294 OR 0.75 1-18 18 X-9138B 1 PWR GND 2

26 54 1-54 EXHAUST GAS PRESS SENS SIG (P3) E180 BL 0.5 21 21 EN-9143 GY/YE 0.5
1 2
7.5 A S293 OR 0.75 S295 OR 0.75 IGNITION
SP-154 1-57 57 3 OUT
X-101 8 1-8 EXHAUST GAS PRESS SENS SIG (P3) E570 BL 0.5 23 23 EN-9120 WH/BL 0.5 X-9018
SH3: D-1 S506 OR 0.75 START SW SIGNAL 1-37 37 X-9018
EXHAUST GAS PRESS SENS SIG (P3) E370 BL 0.5 22 22 EN-9118 BR 0.5
27 1-27 X-470
SH2: C-1 E270 YE 0.75 STARTER RELAY LOW SIDE X-461
53 1-53
SH2: C-6 E530 YE 0.75 STARTER RELAY HIGH SIDE
R-9001
GLOW PLUG - CYLINDER 1 A-010
X-9040A X-9138B
1 GCU
GP-9001 GN/WH 2.5 4 4 EN-9058 GN/WH 2.5 61 61 1560 WH 2.0
B X-9034 4 VBAT B
R-9002 8 26 1-26
CTRL LINE
E260 YE 0.5 GLOW PLUG SIGNAL
GLOW PLUG - CYLINDER 2
1
GP-9002 YE 2.5 3 3 EN-9059 YE 2.5 60 60 3 22 1-22
DIAGNOSIS
E220 YE 0.5 GLOW PLUG SIGNAL
X-9035
2 PLUG 1
R-9003
GLOW PLUG - CYLINDER 3 7 PLUG 2
1 1570 WH 2.0
GP-9003 PRP 2.5 2 2 EN-9060 PRP 2.5 58 58 1 PLUG 3
1580 WH 2.0 SP-205 1-41
GND 5 41
X-9036
E411 BK 4.0 E410 BK 0.75 GLOW PLUG GROUND
R-9004 6 PLUG 4
GLOW PLUG - CYLINDER 4 1590 WH 2.0
1 X-469 X-461
GP-9004 BL 2.5 1 1 EN-9061 BL 2.5 57 57 X-469 SH7:B-4, SH7:D-4, SH6:A-4
X-9040B X-470
X-9037
A-013
J-CASE FUSE HOLDER
A A
60.0 A P008 RD 6.0
IN B B
A SH2: C-4 P007 RD 25.0 40.0 A P009 RD 6.0 SH9: B-6 A
X-P13
C C
20.0 A P010 RD 4.0 SH2: B-6
X-475
6 5 4 3 2 1
SHT_5 1
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Wiring harnesses - Electrical schematic sheet 06 SH06 - ENGINE CONTROL

ECU A-001 - ENGINE CONTROLLER UNIT (ECU) X-462 - ECU [A-001] (84474053) Connector X-9011 - THROTTLE VALVE ACTUATOR [Z-9001] (84360293)
Sensor B-9001 - BOOST PRESSURE AND TEMPERATURE SENSOR X-9003 - BOOST PRESSURE AND TEMPERATURE S Connector X-9016 - OIL PRESSURE SWITCH [S-9016] (87687239)
(Sensor) [B-9001] (87709809) Connector X-9021 - INCREMENT SPEED SENSOR (CRANKSHA
Sensor B-9002 - FUEL TEMPERATURE SENSOR (T) (Sensor) X-9005 - FUEL TEMPERATURE SENSOR (T) [B-9002] [B-9007] (Not Serviceable)
(87709793) Connector X-9026 - RAIL PRESSURE SENSOR (P) [B-9004] (84146683)
Sensor B-9003 - COOLANT TEMPERATURE SENSOR (T) (Sensor) X-9006 - COOLANT TEMPERATURE SENSOR (T) [B-9003] Connector X-9030 - INJECTOR 1 [Y-9001] (Not Serviceable)
(87709793) Connector X-9030A - INJECTOR 1 [Y-9001] (Not Serviceable)
Sensor B-9004 - RAIL PRESSURE SENSOR (P) (Sensor) X-9026 - RAIL PRESSURE SENSOR (P) [B-9004] (84146683) Connector X-9031 - INJECTOR 3 [Y-9003] (Not Serviceable)
Sensor B-9007 - INCREMENT SPEED SENSOR (CRANKSHAFT) X-9021 - INCREMENT SPEED SENSOR (CRANKSHA Connector X-9031A - INJECTOR 3 [Y-9003] (Not Serviceable)
(Sensor) [B-9007] (Not Serviceable) Connector X-9032 - INJECTOR 4 [Y-9004] (Not Serviceable)
Sensor B-9017 - SEGMENT SPEED SENSOR (CAMSHAFT) (Sensor) X-9008 - SEGMENT SPEED SENSOR (CAMSHAFT)â Connector X-9032A - INJECTOR 4 [Y-9004] (Not Serviceable)
[B-9017] (Not Serviceable)
Connector X-9033 - INJECTOR 2 [Y-9002] (Not Serviceable)
Sensor B-9018 - EXHAUST MANIFOLD TEMPERATURE SENSOR X-9009 - EXHAUST MANIFOLD TEMPERATURE SEN
Connector X-9033A - INJECTOR 2 [Y-9002] (Not Serviceable)
(Sensor) [B-9018] (Not Serviceable)
Connector X-9038 - WASTEGATE PRESSURE MODULATOR VAL
Switch S-9016 - OIL PRESSURE SWITCH (Switch) X-9016 - OIL PRESSURE SWITCH [S-9016] (87687239)
[Y-9008] (Not Serviceable)
Connector X-462 - ECU [A-001] (84474053)
Connector X-9138B - ENGINE SENSOR HARNESS TO VEHICLE
Connector X-470 - EINGINE INTERFACE (84154706) (84154706)
Connector X-471 - ELECTRIC VALVE (87698252) Connector X-9139B - ENGINE INJECTORS HARNESS TO VEHI (Not
Connector X-9003 - BOOST PRESSURE AND TEMPERATURE S Serviceable)
[B-9001] (87709809) Solenoid Y-9000 - FUEL METERING UNIT HP FUEL PUMP (Solenoid) X-9007 - FUEL METERING UNIT HP FUEL PUMP [Y-9000]
Connector X-9005 - FUEL TEMPERATURE SENSOR (T) [B-9002] (87709798)
(87709793) Solenoid Y-9001 - INJECTOR 1 (Solenoid) X-9030A - INJECTOR 1 [Y-9001] (Not Serviceable)
Connector X-9006 - COOLANT TEMPERATURE SENSOR (T) [B-9003] Solenoid Y-9002 - INJECTOR 2 (Solenoid) X-9033A - INJECTOR 2 [Y-9002] (Not Serviceable)
(87709793)
Solenoid Y-9003 - INJECTOR 3 (Solenoid) X-9031A - INJECTOR 3 [Y-9003] (Not Serviceable)
Connector X-9007 - FUEL METERING UNIT HP FUEL PUMP [Y-9000]
Solenoid Y-9004 - INJECTOR 4 (Solenoid) X-9032A - INJECTOR 4 [Y-9004] (Not Serviceable)
(87709798)
Solenoid Y-9008 - WASTEGATE PRESSURE MODULATOR VALVE X-9038 - WASTEGATE PRESSURE MODULATOR VAL
Connector X-9008 - SEGMENT SPEED SENSOR (CAMSHAFT)â
(Solenoid) [Y-9008] (Not Serviceable)
Sub-Assembly Z-9000 - EXHAUST GAS RECIRCULATION (EGR) VALVE X-9010 - EXHAUST GAS RECIRCULATION (EGR) [Z-9000]
Connector X-9009 - EXHAUST MANIFOLD TEMPERATURE SEN
(Sub-Assembly) (84360293)
Sub-Assembly Z-9001 - THROTTLE VALVE ACTUATOR (Sub-Assembly) X-9011 - THROTTLE VALVE ACTUATOR [Z-9001] (84360293)
Connector X-9010 - EXHAUST GAS RECIRCULATION (EGR) [Z-9000]
(84360293)
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Y-9001 A-001
INJECTOR 1 ENGINE CONTROLLER UNIT
TP-001 X-9139B TP-301

1 N 2 32 2-32
P
INJ-269 BR 1.5 B B F320 GY 1.5 INJECTOR LOW BANK 1
X-9030 X-9030A S410 RD 1.0 SH5: D-6
16 2-16
INJ-268 BL 1.5 A A F160 WH 1.5 INJECTOR HIGH BANK 1
Y-9008
Y-9003 WASTEGATE PRESSURE MODULATOR VALVE
INJECTOR 3 X-9138B
D TP-016 TP-016
D
1 P N 2
TP-003 TP-302 28 28 EN-9024 WH/BR 0.75
1 N 2 31 2-31
P
INJ-271 WH 1.5 C C F310 GY 1.5 INJECTOR 1 LOW BANK 2
X-9031 X-9031A 4 X-9038 X-9038
2-4
1 2-1 BOOST PRESSURE ACTUATOR 1 F040 GY 1.0 27 27 EN-9133 RD 0.75
INJ-270 PRP 1.5 D D F010 WH 1.5 INJECTOR 1 HIGH BANK 2
Y-9004
INJECTOR 4
TP-005 TP-303 B-9018

1 N 2 48 2-48
P EXHAUST MANIFOLD TEMPERATURE SENSOR
INJ-573 GN/PRP 1.5 F F F480 GY 1.5 INJECTOR 2 LOW BANK 1
X-9032 X-9032A 27 1
2-27 2 N T P
17 2-17 INLET TURBINE TEMP SENS GND 2270 BL 0.5 25 25 EN-9119 YE/BR 0.5
INJ-572 OR/BL 1.5 E E F170 WH 1.5 INJECTOR 2 HIGH BANK 1
X-9009 X-9009
Y-9002
2-43 43
INJECTOR 2 EN-9121 WH/GN 0.5
INLET TURBINE TEMP SENS SIGNAL 2430 YE 0.5 26 26
1 2 TP-007 TP-304 46 2-46

P N
INJ-575 GY 1.5 G G F460 GY 1.5 INJECTOR 2 LOW BANK 2
X-9033 X-9033A
2 2-2
INJ-574 YE/OR 1.5 H H F020 WH 1.5 INJECTOR 2 HIGH BANK 2 Z-9000
X-471 EXHAUST GAS RECIRCULATION (EGR) VALVE
S-9016
2-39 39 2
OIL PRESSURE SWITCH F390 YE 0.5 34 34 EN-9093 BL/WH 0.5
C EGR POSITION SENSOR SIGNAL
2-9 9 6 4
C
P EGR POSITION SENSOR SUPPLY F090 PK 0.5 33 33 EN-9094 BL 0.5
1 X-9138B 50 TP-307 TP-307 5
OUT IN 6 2-6 2-50 1
EN-9105 GY/BL 0.5 3 3 F060 WH 0.5 OIL PRESSURE SWITCH SIGNAL EGR ACTUATOR MOTOR + F500 WH 0.75 29 29 EN-9095 BL/WH 0.75
X-9016
35 X-9010 X-9010
2-35
EGR ACTUATOR MOTOR - F350 GY 0.75 30 30 EN-9096 GY/OR 0.75
B-9004 24
2-24
RAIL PRESSURE SENSOR (P) EGR POSITION SENSOR GND F240 WH 0.5 35 35 EN-9097 PRP 0.5
3 TP-305
PWR GND 1 26 2-26
EN-9106 GN/OR 0.5 5 5 F260 BL 0.5 RAIL PRESSURE SENSOR GND
OUT 2 41 2-41
X-9026 EN-9107 YE/BL 0.5 6 6 F410 YE 0.5 RAIL PRESSURE SENSOR SIGNAL
Z-9001
X-9026 THROTTLE VALVE ACTUATOR
11 2-11
EN-9108 GY/GN 0.5 7 7 F110 PK 0.5 RAIL PRESSURE SENSOR SUPPLY 2-53 53 5
TVA POSITION SENSOR SIGNAL F530 YE 0.5 42 42 EN-9099 BL/OR 0.5
B-9007 2-8 8 1 3
INCREMENT SPEED SENSOR (CRANKSHAFT) TVA POSITION SENSOR SUPPLY F080 PK 0.5 41 41 EN-9098 BR/BL 0.5
1 TP-306 49 TP-308 TP-308 2
1 59 2-59 2-49 6
EN-9113 BL 0.5 9 9 F590 YE 0.5 CRANK SPEED SIGNAL + TVA ACTUATOR MOTOR + F490 WH 0.75 37 37 EN-9134 OR/GN 0.75
34 X-9011 X-9011
2-34
TVA ACTUATOR MOTOR - F340 GY 0.75 38 38 EN-9135 BL/OR 0.75
2 2 44 2-44 2-37 37
B EN-9112 PRP 0.5 10 10 F440 YE 0.5 CRANK SPEED SIGNAL - TVA POSITION SENSOR GROUND F370 WH 0.5 43 43 EN-9100 WH/OR 0.5
B
X-9021
B-9017
SEGMENT SPEED SENSOR (CAMSHAFT)
Y-9000
1 GND PWR 3 13 2-13 FUEL METERING UNIT HP FUEL PUMP
EN-9109 WH 0.5 12 12 F130 PK 0.5 SEGMENT SPEED SUPPLY
OUT 2 15 TP-309 TP-309 2

14 2-14 2-15 1 P N
X-9008 EN-9111 GY 0.5 4 4 F140 YE 0.5 SEMENT SPEED SIGNAL FUEL METERING UNIT SUPPLY F150 WH 1.0 1 1 EN-9137 PRP/WH 0.75
X-9008 X-9007 X-9007

28 2-28 2-60 60
EN-9110 PRP/GN 0.5 8 8 F280 BL 0.5 SEGMENT SPEED GND FUEL METERING UNIT F600 GY 1.0 2 2 EN-9136 OR/WH 0.75
B-9003
COOLANT TEMPERATURE SENSOR (T) B-9001
2 1 57 2-57 BOOST PRESSURE AND TEMPERATURE SENSOR
T
EN-9115 YE 0.5 14 14 F570 YE 0.5 COOLANT TEMP SIGNAL
N P
2-25 25 1 GND PWR 3
X-9006 X-9006 58 2-58 BOOST PRESSURE SENSOR GND F250 WH 0.5 19 19 EN-9103 BR/PRP 0.5
EN-9114 GN 0.5 13 13 F580 BL 0.5 COOLANT TEMP GND
X-9003
2-40 40 4 P
BOOST PRESSURE SENSOR SIGNAL F400 YE 0.5 18 18 EN-9101 BL/BR 0.5
B-9002
FUEL TEMPERATURE SENSOR (T)
1 T 2 23 2-23 2-55 55 2 T
EN-9116 PK 0.5 15 15 F230 BL 0.5 FUEL TEMP GND BOOST PRESSURE TEMP SENSOR SIGNAL F550 YE 0.5 20 20 EN-9104 WH 0.5
N P
A X-9005 X-9005
X-9003
A
38 2-38 2-10 10
EN-9117 BR/WH 0.5 16 16 F380 YE 0.5 FUEL TEMP SIGNAL BOOST PRESSURE SENSOR SUPPLY F100 PK 0.5 17 17 EN-9102 PRP/OR 0.5
X-470 X-462 X-462 X-470
SH5:B-3
6 5 4 3 2 1
SHT_6 1
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Wiring harnesses - Electrical schematic sheet 07 SH07 - ENGINE

CONTROL
ECU A-001 - ENGINE CONTROLLER UNIT (ECU) X-462 - ECU [A-001] (84474053)
Sensor B-009 - CATALYST TEMP (DOWNSTREAM) (Sensor) X-618 - CATALYST TEMP (DOWNSTREAM) [B-009]
(84532147)
Sensor B-011 - CATALYST TEMP (UPSTREAM) (Sensor) X-617 - CAT TEMP SENSOR UPSTREAM [B-011] (84532147)
Fuse F-105 - SCR PUMP MODULE/SCR HEATING VALVE (Fuse)
Fuse F-106 - SCR PUMP MODULE (Fuse)
Fuse F-112 - AUXULIARY IGNTION (Fuse)
Relay K-101 - AUXILIARY MAIN RELAY (Relay)
Relay K-102 - SCR MAIN RELAY (Relay)
Connector X-461 - ECU (84474047)
Connector X-462 - ECU [A-001] (84474053)
Connector X-617 - CAT TEMP SENSOR UPSTREAM [B-011] (84532147)
Connector X-618 - CATALYST TEMP (DOWNSTREAM) [B-009]
(84532147)
Connector X-636A - RIGHT SIDE POD HARNESS (47416278)
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A-001
ENGINE CONTROLLER UNIT
3 2-3
SH9: D-6 F030 YE 1.5 DOSING VALVE L
18 2-18
D SH9: D-1 F180 BL 1.5 DOSING VALVE H D
45 2-45
SH9: B-1 F450 YE 1.5 PURGING PUMP SIGNAL
20 2-20
SH7: A-1 F200 YE 0.75 SCR MAIN RELAY 2-7 7
PRESSURE SENSOR SUPPLY F070 PK 0.75 SH9: B-1
X-462
2-56 56
PRESSURE SENSOR SIGNAL F560 YE 0.75 SH9: B-1
2-5 5
PRESSURE SENSOR GND F050 BL 0.75 SH9: B-1
X-462
SH5:B-3
A-001
ENGINE CONTROLLER UNIT
7 1-7
SH9: C-1 E070 YE 0.75
C SCR TANK HEATING VALVE SIGNAL
1-81 81
C
TP-201 TP-201 CAT TEMP SENS UPSTREAM GND E810 BL 0.5
23 1-23
SH8: D-6 H201 YE 0.5 CAN 2 HIGH
B-011
45 1-45
SH8: D-6 L201 GN 0.5 CATALYST TEMP (UPSTREAM)
CAN 2 LOW
1-82 82 1 T 2
CAT TEMP SENS UPSTREAM SIGNAL E820 YE 0.5
B-009 P N
CATALYST TEMP (DOWNSTREAM) X-461 X-617 X-617

1 2 X-636A 79
T 1-79
E791 BL 0.5 1 1 E790 BL 0.5 CAT TEMP SENS DOWNSTREAM GND
P N
X-618 X-618
80 1-80
E801 YE 0.5 2 2 E800 YE 0.5 CAT TEMP SENS SIG DOWNSTREAM
X-636B
X-461
SH5:B-3
P113 RD 0.75 SH27: C-6
K-101
B AUXILIARY MAIN RELAY

F-112
B
87A
1 30 47 48
1 2
SH5: C-6 P210 RD 6.0 P111 RD 3.0 9 S601 OR 3.0 25.0 A S602 OR 3.0 SH8: C-6
87
SP-P21 X-101 X-101
3 86 85 7
SH5: D-6 S411 RD 0.75 G405 BK 0.75 SH5: C-6
X-101 X-101
K-102
SCR MAIN RELAY
F-105
87A SP-S70
4 30 27 28
1 2
P112 RD 3.0 12 S701 OR 3.0 S702 OR 2.0 10.0 A S703 OR 2.0 SH9: B-6
87
6 86 85 10
SH5: D-6 S412 RD 0.75 F-106
33 34
1 2
X-101 X-101 S710 OR 2.0 10.0 A S711 OR 2.0 SH9: B-6
X-101 X-101
F200 YE 0.75 SH7: D-6

A A
6 5 4 3 2 1
SHT_7 1
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Wiring harnesses - Electrical schematic sheet 08 SH08 - EXAUST SYTEM

AND CAN BUS
Sensor B-012 - NOX SENSOR UPSTREAM (Sensor) X-607 - NOX SENSOR UPSTREAM [B-012] (47514978)
Sensor B-013 - UREA SESNOR QUALITY/TEMP/LEVEL (Sensor) X-608 - UREA SENSOR [B-013] (87688719)
Sensor B-014 - NOX DOWNSTREAM SENSOR (Sensor) X-606 - NOX SENSOR DOWNSTREAM [B-014] (47514978)
Sensor B-015 - NH3 SENSOR (Sensor) X-624 - NH3 SENSOR [B-015] (84146686)
Resistor R-001 - CAN BUS TERMINATING RESISTOR (Resistor) X-460 - CAN BUS TERMINATING RESISTOR [R-001]
(47416266)
Resistor R-003 - (Resistor)
Connector X-460 - CAN BUS TERMINATING RESISTOR [R-001]
(47416266)
Connector X-606 - NOX SENSOR DOWNSTREAM [B-014] (47514978)
Connector X-607 - NOX SENSOR UPSTREAM [B-012] (47514978)
Connector X-608 - UREA SENSOR [B-013] (87688719)
Connector X-624 - NH3 SENSOR [B-015] (84146686)
Connector X-636A - RIGHT SIDE POD HARNESS (47416278)
Connector X-640A - LEFT SIDE POD HARNESS (47416277)
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SP-L21 SP-L22 SP-L23

TP-201 TP-201 TP-204 TP-204 TP-206 TP-206 TP-207 TP-207
SH7: C-6 L201 GN 0.5 L204 GN 0.5 L206 GN 0.5 L207 GN 0.5 SH9: B-6
SP-H21 SP-H22 SP-H23

SH7: C-6 H201 YE 0.5 H204 YE 0.5 H206 YE 0.5 H207 YE 0.5 SH9: A-6
TP-202
TP-200
TP-208
D D
L202 GN 0.5
H202 YE 0.5
L200 GN 0.5
H200 YE 0.5
L208 GN 0.5
H208 YE 0.5
TP-202
B-013
UREA SESNOR QUALITY/TEMP/LEVEL
X-640A TP-203 TP-203 X-640A

1 4
IG01 OR 1.0 E454 GN 0.5
TP-200
1 1 4 4
TP-208
X-640B
5
E234 YE 0.5 5 5
2
X-608 G228 BK 1.0 2 2 G412 BK 0.75
X-608 X-640B
S604 OR 0.75
B-014
NOX DOWNSTREAM SENSOR
C X-636A
2
X-636A C
SP-S61 GND G229 BK 0.75 8 8 G416 BK 1.0
1
SH7: B-1 S602 OR 3.0 S606 OR 1.0 7 7 IG02 OR 0.75 (+) UB TP-008 TP-008 SP-170 TP-007 TP-007 TP-208
3
CAN L E456 GN 0.5 E455 GN 0.5 3 3
X-606 SP-171
UC 4
CAN H E236 YE 0.5 E235 YE 0.5 4 4
X-636B
TP-009
ADRS SW G410 BK 4.0 SH4: D-6
X-606
SP-G41
E457 GN 0.5
E237 YE 0.5
G411 BK 1.5 SH9: A-1
B-015
R-001
TP-009
NH3 SENSOR
CAN BUS TERMINATING RESISTOR
TP-010 TP-010 TP-011 TP-011 X-636A TP-312 TP-312 SP-L14 TP-314
1 3 A P N B
S608 OR 1.0 5 5 IG03 OR 1.0 E458 GN 0.5 E459 GN 0.5 12 12 L312 GN 0.5 L314 GN 0.5
2 SP-173
H312 YE 0.5 H314 YE 0.5 120.0
X-636B X-624 E238 YE 0.5 E239 YE 0.5 11 11 X-460 X-460
SP-174 X-636B SP-H14
4 X-636A
G237 BK 1.0 6 6 G418 BK 1.0
X-636B
X-624
B B
B-012
NOX SENSOR UPSTREAM
2
1 GND G414 BK 1.0
(+) UB
S603 OR 1.0 3 TP-205 TP-205
CAN H L205 GN 0.5
X-607 UC 4
CAN L H205 YE 0.5
5
ADRS SW G415 BK 0.5
X-607
A A
6 5 4 3 2 1
SHT_8 1
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Wiring harnesses - Electrical schematic sheet 09 SH09 - PRE START

ECU A-008 - HCU (ECU) X-612 - HEATER CONTROL UNIT [A-008] (47514457)
ECU A-009 - PUMP MODULE (ECU) X-605 - DNOX SUPPLY MODULE [A-009] (84152570)
Sensor B-001 - SCR TANK HEATING VALVE (Sensor) X-130 - SCR TANK HEATING VALVE [B-001] (84146685)
Connector X-128 - DOSING VALVE [Y-101] (87709793)
Connector X-130 - SCR TANK HEATING VALVE [B-001] (84146685)
Connector X-195 - (47486930)
Connector X-197 - (Not serviceable)
Connector X-605 - DNOX SUPPLY MODULE [A-009] (84152570)
Connector X-612 - HEATER CONTROL UNIT [A-008] (47514457)
Connector X-633 - DEF HEATER 1 (87695900)
Connector X-634 - DEF HEATER 2 (84277533)
Solenoid Y-101 - REDUCTION AGENT DOSING VALVE (Solenoid) X-128 - DOSING VALVE [Y-101] (87709793)
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D Y-101
D
REDUCTION AGENT DOSING VALVE
2 P N 1
SH7: D-6 F030 YE 1.5 F180 BL 1.5 SH7: D-6
X-128 X-128
C C
B-001
SCR TANK HEATING VALVE
1 3
S704 OR 0.75 E070 YE 0.75 SH7: C-6
X-130 X-130
A-009
PUMP MODULE
X-638A 5 5
SH7: A-1 S703 OR 2.0 S705 OR 1.5 5 5 IG04 OR 1.5 X-638A
PURGING PUMP B+ 9 9
SP-S71 PRESSURE SENSOR SIGNAL F560* YE 0.75 9 9 F560 YE 0.75 SH7: D-1
2 2
3 PUMP MOTOR CONTROL SIGNAL E701 YE 1.5 2 2 E721 YE 1.5 SH5: D-1
3
SH7: A-1 S711 OR 2.0 3 3 IGNC OR 1.5 PUMP MOTOR B+
6 6
PURGING PUMP SIGNAL F451 YE 1.5 6 6 F450 YE 1.5 SH7: D-6
8 8
B PRESSURE SENSOR GROUND F051 BL 0.75 8 8 F050 BL 0.75 SH7: C-1
B
11 11 10 10
A-008 11 11 5051 OR 1.5 PRESSURE SENSOR B+ F071 PK 0.75 10 10 F070 PK 0.75 SH7: D-1
HEATER B+
HCU X-638B
X-605
12 12
HEATER SIGNAL G286 BK 1.5 12 12 G480 BK 1.5 SH4: D-6
X-638 ENG 4 4
X-639 L POD SH4: D-6
11 PUMP MOTOR GROUND G287 BK 1.5 4 4 G490 BK 1.5
SH5: A-1 P009 RD 6.0 X-638B
1 X-640A
5057 OR 1.5 X-605
TP-207 TP-207 9 9 6 6 1206 WH 1.5
SH8: D-1 L207 GN 0.5 CAN LOW 2
1206* WH 1.5
10 10 X-634
SH8: D-1 H207 YE 0.5 CAN HIGH X-633
4
1204 WH 1.5 7 7 1204* WH 1.5 1 1 1 1
X-640B X-633 X-634
DEF LINE HTR 1 (BLACK) DEF LINE HTR 2 (BLUE)
6 GROUND 7
SH5: D-6 S413 RD 0.75 2 2 G291 BK 2.0 2 2
X-197
X-612 X-612 X-195
X-640 ENG
X-641 L POD
A X-640A A
G290 BK 2.0 G289 BK 2.0 8 8 G450 BK 2.0 SH4: D-6
SP-282 X-640B
G411 BK 1.5 SH8: C-1
6 5 4 3 2 1
SHT_9 1
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Wiring harnesses - Electrical schematic sheet 10 SH10 - DRIVES

Fuse F-009 - TRANSMISSION (Fuse) Connector X-017B - TO MAIN CAB HARNESS (47696624)
Relay K-003 - FORWARD RELAY (Relay) Connector X-035 - LHS COMBINATION SWITCH [S-035] (84600543)
Relay K-004 - REVERSE RELAY (Relay) Connector X-045 - UNLOADING VALVE [Y-004] (84607243)
Relay K-005 - TRANSMISSION CUTOUT RELAY (Relay) Connector X-051 - BRAKE DECLUTCH SWITCH [S-010] (87716755)
Relay K-006 - NEUTRAL RELAY (Relay) Connector X-057 - DIODE [V-200] (87695900)
Switch S-010 - BRAKE DECLUTCH SWITCH (Switch) X-051 - BRAKE DECLUTCH SWITCH [S-010] (87716755) Connector X-082 - CLUTCH SHUT OFF SW. [S-026] (84182898)
Switch S-018 - CLUTCH SHUT OFF SW 2 (Switch) X-083 - CLUTCH SHUT OFF SW. [S-018] (84182898) Connector X-083 - CLUTCH SHUT OFF SW. [S-018] (84182898)
Switch S-026 - CLUTCH SHUT OFF SW 1 (Switch) X-082 - CLUTCH SHUT OFF SW. [S-026] (84182898) Connector X-107A - TO MAIN CAB HARNESS (47696599)
Switch S-035 - LHS COMBINATION SW (Switch) X-035 - LHS COMBINATION SWITCH [S-035] (84600543) Connector X-107B - TO FRONT HARNESS (47696620)
Connector X-001 - FUSES AND RELAYS BLOCK (47944422) Solenoid Y-001 - REVERSE SPEED SOL VALVE (Solenoid) X-013 - REVERSE SPEED SOLENOID VALVE (BL [Y-001]
Connector X-002 - FUSES AND RELAYS BLOCK (47944422) (47933788)
Connector X-012 - FORWARD SPEED SOLENOID VALVE (YE [Y-002] Solenoid Y-002 - FORWARD SPEED SOL VALVE (Solenoid) X-012 - FORWARD SPEED SOLENOID VALVE (YE [Y-002]
(47933796) (47933796)
Connector X-013 - REVERSE SPEED SOLENOID VALVE (BL [Y-001] Solenoid Y-004 - HIGH SPEED SOLENOID (UNLOADING VALVE) X-045 - UNLOADING VALVE [Y-004] (84607243)
(47933788) (Solenoid)
Connector X-017A - TO CHASSIS HARNESS (47696606)
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K-004
REVERSE RELAY
Y-001
87A
16 30 REVERSE SPEED SOL VALVE
S27B OR 1.0 87 X-017B 1
24 P N 2
7080 WH 1.0 H H 7081 WH 1.0 G333 BK 1.0 SH4: D-1
18 86 85 22 X-017A
5261 WH 0.75 G564 BK 0.75 X-013 X-013
V-047
X-001 X-001 39 40
P N SH20: C-1
G602 BK 0.75
D X-002 X-002
D
5262 WH 1.0 SH26: D-6
5264 WH 1.0 SH13: A-6
S-035 SP-526
V-020
LHS COMBINATION SW 45 46
P N SH27: B-6
X-107A 5263 WH 1.0 1191 YE 1.0 1192 YE 0.75
1 4
5220 WH 1.0 18 18 5260 WH 1.0
X-107A 3 X-001 V-019 X-001 SP-119
IN
17 17 S274 OR 1.0 43 44
P N
X-107B 5272 VT 1.0 1190 YE 1.0
2 6
X-035 5230 VT 1.0 19 19 5270 VT 1.0
X-107B X-001 X-001
X-035
S273 OR 1.0
SP-527
K-003
FORWARD RELAY
Y-002
87A
13 30 FORWARD SPEED SOL VALVE
S27C OR 1.0 87 21 X-017B 1 2
P N
1230 VT 1.0 G G 1231 VT 1.0 G332 BK 1.0 SH4: D-1
86 19 X-017A
C SH3: A-1 S270 OR 1.0
SP-S27
5271 VT 0.75
15 85
G563 BK 0.75 X-012 X-012 C
V-046
X-001 X-001 37 38
P N SH20: C-1
71 G601 BK 0.75
S27A OR 1.0
F-009 X-002 X-002
SP-121 K-005
1 2 72
10.0 A S271 OR 1.0 TRANSMISSION CUTOUT RELAY
87A 32
X-001 25 30
S272 OR 1.0 G565 BK 0.75 SH4: C-6
87
27 86 85 31
1030 YE 0.75 SH19: B-6
X-001 X-001 SP-103

1032 YE 0.75 SH2: B-6
K-006
NEUTRAL RELAY
Y-004
87A 35
28 30 1031 YE 0.75 HIGH SPEED SOLENOID (UNLOADING VALVE)
X-017B
P P S276 OR 0.75 S275 OR 1.0 87 36 X-017B 1 2
P N
X-017A 1195 YE 1.0 R R 1196 YE 1.0 G312 BK 1.0 SH4: D-1
30 86 85 34 X-017A
X-045 X-045
2035 YE 0.75
X-001 X-001 G566 BK 0.75 SH4: C-6
B S-026
B
CLUTCH SHUT OFF SW 1 1193 YE 0.75
SP-204
1 2 1 2
S277 OR 0.75 S278 OR 0.75 2031 YE 0.75
X-082 X-082
S-018
CLUTCH SHUT OFF SW 2
1 2 2 X-017B X-107A
1
S279 OR 0.75 2032 YE 0.75 2030 YE 0.75 Q Q 2033 YE 0.75 2034 YE 0.75 16 16 2070 YE 0.75
SP-203 X-017A X-107B
SP-122
X-083 X-083
SWITCH CLOSES WHEN THE OPERATOR

PRESSES THE DECLUTCH BUTTON
S-010
BRAKE DECLUTCH SWITCH
8 P N 7
G123 BK 0.75 SH4: A-1
2 IN
SH13: C-1 4403 VT 0.75 V-200
A OUT 3
SP-206
2 P N 1 A
X-051 2062 YE 0.75 2060 YE 0.75
X-051 X-057 X-057
2061 YE 0.75
BRAKE DECLUTCH WILL BE ENABLED WHEN

THE SWITCH IS IN CLOSED POSITION
6 5 4 3 2 1
SHT_10 1
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Wiring harnesses - Electrical schematic sheet 11 SH11 - HYDRAULICS

Fuse F-028 - 4WD (Fuse)
Fuse F-029 - SIDE SHIFT LOCK (Fuse)
Switch S-019 - SIDE SHIFT LOCK SWITCH (Switch) X-078 - SIDE SHIFT LOCK SWITCH [S-019] (87716755)
Switch S-043 - 2WD SWITCH (Switch) X-043 - 2WD SWITCH [S-043] (87716755)
Connector X-014A - 4WD SOLENOID VALVE (BK) [Y-003] (87695900)
Connector X-017B - TO MAIN CAB HARNESS (47696624)
Connector X-043 - 2WD SWITCH [S-043] (87716755)
Connector X-047 - SIDE SHIFT LOCK SOL.VALVE [Y-006] (84607243)
Connector X-078 - SIDE SHIFT LOCK SWITCH [S-019] (87716755)
Solenoid Y-003 - 2WD SOLENOID VALVE (Solenoid) X-014A - 4WD SOLENOID VALVE (BK) [Y-003] (87695900)
Solenoid Y-006 - SIDE SHIFT LOCK SOLENOID VALVE (Solenoid) X-047 - SIDE SHIFT LOCK SOL.VALVE [Y-006] (84607243)
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D D
SH12: C-1
S-043
SH3: B-1 S230 OR 1.0 G537 BK 0.75 SH4: B-6
2WD SWITCH
8 P N 7 Y-003
73 4227 VT 0.75 2WD SOLENOID VALVE
OUT 1 X-017B 1 P N 2
F-028 25E1 YE 1.0 F F 25E2 YE 1.0 G334 BK 1.0 SH4: D-1
74 2 IN X-017A
1 2
10.0 A S231 OR 1.0 X-043 X-014A X-014A
X-002 X-043
C C
SH12: C-1
S-019
SH3: A-1 S240 OR 1.0 SIDE SHIFT LOCK SWITCH
8 P N 7
4231 VT 0.75 G527 BK 0.75 SH4: B-6
75
F-029
2 Y-006
1 2 76 IN
B 10.0 A S241 OR 1.0
X-017B
SIDE SHIFT LOCK SOLENOID VALVE
B
OUT 3 1 P N 2
X-002 X-078 2240 WH 1.0 L L 2000 WH 1.0 G321 BK 1.0 SH4: D-1
X-017A
X-078 X-047 X-047
A A
6 5 4 3 2 1
SHT_11 1
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Wiring harnesses - Electrical schematic sheet 12 SH12 - FRONT DRIVING

LIGHTS
Lamp E-001 - LEFT FRONT DRIVING LIGHT (Lamp) X-112 - TO LEFT FRONT LIGHT [E-001] (47511912)
Lamp E-002 - RIGHT DRIVING LIGHT (Lamp) X-112A - TO RIGHT FRONT LIGHT [E-002] (47511912)
Lamp E-011 - LICENSE PLATE LAMP (Lamp) X-163 - LICENSE PLATE LAMP 3 [E-011] (84182898)
Fuse F-001 - LOW BEAM LIGHTS (Fuse)
Fuse F-002 - HIGH BEAM LIGHTS (Fuse)
Fuse F-013 - SIDE SWITCHES BACKLIGHT (Fuse)
Relay K-001 - LOW BEAM RELAY (Relay)
Relay K-002 - HIGH BEAM RELAY (Relay)
Connector X-060 - RIGHT FRONT LIGHT (47416268)
Connector X-060A - LEFT FRONT LIGHT (47416268)
Connector X-102 - HARN FRONT RH (47416275)
Connector X-104 - HARN FRONT LH (47416275)
Connector X-112 - TO LEFT FRONT LIGHT [E-001] (47511912)
Connector X-112A - TO RIGHT FRONT LIGHT [E-002] (47511912)
Connector X-163 - LICENSE PLATE LAMP 3 [E-011] (84182898)
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6 5 4 3 2 1
5200 YE 1.0 SH26: B-6
4201 VT 0.75 SH21: C-6
4202 VT 0.75 SH26: D-6
D S-035
4203 VT 0.75 SH14: B-6
D
LHS COMBINATION SW
5 E-011
5
LICENSE PLATE LAMP
IN
1 P N 2
4242 VT 1.0 G522 BK 1.0 SH4: B-6
X-163 X-163
OUT
4220 VT 0.75 SH19: D-6
56 SP-422
4214 VT 1.5 4221 VT 0.75 SH19: C-6
F-013
GND-102 1 2 55
5.0 A 4213 VT 1.5 4222 VT 0.75 SH22: B-6
X-001
4223 VT 0.75 SH22: C-1
7 7 SP-420
1
4200 VT 2.0
1 4226 VT 0.75 SH23: C-6
C SH16: D-1 P027 RD 2.0
2 2 IN 2 1
SP-423 C
X-107A SP-421 4225 VT 1.5
3 8 8
X-035 4204 VT 2.0 5 5 4210 VT 2.0 4227 VT 0.75 SH11: D-6
X-107B
SH10:D-5 X-035 4228 VT 0.75 SH19: C-6
4231 VT 0.75 SH11: C-6

SP-424
4230 VT 1.5
4232 VT 0.75 SH15: C-6
4212 VT 1.0
4211 VT 1.0
4233 VT 1.0 SH13: B-6
5170 WH 0.75
5160 OR 0.75
4234 VT 0.75 SH18: D-6
3431 OR 0.75 SH19: A-6

SH3: B-1 S210 OR 2.0 E-001
LEFT FRONT DRIVING LIGHT
81 K-002 X-104 POS

1
B HIGH BEAM RELAY 1 1 420A* VT 1.0
B
F-002 87A
82 4 30
1 2 SP-343
15.0 A S211 OR 2.0 87 12 2 HB
3430 OR 2.0 3432 OR 1.5 2 2 343A GN 1.5
X-001 X-107A 6 86 85 10 4 X-104
GND
2 2 5290 WH 0.75 G562 BK 0.75 SH4: D-6 G164* BK 1.5 6 6 G571 BK 1.5 SH4: A-1
X-107B 3 LB X-060A
X-001 X-001 3451 OR 1.5 3 3 345A* LB 1.5 X-112
5 LEFT
SH16: B-1 3528 VT 1.0 5 5 350A* YE 1.0
X-060A
X-112
SH3: B-1 S220 OR 2.0 E-002

RIGHT DRIVING LIGHT
K-001 X-102 POS

79 1
LOW BEAM RELAY 1 1 420A VT 1.0
F-001 87A
80 1 30
1 2 SP-345
15.0 A S221 OR 2.0 87 9 2 HB
3450 OR 2.0 3433 OR 1.5 2 2 343A* GN 1.5
X-001 X-107A 3 86 85 7 4 X-102
GND
A 3 3 5300 OR 0.75 G561 BK 0.75 SH4: D-6 G164 BK 1.5 6 6 G572 BK 1.5 SH4: A-1 A
X-107B 3 LB X-060
X-001 X-001 3452 OR 1.5 3 3 345A LB 1.5 X-112A
5 LEFT
SH16: B-1 3518 WH 1.0 5 5 350A YE 1.0
X-060
X-112A
6 5 4 3 2 1
SHT_12 1
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Wiring harnesses - Electrical schematic sheet 13 SH13 - REAR DRIVING

LIGHTS
Lamp E-009 - REAR LEFT LIGHTS (Lamp) X-089 - TAIL LIGHTS [E-009] (47511912)
Lamp E-010 - REAR RIGHT LIGHTS (Lamp) X-090 - TAIL LIGHTS [E-010] (47511912)
Fuse F-004 - BRAKE LIGHTS (Fuse)
Switch S-022 - BRAKE SWITCH (Switch)
Switch S-023 - BRAKE SWITCH (Switch)
Connector X-039 - STOP LIGHT SWITCH 2 (84600562)
Connector X-040 - STOP LIGHT SWITCH 1 (84600562)
Connector X-089 - TAIL LIGHTS [E-009] (47511912)
Connector X-090 - TAIL LIGHTS [E-010] (47511912)
Connector X-090A - TO TAIL LIGHTS HARNESS (47416275)
Connector X-090B - TO MAIN CABIN HARNESS (47416268)
Connector X-091A - TO TAIL LIGHT HARNESS (47416275)
Connector X-091B - TO MAIN CABIN HARNESS (47416268)
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6 5 4 3 2 1
D D
SH3: C-1 S120 OR 1.0
S125 OR 0.75 SH19: D-1
73
F-004
74 X-107A SP-150 X-040 S-023
1 2
10.0 A S121 OR 1.0 7 7 S122 OR 1.0 S123 OR 1.0 1 1
BRAKE SWITCH
X-001 2 1
4402 VT 1.0 2 2
X-053
C C
X-039 S-022
S124 OR 1.0 1 1
BRAKE SWITCH
SP-440 2 1
4405 VT 1.0 8 8 4404 VT 1.0 4401 VT 1.0 2 2
X-107B X-054
4403 VT 0.75 SH10: A-6
4408 VT 0.75 SH19: B-6
E-009
REAR LEFT LIGHTS
SP-441
X-091A 1 BRAKE
4407 VT 1.0 4411 VT 1.0 1 1 4410 WH 1.0
SP-222
2 TAIL
4241 VT 1.0 2 2 4240 RD 1.0
GND 4 X-091A
G212 BK 1.0 6 6 G211 BK 1.0 SH4: A-6
3 TURN X-091B
SH16: B-1 3526 VT 1.0 3 3 3527 OR 1.0 X-089
B B
6 REVERSE
5266 WH 1.0 4 4 5268 PK 1.0
X-091B
X-089
SH12: C-1 4233 VT 1.0 SP-425
E-010
REAR RIGHT LIGHTS
X-090A 1 BRAKE
4412 VT 1.0 1 1 4413 WH 1.0
2 TAIL
4243 VT 1.0 2 2 4244 RD 1.0
GND 4 X-090A
G214 BK 1.0 6 6 G213 BK 1.0 SH4: A-6
3 TURN X-090B
SH16: B-1 3516 WH 1.0 3 3 3517 OR 1.0 X-090
6 REVERSE
SH10: D-1 5264 WH 1.0 5267 WH 1.0 4 4 5265 PK 1.0
SP-52A
A X-090B A
X-090
6 5 4 3 2 1
SHT_13 1
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Wiring harnesses - Electrical schematic sheet 14 SH14 - FRONT WORK

LIGHTS
Lamp E-003 - FRONT WORK LIGHT 1 (Lamp) X-071 - FRONT WORK LAMP 1 [E-003] (84182898)
Lamp E-004 - FRONT WORK LIGHT 2 (Lamp) X-058 - FRONT HEAD LAMP 2 [E-004] (84182898)
Fuse F-025 - FRONT WORK LIGHTS (Fuse)
Relay K-010 - FRONT WORK LIGHTS RELAY (Relay)
Switch S-011 - FRONT WORK LIGHTS SWITCH (Switch) X-074 - FRONT WORK LIGHTS SWITCH [S-011] (87716755)
Connector X-058 - FRONT HEAD LAMP 2 [E-004] (84182898)
Connector X-071 - FRONT WORK LAMP 1 [E-003] (84182898)
Connector X-074 - FRONT WORK LIGHTS SWITCH [S-011] (87716755)
Connector X-094B - TO UPPER CAB HARNESS (48126491)
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6 5 4 3 2 1
D D
C SH2: C-1 P037 RD 2.0 C

3222 VT 0.75 SH19: C-6
K-010
79
FRONT WORK LIGHTS RELAY E-003
F-025 87A FRONT WORK LIGHT 1
80 1 30
1 2 SP-300
15.0 A P038 RD 2.0 87 9 SP-332 X-094A 1 P 2
N
3320 VT 2.0 3321 VT 2.0 1 1 3000 VT 2.0 3001 VT 1.5 G192 BK 1.5 SH4: C-1
X-002 3 86 85 7 X-094B
X-071 X-071
E-004
X-002 X-002 FRONT WORK LIGHT 2
1 P N 2
3002 VT 1.5 G193 BK 1.5 SH4: B-1
X-107A
3610 YE 0.75 12 12 3611 YE 0.75 X-058 X-058
X-107B
G551 BK 0.75 SH4: C-6

S-011
FRONT WORK LIGHTS SWITCH
8 P N 7
SH12: D-1 4203 VT 0.75 G111 BK 0.75 SH4: B-1
B X-107A 2
B
IN
SH16: C-1 S135 OR 0.75 11 11 S136 OR 0.75
X-107B OUT 3
X-074
X-074
A A
6 5 4 3 2 1
SHT_14 1
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Wiring harnesses - Electrical schematic sheet 15 SH15 - REAR WORK

LIGHTS
Lamp E-005 - REAR WORK LIGHT 1 (Lamp) X-068 - REAR WORKING LAMP 1 [E-005] (84182898)
Fuse F-026 - REAR WORKING LIGHTS (Fuse)
Fuse F-027 - REAR WORK LIGHTS (Fuse)
Relay K-011 - REAR WORKING LIGHTS RELAY (Relay)
Relay K-013 - REAR WORKING LIGHTS RELAY (Relay)
Switch S-012 - REAR WORK LIGHTS SWITCH (Switch) X-077 - REAR WORK LIGHTS SWITCH [S-012] (87716755)
Connector X-065 - REAR WORKING LAMP 3 [E-007] (84182898)
Connector X-077 - REAR WORK LIGHTS SWITCH [S-012] (87716755)
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6 5 4 3 2 1
D D
SH2: C-1 P033 RD 2.0

42C1 VT 0.75 SH19: C-6
K-011
81
REAR WORKING LIGHTS RELAY E-005
F-026 87A REAR WORK LIGHT 1
1 82 4 30
2
15.0 A P034 RD 2.0 X-094A SP-301 P N
87 12 SP-42C 1 2
42C0 VT 2.0 42C2 VT 2.0 2 2 42C3 VT 2.0 42C4 VT 1.5 G204 BK 1.5 SH4: C-1
X-002 6 86 85 10 X-094B
X-068 X-068
E-006
X-002 X-002 REAR WORK LIGHT 2
1 P N 2
42C5 VT 1.5 G201 BK 1.5 SH4: C-1
X-067 X-067
42C7 YE 0.75
G552 BK 0.75 SH4: C-6
C C
S-012
REAR WORK LIGHTS SWITCH
8 P N 7
SH12: C-1 4232 VT 0.75 G528 BK 0.75 SH4: B-6
2 IN1
SH16: C-1 S137 OR 0.75
OUT1 3
5 IN2
SH16: C-1 S134 OR 0.75
OUT2 6
X-077
X-077
SH2: C-1 P035 RD 2.0 7095 OR 0.75
B 83 K-013
REAR WORKING LIGHTS RELAY E-007
B
F-027 REAR WORK LIGHT 3
87A
1 2 84 16 30
15.0 A P036 RD 2.0 X-094A SP-302
87 24 1 P N 2
7094 WH 2.0 3 3 3023 VT 2.0 3021 VT 1.5 G203 BK 1.5 SH4: C-1
X-002 86 85 22 X-094B
18
X-065 X-065
E-008
X-002 X-002 REAR WORK LIGHT 4
1 P N 2
3022 VT 1.5 G202 BK 1.5 SH4: C-1
X-066 X-066
G554 BK 0.75 SH4: C-6
A A
6 5 4 3 2 1
SHT_15 1
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Wiring harnesses - Electrical schematic sheet 16 SH16 - HAZARD

Lamp E-002A - TURN INDICATOR (Lamp) X-141 - TURN SIGNAL GROUND [E-002A] (87705140)
X-139 - RIGHT TURN INDICATOR [E-002A] (87705140)
X-140 - LEFT TURN INDICATOR [E-002A] (87705140)
Fuse F-003 - HAZARD LIGHTS / DRIVING LIGHTS (Fuse)
Fuse F-005 - HAZARD / WORK LIGHT SWITCHES (Fuse)
Relay K-030 - FLASHER RELAY (Relay) X-030 - FLASHER [K-030] (84479009)
Switch S-024 - RHS COMBINATION SW (Switch)
Switch S-037 - HAZARD SWITCH (Switch) X-151 - HAZARD SWITCH [S-037] (87632725)
Connector X-030 - FLASHER [K-030] (84479009)
Connector X-034 - RHS COMBINATION SWITCH [S-009] (84600631)
Connector X-139 - RIGHT TURN INDICATOR [E-002A] (87705140)
Connector X-140 - LEFT TURN INDICATOR [E-002A] (87705140)
Connector X-141 - TURN SIGNAL GROUND [E-002A] (87705140)
Connector X-151 - HAZARD SWITCH [S-037] (87632725)
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6 5 4 3 2 1
SH2: D-1 P023 RD 1.5
D 83 D
F-003
SP-514
84 X-107A
1 2
15.0 A P024 RD 1.5 34 34 P025 RD 1.5 P027 RD 2.0 SH12: C-6
X-107B
X-001
S-037
HAZARD SWITCH
P N 10
8 G122 BK 0.75 SH4: A-1
OUT1 1 X-107A
S133 OR 1.0 15 15 S132 OR 1.0
2 IN1 X-107B
5340 YE 1.0
OUT2 3
P026 RD 1.0
S134 OR 0.75 SH15: B-6

5 IN2
5332 BR 1.0
OUT3 17
X-151 3512 WH 1.0 S135 OR 0.75 SH14: B-6
C OUT4 18
3522 VT 1.0 C
X-151
SH3: C-1 S130 OR 1.0
75
F-005
1 2 76
10.0 A S131 OR 1.0 S137 OR 0.75 SH15: C-6
SP-007
X-001 K-030
FLASHER RELAY
X-107A
2 4
B P SH19: A-6
13 13 3230 YE 1.0 3240 VT 0.75
SP-533 1 3
L E SH4: B-6
5331 BR 1.0 14 14 3220 BR 1.0 G533 BK 1.0
X-107B
X-030
X-030
3528 VT 1.0 SH12: B-6
B SP-352 3524 VT 1.0

X-107A
10 10 3525 VT 1.0
SP-353
3526 VT 1.0 SH13: B-6
B
S-024
RHS COMBINATION SW
1 5
3521 VT 1.0
3518 WH 1.0 SH12: A-6
1 IN
5330 BR 1.0
3 6 SP-351 SP-354
2
3511 WH 1.0 3514 WH 1.0 9 9 3515 WH 1.0 3516 WH 1.0 SH13: A-6
X-107B
X-034 X-034
G121 BK 1.0 SH4: A-1
E-002A
TURN INDICATOR
1
N
X-141
1 P1 P N
3513 WH 1.0
X-139
1 P2
A 3523 VT 1.0
X-140
P N
A
G113 BK 1.0 SH4: B-1
6 5 4 3 2 1
SHT_16 1
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Wiring harnesses - Electrical schematic sheet 17 SH17 - DOME LIGHT

Lamp E-016 - DOME LIGHT (Lamp) X-062A - ROOF LIGHT [E-016] (84491249)
X-062B - ROOF LIGHT [E-016] (84491249)
Fuse F-032 - DOME LIGHT (Fuse)
Connector X-062A - ROOF LIGHT [E-016] (84491249)
Connector X-062B - ROOF LIGHT [E-016] (84491249)
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6 5 4 3 2 1
D D
C C
SH2: C-1 P039 RD 1.0
69 E-016
DOME LIGHT
F-032
70 X-093A 1 P N 1
1 2
5.0 A P040 RD 1.0 1 1 P041 RD 1.0 G195 BK 1.0 SH4: B-1
X-093B
X-062A X-062B
X-002
B B
A A
6 5 4 3 2 1
SHT_17 1
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Wiring harnesses - Electrical schematic sheet 18 SH18 - WIPER/WASHER

Fuse F-010 - FRONT WIPER AND WASHER (Fuse) Connector X-070 - WIPER MOTOR [M-064] (84182898)
Fuse F-011 - REAR WASHER AND WIPER (Fuse) Connector X-079 - BEACON SWITCH [S-015] (87716755)
Fuse F-202 - BEACON FUSE (Fuse) X-121 - BEACON FUSE [F-202] (47435876) Connector X-093A - TO MAIN CAB HARNESS (47511912)
Power outlet J-158 - BEACON SOCKET (Power outlet) X-158 - BEACON SOCKET [J-158] (84015523) Connector X-093B - TO UPPER CAB HARNESS (47511905)
Motor M-003 - REAR WASHER MOTOR (Motor) X-150 - REAR WASHER MOTOR [M-003] (87693325) Connector X-107A - TO MAIN CAB HARNESS (47696599)
Motor M-009 - FRONT WASHER MOTOR (Motor) X-149 - FRONT WASHER MOTOR [M-009] (87693325) Connector X-107B - TO FRONT HARNESS (47696620)
Motor M-064 - FRONT WIPER MOTOR (Motor) X-070 - WIPER MOTOR [M-064] (84182898) Connector X-121 - BEACON FUSE [F-202] (47435876)
Switch S-009 - RHS COMBINATION SW (Switch) X-034 - RHS COMBINATION SWITCH [S-009] (84600631) Connector X-129A - TO WIPER/WASHER (47416267)
X-037 - COMBINATION SWITCH [S-009] (47461910) Connector X-129B - TO FRONT PANEL HARNESS (87708112)
Switch S-014 - WIPER MOTOR (Switch) X-162 - REAR WIPER MOTOR [S-014] (87680380) Connector X-149 - FRONT WASHER MOTOR [M-009] (87693325)
Switch S-015 - BEACON SWITCH (Switch) X-079 - BEACON SWITCH [S-015] (87716755) Connector X-150 - REAR WASHER MOTOR [M-003] (87693325)
Switch S-016 - REAR WIPER /WASHER SWITCH (Switch) X-161 - REAR WIPER SWITCH [S-016] (87632724) Connector X-158 - BEACON SOCKET [J-158] (84015523)
Connector X-001 - FUSES AND RELAYS BLOCK (47944422) Connector X-161 - REAR WIPER SWITCH [S-016] (87632724)
Connector X-034 - RHS COMBINATION SWITCH [S-009] (84600631) Connector X-162 - REAR WIPER MOTOR [S-014] (87680380)
Connector X-037 - COMBINATION SWITCH [S-009] (47461910)
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6 5 4 3 2 1
1038 YE 1.0
S-016
REAR WIPER /WASHER SWITCH
D D
X-129A 10 P N 9
SH12: B-1 4234 VT 0.75 2 2 4236 VT 0.75 G027 BK 0.75
1A 11
13 IN1
1036 YE 1.0
S-014
SP-021 14 2A WIPER MOTOR
IN2 3
SH3: B-1 S160 OR 1.5 1037 YE 1.0 2 53 (MOTOR +)
3 31b
63 15 IN3 1035 BR 1.0
1040 YE 1.0 M
PARK
F-011 1
SP-020 53a
1 2 64 16 IN4 1B 6
15.0 A S162 OR 1.5 3 3 S163 OR 1.5 S164 OR 1.0 31 (GND)
4
X-129B G029 BK 1.0
X-001 X-161 X-161
X-162 X-162 SP-019 X-129A
S165 OR 1.5 G025 BK 1.5 4 4 G511 BK 1.5 SH4: A-6
M-003
X-129B
REAR WASHER MOTOR
A B
1034 WH 1.0 A M B G028 BK 1.0
X-150 X-150
C C
G026 BK 1.0
M-009
FRONT WASHER MOTOR
X-107A X-129A A B
SH3: B-1 S150 OR 2.0 1028 GY 1.0 32 32 1029 GY 1.0 1 1 102A GY 1.0 A M B
X-129B
S-009 X-149 X-149
RHS COMBINATION SW
61
1 1
F-010 M-064
1 2 62 X-107A 2 IN X-037 FRONT WIPER MOTOR
15.0 A S151 OR 2.0 1 1 S152 OR 2.0
X-107B X-093A 2
2 4 1
X-001 X-034 6301 BR 2.0 4 4 6302 BR 2.0 2 2 6304 BR 2.0 A M B G191 BK 2.0 SH4: C-1
B X-034
X-107B X-093B
X-070 X-070
B
1023 OR 1.0
S-015
BEACON SWITCH
SP-107
8 P N 7
G199 BK 1.0 G198 BK 1.0 SH4: C-1
F-202
BEACON FUSE J-158

2 2 1 1 2 IN BEACON SOCKET
SH3: D-6 P300 RD 1.5 10.0 A P301 RD 1.5
OUT 3 1 IN OUT 2
X-121 X-121 X-079 1021 OR 1.0 1022 OR 1.0 LOAD G207 BK 1.0
SP-106
X-079 X-158 X-158
A A
6 5 4 3 2 1
SHT_18 1
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Wiring harnesses - Electrical schematic sheet 19 SH19 - INSTRUMENT CLUSTER

ECU A-002 - INSTRUMENT CLUSTER (ECU) X-CN1 - CLUSTER CN1 [A-002] (82016219) Connector X-011 - TRANSMISSION OIL TEMPERATURE [R-030]
X-CN2 - CLUSTER CN2 [A-002] (82028493) (84062580)
ECU A-014 - HAND THROTTLE (ECU) X-056 - HAND THROTTLE [A-014] (47587518) Connector X-017A - TO CHASSIS HARNESS (47696606)
ECU A-015 - FOOT THROTTLE (ECU) X-155 - FOOT THROTTLE [A-015] (47416268) Connector X-017B - TO MAIN CAB HARNESS (47696624)
Fuse F-031 - CLUSTER ALWAYS-HOT/CLUSTER SWITCHES Connector X-023A - AIR FILTER SW [S-033] (87705127)
(Fuse) Connector X-026 - AIR FILTER SW [S-033] (87705127)
Fuse F-034 - CLUSTER IGN (Fuse) Connector X-038A - [S-041] (87581782)
Ground GND-008 - (Ground) GND-008 Connector X-038B - [S-041] (87581782)
Speaker H-006 - AUDIBLE ALARM (Speaker) X-044 - AUDIBLE ALARM [H-006] (47415745) Connector X-044 - AUDIBLE ALARM [H-006] (47415745)
Resistor R-002 - FUEL LEVEL SENDER (Resistor) X-146 - FUEL LEVEL SENDER [R-002] (84381192) Connector X-046 - SEAT SWITCH [S-044] (84600602)
Resistor R-030 - TRANSMISSION OIL TEMPERATURE (Resistor) X-011 - TRANSMISSION OIL TEMPERATURE [R-030] Connector X-056 - HAND THROTTLE [A-014] (47587518)
(84062580) Connector X-106A - TO FRONT HARNESS (87698254)
Switch S-006 - HYDRAULIC FILTER RESTRICTION SWITCH (Switch) X-009A - HYDRAULIC FILTER [S-006] (87679525) Connector X-106B - TO ENGINE HARNESS (87698252)
Switch S-031 - UP/DOWN CONTROL SW (Switch) X-116 - UP/DOWN SW [S-031] (87716755) Connector X-107A - TO MAIN CAB HARNESS (47696599)
Switch S-032 - DISPLAY/ENTER CONTROL SW (Switch) X-117 - DISPLAY/ENTER CONTROL SW [S-032] (87716755) Connector X-107B - TO FRONT HARNESS (47696620)
Switch S-033 - AIR FILTER SW (Switch) X-023A - AIR FILTER SW [S-033] (87705127) Connector X-116 - UP/DOWN SW [S-031] (87716755)
X-026 - AIR FILTER SW [S-033] (87705127) Connector X-117 - DISPLAY/ENTER CONTROL SW [S-032] (87716755)
Switch S-039 - AUTO IDLE SWITCH (Switch) X-135 - AUTO IDLE [S-039] (87716755) Connector X-124 - ECO MODE SWITCH [S-040] (87716755)
Switch S-040 - ECO MODE SWITCH (Switch) X-124 - ECO MODE SWITCH [S-040] (87716755) Connector X-135 - AUTO IDLE [S-039] (87716755)
Switch S-041 - BRAKE OIL LEVEL SWITCH (Switch) X-038A - [S-041] (87581782) Connector X-146 - FUEL LEVEL SENDER [R-002] (84381192)
X-038B - [S-041] (87581782)
Connector X-155 - FOOT THROTTLE [A-015] (47416268)
Switch S-044 - SEAT SWITCH (Switch) X-046 - SEAT SWITCH [S-044] (84600602)
Connector X-CN1 - CLUSTER CN1 [A-002] (82016219)
Connector X-CN2 - CLUSTER CN2 [A-002] (82028493)
Connector X-009A - HYDRAULIC FILTER [S-006] (87679525)
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SWITCH CLOSED IN FAULT CONDITION
A-002
S-033
INSTRUMENT CLUSTER AIR FILTER SW
16 X-107A X-106A 1
CN1-16 1
1160 BL 0.75 29 29 1161 BL 1.0 A A 1162 BL 1.0 G430 BK 1.0 SH4: D-6
AIR FILTER RESTRICTION
1 CN2-1 X-106B
X-023A X-026
P044 RD 0.75 UNSW B+
S-041
X-CN2 BRAKE OIL LEVEL SWITCH
SH2: C-1 P042 RD 0.75 9
CN1-9 1 2 1 1
CLUSTER B+ S-031 BRAKE FLUID LEVEL 1090 YE 0.75 30 30 1093 YE 0.75 S125 OR 0.75 SH13: C-1
67 UP/DOWN CONTROL SW X-107B
D DOWN
1 14 CN1-14
X-038B X-038A
D
F-031 1141 RD 0.75 DOWN CTRL
68 SP-P43 2 22 S-006
1 2 CN1-22
5.0 A P043 RD 0.75 P045 RD 0.75 HYD FILTER RESTRICTION 1220 YE 0.75 HYDRAULIC FILTER RESTRICTION SWITCH
3 13 CN1-13 X-017B 1 2 1
X-002 8 UP 1131 RD 0.75 UP CTRL X-CN1 A A 1223 YE 1.0
SH12: D-1 4220 VT 0.75 7
X-009A
X-116 R-002
X-116 GND-008
FUEL LEVEL SENDER
SH4: C-6 G531 BK 0.75 CN2-13 13 1 P N 2
FUEL SENDER 2130 YE 0.75 B B 2133 YE 0.75 G336 BK 0.75 SH4: D-1
S-032
X-146 X-146
DISPLAY/ENTER CONTROL SW
1 12 CN1-12 R-030
ENTER 1121 RD 0.75 ENTER CTRL TRANSMISSION OIL TEMPERATURE
2 CN2-14 14 1 2
P N SH4: D-1
P046 RD 0.75 TRANS TEMP 2140 YE 0.75 C C 2143 YE 0.75 G338 BK 0.75
3 11 CN1-11 X-017A
DISPLAY 1111 RD 0.75 DISPLAY CTRL X-011 X-011
8
SH12: D-1 4221 VT 0.75 7
S007 OR 0.75 SH19: C-6
X-117 A-014
X-117 CN2-21 21 HAND THROTTLE S-040
SH4: C-6 G532 BK 0.75 HAND GND 2211 GN 0.75 ECO MODE SWITCH
V-022
37 38 CN2-19 19 A PWR GND C 8 P N 7
P N
SH12: C-1 4228 VT 0.75 41R9 VT 0.75 +5V SUPPLY 2190 PK 0.75 G526 BK 0.75 SH4: B-6
C V-023 1A 1
C
39 40 SP-141 4 CN1-4 X-056 OUT B
P N
SH14: C-1 3222 VT 0.75 42FP VT 0.75 41RR VT 0.75 LIGHTS INPUT 2 IN1
V-024
41 42 CN2-17 17 X-056 2A 3
P N
SH15: D-1 42C1 VT 0.75 42CP VT 0.75 HAND SIGNAL 2170 YE 0.75
X-001 X-001 X-CN2 1B 4
S008 OR 0.75 5 IN2
2B 6
SH19: C-1 S007 OR 0.75 X-124
X-124
SH3: C-1 S004 OR 0.75
61 1171 YE 0.75
F-034 G507 BK 0.75
1 2 62 2 CN1-2 CN1-17 17
5.0 A S005 OR 0.75 S006 OR 0.75 IGN KEY ECO MODE 1170 BL 0.75
SP-S03 S-044
X-002
SEAT SWITCH
SH19: B-1 S012 OR 0.75 CN1-19 19 3
S-039 SEAT SWITCH 119A YE 0.75
OUT
AUTO IDLE SWITCH
X-CN1 PWR 1
2
B 1603 YE 0.75
8 P N 7
G538 BK 0.75 SH4: B-6
CN2-6
BUZZER
6
2600 WH 0.75
8
P
GND
S012 OR 0.75 SH19: B-6
B
H-006 X-046 X-046
1 X-CN2 AUDIBLE ALARM
2 N SEAT FACING FORWARD: OPEN
2 IN SEAT FACING BACKHOE: CLOSED
SP-160 X-044
OUT 3 6 CN1-6 A-015
1601 YE 0.75 1600 YE 0.75 AUTO IDLE ENABLE G521 BK 0.75 SH4: B-6
X-135 FOOT THROTTLE
X-135
CN1-20 20 6 6
7 IDLE VALIDATION 1200 BL 0.75 IVS3
CN1-7
SH13: C-1 4408 VT 0.75 FOOT BRAKE X-CN1
CN2-20 4 4
20
3 FOOT GND 2200 BL 0.75 APS GROUND
CN1-3
SH10: C-1 1030 YE 0.75 NEUTRAL
CN2-18 5 5
18
5 +5V SUPPLY 2180 PK 0.75 APS SUPPLY 5V
CN1-5
SH16: C-1 3240 VT 0.75 TURN SIGNAL
CN2-16 3 3
16
15 FOOT SIGNAL 2160 YE 0.75 APS SIGNAL
CN1-15
SH3: D-1 S502 OR 0.75 CRANKING KEY
1 1
18 IVS GROUND
CN1-18
SH20: C-1 1180 YE 0.75 PARK BRAKE
X-155
8 G506 BK 0.75 G508 BK 0.75

CN1-8
SH12: B-1 3431 OR 0.75 HIGH BEAM
A X-CN1 CN2-26 26 A
GROUND G505 BK 0.75 G503 BK 0.75 SH27: C-1
SP-G51
G502 BK 1.0 SH4: A-6
TP-005 TP-005
3 CN2-3
SH28: B-1 L005 GN 0.5 G553 BK 0.75 SH20: C-6
CAN LO
CN2-24 24
GROUND 2402 YE 0.75 SH2: A-1
4 CN2-4
SH28: B-1 H005 YE 0.5 CAN HI CN2-2 2
AUTO SHUTDOWN RELAY 2020 YE 0.75 SH3: B-6
X-CN2
X-CN2
6 5 4 3 2 1
SHT_19 1
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Wiring harnesses - Electrical schematic sheet 20 SH20 - PARK BRAKE

Fuse F-041 - BRAKE SW (Fuse)
Relay K-012 - PARK BRAKE RELAY (Relay)
Switch S-027 - PARK BRAKE SWITCH (Switch) X-027 - PARK BRAKE SWITCH [S-027] (47587518)
Connector X-027 - PARK BRAKE SWITCH [S-027] (47587518)
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6 5 4 3 2 1
D D
K-012
PARK BRAKE RELAY 1180 YE 0.75 SH19: A-6
87A 20
30 G601 BK 0.75 SH10: C-1
C SH19: A-1 G553 BK 0.75
13
87 21 SP-G60 C
G600 BK 0.75 G602 BK 0.75 SH10: D-1
15 86 85 19
G534 BK 0.75 SH4: B-6
X-002 X-002
S-027
PARK BRAKE SWITCH
B
F-041 1182 YE 0.75
OUT
BRAKE SW
51 52 A C
SH3: A-1 S280 OR 0.75 5.0 A S281 OR 0.75 G556 BK 0.75 SH4: C-6
PWR GND
X-002 X-002 X-027 X-027

SIGNAL TO HIGH
WITH PARK BRAKE RELEASED
B B
A A
6 5 4 3 2 1
SHT_20 1
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Wiring harnesses - Electrical schematic sheet 21 SH21 - SPEEDOMETER

ECU A-004 - SPEEDOMETER (ECU) X-114 - SPEEDOMETER [A-004] (87686679)
Sensor B-019 - PT SPEED SENSOR (Sensor) X-115 - SPEED SENSOR [B-019] (84062580)
Fuse F-008 - (Fuse)
Connector X-114 - SPEEDOMETER [A-004] (87686679)
Connector X-115 - SPEED SENSOR [B-019] (84062580)
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6 5 4 3 2 1
D D
SH3: C-1 S110 OR 0.75
69
F-008
1 2 70 A-004
5.0 A S111 OR 0.75 SPEEDOMETER
X-001 X-107A 3 3
SP-S04 S112 OR 0.75 23 23 S113 OR 0.75 B+
X-107B 4 4
SH12: D-1 4201 VT 0.75 ILLUMINATION B+
C 1 1
SPEED SIGNAL
C
2 2
GROUND
X-114
S114 OR 0.75
G130 BK 0.75 SH4: A-1
X-107A
2702 YE 0.75 22 22
X-107B
B-019
PT SPEED SENSOR
X-017B 3 PWR GND 2

D D S115 OR 0.75 G331 BK 0.75 SH4: D-1
X-017A
X-115 OUT 1 X-017B
2700 YE 0.75 E E 2701 YE 0.75
X-017A
X-115
B B
A A
6 5 4 3 2 1
SHT_21 1
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Wiring harnesses - Electrical schematic sheet 22 SH22 - MOBILE

CHARGER
ECU A-016 - USB PORT (ECU) X-009 - USB PORT [A-016] (47906572)
Fuse F-007 - POWER SOCKET (Fuse)
Fuse F-016 - (Fuse)
Power outlet J-001 - CHARGER SOCKET (Power outlet) X-025A - CHARGER SOCKET [J-001] (87699736)
X-025B - CHARGER SOCKET [J-001] (87705140)
Connector X-009 - USB PORT [A-016] (47906572)
Connector X-025A - CHARGER SOCKET [J-001] (87699736)
Connector X-025B - CHARGER SOCKET [J-001] (87705140)
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6 5 4 3 2 1
D D
SH3: C-1 S142 OR 0.75
49 A-016
USB PORT
F-016 3
GND
G529 BK 0.75 SH4: A-6
C 1
5.0 A
2 50
S143 OR 0.75
1 POWER C
BACK LIGHT 2
X-001 4223 VT 0.75 SH12: C-1
X-009
X-009
SH3: B-1 S140 OR 3.0
67 J-001
CHARGER SOCKET
F-007
1 2 68 1 P1 N 2
10.0 A S141 OR 3.0 G510 BK 3.0 SH4: A-6
LOAD
X-025A
X-001 1 P2 X-025A
SH12: C-1 4222 VT 0.75
X-025B
B B
A A
6 5 4 3 2 1
SHT_22 1
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Wiring harnesses - Electrical schematic sheet 23 SH23 - CAB FAN

Fuse F-036 - CAB FAN/RADIO (Fuse)
Motor M-005 - CABIN FAN (Motor) X-069 - CABIN FAN [M-005] (84182898)
Switch S-020 - CAB FAN SWITCH (Switch) X-076 - CAB FAN SWITCH [S-020] (87716755)
Connector X-069 - CABIN FAN [M-005] (84182898)
Connector X-076 - CAB FAN SWITCH [S-020] (87716755)
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6 5 4 3 2 1
D D
SH12: C-1 4226 VT 0.75
S-020
SH2: C-1 P047 RD 2.0 CAB FAN SWITCH
8 P N 7
G536 BK 0.75 SH4: B-6
C 65
C
F-036 M-005
SP-403
1 2 66 2 IN CABIN FAN
10.0 A P048 RD 2.0 P049 RD 1.0
OUT 3 X-093A 1 2
X-002 4010 BR 1.0 4 4 4000 BR 1.0 A M B G205 BK 1.0 SH4: C-1
X-076
X-093B
X-076 X-069 X-069
P050 RD 1.0 SH26: D-6
B B
A A
6 5 4 3 2 1
SHT_23 1
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Wiring harnesses - Electrical schematic sheet 24 SH24 - ACCESSORIES

Sensor B-003 - RTD SENSOR (Sensor) X-085 - RTD SENSOR [B-003] (84600602)
Fuse F-014 - B+ (Fuse)
Fuse F-015 - IGN (Fuse)
Fuse F-030 - REAR HAMMER (Fuse)
Fuse F-035 - RETURN TO DIG (Fuse)
Relay K-014 - RETURN TO DIG RELAY (Relay)
Switch S-025 - FOOT SWITCH (Switch) X-075 - FOOT SWITCH [S-025] (87692877)
Connector X-010 - CUSTOMER OPTION BATT+ (Not serviceable)
Connector X-020 - CUSTOMER OPTION IGNITION (Not serviceable)
Connector X-073 - HAMMER_VALVE [Y-008] (84600619)
Connector X-075 - FOOT SWITCH [S-025] (87692877)
Connector X-084 - RTD SOLENOID [Y-005] (87695900)
Connector X-085 - RTD SENSOR [B-003] (84600602)
Connector X-105A - HAMMER VALVE / INSTALLER POWER (47587518)
Connector X-105B - TO MAIN HARNESS (47416272)
Solenoid Y-005 - RTD SOLENOID (Solenoid) X-084 - RTD SOLENOID [Y-005] (87695900)
Solenoid Y-008 - HAMMER_VALVE (Solenoid) X-073 - HAMMER_VALVE [Y-008] (84600619)
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6 5 4 3 2 1
SH3: A-1 S250 OR 1.0 K-014 Y-005

RETURN TO DIG RELAY X-017B RTD SOLENOID
87A 32 1 P N 2
D 63 25 30 1260 WH 1.0 M M 2010 WH 1.0 G311 BK 1.0 SH4: D-1
D
S252 OR 1.0 87
F-035 X-084 X-084
64 SP-124 27 86 85 31
1 2
10.0 A S251 OR 1.0 S253 OR 0.75 1250 YE 0.75 O O 2050 YE 1.0
X-002 X-002 X-002 B-003

RTD SENSOR
1 PWR GND 2
S254 OR 1.0 N N S139 OR 1.0 G337 BK 1.0 SH4: D-1
X-017A
X-085 OUT 3
X-085
SH3: A-1 S260 OR 1.0

Y-008
HAMMER_VALVE
77
S-025
C F-030 FOOT SWITCH C
X-105A SP-102 X-105A
78 B 2 A 1 2
1 2 1
10.0 A S261 OR 1.0 A A 1025 OR 1.0 1024 RD 1.0 1024A RD 1.0 G225 BK 1.0 B B G525 BK 1.0 SH4: B-6
P N X-105B
X-002 X-075 X-075 X-073 X-073
SH27: C-6 1024C RD 0.75 C C 1024B RD 0.75

X-105B
SH2: D-1 P021 RD 3.0
57
F-014
1 2 58 CUSTOMER OPTION BATT+
20.0 A P022 RD 3.0
X-010
X-001
B B
SH3: C-1 S109 OR 3.0
59
F-015
1 2 60
20.0 A S108 OR 3.0 CUSTOMER OPTION IGN
X-020
X-001
A A
6 5 4 3 2 1
SHT_24 1
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Wiring harnesses - Electrical schematic sheet 25 SH25 - HVAC

Fuse F-033 - HVAC (Fuse)
Fuse F-200 - (Fuse)
Relay K-200 - A/C COMPRESSOR RELAY (Relay) X-123 - A/C RELAY [K-200] (84297431)
Motor M-006 - A/C CLUTCH (Motor) X-131 - A/C CLUTCH [M-006] (87687239)
X-064A - [M-006] (2WF 090)
Switch S-069 - A/C PRESSURE SW (Switch) X-132 - A/C PRESSURE SW [S-069] (87679438)
Connector X-007 - BATT+ (47781606)
Connector X-015 - TO CAB AC CONTROLL HARNESS (51543230)
Connector X-017C - TO CAB (84600602)
Connector X-064A - [M-006] (2WF 090)
Connector X-109 - A/C IGNTION TO MAIN (84179570)
Connector X-110 - TO AC HARNESS (84417509)
Connector X-113 - A/C KIT POWER (47706988)
Connector X-123 - A/C RELAY [K-200] (84297431)
Connector X-125 - POWER (51670671)
Connector X-131 - A/C CLUTCH [M-006] (87687239)
Connector X-132 - A/C PRESSURE SW [S-069] (87679438)
Connector X-220 - A/C KIT CONTROL (47373520)
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6 5 4 3 2 1
F-200
1 1 2 2 X-014
SH2: C-4 P005 RD 5.0 40.0 A P017 RD 5.0 1 1 P016 RD 5.0
X-015
X-007 X-007
SH3: B-1 S170 OR 2.0

D D
71
F-033
1 2 72 X-109
20.0 A S171 OR 2.0 1 1 6102 OR 2.0
X-110
X-002
HVAC 1351 YE 1.0
C C
K-200
A/C COMPRESSOR RELAY M-006
87A A/C CLUTCH

5 30 X-017C
SP-60C6
87 3 1 2
60C6A YE 2.5 60C6 YE 1.0 2 2 60C7 YE 1.0 A M B
2 85 86 1
6104 OR 2.5
9 X-131 X-064A
8
7
X-123 X-123
6
5 S-069
4
6103 OR 2.0 A/C PRESSURE SW
3
SP-406
2
P
1
A IN OUT B
1330 YE 1.0 3 3 1331 YE 1.0 G171 BK 1.0 SH4: B-1
X-113
X-016 X-132 X-132
B
G222 BK 5.0 SH4: B-1
A
X-125
B B
4050 OR 1.5
4090 GN 1.0
6105 OR 2.0
4070 GY 1.0
4100 RD 1.0
4040 BR 1.5
4030 YE 1.5
4080 BL 1.0
1
2
3
CONTROL PANEL
4
5
6
7
8
X-220
A A
6 5 4 3 2 1
SHT_25 1
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Wiring harnesses - Electrical schematic sheet 26 SH26 - AUDIO

ECU A-006 - RADIO (ECU) X-061 - RADIO [A-006] (84179570) Connector X-018 - TO BACK-UP ALARM [H-007] (87692855)
X-064 - LH SPEAKER [A-006] (84182898) Connector X-042 - RH SPEAKER [A-006] (84182898)
X-042 - RH SPEAKER [A-006] (84182898) Connector X-048 - TO REAR HORN SWITCH [S-029] (84182898)
Sensor B-016 - RADIO ANTENNA (Sensor) X-061A - RADIO ANTENNA [B-016] (84369030) Connector X-061 - RADIO [A-006] (84179570)
X-061B - [B-016] (2FT) Connector X-061A - RADIO ANTENNA [B-016] (84369030)
Fuse F-039 - HORN (Fuse) Connector X-061B - [B-016] (2FT)
Ground GND-009 - (Ground) GND-009 Connector X-063A - RH SPEAKER [H-001] (47763027)
Speaker H-001 - RIGHT SPEAKER (Speaker) X-063A - RH SPEAKER [H-001] (47763027) Connector X-063B - RH SPEAKER [H-001] (84600636)
X-063B - RH SPEAKER [H-001] (84600636)
Connector X-064 - LH SPEAKER [A-006] (84182898)
Speaker H-002 - LEFT SPEAKER (Speaker) X-072A - LH SPEAKER [H-002] (47763027)
Connector X-072A - LH SPEAKER [H-002] (47763027)
X-072B - LH SPEAKER [H-002] (84600636)
Connector X-072B - LH SPEAKER [H-002] (84600636)
Speaker H-003 - HORN (Speaker) X-142 - TO HORN [H-003] (51621244)
X-143 - TO HORN [H-003] (51621244) Connector X-093A - TO MAIN CAB HARNESS (47511912)
Speaker H-007 - BACK-UP ALARM (Speaker) X-018 - TO BACK-UP ALARM [H-007] (87692855) Connector X-093B - TO UPPER CAB HARNESS (47511905)
Switch S-004 - RADIO SWITCH (Switch) X-138 - RADIO SWITCH [S-004] (87716755) Connector X-107A - TO MAIN CAB HARNESS (47696599)
Switch S-029 - REAR BACKHOE HORN SWITCH (Switch) X-048 - TO REAR HORN SWITCH [S-029] (84182898) Connector X-107B - TO FRONT HARNESS (47696620)
Connector X-002 - FUSES AND RELAYS BLOCK (47944422) Connector X-138 - RADIO SWITCH [S-004] (87716755)
Connector X-017A - TO CHASSIS HARNESS (47696606) Connector X-142 - TO HORN [H-003] (51621244)
Connector X-017B - TO MAIN CAB HARNESS (47696624) Connector X-143 - TO HORN [H-003] (51621244)
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6 5 4 3 2 1
H-007
BACK-UP ALARM
A
SH10: D-1 5262 WH 1.0 P
B
N
X-018
D SH4: B-6
D
G524 BK 1.0
S-004
RADIO SWITCH
8 P N 7
SH12: D-1 4202 VT 0.75 G112 BK 0.75 SH4: B-1
B-016
X-107A IN RADIO ANTENNA

2
SH23: C-1 P050 RD 1.0 24 24 P051 RD 1.0
SP-303
X-107B OUT 3 X-107A X-093A 1 2
X-138 3C05 YE 1.0 25 25 3C06 YE 1.0 3 3 7040 YE 1.0 7042 YE 1.0
X-107B X-093B
X-061A X-061B
X-138
GND-009
7041 YE 1.0
A-006
RADIO
1 2
B+ GROUND SH4: B-1
G194 BK 1.0
H-002
C X-061 X-061 LEFT SPEAKER C
2 1
LEFT SPEAKER
7010 GY 1.0 P
X-072B
1 1
LEFT SPEAKER N
7000 BK 1.0
X-064 X-072A
H-001
RIGHT SPEAKER
2 1
RIGHT SPEAKER
7030 VT 1.0 P
X-063B
1 1
RIGHT SPEAKER N
7020 BK 1.0
X-063A
X-042
B B
X-107A
SH12: D-1 5200 YE 1.0 21 21
X-107B
S-029
5213 YE 1.0
REAR BACKHOE HORN SWITCH

1 2 1 2
5216 YE 1.0 G322 BK 1.0 SH4: D-1
X-048 X-048
SH2: C-1 P052 RD 1.0
H-003
HORN
59 X-017B SP-522 X-142

J J 5214 YE 1.0 5215 YE 1.0 N
A F-039 A
1 2 60 X-143
5.0 A P053 RD 1.0 K K P054 RD 1.0 P
X-017A
X-002
6 5 4 3 2 1
SHT_26 1
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ECU A-003 - TELEMATICS (ECU) X-005 - TELEMATICS [A-003] (51452976)
Fuse F-038 - TELEMATICS (Fuse)
Fuse F-107 - TELEMATICS UNSWITCHED (Fuse)
Connector X-005 - TELEMATICS [A-003] (51452976)
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6 5 4 3 2 1
D D
A-003
SH7: B-1 P113 RD 0.75 TELEMATICS
39
F-107
1 2 40 X-106A X-107A 37 37
5.0 A P114 RD 0.75 G G P115 RD 0.75 28 28 P116 RD 0.75 BATTERY B+
X-106B X-107B
X-101
C C
SH3: C-1 S002 OR 0.75
57
F-038
1 2 58 42 42
5.0 A S003 OR 0.75 IGNITION SWITCH 1
1
G503 BK 0.75 SH19: A-1
ANALOG GROUND
X-002
38 38
G535 BK 0.75 SH4: B-6
GROUND
41 41 X-005
SH24: C-6 1024C RD 0.75 REAR HAMMER SIGNAL
39 39
SH10: D-1 1192 YE 0.75 IN GEAR SIGNAL
B TP-004 TP-004
B
14 14
SH28: B-1 L004 GN 0.5 CAN LO
15 15
SH28: B-1 H004 YE 0.5 CAN HI
X-005
A A
6 5 4 3 2 1
SHT_27 1
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Wiring harnesses - Electrical schematic sheet 28 SH28 -

DIAGNOSTIC/CAN BUS
ECU A-005 - DIAGNOSTIC PORT (ECU) X-031 - DIAGNOSTIC PORT [A-005] (87736919)
Fuse F-006 - DIAGNOSTIC (Fuse)
Connector X-031 - DIAGNOSTIC PORT [A-005] (87736919)
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6 5 4 3 2 1
D D
SH2: D-1 P028 RD 0.75
77
F-006
1 2 78
5.0 A
X-001
C C
A-005
DIAGNOSTIC PORT
B
B+ P029 RD 0.75
X-107A X-106A
E
K LINE E682 YE 0.5 31 31 E681 YE 0.5 B B E680 YE 0.5 SH5: D-1
TP-001 TP-001 SP-H01 TP-002 TP-002 TP-006 TP-006 TP-007 TP-007

C
CAN HI H001 YE 0.5 H002 YE 0.5 35 35 H006 YE 0.5 K K H007 YE 0.5 SH5: C-1
SP-L01
D
CAN LO L001 GN 0.5 L002 GN 0.5 36 36 L006 GN 0.5 E E L007 GN 0.5 SH5: D-1
X-107B X-106B
SP-H02
TP-003 TP-003 TP-004 TP-004
B H003 YE 0.5 H004 YE 0.5 SH27: B-6

B
SP-L02
L003 GN 0.5 L004 GN 0.5 SH27: B-6

A
GROUND
X-031
TP-005 TP-005
H005 YE 0.5 SH19: A-6
L005 GN 0.5 SH19: A-6
G541 BK 0.75 SH4: C-6
A A
6 5 4 3 2 1
SHT_28 1
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Wire connectors - Component diagram 00 Connector X-000 to X-009

X-001 - TO GLOW PLUG [ R-001] (87745375) (Plug)
Pin From Wire Description Color-Size Frame
1 X-010B (Receptacle) pin 1 1185 1185 YE - 2.5 SHEET 07 SH07 - ENGINE CONTROL
- 12V OUTPUT TO COLD
START MODULE (Not
Serviceable)
X-001* - INSTRUMENT CLUSTER 1A [ A-004] (84179604) (Plug)
84179604 1
84179604
1 X-003* (Receptacle) pin 1 - 1558A 1558A OR - 1.0 SHEET 23 SH23 - TELEMATICS
[A-006] (51493688)
2 X-003* (Receptacle) pin 2 - 1310A 1310A YE - 1.0 SHEET 23 SH23 - TELEMATICS
[A-006] (51493688)
3 SP-006*-P-X 1053A 1053A WH - 1.0 SHEET 23 SH23 - TELEMATICS
4 SP-007*-P-X 36H4A 36H4A YE - 1.0 SHEET 23 SH23 - TELEMATICS
5 X-003* (Receptacle) pin 5 - 1401A 1401A BR - 1.0 SHEET 23 SH23 - TELEMATICS
[A-006] (51493688)
6 Not Used
7 Not Used
8 Not Used
9 Not Used
10 SP-009*-P-X 5353A 5353A YE - 1.0 SHEET 23 SH23 - TELEMATICS
11 X-003* (Receptacle) pin 11 - 5195A 5195A VT - 1.0 SHEET 23 SH23 - TELEMATICS
[A-006] (51493688)
[A-006] (51493688)
13 X-003* (Receptacle) pin 13 - 4204A 4204A VT - 1.0 SHEET 23 SH23 - TELEMATICS
[A-006] (51493688)
14 X-003* (Receptacle) pin 14 - 2142A 2142A YE - 1.0 SHEET 23 SH23 - TELEMATICS
[A-006] (51493688)
X-001A - ALTERNATOR B+ [ G-067] (Not Serviceable) (Plug)

1 X-007 (Plug) pin 1 - P004 P004 RD - 25.0 SHEET 03 SH03 - POWER DISTRIBUTION /
FUSE BOX-I/P [F-001] (Not CHARGING SYSTEM
Serviceable)
1 X-007 (Plug) pin 1 - P004* P004* RD - 10.0 SHEET 03 SH03 - POWER DISTRIBUTION /
FUSE BOX-I/P [F-001] (Not CHARGING SYSTEM
Serviceable)
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X-002 - ENG. COOLANT TEMP SWITCH [ S-007] (84491249) (Receptacle)
84491249 2
84491249
1 X-015 (Plug) pin 1 - TO MAIN 1070 1070 YE - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
HARNESS (84182907) SPEEDOMETER
X-002* - INSTRUMENT CLUSTER 1B [ A-005] (84479015) (Receptacle)
84479015 3
84479015
1 SP-005*-P-X 1320A 1320A OR - 1.0 SHEET 23 SH23 - TELEMATICS
4 SP-001-P-X 1517A 1517A OR - 1.0 SHEET 23 SH23 - TELEMATICS
5 X-004* (Plug) pin 5 - 1516A 1516A OR - 1.0 SHEET 23 SH23 - TELEMATICS
INSTRUMENT CLUSTER
2B [A-007] (84478450)
6 SP-002-P-X G066A G066A BK - 1.0 SHEET 23 SH23 - TELEMATICS
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X-003 - ENG. COOLANT TEMP SENDER [ B-015] (84491249) (Receptacle)
84491249 4
84491249
1 X-017 (Receptacle) pin 2 - TO 5351 5351 YE - 1.0 SHEET 07 SH07 - ENGINE CONTROL
MAIN HARNESS (84600598)
X-003* - INSTRUMENT CLUSTER 2A [ A-006] (51493688) (Receptacle)

INSTRUMENT CLUSTER
1A [A-004] (84179604)
2 X-001* (Plug) pin 2 - 1310A 1310A YE - 1.0 SHEET 23 SH23 - TELEMATICS
INSTRUMENT CLUSTER
1A [A-004] (84179604)
3 SP-006*-P-X 1053B 1053B WH - 1.0 SHEET 23 SH23 - TELEMATICS
4 SP-007*-P-X 36H4B 36H4B YE - 1.0 SHEET 23 SH23 - TELEMATICS
5 X-001* (Plug) pin 5 - 1401A 1401A BR - 1.0 SHEET 23 SH23 - TELEMATICS
INSTRUMENT CLUSTER
1A [A-004] (84179604)
6 Not Used
7 Not Used
8 Not Used
9 Not Used
10 SP-009*-P-X 5353B 5353B YE - 1.0 SHEET 23 SH23 - TELEMATICS
11 X-001* (Plug) pin 11 - 5195A 5195A VT - 1.0 SHEET 23 SH23 - TELEMATICS
[A-004] (84179604)
[A-004] (84179604)
13 X-001* (Plug) pin 13 - 4204A 4204A VT - 1.0 SHEET 23 SH23 - TELEMATICS
[A-004] (84179604)
14 X-001* (Plug) pin 14 - 2142A 2142A YE - 1.0 SHEET 23 SH23 - TELEMATICS
[A-004] (84179604)
X-004 - STARTER MOTOR B+ (Not Serviceable) (Plug)

1 X-021 (Receptacle) pin 2 - 1130 1130 RD - 2.5 SHEET 04 SH04 - STARTING SYSTEM
COLD START FUSE [F-025]
(47435876)
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X-004* - INSTRUMENT CLUSTER 2B [ A-007] (84478450) (Plug)
84478450 5
84478450
1 SP-005*-P-X 1320B 1320B OR - 1.0 SHEET 23 SH23 - TELEMATICS
4 SP-001-P-X 1517B 1517B OR - 1.0 SHEET 23 SH23 - TELEMATICS
[A-005] (84479015)
6 SP-002-P-X G066B G066B BK - 1.0 SHEET 23 SH23 - TELEMATICS
X-004A - LOW PRESSURE SWITCH [ S-008] (84491249) (Receptacle)
84491249 6
84491249
1 X-017 (Receptacle) pin 1051 1051 WH - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
14 - TO MAIN HARNESS SPEEDOMETER
(84600598)
X-005 - STARTER MOTOR [ M-004] (Not Serviceable) (Plug)

1 X-008 (Plug) pin 2 - 1090 1090 RD - 10.0 SHEET 04 SH04 - STARTING SYSTEM
FUSEBOX-O/P [F-001]
(65200449)
X-005A - (Not Serviceable) (Plug)

1 X-300 (Plug) pin 1 - [G-001] P017* P017* RD - 70.0 SHEET 04 SH04 - STARTING SYSTEM
(Not Serviceable)
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X-005A* - TELEMATICS BOX [ A-003] (Not Serviceable) (Plug)

1 SP-002-P-X G066C G066C BK - 0.75 SHEET 22 SH22 - TELEMATICS
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 Not Used
8 Not Used
9 Not Used
10 Not Used
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Not Used
16 Not Used
17 SP-003*-P-X 5362C 5362C YE - 0.75 SHEET 22 SH22 - TELEMATICS
18 Not Used
19 Not Used
20 Not Used
21 Not Used
22 Not Used
23 Not Used
24 Not Used
25 Not Used
26 Not Used
27 Not Used
28 Not Used
30 SP-005*-P-X 1320C 1320C OR - 0.75 SHEET 22 SH22 - TELEMATICS
32 Not Used
33 Not Used
34 SP-007*-P-X 36H4C 36H4C YE - 0.75 SHEET 22 SH22 - TELEMATICS
35 Not Used
36 Not Used
37 X-007* (Plug) pin 1 - P018* P018* RD - 0.75 SHEET 22 SH22 - TELEMATICS
UNSWITCHED POWER
(87745375)
38 X-006* (Plug) pin 1 - GROUND G001 G001 BK - 0.75 SHEET 22 SH22 - TELEMATICS
(84488487)
39 X-008* (Receptacle) pin 3 - 1001 1001 YE - 0.75 SHEET 22 SH22 - TELEMATICS
DIODE-5 [V-004] (84179574)
40 Not Used
41 Not Used
42 SP-001-P-X 1517C 1517C OR - 0.75 SHEET 22 SH22 - TELEMATICS
43 Not Used
44 Not Used
45 Not Used
46 Not Used
47 SP-006*-P-X 1053C 1053C WH - 0.75 SHEET 22 SH22 - TELEMATICS
48 Not Used
49 Not Used
51 Not Used
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X-006 - STARTER SOLENOID [ M-004] (84491249) (Receptacle)
84491249 7
84491249
1 SP-014-P-X 1100 1100 WH - 4.0 SHEET 04 SH04 - STARTING SYSTEM
1 X-111 (Receptacle) pin C - 1100* 1100* WH - 2.5 SHEET 04 SH04 - STARTING SYSTEM
ST.RELAY [K-001] (84369037)
X-006* - GROUND (84488487) (Plug)
84488487 8
84488487
1 X-005A* (Plug) pin 38 - G001 G001 BK - 0.75 SHEET 22 SH22 - TELEMATICS
TELEMATICS BOX [A-003]
(Not Serviceable)
X-007 - FUSE BOX-I/P [ F-001] (Not Serviceable) (Plug)

1 X-001A (Plug) pin 1 - P004* P004* RD - 10.0 SHEET 04 SH04 - STARTING SYSTEM
ALTERNATOR B+ [G-067]
(Not Serviceable)
1 X-001A (Plug) pin 1 - P004 P004 RD - 25.0 SHEET 04 SH04 - STARTING SYSTEM
ALTERNATOR B+ [G-067]
(Not Serviceable)
X-007* - UNSWITCHED POWER (87745375) (Plug)

1 X-005A* (Plug) pin 37 - P018* P018* RD - 0.75 SHEET 22 SH22 - TELEMATICS
(Not Serviceable)
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X-008 - FUSEBOX-O/P [ F-001] (65200449) (Plug)

1 SP-112-P-X P001 P001 RD - 10.0 SHEET 04 SH04 - STARTING SYSTEM
2 X-005 (Plug) pin 1 - STARTER 1090 1090 RD - 10.0 SHEET 04 SH04 - STARTING SYSTEM
MOTOR [M-004] (Not
Serviceable)
X-008* - DIODE-5 [ V-004] (84179574) (Receptacle)
84179574 9
84179574
1 SP-1231-P-X 1231C 1231C VT - 1.0 SHEET 22 SH22 - TELEMATICS
2 SP-7081-P-X 7081C 7081C WH - 1.0 SHEET 22 SH22 - TELEMATICS
3 X-005A* (Plug) pin 39 - 1001 1001 YE - 0.75 SHEET 22 SH22 - TELEMATICS
(Not Serviceable)
X-009 - DIODE-1 [ V-001] (84179574) (Receptacle)
84179574 10
84179574
1 SP-1231-P-X 1231A 1231A VT - 1.0 SHEET 22 SH22 - TELEMATICS
2 SP-7081-P-X 7081A 7081A WH - 1.0 SHEET 22 SH22 - TELEMATICS
3 X-010* (Plug) pin 3 - DIODE-1 1191A 1191A YE - 1.0 SHEET 22 SH22 - TELEMATICS
[V-002] (84182904)
91715732 26/07/2021
55.2 [55.100] / 159
X-009A - HYDRAULIC FILTER [ S-006] (84491249) (Receptacle)
84491249 11
84491249
1 X-017 (Receptacle) pin 36H2 36H2 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
13 - TO MAIN HARNESS SPEEDOMETER
(84600598)
X-009B - HYDRAULIC FILTER [ S-006] (84491249) (Receptacle)
84491249 12
84491249
1 SP-G10-P-X G102 G102 BK - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
91715732 26/07/2021
55.2 [55.100] / 160

X-010 - FUSE STARTER [ F-021] (87716284) (Plug)
87716284 1
87716284
1 SP-112-P-X P003 P003 RD - 6.0 SHEET 05 SH05 - COLD START SYSTEM
2 X-111 (Receptacle) pin A - P010 P010 RD - 6.0 SHEET 05 SH05 - COLD START SYSTEM
ST.RELAY [K-001] (84369037)
X-010* - DIODE-1 [ V-002] (84182904) (Plug)
84182904 2
84182904
1 SP-1231-P-X 1231B 1231B VT - 1.0 SHEET 22 SH22 - TELEMATICS
2 SP-7081-P-X 7081B 7081B WH - 1.0 SHEET 22 SH22 - TELEMATICS
3 X-009 (Receptacle) pin 3 - 1191A 1191A YE - 1.0 SHEET 22 SH22 - TELEMATICS
DIODE-1 [V-001] (84179574)
X-010A - 12V INPUT TO COLD START MODULE (Not Serviceable) (Receptacle)

1 X-021 (Receptacle) pin 1 - 1135 1135 RD - 2.5 SHEET 05 SH05 - COLD START SYSTEM
COLD START FUSE [F-025]
(47435876)
X-010AP - (Not Serviceable) (Plug)
X-010B - 12V OUTPUT TO COLD START MODULE (Not Serviceable) (Receptacle)

1 X-001 (Plug) pin 1 - TO GLOW 1185 1185 YE - 2.5 SHEET 05 SH05 - COLD START SYSTEM
PLUG [R-001] (87745375)
91715732 26/07/2021
55.2 [55.100] / 161
X-010BP - (Not Serviceable) (Plug)

1 X-160 (Plug) pin 5 - COLD 1185* 1185* SHEET 05 SH05 - COLD START SYSTEM
START MODULE [A-001] (Not
Serviceable)
X-011 - TRANS HIGH OIL TEMP SW. [ S-030] (84062580) (Receptacle)
84062580 3
84062580
1 Not Used
SPEEDOMETER
3 X-017 (Receptacle) pin 5 - TO 5371 5371 YE - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
MAIN HARNESS (84600598) SPEEDOMETER
X-012 - FOR SPEED SOL. VALVE [ Y-002] (87695582) (Receptacle)
87695582 4
87695582
1 X-017 (Receptacle) pin 9 - TO 2100 2100 VT - 1.0 SHEET 09 SH09 - HYDRAULICS
2 SP-G13-P-X G135 G135 BK - 1.0 SHEET 09 SH09 - HYDRAULICS
91715732 26/07/2021
55.2 [55.100] / 162
X-013 - REV SPEED SOL. VALVE [ Y-001] (87695582) (Receptacle)
87695582 5
87695582
1 X-017 (Receptacle) pin 2110 2110 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
10 - TO MAIN HARNESS
(84600598)
X-014 - 4WD SOL. VALVE [ Y-003] (87695582) (Receptacle)
87695582 6
87695582
1 X-017 (Receptacle) pin 8 - TO 25E2 25E2 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
X-015 - TO MAIN HARNESS (84182907) (Plug)
84182907 7
84182907
91715732 26/07/2021
55.2 [55.100] / 163

1 X-002 (Receptacle) pin 1 1070 1070 YE - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
- ENG. COOLANT TEMP SPEEDOMETER
SWITCH [S-007] (84491249)
2 X-115 (Plug) pin 3 - SPEED 1514 1514 OR - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SENSOR [B-019] (84062580) SPEEDOMETER
3 X-115 (Plug) pin 1 - SPEED 2700 2700 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SENSOR [B-019] (84062580) SPEEDOMETER
X-016 - TO MAIN HARNESS (84600599) (Receptacle)
84600599 8
84600599
2 SP-G13-P-X G131 G131 BK - 2.5 SHEET 06 SH06 - GROUNDING
X-017 - TO MAIN HARNESS (84600598) (Receptacle)
84600598 9
84600598
1 X-111 (Receptacle) pin B - 1110* 1110* YE - 1.0 SHEET 05 SH05 - COLD START SYSTEM
ST.RELAY [K-001] (84369037)
1 X-111 (Receptacle) pin B - 1110 1110 YE - 1.5 SHEET 05 SH05 - COLD START SYSTEM
ST.RELAY [K-001] (84369037)
2 X-003 (Receptacle) pin 1 5351 5351 YE - 1.0 SHEET 07 SH07 - ENGINE CONTROL
- ENG. COOLANT TEMP
SENDER [B-015] (84491249)
3 X-143 (Receptacle) pin 1 - 1030 1030 OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION /
ALTERNATOR D+ [G-067] CHARGING SYSTEM
(84179570)
4 X-143 (Receptacle) pin 2 - 1020 1020 YE - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION /
ALTERNATOR D+ [G-067] CHARGING SYSTEM
(84179570)
5 X-011 (Receptacle) pin 3 - 5371 5371 YE - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
TRANS HIGH OIL TEMP SW. SPEEDOMETER
[S-030] (84062580)
91715732 26/07/2021
55.2 [55.100] / 164

6 X-160A (Receptacle) pin 85 1400 1400 BR - 1.0 SHEET 05 SH05 - COLD START SYSTEM
- COLD START MODULE
[A-001] (87705703)
7 X-146 (Plug) pin 1 - FUEL 5361 5361 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
LEVEL SENSOR [B-001] (Not SPEEDOMETER
Serviceable)
8 X-014 (Receptacle) pin 1 - 25E2 25E2 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
4WD SOL. VALVE [Y-003]
(87695582)
9 X-012 (Receptacle) pin 1 - 2100 2100 VT - 1.0 SHEET 09 SH09 - HYDRAULICS
FOR SPEED SOL. VALVE
[Y-002] (87695582)
10 X-013 (Receptacle) pin 1 - 2110 2110 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
REV SPEED SOL. VALVE
[Y-001] (87695582)
11 Not Used
12 X-135P (Plug) pin 1 - FUEL 1552* 1552* OR - 1.0 SHEET 07 SH07 - ENGINE CONTROL
SHUT OFF (87687239)
12 SP-015-P-X 1552 1552 RD - 1.0 SHEET 07 SH07 - ENGINE CONTROL
13 X-009A (Receptacle) pin 1 - 36H2 36H2 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
HYDRAULIC FILTER [S-006] SPEEDOMETER
(84491249)
14 X-004A (Receptacle) pin 1 - 1051 1051 WH - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
LOW PRESSURE SWITCH SPEEDOMETER
[S-008] (84491249)
X-018 - TO BACK-UP ALARM [ H-007] (87692855) (Plug)
87692855 10
87692855
A X-029 (Plug) pin 1 - TO 7088 7088 WH - 1.0 SHEET 18 SH18 - AUDIO
HARNESS (84477032)
B X-029 (Plug) pin 2 - TO G158 G158 BK - 1.0 SHEET 18 SH18 - AUDIO
HARNESS (84477032)
X-019 - HARNESS FRONT PANEL (47731489) (Plug)
47731489 11
47731489
91715732 26/07/2021
55.2 [55.100] / 165

1 SP-122-P-X 1222 1222 YE - 1.0 SHEET 08 SH08 - DRIVES
2 X-130R (Receptacle) pin 34 - 64B0 64B0 RD - 1.5 SHEET 15 SH15 - HAZARD
FUSE BOX (Not Serviceable)
3 SP-008-P-X 1537 1537 OR - 2.0 SHEET 13 SH13 - WIPER/WASHER
4 SP-006-P-X 45R3 45R3 WH - 1.0 SHEET 15 SH15 - HAZARD
5 SP-007-P-X 1525 1525 OR - 1.0 SHEET 15 SH15 - HAZARD
6 X-108 (Receptacle) pin 3 - 5260 5260 BR - 1.0 SHEET 08 SH08 - DRIVES
RELAY SHUTTLE CONTROL
REV. / FOR [K-010] (47781081)
7 X-096 (Receptacle) pin 2701 2701 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
3 - HARNESS ENGINE SPEEDOMETER
(84182893)
8 Not Used
9 Not Used
10 SP-117-P-X 1512 1512 OR - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
11 SP-222-P-X 4404 4404 VT - 1.5 SHEET 12 SH12 - REAR LIGHTING
12 SP-521-P-X 5210 5210 YE - 1.0 SHEET 18 SH18 - AUDIO
13 X-130R (Receptacle) pin 26 - 1520 1520 OR - 1.5 SHEET 12 SH12 - REAR LIGHTING
RELAY SHUTTLE CONTROL
REV. / FOR [K-010] (47781081)
RELAY TRANS. FORW. &
REV. / [K-005] (47781081)
16 SP-519-P-X 4201 4201 VT - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
91715732 26/07/2021
55.2 [55.100] / 166

X-020 - HARNESS FRONT PANEL (47731490) (Receptacle)
47731490 1
47731490
1 SP-007-P-X 1528 1528 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
3 SP-403-P-X 3C02 3C02 RD - 1.5 SHEET 18 SH18 - AUDIO
4 X-093 (Receptacle) pin 4 - TO 3C06 3C06 YE - 1.5 SHEET 18 SH18 - AUDIO
CAB HARNESS (84600543)
5 SP-005-P-X 45L3 45L3 VT - 1.0 SHEET 15 SH15 - HAZARD
6 X-130R (Receptacle) pin 38 - 3450 3450 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
7 X-130R (Receptacle) pin 7 - 6302 6302 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
8 Not Used
9 Not Used
10 SP-009-P-X 3462 3462 YE - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
11 X-106 (Receptacle) pin 3610 3610 YE - 1.0 SHEET 11 SH11 - FRONT LIGHTING
8 - RELAY LOW BEAM /
FRONT WORK LIGH [K-012]
(47781081)
12 X-030 (Receptacle) pin 2 - 3230 3230 YE - 1.0 SHEET 15 SH15 - HAZARD
FLASHER [K-030] (84479009)
13 X-030 (Receptacle) pin 1 - 3220 3220 BR - 1.0 SHEET 15 SH15 - HAZARD
FLASHER [K-030] (84479009)
14 X-100 (Receptacle) pin 6 - 5290 5290 WH - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
REV. / [K-005] (47781081)
15 Not Used
16 X-106 (Receptacle) pin 5300 5300 OR - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
(47781081)
91715732 26/07/2021
55.2 [55.100] / 167
X-021 - COLD START FUSE [ F-025] (47435876) (Receptacle)
47435876 2
47435876
1 X-010A (Receptacle) pin 1 - 1135 1135 RD - 2.5 SHEET 04 SH04 - STARTING SYSTEM
12V INPUT TO COLD START
MODULE (Not Serviceable)
2 X-004 (Plug) pin 1 - STARTER 1130 1130 RD - 2.5 SHEET 04 SH04 - STARTING SYSTEM
MOTOR B+ (Not Serviceable)
X-022A - TO HARNESS MAIN (84600552) (Plug)
84600552 3
84600552
1 X-047 (Receptacle) pin 2000 2000 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
1 - SIDE SHIFT LOCK
SOL.VALVE [Y-006]
(84607243)
2 X-050A (Receptacle) pin 2043 2043 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
1 - RTD SENSOR [B-003]
(84600602)
4 X-048A (Plug) pin 1 - TO 7050 7050 YE - 1.0 SHEET 18 SH18 - AUDIO
REAR HORN SWITCH [S-029]
(87581782)
5 X-046A (Receptacle) pin 1 2010 2010 WH - 1.0 SHEET 16 SH16 - ACCESSORIES
- RTD SOLENOID [Y-005]
(87695582)
6 SP-204-P-X 19E7 19E7 OR - 1.0 SHEET 08 SH08 - DRIVES
7 Not Used
8 X-045A (Receptacle) pin 1 - 2020 2020 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
UNLOADING VALVE [Y-004]
(84607243)
9 X-050A (Receptacle) pin 2050 2050 YE - 1.0 SHEET 16 SH16 - ACCESSORIES
3 - RTD SENSOR [B-003]
(84600602)
91715732 26/07/2021
55.2 [55.100] / 168
X-023 - HARNESS REAR LAMPS (84605163) (Plug)
84605163 4
84605163
2 SP-006-P-X 45R2 45R2 WH - 1.0 SHEET 12 SH12 - REAR LIGHTING
5 SP-005-P-X 45L2 45L2 VT - 1.0 SHEET 12 SH12 - REAR LIGHTING
7 Not Used
8 Not Used
9 SP-708-P-X 7085 7085 WH - 1.0 SHEET 12 SH12 - REAR LIGHTING
10 SP-708-P-X 7084 7084 WH - 1.0 SHEET 12 SH12 - REAR LIGHTING
11 SP-G15-P-X G153 G153 BK - 1.5 SHEET 12 SH12 - REAR LIGHTING
X-024 - FUSE HOLDER [ F-023] (47435876) (Receptacle)
47435876 5
47435876
1 X-119P (Plug) pin 7 - IGN. 1140 1140 YE - 1.5 SHEET 04 SH04 - STARTING SYSTEM
KEY SW. (87714250)
2 X-101 (Receptacle) pin 10 - 1145 1145 YE - 1.5 SHEET 04 SH04 - STARTING SYSTEM
RELAY ALARM HAND BRAKE
& SPE [K-003] (47781081)
91715732 26/07/2021
55.2 [55.100] / 169
X-025A - CHARGER SOCKET [ J-001] (84491249) (Receptacle)
84491249 6
84491249
1 SP-G14-P-X G025 G025 BK - 1.0 SHEET 21 SH21 - MOBILE CHARGER
X-025B - CHARGER SOCKET [ J-001] (84491249) (Receptacle)
84491249 7
84491249
1 SP-519-P-X 4203 4203 VT - 1.0 SHEET 21 SH21 - MOBILE CHARGER
X-025C - CHARGER SOCKET [ J-001] (84491249) (Receptacle)
84491249 8
84491249
1 X-130R (Receptacle) pin 32 - 1508 1508 OR - 1.0 SHEET 21 SH21 - MOBILE CHARGER
91715732 26/07/2021
55.2 [55.100] / 170
X-026A - [ S-017] (3302911) (Plug)

1 X-118P (Plug) pin 1 - (Not 1150 1150 SHEET 04 SH04 - STARTING SYSTEM
Serviceable)
X-026B - [ S-017] (3302911) (Plug)

1 X-119R (Receptacle) pin 7 - WIRE17 WIRE17 SHEET 04 SH04 - STARTING SYSTEM
(Not Serviceable)
X-026C - [ S-017] (3302911) (Plug)
X-027 - PARK BRAKE LIMIT SW. [ S-027] (84606396) (Receptacle)
84606396 9
84606396
2 SP-G15-P-X G154 G154 BK - 1.0 SHEET 18 SH18 - AUDIO
X-028 - BACK-UP ALARM (84182898) (Receptacle)
84182898 10
84182898
1 SP-708-P-X 7080 7080 WH - 1.0 SHEET 18 SH18 - AUDIO
91715732 26/07/2021
55.2 [55.100] / 171
X-029 - TO HARNESS (84477032) (Plug)
84477032 11
84477032
1 X-018 (Plug) pin A - TO 7088 7088 WH - 1.0 SHEET 18 SH18 - AUDIO
BACK-UP ALARM [H-007]
(87692855)
2 X-018 (Plug) pin B - TO G158 G158 BK - 1.0 SHEET 18 SH18 - AUDIO
BACK-UP ALARM [H-007]
(87692855)
91715732 26/07/2021
55.2 [55.100] / 172

X-030 - FLASHER [ K-030] (84479009) (Receptacle)
84479009 1
84479009
1 X-020 (Receptacle) pin 13 3220 3220 BR - 1.0 SHEET 15 SH15 - HAZARD
- HARNESS FRONT PANEL
(47731490)
2 X-020 (Receptacle) pin 12 3230 3230 YE - 1.0 SHEET 15 SH15 - HAZARD
(47731490)
3 SP-G14-P-X G024 G024 BK - 1.0 SHEET 15 SH15 - HAZARD
84179574 2
84179574
1 SP-123-P-X 1231 1231 VT - 1.0 SHEET 09 SH09 - HYDRAULICS
2 SP-708-P-X 7081 7081 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
3 SP-119-P-X 1191 1191 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
91715732 26/07/2021
55.2 [55.100] / 173
X-032 - FUSE HOLDER [ F-022] (84177914) (Plug)
84177914 3
84177914
1 X-118 (Receptacle) pin 1 - 1150** 1150** RD - 6.0 SHEET 04 SH04 - STARTING SYSTEM
IGN. KEY SW. (84599241)
2 SP-115-P-X 1151 1151 RD - 6.0 SHEET 04 SH04 - STARTING SYSTEM
84179574 4
84179574
2 X-101 (Receptacle) pin 1 - 1300 1300 YE - 1.0 SHEET 18 SH18 - AUDIO
& SPE [K-003] (47781081)
X-034 - RHS COMBINATION SWITCH [ S-009] (84600631) (Plug)
84600631 5
84600631
91715732 26/07/2021
55.2 [55.100] / 174

1 SP-533-P-X 5330 5330 BR - 1.0 SHEET 15 SH15 - HAZARD
2 X-107 (Receptacle) pin 3 - TO 1538 1538 OR - 2.0 SHEET 13 SH13 - WIPER/WASHER
MAIN (47731490)
4 X-099 (Plug) pin 7 - TO MAIN 6301 6301 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
(47731489)
5 SP-352-P-X 3523 3523 VT - 1.0 SHEET 15 SH15 - HAZARD
6 SP-351-P-X 3511 3511 WH - 1.0 SHEET 15 SH15 - HAZARD
X-035 - LHS COMBINATION SWITCH [ S-035] (84600543) (Receptacle)
84600543 6
84600543
1 X-099 (Plug) pin 16 - TO MAIN 5160 5160 OR - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
(47731489)
2 SP-514-P-X 64B4 64B4 RD - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
TO MAIN (47731490)
4 X-107 (Receptacle) pin 6 - TO 5220 5220 BR - 1.0 SHEET 08 SH08 - DRIVES
MAIN (47731490)
5 SP-520-P-X 5200 5200 YE - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
TO MAIN (47731490)
8 X-099 (Plug) pin 14 - TO MAIN 5170 5170 WH - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
(47731489)
X-036P - BRAKE DECLUTCH (84606400) (Plug)
84606400 7
84606400
1 X-107 (Receptacle) pin 1 - TO 2150 2150 YE - 1.0 SHEET 08 SH08 - DRIVES
MAIN (47731490)
91715732 26/07/2021
55.2 [55.100] / 175
X-036R - COMBINATION SWITCH (84606396) (Receptacle)
84606396 8
84606396
1 X-057 (Receptacle) pin 2 - 2070 2070 YE - 1.0 SHEET 08 SH08 - DRIVES
DIODE [V-018] (84179570)
X-037 - COMBINATION SWITCH [ S-009] (47461910) (Plug)
47461910 9
47461910
1 X-164 (Receptacle) pin 1 1028 1028 GY - 1.0 SHEET 13 SH13 - WIPER/WASHER
- FUSE HOLDER-INLINE
[F-024] (47435876)
X-038 - BRAKE FLUID BOTTLE SW. [ S-038] (84417509) (Plug)
84417509 10
84417509
91715732 26/07/2021
55.2 [55.100] / 176

SPEEDOMETER
(47731489) SPEEDOMETER
X-039P - (Not Serviceable) (Plug)
X-039R - STOP LIGHT SW.2 (84606396) (Receptacle)
84606396 11
84606396
1 SP-150-P-X 1553 1553 OR - 1.0 SHEET 12 SH12 - REAR LIGHTING
91715732 26/07/2021
55.2 [55.100] / 177

X-040R - STOP LIGHT SW.1 (84606396) (Receptacle)
84606396 1
84606396
X-041 - RIGHT FRONT LIGHT (84253886) (Plug)
84253886 2
84253886
1 X-059 (Receptacle) pin 2 - TO 3210 3210 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
RIGHT FRONT LIGHT [E-005]
(47511912)
2 X-059 (Receptacle) pin 1 - TO 3200 3200 VT - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47511912)
3 Not Used
4 X-059 (Receptacle) pin 4 - TO G165 G165 BK - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47511912)
5 X-059 (Receptacle) pin 5 - TO 3180 3180 WH - 1.0 SHEET 11 SH11 - FRONT LIGHTING
(47511912)
(47511912)
91715732 26/07/2021
55.2 [55.100] / 178
X-042 - RH SPEAKER [ H-001] (84182898) (Receptacle)
84182898 3
84182898
1 X-063A (Plug) pin 1 - 7020 7020 BK - 1.0 SHEET 18 SH18 - AUDIO
RH SPEAKER IN [A-053]
(84600637)
2 X-063B (Plug) pin 1 - 7030 7030 VT - 1.0 SHEET 18 SH18 - AUDIO
RH SPEAKER IN [A-053]
(84600636)
X-043 - 4WD SW. [ S-043] (87716755) (Receptacle)
87716755 4
87716755
1 X-098 (Plug) pin 8 - HARNESS 25E1 25E1 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
ENGINE (84600605)
2 X-130R (Receptacle) pin 29 - 3301 3301 OR - 1.5 SHEET 09 SH09 - HYDRAULICS
3 Not Used
4 Not Used
5 Not Used
6 Not Used
91715732 26/07/2021
55.2 [55.100] / 179
X-044A - CLUTCH SHUT OFF SW. [ S-026] (84182898) (Receptacle)
84182898 5
84182898
X-045A - UNLOADING VALVE [ Y-004] (84607243) (Receptacle)
84607243 6
84607243
1 X-022A (Plug) pin 8 - TO 2020 2020 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
HARNESS MAIN (84600552)
X-046A - RTD SOLENOID [ Y-005] (87695582) (Receptacle)
87695582 7
87695582
91715732 26/07/2021
55.2 [55.100] / 180

1 X-022A (Plug) pin 5 - TO 2010 2010 WH - 1.0 SHEET 16 SH16 - ACCESSORIES
2 SP-G18-P-X G184 G184 BK - 1.0 SHEET 16 SH16 - ACCESSORIES
X-047 - SIDE SHIFT LOCK SOL.VALVE [ Y-006] (84607243) (Receptacle)
84607243 8
84607243
1 X-022A (Plug) pin 1 - TO 2000 2000 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
X-048A - TO REAR HORN SWITCH [ S-029] (87581782) (Plug)
87581782 9
87581782
1 X-022A (Plug) pin 4 - TO 7050 7050 YE - 1.0 SHEET 18 SH18 - AUDIO
91715732 26/07/2021
55.2 [55.100] / 181
X-048B - TO REAR HORN SWITCH [ S-029] (87581782) (Plug)
87581782 10
87581782
X-049A - CLUTCH SHUT OFF SW. [ S-018] (84182898) (Receptacle)
84182898 11
84182898
91715732 26/07/2021
55.2 [55.100] / 182

X-050A - RTD SENSOR [ B-003] (84600602) (Receptacle)
84600602 1
84600602
1 X-022A (Plug) pin 2 - TO 2043 2043 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
3 X-022A (Plug) pin 9 - TO 2050 2050 YE - 1.0 SHEET 16 SH16 - ACCESSORIES
X-051 - DECLUTCH SW [ S-002] (87716755) (Receptacle)
87716755 2
87716755
1 Not Used
2 SP-441-P-X 4411 4411 VT - 1.0 SHEET 08 SH08 - DRIVES
4 Not Used
5 Not Used
6 Not Used
7 X-207 (Plug) pin 1 - GROUND G170 G170 BK - 1.0 SHEET 08 SH08 - DRIVES
(Not Serviceable)
91715732 26/07/2021
55.2 [55.100] / 183
X-052 - TAIL LAMP (47749801) (Receptacle)
47749801 3
47749801
1 X-090 (Receptacle) pin 2 - 3563 3563 VT - 1.5 SHEET 12 SH12 - REAR LIGHTING
REAR RIGHT LIGHT [E-009]
(47511912)
2 X-090 (Receptacle) pin 3 - 45R1 45R1 WH - 1.0 SHEET 12 SH12 - REAR LIGHTING
(47511912)
(47511912)
REAR LEFT LIGHT [E-010]
(47511912)
5 X-089 (Receptacle) pin 3 - 45L1 45L1 VT - 1.0 SHEET 12 SH12 - REAR LIGHTING
(47511912)
7 Not Used
8 Not Used
9 X-090 (Receptacle) pin 6 - 7087 7087 WH - 1.0 SHEET 12 SH12 - REAR LIGHTING
(47511912)
(47511912)
11 X-090 (Receptacle) pin 4 - G157 G157 BK - 1.5 SHEET 12 SH12 - REAR LIGHTING
(47511912)
12 SP-223-P-X G156 G156 BK - 1.5 SHEET 12 SH12 - REAR LIGHTING
X-053 - L.S. 1 (84606396) (Receptacle)
84606396 4
84606396
91715732 26/07/2021
55.2 [55.100] / 184
X-054 - L.S. 2 (84606396) (Receptacle)
84606396 5
84606396
X-055 - (Not Serviceable) (Receptacle)
X-055P - W/H MAIN 2 (84606400) (Plug)
84606400 6
84606400
91715732 26/07/2021
55.2 [55.100] / 185
X-056P - W/H MAIN 1 (84606400) (Plug)
84606400 7
84606400
1 Not Used
X-057 - DIODE [ V-018] (84179570) (Receptacle)
84179570 8
84179570
2 X-036R (Receptacle) pin 1 2070 2070 YE - 1.0 SHEET 08 SH08 - DRIVES
- COMBINATION SWITCH
(84606396)
X-058 - FRONT HEAD LAMP 2 [ E-011] (84182898) (Receptacle)
84182898 9
84182898
91715732 26/07/2021
55.2 [55.100] / 186

1 SP-300-P-X 3002 3002 VT - 1.5 SHEET 11 SH11 - FRONT LIGHTING
2 SP-G19-P-X G193 G193 BK - 1.5 SHEET 11 SH11 - FRONT LIGHTING
X-059 - TO RIGHT FRONT LIGHT [ E-005] (47511912) (Receptacle)
47511912 10
47511912
1 X-041 (Plug) pin 2 - RIGHT 3200 3200 VT - 1.5 SHEET 11 SH11 - FRONT LIGHTING
FRONT LIGHT (84253886)
2 X-041 (Plug) pin 1 - RIGHT 3210 3210 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
3 X-041 (Plug) pin 6 - RIGHT 3190 3190 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
4 X-041 (Plug) pin 4 - RIGHT G165 G165 BK - 1.5 SHEET 11 SH11 - FRONT LIGHTING
5 X-041 (Plug) pin 5 - RIGHT 3180 3180 WH - 1.0 SHEET 11 SH11 - FRONT LIGHTING
91715732 26/07/2021
55.2 [55.100] / 187

X-060 - LEFT FRONT LIGHT (47761028) (Receptacle)
47761028 1
47761028
LEFT FRONT LIGHT [E-008]
(47511912)
(47511912)
(47511912)
4 X-400 (Receptacle) pin 1 - TO 3159 3159 YE - 1.0 SHEET 18 SH18 - AUDIO
HORN JUMPER HARNESS
(84182898)
5 X-400 (Receptacle) pin 2 - TO 3149 3149 RD - 1.0 SHEET 18 SH18 - AUDIO
HORN JUMPER HARNESS
(84182898)
6 Not Used
7 X-112 (Receptacle) pin 4 - TO G164 G164 BK - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47511912)
(47511912)
X-061 - RADIO [ H-004] (84179570) (Receptacle)
84179570 2
84179570
91715732 26/07/2021
55.2 [55.100] / 188
X-061A - RADIO ANTENNA [ S-013] (84369030) (Receptacle)
84369030 3
84369030
X-061B - [ S-013] (2FT) (Plug)
X-062A - ROOF LIGHT [ E-016] (84491249) (Receptacle)
84491249 4
84491249
1 X-092 (Plug) pin 5 - TO MAIN P009 P009 RD - 1.0 SHEET 20 SH20 - DOME LIGHT
(84600597)
X-062B - ROOF LIGHT [ E-016] (84491249) (Receptacle)
84491249 5
84491249
1 SP-G19-P-X G195 G195 BK - 1.0 SHEET 20 SH20 - DOME LIGHT
91715732 26/07/2021
55.2 [55.100] / 189
X-063A - RH SPEAKER IN [ A-053] (84600637) (Plug)

1 X-042 (Receptacle) pin 1 - RH 7020 7020 BK - 1.0 SHEET 18 SH18 - AUDIO
SPEAKER [H-001] (84182898)
X-063B - RH SPEAKER IN [ A-053] (84600636) (Plug)

1 X-042 (Receptacle) pin 2 - RH 7030 7030 VT - 1.0 SHEET 18 SH18 - AUDIO
SPEAKER [H-001] (84182898)
X-064* - [ M-006] (2WF 090) (Plug)
X-064A - LH SPEAKER [ H-002] (84182898) (Receptacle)
84182898 6
84182898
1 X-072A (Plug) pin 1 - LH 7000 7000 BK - 1.0 SHEET 18 SH18 - AUDIO
SPEAKER [A-053] (84600637)
2 X-072B (Plug) pin 1 - LH 7010 7010 GY - 1.0 SHEET 18 SH18 - AUDIO
SPEAKER [A-053] (84600636)
X-065 - REAR WORKING LAMP 3 [ E-013] (84182898) (Receptacle)
84182898 7
84182898
91715732 26/07/2021
55.2 [55.100] / 190
84182898 8
84182898
84182898 9
84182898
1 SP-301-P-X 42C5 42C5 VT - 1.5 SHEET 12 SH12 - REAR LIGHTING
84182898 10
84182898
91715732 26/07/2021
55.2 [55.100] / 191
X-069 - CABIN FAN [ M-001] (84182898) (Receptacle)
84182898 11
84182898
1 X-092 (Plug) pin 8 - TO MAIN 4000 4000 BR - 1.5 SHEET 17 SH17 - CAB FAN
(84600597)
2 SP-G20-P-X G205 G205 BK - 1.5 SHEET 17 SH17 - CAB FAN
91715732 26/07/2021
55.2 [55.100] / 192

X-070 - WIPER MOTOR [ M-064] (84182898) (Receptacle)
84182898 1
84182898
1 X-092 (Plug) pin 6 - TO MAIN 6304 6304 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
(84600597)
2 SP-G19-P-X G191 G191 BK - 2.0 SHEET 13 SH13 - WIPER/WASHER
X-071 - FRONT WORK LAMP 1 [ E-018] (84182898) (Receptacle)
84182898 2
84182898
X-072A - LH SPEAKER [ A-053] (84600637) (Plug)

1 X-064A (Receptacle) pin 7000 7000 BK - 1.0 SHEET 18 SH18 - AUDIO
1 - LH SPEAKER [H-002]
(84182898)
X-072B - LH SPEAKER [ A-053] (84600636) (Plug)

1 X-064A (Receptacle) pin 7010 7010 GY - 1.0 SHEET 18 SH18 - AUDIO
2 - LH SPEAKER [H-002]
(84182898)
91715732 26/07/2021
55.2 [55.100] / 193
X-073 - HAMMER_VALVE [ Y-008] (84600619) (Receptacle)
84600619 3
84600619
1 X-075 (Plug) pin C - FOOT 1024 1024 RD - 1.0 SHEET 16 SH16 - ACCESSORIES
SWITCH [S-025] (87706470)
2 X-105* (Plug) pin 2 - TO G225 G225 BK - 1.0 SHEET 16 SH16 - ACCESSORIES
WIPER (87696073)
X-074 - FR WORKING LIGHT SW. [ S-011] (87716755) (Receptacle)
87716755 4
87716755
1 Not Used
2 X-099 (Plug) pin 1 - TO MAIN 1530 1530 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47731489)
3 X-099 (Plug) pin 11 - TO MAIN 3240 3240 YE - 1.0 SHEET 11 SH11 - FRONT LIGHTING
(47731489)
4 Not Used
5 Not Used
6 Not Used
91715732 26/07/2021
55.2 [55.100] / 194
X-075 - FOOT SWITCH [ S-025] (87706470) (Plug)
87706470 5
87706470
A Not Used
B X-105* (Plug) pin 1 - TO 1025 1025 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
WIPER (87696073)
C X-073 (Receptacle) pin 1 1024 1024 RD - 1.0 SHEET 16 SH16 - ACCESSORIES
- HAMMER_VALVE [Y-008]
(84600619)
X-076 - CAB FAN SW. [ S-020] (87716755) (Receptacle)
87716755 6
87716755
1 Not Used
2 SP-403-P-X 3C03 3C03 RD - 1.5 SHEET 17 SH17 - CAB FAN
3 X-093 (Receptacle) pin 8 - TO 4010 4010 BR - 1.5 SHEET 17 SH17 - CAB FAN
4 Not Used
5 Not Used
6 Not Used
7 SP-G15-P-X G022 G022 BK - 1.0 SHEET 17 SH17 - CAB FAN
8 SP-519-P-X 3263 3263 VT - 1.0 SHEET 17 SH17 - CAB FAN
91715732 26/07/2021
55.2 [55.100] / 195
X-077 - REAR WORK LIGHT SW. [ S-012] (87716755) (Receptacle)
87716755 7
87716755
1 Not Used
3 X-103 (Receptacle) pin 8 - 42C7 42C7 YE - 1.0 SHEET 12 SH12 - REAR LIGHTING
RELAY LOADER SEF LEVEL /
REAR WO [K-004] (47781081)
4 Not Used
5 X-166 (Receptacle) pin B - 7095 7095 OR - 1.0 SHEET 12 SH12 - REAR LIGHTING
REAR WORK LAMP [K-013]
(84369037)
X-078 - SIDE SHIFT LOCK SW. [ S-019] (87716755) (Receptacle)
87716755 8
87716755
1 Not Used
2 X-130R (Receptacle) pin 23 - 1559 1559 OR - 1.5 SHEET 09 SH09 - HYDRAULICS
3 X-095 (Receptacle) pin 1 - 2240 2240 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
HARNESS TRANSMISSION
(84600606)
4 Not Used
5 Not Used
6 Not Used
7 SP-329-P-X G021 G021 BK - 1.0 SHEET 09 SH09 - HYDRAULICS
91715732 26/07/2021
55.2 [55.100] / 196
X-079 - BEACON SW. [ S-015] (87716755) (Receptacle)
87716755 9
87716755
1 Not Used
2 X-121 (Receptacle) pin 1 P020 P020 RD - 1.0 SHEET 13 SH13 - WIPER/WASHER
- BEACON FUSE [F-026]
(47435876)
4 Not Used
5 Not Used
6 Not Used
7 SP-17-P-X G199 G199 BK - 1.0 SHEET 13 SH13 - WIPER/WASHER
91715732 26/07/2021
55.2 [55.100] / 197

X-080 - TO AC HARNESS ON ENGINE SIDE (47525005) (Plug)
47525005 1
47525005
1 X-125 (Receptacle) pin 1 - A/C P016 P016 RD - 6.0 SHEET 19 SH19 - HVAC
POWER [A-111] (47415744)
2 X-125 (Receptacle) pin 2 - A/C G222 G222 BK - 6.0 SHEET 19 SH19 - HVAC
POWER [A-111] (47415744)
3 X-123 (Receptacle) pin E - A/C 1330 1330 YE - 2.0 SHEET 19 SH19 - HVAC
RELAY [K-105] (84369037)
4 X-123 (Receptacle) pin 60C6 60C6 YE - 2.0 SHEET 19 SH19 - HVAC
C - A/C RELAY [K-105]
(84369037)
X-081 - TO CAB (47525012) (Receptacle)
47525012 2
47525012
1 X-122R (Receptacle) pin P017 P017 RD - 6.0 SHEET 19 SH19 - HVAC
2 - 40A FUSE HOLDER
(47781606)
2 X-134 (Plug) pin 1 - TO G223 G223 BK - 6.0 SHEET 19 SH19 - HVAC
GROUND (47663137)
3 X-132 (Receptacle) pin A - 1331 1331 YE - 2.0 SHEET 19 SH19 - HVAC
A/C PRESSURE SW [S-069]
(87679438)
4 X-131 (Plug) pin A - A/C 60C7 60C7 YE - 2.0 SHEET 19 SH19 - HVAC
CLUTCH [M-006] (87693744)
91715732 26/07/2021
55.2 [55.100] / 198
X-089 - REAR LEFT LIGHT [ E-010] (47511912) (Receptacle)
47511912 3
47511912
TAIL LAMP (47749801)
3 X-052 (Receptacle) pin 5 - 45L1 45L1 VT - 1.0 SHEET 12 SH12 - REAR LIGHTING
5 Not Used
91715732 26/07/2021
55.2 [55.100] / 199

X-090 - REAR RIGHT LIGHT [ E-009] (47511912) (Receptacle)
47511912 1
47511912
3 X-052 (Receptacle) pin 2 - 45R1 45R1 WH - 1.0 SHEET 12 SH12 - REAR LIGHTING
4 X-052 (Receptacle) pin 11 - G157 G157 BK - 1.5 SHEET 12 SH12 - REAR LIGHTING
5 Not Used
X-091 - TO HORN [ H-003] (Not Serviceable) (Plug)

1 X-401 (Plug) pin 2 - 3150 3150 RD - 1.0 SHEET 18 SH18 - AUDIO
(84477032)
X-092 - TO MAIN (84600597) (Plug)
84600597 2
84600597
1 Not Used
5 X-062A (Receptacle) pin P009 P009 RD - 1.0 SHEET 20 SH20 - DOME LIGHT
1 - ROOF LIGHT [E-016]
(84491249)
91715732 26/07/2021
55.2 [55.100] / 200

6 X-070 (Receptacle) pin 1 6304 6304 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
- WIPER MOTOR [M-064]
(84182898)
7 SP-302-P-X 3023 3023 VT - 2.0 SHEET 16 SH16 - ACCESSORIES
8 X-069 (Receptacle) pin 4000 4000 BR - 1.5 SHEET 17 SH17 - CAB FAN
1 - CABIN FAN [M-001]
(84182898)
X-093 - TO CAB HARNESS (84600543) (Receptacle)
84600543 3
84600543
1 Not Used
2 X-106 (Receptacle) pin 3320 3320 VT - 2.0 SHEET 11 SH11 - FRONT LIGHTING
(47781081)
3 X-103 (Receptacle) pin 9 - 42C1 42C1 VT - 2.0 SHEET 12 SH12 - REAR LIGHTING
REAR WO [K-004] (47781081)
4 X-020 (Receptacle) pin 4 - 3C06 3C06 YE - 1.5 SHEET 18 SH18 - AUDIO
HARNESS FRONT PANEL
(47731490)
5 X-130R (Receptacle) pin 40 - P008 P008 RD - 1.0 SHEET 20 SH20 - DOME LIGHT
6 X-130R (Receptacle) pin 37 - 6303 6303 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
7 X-166 (Receptacle) pin C - 7094 7094 WH - 2.0 SHEET 16 SH16 - ACCESSORIES
(84369037)
8 X-076 (Receptacle) pin 3 4010 4010 BR - 1.5 SHEET 17 SH17 - CAB FAN
- CAB FAN SW. [S-020]
(87716755)
X-095 - HARNESS TRANSMISSION (84600606) (Receptacle)
84600606 4
84600606
91715732 26/07/2021
55.2 [55.100] / 201

1 X-078 (Receptacle) pin 3 2240 2240 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
- SIDE SHIFT LOCK SW.
[S-019] (87716755)
2 SP-124-P-X 5305 5305 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
2 SP-124-P-X 5305* 5305* OR - 1.5 SHEET 16 SH16 - ACCESSORIES
5 X-103 (Receptacle) pin 2 - 1260 1260 WH - 1.0 SHEET 16 SH16 - ACCESSORIES
REAR WO [K-004] (47781081)
7 Not Used
8 SP-119-P-X 2025 2025 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
9 X-103 (Receptacle) pin 3 - 1250 1250 YE - 1.0 SHEET 16 SH16 - ACCESSORIES
REAR WO [K-004] (47781081)
X-096 - HARNESS ENGINE (84182893) (Receptacle)
84182893 5
84182893
SPEEDOMETER
SPEEDOMETER
3 X-019 (Plug) pin 7 - HARNESS 2701 2701 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
FRONT PANEL (47731489) SPEEDOMETER
X-097 - HARNESS ENGINE (84600603) (Plug)
84600603 6
84600603
91715732 26/07/2021
55.2 [55.100] / 202
X-098 - HARNESS ENGINE (84600605) (Plug)
84600605 7
84600605
1 X-101 (Receptacle) pin 7 - 1180* 1180* YE - 1.0 SHEET 05 SH05 - COLD START SYSTEM
& SPE [K-003] (47781081)
1 X-101 (Receptacle) pin 7 - 1180 1180 YE - 1.5 SHEET 05 SH05 - COLD START SYSTEM
& SPE [K-003] (47781081)
2 X-117 (Receptacle) pin 3 - 7060 7060 YE - 0.75 SHEET 07 SH07 - ENGINE CONTROL
INST. CLUSTER 2 [A-002]
(84479015)
3 X-117 (Receptacle) pin 1 - 1320 1320 OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION /
INST. CLUSTER 2 [A-002] CHARGING SYSTEM
(84479015)
4 X-116 (Receptacle) pin 2 1310 1310 YE - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION /
- INST. CLUSTER [A-002] CHARGING SYSTEM
(84179604)
SPEEDOMETER
6 X-116 (Receptacle) pin 5 1401 1401 BR - 1.0 SHEET 05 SH05 - COLD START SYSTEM
- INST. CLUSTER [A-002]
(84179604)
7 X-117 (Receptacle) pin 2 - 5362 5362 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
INST. CLUSTER 2 [A-002] SPEEDOMETER
(84479015)
8 X-043 (Receptacle) pin 1 - 25E1 25E1 YE - 1.0 SHEET 09 SH09 - HYDRAULICS
4WD SW. [S-043] (87716755)
10 SP-708-P-X 7082 7082 WH - 1.0 SHEET 09 SH09 - HYDRAULICS
11 Not Used
12 X-130R (Receptacle) pin 28 - 1510 1510 OR - 1.0 SHEET 07 SH07 - ENGINE CONTROL
13 SP-012-P-X 36H3 36H3 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
14 SP-010-P-X 1052 1052 WH - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
91715732 26/07/2021
55.2 [55.100] / 203
X-099 - TO MAIN (47731489) (Plug)
47731489 8
47731489
1 X-074 (Receptacle) pin 2 - FR 1530 1530 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
WORKING LIGHT SW. [S-011]
(87716755)
3 X-138 (Receptacle) pin 2 - 3C04 3C04 RD - 1.5 SHEET 18 SH18 - AUDIO
RADIO SW [S-004] (87716755)
4 X-138 (Receptacle) pin 3 - 3C05 3C05 YE - 1.5 SHEET 18 SH18 - AUDIO
RADIO SW [S-004] (87716755)
7 X-034 (Plug) pin 4 - RHS 6301 6301 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
COMBINATION SWITCH
[S-009] (84600631)
8 Not Used
9 Not Used
10 X-038 (Plug) pin 2 - BRAKE 3461 3461 YE - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
FLUID BOTTLE SW. [S-038] SPEEDOMETER
(84417509)
11 X-074 (Receptacle) pin 3 - FR 3240 3240 YE - 1.0 SHEET 11 SH11 - FRONT LIGHTING
WORKING LIGHT SW. [S-011]
(87716755)
12 X-151 (Receptacle) pin 5340 5340 YE - 1.0 SHEET 15 SH15 - HAZARD
2 - HAZARD SW. [S-037]
(87632725)
14 X-035 (Receptacle) pin 8 - 5170 5170 WH - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
LHS COMBINATION SWITCH
[S-035] (84600543)
15 Not Used
16 X-035 (Receptacle) pin 1 - 5160 5160 OR - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
[S-035] (84600543)
91715732 26/07/2021
55.2 [55.100] / 204

X-100 - RELAY TRANS. FORW. & REV. / [ K-005] (47781081) (Receptacle)
47781081 1
47781081
1 SP-G14-P-X G143 G143 BK - 1.0 SHEET 08 SH08 - DRIVES
4 Not Used
5 X-019 (Plug) pin 15 - 5280 5280 BR - 1.0 SHEET 08 SH08 - DRIVES
HARNESS FRONT PANEL
(47731489)
6 X-020 (Receptacle) pin 14 5290 5290 WH - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
(47731490)
7 Not Used
8 SP-G14-P-X G144 G144 BK - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
9 X-130R (Receptacle) pin 9 - 3420 3420 OR - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
10 SP-008-P-X 1539 1539 OR - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
X-101 - RELAY ALARM HAND BRAKE & SPE [ K-003] (47781081) (Receptacle)
47781081 2
47781081
1 X-033 (Receptacle) pin 2 - 1300 1300 YE - 1.0 SHEET 18 SH18 - AUDIO
DIODE-3 [V-003] (84179574)
2 Not Used
6 SP-G14-P-X G146 G146 BK - 1.0 SHEET 05 SH05 - COLD START SYSTEM
7 X-098 (Plug) pin 1 - HARNESS 1180 1180 YE - 1.5 SHEET 05 SH05 - COLD START SYSTEM
ENGINE (84600605)
7 X-098 (Plug) pin 1 - HARNESS 1180* 1180* YE - 1.0 SHEET 05 SH05 - COLD START SYSTEM
ENGINE (84600605)
91715732 26/07/2021
55.2 [55.100] / 205

8 SP-119-P-X 1190 1190 YE - 1.0 SHEET 05 SH05 - COLD START SYSTEM
9 Not Used
10 X-024 (Receptacle) pin 2 1145 1145 YE - 1.5 SHEET 05 SH05 - COLD START SYSTEM
- FUSE HOLDER [F-023]
(47435876)
10 X-119P (Plug) pin 7 - IGN. 1140* 1140* YE - 1.5 SHEET 05 SH05 - COLD START SYSTEM
KEY SW. (87714250)
X-102 - HARN FRONT RH (84253888) (Receptacle)
84253888 3
84253888
3 Not Used
5 SP-351-P-X 3513 3513 WH - 1.0 SHEET 11 SH11 - FRONT LIGHTING
X-103 - RELAY LOADER SEF LEVEL / REAR WO [ K-004] (47781081) (Receptacle)
47781081 4
47781081
2 X-095 (Receptacle) pin 5 - 1260 1260 WH - 1.0 SHEET 16 SH16 - ACCESSORIES
(84600606)
3 X-095 (Receptacle) pin 9 - 1250 1250 YE - 1.0 SHEET 16 SH16 - ACCESSORIES
(84600606)
4 Not Used
7 Not Used
8 X-077 (Receptacle) pin 3 - 42C7 42C7 YE - 1.0 SHEET 12 SH12 - REAR LIGHTING
REAR WORK LIGHT SW.
[S-012] (87716755)
91715732 26/07/2021
55.2 [55.100] / 206

9 X-093 (Receptacle) pin 3 - TO 42C1 42C1 VT - 2.0 SHEET 12 SH12 - REAR LIGHTING
10 X-130R (Receptacle) pin 33 - P014 P014 RD - 2.0 SHEET 12 SH12 - REAR LIGHTING
X-104 - HARN FRONT LH (84600601) (Receptacle)
84600601 5
84600601
5 SP-514-P-X 64B3 64B3 RD - 1.0 SHEET 18 SH18 - AUDIO
6 Not Used
X-105* - TO WIPER (87696073) (Plug)
87696073 6
87696073
1 X-075 (Plug) pin B - FOOT 1025 1025 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
SWITCH [S-025] (87706470)
2 X-073 (Receptacle) pin 2 G225 G225 BK - 1.0 SHEET 16 SH16 - ACCESSORIES
- HAMMER_VALVE [Y-008]
(84600619)
91715732 26/07/2021
55.2 [55.100] / 207
X-105R - HAMMER VALVE / INSTALLAER POWER (87708145) (Receptacle)
87708145 7
87708145
1 X-130R (Receptacle) pin 36 - 1551 1551 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
X-106 - RELAY LOW BEAM / FRONT WORK LIGH [ K-012] (47781081) (Receptacle)
47781081 8
47781081
1 SP-G14-P-X G166 G166 BK - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
2 Not Used
3 X-020 (Receptacle) pin 16 5300 5300 OR - 1.0 SHEET 10 SH10 - FRONT LIGHTING 1
(47731490)
4 X-130R (Receptacle) pin 8 - 3440 3440 OR - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
7 Not Used
8 X-020 (Receptacle) pin 11 - 3610 3610 YE - 1.0 SHEET 11 SH11 - FRONT LIGHTING
HARNESS FRONT PANEL
(47731490)
10 X-130R (Receptacle) pin 31 - 3330 3330 RD - 2.0 SHEET 11 SH11 - FRONT LIGHTING
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X-107 - TO MAIN (47731490) (Receptacle)
47731490 9
47731490
1 X-036P (Plug) pin 1 - BRAKE 2150 2150 YE - 1.0 SHEET 08 SH08 - DRIVES
DECLUTCH (84606400)
2 SP-514-P-X 64B1 64B1 RD - 1.5 SHEET 15 SH15 - HAZARD
3 X-034 (Plug) pin 2 - RHS 1538 1538 OR - 2.0 SHEET 13 SH13 - WIPER/WASHER
COMBINATION SWITCH
[S-009] (84600631)
5 X-151 (Receptacle) pin 1526 1526 OR - 1.0 SHEET 15 SH15 - HAZARD
1 - HAZARD SW. [S-037]
(87632725)
[S-035] (84600543)
7 X-114 (Plug) pin 1 - 2702 2702 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER [E-017] SPEEDOMETER
(87686679)
8 Not Used
9 Not Used
10 X-114 (Plug) pin 3 - 1546 1546 OR - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER [E-017] SPEEDOMETER
(87686679)
[S-035] (84600543)
[S-035] (84600543)
X-108 - RELAY SHUTTLE CONTROL REV. / FOR [ K-010] (47781081) (Receptacle)
47781081 10
47781081
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2 Not Used
3 X-019 (Plug) pin 6 - HARNESS 5260 5260 BR - 1.0 SHEET 08 SH08 - DRIVES
FRONT PANEL (47731489)
4 SP-708-P-X 7083 7083 WH - 1.0 SHEET 08 SH08 - DRIVES
6 X-019 (Plug) pin 14 - 5270 5270 BR - 1.0 SHEET 08 SH08 - DRIVES
HARNESS FRONT PANEL
(47731489)
7 Not Used
9 SP-123-P-X 1230 1230 VT - 1.0 SHEET 08 SH08 - DRIVES
X-109 - A/C IGNTION TO MAIN (84179570) (Receptacle)
84179570 11
84179570
1 SP-406-P-X 6102 6102 OR - 2.5 SHEET 19 SH19 - HVAC
2 X-220 (Receptacle) pin 10 4064 4064 BK - 2.5 SHEET 19 SH19 - HVAC
- A/C CONTROL [A-220]
(47373520)
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X-110 - TO AC HARNESS (84417509) (Plug)
84417509 1
84417509
1 X-130R (Receptacle) pin 21 - 6101 6101 OR - 2.5 SHEET 19 SH19 - HVAC
2 SP-G15-P-X G243 G243 BK - 2.5 SHEET 19 SH19 - HVAC
X-111 - ST.RELAY [ K-001] (84369037) (Receptacle)
84369037 2
84369037
A SP-112-P-X P003* P003* RD - 2.5 SHEET 05 SH05 - COLD START SYSTEM
A X-010 (Plug) pin 2 - FUSE P010 P010 RD - 6.0 SHEET 05 SH05 - COLD START SYSTEM
STARTER [F-021] (87716284)
B X-017 (Receptacle) pin 1 - TO 1110 1110 YE - 1.5 SHEET 05 SH05 - COLD START SYSTEM
B X-017 (Receptacle) pin 1 - TO 1110* 1110* YE - 1.0 SHEET 05 SH05 - COLD START SYSTEM
C X-006 (Receptacle) pin 1 - 1100* 1100* WH - 2.5 SHEET 05 SH05 - COLD START SYSTEM
STARTER SOLENOID [M-004]
(84491249)
C SP-014-P-X 1120 1120 WH - 6.0 SHEET 05 SH05 - COLD START SYSTEM
D Not Used
E SP-G10-P-X G103 G103 BK - 1.5 SHEET 05 SH05 - COLD START SYSTEM
E SP-G10-P-X G103* G103* BK - 1.0 SHEET 05 SH05 - COLD START SYSTEM
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X-112 - TO LEFT FRONT LIGHT [ E-008] (47511912) (Receptacle)
47511912 3
47511912
3 - LEFT FRONT LIGHT
(47761028)
2 X-060 (Receptacle) pin 3110 3110 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47761028)
3 X-060 (Receptacle) pin 3100 3100 OR - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47761028)
4 X-060 (Receptacle) pin G164 G164 BK - 1.5 SHEET 11 SH11 - FRONT LIGHTING
(47761028)
(47761028)
X-113 - A/C KIT [ A-111] (47706988) (Plug)
47706988 4
47706988
1 X-220 (Receptacle) pin 1 - A/C 4030 4030 YE - 1.5 SHEET 19 SH19 - HVAC
CONTROL [A-220] (47373520)
CONTROL [A-220] (47373520)
CONTROL [A-220] (47373520)
CONTROL [A-220] (47373520)
CONTROL [A-220] (47373520)
CONTROL [A-220] (47373520)
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CONTROL [A-220] (47373520)
CONTROL [A-220] (47373520)
X-114 - SPEEDOMETER [ E-017] (87686679) (Plug)
87686679 5
87686679
MAIN (47731490) SPEEDOMETER
SPEEDOMETER
3 X-107 (Receptacle) pin 10 - 1546 1546 OR - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
TO MAIN (47731490) SPEEDOMETER
4 SP-420-P-X 4209 4209 VT - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
X-115 - SPEED SENSOR [ B-019] (84062580) (Plug)
84062580 6
84062580
SPEEDOMETER
3 X-015 (Plug) pin 2 - TO MAIN 1514 1514 OR - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
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X-116 - INST. CLUSTER [ A-002] (84179604) (Receptacle)
84179604 7
84179604
SPEEDOMETER
ENGINE (84600605) SPEEDOMETER
3 SP-010-P-X 1053 1053 WH - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
4 SP-012-P-X 36H4 36H4 YE - 0.75 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
5 X-098 (Plug) pin 6 - HARNESS 1401 1401 BR - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
6 Not Used
7 Not Used
8 Not Used
9 Not Used
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
X-117 - INST. CLUSTER 2 [ A-002] (84479015) (Receptacle)
84479015 8
84479015
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1 X-098 (Plug) pin 3 - HARNESS 1320 1320 OR - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
SPEEDOMETER
6 SP-329-P-X G066 G066 BK - 1.0 SHEET 14 SH14 - INSTRUMENT CLUSTER /
SPEEDOMETER
X-118 - IGN. KEY SW. (84599241) (Receptacle)
84599241 9
84599241
1 SP-115-P-X 1150* 1150* RD - 6.0 SHEET 04 SH04 - STARTING SYSTEM
1 X-032 (Plug) pin 1 - FUSE 1150** 1150** RD - 6.0 SHEET 04 SH04 - STARTING SYSTEM
HOLDER [F-022] (84177914)

1 X-026A (Plug) pin 1 - [S-017] 1150 1150 SHEET 04 SH04 - STARTING SYSTEM
(3302911)
X-119P - IGN. KEY SW. (87714250) (Plug)
87714250 10
87714250
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 SP-116-P-X 1501 1501 OR - 2.5 SHEET 04 SH04 - STARTING SYSTEM
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5 SP-116-P-X 1501* 1501* OR - 6.0 SHEET 04 SH04 - STARTING SYSTEM
6 SP-008-P-X 1545 1545 OR - 2.5 SHEET 04 SH04 - STARTING SYSTEM
6 SP-008-P-X 1545* 1545* OR - 6.0 SHEET 04 SH04 - STARTING SYSTEM
7 X-024 (Receptacle) pin 1 1140 1140 YE - 1.5 SHEET 04 SH04 - STARTING SYSTEM
- FUSE HOLDER [F-023]
(47435876)
7 X-101 (Receptacle) pin 10 - 1140* 1140* YE - 1.5 SHEET 04 SH04 - STARTING SYSTEM
& SPE [K-003] (47781081)
X-119R - (Not Serviceable) (Receptacle)

1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 X-026B (Plug) pin 1 - [S-017] WIRE17 WIRE17 SHEET 04 SH04 - STARTING SYSTEM
(3302911)
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X-120 - UNSWITCHED POWER (Not Serviceable) (Plug)
1 X-121 (Receptacle) pin 2 P018 P018 RD - 1.0 SHEET 04 SH04 - STARTING SYSTEM
(47435876)
X-121 - BEACON FUSE [ F-026] (47435876) (Receptacle)
47435876 1
47435876
1 X-079 (Receptacle) pin P020 P020 RD - 1.0 SHEET 13 SH13 - WIPER/WASHER
2 - BEACON SW. [S-015]
(87716755)
2 X-120 (Plug) pin 1 - P018 P018 RD - 1.0 SHEET 13 SH13 - WIPER/WASHER
UNSWITCHED POWER
(Not Serviceable)
X-122R - 40A FUSE HOLDER (47781606) (Receptacle)
47781606 2
47781606
1 X-133 (Plug) pin 1 - TO P005 P005 RD - 6.0 SHEET 19 SH19 - HVAC
STARTER (47663693)
2 X-081 (Receptacle) pin 1 - TO P017 P017 RD - 6.0 SHEET 19 SH19 - HVAC
CAB (47525012)
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X-123 - A/C RELAY [ K-105] (84369037) (Receptacle)
84369037 3
84369037
A SP-406-P-X 6104 6104 OR - 2.0 SHEET 19 SH19 - HVAC
B X-220 (Receptacle) pin 11 1351 1351 YE - 1.5 SHEET 19 SH19 - HVAC
- A/C CONTROL [A-220]
(47373520)
C X-080 (Plug) pin 4 - TO AC 60C6 60C6 YE - 2.0 SHEET 19 SH19 - HVAC
HARNESS ON ENGINE SIDE
(47525005)
D Not Used
E X-080 (Plug) pin 3 - TO AC 1330 1330 YE - 2.0 SHEET 19 SH19 - HVAC
(47525005)
X-125 - A/C POWER [ A-111] (47415744) (Receptacle)
47415744 4
47415744
1 X-080 (Plug) pin 1 - TO AC P016 P016 RD - 6.0 SHEET 19 SH19 - HVAC
(47525005)
2 X-080 (Plug) pin 2 - TO AC G222 G222 BK - 6.0 SHEET 19 SH19 - HVAC
(47525005)
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X-126 - TO HAMMER VALVE/CUSTOMER OPTION (87696073) (Plug)
87696073 5
87696073
2 SP-017-P-X G227 G227 BK - 1.0 SHEET 16 SH16 - ACCESSORIES
X-127 - TO HAMMER VALVE (87708145) (Receptacle)
87708145 6
87708145
2 SP-017-P-X G226 G226 BK - 1.0 SHEET 16 SH16 - ACCESSORIES
X-129 - TO WIPER/WASHER (87696073) (Plug)
87696073 7
87696073
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1 X-164 (Receptacle) pin 2 1039 1039 GY - 1.0 SHEET 13 SH13 - WIPER/WASHER
- FUSE HOLDER-INLINE
[F-024] (47435876)
2 SP-349-P-X 4212 4212 VT - 1.0 SHEET 13 SH13 - WIPER/WASHER
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55.2 [55.100] / 220

X-130R - FUSE BOX (Not Serviceable) (Receptacle)

1 SP-115-P-X 1153 1153 RD - 2.5 SHEET 11 SH11 - FRONT LIGHTING
2 SP-008-P-X 1504 1504 OR - 2.5 SHEET 21 SH21 - MOBILE CHARGER
3 SP-115-P-X P013 P013 RD - 2.5 SHEET 12 SH12 - REAR LIGHTING
4 SP-115-P-X P011 P011 RD - 2.5 SHEET 15 SH15 - HAZARD
5 SP-115-P-X P012 P012 RD - 2.5 SHEET 17 SH17 - CAB FAN
6 SP-008-P-X 1550* 1550* OR - 2.5 SHEET 16 SH16 - ACCESSORIES
7 X-020 (Receptacle) pin 7 - 6302 6302 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
HARNESS FRONT PANEL
(47731490)
8 X-106 (Receptacle) pin 3440 3440 OR - 1.5 SHEET 10 SH10 - FRONT LIGHTING 1
(47781081)
REV. / [K-005] (47781081)
10 SP-115-P-X P007 P007 RD - 2.5 SHEET 20 SH20 - DOME LIGHT
13 SP-116-P-X 1522 1522 OR - 2.5 SHEET 09 SH09 - HYDRAULICS
SPEEDOMETER
SPEEDOMETER
18 SP-008-P-X 1509 1509 OR - 2.5 SHEET 07 SH07 - ENGINE CONTROL
19 SP-116-P-X 1518 1518 OR - 2.5 SHEET 09 SH09 - HYDRAULICS
20 SP-116-P-X 1505 1505 OR - 2.5 SHEET 08 SH08 - DRIVES
21 X-110 (Plug) pin 1 - TO AC 6101 6101 OR - 2.5 SHEET 19 SH19 - HVAC
HARNESS (84417509)
23 X-078 (Receptacle) pin 2 1559 1559 OR - 1.5 SHEET 09 SH09 - HYDRAULICS
- SIDE SHIFT LOCK SW.
[S-019] (87716755)
SPEEDOMETER
SPEEDOMETER
26 X-019 (Plug) pin 13 - 1520 1520 OR - 1.5 SHEET 12 SH12 - REAR LIGHTING
HARNESS FRONT PANEL
(47731489)
28 X-098 (Plug) pin 12 1510 1510 OR - 1.0 SHEET 07 SH07 - ENGINE CONTROL
- HARNESS ENGINE
(84600605)
29 X-043 (Receptacle) pin 2 - 3301 3301 OR - 1.5 SHEET 09 SH09 - HYDRAULICS
4WD SW. [S-043] (87716755)
31 X-106 (Receptacle) pin 3330 3330 RD - 2.0 SHEET 11 SH11 - FRONT LIGHTING
(47781081)
32 X-025C (Receptacle) pin 1 - 1508 1508 OR - 1.0 SHEET 21 SH21 - MOBILE CHARGER
CHARGER SOCKET [J-001]
(84491249)
33 X-103 (Receptacle) pin 10 - P014 P014 RD - 2.0 SHEET 12 SH12 - REAR LIGHTING
REAR WO [K-004] (47781081)
34 X-019 (Plug) pin 2 - HARNESS 64B0 64B0 RD - 1.5 SHEET 15 SH15 - HAZARD
FRONT PANEL (47731489)
35 SP-403-P-X 3C01 3C01 RD - 2.5 SHEET 17 SH17 - CAB FAN
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36 X-105R (Receptacle) pin 1551 1551 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
1 - HAMMER VALVE
/ INSTALLAER POWER
(87708145)
37 X-093 (Receptacle) pin 6 - TO 6303 6303 BR - 2.0 SHEET 13 SH13 - WIPER/WASHER
HARNESS FRONT PANEL
(47731490)
40 X-093 (Receptacle) pin 5 - TO P008 P008 RD - 1.0 SHEET 20 SH20 - DOME LIGHT
X-131 - A/C CLUTCH [ M-006] (87693744) (Plug)
87693744 1
87693744
A X-081 (Receptacle) pin 4 - TO 60C7 60C7 YE - 2.0 SHEET 19 SH19 - HVAC
CAB (47525012)
X-132 - A/C PRESSURE SW [ S-069] (87679438) (Receptacle)
87679438 2
87679438
A X-081 (Receptacle) pin 3 - TO 1331 1331 YE - 2.0 SHEET 19 SH19 - HVAC
CAB (47525012)
B X-134 (Plug) pin 1 - TO G171 G171 BK - 2.0 SHEET 19 SH19 - HVAC
GROUND (47663137)
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55.2 [55.100] / 222
X-133 - TO STARTER (47663693) (Plug)
47663693 3
47663693
1 X-122R (Receptacle) pin P005 P005 RD - 6.0 SHEET 04 SH04 - STARTING SYSTEM
1 - 40A FUSE HOLDER
(47781606)
X-134 - TO GROUND (47663137) (Plug)
47663137 4
47663137
1 X-081 (Receptacle) pin 2 - TO G223 G223 BK - 6.0 SHEET 06 SH06 - GROUNDING
CAB (47525012)
1 X-132 (Receptacle) pin B - G171 G171 BK - 2.0 SHEET 06 SH06 - GROUNDING
(87679438)
X-135 - FUEL SHUT OFF [ Y-007] (87687239) (Receptacle)
87687239 5
87687239
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1 SP-015-P-X 1425 1425 RD - 1.0 SHEET 07 SH07 - ENGINE CONTROL
X-135A - FUEL SHUT OFF (87679525) (Receptacle)
87679525 6
87679525
1 X-135B (Plug) pin 1 - TO 1426 1426 RD - 1.0 SHEET 07 SH07 - ENGINE CONTROL
FUEL SHUT OFF [Y-007A]
(87581782)
X-135B - TO FUEL SHUT OFF [ Y-007A] (87581782) (Plug)
87581782 7
87581782
1 X-135A (Receptacle) pin 1 - 1426 1426 RD - 1.0 SHEET 07 SH07 - ENGINE CONTROL
FUEL SHUT OFF (87679525)
X-135P - FUEL SHUT OFF (87687239) (Plug)
87687239 8
87687239
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1 X-017 (Receptacle) pin 1552* 1552* OR - 1.0 SHEET 07 SH07 - ENGINE CONTROL
12 - TO MAIN HARNESS
(84600598)
X-138 - RADIO SW [ S-004] (87716755) (Receptacle)
87716755 9
87716755
1 Not Used
2 X-099 (Plug) pin 3 - TO MAIN 3C04 3C04 RD - 1.5 SHEET 18 SH18 - AUDIO
(47731489)
3 X-099 (Plug) pin 4 - TO MAIN 3C05 3C05 YE - 1.5 SHEET 18 SH18 - AUDIO
(47731489)
4 Not Used
5 Not Used
6 Not Used
8 SP-420-P-X 4207 4207 VT - 1.5 SHEET 18 SH18 - AUDIO
X-139 - RIGHT TURN INDICATOR [ E-002] (84491249) (Receptacle)
84491249 10
84491249
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X-140 - LEFT TURN INDICATOR [ E-002] (84491249) (Receptacle)
84491249 1
84491249
X-141 - TURN SIGNAL GROUND [ E-002] (84491249) (Receptacle)
84491249 2
84491249
X-142 - TO HORN [ H-003] (Not Serviceable) (Plug)

1 X-401 (Plug) pin 1 - 3160 3160 YE - 1.0 SHEET 18 SH18 - AUDIO
(84477032)
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55.2 [55.100] / 226
X-143 - ALTERNATOR D+ [ G-067] (84179570) (Receptacle)
84179570 3
84179570
1 X-017 (Receptacle) pin 3 - TO 1030 1030 OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION /
MAIN HARNESS (84600598) CHARGING SYSTEM
2 X-017 (Receptacle) pin 4 - TO 1020 1020 YE - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION /
MAIN HARNESS (84600598) CHARGING SYSTEM
X-144 - BUZZER [ H-005] (87679493) (Plug)
87679493 4
87679493
1 SP-006-P-X 45R4 45R4 WH - 1.0 SHEET 18 SH18 - AUDIO
2 SP-005-P-X 45L4 45L4 VT - 1.0 SHEET 18 SH18 - AUDIO
X-145 - BUZZER [ S-010] (47415745) (Plug)
47415745 5
47415745
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3 SP-012-P-X 36H5 36H5 YE - 0.75 SHEET 18 SH18 - AUDIO
6 SP-010-P-X 1054 1054 WH - 1.0 SHEET 18 SH18 - AUDIO
7 Not Used
8 SP-003-P-X 1560 1560 OR - 0.75 SHEET 18 SH18 - AUDIO
9 SP-329-P-X G187 G187 BK - 1.0 SHEET 18 SH18 - AUDIO
X-146 - FUEL LEVEL SENSOR [ B-001] (Not Serviceable) (Plug)

MAIN HARNESS (84600598) SPEEDOMETER
X-147 - FUEL LEVEL SENSOR [ B-001] (Not Serviceable) (Plug)

SPEEDOMETER
X-148 - TO FRONT PANEL HARNESS (87708145) (Receptacle)
87708145 6
87708145
1 X-149 (Receptacle) pin A - 1029 1029 GY - 1.0 SHEET 13 SH13 - WIPER/WASHER
FRONT WASHER MOTOR
[M-009] (87693325)
2 X-161 (Receptacle) pin 10 - 4213 4213 VT - 1.0 SHEET 13 SH13 - WIPER/WASHER
TO REAR WIPER/WASHER
SWITCH [S-016] (87632724)
X-149 - FRONT WASHER MOTOR [ M-009] (87693325) (Receptacle)
87693325 7
87693325
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A X-148 (Receptacle) pin 1 - 1029 1029 GY - 1.0 SHEET 13 SH13 - WIPER/WASHER
TO FRONT PANEL HARNESS
(87708145)
B SP-018-P-X G026 G026 BK - 1.0 SHEET 13 SH13 - WIPER/WASHER
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X-150 - REAR WASHER MOTOR [ M-003] (87693325) (Receptacle)
87693325 1
87693325
A X-161 (Receptacle) pin 6 - 1034 1034 WH - 1.0 SHEET 13 SH13 - WIPER/WASHER
SWITCH [S-016] (87632724)
B SP-019-P-X G028 G028 BK - 1.0 SHEET 13 SH13 - WIPER/WASHER
X-151 - HAZARD SW. [ S-037] (87632725) (Receptacle)
87632725 2
87632725
1 X-107 (Receptacle) pin 5 - TO 1526 1526 OR - 1.0 SHEET 15 SH15 - HAZARD
MAIN (47731490)
2 X-099 (Plug) pin 12 - TO MAIN 5340 5340 YE - 1.0 SHEET 15 SH15 - HAZARD
(47731489)
3 SP-514-P-X 64B2 64B2 RD - 1.0 SHEET 15 SH15 - HAZARD
4 Not Used
6 Not Used
7 Not Used
8 Not Used
9 Not Used
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Not Used
16 Not Used
91715732 26/07/2021
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X-158 - BEACON SOCKET [ J-158] (84015523) (Receptacle)
84015523 3
84015523
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X-160 - COLD START MODULE [ A-001] (Not Serviceable) (Plug)
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 X-010BP (Plug) pin 1 - (Not 1185* 1185* SHEET 05 SH05 - COLD START SYSTEM
Serviceable)
X-160A - COLD START MODULE [ A-001] (87705703) (Receptacle)
87705703 1
87705703
30 SP-G10-P-X G030 G030 BK - 2.5 SHEET 05 SH05 - COLD START SYSTEM
85 X-017 (Receptacle) pin 6 - TO 1400 1400 BR - 1.0 SHEET 05 SH05 - COLD START SYSTEM
86 SP-015-P-X 1420 1420 RD - 1.0 SHEET 05 SH05 - COLD START SYSTEM
87A SP-014-P-X 1105 1105 WH - 2.5 SHEET 05 SH05 - COLD START SYSTEM
X-161 - TO REAR WIPER/WASHER SWITCH [ S-016] (87632724) (Receptacle)
87632724 2
87632724
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 X-150 (Receptacle) pin A 1034 1034 WH - 1.0 SHEET 13 SH13 - WIPER/WASHER
- REAR WASHER MOTOR
[M-003] (87693325)
7 Not Used
8 Not Used
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10 X-148 (Receptacle) pin 2 - 4213 4213 VT - 1.0 SHEET 13 SH13 - WIPER/WASHER
(87708145)
REAR WIPER MOTOR [S-014]
(87680380)
12 Not Used
13 SP-021-P-X 1036 1036 BR - 1.0 SHEET 13 SH13 - WIPER/WASHER
14 SP-021-P-X 1037 1037 YE - 1.0 SHEET 13 SH13 - WIPER/WASHER
X-162 - REAR WIPER MOTOR [ S-014] (87680380) (Receptacle)
87680380 3
87680380
SWITCH [S-016] (87632724)
X-163 - LICENSE PLATE LAMP 3 [ E-007] (84182898) (Receptacle)
84182898 4
84182898
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X-164 - FUSE HOLDER-INLINE [ F-024] (47435876) (Receptacle)
47435876 5
47435876
1 X-037 (Plug) pin 1 - 1028 1028 GY - 1.0 SHEET 13 SH13 - WIPER/WASHER
COMBINATION SWITCH
[S-009] (47461910)
2 X-129 (Plug) pin 1 - TO 1039 1039 GY - 1.0 SHEET 13 SH13 - WIPER/WASHER
WIPER/WASHER (87696073)
X-166 - REAR WORK LAMP [ K-013] (84369037) (Receptacle)
84369037 6
84369037
A X-167 (Receptacle) pin 1 - 7093 7093 RD - 2.0 SHEET 16 SH16 - ACCESSORIES
FUSE HOLDER (47435876)
B X-077 (Receptacle) pin 5 - 7095 7095 OR - 1.0 SHEET 16 SH16 - ACCESSORIES
REAR WORK LIGHT SW.
[S-012] (87716755)
C X-093 (Receptacle) pin 7 - TO 7094 7094 WH - 2.0 SHEET 16 SH16 - ACCESSORIES
D Not Used
E SP-G14-P-X G212 G212 BK - 1.0 SHEET 16 SH16 - ACCESSORIES
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X-167 - FUSE HOLDER (47435876) (Receptacle)
47435876 7
47435876
1 X-166 (Receptacle) pin A - 7093 7093 RD - 2.0 SHEET 16 SH16 - ACCESSORIES
(84369037)
2 SP-115-P-X 7092 7092 RD - 2.5 SHEET 16 SH16 - ACCESSORIES
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X-198 - BEACON GROUND (Not Serviceable) (Plug)
1 SP-17-P-X G198 G198 BK - 1.0 SHEET 06 SH06 - GROUNDING
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X-200 - GROUND (Not Serviceable) (Plug)
X-201 - ENGINE GROUND (Not Serviceable) (Plug)

X-202 - GROUND (84182883) (Plug)
84182883 1
84182883
X-203 - GROUND (84182883) (Plug)
84182883 2
84182883
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X-204 - GROUND (47763000) (Plug)
47763000 3
47763000


1 X-051 (Receptacle) pin 7 G170 G170 BK - 1.0 SHEET 06 SH06 - GROUNDING
- DECLUTCH SW [S-002]
(87716755)
X-208 - GROUND (84606401) (Plug)
84606401 4
84606401
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X-220 - A/C CONTROL [ A-220] (47373520) (Receptacle)
47373520 1
47373520
1 X-113 (Plug) pin 1 - A/C KIT 4030 4030 YE - 1.5 SHEET 19 SH19 - HVAC
[A-111] (47706988)
[A-111] (47706988)
[A-111] (47706988)
[A-111] (47706988)
[A-111] (47706988)
[A-111] (47706988)
[A-111] (47706988)
[A-111] (47706988)
10 X-109 (Receptacle) pin 2 4064 4064 BK - 2.5 SHEET 19 SH19 - HVAC
- A/C IGNTION TO MAIN
(84179570)
11 X-123 (Receptacle) pin 1351 1351 YE - 1.5 SHEET 19 SH19 - HVAC
B - A/C RELAY [K-105]
(84369037)
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X-300 - [ G-001] (Not Serviceable) (Plug)
1 X-005A (Plug) pin 1 - (Not P017* P017* RD - 70.0 SHEET 03 SH03 - POWER DISTRIBUTION /
Serviceable) CHARGING SYSTEM
X-300A - [ G-001A] (Not Serviceable) (Plug)

1 X-301P (Plug) pin 1 - (Not P015 P015 RD - 70.0 SHEET 03 SH03 - POWER DISTRIBUTION /

1 S-021-PLUG-P-2 3 3 SHEET 03 SH03 - POWER DISTRIBUTION /
CHARGING SYSTEM

1 X-300A (Plug) pin 1 - [G-001A] P015 P015 RD - 70.0 SHEET 03 SH03 - POWER DISTRIBUTION /
(Not Serviceable) CHARGING SYSTEM

1 X-303 (Plug) pin 1 - (Not P016* P016* RD - 70.0 SHEET 03 SH03 - POWER DISTRIBUTION /

1 S-021-PLUG-P-1 2 2 SHEET 03 SH03 - POWER DISTRIBUTION /
CHARGING SYSTEM
X-303 - (Not Serviceable) (Plug)

1 X-302 (Receptacle) pin 1 - P016* P016* RD - 70.0 SHEET 04 SH04 - STARTING SYSTEM
(Not Serviceable)
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X-400 - TO HORN JUMPER HARNESS (84182898) (Receptacle)
84182898 1
84182898
1 X-060 (Receptacle) pin 3159 3159 YE - 1.0 SHEET 18 SH18 - AUDIO
(47761028)
2 X-060 (Receptacle) pin 3149 3149 RD - 1.0 SHEET 18 SH18 - AUDIO
(47761028)
X-401 - (84477032) (Plug)
84477032 2
84477032
1 X-142 (Plug) pin 1 - TO HORN 3160 3160 YE - 1.0 SHEET 18 SH18 - AUDIO
[H-003] (Not Serviceable)
2 X-091 (Plug) pin 1 - TO HORN 3150 3150 RD - 1.0 SHEET 18 SH18 - AUDIO
[H-003] (Not Serviceable)
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X-502 - [ G-001] (Not Serviceable) (Plug)
1 GND-001-PLUG-P-1 P021* P021* BK - 70.0 SHEET 03 SH03 - POWER DISTRIBUTION /
CHARGING SYSTEM
X-502A - [ G-001A] (Not Serviceable) (Plug)

1 GND-001A-PLUG-P-1 P021 P021 BK - 70.0 SHEET 03 SH03 - POWER DISTRIBUTION /
CHARGING SYSTEM
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X-001 - FUSES AND RELAYS BLOCK (47944422) (Receptacle)
47944422 1
47944422
1 X-001 (Receptacle) pin 80 - S221 LOW BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
FUSES AND RELAYS BLOCK B+
(47944422)
2 Not Used
3 X-107B (Plug) pin 3 - 5300 LOW BEAM SIGNAL OR - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
TO FRONT HARNESS
(47696620)
4 X-001 (Receptacle) pin 82 - S211 HIGH BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47944422)
5 Not Used
6 X-107B (Plug) pin 2 - 5290 HIGH BEAM SIGNAL WH - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
TO FRONT HARNESS
(47696620)
7 SP-G56-P-X G561 LOW BEAM RELAY COIL BK - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
GROUND
8 Not Used
9 SP-345-P-X 3450 LOW BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
B+
10 SP-G56-P-X G562 HIGH BEAM RELAY COIL BK - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
GROUND
11 Not Used
12 SP-343-P-X 3430 HIGH BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
B+
13 SP-S27-P-X S27C FORWARD RELAY B+ OR - 1.0 SHEET 10 SH10 - DRIVES
14 Not Used
15 SP-527-P-X 5271 FORWARD SIGNAL VT - 0.75 SHEET 10 SH10 - DRIVES
16 SP-S27-P-X S27B REVERSE RELAY B+ OR - 1.0 SHEET 10 SH10 - DRIVES
17 Not Used
18 SP-526-P-X 5261 REVERSE SIGNAL WH - 0.75 SHEET 10 SH10 - DRIVES
19 X-002 (Receptacle) pin 37 - G563 FORWARD RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
FUSES AND RELAYS BLOCK GROUND
(47944422)
20 Not Used
21 X-017A (Receptacle) pin G 1230 FORWARD SIGNAL VT - 1.0 SHEET 10 SH10 - DRIVES
- TO CHASSIS HARNESS
(47696606)
22 X-002 (Receptacle) pin 39 - G564 REVERSE RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
(47944422)
23 Not Used
24 X-017A (Receptacle) pin H 7080 REVERSE SIGNAL WH - 1.0 SHEET 10 SH10 - DRIVES
(47696606)
25 SP-121-P-X S272 TRANSMISSION CUTOUT OR - 1.0 SHEET 10 SH10 - DRIVES
RELAY B+
26 Not Used
27 SP-122-P-X 2035 DECLUTCH SIGNAL YE - 0.75 SHEET 10 SH10 - DRIVES
28 SP-121-P-X S275 NEUTRAL RELAY OR - 1.0 SHEET 10 SH10 - DRIVES
SWITCH B+
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29 Not Used
30 SP-119-P-X 1193 IN GEAR SIGNAL YE - 0.75 SHEET 10 SH10 - DRIVES
31 SP-G56-P-X G565 TRANSMISSION CUTOUT BK - 0.75 SHEET 10 SH10 - DRIVES
RELAY GROUND
32 SP-S27-P-X S27A FORWARD AND OR - 1.0 SHEET 10 SH10 - DRIVES
REVERSE RELAYS B+
33 Not Used
34 SP-G56-P-X G566 NEUTRAL RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
GROUND
35 SP-103-P-X 1031 NEUTRAL SIGNAL YE - 0.75 SHEET 10 SH10 - DRIVES
36 X-017A (Receptacle) pin R 1195 IN GEAR SIGNAL YE - 1.0 SHEET 10 SH10 - DRIVES
(47696606)
37 SP-423-P-X 4228 DRIVING LIGHTS SIGNAL VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
38 SP-141-P-X 41R9 BACK LIGHT VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
39 SP-332-P-X 3222 FRONT WORK LIGHTS VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
SIGNAL
40 SP-141-P-X 42FP BACK LIGHT VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
41 SP-42C-P-X 42C1 REAR WORK LIGHTS VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
SIGNAL
42 SP-141-P-X 42CP BACK LIGHT VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
44 SP-119-P-X 1190 FORWARD SIGNAL YE - 1.0 SHEET 10 SH10 - DRIVES
46 SP-119-P-X 1191 REVERSE SIGNAL YE - 1.0 SHEET 10 SH10 - DRIVES
47 Not Used
48 Not Used
49 SP-S10-P-X S142 USB PORT POWER OR - 0.75 SHEET 22 SH22 - MOBILE CHARGER
49 F-016-PLUG-P-1 WIRE1407 WIRE1407 SHEET 22 SH22 - MOBILE CHARGER
50 F-016-PLUG-P-2 WIRE1408 WIRE1408 SHEET 22 SH22 - MOBILE CHARGER
50 X-009 (Plug) pin 1 - USB S143 USB PORT POWER OR - 0.75 SHEET 22 SH22 - MOBILE CHARGER
PORT [A-016] (47906572)
51 Not Used
52 Not Used
53 Not Used
54 Not Used
55 SP-421-P-X 4213 SWITCHES BACKLIGTH VT - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
56 SP-422-P-X 4214 SWITCHES BACKLIGTH VT - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
57 SP-P02-P-X P021 CUSTOMER OPTION B+ RD - 3.0 SHEET 24 SH24 - ACCESSORIES
57 F-014-PLUG-P-1 WIRE1312 WIRE1312 SHEET 24 SH24 - ACCESSORIES
58 X-010 (Plug) pin CUSTOMER P022 Customer Option B+ RD - 3.0 SHEET 24 SH24 - ACCESSORIES
OPT - CUSTOMER OPTION
BATT+ (Not serviceable)
59 SP-S10-P-X S109 Customer option IGN OR - 3.0 SHEET 24 SH24 - ACCESSORIES
60 X-020 (Plug) pin CUSTOMER S108 Customer option IGN OR - 3.0 SHEET 24 SH24 - ACCESSORIES
OPT - CUSTOMER OPTION
IGNITION (Not serviceable)
61 SP-S10-P-X S150 FRONT WIPER AND OR - 2.0 SHEET 18 SH18 - WIPER/WASHER
WASHER B+
62 X-107B (Plug) pin 1 - S151 FRONT WIPER AND OR - 2.0 SHEET 18 SH18 - WIPER/WASHER
TO FRONT HARNESS WASHER B+
(47696620)
63 SP-S10-P-X S160 REAR WIPER AND OR - 1.5 SHEET 18 SH18 - WIPER/WASHER
WASHER B+
64 X-129A (Plug) pin 3 - TO S162 REAR WIPER AND OR - 1.5 SHEET 18 SH18 - WIPER/WASHER
WIPER/WASHER (47416267) WASHER B+
65 X-119 (Plug) pin 7 - IGNITION S500 CRANK SIGNAL OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION
SWITCH [S-001] (87714250)
66 SP-S51-P-X S501 CRANK SIGNAL OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION
67 SP-S10-P-X S140 POWER SOCKET B+ OR - 3.0 SHEET 22 SH22 - MOBILE CHARGER
68 X-025A (Plug) pin 1 - S141 POWER SOCKET B+ OR - 3.0 SHEET 22 SH22 - MOBILE CHARGER
CHARGER SOCKET [J-001]
(87699736)
69 SP-S10-P-X S110 SPEEDOMETER OR - 0.75 SHEET 21 SH21 - SPEEDOMETER
SWITCHED B+
SWITCHED B+
71 SP-S20-P-X S270 TRANSMISION B+ OR - 1.0 SHEET 10 SH10 - DRIVES
72 SP-121-P-X S271 TRANSMISSION B+ OR - 1.0 SHEET 10 SH10 - DRIVES
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73 SP-S10-P-X S120 BRAKE LIGHTS OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
SWITCHED B+
74 X-107B (Plug) pin 7 - S121 BRAKE LIGHTS OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
TO FRONT HARNESS SWITCHED B+
(47696620)
75 SP-S10-P-X S130 HAZARD / LIGHTS OR - 1.0 SHEET 16 SH16 - HAZARD
SWICTHES B+
76 SP-007-P-X S131 HAZARD / LIGHTS OR - 1.0 SHEET 16 SH16 - HAZARD
SWICTHES B+
77 SP-P02-P-X P028 DIAGNOSTIC B+ RD - 0.75 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
78 X-031 (Plug) pin B - P029 DIAGNOSTIC B+ RD - 0.75 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
DIAGNOSTIC PORT [A-005]
(87736919)
79 SP-S20-P-X S220 LOW BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
B+
80 X-001 (Receptacle) pin 1 - S221 LOW BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47944422)
81 SP-S20-P-X S210 HIGH BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
B+
82 X-001 (Receptacle) pin 4 - S211 HIGH BEAM SWITCHED OR - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47944422)
83 SP-P02-P-X P023 HORN / HAZARD LIGHTS RD - 1.5 SHEET 16 SH16 - HAZARD
/ DRIVING LIGHTS B+
84 X-107B (Plug) pin 34 - P024 HORN AND HAZARD RD - 1.5 SHEET 16 SH16 - HAZARD
TO FRONT HARNESS LIGHTS B+
(47696620)
47944422 2
47944422
1 X-002 (Receptacle) pin 80 - P038 FRONT WORK LIGHTS RD - 2.0 SHEET 14 SH14 - FRONT WORK LIGHTS
(47944422)
2 Not Used
3 X-107B (Plug) pin 12 - 3610 FRONT WORK LIGHTS YE - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
TO FRONT HARNESS SIGNAL
(47696620)
4 X-002 (Receptacle) pin 82 - P034 REAR WORK LIGHTS B+ RD - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
FUSES AND RELAYS BLOCK
(47944422)
5 Not Used
6 X-077 (Receptacle) pin 3 42C7 REAR WORK LIGHTS YE - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
- REAR WORK LIGHTS SIGNAL
SWITCH [S-012] (87716755)
7 SP-G55-P-X G551 FRONT WORKLIGHTS BK - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
RELAY COIL GROUND
8 Not Used
9 SP-332-P-X 3320 FRONT WORK LIGHTS VT - 2.0 SHEET 14 SH14 - FRONT WORK LIGHTS
B+
10 SP-G55-P-X G552 REAR WORK LIGHTS BK - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
RELAY COIL GROUND
11 Not Used
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12 SP-42C-P-X 42C0 REAR WORK LIGHTS B+ VT - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
13 SP-G51-P-X G553 HAND BRAKE BK - 0.75 SHEET 20 SH20 - PARK BRAKE
14 Not Used
15 X-027 (Plug) pin B - PARK 1182 PARK BRAKE SIGNAL YE - 0.75 SHEET 20 SH20 - PARK BRAKE
BRAKE SWITCH [S-027]
(47587518)
(47944422)
17 Not Used
18 X-077 (Receptacle) pin 6 7095 REAR WORK LIGHTS OR - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
- REAR WORK LIGHTS SIGNAL
SWITCH [S-012] (87716755)
19 SP-G53-P-X G534 PARK BRAKE SWITCH BK - 0.75 SHEET 20 SH20 - PARK BRAKE
GROUND
20 X-CN1 (Receptacle) pin 18 1180 PARK BRAKE SIGNAL YE - 0.75 SHEET 20 SH20 - PARK BRAKE
- CLUSTER CN1 [A-002]
(82016219)
21 K-012-PLUG-P-87 WIRE1807 WIRE1807 SHEET 20 SH20 - PARK BRAKE
21 SP-G60-P-X G600 FORWARD AND BK - 0.75 SHEET 20 SH20 - PARK BRAKE
REVERSE RELAYS
GROUND
RELAY COIL GROUND
23 Not Used
24 X-094B (Receptacle) pin 3 - 7094 REAR WORK LIGHTS B+ WH - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
TO UPPER CAB HARNESS
(48126491)
25 SP-124-P-X S252 RETURN TO DIG B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
26 Not Used
28 X-002 (Receptacle) pin 54 - S009 IGNITION SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
(47944422)
29 Not Used
30 SP-202-P-X 2022 AUTO SHUTDOWN YE - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
RELAY
31 X-017A (Receptacle) pin O 1250 RETURN TO DIG YE - 0.75 SHEET 24 SH24 - ACCESSORIES
- TO CHASSIS HARNESS SENSOR SIGNAL
(47696606)
32 X-017A (Receptacle) pin M 1260 RETURN TO DIG WH - 1.0 SHEET 24 SH24 - ACCESSORIES
- TO CHASSIS HARNESS SOLENOID B+
(47696606)
33 Not Used
34 SP-G55-P-X G555 AUTO SHUTDOWN BK - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
RELAY GROUND
35 SP-401-P-X 4001 IGNITION SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
RELAY
37 X-001 (Receptacle) pin 19 - G563 FORWARD RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
(47944422)
37 V-046-P-P WIRE1804 WIRE1804 SHEET 10 SH10 - DRIVES
38 V-046-P-N WIRE1803 WIRE1803 SHEET 10 SH10 - DRIVES
38 SP-G60-P-X G601 FORWARD RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
GROUND
39 X-001 (Receptacle) pin 22 - G564 REVERSE RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
(47944422)
39 V-047-P-P WIRE1802 WIRE1802 SHEET 10 SH10 - DRIVES
40 V-047-P-N WIRE1801 WIRE1801 SHEET 10 SH10 - DRIVES
40 SP-G60-P-X G602 REVERSE RELAY BK - 0.75 SHEET 10 SH10 - DRIVES
GROUND
41 X-CN2 (Receptacle) pin 2 2020 AUTO SHUTDOWN YE - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
- CLUSTER CN2 [A-002] RELAY
(82028493)
RELAY
43 Not Used
44 Not Used
45 Not Used
46 Not Used
47 Not Used
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48 Not Used
49 Not Used
50 Not Used
51 F-041-PLUG-P-1 WIRE1305 WIRE1305 SHEET 20 SH20 - PARK BRAKE
51 SP-S20-P-X S280 PARK BRAKE SW B+ OR - 0.75 SHEET 20 SH20 - PARK BRAKE
52 X-027 (Plug) pin A - PARK S281 PARK BRAKE SW B+ OR - 0.75 SHEET 20 SH20 - PARK BRAKE
BRAKE SWITCH [S-027]
(47587518)
52 F-041-PLUG-P-2 WIRE1306 WIRE1306 SHEET 20 SH20 - PARK BRAKE
53 SP-S01-P-X S010 AUTO SHUTDOWN OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
RELAY POWER
53 F-042-PLUG-P-1 WIRE1424 WIRE1424 SHEET 03 SH03 - POWER DISTRIBUTION
54 X-002 (Receptacle) pin 28 - S009 IGNITION SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
(47944422)
54 F-042-PLUG-P-2 WIRE1425 WIRE1425 SHEET 03 SH03 - POWER DISTRIBUTION
55 SP-P03-P-X P031 IGNITION SWITCH B+ RD - 1.5 SHEET 03 SH03 - POWER DISTRIBUTION
56 X-118 (Receptacle) pin 1 - P032 IGNITION SWITCH B+ RD - 1.5 SHEET 03 SH03 - POWER DISTRIBUTION
IGNITION SWITCH [S-001]
(84599241)
57 SP-S01-P-X S002 TELEMATICS IGNITION OR - 0.75 SHEET 27 SH27 - TELEMATICS
58 X-005 (Receptacle) pin S003 TELEMATICS IGNITION OR - 0.75 SHEET 27 SH27 - TELEMATICS
42 - TELEMATICS [A-003]
(51452976)
59 SP-P03-P-X P052 HORN UNSWITCHED B+ RD - 1.0 SHEET 26 SH26 - AUDIO
60 X-017A (Receptacle) pin K P053 HORN UNSWITCHED B+ RD - 1.0 SHEET 26 SH26 - AUDIO
(47696606)
61 SP-S01-P-X S004 INTRUMENT CLUSTER OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
IGNITION
62 SP-S03-P-X S005 INSTRUMENT CLUSTER OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
IGNITION
63 SP-S20-P-X S250 RETURN TO DIG B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
65 SP-P03-P-X P047 CAB FAN / RADIO B+ RD - 2.0 SHEET 23 SH23 - CAB FAN
66 SP-403-P-X P048 CAB FAN / RADIO B+ RD - 2.0 SHEET 23 SH23 - CAB FAN
67 SP-P03-P-X P042 INSTRUMENT CLUSTER RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
UNSWITCHED B+
UNSWITCHED B+
69 SP-P03-P-X P039 DOMELIGHT B+ RD - 1.0 SHEET 17 SH17 - DOME LIGHT
70 X-093B (Plug) pin 1 - TO P040 DOMELIGHT B+ RD - 1.0 SHEET 17 SH17 - DOME LIGHT
UPPER CAB HARNESS
(47511905)
71 SP-S10-P-X S170 HVAC B+ OR - 2.0 SHEET 25 SH25 - HVAC
72 X-110 (Plug) pin 1 - TO AC S171 HVAC B+ OR - 2.0 SHEET 25 SH25 - HVAC
HARNESS (84417509)
73 SP-S20-P-X S230 2WD SWITCH B+ OR - 1.0 SHEET 11 SH11 - HYDRAULICS
74 X-043 (Receptacle) pin 2 S231 2WD SWITCH B+ OR - 1.0 SHEET 11 SH11 - HYDRAULICS
- 2WD SWITCH [S-043]
(87716755)
75 SP-S20-P-X S240 SIDE SHIFT LOCK OR - 1.0 SHEET 11 SH11 - HYDRAULICS
SWITCH B+
76 X-078 (Receptacle) pin 2 - S241 SIDE SHIFT LOCK OR - 1.0 SHEET 11 SH11 - HYDRAULICS
SIDE SHIFT LOCK SWITCH SWITCH B+
[S-019] (87716755)
77 SP-S20-P-X S260 REAR HAMMER B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
78 X-105A (Plug) pin A S261 REAR HAMMER B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
- HAMMER VALVE /
INSTALLER POWER
(47587518)
79 SP-P03-P-X P037 FRONT WORK LIGHTS RD - 2.0 SHEET 14 SH14 - FRONT WORK LIGHTS
B+
80 X-002 (Receptacle) pin 1 - P038 FRONT WORK LIGHTS RD - 2.0 SHEET 14 SH14 - FRONT WORK LIGHTS
(47944422)
81 SP-P03-P-X P033 REAR WORK LIGHTS B+ RD - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
(47944422)
83 SP-P03-P-X P035 REAR WORK LIGHTS B+ RD - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
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(47944422)
X-003 - SHUTDOWN POWER RELAY 1 [ K-025] (84297431) (Receptacle)
84297431 3
84297431
2 SP-G54-P-X G542 SHUTDOWN RELAY BK - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
GROUND
3 SP-S10-P-X S100 SWICTHED B+ OR - 6.0 SHEET 03 SH03 - POWER DISTRIBUTION
4 Not Used
5 SP-P01-P-X P013 UNSWITCHED B+ RD - 6.0 SHEET 03 SH03 - POWER DISTRIBUTION
X-004 - SHUTDOWN POWER RELAY 2 [ K-026] (84297431) (Receptacle)
84297431 4
84297431
2 SP-G54-P-X G543 SHUTDOWN RELAY BK - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
GROUND
3 SP-S20-P-X S200 SWICTHED B+ OR - 6.0 SHEET 03 SH03 - POWER DISTRIBUTION
4 Not Used
5 SP-P01-P-X P014 UNSWITCHED B+ RD - 6.0 SHEET 03 SH03 - POWER DISTRIBUTION
X-005 - TELEMATICS [ A-003] (51452976) (Receptacle)

1 SP-G51-P-X G503 TELEMATICS GROUND BK - 0.75 SHEET 27 SH27 - TELEMATICS
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 Not Used
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8 Not Used
9 Not Used
10 Not Used
11 Not Used
12 Not Used
13 Not Used
14 SP-L02-P-X L004 CONTROLLER AREA GN - 0.5 SHEET 27 SH27 - TELEMATICS
NETWORK LO
15 SP-H02-P-X H004 CONTROLLER AREA YE - 0.5 SHEET 27 SH27 - TELEMATICS
NETWORK HI
16 Not Used
17 Not Used
18 Not Used
19 Not Used
20 Not Used
21 Not Used
22 Not Used
23 Not Used
24 Not Used
25 Not Used
26 Not Used
27 Not Used
28 Not Used
29 Not Used
30 Not Used
31 Not Used
32 Not Used
33 Not Used
34 Not Used
35 Not Used
36 Not Used
37 X-107B (Plug) pin 28 - P116 TELEMATICS RD - 0.75 SHEET 27 SH27 - TELEMATICS
TO FRONT HARNESS UNSWITCHED B+
(47696620)
38 SP-G53-P-X G535 TELEMATICS GROUND BK - 0.75 SHEET 27 SH27 - TELEMATICS
39 SP-119-P-X 1192 IN GEAR SIGNAL YE - 0.75 SHEET 27 SH27 - TELEMATICS
40 Not Used
41 X-105A (Plug) pin C 1024C REAR HAMMER SIGNAL RD - 0.75 SHEET 27 SH27 - TELEMATICS
- HAMMER VALVE /
INSTALLER POWER
(47587518)
42 X-002 (Receptacle) pin 58 - S003 TELEMATICS IGNITION OR - 0.75 SHEET 27 SH27 - TELEMATICS
(47944422)
X-006 - STARTER SOLENOID [ M-001] (87679490) (Plug)
87679490 5
87679490
1 X-103 (Receptacle) pin 3 1100 STARTER COIL B+ WH - 4.0 SHEET 02 SH02 - POWER DISTRIBUTION /
- STARTER RELAY [K-125] CHARGING SYSTEM / STARTING
(84297431)
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X-007 - BATT+ (47781606) (Receptacle)
47781606 6
47781606
1 X-133 (Plug) pin 1 - TO P005 HVAC BATT POWER RD - 5.0 SHEET 25 SH25 - HVAC
STARTER [J-002] (47663693)
2 X-015 (Plug) pin 1 - TO CAB P017 HVAC BATT POWER RD - 5.0 SHEET 25 SH25 - HVAC
AC CONTROLL HARNESS
(51543230)
X-008 - GROUND (84401295) (Plug)
84401295 7
84401295
1 SP-G40-P-X G400 ECU GROUND BK - 8.0 SHEET 04 SH04 - GROUNDING
1 X-640A (Receptacle) pin 8 - G450 DIESEL EXHAUST FLUID BK - 2.0 SHEET 04 SH04 - GROUNDING
LEFT SIDE POD HARNESS HEATER LINES GROUND
(47416277)
1 SP-G46-P-X G460 GROUND BK - 1.0 SHEET 04 SH04 - GROUNDING
1 X-638A (Receptacle) pin 12 G480 GROUND BK - 1.5 SHEET 04 SH04 - GROUNDING
- LEFT SIDE POD HARNESS
(47416278)
1 X-638A (Receptacle) pin 4 - G490 GROUND BK - 1.5 SHEET 04 SH04 - GROUNDING
LEFT SIDE POD HARNESS
(47416278)
1 X-106A (Plug) pin H - G500 D+ BK - 0.75 SHEET 04 SH04 - GROUNDING
TO FRONT HARNESS
(87698254)
1 SP-G41-P-X G410 AFTER-TREATMENT BK - 4.0 SHEET 04 SH04 - GROUNDING
GROUND
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X-009 - USB PORT [ A-016] (47906572) (Plug)
47906572 8
47906572
1 X-001 (Receptacle) pin 50 - S143 USB PORT POWER OR - 0.75 SHEET 22 SH22 - MOBILE CHARGER
(47944422)
2 SP-422-P-X 4223 USB PORT VT - 0.75 SHEET 22 SH22 - MOBILE CHARGER
ILLUMINATION
3 SP-G52-P-X G529 USB PORT GND BK - 0.75 SHEET 22 SH22 - MOBILE CHARGER
X-009A - HYDRAULIC FILTER [ S-006] (87679525) (Receptacle)
87679525 9
87679525
1 X-017B (Plug) pin A - 1223 HYDRAULIC FILTER YE - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO MAIN CAB HARNESS RESTRICTION SIGNAL
(47696624)
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X-CN1 - CLUSTER CN1 [ A-002] (82016219) (Receptacle)
82016219 10
82016219
1 Not Used
2 SP-S03-P-X S006 INSTRUMENT CLUSTER OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
IGNITION
3 SP-103-P-X 1030 NEUTRAL SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
4 SP-141-P-X 41RR BACK LIGHT VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
5 X-030 (Receptacle) pin 4 - 3240 FLASHER SIGNAL TO VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
FLASHER [K-030] (84479009) CLUSTER
6 SP-160-P-X 1600 AUTO IDLE ENABLE YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
7 SP-222-P-X 4408 BRAKE SIGNAL VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
8 SP-343-P-X 3431 HIGH BEAM SWITCHED OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
B+
9 X-107B (Plug) pin 30 - 1090 BRAKE OIL LEVEL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO FRONT HARNESS
(47696620)
10 Not Used
11 X-117 (Receptacle) pin 3 - 1111 DISPLAY CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
DISPLAY/ENTER CONTROL
SW [S-032] (87716755)
12 X-117 (Receptacle) pin 1 - 1121 ENTER CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
DISPLAY/ENTER CONTROL
SW [S-032] (87716755)
13 X-116 (Receptacle) pin 3 1131 UP CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- UP/DOWN SW [S-031]
(87716755)
14 X-116 (Receptacle) pin 1 1141 DOWN CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- UP/DOWN SW [S-031]
(87716755)
15 SP-S51-P-X S502 CRANK SIGNAL OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
16 X-107B (Plug) pin 29 - 1160 AIR FILTER BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO FRONT HARNESS RESTRICTION SW
(47696620)
17 X-124 (Receptacle) pin 6 - 1170 ECO MODE SIGNAL BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
ECO MODE SWITCH [S-040]
(87716755)
18 X-002 (Receptacle) pin 20 - 1180 PARK BRAKE SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(47944422)
19 X-046 (Receptacle) pin 3 119A SEAT SWITCH SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- SEAT SWITCH [S-044]
(84600602)
20 X-155 (Plug) pin 6 - 1200 FOOT THROTTLE IDLE BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
FOOT THROTTLE [A-015] VALIDATION
(47416268)
21 Not Used
22 X-017A (Receptacle) pin A 1220 HYDRAULIC FILTER YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- TO CHASSIS HARNESS RESTRICTION SIGNAL
(47696606)
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X-CN2 - CLUSTER CN2 [ A-002] (82028493) (Receptacle)
82028493 11
82028493
UNSWITCHED B+
2 X-002 (Receptacle) pin 41 - 2020 AUTO SHUTDOWN YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
FUSES AND RELAYS BLOCK RELAY
(47944422)
3 SP-L02-P-X L005 CONTROLLER AREA GN - 0.5 SHEET 19 SH19 - INSTRUMENT CLUSTER
NETWORK LOW
4 SP-H02-P-X H005 CONTROLLER AREA YE - 0.5 SHEET 19 SH19 - INSTRUMENT CLUSTER
NETWORK HIGH
5 Not Used
6 X-044 (Plug) pin 8 - AUDIBLE 2600 AUDIBLE ALARM WH - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
ALARM [H-006] (47415745) OUTPUT
7 Not Used
8 Not Used
9 Not Used
10 Not Used
11 Not Used
12 Not Used
13 X-017A (Receptacle) pin B 2130 FUEL LEVEL SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(47696606)
14 X-017A (Receptacle) pin C 2140 TRANSMISSION HIGH YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- TO CHASSIS HARNESS TEMPERATURE
(47696606)
15 Not Used
16 X-155 (Plug) pin 3 - 2160 FOOT THROTTLE YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
FOOT THROTTLE [A-015] SIGNAL
(47416268)
17 X-056 (Plug) pin B - 2170 HAND THROTTLE YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
HAND THROTTLE [A-014] SIGNAL
(47587518)
18 X-155 (Plug) pin 5 - 2180 FOOT THROTTLE 5V PK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
FOOT THROTTLE [A-015]
(47416268)
19 X-056 (Plug) pin A - 2190 HAND THROTTLE 5V PK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
HAND THROTTLE [A-014]
(47587518)
20 X-155 (Plug) pin 4 - 2200 FOOT THROTTLE GND BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
FOOT THROTTLE [A-015]
(47416268)
21 X-056 (Plug) pin C - 2211 HAND THROTTLE GND GN - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
HAND THROTTLE [A-014]
(47587518)
22 Not Used
23 Not Used
24 X-107B (Plug) pin 33 - 2402 CLUSTER GROUND YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO FRONT HARNESS
(47696620)
25 Not Used
26 SP-G51-P-X G505 CLUSTER GROUND BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
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X-G01 - (Not serviceable) (Plug)

PIN1 X-G02 (Plug) pin PIN1 - G001 GROUND BK - 70.0 SHEET 02 SH02 - POWER DISTRIBUTION /
[G-001] (Not serviceable) CHARGING SYSTEM / STARTING
X-G02 - [ G-001] (Not serviceable) (Plug)

PIN1 X-G01 (Plug) pin PIN1 - (Not G001 GROUND BK - 70.0 SHEET 02 SH02 - POWER DISTRIBUTION /
serviceable) CHARGING SYSTEM / STARTING
X-P01 - [ G-001] (Not serviceable) (Plug)

PIN1 X-P02 (Plug) pin PIN1 - P001 UNSWITCHED B+ RD - 70.0 SHEET 02 SH02 - POWER DISTRIBUTION /
[S-002] (Not serviceable) CHARGING SYSTEM / STARTING
X-P02 - [ S-002] (Not serviceable) (Plug)

X-P03 - (Not serviceable) (Plug)

PIN1 X-P04 (Plug) pin PIN1 - P002 STARTER B+ RD - 70.0 SHEET 02 SH02 - POWER DISTRIBUTION /
[M-001] (Not serviceable) CHARGING SYSTEM / STARTING
X-P04 - [ M-001] (Not serviceable) (Plug)

PIN1 X-P03 (Plug) pin PIN1 - (Not P002 STARTER B+ RD - 70.0 SHEET 02 SH02 - POWER DISTRIBUTION /

PIN1 X-P06 (Plug) pin PIN1 - P003 UNSWICTHED B+ RD - 25.0 SHEET 02 SH02 - POWER DISTRIBUTION /
[F-201] (Not serviceable) CHARGING SYSTEM / STARTING
X-P06 - [ F-201] (Not serviceable) (Plug)

PIN1 X-P05 (Plug) pin PIN1 - (Not P003 UNSWICTHED B+ RD - 25.0 SHEET 02 SH02 - POWER DISTRIBUTION /
X-P07 - TO MAIN FUSE [ F-201] (84176552) (Plug)
84176552 12
84176552
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1 X-016A (Receptacle) pin P011 UNSWITCHED B+ RD - 16.0 SHEET 02 SH02 - POWER DISTRIBUTION /
1 - TO MAIN HARNESS CHARGING SYSTEM / STARTING
(84144194)

PIN1 X-P09 (Plug) pin PIN1 - P004 JUNCTION BLOCK RD - 62.0 SHEET 02 SH02 - POWER DISTRIBUTION /
[J-002] (Not serviceable) UNSWITCHED B+ CHARGING SYSTEM / STARTING
X-P09 - [ J-002] (Not serviceable) (Plug)

PIN1 X-P08 (Plug) pin PIN1 - (Not P004 JUNCTION BLOCK RD - 62.0 SHEET 02 SH02 - POWER DISTRIBUTION /
serviceable) UNSWITCHED B+ CHARGING SYSTEM / STARTING
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X-010 - CUSTOMER OPTION BATT+ (Not serviceable) (Plug)
CUST- X-001 (Receptacle) pin 58 - P022 Customer Option B+ RD - 3.0 SHEET 24 SH24 - ACCESSORIES
OMER FUSES AND RELAYS BLOCK
OPT (47944422)
X-011 - TRANSMISSION OIL TEMPERATURE [ R-030] (84062580) (Plug)
84062580 1
84062580
1 X-017B (Plug) pin C - 2143 TRANSMISSION HIGH YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO MAIN CAB HARNESS TEMPERATURE
(47696624)
2 SP-G33-P-X G338 TRANS HIGH OIL GND BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
X-012 - FORWARD SPEED SOLENOID VALVE (YE [ Y-002] (47933796) (Plug)
47933796 2
47933796
1 X-017B (Plug) pin G - 1231 FORWARD SIGNAL VT - 1.0 SHEET 10 SH10 - DRIVES
TO MAIN CAB HARNESS
(47696624)
2 SP-G33-P-X G332 FORWARD SOLENOID BK - 1.0 SHEET 10 SH10 - DRIVES
GROUND
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X-013 - REVERSE SPEED SOLENOID VALVE (BL [ Y-001] (47933788) (Plug)
47933788 3
47933788
1 X-017B (Plug) pin H - 7081 REVERSE SIGNAL WH - 1.0 SHEET 10 SH10 - DRIVES
TO MAIN CAB HARNESS
(47696624)
2 SP-G33-P-X G333 REVERSE SOLENOID BK - 1.0 SHEET 10 SH10 - DRIVES
GROUND
X-014 - TO AC HARNESS ON ENGINE SIDE (51543229) (Receptacle)

1 X-125 (Plug) pin A - POWER P016 HVAC BATT POWER RD - 5.0 SHEET 25 SH25 - HVAC
(51670671)
X-014A - 4WD SOLENOID VALVE (BK) [ Y-003] (87695900) (Plug)
87695900 4
87695900
1 X-017B (Plug) pin F - TO MAIN 25E2 2WD SOLENOID B+ YE - 1.0 SHEET 11 SH11 - HYDRAULICS
2 SP-G33-P-X G334 2WD GROUND BK - 1.0 SHEET 11 SH11 - HYDRAULICS
X-015 - TO CAB AC CONTROLL HARNESS (51543230) (Plug)

1 X-007 (Receptacle) pin 2 - P017 HVAC BATT POWER RD - 5.0 SHEET 25 SH25 - HVAC
BATT+ (47781606)
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X-016 - TO AC HARNESS ON ENGINE SIDE (48126491) (Receptacle)
48126491 5
48126491
1 X-134 (Plug) pin 1 - TO G170 A/C SWITCH GROUND BK - 1.0 SHEET 04 SH04 - GROUNDING
GROUND (47763001)
2 SP-60C6-P-X 60C6 POWER TO AC CLUTCH YE - 1.0 SHEET 25 SH25 - HVAC
3 X-123 (Receptacle) pin 2 - A/C 1330 AC SWITCH YE - 1.0 SHEET 25 SH25 - HVAC
RELAY [K-200] (84297431)
X-016A - TO MAIN HARNESS (84144194) (Receptacle)
84144194 6
84144194
1 X-P07 (Plug) pin 1 - TO MAIN P011 UNSWITCHED B+ RD - 16.0 SHEET 02 SH02 - POWER DISTRIBUTION /
FUSE [F-201] (84176552) CHARGING SYSTEM / STARTING
X-016B - HARNESS ENGINE (47955799) (Plug)
47955799 7
47955799
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1 SP-P01-P-X P012 UNSWITCHED B+ RD - 16.0 SHEET 02 SH02 - POWER DISTRIBUTION /
CHARGING SYSTEM / STARTING
X-017 - GROUND (84401295) (Plug)
84401295 8
84401295
1 X-025A (Plug) pin 2 - G510 POWER SOCKET BK - 3.0 SHEET 04 SH04 - GROUNDING
CHARGER SOCKET [J-001] GROUND
(87699736)
1 X-129A (Plug) pin 4 - TO G511 REAR WIPER GROUND BK - 1.5 SHEET 04 SH04 - GROUNDING
1 SP-G51-P-X G502 CLUSTER GROUND BK - 1.0 SHEET 04 SH04 - GROUNDING
X-017A - TO CHASSIS HARNESS (47696606) (Receptacle)
47696606 9
47696606
A X-CN1 (Receptacle) pin 22 1220 HYDRAULIC FILTER YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN1 [A-002] RESTRICTION SIGNAL
(82016219)
B X-CN2 (Receptacle) pin 13 2130 FUEL LEVEL SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82028493)
C X-CN2 (Receptacle) pin 14 2140 TRANSMISSION HIGH YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN2 [A-002] TEMPERATURE
(82028493)
D SP-S04-P-X S114 SPEED SENSOR OR - 0.75 SHEET 21 SH21 - SPEEDOMETER
SWITCHED B+
E X-107B (Plug) pin 22 - 2701 SPEED SENSOR SIGNAL YE - 0.75 SHEET 21 SH21 - SPEEDOMETER
TO FRONT HARNESS
(47696620)
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F X-043 (Receptacle) pin 1 25E1 2WD SOLENOID B+ YE - 1.0 SHEET 11 SH11 - HYDRAULICS
- 2WD SWITCH [S-043]
(87716755)
G X-001 (Receptacle) pin 21 - 1230 FORWARD SIGNAL VT - 1.0 SHEET 10 SH10 - DRIVES
(47944422)
H X-001 (Receptacle) pin 24 - 7080 REVERSE SIGNAL WH - 1.0 SHEET 10 SH10 - DRIVES
(47944422)
I Not Used
J X-107B (Plug) pin 21 - 5213 HORN GROUND YE - 1.0 SHEET 26 SH26 - AUDIO
TO FRONT HARNESS
(47696620)
K X-002 (Receptacle) pin 60 - P053 HORN UNSWITCHED B+ RD - 1.0 SHEET 26 SH26 - AUDIO
(47944422)
L X-078 (Receptacle) pin 3 - 2240 SIDE SHIFT LOCK WH - 1.0 SHEET 11 SH11 - HYDRAULICS
SIDE SHIFT LOCK SWITCH SOLENOID B+
[S-019] (87716755)
M X-002 (Receptacle) pin 32 - 1260 RETURN TO DIG WH - 1.0 SHEET 24 SH24 - ACCESSORIES
FUSES AND RELAYS BLOCK SOLENOID B+
(47944422)
N SP-124-P-X S254 RETURN TO DIG OR - 1.0 SHEET 24 SH24 - ACCESSORIES
SENSOR B+
O X-002 (Receptacle) pin 31 - 1250 RETURN TO DIG YE - 0.75 SHEET 24 SH24 - ACCESSORIES
FUSES AND RELAYS BLOCK SENSOR SIGNAL
(47944422)
P SP-121-P-X S276 DECLUTCH SWITCH B+ OR - 0.75 SHEET 10 SH10 - DRIVES
Q SP-122-P-X 2033 DECLUTCH SIGNAL YE - 0.75 SHEET 10 SH10 - DRIVES
R X-001 (Receptacle) pin 36 - 1195 IN GEAR SIGNAL YE - 1.0 SHEET 10 SH10 - DRIVES
(47944422)
X-017B - TO MAIN CAB HARNESS (47696624) (Plug)
47696624 10
47696624
A X-009A (Receptacle) pin 1 - 1223 HYDRAULIC FILTER YE - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
HYDRAULIC FILTER [S-006] RESTRICTION SIGNAL
(87679525)
B X-146 (Receptacle) pin 1 2133 FUEL LEVEL SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- FUEL LEVEL SENDER
[R-002] (84381192)
C X-011 (Plug) pin 1 - 2143 TRANSMISSION HIGH YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
TRANSMISSION OIL TEMPERATURE
TEMPERATURE [R-030]
(84062580)
D X-115 (Plug) pin 3 - SPEED S115 SPEED SENSOR OR - 0.75 SHEET 21 SH21 - SPEEDOMETER
SENSOR [B-019] (84062580) SWITCHED B+
E X-115 (Plug) pin 1 - SPEED 2700 SPEED SENSOR SIGNAL YE - 0.75 SHEET 21 SH21 - SPEEDOMETER
SENSOR [B-019] (84062580)
F X-014A (Plug) pin 1 - 4WD 25E2 2WD SOLENOID B+ YE - 1.0 SHEET 11 SH11 - HYDRAULICS
SOLENOID VALVE (BK)
[Y-003] (87695900)
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G X-012 (Plug) pin 1 1231 FORWARD SIGNAL VT - 1.0 SHEET 10 SH10 - DRIVES
- FORWARD SPEED
SOLENOID VALVE (YE
[Y-002] (47933796)
H X-013 (Plug) pin 1 - REVERSE 7081 REVERSE SIGNAL WH - 1.0 SHEET 10 SH10 - DRIVES
SPEED SOLENOID VALVE
(BL [Y-001] (47933788)
I Not Used
J SP-522-P-X 5214 HORN GROUND YE - 1.0 SHEET 26 SH26 - AUDIO
K X-143 (Plug) pin 1 - TO HORN P054 HORN UNSWITCHED B+ RD - 1.0 SHEET 26 SH26 - AUDIO
[H-003] (51621244)
L X-047 (Receptacle) pin 2000 SIDE SHIFT LOCK WH - 1.0 SHEET 11 SH11 - HYDRAULICS
1 - SIDE SHIFT LOCK SOLENOID
SOL.VALVE [Y-006]
(84607243)
M X-084 (Plug) pin 1 - 2010 RETURN TO DIG WH - 1.0 SHEET 24 SH24 - ACCESSORIES
RTD SOLENOID [Y-005] SOLENOID B+
(87695900)
N X-085 (Receptacle) pin 1 S139 RETURN TO DIG OR - 1.0 SHEET 24 SH24 - ACCESSORIES
- RTD SENSOR [B-003] SENSOR B+
(84600602)
O X-085 (Receptacle) pin 3 2050 RETURN TO DIG YE - 1.0 SHEET 24 SH24 - ACCESSORIES
- RTD SENSOR [B-003] SENSOR SIGNAL
(84600602)
P SP-204-P-X S277 DECLUTCH SWITCH B+ OR - 0.75 SHEET 10 SH10 - DRIVES
Q SP-203-P-X 2030 DECLUTCH SIGNAL YE - 0.75 SHEET 10 SH10 - DRIVES
R X-045 (Receptacle) pin 1 - 1196 IN GEAR SIGNAL YE - 1.0 SHEET 10 SH10 - DRIVES
UNLOADING VALVE [Y-004]
(84607243)
X-017C - TO CAB (84600602) (Receptacle)
84600602 11
84600602
1 X-132 (Receptacle) pin B - G171 A/C SWITCH GROUND BK - 1.0 SHEET 04 SH04 - GROUNDING
(87679438)
2 X-131 (Plug) pin 1 - A/C 60C7 AC CLUTCH YE - 1.0 SHEET 25 SH25 - HVAC
CLUTCH [M-006] (87687239)
3 X-132 (Receptacle) pin A - 1331 A/C PRESSURE SWITCH YE - 1.0 SHEET 25 SH25 - HVAC
(87679438)
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X-018 - TO BACK-UP ALARM [ H-007] (87692855) (Plug)
87692855 12
87692855
A SP-526-P-X 5262 REVERSE SIGNAL WH - 1.0 SHEET 26 SH26 - AUDIO
B SP-G52-P-X G524 BACK-UP ALARM BK - 1.0 SHEET 26 SH26 - AUDIO
GROUND

PIN1 X-P11 (Plug) pin PIN1 - P006 ALTERNATOR B+ RD - 25.0 SHEET 02 SH02 - POWER DISTRIBUTION /
X-P11 - [ G-002] (Not serviceable) (Plug)

PIN1 X-P10 (Plug) pin PIN1 - P006 ALTERNATOR B+ RD - 25.0 SHEET 02 SH02 - POWER DISTRIBUTION /
[J-002] (Not serviceable) CHARGING SYSTEM / STARTING

[A-013] (Not serviceable) CHARGING SYSTEM / STARTING
X-P13 - [ A-013] (Not serviceable) (Plug)

PIN1 X-P12 (Plug) pin PIN1 - P007 UNSWITCHED B+ RD - 25.0 SHEET 05 SH05 - ENGINE CONTROL
[J-002] (Not serviceable)
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X-020 - CUSTOMER OPTION IGNITION (Not serviceable) (Plug)
CUST- X-001 (Receptacle) pin 60 - S108 Customer option IGN OR - 3.0 SHEET 24 SH24 - ACCESSORIES
OMER FUSES AND RELAYS BLOCK
OPT (47944422)
X-023A - AIR FILTER SW [ S-033] (87705127) (Plug)
87705127 1
87705127
1 X-106A (Plug) pin A - 1162 AIR FILTER BL - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO FRONT HARNESS RESTRICTION SW
(87698254)
X-025A - CHARGER SOCKET [ J-001] (87699736) (Plug)
87699736 2
87699736
1 X-001 (Receptacle) pin 68 - S141 POWER SOCKET B+ OR - 3.0 SHEET 22 SH22 - MOBILE CHARGER
(47944422)
2 X-017 (Plug) pin 1 - GROUND G510 POWER SOCKET BK - 3.0 SHEET 22 SH22 - MOBILE CHARGER
(84401295) GROUND
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X-025B - CHARGER SOCKET [ J-001] (87705140) (Plug)
87705140 3
87705140
1 SP-422-P-X 4222 POWER PORT LED B+ VT - 0.75 SHEET 22 SH22 - MOBILE CHARGER
X-026 - AIR FILTER SW [ S-033] (87705127) (Plug)
87705127 4
87705127
1 SP-G46-P-X G430 AIR FILTER BK - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
RESTRICTION GROUND
X-027 - PARK BRAKE SWITCH [ S-027] (47587518) (Plug)
47587518 5
47587518
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A X-002 (Receptacle) pin 52 - S281 PARK BRAKE SW B+ OR - 0.75 SHEET 20 SH20 - PARK BRAKE
(47944422)
B X-002 (Receptacle) pin 15 - 1182 PARK BRAKE SIGNAL YE - 0.75 SHEET 20 SH20 - PARK BRAKE
(47944422)
C SP-G55-P-X G556 GROUND BK - 0.75 SHEET 20 SH20 - PARK BRAKE
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X-030 - FLASHER [ K-030] (84479009) (Receptacle)
84479009 1
84479009
1 X-107B (Plug) pin 14 - 3220 FLASHER RELAY SIGNAL BR - 1.0 SHEET 16 SH16 - HAZARD
TO FRONT HARNESS
(47696620)
2 X-107B (Plug) pin 13 - 3230 FLASHER RELAY B+ YE - 1.0 SHEET 16 SH16 - HAZARD
TO FRONT HARNESS
(47696620)
3 SP-G53-P-X G533 FLASHER RELAY BK - 1.0 SHEET 16 SH16 - HAZARD
GROUND
4 X-CN1 (Receptacle) pin 5 3240 FLASHER SIGNAL TO VT - 0.75 SHEET 16 SH16 - HAZARD
- CLUSTER CN1 [A-002] CLUSTER
(82016219)
X-031 - DIAGNOSTIC PORT [ A-005] (87736919) (Plug)
87736919 2
87736919
A SP-G54-P-X G541 DIAGNOSTIC GROUND BK - 0.75 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
B X-001 (Receptacle) pin 78 - P029 DIAGNOSTIC B+ RD - 0.75 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
(47944422)
C SP-H01-P-X H001 CONTROLLER AREA YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
NETWORK HIGH
D SP-L01-P-X L001 CONTROLLER AREA GN - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
NETWORK LOW
E X-107B (Plug) pin 31 - E682 ECU K LINE YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
TO FRONT HARNESS
(47696620)
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X-034 - RHS COMBINATION SWITCH [ S-009] (84600631) (Plug)
84600631 3
84600631
1 SP-533-P-X 5330 FLASHER RELAY SIGNAL BR - 1.0 SHEET 16 SH16 - HAZARD
1 S-024-PLUG-P-IN WIRE1402 WIRE1402 SHEET 16 SH16 - HAZARD
2 X-107A (Receptacle) pin 1 S152 FRONT WIPER AND OR - 2.0 SHEET 18 SH18 - WIPER/WASHER
- TO MAIN CAB HARNESS WASHER B+
(47696599)
3 SP-G11-P-X G113 COMBINATION SWITCH BK - 1.0 SHEET 16 SH16 - HAZARD
GROUND
4 X-107A (Receptacle) pin 4 6301 FRONT WIPER MOTOR BR - 2.0 SHEET 18 SH18 - WIPER/WASHER
- TO MAIN CAB HARNESS B+
(47696599)
5 SP-352-P-X 3521 LEFT TURN SIGNAL VT - 1.0 SHEET 16 SH16 - HAZARD
5 S-024-PLUG-P-1 WIRE1403 WIRE1403 SHEET 16 SH16 - HAZARD
6 SP-351-P-X 3511 RIGHT TURN SIGNAL WH - 1.0 SHEET 16 SH16 - HAZARD
6 S-024-PLUG-P-2 WIRE1404 WIRE1404 SHEET 16 SH16 - HAZARD
X-035 - LHS COMBINATION SWITCH [ S-035] (84600543) (Receptacle)
84600543 4
84600543
1 X-107A (Receptacle) pin 3 5160 LOW BEAM SIGNAL OR - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
- TO MAIN CAB HARNESS
(47696599)
2 SP-514-P-X P027 DRIVING LIGHTS B+ RD - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
3 X-107A (Receptacle) pin 17 S274 TRANSMISSION FNR B+ OR - 1.0 SHEET 10 SH10 - DRIVES
(47696599)
4 X-107A (Receptacle) pin 18 5220 REVERSE SIGNAL WH - 1.0 SHEET 10 SH10 - DRIVES
(47696599)
5 X-107A (Receptacle) pin 21 5200 HORN GROUND YE - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47696599)
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6 X-107A (Receptacle) pin 19 5230 FORWARD SIGNAL VT - 1.0 SHEET 10 SH10 - DRIVES
(47696599)
7 SP-420-P-X 4200 POSITION LIGHTS VT - 2.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
8 X-107A (Receptacle) pin 2 5170 HIGH BEAM SIGNAL WH - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47696599)
X-037 - COMBINATION SWITCH [ S-009] (47461910) (Plug)
47461910 5
47461910
1 X-107A (Receptacle) pin 32 1028 FRONT WASHER B+ GY - 1.0 SHEET 18 SH18 - WIPER/WASHER
(47696599)
X-038A - [ S-041] (87581782) (Plug)
87581782 6
87581782
1 SP-150-P-X S125 BRAKE OIL LEVEL OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
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X-038B - [ S-041] (87581782) (Plug)
87581782 7
87581782
1 X-107A (Receptacle) pin 30 1093 BRAKE OIL LEVEL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(47696599)
X-039 - STOP LIGHT SWITCH 2 (84600562) (Receptacle)
84600562 8
84600562
1 SP-150-P-X S124 BRAKE LIGHTS OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
SWITCHED B+
2 SP-440-P-X 4401 BRAKE LIGHTS SIGNAL VT - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
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X-040 - STOP LIGHT SWITCH 1 (84600562) (Receptacle)
84600562 1
84600562
SWITCHED B+
X-042 - RH SPEAKER [ A-006] (84182898) (Receptacle)
84182898 2
84182898
1 X-063A (Plug) pin 1 - RH 7020 RIGHT SPEAKER BK - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [H-001] (47763027)
2 X-063B (Plug) pin 1 - RH 7030 RIGHT SPEAKER VT - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [H-001] (84600636)
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X-043 - 2WD SWITCH [ S-043] (87716755) (Receptacle)
87716755 3
87716755
1 X-017A (Receptacle) pin F 25E1 2WD SOLENOID B+ YE - 1.0 SHEET 11 SH11 - HYDRAULICS
(47696606)
2 X-002 (Receptacle) pin 74 - S231 2WD SWITCH B+ OR - 1.0 SHEET 11 SH11 - HYDRAULICS
(47944422)
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 SP-G53-P-X G537 2WD SWITCH GROUND BK - 0.75 SHEET 11 SH11 - HYDRAULICS
8 SP-423-P-X 4227 2WD SWITCH LED B+ VT - 0.75 SHEET 11 SH11 - HYDRAULICS
X-044 - AUDIBLE ALARM [ H-006] (47415745) (Plug)
47415745 4
47415745
1 Not Used
2 SP-G52-P-X G521 BUZZER GROUND BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 Not Used
8 X-CN2 (Receptacle) pin 6 2600 AUDIBLE ALARM WH - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN2 [A-002] OUTPUT
(82028493)
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X-045 - UNLOADING VALVE [ Y-004] (84607243) (Receptacle)
84607243 5
84607243
1 X-017B (Plug) pin R - 1196 IN GEAR SIGNAL YE - 1.0 SHEET 10 SH10 - DRIVES
TO MAIN CAB HARNESS
(47696624)
2 SP-G31-P-X G312 HIGH SPEED SOLENOID BK - 1.0 SHEET 10 SH10 - DRIVES
GROUND
X-046 - SEAT SWITCH [ S-044] (84600602) (Receptacle)
84600602 6
84600602
1 SP-S03-P-X S012 SEAT SWITCH POWER OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
2 SP-G51-P-X G508 SEAT SWITCH GROUND BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
3 X-CN1 (Receptacle) pin 19 119A SEAT SWITCH SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
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X-047 - SIDE SHIFT LOCK SOL.VALVE [ Y-006] (84607243) (Receptacle)
84607243 7
84607243
1 X-017B (Plug) pin L - TO MAIN 2000 SIDE SHIFT LOCK WH - 1.0 SHEET 11 SH11 - HYDRAULICS
CAB HARNESS (47696624) SOLENOID
2 SP-G32-P-X G321 SIDE SHIFT LOCK BK - 1.0 SHEET 11 SH11 - HYDRAULICS
SOLENOID GROUND
X-048 - TO REAR HORN SWITCH [ S-029] (84182898) (Receptacle)
84182898 8
84182898
1 SP-522-P-X 5216 HORN GROUND YE - 1.0 SHEET 26 SH26 - AUDIO
2 SP-G32-P-X G322 HORN GROUND BK - 1.0 SHEET 26 SH26 - AUDIO
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X-051 - BRAKE DECLUTCH SWITCH [ S-010] (87716755) (Receptacle)
87716755 1
87716755
1 Not Used
2 SP-440-P-X 4403 BRAKE DECLUTCH VT - 0.75 SHEET 10 SH10 - DRIVES
SIGNAL
3 SP-206-P-X 2062 BRAKE DECLUTCH YE - 0.75 SHEET 10 SH10 - DRIVES
SIGNAL
4 Not Used
5 Not Used
6 Not Used
7 SP-G12-P-X G123 BRAKE DECLUTCH BK - 0.75 SHEET 10 SH10 - DRIVES
SWITCH GROUND
SIGNAL
X-053 - (Not serviceable) (Plug)
X-056 - HAND THROTTLE [ A-014] (47587518) (Plug)
47587518 2
47587518
A X-CN2 (Receptacle) pin 19 2190 HAND THROTTLE 5V PK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82028493)
B X-CN2 (Receptacle) pin 17 2170 HAND THROTTLE YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN2 [A-002] SIGNAL
(82028493)
C X-CN2 (Receptacle) pin 21 2211 HAND THROTTLE GND GN - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82028493)
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X-057 - DIODE [ V-200] (87695900) (Plug)
87695900 3
87695900
1 X-107A (Receptacle) pin 16 2070 BRAKE DECLUTCH YE - 0.75 SHEET 10 SH10 - DRIVES
- TO MAIN CAB HARNESS SIGNAL
(47696599)
SIGNAL
X-058 - FRONT HEAD LAMP 2 [ E-004] (84182898) (Receptacle)
84182898 4
84182898
1 SP-300-P-X 3002 FRONT WORK LIGHT B+ VT - 1.5 SHEET 14 SH14 - FRONT WORK LIGHTS
2 SP-G19-P-X G193 FRONT WORK LIGHT BK - 1.5 SHEET 14 SH14 - FRONT WORK LIGHTS
GROUND
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X-060 - RIGHT FRONT LIGHT (47416268) (Plug)
47416268 1
47416268
1 X-112A (Receptacle) pin 1 420A POSITION LIGHTS VT - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
- TO RIGHT FRONT LIGHT
[E-002] (47511912)
2 X-112A (Receptacle) pin 2 343A* HIGH BEAM SIGNAL GN - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
[E-002] (47511912)
3 X-112A (Receptacle) pin 3 345A LOW BEAM SWITCHED LB - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
- TO RIGHT FRONT LIGHT B+
[E-002] (47511912)
4 Not Used
5 X-112A (Receptacle) pin 5 350A RIGHT TURN SIGNAL YE - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
[E-002] (47511912)
6 X-112A (Receptacle) pin 4 G164 G164 BK - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
[E-002] (47511912)
X-060A - LEFT FRONT LIGHT (47416268) (Plug)
47416268 2
47416268
1 X-112 (Receptacle) pin 1 - TO 420A* POSITION LIGHTS VT - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47511912)
2 X-112 (Receptacle) pin 2 - TO 343A HIGH BEAM SIGNAL GN - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47511912)
3 X-112 (Receptacle) pin 3 - TO 345A* LOW BEAM SWITCHED LB - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
LEFT FRONT LIGHT [E-001] B+
(47511912)
4 Not Used
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5 X-112 (Receptacle) pin 5 - TO 350A* LEFT TURN SIGNAL YE - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47511912)
6 X-112 (Receptacle) pin 4 - TO G164* GROUND BK - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47511912)
X-061 - RADIO [ A-006] (84179570) (Receptacle)
84179570 3
84179570
1 SP-303-P-X 7041 RADIO B+ YE - 1.0 SHEET 26 SH26 - AUDIO
2 X-207 (Plug) pin 1 - RADIO G194 RADIO GROUND BK - 1.0 SHEET 26 SH26 - AUDIO
GROUND (84398832)
X-061A - RADIO ANTENNA [ B-016] (84369030) (Receptacle)
84369030 4
84369030
1 SP-303-P-X 7042 RADIO ANTENNA B+ YE - 1.0 SHEET 26 SH26 - AUDIO
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X-061B - [ B-016] (2FT) (Plug)
X-062A - ROOF LIGHT [ E-016] (84491249) (Receptacle)
84491249 5
84491249
1 X-093A (Receptacle) pin 1 P041 DOMELIGHT B+ RD - 1.0 SHEET 17 SH17 - DOME LIGHT
(47511912)
X-062B - ROOF LIGHT [ E-016] (84491249) (Receptacle)
84491249 6
84491249
1 SP-G19-P-X G195 DOMELIGHT GROUND BK - 1.0 SHEET 17 SH17 - DOME LIGHT
X-063A - RH SPEAKER [ H-001] (47763027) (Plug)
47763027 7
47763027
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1 X-042 (Receptacle) pin 1 - RH 7020 RIGHT SPEAKER BK - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [A-006] (84182898)
X-063B - RH SPEAKER [ H-001] (84600636) (Plug)

1 X-042 (Receptacle) pin 2 - RH 7030 RIGHT SPEAKER VT - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [A-006] (84182898)
X-064 - LH SPEAKER [ A-006] (84182898) (Receptacle)
84182898 8
84182898
1 X-072A (Plug) pin 1 - LH 7000 LEFT SPEAKER BK - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [H-002] (47763027)
2 X-072B (Plug) pin 1 - LH 7010 LEFT SPEAKER GY - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [H-002] (84600636)
X-064A - [ M-006] (2WF 090) (Plug)
84182898 9
84182898
1 SP-302-P-X 3021 REAR WORK LIGHTS B+ VT - 1.5 SHEET 15 SH15 - REAR WORK LIGHTS
GROUND
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84182898 10
84182898
GROUND
84182898 11
84182898
1 SP-301-P-X 42C5 REAR WORK LIGHTS B+ VT - 1.5 SHEET 15 SH15 - REAR WORK LIGHTS
2 SP-G20-P-X G201 REAR WORK LIGHTS B+ BK - 1.5 SHEET 15 SH15 - REAR WORK LIGHTS
84182898 12
84182898
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GROUND
X-069 - CABIN FAN [ M-005] (84182898) (Receptacle)
84182898 13
84182898
1 X-093A (Receptacle) pin 4 4000 CAB FAN B+ BR - 1.0 SHEET 23 SH23 - CAB FAN
(47511912)
2 SP-G20-P-X G205 CAB FAN B+ BK - 1.0 SHEET 23 SH23 - CAB FAN
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X-070 - WIPER MOTOR [ M-064] (84182898) (Receptacle)
84182898 1
84182898
1 X-093A (Receptacle) pin 2 6304 FRONT WIPER MOTOR BR - 2.0 SHEET 18 SH18 - WIPER/WASHER
- TO MAIN CAB HARNESS B+
(47511912)
2 SP-G19-P-X G191 FRONT WIPER MOTOR BK - 2.0 SHEET 18 SH18 - WIPER/WASHER
GROUND
X-071 - FRONT WORK LAMP 1 [ E-003] (84182898) (Receptacle)
84182898 2
84182898
1 SP-300-P-X 3001 FRONT WORK LIGHT B+ VT - 1.5 SHEET 14 SH14 - FRONT WORK LIGHTS
2 SP-G19-P-X G192 FRONT WORK LIGHT BK - 1.5 SHEET 14 SH14 - FRONT WORK LIGHTS
GROUND
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X-072A - LH SPEAKER [ H-002] (47763027) (Plug)
47763027 3
47763027
1 X-064 (Receptacle) pin 1 - LH 7000 LEFT SPEAKER BK - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [A-006] (84182898)
X-072B - LH SPEAKER [ H-002] (84600636) (Plug)

1 X-064 (Receptacle) pin 2 - LH 7010 LEFT SPEAKER GY - 1.0 SHEET 26 SH26 - AUDIO
SPEAKER [A-006] (84182898)
X-073 - HAMMER_VALVE [ Y-008] (84600619) (Receptacle)
84600619 4
84600619
1 SP-102-P-X 1024A REAR HAMMER B+ RD - 1.0 SHEET 24 SH24 - ACCESSORIES
2 X-105B (Receptacle) pin G225 REAR HAMMER BK - 1.0 SHEET 24 SH24 - ACCESSORIES
B - TO MAIN HARNESS GROUND
(47416272)
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X-074 - FRONT WORK LIGHTS SWITCH [ S-011] (87716755) (Receptacle)
87716755 5
87716755
1 Not Used
2 X-107A (Receptacle) pin 11 S136 FRONT WORK LIGHTS OR - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
- TO MAIN CAB HARNESS SWITCH B+
(47696599)
3 X-107A (Receptacle) pin 12 3611 FRONT WORK LIGHTS YE - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
- TO MAIN CAB HARNESS SIGNAL
(47696599)
4 Not Used
5 Not Used
6 Not Used
7 SP-G11-P-X G111 FRONT WORK LIGHTS BK - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
SWITCH GROUND
SWITCH LED B+
X-075 - FOOT SWITCH [ S-025] (87692877) (Plug)
87692877 6
87692877
A SP-102-P-X 1024 REAR HAMMER B+ RD - 1.0 SHEET 24 SH24 - ACCESSORIES
B X-105B (Receptacle) pin 1025 REAR HAMMER B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
A - TO MAIN HARNESS
(47416272)
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X-076 - CAB FAN SWITCH [ S-020] (87716755) (Receptacle)
87716755 7
87716755
1 Not Used
2 SP-403-P-X P049 CAB FAN B+ RD - 1.0 SHEET 23 SH23 - CAB FAN
3 X-093B (Plug) pin 4 - TO 4010 CAB FAN B+ BR - 1.0 SHEET 23 SH23 - CAB FAN
UPPER CAB HARNESS
(47511905)
4 Not Used
5 Not Used
6 Not Used
7 SP-G53-P-X G536 CAB FAN SWITCH BK - 0.75 SHEET 23 SH23 - CAB FAN
GROUND
8 SP-423-P-X 4226 CAB FAN SWITCH LED VT - 0.75 SHEET 23 SH23 - CAB FAN
B+
X-077 - REAR WORK LIGHTS SWITCH [ S-012] (87716755) (Receptacle)
87716755 8
87716755
1 Not Used
2 SP-007-P-X S137 REAR WORK LIGHTS OR - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
SWITCH B+
3 X-002 (Receptacle) pin 6 - 42C7 REAR WORK LIGHTS YE - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
FUSES AND RELAYS BLOCK SIGNAL
(47944422)
4 Not Used
5 SP-007-P-X S134 REAR WORK LIGHTS OR - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
SWITCH B+
6 X-002 (Receptacle) pin 18 - 7095 REAR WORK LIGHTS OR - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
(47944422)
SWITCH GROUND
8 SP-424-P-X 4232 REAR WORK LIGHTS VT - 0.75 SHEET 15 SH15 - REAR WORK LIGHTS
SWITCH LED B+
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X-078 - SIDE SHIFT LOCK SWITCH [ S-019] (87716755) (Receptacle)
87716755 9
87716755
1 Not Used
2 X-002 (Receptacle) pin 76 - S241 SIDE SHIFT LOCK OR - 1.0 SHEET 11 SH11 - HYDRAULICS
FUSES AND RELAYS BLOCK SWITCH B+
(47944422)
3 X-017A (Receptacle) pin L 2240 SIDE SHIFT LOCK WH - 1.0 SHEET 11 SH11 - HYDRAULICS
- TO CHASSIS HARNESS SOLENOID B+
(47696606)
4 Not Used
5 Not Used
6 Not Used
7 SP-G52-P-X G527 SIDE SHIFT LOCK BK - 0.75 SHEET 11 SH11 - HYDRAULICS
SWITCH GROUND
8 SP-424-P-X 4231 SIDE SHIFT LOCK VT - 0.75 SHEET 11 SH11 - HYDRAULICS
SWITCH LED B+
X-079 - BEACON SWITCH [ S-015] (87716755) (Receptacle)
87716755 10
87716755
1 Not Used
2 X-121 (Receptacle) pin 1 P301 BEACON B+ RD - 1.5 SHEET 18 SH18 - WIPER/WASHER
(47435876)
4 Not Used
5 Not Used
6 Not Used
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X-082 - CLUTCH SHUT OFF SW. [ S-026] (84182898) (Receptacle)
84182898 1
84182898
1 SP-204-P-X S278 DECLUTCH SWITCH B+ OR - 0.75 SHEET 10 SH10 - DRIVES
X-083 - CLUTCH SHUT OFF SW. [ S-018] (84182898) (Receptacle)
84182898 2
84182898
1 SP-204-P-X S279 DECLUTCH SWITCH B+ OR - 0.75 SHEET 10 SH10 - DRIVES
X-084 - RTD SOLENOID [ Y-005] (87695900) (Plug)
87695900 3
87695900
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1 X-017B (Plug) pin M - 2010 RETURN TO DIG WH - 1.0 SHEET 24 SH24 - ACCESSORIES
TO MAIN CAB HARNESS SOLENOID B+
(47696624)
2 SP-G31-P-X G311 RETURN TO DIG BK - 1.0 SHEET 24 SH24 - ACCESSORIES
SOLENOID GROUND
X-085 - RTD SENSOR [ B-003] (84600602) (Receptacle)
84600602 4
84600602
1 X-017B (Plug) pin N - S139 RETURN TO DIG OR - 1.0 SHEET 24 SH24 - ACCESSORIES
TO MAIN CAB HARNESS SENSOR B+
(47696624)
2 SP-G33-P-X G337 RETURN TO DIG BK - 1.0 SHEET 24 SH24 - ACCESSORIES
SENSOR GROUND
3 X-017B (Plug) pin O - 2050 RETURN TO DIG YE - 1.0 SHEET 24 SH24 - ACCESSORIES
TO MAIN CAB HARNESS SENSOR SIGNAL
(47696624)
X-089 - TAIL LIGHTS [ E-009] (47511912) (Receptacle)
47511912 5
47511912
1 X-091B (Plug) pin 1 - TO MAIN 4410 LEFT BRAKE LIGHT WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
CABIN HARNESS (47416268)
2 X-091B (Plug) pin 2 - TO MAIN 4240 LEFT TAIL LIGHT RD - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
3 X-091B (Plug) pin 3 - TO MAIN 3527 LEFT TURN SIGNAL OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
4 X-091B (Plug) pin 6 - TO MAIN G212 REAR LEFT DRIVING BK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
CABIN HARNESS (47416268) LIGHTS GROUND
5 Not Used
6 X-091B (Plug) pin 4 - TO MAIN 5268 LEFT REVERSE LIGHT PK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
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X-090 - TAIL LIGHTS [ E-010] (47511912) (Receptacle)
47511912 1
47511912
1 X-090B (Plug) pin 1 - TO MAIN 4413 RIGHT BRAKE LIGHT WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
2 X-090B (Plug) pin 2 - TO MAIN 4244 RIGHT TAIL LIGHT RD - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
3 X-090B (Plug) pin 3 - TO MAIN 3517 RIGHT TURN SIGNAL OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
4 X-090B (Plug) pin 6 - TO MAIN G214 TAIL LIGHTS GROUND BK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
5 Not Used
6 X-090B (Plug) pin 4 - TO MAIN 5265 RIGHT REVERSE SIGNAL PK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
X-090A - TO TAIL LIGHTS HARNESS (47416275) (Receptacle)
47416275 2
47416275
2 SP-425-P-X 4243 TAIL LIGHT B+ VT - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
3 SP-354-P-X 3516 RIGHT TURN SIGNAL WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
4 SP-52A-P-X 5267 REVERSE SIGNAL WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
5 Not Used
6 SP-G58-P-X G213 REAR RIGHT TAIL BK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
LIGHTS GROUND
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X-090B - TO MAIN CABIN HARNESS (47416268) (Plug)
47416268 3
47416268
1 X-090 (Receptacle) pin 4413 RIGHT BRAKE LIGHT WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
1 - TAIL LIGHTS [E-010]
(47511912)
2 X-090 (Receptacle) pin 4244 RIGHT TAIL LIGHT RD - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
3 X-090 (Receptacle) pin 3517 RIGHT TURN SIGNAL OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
4 X-090 (Receptacle) pin 5265 RIGHT REVERSE SIGNAL PK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
5 Not Used
6 X-090 (Receptacle) pin G214 TAIL LIGHTS GROUND BK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
X-091A - TO TAIL LIGHT HARNESS (47416275) (Receptacle)
47416275 4
47416275
2 SP-425-P-X 4241 TAIL LIGHT B+ VT - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
3 SP-353-P-X 3526 LEFT TURN SIGNAL VT - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
4 SP-52A-P-X 5266 REVERSE SIGNAL WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
5 Not Used
6 SP-G58-P-X G211 REAR LEFT TAIL LIGHTS BK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
GROUND
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X-091B - TO MAIN CABIN HARNESS (47416268) (Plug)
47416268 5
47416268
1 X-089 (Receptacle) pin 4410 LEFT BRAKE LIGHT WH - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
2 X-089 (Receptacle) pin 4240 LEFT TAIL LIGHT RD - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
3 X-089 (Receptacle) pin 3527 LEFT TURN SIGNAL OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
4 X-089 (Receptacle) pin 5268 LEFT REVERSE LIGHT PK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
(47511912)
5 Not Used
6 X-089 (Receptacle) pin G212 REAR LEFT DRIVING BK - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
4 - TAIL LIGHTS [E-009] LIGHTS GROUND
(47511912)
X-093A - TO MAIN CAB HARNESS (47511912) (Receptacle)
47511912 6
47511912
1 X-062A (Receptacle) pin P041 DOMELIGHT B+ RD - 1.0 SHEET 17 SH17 - DOME LIGHT
1 - ROOF LIGHT [E-016]
(84491249)
2 X-070 (Receptacle) pin 1 6304 FRONT WIPER MOTOR BR - 2.0 SHEET 18 SH18 - WIPER/WASHER
- WIPER MOTOR [M-064] B+
(84182898)
3 SP-303-P-X 7040 RADIO B+ YE - 1.0 SHEET 26 SH26 - AUDIO
4 X-069 (Receptacle) pin 4000 CAB FAN B+ BR - 1.0 SHEET 23 SH23 - CAB FAN
1 - CABIN FAN [M-005]
(84182898)
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X-093B - TO UPPER CAB HARNESS (47511905) (Plug)
47511905 7
47511905
1 X-002 (Receptacle) pin 70 - P040 DOMELIGHT B+ RD - 1.0 SHEET 17 SH17 - DOME LIGHT
(47944422)
2 X-107B (Plug) pin 4 - 6302 FRONT WIPER MOTOR BR - 2.0 SHEET 18 SH18 - WIPER/WASHER
TO FRONT HARNESS B+
(47696620)
3 X-107B (Plug) pin 25 - 3C06 RADIO B+ YE - 1.0 SHEET 26 SH26 - AUDIO
TO FRONT HARNESS
(47696620)
4 X-076 (Receptacle) pin 3 - 4010 CAB FAN B+ BR - 1.0 SHEET 23 SH23 - CAB FAN
CAB FAN SWITCH [S-020]
(87716755)
84600602 8
84600602
B+
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X-094B - TO UPPER CAB HARNESS (48126491) (Receptacle)
48126491 9
48126491
B+
2 SP-42C-P-X 42C2 REAR WORK LIGHTS B+ VT - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
3 X-002 (Receptacle) pin 24 - 7094 REAR WORK LIGHTS B+ WH - 2.0 SHEET 15 SH15 - REAR WORK LIGHTS
(47944422)
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47944420 1
47944420
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 Not Used
8 Not Used
9 X-101 (Receptacle) pin 47 - S601 SWITCHED B+ OR - 3.0 SHEET 07 SH07 - ENGINE CONTROL
(47944420)
10 X-462 (Receptacle) pin 20 - F200 SCR MAIN RELAY YE - 0.75 SHEET 07 SH07 - ENGINE CONTROL
ECU [A-001] (84474053)
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 X-461 (Receptacle) pin 53 - E530 STARTER RELAY HIGH YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
ECU (84474047) SIDE CHARGING SYSTEM / STARTING
16 Not Used
17 Not Used
18 Not Used
19 X-461 (Receptacle) pin 27 - E270 STARTER RELAY LOW YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
ECU (84474047) SIDE CHARGING SYSTEM / STARTING
20 Not Used
21 Not Used
22 SP-G46-P-X G445 STARTER INTERLOCK BK - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
RELAY GROUND CHARGING SYSTEM / STARTING
23 Not Used
24 Not Used
25 X-106A (Plug) pin C - S292 ENGINE IGNITION OR - 0.75 SHEET 05 SH05 - ENGINE CONTROL
TO FRONT HARNESS
(87698254)
26 Not Used
27 Not Used
28 Not Used
29 Not Used
30 Not Used
31 Not Used
32 Not Used
33 SP-S70-P-X S710 SWITCHED B+ OR - 2.0 SHEET 07 SH07 - ENGINE CONTROL
34 Not Used
35 Not Used
36 Not Used
37 Not Used
38 Not Used
39 Not Used
40 Not Used
41 Not Used
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42 Not Used
43 Not Used
44 Not Used
45 Not Used
46 Not Used
47 X-101 (Receptacle) pin 9 - S601 SWITCHED B+ OR - 3.0 SHEET 07 SH07 - ENGINE CONTROL
(47944420)
48 SP-S61-P-X S602 SWICTHED B+ OR - 3.0 SHEET 07 SH07 - ENGINE CONTROL
X-102 - HARN FRONT RH (47416275) (Receptacle)
47416275 2
47416275
B+
B+
4 Not Used
5 SP-354-P-X 3518 RIGHT TURN SIGNAL WH - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
6 SP-G57-P-X G572 RIGHT DRIVING LIGHTS BK - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
GROUND
X-103 - STARTER RELAY [ K-125] (84297431) (Receptacle)
84297431 3
84297431
1 SP-S55-P-X S507 CRANKING SIGNAL OR - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
2 X-101 (Plug) pin 16 G442 STARTER RELAY BK - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
GROUND CHARGING SYSTEM / STARTING
3 X-006 (Plug) pin 1 - 1100 STARTER COIL B+ WH - 4.0 SHEET 02 SH02 - POWER DISTRIBUTION /
STARTER SOLENOID [M-001] CHARGING SYSTEM / STARTING
(87679490)
4 Not Used
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5 X-475 (Receptacle) pin C P010 STARTER RELAY B+ RD - 4.0 SHEET 02 SH02 - POWER DISTRIBUTION /
- J-CASE FUSE HOLDER CHARGING SYSTEM / STARTING
[A-013] (87693326)
X-104 - HARN FRONT LH (47416275) (Receptacle)
47416275 4
47416275
B+
B+
4 Not Used
5 SP-353-P-X 3528 LEFT TURN SIGNAL VT - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
6 SP-G57-P-X G571 LEFT DRIVING LIGHTS BK - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
GROUND
X-105A - HAMMER VALVE / INSTALLER POWER (47587518) (Plug)
47587518 5
47587518
A X-002 (Receptacle) pin 78 - S261 REAR HAMMER B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
(47944422)
B SP-G52-P-X G525 REAR WIPER HARNESS BK - 1.0 SHEET 24 SH24 - ACCESSORIES
GROUND
C X-005 (Receptacle) pin 1024C REAR HAMMER SIGNAL RD - 0.75 SHEET 24 SH24 - ACCESSORIES
41 - TELEMATICS [A-003]
(51452976)
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X-105B - TO MAIN HARNESS (47416272) (Receptacle)
47416272 6
47416272
A X-075 (Plug) pin B - FOOT 1025 REAR HAMMER B+ OR - 1.0 SHEET 24 SH24 - ACCESSORIES
SWITCH [S-025] (87692877)
B X-073 (Receptacle) pin 2 G225 REAR HAMMER BK - 1.0 SHEET 24 SH24 - ACCESSORIES
- HAMMER_VALVE [Y-008] GROUND
(84600619)
C SP-102-P-X 1024B REAR HAMMER SIGNAL RD - 0.75 SHEET 24 SH24 - ACCESSORIES
X-106A - TO FRONT HARNESS (87698254) (Plug)
87698254 7
87698254
A X-023A (Plug) pin 1 - 1162 AIR FILTER BL - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
AIR FILTER SW [S-033] RESTRICTION SW
(87705127)
B X-461 (Receptacle) pin 68 - E680 ECU K LINE YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
ECU (84474047)
C X-101 (Receptacle) pin 25 - S292 ENGINE IGNITION OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
(47944420)
D SP-S55-P-X S505 CRANKING SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
E X-461 (Receptacle) pin 25 - L007 CONTROLLER AREA GN - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
ECU (84474047) NETWORK LOW
F X-101 (Plug) pin 18 103A IN GEAR SIGNAL YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
G X-101 (Plug) pin 40 P114 TELEMATICS RD - 0.75 SHEET 27 SH27 - TELEMATICS
UNSWITCHED B+
H X-008 (Plug) pin 1 - GROUND G500 D+ BK - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
(84401295) CHARGING SYSTEM / STARTING
I Not Used
J Not Used
K X-461 (Receptacle) pin 24 - H007 CONTROLLER AREA YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
ECU (84474047) NETWORK HIGH
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X-106B - TO ENGINE HARNESS (87698252) (Receptacle)
87698252 8
87698252
A X-107A (Receptacle) pin 29 1161 AIR FILTER BL - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
- TO MAIN CAB HARNESS RESTRICTION SW
(47696599)
B X-107A (Receptacle) pin 31 E681 ECU K LINE YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
(47696599)
C X-107A (Receptacle) pin 26 S291 ENGINE IGNITION OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
(47696599)
D X-107A (Receptacle) pin 27 S504 CRANKING SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
(47696599)
E X-107A (Receptacle) pin 36 L006 CONTROLLER AREA GN - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
- TO MAIN CAB HARNESS NETWORK LOW
(47696599)
F X-107A (Receptacle) pin 20 1033 IN GEAR SIGNAL YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
- TO MAIN CAB HARNESS CHARGING SYSTEM / STARTING
(47696599)
G X-107A (Receptacle) pin 28 P115 TELEMATICS RD - 0.75 SHEET 27 SH27 - TELEMATICS
- TO MAIN CAB HARNESS UNSWITCHED B+
(47696599)
H X-107A (Receptacle) pin 33 2401 ALTERNATOR D+ YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
- TO MAIN CAB HARNESS CHARGING SYSTEM / STARTING
(47696599)
I Not Used
J Not Used
K X-107A (Receptacle) pin 35 H006 CONTROLLER AREA YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
- TO MAIN CAB HARNESS NETWORK HIGH
(47696599)
47696599 9
47696599
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1 X-034 (Plug) pin 2 - RHS S152 FRONT WIPER AND OR - 2.0 SHEET 18 SH18 - WIPER/WASHER
COMBINATION SWITCH WASHER B+
[S-009] (84600631)
2 X-035 (Receptacle) pin 8 - 5170 HIGH BEAM SIGNAL WH - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
[S-035] (84600543)
3 X-035 (Receptacle) pin 1 - 5160 LOW BEAM SIGNAL OR - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
[S-035] (84600543)
4 X-034 (Plug) pin 4 - RHS 6301 FRONT WIPER MOTOR BR - 2.0 SHEET 18 SH18 - WIPER/WASHER
COMBINATION SWITCH B+
[S-009] (84600631)
6 Not Used
SWITCHED B+
11 X-074 (Receptacle) pin 2 S136 FRONT WORK LIGHTS OR - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
- FRONT WORK LIGHTS SWITCH B+
SWITCH [S-011] (87716755)
12 X-074 (Receptacle) pin 3 3611 FRONT WORK LIGHTS YE - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
- FRONT WORK LIGHTS SIGNAL
SWITCH [S-011] (87716755)
13 X-151 (Receptacle) pin 2 - 5340 FLASHER RELAY B+ YE - 1.0 SHEET 16 SH16 - HAZARD
HAZARD SWITCH [S-037]
(87632725)
15 X-151 (Receptacle) pin 1 - S133 HAZARD SWICTH B+ OR - 1.0 SHEET 16 SH16 - HAZARD
HAZARD SWITCH [S-037]
(87632725)
16 X-057 (Plug) pin 1 - DIODE 2070 BRAKE DECLUTCH YE - 0.75 SHEET 10 SH10 - DRIVES
[V-200] (87695900) SIGNAL
17 X-035 (Receptacle) pin 3 - S274 TRANSMISSION FNR B+ OR - 1.0 SHEET 10 SH10 - DRIVES
[S-035] (84600543)
18 X-035 (Receptacle) pin 4 - 5220 REVERSE SIGNAL WH - 1.0 SHEET 10 SH10 - DRIVES
[S-035] (84600543)
19 X-035 (Receptacle) pin 6 - 5230 FORWARD SIGNAL VT - 1.0 SHEET 10 SH10 - DRIVES
[S-035] (84600543)
20 X-106B (Receptacle) pin 1033 IN GEAR SIGNAL YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
F - TO ENGINE HARNESS CHARGING SYSTEM / STARTING
(87698252)
21 X-035 (Receptacle) pin 5 - 5200 HORN GROUND YE - 1.0 SHEET 26 SH26 - AUDIO
[S-035] (84600543)
22 X-114 (Plug) pin 1 - 2702 SPEED SENSOR SIGNAL YE - 0.75 SHEET 21 SH21 - SPEEDOMETER
SPEEDOMETER [A-004]
(87686679)
23 X-114 (Plug) pin 3 - S113 SPEEDOMETER OR - 0.75 SHEET 21 SH21 - SPEEDOMETER
SPEEDOMETER [A-004] SWITCHED B+
(87686679)
24 X-138 (Receptacle) pin 2 P051 RADIO B+ RD - 1.0 SHEET 26 SH26 - AUDIO
- RADIO SWITCH [S-004]
(87716755)
25 X-138 (Receptacle) pin 3 3C05 RADIO B+ YE - 1.0 SHEET 26 SH26 - AUDIO
- RADIO SWITCH [S-004]
(87716755)
26 X-106B (Receptacle) pin S291 ENGINE IGNITION OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
C - TO ENGINE HARNESS
(87698252)
27 X-106B (Receptacle) pin S504 CRANKING SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
D - TO ENGINE HARNESS
(87698252)
28 X-106B (Receptacle) pin P115 TELEMATICS RD - 0.75 SHEET 27 SH27 - TELEMATICS
G - TO ENGINE HARNESS UNSWITCHED B+
(87698252)
29 X-106B (Receptacle) pin 1161 AIR FILTER BL - 1.0 SHEET 19 SH19 - INSTRUMENT CLUSTER
A - TO ENGINE HARNESS RESTRICTION SW
(87698252)
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30 X-038B (Plug) pin 1 - [S-041] 1093 BRAKE OIL LEVEL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(87581782)
31 X-106B (Receptacle) pin E681 ECU K LINE YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
B - TO ENGINE HARNESS
(87698252)
32 X-037 (Plug) pin 1 - 1028 FRONT WASHER B+ GY - 1.0 SHEET 18 SH18 - WIPER/WASHER
COMBINATION SWITCH
[S-009] (47461910)
33 X-106B (Receptacle) pin 2401 ALTERNATOR D+ YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
H - TO ENGINE HARNESS CHARGING SYSTEM / STARTING
(87698252)
34 SP-514-P-X P025 HORN / HAZARD LIGHTS RD - 1.5 SHEET 16 SH16 - HAZARD
/ DRIVING LIGHTS B+
35 X-106B (Receptacle) pin H006 CONTROLLER AREA YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
K - TO ENGINE HARNESS NETWORK HIGH
(87698252)
36 X-106B (Receptacle) pin L006 CONTROLLER AREA GN - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
E - TO ENGINE HARNESS NETWORK LOW
(87698252)
X-107B - TO FRONT HARNESS (47696620) (Plug)
47696620 10
47696620
1 X-001 (Receptacle) pin 62 - S151 FRONT WIPER AND OR - 2.0 SHEET 18 SH18 - WIPER/WASHER
FUSES AND RELAYS BLOCK WASHER B+
(47944422)
2 X-001 (Receptacle) pin 6 - 5290 HIGH BEAM SIGNAL WH - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47944422)
3 X-001 (Receptacle) pin 3 - 5300 LOW BEAM SIGNAL OR - 0.75 SHEET 12 SH12 - FRONT DRIVING LIGHTS
(47944422)
4 X-093B (Plug) pin 2 - TO 6302 FRONT WIPER MOTOR BR - 2.0 SHEET 18 SH18 - WIPER/WASHER
UPPER CAB HARNESS B+
(47511905)
6 Not Used
7 X-001 (Receptacle) pin 74 - S121 BRAKE LIGHTS OR - 1.0 SHEET 13 SH13 - REAR DRIVING LIGHTS
FUSES AND RELAYS BLOCK SWITCHED B+
(47944422)
11 SP-007-P-X S135 FRONT WORK LIGHTS OR - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
SWITCH B+
12 X-002 (Receptacle) pin 3 - 3610 FRONT WORK LIGHTS YE - 0.75 SHEET 14 SH14 - FRONT WORK LIGHTS
(47944422)
13 X-030 (Receptacle) pin 2 - 3230 FLASHER RELAY B+ YE - 1.0 SHEET 16 SH16 - HAZARD
FLASHER [K-030] (84479009)
14 X-030 (Receptacle) pin 1 - 3220 FLASHER RELAY SIGNAL BR - 1.0 SHEET 16 SH16 - HAZARD
FLASHER [K-030] (84479009)
15 SP-007-P-X S132 HAZARD SWICTH B+ OR - 1.0 SHEET 16 SH16 - HAZARD
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SIGNAL
17 SP-121-P-X S273 TRANSMISSION FNR B+ OR - 1.0 SHEET 10 SH10 - DRIVES
20 SP-103-P-X 1032 NEUTRAL SIGNAL YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
21 X-017A (Receptacle) pin J 5213 HORN GROUND YE - 1.0 SHEET 26 SH26 - AUDIO
(47696606)
22 X-017A (Receptacle) pin E 2701 SPEED SENSOR SIGNAL YE - 0.75 SHEET 21 SH21 - SPEEDOMETER
(47696606)
SWITCHED B+
24 SP-403-P-X P050 RADIO B+ RD - 1.0 SHEET 26 SH26 - AUDIO
25 X-093B (Plug) pin 3 - TO 3C06 RADIO B+ YE - 1.0 SHEET 26 SH26 - AUDIO
UPPER CAB HARNESS
(47511905)
26 SP-S20-P-X S290 ENGINE IGNITION OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
27 SP-S51-P-X S503 CRANK SIGNAL OR - 0.75 SHEET 03 SH03 - POWER DISTRIBUTION
28 X-005 (Receptacle) pin P116 TELEMATICS RD - 0.75 SHEET 27 SH27 - TELEMATICS
37 - TELEMATICS [A-003] UNSWITCHED B+
(51452976)
29 X-CN1 (Receptacle) pin 16 1160 AIR FILTER BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN1 [A-002] RESTRICTION SW
(82016219)
30 X-CN1 (Receptacle) pin 9 1090 BRAKE OIL LEVEL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
31 X-031 (Plug) pin E - E682 ECU K LINE YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
DIAGNOSTIC PORT [A-005]
(87736919)
32 X-129A (Plug) pin 1 - TO 1029 FRONT WASHER B+ GY - 1.0 SHEET 18 SH18 - WIPER/WASHER
33 X-CN2 (Receptacle) pin 24 2402 CLUSTER GROUND YE - 0.75 SHEET 02 SH02 - POWER DISTRIBUTION /
- CLUSTER CN2 [A-002] CHARGING SYSTEM / STARTING
(82028493)
34 X-001 (Receptacle) pin 84 - P024 HORN AND HAZARD RD - 1.5 SHEET 16 SH16 - HAZARD
FUSES AND RELAYS BLOCK LIGHTS B+
(47944422)
35 SP-H01-P-X H002 CONTROLLER AREA YE - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
NETWORK HIGH
36 SP-L01-P-X L002 CONTROLLER AREA GN - 0.5 SHEET 28 SH28 - DIAGNOSTIC/CAN BUS
NETWORK LOW
X-108 - MAIN ECU RELAY [ K-100] (84297431) (Receptacle)
84297431 11
84297431
1 X-461 (Receptacle) pin 28 - E280 MAIN RELAY BL - 0.5 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047)
2 SP-P20-P-X P103 UNSWITCHED B+ RD - 0.5 SHEET 05 SH05 - ENGINE CONTROL
3 SP-S41-P-X S401 SWITCHED B+ RD - 10.0 SHEET 05 SH05 - ENGINE CONTROL
4 Not Used
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5 SP-P20-P-X P102 UNSWITCHED B+ RD - 10.0 SHEET 05 SH05 - ENGINE CONTROL
X-109 - A/C IGNTION TO MAIN (84179570) (Receptacle)
84179570 12
84179570
1 SP-406-P-X 6102 HVAC B+ OR - 2.0 SHEET 25 SH25 - HVAC
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X-110 - TO AC HARNESS (84417509) (Plug)
84417509 1
84417509
1 X-002 (Receptacle) pin 72 - S171 HVAC B+ OR - 2.0 SHEET 25 SH25 - HVAC
(47944422)
X-111 - B+ (84364890) (Receptacle)
84364890 2
84364890
1 SP-P20-P-X P201 UNSWITCHED B+ RD - 16.0 SHEET 02 SH02 - POWER DISTRIBUTION /
X-112 - TO LEFT FRONT LIGHT [ E-001] (47511912) (Receptacle)
47511912 3
47511912
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1 X-060A (Plug) pin 1 - LEFT 420A* POSITION LIGHTS VT - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
2 X-060A (Plug) pin 2 - LEFT 343A HIGH BEAM SIGNAL GN - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
3 X-060A (Plug) pin 3 - LEFT 345A* LOW BEAM SWITCHED LB - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
FRONT LIGHT (47416268) B+
4 X-060A (Plug) pin 6 - LEFT G164* GROUND BK - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
5 X-060A (Plug) pin 5 - LEFT 350A* LEFT TURN SIGNAL YE - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
X-112A - TO RIGHT FRONT LIGHT [ E-002] (47511912) (Receptacle)
47511912 4
47511912
1 X-060 (Plug) pin 1 - RIGHT 420A POSITION LIGHTS VT - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
2 X-060 (Plug) pin 2 - RIGHT 343A* HIGH BEAM SIGNAL GN - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
3 X-060 (Plug) pin 3 - RIGHT 345A LOW BEAM SWITCHED LB - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
FRONT LIGHT (47416268) B+
4 X-060 (Plug) pin 6 - RIGHT G164 G164 BK - 1.5 SHEET 12 SH12 - FRONT DRIVING LIGHTS
5 X-060 (Plug) pin 5 - RIGHT 350A RIGHT TURN SIGNAL YE - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
X-113 - A/C KIT POWER (47706988) (Plug)
47706988 5
47706988
1 X-220 (Plug) pin 1 - A/C KIT 4030 A/C 1ST SPEED YE - 1.5 SHEET 25 SH25 - HVAC
CONTROL (47373520)
2 X-220 (Plug) pin 2 - A/C KIT 4040 A/C 2ND SPEED BR - 1.5 SHEET 25 SH25 - HVAC
CONTROL (47373520)
3 X-220 (Plug) pin 3 - A/C KIT 4050 A/C 3RD SPEED OR - 1.5 SHEET 25 SH25 - HVAC
CONTROL (47373520)
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4 SP-406-P-X 6103 A/C SUPPLY OR - 2.0 SHEET 25 SH25 - HVAC
5 X-220 (Plug) pin 5 - A/C KIT 4070 A/C POT GY - 1.0 SHEET 25 SH25 - HVAC
CONTROL (47373520)
6 X-220 (Plug) pin 6 - A/C KIT 4080 A/C POT BL - 1.0 SHEET 25 SH25 - HVAC
CONTROL (47373520)
7 X-220 (Plug) pin 7 - A/C KIT 4090 A/C POT GN - 1.0 SHEET 25 SH25 - HVAC
CONTROL (47373520)
8 X-220 (Plug) pin 8 - A/C KIT 4100 A/C POT RD - 1.0 SHEET 25 SH25 - HVAC
CONTROL (47373520)
9 X-123 (Receptacle) pin 1 - A/C 1351 AC RELAY COIL YE - 1.0 SHEET 25 SH25 - HVAC
RELAY [K-200] (84297431)
X-114 - SPEEDOMETER [ A-004] (87686679) (Plug)
87686679 6
87686679
1 X-107A (Receptacle) pin 22 2702 SPEED SENSOR SIGNAL YE - 0.75 SHEET 21 SH21 - SPEEDOMETER
(47696599)
2 X-208 (Plug) pin 1 - GROUND G130 SPEEDOMETER BK - 0.75 SHEET 21 SH21 - SPEEDOMETER
(47763001) GROUND
3 X-107A (Receptacle) pin 23 S113 SPEEDOMETER OR - 0.75 SHEET 21 SH21 - SPEEDOMETER
- TO MAIN CAB HARNESS SWITCHED B+
(47696599)
4 SP-420-P-X 4201 SPEEDOMETER VT - 0.75 SHEET 21 SH21 - SPEEDOMETER
ILLUMINATION
X-115 - SPEED SENSOR [ B-019] (84062580) (Plug)
84062580 7
84062580
1 X-017B (Plug) pin E - TO MAIN 2700 SPEED SENSOR SIGNAL YE - 0.75 SHEET 21 SH21 - SPEEDOMETER
2 SP-G33-P-X G331 SPEED SENSOR BK - 0.75 SHEET 21 SH21 - SPEEDOMETER
GROUND
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3 X-017B (Plug) pin D - S115 SPEED SENSOR OR - 0.75 SHEET 21 SH21 - SPEEDOMETER
TO MAIN CAB HARNESS SWITCHED B+
(47696624)
X-116 - UP/DOWN SW [ S-031] (87716755) (Receptacle)
87716755 8
87716755
1 X-CN1 (Receptacle) pin 14 1141 DOWN CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
2 SP-P43-P-X P045 UP/DOWN SW RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
UNSWITCHED B+
3 X-CN1 (Receptacle) pin 13 1131 UP CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
4 Not Used
5 Not Used
6 Not Used
7 SP-G53-P-X G531 UP/DOWN SWITCH BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
GROUND
8 SP-422-P-X 4220 UP/DOWN SWITCH LED VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
B+
X-117 - DISPLAY/ENTER CONTROL SW [ S-032] (87716755) (Receptacle)
87716755 9
87716755
1 X-CN1 (Receptacle) pin 12 1121 ENTER CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
2 SP-P43-P-X P046 DISPLAY/ENTER SW RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
UNSWITCHED B+
3 X-CN1 (Receptacle) pin 11 1111 DISPLAY CONTROL RD - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
4 Not Used
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5 Not Used
6 Not Used
7 SP-G53-P-X G532 DISPLAY/ENTER SWITCH BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
GROUND
8 SP-422-P-X 4221 DISPALY/ENTER SWITCH VT - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
LED B+
X-118 - IGNITION SWITCH [ S-001] (84599241) (Receptacle)
84599241 10
84599241
1 X-002 (Receptacle) pin 56 - P032 IGNITION SWITCH B+ RD - 1.5 SHEET 03 SH03 - POWER DISTRIBUTION
(47944422)
X-119 - IGNITION SWITCH [ S-001] (87714250) (Plug)
87714250 11
87714250
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 SP-S01-P-X S001 IGNITION OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION
6 Not Used
7 X-001 (Receptacle) pin 65 - S500 CRANK SIGNAL OR - 1.0 SHEET 03 SH03 - POWER DISTRIBUTION
(47944422)
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X-120 - UNSWITCHED POWER (87745375) (Plug)
1 X-121 (Receptacle) pin 2 P300 BEACON B+ RD - 1.5 SHEET 03 SH03 - POWER DISTRIBUTION
(47435876)
X-121 - BEACON FUSE [ F-202] (47435876) (Receptacle)
47435876 1
47435876
1 X-079 (Receptacle) pin 2 - P301 BEACON B+ RD - 1.5 SHEET 18 SH18 - WIPER/WASHER
BEACON SWITCH [S-015]
(87716755)
2 X-120 (Plug) pin 1 - P300 BEACON B+ RD - 1.5 SHEET 18 SH18 - WIPER/WASHER
UNSWITCHED POWER
(87745375)
X-123 - A/C RELAY [ K-200] (84297431) (Receptacle)
84297431 2
84297431
1 X-113 (Plug) pin 9 - A/C KIT 1351 AC RELAY COIL YE - 1.0 SHEET 25 SH25 - HVAC
POWER (47706988)
2 X-016 (Receptacle) pin 3 - TO 1330 AC SWITCH YE - 1.0 SHEET 25 SH25 - HVAC
AC HARNESS ON ENGINE
SIDE (48126491)
3 SP-60C6-P-X 60C6A POWER TO AC CLUTCH YE - 2.5 SHEET 25 SH25 - HVAC
4 Not Used
5 SP-406-P-X 6104 A/C SUPPLY OR - 2.5 SHEET 25 SH25 - HVAC
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X-124 - ECO MODE SWITCH [ S-040] (87716755) (Receptacle)
87716755 3
87716755
1 Not Used
2 SP-S03-P-X S007 ECO MODE SWITCH OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
IGNTION
3 X-124 (Receptacle) pin 8 - 1171 ECO SW LAMP YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(87716755)
4 Not Used
5 SP-G51-P-X G507 ECO MODE SWITH BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
GROUND
6 X-CN1 (Receptacle) pin 17 1170 ECO MODE SIGNAL BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82016219)
7 SP-G52-P-X G526 ECO MODE SWITCH BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
GROUND
8 X-124 (Receptacle) pin 3 - 1171 ECO SW LAMP YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(87716755)
X-125 - POWER (51670671) (Plug)

A X-014 (Receptacle) pin 1 - TO P016 HVAC BATT POWER RD - 5.0 SHEET 25 SH25 - HVAC
SIDE (51543229)
B X-134 (Plug) pin 1 - TO G222 POWER B+ BK - 5.0 SHEET 25 SH25 - HVAC
GROUND (47763001)
X-128 - DOSING VALVE [ Y-101] (87709793) (Receptacle)
87709793 4
87709793
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1 X-462 (Receptacle) pin 18 - F180 DOSING VALVE H BL - 1.5 SHEET 09 SH09 - PRE START
ECU [A-001] (84474053)
2 X-462 (Receptacle) pin 3 - F030 DOSING VALVE L YE - 1.5 SHEET 09 SH09 - PRE START
ECU [A-001] (84474053)
X-129A - TO WIPER/WASHER (47416267) (Plug)
47416267 5
47416267
1 X-107B (Plug) pin 32 - 1029 FRONT WASHER B+ GY - 1.0 SHEET 18 SH18 - WIPER/WASHER
TO FRONT HARNESS
(47696620)
2 SP-424-P-X 4234 REAR WIPER SWITCH VT - 0.75 SHEET 18 SH18 - WIPER/WASHER
LED B+
3 X-001 (Receptacle) pin 64 - S162 REAR WIPER AND OR - 1.5 SHEET 18 SH18 - WIPER/WASHER
FUSES AND RELAYS BLOCK WASHER B+
(47944422)
4 X-017 (Plug) pin 1 - GROUND G511 REAR WIPER GROUND BK - 1.5 SHEET 18 SH18 - WIPER/WASHER
(84401295)
X-129B - TO FRONT PANEL HARNESS (87708112) (Receptacle)
87708112 6
87708112
1 X-149 (Receptacle) pin A - 102A FRONT WASHER B+ GY - 1.0 SHEET 18 SH18 - WIPER/WASHER
FRONT WASHER MOTOR
[M-009] (87693325)
2 X-161 (Receptacle) pin 10 4236 REAR WIPER SWICH VT - 0.75 SHEET 18 SH18 - WIPER/WASHER
- REAR WIPER SWITCH LED B+
[S-016] (87632724)
3 SP-020-P-X S163 REAR WIPER AND OR - 1.5 SHEET 18 SH18 - WIPER/WASHER
WASHER B+
4 SP-019-P-X G025 GROUND BK - 1.5 SHEET 18 SH18 - WIPER/WASHER
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X-130 - SCR TANK HEATING VALVE [ B-001] (84146685) (Receptacle)
84146685 1
84146685
1 SP-S71-P-X S704 SCR TANK HEATING OR - 0.75 SHEET 09 SH09 - PRE START
VALVE B+
2 Not Used
3 X-461 (Receptacle) pin 7 - E070 SCR TANK HEATING YE - 0.75 SHEET 09 SH09 - PRE START
ECU (84474047) VALVE SIGNAL
X-131 - A/C CLUTCH [ M-006] (87687239) (Plug)
87687239 2
87687239
1 X-017C (Receptacle) pin 2 - 60C7 AC CLUTCH YE - 1.0 SHEET 25 SH25 - HVAC
TO CAB (84600602)
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X-132 - A/C PRESSURE SW [ S-069] (87679438) (Receptacle)
87679438 3
87679438
A X-017C (Receptacle) pin 3 - 1331 A/C PRESSURE SWITCH YE - 1.0 SHEET 25 SH25 - HVAC
TO CAB (84600602)
B X-017C (Receptacle) pin 1 - G171 A/C SWITCH GROUND BK - 1.0 SHEET 25 SH25 - HVAC
TO CAB (84600602)
X-133 - TO STARTER [ J-002] (47663693) (Plug)
47663693 4
47663693
1 X-007 (Receptacle) pin 1 - P005 HVAC BATT POWER RD - 5.0 SHEET 02 SH02 - POWER DISTRIBUTION /
BATT+ (47781606) CHARGING SYSTEM / STARTING
X-134 - TO GROUND (47763001) (Plug)
47763001 5
47763001
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1 X-016 (Receptacle) pin 1 - TO G170 A/C SWITCH GROUND BK - 1.0 SHEET 04 SH04 - GROUNDING
SIDE (48126491)
1 X-125 (Plug) pin B - POWER G222 POWER B+ BK - 5.0 SHEET 04 SH04 - GROUNDING
(51670671)
X-135 - AUTO IDLE [ S-039] (87716755) (Receptacle)
87716755 6
87716755
1 Not Used
2 SP-S03-P-X S008 AUTO IDLE SWITCH OR - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
IGNITION
4 Not Used
5 Not Used
6 Not Used
7 SP-G53-P-X G538 AUTO IDLE SWITCH BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
GROUND
X-138 - RADIO SWITCH [ S-004] (87716755) (Receptacle)
87716755 7
87716755
1 Not Used
2 X-107A (Receptacle) pin 24 P051 RADIO B+ RD - 1.0 SHEET 26 SH26 - AUDIO
(47696599)
3 X-107A (Receptacle) pin 25 3C05 RADIO B+ YE - 1.0 SHEET 26 SH26 - AUDIO
(47696599)
4 Not Used
5 Not Used
6 Not Used
7 SP-G11-P-X G112 RADIO SWITCH GROUND BK - 0.75 SHEET 26 SH26 - AUDIO
8 SP-420-P-X 4202 RADIO SWITCH LED B+ VT - 0.75 SHEET 26 SH26 - AUDIO
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X-139 - RIGHT TURN INDICATOR [ E-002A] (87705140) (Plug)
87705140 8
87705140
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X-140 - LEFT TURN INDICATOR [ E-002A] (87705140) (Plug)
87705140 1
87705140
X-141 - TURN SIGNAL GROUND [ E-002A] (87705140) (Plug)
87705140 2
87705140
1 SP-G12-P-X G121 TURN INDICATOR BK - 1.0 SHEET 16 SH16 - HAZARD
GROUND
X-142 - TO HORN [ H-003] (51621244) (Plug)

1 SP-522-P-X 5215 HORN GROUND YE - 1.0 SHEET 26 SH26 - AUDIO
X-143 - TO HORN [ H-003] (51621244) (Plug)

1 X-017B (Plug) pin K - P054 HORN UNSWITCHED B+ RD - 1.0 SHEET 26 SH26 - AUDIO
TO MAIN CAB HARNESS
(47696624)
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X-146 - FUEL LEVEL SENDER [ R-002] (84381192) (Receptacle)
84381192 3
84381192
1 X-017B (Plug) pin B - 2133 FUEL LEVEL SIGNAL YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
TO MAIN CAB HARNESS
(47696624)
2 SP-G33-P-X G336 FUEL LEVEL SENDER BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
GROUND
X-149 - FRONT WASHER MOTOR [ M-009] (87693325) (Receptacle)
87693325 4
87693325
A X-129B (Receptacle) pin 1 - 102A FRONT WASHER B+ GY - 1.0 SHEET 18 SH18 - WIPER/WASHER
(87708112)
B SP-019-P-X G026 FRONT WASHER BK - 1.0 SHEET 18 SH18 - WIPER/WASHER
GROUND
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X-150 - REAR WASHER MOTOR [ M-003] (87693325) (Receptacle)
87693325 1
87693325
A X-161 (Receptacle) pin 6 1034 REAR WASHER B+ WH - 1.0 SHEET 18 SH18 - WIPER/WASHER
- REAR WIPER SWITCH
[S-016] (87632724)
B SP-019-P-X G028 REAR WASHER GROUND BK - 1.0 SHEET 18 SH18 - WIPER/WASHER
X-151 - HAZARD SWITCH [ S-037] (87632725) (Receptacle)
87632725 2
87632725
1 X-107A (Receptacle) pin 15 S133 HAZARD SWICTH B+ OR - 1.0 SHEET 16 SH16 - HAZARD
(47696599)
2 X-107A (Receptacle) pin 13 5340 FLASHER RELAY B+ YE - 1.0 SHEET 16 SH16 - HAZARD
(47696599)
3 SP-514-P-X P026 HAZARD LIGHTS B+ RD - 1.0 SHEET 16 SH16 - HAZARD
4 Not Used
6 Not Used
7 Not Used
8 Not Used
9 Not Used
10 SP-G12-P-X G122 HAZARD SWITCH BK - 0.75 SHEET 16 SH16 - HAZARD
GROUND
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Not Used
16 Not Used
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X-155 - FOOT THROTTLE [ A-015] (47416268) (Plug)
47416268 3
47416268
1 SP-G51-P-X G506 IVS GROUND BK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
2 Not Used
3 X-CN2 (Receptacle) pin 16 2160 FOOT THROTTLE YE - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN2 [A-002] SIGNAL
(82028493)
4 X-CN2 (Receptacle) pin 20 2200 FOOT THROTTLE GND BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82028493)
5 X-CN2 (Receptacle) pin 18 2180 FOOT THROTTLE 5V PK - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
(82028493)
6 X-CN1 (Receptacle) pin 20 1200 FOOT THROTTLE IDLE BL - 0.75 SHEET 19 SH19 - INSTRUMENT CLUSTER
- CLUSTER CN1 [A-002] VALIDATION
(82016219)
X-158 - BEACON SOCKET [ J-158] (84015523) (Receptacle)
84015523 4
84015523
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X-161 - REAR WIPER SWITCH [ S-016] (87632724) (Receptacle)
87632724 1
87632724
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 Not Used
6 X-150 (Receptacle) pin A 1034 REAR WASHER B+ WH - 1.0 SHEET 18 SH18 - WIPER/WASHER
- REAR WASHER MOTOR
[M-003] (87693325)
7 Not Used
8 Not Used
9 SP-019-P-X G027 REAR WIPER SWITCH BK - 0.75 SHEET 18 SH18 - WIPER/WASHER
GROUND
10 X-129B (Receptacle) pin 2 - 4236 REAR WIPER SWICH VT - 0.75 SHEET 18 SH18 - WIPER/WASHER
TO FRONT PANEL HARNESS LED B+
(87708112)
11 X-162 (Receptacle) pin 3 - 1035 WIPER MOTOR 31B BR - 1.0 SHEET 18 SH18 - WIPER/WASHER
REAR WIPER MOTOR [S-014]
(87680380)
12 Not Used
13 SP-021-P-X 1036 WIPER MOTOR + YE - 1.0 SHEET 18 SH18 - WIPER/WASHER
16 SP-020-P-X S164 REAR WASHER B+ OR - 1.0 SHEET 18 SH18 - WIPER/WASHER
X-162 - REAR WIPER MOTOR [ S-014] (87680380) (Receptacle)
87680380 2
87680380
1 SP-020-P-X S165 REAR WIPER B+ OR - 1.5 SHEET 18 SH18 - WIPER/WASHER
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3 X-161 (Receptacle) pin 11 1035 WIPER MOTOR 31B BR - 1.0 SHEET 18 SH18 - WIPER/WASHER
- REAR WIPER SWITCH
[S-016] (87632724)
4 SP-019-P-X G029 REAR WIPER MOTOR BK - 1.0 SHEET 18 SH18 - WIPER/WASHER
GROUND
X-163 - LICENSE PLATE LAMP 3 [ E-011] (84182898) (Receptacle)
84182898 3
84182898
1 SP-422-P-X 4242 LICENSE PLATE B+ VT - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
2 SP-G52-P-X G522 LICENSE PLATE BK - 1.0 SHEET 12 SH12 - FRONT DRIVING LIGHTS
GROUND
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X-195 - (47486930) (Plug)
47486930 1
47486930
X-198 - BEACON GROUND (84398832) (Plug)
84398832 2
84398832
1 SP-107-P-X G198 G198 BK - 1.0 SHEET 04 SH04 - GROUNDING
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X-200 - GROUND (47763001) (Plug)
47763001 1
47763001
X-206 - GROUND (47763001) (Plug)
47763001 2
47763001
X-207 - RADIO GROUND (84398832) (Plug)
84398832 3
84398832
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1 X-061 (Receptacle) pin 2 - G194 RADIO GROUND BK - 1.0 SHEET 04 SH04 - GROUNDING
RADIO [A-006] (84179570)
1 X-207 (Plug) pin 1 - RADIO WIRE103 WIRE103 SHEET 04 SH04 - GROUNDING
GROUND (84398832)
1 X-207 (Plug) pin 1 - RADIO WIRE103 WIRE103 SHEET 04 SH04 - GROUNDING
GROUND (84398832)
X-208 - GROUND (47763001) (Plug)
47763001 4
47763001
1 X-114 (Plug) pin 2 - G130 SPEEDOMETER BK - 0.75 SHEET 04 SH04 - GROUNDING
SPEEDOMETER [A-004] GROUND
(87686679)
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X-220 - A/C KIT CONTROL (47373520) (Plug)
47373520 1
47373520
1 X-113 (Plug) pin 1 - A/C KIT 4030 A/C 1ST SPEED YE - 1.5 SHEET 25 SH25 - HVAC
POWER (47706988)
2 X-113 (Plug) pin 2 - A/C KIT 4040 A/C 2ND SPEED BR - 1.5 SHEET 25 SH25 - HVAC
POWER (47706988)
3 X-113 (Plug) pin 3 - A/C KIT 4050 A/C 3RD SPEED OR - 1.5 SHEET 25 SH25 - HVAC
POWER (47706988)
4 SP-406-P-X 6105 HVAC SUPPLY OR - 2.0 SHEET 25 SH25 - HVAC
5 X-113 (Plug) pin 5 - A/C KIT 4070 A/C POT GY - 1.0 SHEET 25 SH25 - HVAC
POWER (47706988)
6 X-113 (Plug) pin 6 - A/C KIT 4080 A/C POT BL - 1.0 SHEET 25 SH25 - HVAC
POWER (47706988)
7 X-113 (Plug) pin 7 - A/C KIT 4090 A/C POT GN - 1.0 SHEET 25 SH25 - HVAC
POWER (47706988)
8 X-113 (Plug) pin 8 - A/C KIT 4100 A/C POT RD - 1.0 SHEET 25 SH25 - HVAC
POWER (47706988)
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X-460 - CAN BUS TERMINATING RESISTOR [ R-001] (47416266) (Plug)
47416266 1
47416266
A SP-L14-P-X L314 CONTROLLER AREA GN - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
NETWORK 2 LOW CAN BUS
B SP-H14-P-X H314 CONTROLLER AREA YE - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
NETWORK 2 HIGH CAN BUS
X-461 - ECU (84474047) (Receptacle)
84474047 2
84474047
1 X-101 (Plug) pin 38 S407 BATTERY VOLTAGE RD - 2.5 SHEET 05 SH05 - ENGINE CONTROL
2 SP-G40-P-X G401 ECU GROUND BK - 2.5 SHEET 05 SH05 - ENGINE CONTROL
3 SP-S42-P-X S405 ECU BATTERY B+ RD - 2.5 SHEET 05 SH05 - ENGINE CONTROL
5 SP-S42-P-X S404 ECU BATTERY B+ RD - 2.5 SHEET 05 SH05 - ENGINE CONTROL
7 X-130 (Receptacle) pin 3 - E070 SCR TANK HEATING YE - 0.75 SHEET 07 SH07 - ENGINE CONTROL
SCR TANK HEATING VALVE VALVE SIGNAL
[B-001] (84146685)
8 SP-S55-P-X S506 CRANK SIGNAL OR - 0.75 SHEET 05 SH05 - ENGINE CONTROL
9 Not Used
10 Not Used
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Not Used
16 Not Used
17 Not Used
18 X-470 (Receptacle) pin E180 EXHAUST GAS PRESS BL - 0.5 SHEET 05 SH05 - ENGINE CONTROL
21 - EINGINE INTERFACE SENSE SIG
(84154706)
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19 X-474 (Receptacle) pin 1 - E190 AIR TEMP SENSOR YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
AIR TEMP SENSOR [B-010] SIGNAL
(84607243)
20 X-474 (Receptacle) pin 2 - E200 AIR TEMP SENSOR GND WH - 0.5 SHEET 05 SH05 - ENGINE CONTROL
AIR TEMP SENSOR [B-010]
(84607243)
21 Not Used
22 X-469 (Receptacle) pin 3 - E220 GLOW PLUG FEEDBACK YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
GCU [A-010] (84356962) SIGNAL
23 SP-H21-P-X H201 CONTROLLER AREA YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
NETWORK 2 HIGH
24 X-106A (Plug) pin K - H007 CONTROLLER AREA YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
TO FRONT HARNESS NETWORK HIGH
(87698254)
25 X-106A (Plug) pin E - L007 CONTROLLER AREA GN - 0.5 SHEET 05 SH05 - ENGINE CONTROL
TO FRONT HARNESS NETWORK LOW
(87698254)
26 X-469 (Receptacle) pin 8 - E260 GLOW PLUG UNIT YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
GCU [A-010] (84356962) COMMAND SIGNAL
27 X-101 (Receptacle) pin 19 - E270 STARTER RELAY LOW YE - 0.75 SHEET 05 SH05 - ENGINE CONTROL
FUSES AND RELAYS BLOCK SIDE
(47944420)
28 X-108 (Receptacle) pin 1 - E280 MAIN RELAY BL - 0.5 SHEET 05 SH05 - ENGINE CONTROL
MAIN ECU RELAY [K-100]
(84297431)
29 Not Used
30 X-463 (Receptacle) pin 1 - E300 WATER IN FUEL LEVEL YE - 0.75 SHEET 05 SH05 - ENGINE CONTROL
WATER IN FUEL SWITCH SENSOR SIGNAL
[B-007] (87709663)
31 Not Used
32 Not Used
33 Not Used
34 Not Used
35 Not Used
36 Not Used
22 - EINGINE INTERFACE SENSE GND
(84154706)
38 Not Used
39 Not Used
40 Not Used
41 SP-205-P-X E410 GLOW PLUG UNIT GND BK - 0.75 SHEET 05 SH05 - ENGINE CONTROL
42 Not Used
43 Not Used
44 Not Used
45 SP-L21-P-X L201 CONTROLLER AREA GN - 0.5 SHEET 07 SH07 - ENGINE CONTROL
NETWORK 2 LOW
46 Not Used
47 Not Used
48 Not Used
49 Not Used
50 Not Used
51 Not Used
52 Not Used
53 X-101 (Receptacle) pin 15 - E530 STARTER RELAY HIGH YE - 0.75 SHEET 05 SH05 - ENGINE CONTROL
FUSES AND RELAYS BLOCK SIDE
(47944420)
54 SP-154-P-X S295 ENGINE IGNITION OR - 0.75 SHEET 05 SH05 - ENGINE CONTROL
55 Not Used
56 Not Used
23 - EINGINE INTERFACE SENSE SIG
(84154706)
58 Not Used
59 Not Used
60 Not Used
61 Not Used
62 Not Used
63 Not Used
64 Not Used
65 Not Used
66 Not Used
67 Not Used
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68 X-106A (Plug) pin B - E680 ECU K LINE YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
TO FRONT HARNESS
(87698254)
69 Not Used
70 Not Used
71 Not Used
72 SP-E72-P-X E720 SUPPLY MODULE PUMP YE - 0.75 SHEET 05 SH05 - ENGINE CONTROL
CONTROL SIG
73 Not Used
74 Not Used
75 Not Used
76 SP-E72-P-X E760 SUPPLY MODULE PUMP YE - 0.75 SHEET 05 SH05 - ENGINE CONTROL
CONTROL SIG
77 Not Used
78 Not Used
79 X-636A (Receptacle) pin 1 - E790 CAT TEMP SENS BL - 0.5 SHEET 07 SH07 - ENGINE CONTROL
RIGHT SIDE POD HARNESS DOWNSTREAM GND
(47416278)
80 X-636A (Receptacle) pin 2 - E800 CAT TEMP SENS SIG YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
RIGHT SIDE POD HARNESS DOWNSTREAM
(47416278)
81 X-617 (Receptacle) pin E810 CAT TEMP SENS BL - 0.5 SHEET 07 SH07 - ENGINE CONTROL
2 - CAT TEMP SENSOR UPSTREAM GND
UPSTREAM [B-011]
(84532147)
82 X-617 (Receptacle) pin E820 CAT TEMP SENS YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
1 - CAT TEMP SENSOR UPSTREAM SIGNAL
UPSTREAM [B-011]
(84532147)
X-462 - ECU [ A-001] (84474053) (Receptacle)
84474053 3
84474053
1 X-471 (Receptacle) pin D - F010 INJECTOR HIGH BANK 2 WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ELECTRIC VALVE (87698252)
2 X-471 (Receptacle) pin H - F020 INJECTOR 2 HIGH BANK WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ELECTRIC VALVE (87698252) 2
3 X-128 (Receptacle) pin 2 F030 DOSING VALVE L YE - 1.5 SHEET 07 SH07 - ENGINE CONTROL
- DOSING VALVE [Y-101]
(87709793)
4 X-470 (Receptacle) pin F040 BOOST PRESSURE GY - 1.0 SHEET 06 SH06 - ENGINE CONTROL
27 - EINGINE INTERFACE ACTUATOR 1
(84154706)
5 X-638A (Receptacle) pin 8 - F050 PRESSURE SENSOR BL - 0.75 SHEET 07 SH07 - ENGINE CONTROL
LEFT SIDE POD HARNESS GND
(47416278)
6 X-470 (Receptacle) pin F060 OIL PRESSURE SWITCH WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
3 - EINGINE INTERFACE SIGNAL
(84154706)
7 X-638A (Receptacle) pin 10 F070 PRESSURE SENSOR PK - 0.75 SHEET 07 SH07 - ENGINE CONTROL
- LEFT SIDE POD HARNESS SUPPLY
(47416278)
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8 X-470 (Receptacle) pin F080 TVA POSITION SENSOR PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
41 - EINGINE INTERFACE SUPPLY
(84154706)
9 X-470 (Receptacle) pin F090 EXHAUST GAS PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
33 - EINGINE INTERFACE RECIRCULATION (EGR)
(84154706) POSITION SENSOR
SUPPLY
10 X-470 (Receptacle) pin F100 BOOST PRESSURE PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
17 - EINGINE INTERFACE SENSOR SUPPLY
(84154706)
11 X-470 (Receptacle) pin F110 RAIL PRESSURE PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
7 - EINGINE INTERFACE SENSOR SUPPLY
(84154706)
12 Not Used
13 X-470 (Receptacle) pin F130 SEGMENT SPEED PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
14 X-470 (Receptacle) pin F140 SEGMENT SPEED YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
15 X-470 (Receptacle) pin F150 FUEL METERING UNIT WH - 1.0 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
16 X-471 (Receptacle) pin A - F160 INJECTOR 1 HIGH BANK WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
17 X-471 (Receptacle) pin E - F170 INJECTOR 2 HIGH BANK WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
18 X-128 (Receptacle) pin 1 F180 DOSING VALVE H BL - 1.5 SHEET 07 SH07 - ENGINE CONTROL
- DOSING VALVE [Y-101]
(87709793)
19 Not Used
20 X-101 (Receptacle) pin 10 - F200 SCR MAIN RELAY YE - 0.75 SHEET 07 SH07 - ENGINE CONTROL
(47944420)
21 Not Used
22 Not Used
23 X-470 (Receptacle) pin F230 FUEL TEMP GND BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
15 - EINGINE INTERFACE
(84154706)
24 X-470 (Receptacle) pin F240 EXHAUST GAS WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706) POSITION SENSOR GND
25 X-470 (Receptacle) pin F250 BOOST PRESSURE WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
19 - EINGINE INTERFACE SENSOR GND
(84154706)
26 X-470 (Receptacle) pin F260 RAIL PRESSURE BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
5 - EINGINE INTERFACE SENSOR GND
(84154706)
27 X-470 (Receptacle) pin 2270 INLET TURBINE TEMP BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
25 - EINGINE INTERFACE SENS GND
(84154706)
28 X-470 (Receptacle) pin F280 SEGMENT SPEED GND BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
29 Not Used
30 Not Used
31 X-471 (Receptacle) pin C - F310 INJECTOR 1 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
32 X-471 (Receptacle) pin B - F320 INJECTOR 1 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
33 Not Used
34 X-470 (Receptacle) pin F340 TVA ACTUATOR MOTOR GY - 0.75 SHEET 06 SH06 - ENGINE CONTROL
38 - EINGINE INTERFACE -
(84154706)
35 X-470 (Receptacle) pin F350 EXHAUST GAS GY - 0.75 SHEET 06 SH06 - ENGINE CONTROL
(84154706) ACTUATOR MOTOR -
36 Not Used
37 X-470 (Receptacle) pin F370 TVA POSITION SENSOR WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
43 - EINGINE INTERFACE GROUND
(84154706)
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38 X-470 (Receptacle) pin F380 COOLANT TEMP SIGNAL YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
39 X-470 (Receptacle) pin F390 EXHAUST GAS YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706) POSITION SENSOR
SIGNAL
40 X-470 (Receptacle) pin F400 BOOST PRESSURE YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
18 - EINGINE INTERFACE SENSOR SIGNAL
(84154706)
41 X-470 (Receptacle) pin F410 RAIL PRESSURE YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
6 - EINGINE INTERFACE SENSOR SIGNAL
(84154706)
42 Not Used
43 X-470 (Receptacle) pin 2430 INLET TURBINE TEMP YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
26 - EINGINE INTERFACE SENS SIGNAL
(84154706)
44 X-470 (Receptacle) pin F440 CRANK SPEED SIGNAL - YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
45 X-638A (Receptacle) pin 6 - F450 PURGING PUMP SIGNAL YE - 1.5 SHEET 07 SH07 - ENGINE CONTROL
(47416278)
46 X-471 (Receptacle) pin G - F460 INJECTOR 2 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
47 Not Used
48 X-471 (Receptacle) pin F - F480 INJECTOR 2 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
49 X-470 (Receptacle) pin F490 TVA ACTUATOR MOTOR WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
37 - EINGINE INTERFACE +
(84154706)
50 X-470 (Receptacle) pin F500 EXHAUST GAS WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
(84154706) ACTUATOR MOTOR +
51 Not Used
52 Not Used
53 X-470 (Receptacle) pin F530 TVA POSITION SENSOR YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
54 Not Used
55 X-470 (Receptacle) pin F550 BOOST PRESSURE YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
20 - EINGINE INTERFACE TEMP SENSOR SIGNAL
(84154706)
56 X-638A (Receptacle) pin 9 - F560 PRESSURE SENSOR YE - 0.75 SHEET 07 SH07 - ENGINE CONTROL
LEFT SIDE POD HARNESS SIGNAL
(47416278)
57 X-470 (Receptacle) pin F570 COOLANT TEMP SIGNAL YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
58 X-470 (Receptacle) pin F580 COOLANT TEMP GND BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
59 X-470 (Receptacle) pin F590 CRANK SPEED SIGNAL + YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
60 X-470 (Receptacle) pin F600 FUEL METERING UNIT GY - 1.0 SHEET 06 SH06 - ENGINE CONTROL
(84154706)
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X-463 - WATER IN FUEL SWITCH [ B-007] (87709663) (Receptacle)
87709663 4
87709663
1 X-461 (Receptacle) pin 30 - E300 WATER IN FUEL LEVEL YE - 0.75 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047) SENSOR SIGNAL
2 SP-G40-P-X G404 WATER IN FULE SENSOR BK - 0.75 SHEET 05 SH05 - ENGINE CONTROL
GROUND
3 SP-154-P-X S294 WATER IN FUEL SENSOR OR - 0.75 SHEET 05 SH05 - ENGINE CONTROL
B+
X-469 - GCU [ A-010] (84356962) (Receptacle)
84356962 5
84356962
1 X-470 (Receptacle) pin 1580 GLOW PLUG WH - 2.0 SHEET 05 SH05 - ENGINE CONTROL
(84154706)
(84154706)
3 X-461 (Receptacle) pin 22 - E220 GLOW PLUG FEEDBACK YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047) SIGNAL
4 X-475 (Receptacle) pin A P008 GCU UNSWITCHED B+ RD - 6.0 SHEET 05 SH05 - ENGINE CONTROL
- J-CASE FUSE HOLDER
[A-013] (87693326)
5 SP-205-P-X E411 GLOW PLUG UNIT GND BK - 4.0 SHEET 05 SH05 - ENGINE CONTROL
(84154706)
(84154706)
8 X-461 (Receptacle) pin 26 - E260 GLOW PLUG UNIT YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047) COMMAND SIGNAL
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X-470 - EINGINE INTERFACE (84154706) (Receptacle)
84154706 1
84154706
1 X-462 (Receptacle) pin 15 - F150 FUEL METERING UNIT WH - 1.0 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SUPPLY
2 X-462 (Receptacle) pin 60 - F600 FUEL METERING UNIT GY - 1.0 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
3 X-462 (Receptacle) pin 6 - F060 OIL PRESSURE SWITCH WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SIGNAL
4 X-462 (Receptacle) pin 14 - F140 SEGMENT SPEED YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SIGNAL
5 X-462 (Receptacle) pin 26 - F260 RAIL PRESSURE BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENSOR GND
6 X-462 (Receptacle) pin 41 - F410 RAIL PRESSURE YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENSOR SIGNAL
7 X-462 (Receptacle) pin 11 - F110 RAIL PRESSURE PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENSOR SUPPLY
8 X-462 (Receptacle) pin 28 - F280 SEGMENT SPEED GND BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
9 X-462 (Receptacle) pin 59 - F590 CRANK SPEED SIGNAL + YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
10 X-462 (Receptacle) pin 44 - F440 CRANK SPEED SIGNAL - YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
11 Not Used
12 X-462 (Receptacle) pin 13 - F130 SEGMENT SPEED PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SUPPLY
13 X-462 (Receptacle) pin 58 - F580 COOLANT TEMP GND BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
14 X-462 (Receptacle) pin 57 - F570 COOLANT TEMP SIGNAL YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
15 X-462 (Receptacle) pin 23 - F230 FUEL TEMP GND BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
16 X-462 (Receptacle) pin 38 - F380 COOLANT TEMP SIGNAL YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
17 X-462 (Receptacle) pin 10 - F100 BOOST PRESSURE PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENSOR SUPPLY
18 X-462 (Receptacle) pin 40 - F400 BOOST PRESSURE YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENSOR SIGNAL
19 X-462 (Receptacle) pin 25 - F250 BOOST PRESSURE WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENSOR GND
20 X-462 (Receptacle) pin 55 - F550 BOOST PRESSURE YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) TEMP SENSOR SIGNAL
21 X-461 (Receptacle) pin 18 - E180 EXHAUST GAS PRESS BL - 0.5 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047) SENSE SIG
ECU (84474047) SENSE GND
ECU (84474047) SENSE SIG
24 Not Used
25 X-462 (Receptacle) pin 27 - 2270 INLET TURBINE TEMP BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENS GND
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26 X-462 (Receptacle) pin 43 - 2430 INLET TURBINE TEMP YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SENS SIGNAL
27 X-462 (Receptacle) pin 4 - F040 BOOST PRESSURE GY - 1.0 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) ACTUATOR 1
28 SP-S43-P-X S410 B+ TO ELECTRIC VALVE RD - 1.0 SHEET 06 SH06 - ENGINE CONTROL
29 X-462 (Receptacle) pin 50 - F500 EXHAUST GAS WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) RECIRCULATION (EGR)
ACTUATOR MOTOR +
30 X-462 (Receptacle) pin 35 - F350 EXHAUST GAS GY - 0.75 SHEET 06 SH06 - ENGINE CONTROL
ACTUATOR MOTOR -
31 Not Used
32 Not Used
33 X-462 (Receptacle) pin 9 - F090 EXHAUST GAS PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
POSITION SENSOR
SUPPLY
34 X-462 (Receptacle) pin 39 - F390 EXHAUST GAS YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
POSITION SENSOR
SIGNAL
35 X-462 (Receptacle) pin 24 - F240 EXHAUST GAS WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
POSITION SENSOR GND
36 Not Used
37 X-462 (Receptacle) pin 49 - F490 TVA ACTUATOR MOTOR WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) +
38 X-462 (Receptacle) pin 34 - F340 TVA ACTUATOR MOTOR GY - 0.75 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) -
39 Not Used
40 Not Used
41 X-462 (Receptacle) pin 8 - F080 TVA POSITION SENSOR PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SUPPLY
42 X-462 (Receptacle) pin 53 - F530 TVA POSITION SENSOR YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) SIGNAL
43 X-462 (Receptacle) pin 37 - F370 TVA POSITION SENSOR WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) GROUND
44 Not Used
45 Not Used
46 Not Used
47 Not Used
48 Not Used
49 Not Used
50 Not Used
51 Not Used
52 Not Used
53 Not Used
54 Not Used
55 Not Used
56 Not Used
57 X-469 (Receptacle) pin 6 - 1590 GLOW PLUG WH - 2.0 SHEET 05 SH05 - ENGINE CONTROL
GCU [A-010] (84356962)
GCU [A-010] (84356962)
59 Not Used
GCU [A-010] (84356962)
GCU [A-010] (84356962)
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X-471 - ELECTRIC VALVE (87698252) (Receptacle)
87698252 2
87698252
A X-462 (Receptacle) pin 16 - F160 INJECTOR 1 HIGH BANK WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 1
B X-462 (Receptacle) pin 32 - F320 INJECTOR 1 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 1
C X-462 (Receptacle) pin 31 - F310 INJECTOR 1 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 2
D X-462 (Receptacle) pin 1 - F010 INJECTOR HIGH BANK 2 WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053)
E X-462 (Receptacle) pin 17 - F170 INJECTOR 2 HIGH BANK WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 1
F X-462 (Receptacle) pin 48 - F480 INJECTOR 2 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 2
G X-462 (Receptacle) pin 46 - F460 INJECTOR 2 LOW BANK GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 2
H X-462 (Receptacle) pin 2 - F020 INJECTOR 2 HIGH BANK WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
ECU [A-001] (84474053) 2
X-474 - AIR TEMP SENSOR [ B-010] (84607243) (Receptacle)
84607243 3
84607243
1 X-461 (Receptacle) pin 19 - E190 AIR TEMP SENSOR YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047) SIGNAL
2 X-461 (Receptacle) pin 20 - E200 AIR TEMP SENSOR GND WH - 0.5 SHEET 05 SH05 - ENGINE CONTROL
ECU (84474047)
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X-475 - J-CASE FUSE HOLDER [ A-013] (87693326) (Receptacle)
87693326 4
87693326
A X-469 (Receptacle) pin 4 - P008 GCU UNSWITCHED B+ RD - 6.0 SHEET 05 SH05 - ENGINE CONTROL
GCU [A-010] (84356962)
B X-612 (Receptacle) pin 11 P009 HCU UNSWITCHED B+ RD - 6.0 SHEET 05 SH05 - ENGINE CONTROL
- HEATER CONTROL UNIT
[A-008] (47514457)
C X-103 (Receptacle) pin 5 P010 STARTER RELAY B+ RD - 4.0 SHEET 05 SH05 - ENGINE CONTROL
- STARTER RELAY [K-125]
(84297431)
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X-605 - DNOX SUPPLY MODULE [ A-009] (84152570) (Receptacle)
84152570 1
84152570
1 Not Used
2 X-638B (Plug) pin 2 - E701 SUPPLY MODULE PUMP YE - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS CONTROL SIG
(47416270)
3 X-638B (Plug) pin 3 - IGNC PUMP MOTOR B+ OR - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS
(47416270)
4 X-638B (Plug) pin 4 - G287 GROUND BK - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS
(47416270)
5 X-638B (Plug) pin 5 - IG04 PURGING PUMP B+ OR - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS
(47416270)
6 X-638B (Plug) pin 6 - F451 PURGING PUMP SIGNAL YE - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS
(47416270)
7 Not Used
8 X-638B (Plug) pin 8 - F051 PRESSURE SENSOR BL - 0.75 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS GND
(47416270)
9 X-638B (Plug) pin 9 - F560* PRESSURE SENSOR YE - 0.75 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS SIGNAL
(47416270)
10 X-638B (Plug) pin 10 - F071 PRESSURE SENSOR PK - 0.75 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS SUPPLY
(47416270)
11 X-638B (Plug) pin 11 - 5051 5051 OR - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS
(47416270)
12 X-638B (Plug) pin 12 - G286 GROUND BK - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS
(47416270)
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X-606 - NOX SENSOR DOWNSTREAM [ B-014] (47514978) (Receptacle)
47514978 2
47514978
1 X-636B (Plug) pin 7 - IG02 NOX DOWNSTREAM OR - 0.75 SHEET 08 SH08 - EXAUST SYTEM AND
TO ENGINE HARNESS SENSOR B+ CAN BUS
(47416270)
2 X-636B (Plug) pin 8 - G229 NOX SENSOR BK - 0.75 SHEET 08 SH08 - EXAUST SYTEM AND
TO ENGINE HARNESS DOWNSTREAM CAN BUS
(47416270) GROUND
3 SP-170-P-X E456 CONTROLLER AREA GN - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
4 SP-171-P-X E236 CONTROLLER AREA YE - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
X-607 - NOX SENSOR UPSTREAM [ B-012] (47514978) (Receptacle)
47514978 3
47514978
1 SP-S61-P-X S603 NOX SENSOR OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
UPSTREAM B+ CAN BUS
2 SP-G41-P-X G414 NOX SENSOR BK - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
UPSTREAM GROUND CAN BUS
3 SP-L14-P-X L205 CONTROLLER AREA GN - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
4 SP-H14-P-X H205 CONTROLLER AREA YE - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
UPSTREAM ADRRESS CAN BUS
GROUND
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X-608 - UREA SENSOR [ B-013] (87688719) (Receptacle)
87688719 4
87688719
1 X-640B (Plug) pin 1 - IG01 UREA SENSOR B+ OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
TO ENGINE HARNESS CAN BUS
(47416269)
2 X-640B (Plug) pin 2 - G228 UREA SENSOR GROUND BK - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
(47416269)
3 Not Used
4 X-640B (Plug) pin 4 - E454 CONTROLLER AREA GN - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
TO ENGINE HARNESS NETWORK 2 LOW CAN BUS
(47416269)
5 X-640B (Plug) pin 5 - E234 CONTROLLER AREA YE - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
TO ENGINE HARNESS NETWORK 2 HIGH CAN BUS
(47416269)
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X-612 - HEATER CONTROL UNIT [ A-008] (47514457) (Receptacle)
47514457 1
47514457
1 X-638A (Receptacle) pin 11 - 5057 IGNITION OR - 1.5 SHEET 09 SH09 - PRE START
(47416278)
2 X-640A (Receptacle) pin 6 - 1206* DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
LEFT SIDE POD HARNESS HEATER 2
(47416277)
3 Not Used
4 X-640A (Receptacle) pin 7 - 1204 DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
LEFT SIDE POD HARNESS HEATER 1
(47416277)
5 Not Used
6 SP-S43-P-X S413 HCU SWITCHED B+ RD - 0.75 SHEET 09 SH09 - PRE START
7 SP-G41-P-X G411 HCU GROUND BK - 1.5 SHEET 09 SH09 - PRE START
8 Not Used
9 SP-L23-P-X L207 CONTROLLER AREA GN - 0.5 SHEET 09 SH09 - PRE START
NETWORK 2 LOW
10 SP-H23-P-X H207 CONTROLLER AREA YE - 0.5 SHEET 09 SH09 - PRE START
NETWORK 2 HIGH
11 X-475 (Receptacle) pin B P009 HCU UNSWITCHED B+ RD - 6.0 SHEET 09 SH09 - PRE START
- J-CASE FUSE HOLDER
[A-013] (87693326)
X-617 - CAT TEMP SENSOR UPSTREAM [ B-011] (84532147) (Receptacle)
84532147 2
84532147
1 X-461 (Receptacle) pin 82 - E820 CAT TEMP SENS YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
ECU (84474047) UPSTREAM SIGNAL
2 X-461 (Receptacle) pin 81 - E810 CAT TEMP SENS BL - 0.5 SHEET 07 SH07 - ENGINE CONTROL
ECU (84474047) UPSTREAM GND
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X-618 - CATALYST TEMP (DOWNSTREAM) [ B-009] (84532147) (Receptacle)
84532147 3
84532147
1 X-636B (Plug) pin 2 - E801 CAT TEMP SENS SIG YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
TO ENGINE HARNESS DOWNSTREAM
(47416270)
2 X-636B (Plug) pin 1 - E791 CAT TEMP SENS BL - 0.5 SHEET 07 SH07 - ENGINE CONTROL
TO ENGINE HARNESS DOWNSTREAM GND
(47416270)
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X-624 - NH3 SENSOR [ B-015] (84146686) (Receptacle)
84146686 1
84146686
1 X-636B (Plug) pin 5 - IG03 NH3 SENSOR B+ OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
(47416270)
4 X-636B (Plug) pin 6 - G237 NH3 SENSOR GROUND BK - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
(47416270)
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X-633 - DEF HEATER 1 (87695900) (Plug)
87695900 1
87695900
1 X-640B (Plug) pin 7 - 1204* DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS HEATER 1
(47416269)
2 SP-282-P-X G290 DIESEL EXHAUST FLUID BK - 2.0 SHEET 09 SH09 - PRE START
HEATER LINES GROUND
X-634 - DEF HEATER 2 (84277533) (Receptacle)
84277533 2
84277533
1 X-640B (Plug) pin 6 - 1206 DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
TO ENGINE HARNESS HEATER 2
(47416269)
HEATER LINES GROUND
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X-636A - RIGHT SIDE POD HARNESS (47416278) (Receptacle)
47416278 3
47416278
1 X-461 (Receptacle) pin 79 - E790 CAT TEMP SENS BL - 0.5 SHEET 07 SH07 - ENGINE CONTROL
ECU (84474047) DOWNSTREAM GND
2 X-461 (Receptacle) pin 80 - E800 CAT TEMP SENS SIG YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
ECU (84474047) DOWNSTREAM
5 SP-S61-P-X S608 NH3 SENSOR B+ OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
CAN BUS
6 SP-G41-P-X G418 NH3 SENSOR GROUND BK - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
CAN BUS
7 SP-S61-P-X S606 NOX DOWNSTREAM OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
SENSOR B+ CAN BUS
DOWNSTREAM CAN BUS
GROUND
9 Not Used
10 Not Used
X-636B - TO ENGINE HARNESS (47416270) (Plug)
47416270 4
47416270
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1 X-618 (Receptacle) pin E791 CAT TEMP SENS BL - 0.5 SHEET 07 SH07 - ENGINE CONTROL
2 - CATALYST TEMP DOWNSTREAM GND
(DOWNSTREAM) [B-009]
(84532147)
2 X-618 (Receptacle) pin E801 CAT TEMP SENS SIG YE - 0.5 SHEET 07 SH07 - ENGINE CONTROL
1 - CATALYST TEMP DOWNSTREAM
(DOWNSTREAM) [B-009]
(84532147)
5 X-624 (Receptacle) pin 1 IG03 NH3 SENSOR B+ OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
- NH3 SENSOR [B-015] CAN BUS
(84146686)
6 X-624 (Receptacle) pin 4 G237 NH3 SENSOR GROUND BK - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
- NH3 SENSOR [B-015] CAN BUS
(84146686)
7 X-606 (Receptacle) IG02 NOX DOWNSTREAM OR - 0.75 SHEET 08 SH08 - EXAUST SYTEM AND
pin 1 - NOX SENSOR SENSOR B+ CAN BUS
DOWNSTREAM [B-014]
(47514978)
8 X-606 (Receptacle) G229 NOX SENSOR BK - 0.75 SHEET 08 SH08 - EXAUST SYTEM AND
pin 2 - NOX SENSOR DOWNSTREAM CAN BUS
DOWNSTREAM [B-014] GROUND
(47514978)
9 Not Used
10 Not Used
X-638A - LEFT SIDE POD HARNESS (47416278) (Receptacle)
47416278 5
47416278
1 Not Used
2 SP-E72-P-X E721 SUPPLY MODULE PUMP YE - 1.5 SHEET 09 SH09 - PRE START
CONTROL SIG
3 X-101 (Plug) pin 34 S711 PUMP MOTOR B+ OR - 2.0 SHEET 09 SH09 - PRE START
4 X-008 (Plug) pin 1 - GROUND G490 GROUND BK - 1.5 SHEET 09 SH09 - PRE START
(84401295)
5 SP-S71-P-X S705 PURGING PUMP B+ OR - 1.5 SHEET 09 SH09 - PRE START
6 X-462 (Receptacle) pin 45 - F450 PURGING PUMP SIGNAL YE - 1.5 SHEET 09 SH09 - PRE START
ECU [A-001] (84474053)
7 Not Used
8 X-462 (Receptacle) pin 5 - F050 PRESSURE SENSOR BL - 0.75 SHEET 09 SH09 - PRE START
ECU [A-001] (84474053) GND
9 X-462 (Receptacle) pin 56 - F560 PRESSURE SENSOR YE - 0.75 SHEET 09 SH09 - PRE START
ECU [A-001] (84474053) SIGNAL
10 X-462 (Receptacle) pin 7 - F070 PRESSURE SENSOR PK - 0.75 SHEET 09 SH09 - PRE START
ECU [A-001] (84474053) SUPPLY
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11 X-612 (Receptacle) pin 1 - 5057 IGNITION OR - 1.5 SHEET 09 SH09 - PRE START
HEATER CONTROL UNIT
[A-008] (47514457)
12 X-008 (Plug) pin 1 - GROUND G480 GROUND BK - 1.5 SHEET 09 SH09 - PRE START
(84401295)
47416270 6
47416270
1 Not Used
2 X-605 (Receptacle) pin 2 E701 SUPPLY MODULE PUMP YE - 1.5 SHEET 09 SH09 - PRE START
- DNOX SUPPLY MODULE CONTROL SIG
[A-009] (84152570)
3 X-605 (Receptacle) pin 3 IGNC PUMP MOTOR B+ OR - 1.5 SHEET 09 SH09 - PRE START
- DNOX SUPPLY MODULE
[A-009] (84152570)
4 X-605 (Receptacle) pin 4 G287 GROUND BK - 1.5 SHEET 09 SH09 - PRE START
[A-009] (84152570)
5 X-605 (Receptacle) pin 5 IG04 PURGING PUMP B+ OR - 1.5 SHEET 09 SH09 - PRE START
[A-009] (84152570)
6 X-605 (Receptacle) pin 6 F451 PURGING PUMP SIGNAL YE - 1.5 SHEET 09 SH09 - PRE START
[A-009] (84152570)
7 Not Used
8 X-605 (Receptacle) pin 8 F051 PRESSURE SENSOR BL - 0.75 SHEET 09 SH09 - PRE START
- DNOX SUPPLY MODULE GND
[A-009] (84152570)
9 X-605 (Receptacle) pin 9 F560* PRESSURE SENSOR YE - 0.75 SHEET 09 SH09 - PRE START
- DNOX SUPPLY MODULE SIGNAL
[A-009] (84152570)
10 X-605 (Receptacle) pin 10 F071 PRESSURE SENSOR PK - 0.75 SHEET 09 SH09 - PRE START
- DNOX SUPPLY MODULE SUPPLY
[A-009] (84152570)
11 X-605 (Receptacle) pin 11 5051 5051 OR - 1.5 SHEET 09 SH09 - PRE START
[A-009] (84152570)
12 X-605 (Receptacle) pin 12 G286 GROUND BK - 1.5 SHEET 09 SH09 - PRE START
[A-009] (84152570)
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X-640A - LEFT SIDE POD HARNESS (47416277) (Receptacle)
47416277 1
47416277
1 SP-S61-P-X S604 UREA SENSOR B+ OR - 0.75 SHEET 08 SH08 - EXAUST SYTEM AND
CAN BUS
2 SP-G41-P-X G412 UREA SENSOR GROUND BK - 0.75 SHEET 08 SH08 - EXAUST SYTEM AND
CAN BUS
3 Not Used
6 X-612 (Receptacle) pin 2 - 1206* DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
HEATER CONTROL UNIT HEATER 2
[A-008] (47514457)
7 X-612 (Receptacle) pin 4 - 1204 DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
HEATER CONTROL UNIT HEATER 1
[A-008] (47514457)
8 X-008 (Plug) pin 1 - GROUND G450 DIESEL EXHAUST FLUID BK - 2.0 SHEET 09 SH09 - PRE START
(84401295) HEATER LINES GROUND
47416269 2
47416269
1 X-608 (Receptacle) pin 1 IG01 UREA SENSOR B+ OR - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
- UREA SENSOR [B-013] CAN BUS
(87688719)
2 X-608 (Receptacle) pin 2 G228 UREA SENSOR GROUND BK - 1.0 SHEET 08 SH08 - EXAUST SYTEM AND
- UREA SENSOR [B-013] CAN BUS
(87688719)
3 Not Used
4 X-608 (Receptacle) pin 4 E454 CONTROLLER AREA GN - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
- UREA SENSOR [B-013] NETWORK 2 LOW CAN BUS
(87688719)
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5 X-608 (Receptacle) pin 5 E234 CONTROLLER AREA YE - 0.5 SHEET 08 SH08 - EXAUST SYTEM AND
- UREA SENSOR [B-013] NETWORK 2 HIGH CAN BUS
(87688719)
6 X-634 (Receptacle) pin 1 - 1206 DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
DEF HEATER 2 (84277533) HEATER 2
7 X-633 (Plug) pin 1 - DEF 1204* DIESEL EXHAUST FLUID WH - 1.5 SHEET 09 SH09 - PRE START
HEATER 1 (87695900) HEATER 1
HEATER LINES GROUND
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X-9003 - BOOST PRESSURE AND TEMPERATURE S [ B-9001] (87709809) (Plug)
87709809 1
87709809
1 X-9138B (Receptacle) pin 19 - EN-9103 EN-9103 BR/PRP - 0.5 SHEET 06 SH06 - ENGINE CONTROL
ENGINE SENSOR HARNESS
TO VEHICLE (84154706)
2 X-9138B (Receptacle) pin 20 - EN-9104 EN-9104 WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
3 X-9138B (Receptacle) pin 17 - EN-9102 EN-9102 PRP/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
4 X-9138B (Receptacle) pin 18 - EN-9101 EN-9101 BL/BR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
X-9005 - FUEL TEMPERATURE SENSOR (T) [ B-9002] (87709793) (Receptacle)
87709793 2
87709793
1 X-9138B (Receptacle) pin 16 - EN-9117 EN-9117 BR/WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 15 - EN-9116 EN-9116 PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
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X-9006 - COOLANT TEMPERATURE SENSOR (T) [ B-9003] (87709793) (Receptacle)
87709793 3
87709793
1 X-9138B (Receptacle) pin 14 - EN-9115 EN-9115 YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 13 - EN-9114 EN-9114 GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
X-9007 - FUEL METERING UNIT HP FUEL PUMP [ Y-9000] (87709798) (Plug)
87709798 4
87709798
1 X-9138B (Receptacle) pin 1 - EN-9137 EN-9137 PRP/WH - SHEET 06 SH06 - ENGINE CONTROL
ENGINE SENSOR HARNESS 0.75
2 X-9138B (Receptacle) pin 2 - EN-9136 EN-9136 OR/WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
X-9008 - SEGMENT SPEED SENSOR (CAMSHAFT)â [ B-9017] (Not Serviceable) (Plug)

1 X-9138B (Receptacle) pin 8 - EN-9110 EN-9110 PRP/GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 4 - EN-9111 EN-9111 GY - 0.5 SHEET 06 SH06 - ENGINE CONTROL
3 X-9138B (Receptacle) pin 12 - EN-9109 EN-9109 WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
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X-9009 - EXHAUST MANIFOLD TEMPERATURE SEN [ B-9018] (Not Serviceable) (Plug)

1 X-9138B (Receptacle) pin 26 - EN-9121 EN-9121 WH/GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 25 - EN-9119 EN-9119 YE/BR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
X-9010 - EXHAUST GAS RECIRCULATION (EGR) [ Z-9000] (84360293) (Receptacle)
84360293 5
84360293
1 X-9138B (Receptacle) pin 29 - EN-9095 EN-9095 BL/WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 34 - EN-9093 EN-9093 BL/WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
3 Not Used
4 X-9138B (Receptacle) pin 35 - EN-9097 EN-9097 PRP - 0.5 SHEET 06 SH06 - ENGINE CONTROL
5 X-9138B (Receptacle) pin 30 - EN-9096 EN-9096 GY/OR - 0.75 SHEET 06 SH06 - ENGINE CONTROL
6 X-9138B (Receptacle) pin 33 - EN-9094 EN-9094 BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
X-9011 - THROTTLE VALVE ACTUATOR [ Z-9001] (84360293) (Receptacle)
84360293 6
84360293
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1 X-9138B (Receptacle) pin 41 - EN-9098 EN-9098 BR/BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 38 - EN-9135 EN-9135 BL/OR - 0.75 SHEET 06 SH06 - ENGINE CONTROL
3 X-9138B (Receptacle) pin 43 - EN-9100 EN-9100 WH/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
4 Not Used
5 X-9138B (Receptacle) pin 42 - EN-9099 EN-9099 BL/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
6 X-9138B (Receptacle) pin 37 - EN-9134 EN-9134 OR/GN - 0.75 SHEET 06 SH06 - ENGINE CONTROL
X-9016 - OIL PRESSURE SWITCH [ S-9016] (87687239) (Plug)
87687239 7
87687239
1 X-9138B (Receptacle) pin 3 - EN-9105 EN-9105 GY/BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
X-9018 - EXHAUST GAS ABSOLUTE PRESSURE SE [ B-9005] (84146681) (Plug)
84146681 8
84146681
1 X-9138B (Receptacle) pin 21 - EN-9143 EN-9143 GY/YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 22 - EN-9118 EN-9118 BR - 0.5 SHEET 05 SH05 - ENGINE CONTROL
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3 X-9138B (Receptacle) pin 23 - EN-9120 EN-9120 WH/BL - 0.5 SHEET 05 SH05 - ENGINE CONTROL
X-9021 - INCREMENT SPEED SENSOR (CRANKSHA [ B-9007] (Not Serviceable) (Plug)

X-9026 - RAIL PRESSURE SENSOR (P) [ B-9004] (84146683) (Receptacle)
84146683 9
84146683
1 X-9138B (Receptacle) pin 5 - EN-9106 EN-9106 GN/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 6 - EN-9107 EN-9107 YE/BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
3 X-9138B (Receptacle) pin 7 - EN-9108 EN-9108 GY/GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
X-9030 - INJECTOR 1 [ Y-9001] (Not Serviceable) (Plug)

1 X-9139B (Receptacle) pin INJ-268 INJ-268 BL - 1.5 SHEET 06 SH06 - ENGINE CONTROL
A - ENGINE INJECTORS
HARNESS TO VEHI (Not
Serviceable)
X-9030A - INJECTOR 1 [ Y-9001] (Not Serviceable) (Plug)

1 Not Used
2 X-9139B (Receptacle) pin INJ-269 INJ-269 BR - 1.5 SHEET 06 SH06 - ENGINE CONTROL
B - ENGINE INJECTORS
Serviceable)

1 X-9139B (Receptacle) pin INJ-270 INJ-270 PRP - 1.5 SHEET 06 SH06 - ENGINE CONTROL
D - ENGINE INJECTORS
Serviceable)
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1 Not Used
2 X-9139B (Receptacle) pin INJ-271 INJ-271 WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
C - ENGINE INJECTORS
Serviceable)

1 X-9139B (Receptacle) pin INJ-572 INJ-572 OR/BL - 1.5 SHEET 06 SH06 - ENGINE CONTROL
E - ENGINE INJECTORS
Serviceable)

1 Not Used
2 X-9139B (Receptacle) pin INJ-573 INJ-573 GN/PRP - 1.5 SHEET 06 SH06 - ENGINE CONTROL
F - ENGINE INJECTORS
Serviceable)

1 X-9139B (Receptacle) pin INJ-574 INJ-574 YE/OR - 1.5 SHEET 06 SH06 - ENGINE CONTROL
H - ENGINE INJECTORS
Serviceable)

1 Not Used
2 X-9139B (Receptacle) pin INJ-575 INJ-575 GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
G - ENGINE INJECTORS
Serviceable)
X-9034 - GLOW PLUG - CYLINDER 1 [ R-9001] (1-928-404-879) (Plug)
1-928-404-879 10
1-928-404-879
1 X-9040B (Plug) pin 4 - (Not GP-9001 GP-9001 GN/WH - 2.5 SHEET 05 SH05 - ENGINE CONTROL
Serviceable)
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1-928-404-879 11
1-928-404-879
1 X-9040B (Plug) pin 3 - (Not GP-9002 GP-9002 YE - 2.5 SHEET 05 SH05 - ENGINE CONTROL
Serviceable)
1-928-404-879 12
1-928-404-879
1 X-9040B (Plug) pin 2 - (Not GP-9003 GP-9003 PRP - 2.5 SHEET 05 SH05 - ENGINE CONTROL
Serviceable)
1-928-404-879 13
1-928-404-879
1 X-9040B (Plug) pin 1 - (Not GP-9004 GP-9004 BL - 2.5 SHEET 05 SH05 - ENGINE CONTROL
Serviceable)
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X-9038 - WASTEGATE PRESSURE MODULATOR VAL [ Y-9008] (Not Serviceable) (Plug)

1 X-9138B (Receptacle) pin 28 - EN-9024 EN-9024 WH/BR - 0.75 SHEET 06 SH06 - ENGINE CONTROL
2 X-9138B (Receptacle) pin 27 - EN-9133 EN-9133 RD - 0.75 SHEET 06 SH06 - ENGINE CONTROL
X-9040A - (Not Serviceable) (Receptacle)

3 X-9138B (Receptacle) pin 60 - EN-9059 EN-9059 YE - 2.5 SHEET 05 SH05 - ENGINE CONTROL
4 X-9138B (Receptacle) pin 61 - EN-9058 EN-9058 GN/WH - 2.5 SHEET 05 SH05 - ENGINE CONTROL
X-9040B - (Not Serviceable) (Plug)

1 X-9037 (Plug) pin 1 - GLOW GP-9004 GP-9004 BL - 2.5 SHEET 05 SH05 - ENGINE CONTROL
PLUG - CYLINDER 4 [R-9004]
(1-928-404-879)
2 X-9036 (Plug) pin 1 - GLOW GP-9003 GP-9003 PRP - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(1-928-404-879)
3 X-9035 (Plug) pin 1 - GLOW GP-9002 GP-9002 YE - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(1-928-404-879)
4 X-9034 (Plug) pin 1 - GLOW GP-9001 GP-9001 GN/WH - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(1-928-404-879)
X-9138B - ENGINE SENSOR HARNESS TO VEHICLE (84154706) (Receptacle)
84154706 14
84154706
1 X-9007 (Plug) pin 1 - FUEL EN-9137 EN-9137 PRP/WH - SHEET 06 SH06 - ENGINE CONTROL
METERING UNIT HP FUEL 0.75
PUMP [Y-9000] (87709798)
2 X-9007 (Plug) pin 2 - FUEL EN-9136 EN-9136 OR/WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
METERING UNIT HP FUEL
PUMP [Y-9000] (87709798)
3 X-9016 (Plug) pin 1 - OIL EN-9105 EN-9105 GY/BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
PRESSURE SWITCH [S-9016]
(87687239)
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4 X-9008 (Plug) pin 2 - EN-9111 EN-9111 GY - 0.5 SHEET 06 SH06 - ENGINE CONTROL
SEGMENT SPEED SENSOR
(CAMSHAFT)â [B-9017] (Not
Serviceable)
5 X-9026 (Receptacle) pin 1 - EN-9106 EN-9106 GN/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
RAIL PRESSURE SENSOR
(P) [B-9004] (84146683)
6 X-9026 (Receptacle) pin 2 - EN-9107 EN-9107 YE/BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(P) [B-9004] (84146683)
7 X-9026 (Receptacle) pin 3 - EN-9108 EN-9108 GY/GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
(P) [B-9004] (84146683)
8 X-9008 (Plug) pin 1 - EN-9110 EN-9110 PRP/GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
9 X-9021 (Plug) pin 1 - EN-9113 EN-9113 BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
INCREMENT SPEED
SENSOR (CRANKSHA
10 X-9021 (Plug) pin 2 - EN-9112 EN-9112 PRP - 0.5 SHEET 06 SH06 - ENGINE CONTROL
INCREMENT SPEED
SENSOR (CRANKSHA
11 Not Used
12 X-9008 (Plug) pin 3 - EN-9109 EN-9109 WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
13 X-9006 (Receptacle) pin 2 - EN-9114 EN-9114 GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
COOLANT TEMPERATURE
SENSOR (T) [B-9003]
(87709793)
14 X-9006 (Receptacle) pin 1 - EN-9115 EN-9115 YE - 0.5 SHEET 06 SH06 - ENGINE CONTROL
COOLANT TEMPERATURE
SENSOR (T) [B-9003]
(87709793)
15 X-9005 (Receptacle) pin EN-9116 EN-9116 PK - 0.5 SHEET 06 SH06 - ENGINE CONTROL
2 - FUEL TEMPERATURE
SENSOR (T) [B-9002]
(87709793)
16 X-9005 (Receptacle) pin EN-9117 EN-9117 BR/WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
1 - FUEL TEMPERATURE
SENSOR (T) [B-9002]
(87709793)
17 X-9003 (Plug) pin 3 - EN-9102 EN-9102 PRP/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
BOOST PRESSURE AND
TEMPERATURE S [B-9001]
(87709809)
18 X-9003 (Plug) pin 4 - EN-9101 EN-9101 BL/BR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
BOOST PRESSURE AND
(87709809)
19 X-9003 (Plug) pin 1 - EN-9103 EN-9103 BR/PRP - 0.5 SHEET 06 SH06 - ENGINE CONTROL
BOOST PRESSURE AND
(87709809)
20 X-9003 (Plug) pin 2 - EN-9104 EN-9104 WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
BOOST PRESSURE AND
(87709809)
21 X-9018 (Plug) pin 1 - EN-9143 EN-9143 GY/YE - 0.5 SHEET 05 SH05 - ENGINE CONTROL
EXHAUST GAS ABSOLUTE
PRESSURE SE [B-9005]
(84146681)
22 X-9018 (Plug) pin 2 - EN-9118 EN-9118 BR - 0.5 SHEET 05 SH05 - ENGINE CONTROL
(84146681)
23 X-9018 (Plug) pin 3 - EN-9120 EN-9120 WH/BL - 0.5 SHEET 05 SH05 - ENGINE CONTROL
(84146681)
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24 Not Used
25 X-9009 (Plug) pin 2 - EN-9119 EN-9119 YE/BR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
EXHAUST MANIFOLD
TEMPERATURE SEN [B-9018]
(Not Serviceable)
26 X-9009 (Plug) pin 1 - EN-9121 EN-9121 WH/GN - 0.5 SHEET 06 SH06 - ENGINE CONTROL
EXHAUST MANIFOLD
TEMPERATURE SEN [B-9018]
(Not Serviceable)
27 X-9038 (Plug) pin 2 - EN-9133 EN-9133 RD - 0.75 SHEET 06 SH06 - ENGINE CONTROL
WASTEGATE PRESSURE
MODULATOR VAL [Y-9008]
(Not Serviceable)
28 X-9038 (Plug) pin 1 - EN-9024 EN-9024 WH/BR - 0.75 SHEET 06 SH06 - ENGINE CONTROL
WASTEGATE PRESSURE
MODULATOR VAL [Y-9008]
(Not Serviceable)
29 X-9010 (Receptacle) EN-9095 EN-9095 BL/WH - 0.75 SHEET 06 SH06 - ENGINE CONTROL
pin 1 - EXHAUST GAS
RECIRCULATION (EGR)
[Z-9000] (84360293)
30 X-9010 (Receptacle) EN-9096 EN-9096 GY/OR - 0.75 SHEET 06 SH06 - ENGINE CONTROL
pin 5 - EXHAUST GAS
RECIRCULATION (EGR)
[Z-9000] (84360293)
31 Not Used
32 Not Used
33 X-9010 (Receptacle) EN-9094 EN-9094 BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
pin 6 - EXHAUST GAS
RECIRCULATION (EGR)
[Z-9000] (84360293)
34 X-9010 (Receptacle) EN-9093 EN-9093 BL/WH - 0.5 SHEET 06 SH06 - ENGINE CONTROL
pin 2 - EXHAUST GAS
RECIRCULATION (EGR)
[Z-9000] (84360293)
35 X-9010 (Receptacle) EN-9097 EN-9097 PRP - 0.5 SHEET 06 SH06 - ENGINE CONTROL
pin 4 - EXHAUST GAS
RECIRCULATION (EGR)
[Z-9000] (84360293)
36 Not Used
37 X-9011 (Receptacle) pin EN-9134 EN-9134 OR/GN - 0.75 SHEET 06 SH06 - ENGINE CONTROL
6 - THROTTLE VALVE
ACTUATOR [Z-9001]
(84360293)
38 X-9011 (Receptacle) pin EN-9135 EN-9135 BL/OR - 0.75 SHEET 06 SH06 - ENGINE CONTROL
2 - THROTTLE VALVE
ACTUATOR [Z-9001]
(84360293)
39 Not Used
40 Not Used
41 X-9011 (Receptacle) pin EN-9098 EN-9098 BR/BL - 0.5 SHEET 06 SH06 - ENGINE CONTROL
1 - THROTTLE VALVE
ACTUATOR [Z-9001]
(84360293)
42 X-9011 (Receptacle) pin EN-9099 EN-9099 BL/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
5 - THROTTLE VALVE
ACTUATOR [Z-9001]
(84360293)
43 X-9011 (Receptacle) pin EN-9100 EN-9100 WH/OR - 0.5 SHEET 06 SH06 - ENGINE CONTROL
3 - THROTTLE VALVE
ACTUATOR [Z-9001]
(84360293)
44 Not Used
45 Not Used
46 Not Used
47 Not Used
48 Not Used
49 Not Used
50 Not Used
51 Not Used
52 Not Used
53 Not Used
54 Not Used
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55 Not Used
56 Not Used
57 X-9040A (Receptacle) pin 1 - EN-9061 EN-9061 BL - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(Not Serviceable)
58 X-9040A (Receptacle) pin 2 - EN-9060 EN-9060 PRP - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(Not Serviceable)
59 Not Used
60 X-9040A (Receptacle) pin 3 - EN-9059 EN-9059 YE - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(Not Serviceable)
61 X-9040A (Receptacle) pin 4 - EN-9058 EN-9058 GN/WH - 2.5 SHEET 05 SH05 - ENGINE CONTROL
(Not Serviceable)
X-9139B - ENGINE INJECTORS HARNESS TO VEHI (Not Serviceable) (Receptacle)

A X-9030 (Plug) pin 1 - INJ-268 INJ-268 BL - 1.5 SHEET 06 SH06 - ENGINE CONTROL
INJECTOR 1 [Y-9001] (Not
Serviceable)
B X-9030A (Plug) pin 2 - INJ-269 INJ-269 BR - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
C X-9031A (Plug) pin 2 - INJ-271 INJ-271 WH - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
D X-9031 (Plug) pin 1 - INJ-270 INJ-270 PRP - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
E X-9032 (Plug) pin 1 - INJ-572 INJ-572 OR/BL - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
F X-9032A (Plug) pin 2 - INJ-573 INJ-573 GN/PRP - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
G X-9033A (Plug) pin 2 - INJ-575 INJ-575 GY - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
H X-9033 (Plug) pin 1 - INJ-574 INJ-574 YE/OR - 1.5 SHEET 06 SH06 - ENGINE CONTROL
Serviceable)
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Index

Electrical components - ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical components - ECU description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electrical components - Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical components - Fuse description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical components - Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical components - Ground description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical components - Lamp description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical components - Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical components - Motor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Electrical components - Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical components - Power outlet description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical components - Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical components - Relay description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Electrical components - Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical components - Resistor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical components - Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical components - Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Electrical components - Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical components - Solenoid description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electrical components - Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical components - Speaker description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical components - Sub-Assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Electrical components - Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical components - Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical components - Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical components - Voltage source description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wire connectors - Component diagram 00 Connector X-000 to X-009 . . . . . . . . . . . . . . . . . . . . . . . . . 153
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Wiring harnesses - Electrical schematic sheet 02 SH02 - POWER DISTRIBUTION / CHARGING
SYSTEM / STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wiring harnesses - Electrical schematic sheet 03 SH03 - POWER DISTRIBUTION . . . . . . . . . . . . . 100
Wiring harnesses - Electrical schematic sheet 03 SH03 - POWER DISTRIBUTION / CHARGING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wiring harnesses - Electrical schematic sheet 04 SH04 - GROUNDING . . . . . . . . . . . . . . . . . . . . . . . 102
Wiring harnesses - Electrical schematic sheet 04 SH04 - STARTING SYSTEM . . . . . . . . . . . . . . . . . 58
Wiring harnesses - Electrical schematic sheet 05 SH05 - COLD START SYSTEM . . . . . . . . . . . . . . 60
Wiring harnesses - Electrical schematic sheet 05 SH05 - ENGINE CONTROL . . . . . . . . . . . . . . . . . 104
Wiring harnesses - Electrical schematic sheet 06 SH06 - GROUNDING . . . . . . . . . . . . . . . . . . . . . . . 62
Wiring harnesses - Electrical schematic sheet 08 SH08 - DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Wiring harnesses - Electrical schematic sheet 08 SH08 - EXAUST SYTEM AND CAN BUS . . . . . . 110
Wiring harnesses - Electrical schematic sheet 09 SH09 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . 68
Wiring harnesses - Electrical schematic sheet 09 SH09 - PRE START . . . . . . . . . . . . . . . . . . . . . . . . 112
Wiring harnesses - Electrical schematic sheet 10 SH10 - DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Wiring harnesses - Electrical schematic sheet 10 SH10 - FRONT LIGHTING 1 . . . . . . . . . . . . . . . . . 70
Wiring harnesses - Electrical schematic sheet 11 SH11 - FRONT LIGHTING . . . . . . . . . . . . . . . . . . . 72
Wiring harnesses - Electrical schematic sheet 11 SH11 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . 116
Wiring harnesses - Electrical schematic sheet 12 SH12 - FRONT DRIVING LIGHTS . . . . . . . . . . . . 118
Wiring harnesses - Electrical schematic sheet 12 SH12 - REAR LIGHTING . . . . . . . . . . . . . . . . . . . . 74
Wiring harnesses - Electrical schematic sheet 13 SH13 - REAR DRIVING LIGHTS . . . . . . . . . . . . . 120
Wiring harnesses - Electrical schematic sheet 13 SH13 - WIPER/WASHER . . . . . . . . . . . . . . . . . . . 76
Wiring harnesses - Electrical schematic sheet 14 SH14 - FRONT WORK LIGHTS . . . . . . . . . . . . . . 122
Wiring harnesses - Electrical schematic sheet 14 SH14 - INSTRUMENT CLUSTER / SPEEDOME-
TER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Wiring harnesses - Electrical schematic sheet 15 SH15 - HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Wiring harnesses - Electrical schematic sheet 15 SH15 - REAR WORK LIGHTS . . . . . . . . . . . . . . . 124
Wiring harnesses - Electrical schematic sheet 16 SH16 - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 82
Wiring harnesses - Electrical schematic sheet 16 SH16 - HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Wiring harnesses - Electrical schematic sheet 17 SH17 - CAB FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Wiring harnesses - Electrical schematic sheet 17 SH17 - DOME LIGHT . . . . . . . . . . . . . . . . . . . . . . . 128
Wiring harnesses - Electrical schematic sheet 18 SH18 - AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wiring harnesses - Electrical schematic sheet 18 SH18 - WIPER/WASHER . . . . . . . . . . . . . . . . . . . 130
Wiring harnesses - Electrical schematic sheet 19 SH19 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Wiring harnesses - Electrical schematic sheet 19 SH19 - INSTRUMENT CLUSTER . . . . . . . . . . . . 132
Wiring harnesses - Electrical schematic sheet 20 SH20 - DOME LIGHT . . . . . . . . . . . . . . . . . . . . . . . 90
Wiring harnesses - Electrical schematic sheet 20 SH20 - PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . 134
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Wiring harnesses - Electrical schematic sheet 21 SH21 - MOBILE CHARGER . . . . . . . . . . . . . . . . . 92
Wiring harnesses - Electrical schematic sheet 21 SH21 - SPEEDOMETER . . . . . . . . . . . . . . . . . . . . 136
Wiring harnesses - Electrical schematic sheet 22 SH22 - MOBILE CHARGER . . . . . . . . . . . . . . . . . 138
Wiring harnesses - Electrical schematic sheet 22 SH22 - TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . 94
Wiring harnesses - Electrical schematic sheet 23 SH23 - CAB FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Wiring harnesses - Electrical schematic sheet 24 SH24 - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 142
Wiring harnesses - Electrical schematic sheet 25 SH25 - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Wiring harnesses - Electrical schematic sheet 26 SH26 - AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Wiring harnesses - Electrical schematic sheet 28 SH28 - DIAGNOSTIC/CAN BUS . . . . . . . . . . . . . 150
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Engine starting system - 201
851FX Plus
851FX
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Contents
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Engine starting system
Engine starter - Remove

NOTE: The starter is located on the engine flywheel hous-
ing.
and lock the support strut (1) to hold the loader. Stop
the engine and apply the parking brake.
PTIL13TLB1190AB 1
2. Remove the battery cover on the right hand step of the

machine.
3. Remove the negative battery cable (1) from the battery.
Move the cable away from the battery terminals.
4. Remove the positive battery cable (2) from the battery.
Move the cable away from the battery terminals.
PTIL21TLB0192AB 2
5. Open the hood.

6. Tag and disconnect the wires and cables from the ter-
minals on the starter.
NOTE: Starter wire is coated with RTV silicone sealant.
7. Remove the bolts (1) that fasten the starter (2) to the
flywheel housing.
8. Remove the starter.
PTIL13TLB1193AB 3
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Electrical systems - Engine starting system
Engine starter - Install

1. Put the starter (2) in place on the flywheel housing.
2. Install the bolts (1) that fasten the starter to the flywheel
housing.
3. Make sure the ground cable is installed under the upper
bolt.
4. Torque bolts to 40 N·m (29.50 lb ft).
5. Connect the wires and cables to the terminals on the
starter.
6. Cover the starter wire terminal with 737 RTV silicone
sealant.
PTIL13TLB1193AB 1
NOTICE: Use only 737 RTV silicone sealant. Other
sealants can corrode the terminal.
7. Close the hood.
8. Reconnect the positive battery cable (1) to the battery.
9. Reconnect the negative battery cable (2) to the battery.
10. Install the battery cover.
PTIL21TLB0192AB 2
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Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Alternator - 301
851FX Plus
851FX
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55.4 [55.301] / 1
Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Alternator
Alternator - Remove
WARNING
Maintenance hazard!
The engine must be OFF when you loosen or tighten alternator mounting bolts.
W1096A

ing brake.
2. Raise the loader to upright position and lock it using the
locking strut.
3. Disconnect the battery negative terminal, see Battery
Basic instructions () .
4. Open the engine hood, see Hood - Remove (90.100).
PTIL21TLB0164AA 1
5. Open the electrical insulator (1) from the alternator.
PTIL21TLB0210AA 2
6. Loosen and remove the nut (2) and disconnect the elec-
trical terminal (3) from the alternator.
PTIL21TLB0211AA 3
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7. Loosen the alternator adjusting bolt (4) and mounting

bolt (5) along with nut.
8. Push the alternator towards engine to release the belt
tension and remove the drive belt (6).
9. Remove the alternator adjusting bolt (4) and mounting
bolt (5) along with nut and remove the alternator (7).
PTIL21TLB0212AA 4
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Alternator - Install
WARNING
Maintenance hazard!
The engine must be OFF when you loosen or tighten alternator mounting bolts.
W1096A
1. Position the alternator (7) with the adjusting bracket

and mounting bracket.
2. Install the adjusting bolt (4) and mounting bolt (5) along
with nut to the alternator.
3. Adjust the belt tension, see Pump drive belts - Adjust
(10.114).
4. Tighten the mounting nut (5) to a torque of 85 – 115 N·m
(63 – 85 lb ft).
PTIL21TLB0212AA 1
5. Connect the electrical terminal (3) to the alternator and

secure with the nut (2).
PTIL21TLB0211AA 2
6. Close the electrical insulator (1) to the alternator.

7. Close the engine hood, see Hood - Install (90.100).
8. Connect the battery negative terminal, see Battery Ba-
sic instructions () .
9. Start the engine and lower the loader arm.
PTIL21TLB0210AA 3
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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Fuel tank system - 011
851FX Plus
851FX
91715732 26/07/2021
55.5 [55.011] / 1
Contents
FUNCTIONAL DATA
Fuel level sensor

SERVICE
Fuel level sensor

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSTIC
Fuel level sensor

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Fuel tank system
Fuel level sensor - Component identification
PTIL21TLB0424FB 1
1. Float 4. Support plate

2. Lever rod 5. Flange
3. TFR 6 Output connector
Specification
Float position Empty Reserve Full
Resistance value 120 Ω 100 Ω 8Ω
Tolerance ±2 ±3 ±2
Height 22.5 mm 65.8 mm 387 mm
Volume 9.2 L 25 L 142.2 L
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Fuel level sensor - Cleaning

Before cleaning Fuel Level Sensor (FLS)
1. Connect the multimeter (1) to the fuel level sensor (2)
and switch “ON” the multimeter in resistance mode.
2. Hold the FLS flange (3) by one hand and use the other
hand to slowly lift up the float lever rod (4).
3. To verify the resistance error value in the multimeter,
reading in multimeter shows erratic where the black
deposition occurs.
Example: Multimeter showing kilo ohms (or) OL display,
see image 1.
PTIL21TLB0430BB 1
Fuel Level Sensor (FLS) cleaning method

4. Black deposition over TFR - Before cleaning.
PTIL21TLB0425AB 2
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5. Use soft hair bristle brush as shown in the image 3.
PTIL21TLB0426AB 3
6. Dip the brush in the petrol.
PTIL21TLB0427AB 4
7. Clean the TFR track (1) gently and flash with petrol or
diesel.
NOTE: Don’t disturb the spring contact during TFR clean-
ing.
PTIL21TLB0428AB 5
8. Black deposition over TFR - After cleaning.
PTIL21TLB0429AB 6
NOTE: If the cleaning solution applied on the TFR with brush, then the contact surface will also gets cleaned by wiped
in the tracks.
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Fuel level sensor - Check

Prior operation:
See Fuel level sensor - Cleaning (55.011).
Do's & Don'ts

Do's Don'ts
Use the multimeter to check continuity and output Don’t use the battery supply voltage for checking
resistance value. (Use resistance mode in the multi continuity and resistance value.
meter)
Use only proper tools to disassemble / assemble the Do not use oversize / under size tools to disassemble /
Fuel level sensor (FLS) in the vehicle. assemble. This may cause the damages of nuts and
screws.
Always use proper torque value to tighten the FLS in Excess tightening torque damages the flange and lower
the tank. torque leads to loosening of FLS in the vehicle vibration.
Use the soft hair bristle brush to clean the TFR in the Don’t use wire bristle brush / scratch brush / hard tool
FLS. to clean TFR track. This leads to TFR worn-out and
improper / not working of FLS.
Performance check after FLS cleaning

See Fuel level sensor - Troubleshooting (55.011).
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Fuel level sensor - Troubleshooting

Fuel level sensor (FLS) - Black deposition occurs. 1. Clean the fuel level sensor, see Fuel
Resistance error level sensor - Cleaning (55.011).
2. After the cleaning process, connect
the multimeter to fuel level sensor and
switch “ON” the multimeter in resis-
tance Mode.
3. To verify the resistance value is at lever
rod with down position, then resistance
value observed was 120 +/- 2 Ω.
4. Holding the FLS flange by one hand,
use the other hand to slowly lift up the
float lever rod.
5. The resistance value slowly decreasing
from 120 +/- 2 Ω to 8 +/- 2 Ω at lever rod
top position.
6. After slowly down the lever rod, observe
the resistance value to 8 +/- 2 Ω and
increasing to 120 +/- 2 Ω.
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Index

Fuel level sensor - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel level sensor - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel level sensor - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel level sensor - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Wiper and washer system - 518
851FX Plus
851FX
91715732 26/07/2021
55.6 [55.518] / 1
Contents
SERVICE
Windshield wiper motor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Wiper and washer system
Windshield wiper motor - Remove

1. Unscrew the hexagonal bolts (1) to remove the wiper
motor from the machine.
PTIL13TLB1755AB 1
2. Secure the hexagonal bolt (1), washer (2) and lock

washer (3) in safe place for easy retrieval.
PTIL13TLB1756AB 2
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Electrical systems - Wiper and washer system
Windshield wiper motor - Install

1. Using hexagonal bolt (1), washer (2) and lock washer
(3) align the wiper motor to the cabin panel.
PTIL13TLB1756AB 1
2. Install the wiper motor by tightening the bolts (1).
PTIL13TLB1755AB 2
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Index

Windshield wiper motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Windshield wiper motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Front loader and bucket
851FX Plus
851FX
91715732 26/07/2021
82
Contents
Front loader and bucket - 82
[82.100] Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1
[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2
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Arm - 100
851FX Plus
851FX
91715732 26/07/2021
82.1 [82.100] / 1
Contents
Arm - 100
SERVICE
Front loader arm

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove - (Bent loader arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - (Bent loader arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Front loader and bucket - Arm
Front loader arm - Remove

Remove loader bucket. Refer to Bucket - Remove
(82.300).
Remove loader cylinder. Refer to Loader bucket con-
trol cylinder - Remove (35.723).
Remove loader lift cylinder. Refer to Lift arm cylinder
- Remove (35.701).
1. Lower the loader assembly to the ground and attach a
suitable lifting device.
PTIL14TLB0136AA 1
2. Disconnect the linkages (1) by removing the retainer

bracket bolts (2) and washers from the right hand side
of the loader frame.
PTIL13TLB0470AB 2
3. Remove the retainer bracket (1), shims (2), washers (3)

and bolt (4).
PTIL13TLB0471AB 3
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4. Remove the pivot bolt (1), shim (2) and washer (3) from
the left hand side of the loader frame.
PTIL13TLB0472AB 4
5. Remove the locking bolt (1) located at the loader frame

center to release the pivot pin.
PTIL13TLB0473AB 5
6. Tap and remove the pivot pin (1) using a mandrel and
wooden hammer to slide the loader from the machine.
PTIL13TLB0474AB 6
7. Lift the suspending loader frame assembly (1) using the

attached lifting device and place it aside.
PTIL13TLB0476AB 7
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Front loader arm - Install

1. Lift the suspending loader frame assembly (1) using
the attached lifting device and position on the machine
frame.
PTIL13TLB0476AB 1
2. Tap and install the pivot pin (1) using a wooden hammer
to attach the loader to the machine.
PTIL13TLB0474AB 2
3. Install the locking bolt (1) located at the loader frame

center to fix the pivot pin.
PTIL13TLB0473AB 3
4. Install the pivot bolt (1), shim (2) and washer (3) from
the left hand side of the loader frame.
PTIL13TLB0472AB 4
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5. Install the retainer bracket (1), shims (2) and washers

(3) on the right hand side of the machine.
moval.
PTIL13TLB0471AB 5
6. Connect the linkages (1) by installing the retainer

bracket bolt (2) and washer on the loader frame using
LOCTITE® 242®. Torque: 186 N·m (137 lb ft).
PTIL13TLB0470AB 6
7. Install the loader bucker. Refer to Bucket - Install

(82.300).
8. Install loader lift cylinder. Refer Lift arm cylinder -
Install (35.701).
9. Install loader cylinder. Refer Loader bucket control
cylinder - Install (35.723).
10. Release the lifting device and lower the loader assem-
bly to the ground.
PTIL14TLB0136AA 7
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Front loader arm - Remove - (Bent loader arm)

Prior operation:
Remove the loader bucket.
1. Fully retract bucket cylinders and raise arm until lift

cylinder pivots can be seen above engine guard.
2. Support the loader arm with a suitable stand under the
end of the arm.
3. Turn off the engine and relieve hydraulic pressure.
LELI12TLB2543AA 1
4. Remove the safety pins (2) and drive out the pins (1).
Detach the cylinder rod end from the loader arm.
LELI12TLB2544AB 2
5. Remove the snap rings (3) and drive out the pins (4) .
Detach the Idler link from the loader arm.
LELI12TLB2545AB 3
6. Disconnect and cap the lift cylinder hoses (5) at the top
of the loader arm on each side of the machine.
7. If the 4x1 bucket is fitted, disconnect and cap hose (6)
on each side of the loader.
LELI12TLB2546AB 4
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8. Support loader using a suitable lifting device.
LELI12TLB2548A 5
9. Remove the safety ring and pins. Pull out the pin (7).
LELI12TLB2549AB 6
10. Remove the loader from the machine.
LELI12TLB2550AA 7
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Front loader arm - Install - (Bent loader arm)

1. Support loader using a suitable lifting device and align
the mounting hole with the chassis hole.
LELI12TLB2548A 1
2. Install the safety pin (1) and secure it with safety rings
(2).
LELI12TLB2549AB 2
3. Install the lift cylinder hoses (3) at the top of the loader
arm on each side of the machine with a torque of
65 N·m.
4. If the 4x1 bucket is fitted, Install the hose (4) on each
side of the loader with a torque of 100 N·m.
LELI12TLB2546AB 3
5. Align the idler link to the loader arm. Install the pins (5)
and secure them by snap rings (6).
LELI12TLB2545AB 4
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6. Align the cylinder rod end to the loader arm. Install the
pins (7) and secure them by snap rings (8).
LELI12TLB2544AB 5
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Index
Arm - 100
Front loader arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front loader arm - Install - (Bent loader arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front loader arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front loader arm - Remove - (Bent loader arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Bucket - 300
851FX Plus
851FX
91715732 26/07/2021
82.2 [82.300] / 1
Contents
Bucket - 300
SERVICE
Bucket
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Front loader and bucket - Bucket
Bucket - Remove
1. Move the machine to a level and firm ground.
2. Lower the bucket to the ground in dump position (tilted
completely forward).
3. Stop the engine and remove the starter switch key.
4. Remove the retaining rings and pins and drive out the
pins (1).
PTIL12TLB0149AB 1
If fitted with bottom dump bucket:

5. If the machine is fitted with a bottom dump bucket, re-
lease the pressure form the bucket circuit.
6. Retain the rear cylinders (1) and pins safely in a secure
place.
7. Remove the pins (2) from the lower end of the bucket on
both sides after releasing and disconnecting pressure
from the hydraulic lines.
8. Loosen and remove the grease nipples (3) from the
upper joint of the bucket.
ATTENTION: Do not stand in the way of the bucket which
may roll on the foot and cause serious injury.
PTIL13TLB1769AB 2
NOTE: Always wear eye protection when using a tool
which might project metal particles. Use a hammer with a
soft face, such as copper, for pins assembly/disassembly.
9. Remove the pin (4) by hammering from one end.
10. Retain the cylinder (5) and pins from both sides of the
bucket.
12. Operate the attachment controls so as to release the
bucket.
13. Reverse the machine from the bucket.
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Front loader and bucket - Bucket
Bucket - Install
1. Make sure all bushings are completely clean.
2. Remove any dirt or foreign matter, if necessary.
4. Use the attachment controls to engage the attachment
between the bucket lugs.
PTIL12TLB0149AB 1
If fitted with bottom dump bucket:

5. Follow the same procedure of “ Bucket - Remove
(82.300)” in reverse order for installation.
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Index
Bucket - 300
Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bucket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Booms, dippers, and buckets
851FX Plus
851FX
91715732 26/07/2021
84
Contents
Booms, dippers, and buckets - 84
[84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1
[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2
[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3
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84
Boom pivoting support - 114
851FX Plus
851FX
91715732 26/07/2021
84.1 [84.114] / 1
Contents
SERVICE
Sliding support
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Booms, dippers, and buckets - Boom pivoting support
Sliding support - Remove

1. Remove the boom from the swing tower.
Refer Boom - Remove (84.910).
2. Disconnect all the hydraulic lines (1) from the backhoe
control valve to the swing cylinders (2).
3. Cap the oil ports and the control valve hydraulic lines
immediately.
4. Disconnect the hydraulic lines to the locking pistons.
PTIL13TLB0466AB 1
5. Attach a suitable lifting device to the slide frame before

proceeding.
PTIL13TLB0467AA 2
6. Remove the slide frame mounting bolts (1) from the

retainer plate (2).
Lift the slide frame along with the swing cylinders from
the machine and place it aside securely.
PTIL13TLB0468AB 3
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Booms, dippers, and buckets - Boom pivoting support
Sliding support - Install

1. Place the slide frame along with the swing cylinders on
the machine.
2. Install the slide frame mounting bolts (1) to the re-
tainer plate (2). Tighten to the torque of 75.00 kgm
(542.48 ftlbs.).
PTIL13TLB0468AB 1
3. Release the lifting device from the slide frame.
PTIL13TLB0467AA 2
4. Connect the hydraulic lines (1) and hoses from the con-
trol valve to the swing cylinders (2).
5. Install the boom to the swing tower. Refer to Boom -
Install (84.910).
PTIL13TLB0466AB 3
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Index

Sliding support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sliding support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Boom - 910
851FX Plus
851FX
91715732 26/07/2021
84.2 [84.910] / 1
Contents
Boom - 910
SERVICE
Boom
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Booms, dippers, and buckets - Boom
Boom - Remove
1. Stretch the backhoe attachment on the ground.
2. Attach a suitable lifting device to the boom and support
the arm.
3. Remove boom cylinder. Refer to Boom cylinder - Re-
move (35.736).
4. Remove arm cylinder. Refer to Dipper cylinder - Re-
move (35.737), Dipper arm - Remove (84.912).
PTIL13TLB0461AA 1
5. Disconnect the hydraulic lines (1) from the control

valves to the cylinders and tag them immediately.
6. Remove the hydraulic lines fitment attached to the
boom frame.
PTIL13TLB0462AB 2
7. Remove the retainer bracket bolt (1) and washer from

the boom end connecting the swing tower.
PTIL13TLB0463AB 3
8. Disconnect the boom from the dipper by removing the

retainer bracket (1) and disconnecting the hydraulic
lines from the bucket cylinder.
NOTE: Cap the hydraulic lines and plugs immediately after
removal.
NOTE: Ensure to collect the shims for easy retainment dur-
ing installation.
PTIL13TLB1525AB 4
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84.2 [84.910] / 3
9. Tap the retainer bracket (1) from the other side using a
wooden hammer and remove it to free the boom from
the machine. Repeat procedure for other side pin also.
PTIL13TLB0464AB 5
10. Using a lifting device move the boom assembly and

place it securely in a place.
PTIL13TLB0465AA 6
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Boom - Install
1. Using a lifting device move the boom assembly and
position it on the machine carefully.
PTIL13TLB0465AA 1
2. Tap the retainer bracket (1) and pivot into the boom
using a wooden hammer and install it to fix one end
of the boom to the swing tower.
PTIL13TLB0464AB 2
3. Tighten the retainer bracket bolt (1) and washer to the

boom end connecting the swing tower using LOCTITE®
242®. Torque: 186 N·m (137 lb ft).
Repeat the procedure for both pins.
moval.
PTIL13TLB0463AB 3
4. Connect the boom to the dipper by installing the re-

tainer bracket bolt (1), washer and connect the hy-
draulic lines to the bucket cylinder LOCTITE® 242®.
PTIL13TLB1525AB 4
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5. Install all the hydraulic fitments to the boom frame.

6. Connect the hydraulic lines (1) from the cylinders to the
control valves.
PTIL13TLB0462AB 5
7. Install arm cylinder. Refer to Dipper cylinder - Install

(35.737), Dipper arm - Install (84.912).
8. Install boom cylinder. Refer to Boom cylinder - Install
(35.736).
9. Release the lifting device from the boom.
PTIL13TLB0461AA 6
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Index
Boom - 910
Boom - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Dipper arm - 912
851FX Plus
851FX
91715732 26/07/2021
84.3 [84.912] / 1
Contents
Dipper arm - 912
SERVICE
Dipper arm
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust - Extendahoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Telescopic dipper
Remove - Extendable dipstick (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install - Extendable dipstick (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Booms, dippers, and buckets - Dipper arm
Dipper arm - Remove

2. Lower the stabilizers and place the bucket on the
ground.
PTIL13TLB0453AA 1
4. Remove the lock rings, pins and the rod/bucket link pin
(1).
ATTENTION: Wear eye protection. Do not strike steel
parts with a steel hammer. Parts may break. Failure to
comply could result in minor or moderate injury.
6. Retract the bucket cylinder rod.
7. Operate the attachment controls so that the dipper /
bucket pin is not supporting the load of the dipper.
8. Remove the lock rings and pins and the arm/bucket link
pin (2). PTIL12TLB0166AB 2

10. Remove the bucket cylinder. Refer to Bucket cylin-
der - Remove (35.738).
11. De-clamp the hydraulic lines to the dipper arm.
12. Cap the lines and hoses immediately after unplugging.
13. Attach a lifting device to the arm assembly.
14. Disconnect the dipper cylinder at dipper arm end.
PTIL13TLB0458AA 3
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15. Remove the retainer bracket bolt (1) and washer from
the boom and arm joining location.
PTIL13TLB0459AB 4
16. Tap and remove the retainer bracket (1) and pivot pin
from the other side to free the arm assembly.
PTIL13TLB0460AB 5
17. Lift the complete arm assembly and the bucket using
lifting device and place them in a safe location.
PTIL13TLB0475AA 6
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Dipper arm - Install

1. Lift the complete arm assembly using the lifting device
and position it on the machine after aligning with the
boom.
PTIL13TLB0475AA 1
2. Tap and install the retainer bracket (1) and pivot pin to
the arm assembly.
moval.
PTIL13TLB0460AB 2
3. Install the retainer bracket bolt (1) and washer in the

boom and arm joining location using LOCTITE® 242®.
NOTE: Ensure to install the shims, collected during re-
moval.
4. Connect the arm cylinder to the arm. Refer to Dipper
cylinder - Install (35.737).
5. Install the dipper cylinder. Refer to Bucket cylinder -
Install (35.738).
PTIL13TLB0459AB 3
6. Adjust and extend the bucket cylinder rod manually to

bring the connecting rod to their housing.
7. Reinstall the arm/bucket link pin (1) and install the lock
rings and pins.
8. Slightly raise the attachment and operate the bucket
and dipper control to align the dipper hole with the
bucket lugs.
9. Reinstall the rod/bucket link pin (2) and install the lock
rings and pins.
PTIL12TLB0165AB 4
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10. Release the lifting device from the arm assembly.

11. Clamp the hydraulic lines to the dipper arm and bucket
cylinder.
12. Connect the lines and hoses to the cylinder.
PTIL13TLB0458AA 5
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Dipper arm - Adjust - Extendahoe

1. Check the painted condition of extendahoe surface
points (1), (2) as shown in the image 1.
• (1) - Specified surfaces and threads must be clean,
dry, and free of mill scale, shot blast, metal shavings,
paint, rust, rust preventative, and any other coating.
• (2) - Specified surfaces must be painted as shown in
the image 1.
PTIL19TLB0075AB 1
2. Make sure the following components are given on the

extendahoe as shown in the image 2.
• (3) - Bolt
• (4) - Washers
• (5) - Block
• (6) - Washers
PTIL19TLB0076AB 2
3. Tighten the bolt (7) to the upper pad of the extendahoe

to a torque of 45 +/- 4 N·m as shown in the image 3.
4. Make sure that the distance (D) of +/- 0.5 mm must
be same on both sides of extendahoe as shown in the
image 3.
PTIL19TLB0071BB 3
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5. Install and tighten the 8 side bolts (3) on the pad (8)
inside the extendahoe.
6. Make sure the inner guide (9) is in contact with the top
pad (10) at both sides as shown in the image 4.
7. Measure the distance (X) on all the 8 places between
the bolts (3) and the side boss (11).
NOTE: The average distance (X) must be considered.
8. Add 0.5 mm to the distance (X).
NOTE: The above distance will be the measure that needs
to be covered with the available washers, also see the step
10. PTIL19TLB0072AB 4
NOTE: For example, let’s consider the distance (X) as

4 mm, so the adjusted measure will be 4.5 mm. This
means that we have to add washer (6) and washers (4),
so total is 4.5 mm. For washers call outs, see the image 2.
9. Make sure the range of clearance value (Y) is 0.1 –
0.5 mm.
PTIL19TLB0073AB 5
10. Check the pin lock (12) assembly in the inner slot of
the extend hoe.
NOTE: Adjust it by using washers (4), for more details see
the step 8.
PTIL19TLB0074AB 6
11. Tighten the 8 side bolts (3) simultaneously on both

sides to a torque of 350 – 400 N·m.
PTIL19TLB0073AB 7
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Telescopic dipper - Remove - Extendable dipstick (Optional)

2. Lower the stabilizer, engage the extendable dipstick (1)
and place the bucket on the ground.
4. Remove the lock rings, pins (2) and the rod/bucket link
pin (3).
ATTENTION: Wear eye protection. Do not strike steel
parts with a steel hammer. Parts may break. Failure to
comply could result in minor or moderate injury.
PTIL13TLB1768AB 1
6. Retract the extendable dipstick (1) to release the
bucket.
7. Operate the attachment controls so that the dipper /
bucket pin is not supporting the load of the dipper.
8. Remove the lock rings and pins (1) from extendable
dipper.
9. Stop the engine and remove the starter switch key after
extending the dipstick.
10. Remove the bucket cylinder. Refer to Bucket cylin-
der - Remove (35.738)ii
PTIL13TLB1770AB 2
11. Remove the lock ring and pin (1) from the extendable
dipstick End, connected to the extendable dipstick dip-
per.
12. De-clamp the hydraulic lines to the dipper arm.
13. Cap the lines and hoses immediately after unplugging.
14. Attach a lifting device to the arm assembly.
15. Disconnect the dipper cylinder at dipper arm end.
16. Tie the extendable dipper to a rope and hold it using
a hoist.
ATTENTION: Do not stand beneath the components. It PTIL13TLB1771AB 3
may fall and cause serious injuries.
17. Slide the extendable dipstick from the dipper (2) and
place it safely on the ground with the help of hoist.
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Telescopic dipper - Install - Extendable dipstick (Optional)

Follow the same procedure of “Extendable Dipper – Re-
moval” in reverse order for installation. Refer the Tele-
scopic dipper - Remove - Extendable dipstick (Op-
tional) (84.912).
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Index
Dipper arm - 912

Dipper arm - Adjust - Extendahoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dipper arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dipper arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Telescopic dipper - Install - Extendable dipstick (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Telescopic dipper - Remove - Extendable dipstick (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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PRINTED IN INDIA
91715732 26/07/2021
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals
851FX Plus
851FX
91715732 26/07/2021
90
Contents
Platform, cab, bodywork, and decals - 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.156] Cab windshield and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
91715732 26/07/2021
90
Cab - 150
851FX Plus
851FX
91715732 26/07/2021
90.1 [90.150] / 1
Contents
Cab - 150
SERVICE
Cab
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Platform, cab, bodywork, and decals - Cab
Cab - Remove
1. Disconnect the battery. Refer to Basic instructions ()
.
2. Lower the stabilizers (1) to the ground. Keep the back-
hoe in travel position.
3. Lift the loader (3) in the full vertical position and engage
the lock (2).
PTIL14TLB0137AB 1
4. Apply the parking brake (1) and switch OFF the engine.
PTIL21TLB0174AA 2
5. Remove the front floor mats.

6. Remove the screws (1) and remove loader lever control
console.
PTIL21TLB0175AA 3
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7. Disconnect all wiring harnesses and earth connections.

8. Disconnect the hammer kit and extenda hoe connec-
tions.(If fitted.)
PTIL13TLB1483AA 4
PTIL13TLB1484AA 5
9. Remove the screws (1) from the backhoe control con-

sole and remove the console.
PTIL21TLB0176AA 6
10. Disconnect the brake tubes cap them.

11. Disconnect the parking brake connections.
12. Disconnect the throttle linkages.
PTIL21TLB0177AA 7
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13. Disconnect the steering valve hoses (1) and cap them.
14. Mark the hose connection or tie tags to the hoses.
PTIL21TLB0178AA 8
15. Remove the rear cab mount hardware (2).

16. Remove the front cab mount hardware (1).
17. Discharge the refrigerant, disconnect the evaporator
and heater hose connections from the cab.
PTIL13TLB1494AB 9
18. Attach an applicable lifting device (1) and slowly lift

the cab (2).
ATTENTION: When lifting the cab make sure that all the
cables and hoses connected to the cab are free from the
machine.
PTIL14TLB0138AB 10
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Cab - Install
1. Attach a suitable lifting device (1) and slowly lower the
cab (2).
ATTENTION: When lowering the cab make sure that all the
cables and hoses connected to the cab do not get trapped.
PTIL14TLB0138AB 1
2. Install the front (1) and rear (2) cab mounting hardware.
3. Connect the evaporator and heater hoses.
PTIL13TLB1494AB 2
4. Uncap and connect the steering hoses (1) to the fittings

on the control valve.
PTIL21TLB0178AA 3
5. Uncap and connect the brake hoses to the master cylin-

der.
6. Connect the parking brake connections.
7. Connect the throttle linkages.
PTIL21TLB0177AA 4
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8. Connect the wiring harnesses.

ATTENTION: Secure the wiring harness properly to the
chassis. Do not allow any wires, harnesses or connectors
to dangle.
PTIL13TLB1483AA 5
PTIL13TLB1484AA 6
9. Install the loader control lever console and tighten the

screws (1).
PTIL21TLB0176AA 7
10. Install the backhoe control lever console and tighten

the screws (1).
11. Connect the hammer kit and extenda hoe connections
(If fitted).
PTIL21TLB0175AA 8
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90.1 [90.150] / 7
12. Install the floor mats.

13. Tighten the cabin with torque 301 N·m (222.01 lb ft)
mounting bolts.
14. Connect the battery. Refer to Basic instructions () .
16. Raise the stabilizers (1), release the lock (2) and lower
the loader arm (3).
PTIL14TLB0137AB 9
17. Perform brake bleeding. Refer to Brakes - Bleed -

Removing air from the brake system (33.202).
18. Remove air from the steering system by rotating the
steering wheel to extreme ends.
19. Check the hydraulic oil level and top up if required.
21. Release the parking brake (1).
22. Move the vehicle slowly and check before putting it in
operation.
PTIL21TLB0174AA 10
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Index
Cab - 150
Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab doors and hatches - 154
851FX Plus
851FX
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90.2 [90.154] / 1
Contents
FUNCTIONAL DATA
Cab door
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Cab door glass

Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Platform, cab, bodywork, and decals - Cab doors and hatches
Cab door - Exploded view

Front door and side window glass exploded view
PTIL14TLB0139FB 1
1. LH side window frame 4. LH side door frame

2. LH side window glass beading 5. LH side door glass beading
3. LH side window glass 6. LH side door glass
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PTIL14TLB0140FB 2
1. RH side window frame 4. RH side door frame

2. RH side window glass beading 5. RH side door glass beading
3. RH side window glass 6. RH side door glass
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Cab door glass - Replace

851FX
Prior operation:
Stop the machine and park on a level ground.
Prior operation:
Release all the hydraulic pressure.
Prior operation:
Remove all the broken glass pieces from the cabin floor.
1. Use a knife (1) to find the easiest way to have access

to the adhesive joint from the inner side of the cabin.
2. First cut down the vertical adhesive joints.
3. Cut the bottom and top adhesive joints.
NOTE: Make sure that you hold the glass before removing
the top and bottom adhesive joints.
4. Remove the broken and defective glass.
PTIL13TLB0968AB 1
5. Remove the remaining adhesive from the surface of

structure/glass with a knife (1).
PTIL13TLB0970AB 2
6. Apply the emery paper 220 grit on the structure to re-

move the loose particle.
NOTE: Do not apply the emery paper on the glass.
PTIL13TLB0973AA 3
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7. Apply Sika cleaner – 205 on a lint free cloth.
PTIL13TLB0972AA 4
8. Clean the surface with Sika cleaner – 205 and let it to

dry for 10 s.
PTIL13TLB0973AA 5
9. Clean the surface with dry lint free cloth.

NOTE: Make sure that the surface is clean, dry and free
from all signs of grease, oil and dust.
10. Clean the glass (2) surface with Sika cleaner – 205
and let it to dry for 10 s.
PTIL13TLB0974AB 6
11. Clean the surface with dry lint free cloth.

NOTE: Make sure that the surface is clean, dry and free
from all signs of grease, oil and dust.
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12. Apply masking tape (3) at the edge of the outer side
of the glass (2).
13. Keep the vacuum lifter (4) in its position and lock it.
PTIL13TLB0975AB 7
14. Turn the glass (2) around.

15. Apply the masking tape (3) 20 – 30 mm (0.79 –
1.18 in) away from the edge on the ceramic layer
surface of the glass (2).
PTIL13TLB0976AB 8
16. Apply the masking tape (3) on the glass support angle
from the inner side of the cabin.
PTIL13TLB0977AB 9
17. Apply the masking tape (3) at the outer side of the
structure.
PTIL13TLB0978AB 10
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18. Shake the can with the Sika Primer – 206 G+P until
paint is mixed fully. Continue shaking for one more
minute.
PTIL13TLB0979AA 11
19. Put the primer of the necessary quantity in a small cup.

20. Close the container tightly after use. Do not let the
primer to become solid.
PTIL13TLB0972AA 12
21. Apply a thin layer of primer with a brush (5) on the

ceramic layer surface adjacent to the masking tape
(3) on the glass (2).
22. Let the layer to dry for 10 – 30 min.
NOTE: Apply the primer in 10 – 35 °C (50 – 95 °F). Drying
time will increase if the ambient temperature is low.
PTIL13TLB0980AB 13
23. Apply the primer on the machine structure with a brush

(5).
24. Let the layer to dry for 10 – 30 min.
PTIL13TLB0981AB 14
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25. Apply the adhesive solution to the 5 mm (0.20 in) rub-

ber spacer (6).
NOTE: The rubber spacer (6) is necessary to make sure
that the clearance between the structure and glass is equal.
PTIL13TLB0982AB 15
26. Bond the rubber spacer (6) to the structure with equal
space between them.
PTIL13TLB0983AB 16
27. Cut the sealant bottle nozzle (7) in the V-shape to give
a triangular bead of 10 mm (0.39 in) (base) x 10 mm
(0.39 in) (height).
PTIL13TLB0984AB 17
28. Use a manual glass pasting gun (7) to apply adhesive

in a triangular bead continuously on the glass or struc-
ture applied with the primer.
NOTE: Assemble the glass (2) in less than 10 min to pre-
vent the sealant from becoming solid.
PTIL13TLB0985AB 18
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29. Assemble the glass (2) in its position and push the
glass (2) against glass support and hold for 10 –
15 min.
30. Remove the remaining adhesive from the side clear-
ance with a knife immediately after you attach the
glass.
NOTE: Clean the knife in the soap solution.
31. Make sure to keep the clearance of 5 – 8 mm (0.20 –
0.31 in) from all sides of the glass (2).
32. Put the rubber spacer (6) below the glass (2) to hold
and make sure the equal side clearance between the
PTIL14TLB0141AB 19
glass (2) and structure.
NOTE: Remove the support rubber spacer (6) after the
glass (2) is dried.
33. Fill new adhesive in the space generated, from the
inner side of the cabin and apply by finger.
NOTE: Clean the finger in soap solution.
34. Remove the masking tape (3) immediately after com-
pleting and clean the unwanted sealant on the glass
(2) and painted surface.
NOTE: Do not use the machine for 24 – 36 h. Let the
sealant to dry fully.
NOTE: Remove the unwanted rubber spacer (6) from the
glass (2).
PTIL13TLB0987AB 20
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Index

Cab door - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab door glass - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Cab windshield and windows - 156
851FX Plus
851FX
91715732 26/07/2021
90.3 [90.156] / 1
Contents
FUNCTIONAL DATA
Cab windshield glass

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear window
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
91715732 26/07/2021
90.3 [90.156] / 2
Platform, cab, bodywork, and decals - Cab windshield and windows
Cab windshield glass - Exploded view
PTIL13TLB1491FB 1
1. Windshield
2. Front right-hand side lower windshield glass
3. Front left-hand side lower windshield glass
91715732 26/07/2021
90.3 [90.156] / 3
Platform, cab, bodywork, and decals - Cab windshield and windows
Rear window - Exploded view
PTIL14TLB0220FB 1
1. Rear window frame

2. Beading
3. Glass
4. Window glass
91715732 26/07/2021
90.3 [90.156] / 4
Index

Cab windshield glass - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear window - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
91715732 26/07/2021
90.3 [90.156] / 5
91715732 26/07/2021
90.3 [90.156] / 6
Engine hood and panels - 100
851FX Plus
851FX
91715732 26/07/2021
90.4 [90.100] / 1
Contents
SERVICE
Hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
91715732 26/07/2021
90.4 [90.100] / 2
Platform, cab, bodywork, and decals - Engine hood and panels
Hood - Remove
and lock the support strut (3) using locking pin (1) and
(2) to hold the loader.
PTIL13TLB1190AB 1
2. Remove the front grill (1) by loosening the bolts (2).
PTIL13TLB0936AB 2
3. Release the engine hood lock knob (1) and open the
hood completely.
PTIL13TLB0937AB 3
4. Belt the hood firmly using rope (1) fixed to a lifting hoist
for detaching it from the machine.
PTIL14TLB0142AB 4
91715732 26/07/2021
90.4 [90.100] / 3
5. Remove the connecting bolt (1), hood struts (2) and

engine pivot bolt (3) from both sides of the machine.
Lift the hood from the machine and place it aside.
PTIL13TLB0938AB 5
91715732 26/07/2021
90.4 [90.100] / 4
Hood - Install
1. Install the hood on the machine and tighten the hood
pivot point bolts.
Install the engine pivot bolt (3), hood struts (2) and con-
necting bolt (1) on both sides of the machine.
PTIL13TLB0938AB 1
2. Remove the rope (1) attached to the hoist to free the

engine hood.
PTIL14TLB0142AB 2
3. Close the hood and lock the engine hood knob (1).
PTIL13TLB0937AB 3
4. Install the front grill (1) and bolts (2).
PTIL13TLB0936AB 4
91715732 26/07/2021
90.4 [90.100] / 5
5. Start the machine, release the support strut (3) by un-

locking the pin (1) and (2).
Lower the loader to ground.
PTIL13TLB1190AB 5
91715732 26/07/2021
90.4 [90.100] / 6
Index

Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
91715732 26/07/2021
90.4 [90.100] / 7
PRINTED IN INDIA
91715732 26/07/2021
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380040161 [Case M Series Power shuttle transmission - Special tools 21.2 / 5
Transmission Tool Kit]
380002211 [Handle. To Be Power shuttle transmission - Special tools 21.2 / 5
Used With Various Pushers
And Buffers]
380200403 [PTO Shaft Power shuttle transmission - Special tools 21.2 / 5
Bearing driver]
380200404 [Input Shaft Power shuttle transmission - Special tools 21.2 / 6
Bearing driver]
380200405 [Inner Base Power shuttle transmission - Special tools 21.2 / 6
Assembly driver]
380200406 [Teflon Seal ring Power shuttle transmission - Special tools 21.2 / 6
Gauge]
380200414 [Clucth Assy. Power shuttle transmission - Special tools 21.2 / 6
mount.]
380200407 [Charge Pump Power shuttle transmission - Special tools 21.2 / 7
Seal ring driver]
380200408 [Teflon Seal ring Power shuttle transmission - Special tools 21.2 / 7
kit]
380200409 [Teflon seal ring Power shuttle transmission - Special tools 21.2 / 7
pusher]
380001926 [Protection Clutch Power shuttle transmission - Special tools 21.2 / 7
Piston Assembly]
380200410 [Driver] Power shuttle transmission - Special tools 21.2 / 8
380200411 [Idler Shaft Power shuttle transmission - Special tools 21.2 / 8
Bearing]
380001933 [Cover And Shims Power shuttle transmission - Special tools 21.2 / 8
Assembly Of Seal Ring On
Shaft]
380001927 [Calibrator Power shuttle transmission - Special tools 21.2 / 8
Assembly Of Seal Ring
On Shaft]
380001928 [Plunger Power shuttle transmission - Special tools 21.2 / 9
On Shaft]
380200412 [fork removal tool] Power shuttle transmission - Special tools 21.2 / 9
380200413 [Teflon Seal Ring] Power shuttle transmission - Special tools 21.2 / 9
380200410 [Driver] Transmission housing - Assemble 21.2 / 85
380200414 [Clucth Assy. Transmission drive and driven shafts - Disassemble - Input shaft 21.4 / 3
mount.]
mount.]
mount.]
mount.]
mount.]
mount.]
380001926 [Protection Clutch Transmission drive and driven shafts - Assemble 21.4 / 18
Piston Assembly]
Piston Assembly]
380200414 [Clucth Assy. Transmission drive and driven shafts - Assemble 21.4 / 19
mount.]
91715732 26/07/2021
mount.]
380001929 [Shim For Teflon Transmission drive and driven shafts - Assemble 21.4 / 23
Seal Ring]
380001933 [Cover And Shims Transmission drive and driven shafts - Assemble 21.4 / 23
Shaft]
Shaft]
380001928 [Plunger Transmission drive and driven shafts - Assemble 21.4 / 23
On Shaft]
380001927 [Calibrator Transmission drive and driven shafts - Assemble 21.4 / 23
On Shaft]
Shaft]
On Shaft]
On Shaft]
Shaft]
On Shaft]
On Shaft]
Shaft]
On Shaft]
On Shaft]
mount.]
Piston Assembly]
mount.]
mount.]
On Shaft]
380000406 [Disassembly And Powered front axle - Special tools 25.1 / 3
Assembly Of Differential Ring
Nuts]
380200186 [Driver] Powered front axle - Special tools 25.1 / 4
380200455 [False Diff. Box Powered front axle - Special tools 25.1 / 4
disc]
380002214 [False Differential Powered front axle - Special tools 25.1 / 4
Box]
91715732 26/07/2021
380002215 [Driver For The Powered front axle - Special tools 25.1 / 5
Assembly Of Pinion Bearing
Outer Cup]
380002219 [False Pinion For Powered front axle - Special tools 25.1 / 5
The Calculation Of Pinion
Shims]
Disassembly And Assembly
Bushings In The Crown
Retainer Hub]
380200461 [Wrench Socket] Powered front axle - Special tools 25.1 / 7
Assembly Of Pinion Bearing]
380200023 [Special Tool] Powered front axle - Special tools 25.1 / 8
380200026 [Driver for seal Powered front axle - Special tools 25.1 / 9
ring - Axle Beam group]
380200466 [Tool for Pre Load Powered front axle - Special tools 25.1 / 9
Measure]
380000406 [Disassembly And Differential - Remove 25.2 / 8
Nuts]
380000406 [Disassembly And Differential - Assemble 25.2 / 9
Nuts]
380000406 [Disassembly And Differential - Assemble 25.2 / 10
Nuts]
380200466 [Tool for Pre Load Differential - Assemble 25.2 / 11
Measure]
Measure]
Measure]
380002216 [Driver] Differential - Assemble 25.2 / 16
380000021 [Bevel Pinion Ring Axle pinion - Disassemble 25.2 / 18
Nut Wrench]
380200461 [Wrench Socket] Axle pinion - Disassemble 25.2 / 18
380002215 [Driver For The Axle pinion - Assemble 25.2 / 20
Assembly Of Pinion Bearing
Outer Cup]
380002214 [False Differential Axle pinion - Assemble 25.2 / 20
Box]
380200455 [False Diff. Box Axle pinion - Assemble 25.2 / 20
disc]
91715732 26/07/2021
380000021 [Bevel Pinion Ring Axle pinion - Assemble 25.2 / 22
Nut Wrench]
380200461 [Wrench Socket] Axle pinion - Assemble 25.2 / 22
380200466 [Tool for Pre Load Axle pinion - Assemble 25.2 / 23
Measure]
380200186 [Driver] Wheel hub - Assemble 25.3 / 17
380002222 [Driver For The Wheel hub - Assemble 25.3 / 18
Assembly Of Bearing Cups In
The Wheel Hub]
Retainer Hub]
Retainer Hub]
380000221 [Handle] Rear axle - Special tools 27.1 / 9
380000021 [Bevel Pinion Ring Rear axle - Special tools 27.1 / 9
Nut Wrench]
380002213 [Driver For The Rear axle - Special tools 27.1 / 9
Assembly Of Seal Ring In The
Wheel Hub]
380300157 [False Differential Rear axle - Special tools 27.1 / 10
Box]
380200397 [Bearing cup Rear axle - Special tools 27.1 / 10
Driver]
380200398 [Handle] Rear axle - Special tools 27.1 / 10
380200446 [Socket] Rear axle - Special tools 27.1 / 10
Assembly Of Bearing Cups In
The Wheel Hub]
Retainer Hub]
380200426 [Driver] Rear axle - Special tools 27.1 / 11
380002436 [Dummy pinion Rear axle - Special tools 27.1 / 12
depth guage]
380200430 [Wrench] Rear axle - Special tools 27.1 / 12
380200431 [Bearing Insertion Rear axle - Special tools 27.1 / 13
Kit]
380300158 [Tool For Pre-load Rear axle - Special tools 27.1 / 14
Measure]
380200433 [Measurement Rear axle - Special tools 27.1 / 14
tool]
380200435 [Driver] Rear axle - Assemble 27.1 / 24
380200432 [Driver] Rear axle - Assemble - Axle beam trumpet group 27.1 / 27
380200434 [Driver] Rear axle - Assemble - Axle beam trumpet group 27.1 / 28
91715732 26/07/2021
380000021 [Bevel Pinion Ring Bevel pinion - Disassemble 27.2 / 7
Nut Wrench]
380200431 [Bearing Insertion Bevel pinion - Assemble 27.2 / 9
Kit]
380002436 [Dummy pinion Bevel pinion - Assemble 27.2 / 9
depth guage]
380300157 [False Differential Bevel pinion - Assemble 27.2 / 9
Box]
380200428 [Driver] Bevel pinion - Assemble 27.2 / 11
380200428 [Driver] Bevel pinion - Assemble 27.2 / 11
380300158 [Tool For Pre-load Bevel pinion - Assemble 27.2 / 12
Measure]
380300158 [Tool For Pre-load Bevel pinion - Assemble 27.2 / 12
Measure]
380200430 [Wrench] Differential - Disassemble 27.2 / 15
380200397 [Bearing cup Differential - Assemble 27.2 / 16
Driver]
380200430 [Wrench] Differential - Assemble 27.2 / 17
380200433 [Measurement Differential - Assemble 27.2 / 17
tool]
380200430 [Wrench] Differential - Assemble 27.2 / 18
380300158 [Tool For Pre-load Differential - Assemble 27.2 / 18
Measure]
Measure]
Measure]
380200429 [Driver] Differential - Assemble - Bush 27.2 / 22
380200398 [Handle] Differential - Assemble - Bush 27.2 / 22
380002213 [Driver For The Final drive hub, steering knuckles, and shafts - Disassemble 27.3 / 10
Assembly Of Seal Ring In The
Wheel Hub]
380002222 [Driver For The Final drive hub, steering knuckles, and shafts - Assemble - Wheel 27.3 / 12
Assembly Of Bearing Cups In hub group
The Wheel Hub]
Assembly Of Seal Ring In The hub group
Wheel Hub]
Wheel Hub]
Wheel Hub]
380200426 [Driver] Brakes - Assemble 33.1 / 10
380200427 [Driver] Brakes - Assemble 33.1 / 10
380200473 [Loader Arm Cyl.] Hydraulic systems - Special tools 35.1 / 4
380200474 [Swing Cylinder] Hydraulic systems - Special tools 35.1 / 4
380200472 [Lift Cylinder] Hydraulic systems - Special tools 35.1 / 4
380200476 [Boom Cylinder Hydraulic systems - Special tools 35.1 / 4
Dantal]
380200477 [Boom Cylinder ] Hydraulic systems - Special tools 35.1 / 5
380200478 [Dipper Cylinder Hydraulic systems - Special tools 35.1 / 5
Dantal]
380200479 [Dipper Cylinder Hydraulic systems - Special tools 35.1 / 5
Wipro]
380200475 [Backhoe Bucket Hydraulic systems - Special tools 35.1 / 5
Cyl.]
91715732 26/07/2021
PRINTED IN INDIA
91715732 26/07/2021
EN

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851FX

Part number 91715732

[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2

[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

[21.700] Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

Front axle system ....................................................................... 25

[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4

Rear axle system........................................................................ 27

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

[27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.724] Front loader hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.701] Front loader arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

[35.723] Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

[35.726] Excavator and backhoe hydraulic controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9

[35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

[35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11

[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12

[35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13

[35.AAA] Hydraulic systems generic sub-group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14

Frames and ballasting ................................................................. 39

[39.129] Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

Front loader and bucket............................................................... 82

[82.300] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2

Booms, dippers, and buckets ....................................................... 84

[84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2

[84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3

Platform, cab, bodywork, and decals ............................................. 90

[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

[90.156] Cab windshield and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Plastic and resin parts

Safety rules - Ductile iron

Safety rules - Ductile iron

Safety rules - Ecology and the environment