WORKSHOP MANUAL

307.1143.3.6 G 12/ 2008

 SAME DEUTZ-FAHR ITALIA GmbH

WORKSHOP MANUAL
 WORKSHOP MANUAL

Introduction
This publication is intended for the trained technician who must operate on our tractors.

It contains all general information relating to our tractor range, and in particular it highlights the inspection, overhauling
and adjustment procedures as well as the main instructions for dismantling and reassembling operations.

The workshop manual is a natural summary for the mechanic who has attended the vocational training and specializa-
tion courses, which are held every year at our Service School, to permit him to perform a precise and qualified work on
tractor.

Its contents are therefore an exhaustive reference book for the experienced mechanic who desires to refresh his me-
mory on the sequence of the operations to be done. It is then good practice for every authorized dealer mechanic to
have at his disposal this publication, so that it may be consulted quickly when necessary.

We wish to thank in advance for the cooperation all thos people, who will let us have their suggestions in order to make
this publication more complete.
 SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System - Two Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly / Maintenance - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.4 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.5 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.6 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

40.8, 40.9 i
Section Subject Page

Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.8 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.3 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.5 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.6 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
9.7 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.8 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.9 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.10 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.11 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.12 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.13 Switches, Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.14 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30

ii 40.8, 40.9
 Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

40.8, 40.9 1.1

 Safety Practices

1.1 INTRODUCTION 1.2 DISCLAIMER

This service manual provides general directions for All information in this manual is based on the latest
accomplishing service and repair procedures. Following product information available at the time of publication.
the procedures in this manual will help assure safety and SDF reserves the right to make changes and
equipment reliability. improvements to its products, and to discontinue the
Read, understand and follow the information in this manufacture of any product, at its discretion at any time
manual, and obey all locally approved safety practices, without public notice or obligation.
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor 1.3 OPERATION & SAFETY MANUAL
provide directions for meeting every possible contingency
during operation, maintenance, or testing. When additional The mechanic must not operate the machine until the
information is desired consult the local SDF distributor. Operation & Safety Manual has been read & understood,
training has been accomplished and operation of the
Many factors contribute to unsafe conditions: carelessness, machine has been completed under the supervision of an
fatigue, overload, inattentiveness, unfamiliarity, even experienced and qualified operator.
drugs and alcohol, among others. For optimal safety,
encourage everyone to think, and to act, safely. An Operation & Safety Manual is supplied with each
machine and must be kept in the cab. In the event that the
Appropriate service methods and proper repair Operation & Safety Manual is missing, consult the local
procedures are essential for the safety of the individual SDF distributor before proceeding.
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
operator’s seat looking in a forward direction. 1.4 DO NOT OPERATE TAGS
Supplementary information is available from SDF in the
Place Do Not Operate Tags on the ignition key switch and
form of Service Bulletins, Service Campaigns, Service
the steering wheel before attempting to perform any
Training Schools, the SDF website, other literature, and
service or maintenance. Remove key and disconnect
through updates to the manual itself.
battery leads.

1.2 40.8, 40.9

 Safety Practices

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

To avoid possible death or injury, carefully read, Following are general safety statements to consider before
understand and comply with all safety messages. performing maintenance procedures on the telehandler.
In the event of an accident, know where to obtain medical Additional statements related to specific tasks and
assistance and how to use a first-aid kit and fire procedures are located throughout this manual and are
extinguisher/fire suppression system. Keep emergency listed prior to any work instructions to provide safety
telephone numbers (fire department, ambulance, rescue information before the potential of a hazard occurs.
squad/paramedics, police department, etc.) nearby. If For all safety messages, carefully read, understand and
working alone, check with another person routinely to follow the instructions before proceeding.
help assure personal safety.
1.6.1 Personal Hazards
1.5.1 Safety Alert System and Signal Words PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
the job safely. This might include heavy gloves, safety
DANGER glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.
LIFTING: NEVER lift a heavy object without the help of at
DANGER indicates an imminently hazardous situation least one assistant or a suitable sling and hoist.
which, if not avoided, will result in death or serious injury.
1.6.2 Equipment Hazards
WARNING LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
is properly attached.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious NEVER stand or otherwise become positioned under a
injury. suspended load or under raised equipment. The load or
equipment could fall or tip.
DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.

40.8, 40.9 1.3

 Safety Practices

1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: Always wear steam-resistant, heat
protective gloves when opening the radiator cap. Cover
HOUSEKEEPING: Keep the work area and operator’s
the cap with a clean, thick cloth and turn slowly to the first
cab clean, and remove all hazards (debris, oil, tools, etc.).
stop to relieve pressure.
FIRST AID: Immediately clean, dress and report all injuries
FLUID FLAMABILTITY: DO NOT service the fuel or
(cuts, abrasions, burns, etc.), no matter how minor the
hydraulic systems near an open flame, sparks or smoking
injury may seem. Know the location of a First Aid Kit, and
materials.
know how to use it.
NEVER drain or store fluids in an open container. Engine
CLEANLINESS: Wear eye protection, and clean all
fuel and hydraulic fluid are flammable and can cause a
components with a high-pressure or steam cleaner
fire and/or explosion.
before attempting service.
DO NOT mix gasoline or alcohol with diesel fuel. The
When removing hydraulic components, plug hose ends
mixture can cause an explosion.
and connections to prevent excess leakage and
contamination. Place a suitable catch basin beneath the PRESSURE TESTING: When conducting any test, only
machine to capture fluid run-off. use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
Check and obey all Federal, State and/or Local
manner, and make changes or repairs as indicated by the
regulations regarding waste storage, disposal and
test procedure to achieve the desired result.
recycling.
LEAVING MACHINE: Lower the forks or attachment to
1.6.4 Operational Hazards the ground before leaving the machine.

ENGINE: Stop the engine before performing any service TIRES: Always keep tires inflated to the proper pressure
unless specifically instructed otherwise. to help prevent tipover. DO NOT over-inflate tires.

VENTILATION: Avoid prolonged engine operation in NEVER use mismatched tire types, sizes or ply ratings.
enclosed areas without adequate ventilation. Always use matched sets according to machine
specifications.
SOFT SURFACES AND SLOPES: NEVER work on a
machine that is parked on a soft surface or slope. The MAJOR COMPONENTS: Never alter, remove, or
machine must be on a hard level surface, with the wheels substitute any items such as counterweights, tires,
blocked before performing any service. batteries or other items that may reduce or affect the
overall weight or stability of the machine.
FLUID TEMPERATURE: NEVER work on a machine
when the engine, cooling or hydraulic systems are hot. BATTERY: DO NOT charge a frozen battery.Charging a
Hot components and fluids can cause severe burns. frozen battery may cause it to explode. Allow the battery
Allow systems to cool before proceeding. to thaw before jump-starting or connecting a battery
charger.
FLUID PRESSURE: Before loosening any hydraulic or
diesel fuel component, hose or tube, turn the engine
1.7 SAFETY DECALS
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use Check that all safety decals are present and readable on
a piece of cardboard or wood instead. If injured, seek the machine. Refer to the Operation & Safety Manual
medical attention immediately. Diesel fluid leaking under supplied with machine for information.
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an

1.4 40.8, 40.9

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September 30, 2008 - A - Original Issue Of Manual

40.8, 40.9
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40.8, 40.9
 Section 2
General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.2 ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.3 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2.6
2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.4 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3.5 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.1 8 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.2 50 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

40.8, 40.9 2.1

 General Information and Specifications

2.1 REPLACEMENT PARTS AND

WARRANTY INFORMATION
For reference when ordering replacement parts or making
service inquiries about the machine, the machine serial
number is required to help assure the provision of correct
parts and information. Before ordering parts or initiating
service inquiries, make note of the serial number located
on the serial number plate (1).

MZ3000

IMPORTANT: The replacement of any part on this

machine with any other than a SDF authorized
replacement part can adversely affect the performance,
durability, or safety of the machine, and will void the
warranty. SDF disclaims liability for any claims or
damages, whether regarding property damage, personal
injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the SDF
distributor, signed by the purchaser and returned to SDF
when the machine is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the distributor
has returned the business reply card of the warranty
registration form to SDF.

2.2 40.8, 40.9

 2.2

2.2.1
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

40.8, 40.9
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
TORQUES
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB
40 0.00604 380 8 6 — — 540 12 9 — — — — —
4 0.1120
48 0.00661 420 9 7 — — 600 13 10 — — — — —
32 0.00909 580 16 12 — — 820 23 17 — — — — —
6 0.1380
40 0.01015 610 18 13 — — 920 25 19 — — — — —
32 0.01400 900 30 22 — — 1260 41 31 — — — — —
8 0.1640
36 0.01474 940 31 23 — — 1320 43 32 — — — — —
24 0.01750 1120 43 32 — — 1580 60 45 — — — — —
10 0.1900
32 0.02000 1285 49 36 — — 1800 68 51 — — — — —
20 0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168
1/4 0.2500
28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178
IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB
18 0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28
5/16 0.3125
24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30
16 0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50
ASTM Fastener Torque Chart (English)

3/8 0.3750
24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55
14 0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77
7/16 0.4375
20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82
13 0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120
1/2 0.5000
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127
12 0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170
9/16 0.5625
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182
11 0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231
5/8 0.6250
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242
10 0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400
3/4 0.7500
16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440
9 0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645
7/8 0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
8 0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950
1 1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
7 0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365
1-1/8 1.1250
12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520
7 0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925
1-1/4 1.2500
12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070
6 1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550
1-3/8 1.3750
12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685
6 1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345
1-1/2 1.5000
12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600
General Information and Specifications

Note: These torque values do not apply to cadmium plated fasteners.

2.3
2.4
2.2.2
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
40 0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —
4 0.1120
48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —
32 0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —
6 0.1380
40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —
32 0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —
8 0.1640
36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —
24 0.01750 1120 5 3.6 — — 1580 7 5 — — — — —
10 0.1900
32 0.02000 1285 6 4 — — 1800 8 6 — — — — —
20 0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19
1/4 0.2500
28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
18 0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38
5/16 0.3125
24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41
16 0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68
3/8 0.3750
24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75
ASTM Fastener Torque Chart (Metric)
General Information and Specifications

14 0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

7/16 0.4375
20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111
13 0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163
1/2 0.5000
20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172
12 0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230
9/16 0.5625
18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247
11 0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313
5/8 0.6250
18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328
10 0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542
3/4 0.7500
16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597
9 0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874
7/8 0.8750
14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949
8 0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288
1 1.0000
12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356
7 0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851
1-1/8 1.1250
12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061
7 0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610
1-1/4 1.2500
12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807
6 1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457
1-3/8 1.3750
12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640
6 1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535
1-1/2 1.5000
12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881

Note: These torque values do not apply to cadmium plated fasteners.

40.8, 40.9
 General Information and Specifications

2.2.3 Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
CLASS 8.8 METRIC BOLTS & CLASS 10.9 METRIC BOLTS &
CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS
TORQUE TORQUE
TENSILE
CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE
STRESS LOCTITE LOCTITE
SIZE PITCH LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR
AREA 262 262
263 271 263 271
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1
3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
8 1.25 36.6 15.9 25 19 23 28 22.8 37 27 29 40
10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79
12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139
14 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 68.3 219 164 197 241 97.8 313 235 250 344
18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473
20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671
22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915
24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690
30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310
33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860
36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020
42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

Note: These torque values do not apply to cadmium plated fasteners.

METRIC CLASS 8.8 METRIC CLASS 10.9

40.8, 40.9 2.5

 General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

First Gear 5 km/h (3.1 mph)

Second Gear 10 km/h (6.2 mph)
Third Gear 25 km/h (15.5 mph)
Fourth Gear (Turbo Only) 35 km/h (21.7 mph)

2.3.2 Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating
temperature.

Function Approximate Times (sec.)

8M 9M
Boom Extend 11,60 13,30
Boom Retract 9,83 11,27
Boom Lift 9,43 14,0
Boom Lower 6,41 9,65
Attachment Tilt - UP 9,78 9,78
Attachment Tilt - 4,50 4,50
DOWN
Sway 11,0 11,0

2.3.3 Electrical System

Note: Refer to Section 9.5, “Fuses and Relays,” for more information.

Battery:
Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance,
Wet Charged
Quantity 1 (100 Ah) (C20)
Reserve Capacity CCA @ -18° C: 880 EN
Group/Series DIN 600,38
Alternator 12V, 85 Amps
Starter 12V, 3,2 KW Type EV (Gear Reduction)

2.6 40.8, 40.9

 General Information and Specifications

2.3.4 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Description
Engine Make/Model Perkins 1004-40T
Low Idle 925 RPM ±50 RPM
High Idle 2340 RPM ±50 RPM
Horsepower 80,4 BHP/60 KW @ 2200 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.5 Tires
Note: Standard wheel lug nut torque is 500 Nm (369 lb-ft).

Description Tire Air Pressure

405/70-24 MPT01 AG 4,0 Bar (58 psi)
405/70-24 MPT04 CONST 4,0 Bar (58 psi)

40.8, 40.9 2.7

 General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND

CAPACITIES

Engine Crankcase Oil

Capacity w/Filter Change 8,5 liters (9 quarts)
Oil Type 15W-40 DF Super ENGINE OIL
Fuel Tank
Capacity 120 liters (26.4 gallons)
Type of Fuel U.S.A. #2 Diesel
Cooling System
System Capacity 20 L (5 gal)
Type of Fluid 50/50 mix of DF COOLANT & water
Transmission
Capacity with Filter Change 12,9 L (13.6 qt)
Type of Fluid DF UTTO Tractor Hydraulic Fluid (ISO 46)
Transfer Case
Capacity 1,4 L (1.5 qt)
Type of Fluid DF UTTO Tractor Hydraulic Fluid (ISO 46)
Axles
Differential Housing Capacity - Front 7,3 liters (7.8 quarts)
Wheel End Capacity 1,4 liters (1.5 quarts)
Type of Fluid DF UTTO Tractor Hydraulic Fluid (ISO 46)
Hydraulic System
System Capacity 220 liters (58 gallons)
Reservoir Capacity to FULL Mark 150 liters (33 gallons)
Type of Fluid DF UTTO Tractor Hydraulic Fluid (ISO 46)
Brake System
System Capacity 1,0 L (1.1 qt)
Type of Oil DONAX TA

2.8 40.8, 40.9

 General Information and Specifications

2.5 MAINTENANCE SCHEDULES 2.5.2 50, 250 & 500 Hour Maintenance
Schedule
2.5.1 8 & 1st 50 Hour Maintenance Schedule

EVERY
50

EVERY
8 Drain Fuel/
Water
Check Engine
Coolant Level
Check
Battery
Follow Lubrication
Schedule
Separator

EVERY
Check Fuel
Level
Check Tire
Pressure
Air Filter
Restriction
Check Engine
Oil Level
Check Hydraulic
Oil Level
250
Indicator

Change Engine Check Axle Check Wheel Air Filter Check

Oil and Oil Level End Oil Levels Vacuator Fan Belt
Check Brake Check Test Load Filter Valve
Fluid Level Transmission Moment
Oil Level Indicator

1st
50 Check Boom
Bearing
Check Transfer
Case Oil Level
Pads

LB/FT

EVERY
(Nm)

Change Change Wheel Change Engine Change Check Wheel 500

Axle Oil End Oil Oil & Filter Transmission Lug Nut
Oil & Filter Torque
LB/FT
(Nm)

MZ3010
Change Fuel Check Wheel
Filter Lug Nut
Torque

MZ1680

2.5.3 1000 & 1500 Hour Maintenance

Schedule

EVERY
1000

Change Change Change Change Wheel

Transmission Transfer Case Axle Oil End Oil
Oil & Filter Oil

EVERY
1500

Change Change Change Change

Engine Coolant Hydraulic Hydraulic Tank Brake Fluid
Fluid & Filters Breather
MZ1690

40.8, 40.9 2.9

 General Information and Specifications

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule

EVERY Mystik Tetrimoly

(NLGI 2 GC-LB)
8

OZ3360

2.10 40.8, 40.9

 General Information and Specifications

2.6.2 50 Hour Lubrication Schedule

EVERY Mystik Tetrimoly

50
(NLGI 2 GC-LB)

2x

OZ3370

40.8, 40.9 2.11

 General Information and Specifications

This Page Intentionally Left Blank

2.12 40.8, 40.9

 Section 3
Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System - Two Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly / Maintenance - Two Section Boom . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.1 Assembled Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.2 Second Section Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.3 Second Section Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.4 Assembled Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.4 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.4.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.4.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.4.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.5 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.5.1 Connecting with a Mechanical Quick Switch Device. . . . . . . . . . . . . . . . . 3.7
3.5.2 Connecting with a Hydraulic Quick Switch Device . . . . . . . . . . . . . . . . . . 3.7
3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment . . . 3.7
3.5.4 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.5.5 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.6 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

40.8, 40.9 3.1

 Boom

3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the boom system.
The following illustration identifies the components that
are referred to throughout this section.

PIVOT PIN

FIRST
BOOM
SECTION

EXTEND/RETRACT
CYLINDER

ACCESS
PANEL
SECOND
BOOM
SECTION

TILT CYLINDER
TWO SECTION BOOM
MZ3020
QUICK SWITCH

3.2 40.8, 40.9

 Boom

3.2 BOOM SYSTEM - TWO SECTION 3.3.1 Assembled Boom Removal

1. Remove any attachment from the quick switch
3.2.1 Boom System Description assembly. Refer to Section 3.5.1, “Connecting with a
Mechanical Quick Switch Device.”
The boom operates via an interchange among the
electrical, hydraulic and mechanical systems. Components Note: If replacing the innermost boom section, remove
involved include the joystick, tilt cylinder, extend/retract the quick switch assembly. Refer to Section 3.5.4, “Quick
cylinder, lift/lower cylinder, compensation cylinder, Switch Removal.”
electronic sensors, various pivots, supporting hardware
2. Park the machine on a hard, level surface. Be sure
and other components.
there is enough room in front of the machine to allow
the boom sections to be removed.
3.3 BOOM ASSEMBLY / MAINTENANCE -
3. Fully retract the boom then raise the boom to access
TWO SECTION BOOM the rod end pin of the lift/lower cylinder. Place the
transmission control lever in (N) NEUTRAL, engage
IMPORTANT: Boom replacement must be completed in
the park brake and shut the engine OFF.
sequence, one boom section at a time, as described in
these instructions. 4. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel stating that the machine
Before beginning, conduct a visual inspection of the
should not be operated.
machine and work area, and review the task about to be
undertaken. Read, understand and follow these 5. Open the engine cover. Allow the system fluids to
instructions. cool.
6. Disconnect the battery negative (-) cable from the
battery negative (-) terminal.
7. Relieve any trapped pressure in the tilt hydraulic
system by using the handle or wrench (located in the
toolbox) and move the double nut on the side of the
actuator module on the tilt valve section back and
forth. Repeat on the auxiliary valve section and on
the extend/retract section.
8. Label, disconnect and cap hydraulic hoses attached
the hose rack at the left rear corner of the boom.
9. Disconnect the boom angle indicator rod from the
switch at the inside left corner of the main boom
section and frame. Refer to Section 9.13.7, “Boom
Angle Sensor.”
10. Support the front of the boom by placing a sling
behind the boom head. Support the lift/lower cylinder
and remove the lock bolt and then the rod end pin.
Lower the lift/lower cylinder onto the frame rails.
11. Lower the boom to a level position and place a
suitable support under the boom head. Reposition
the slings to each end of the boom.
12. Remove the lock bolt and pin from the compensation
cylinder on each side of the first boom section.
Remove the lock bolt and pivot pin from rear of first
boom section.
13. Lift the complete boom off machine and set on level
ground or supports being careful not to damage the
tubes on the side of the first boom section.

40.8, 40.9 3.3

 Boom

a. If the boom is going to be disassembled after 3.3.2 Second Section Boom Removal
removal:
1. Remove the top left and right side wear pads,
1. Set the complete boom on level ground and by backing plates and shims. Loosen the bottom wear
repositioning the slings, turn boom over on to the top pad bolts and remove the shims from the innermost
side. Set the complete boom on suitable stands to boom section to gain the necessary clearance to
begin teardown. remove the last boom section (7). Tag each pad,
backing plate, shim and bolts from each location.
Note: With the complete boom setting upside down, the
other boom section(s), tilt cylinder and hoses are made 2. Pull out the innermost boom section (7).
more accessible. 3. Remove the remaining wear pads.
2. Remove the access panel from the boom head.
3. Label, disconnect and cap the hoses attached to the
tilt cylinder and the hose rack on the side of the first
boom section.
7
4. Attach a sling through the rod end of the tilt cylinder.
Remove the clip from the barrel end of the tilt
cylinder pin. Remove the tilt cylinder pin and lift the
tilt cylinder out of the boom head.
5. Remove the hose clamp inside the innermost boom
section.
6. Label, disconnect and cap the hoses attached to the
extend/retract cylinder at the rear of the boom.
7. Pull the extend/retract, tilt and auxiliary hoses (1) out
through the rear of the boom.
8. Remove the clip from the rear extend/retract cylinder MZ1730
pin (2).
9. Use a sling around the innermost boom section to
take any pressure off of the wear pads to make pad 3.3.3 Second Section Boom Installation
removal easier. 1. Install the bottom rear wear pads (8) and bolts onto
10. Use a sling to pull the remaining boom section(s) out the innermost boom section. Apply Loctite® #242
far enough to gain access to the rod end of the and torque to 90 Nm (66 lb-ft). Install the bottom rear
extend/retract cylinder. left and right side wear pads, backing plate and bolts
(do not shim or tighten bolts). Install top rear wear
11. Remove the clip from the front extend/retract
pads, backing plates and bolts (do not shim or
cylinder pin. Pull the extend/retract cylinder (3) out
tighten bolts).
through the rear of the boom.

2
3

MZ1720 8

MZ1750

3.4 40.8, 40.9

 Boom

2. Grease the inside of the next boom section on areas 4. Insert the extend/retract, tilt and auxiliary hoses
where the innermost boom section wear pads will through the boom.
slide. 5. Uncap and connect the previously labeled hydraulic
3. Using a suitable sling, balance the innermost boom hoses to the appropriate locations on each cylinder.
section and carefully slide 1 m to 1,5 m (3’ to 4’) into 6. Install the hose clamps inside the innermost boom
the front of the next boom section. Set the innermost section.
boom section head onto suitable supports and reset
sling under the boom head. Carefully slide the 7. Using suitable slings, turn the boom over to its
innermost boom section into the next section. Leave original orientation.
15 cm to 20 cm (6” to 8”) of the innermost boom 8. Rebalance the boom assembly with slings, lift and
section out to be able to install wear pads on the carefully guide the boom into place. Align the frame
front of the next boom section. pivot bore with the boom pivot bore. Install the boom
4. With the boom head still supported, install the top pivot pin. Apply Loctite® #242 and torque to 300 Nm
wear pads, washers and bolts in the front of the (221 lb-ft).
larger boom section. Apply Loctite® #242 and torque 9. With the sling still in place, install both compensation
to 90 Nm (66 lb-ft). Remove the boom head from cylinders, pins and lock bolts. Apply Loctite® #242
supports and install the bottom wear pads, backing and torque to 120 Nm (88 lb-ft).
plates, shims and bolts in the front of the larger 10. With the sling still in place, raise the boom enough to
boom section. Apply Loctite® #242 and torque to install the lift/lower pin and lock bolt. Apply Loctite®
90 Nm (66 lb-ft). Install both left and right side front #242 and torque to 300 Nm (221 lb-ft).
wear pads, backing plates, shims and bolts in the
front of the larger boom section. Apply Loctite® #242 Note: Raising the boom up or down with the sling
and torque to 50 Nm (37 lb-ft). maybe necessary so the boom, compensation and lift/
lower cylinder bores can be aligned for easier pin
Note: Shim ALL side wear pads as needed to maintain installation.
a minimum gap in the horizontal direction or a tight fit.
The number of shims can vary at each shim point except Note: Grease the boom pivot bore, compensation
on the bottom wear pads. cylinder rod ends, lift/lower rod end and pins before
installing.
IMPORTANT: Light lubrication of the boom wear
surfaces with a factory authorized grease is 11. Uncap and connect the previously labeled hydraulic
recommended to keep the boom wear surfaces hoses to the hose rack on the side of the first boom
lubricated properly. section.
5. Tighten all wear pads after ensuring the minimum 12. Connect the boom angle indicator rod from switch at
gap requirements have been met. Refer to Section the inside left rear corner of the main boom section
3.4.1, “Wear Pad Inspection.” and frame. Refer to Section 9.13.7, “Boom Angle
Sensor,” for adjustment information.
3.3.4 Assembled Boom Installation 13. Connect the battery negative (-) cable to the battery
1. Insert the extend/retract cylinder through the rear of negative (-) terminal.
the boom. Align the extend/retract rod end with the 14. Start the engine and operate all boom functions
cylinder pin mounting hole on the last boom section. several times. Check for leaks, and check the
Install the extend/retract cylinder pin and retaining hydraulic fluid level in the reservoir; add fluid if
clip. required.
2. Align the extend/retract barrel end with the cylinder 15. Install the access panel on the boom head.
pin mounting hole on the first boom section. Install 16. Close and secure the engine cover.
the extend/retract cylinder pin and retaining clip.
Note: Grease extend/retract cylinder barrel end bore
and pin before installing.
3. Attach a sling through the rod end of the tilt cylinder
and position the cylinder to its original mounting
location. Install the tilt cylinder pins and retaining
clips.
40.8, 40.9 3.5
 Boom

3.4 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear
pads with metal inserts.
A total of 13 wear pads are installed on the boom sections
of the 8 & 9M machines. 2

3.4.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
worn or damaged.
1 MAH0870
1

Use shims (2) under the wear pads as required to maintain

a maximum gap of 1,5 mm (0.06") (3) between the wear
MA2070 pad on the front and sides of the boom. The gap at the
rear of the boom should be no more than 3 mm (0.12”).
3.4.2 Boom Wear Pad Replacement Shims are available in four thicknesses, 0,5mm (0.02'),
When replacing a wear pad on the boom, replace both 1 mm (0.04”), 1,5mm (0.06”) and 2,0mm (0.08”).
wear pads on that side of the boom; e.g.: replace top front
left and top front right wear pads at the same time. 3
Usually, shimming will remain the same when installing
new wear pads. All wear pads are secured to the boom
using different capscrews and washers. When installing
new wear pads, apply Loctite® #242 to all wear pad
mounting capscrews. Torque right and left side wear
pads to 50 Nm (36 lb-ft) and torque top and bottom side
wear pads to 90 Nm (66 lb-ft). Grease the new pads and
surrounding area.
Note: The first shim next to a wear pad always needs to
have the two hole configuration. The remaining MU4080
pads (2) may have the large slot configuration.
3.4.3 Boom Wear Pad Lubrication
After replacing any wear pad(s), or after prolonged
periods of inoperation, light lubrication of the boom wear
surfaces with a factory authorized grease is recommended
to keep the boom wear surfaces lubricated properly. Light
lubrication of the boom wear surfaces is also
recommended when the machine is stored, to help
prevent rusting.

3.6 40.8, 40.9

 Boom

3.5 QUICK SWITCH ASSEMBLY 3.5.3 Connecting with a Quick Switch to a

Hydraulic Operated Attachment
This machine is equipped with a quick switch system for
1. Lower attachment to ground. Set parking brake, shut
easy attachment changes.
off engine and turn key back to the “ON” position.
3.5.1 Connecting with a Mechanical Quick 2. Relieve pressure in the hydraulic system by
Switch Device actuating the joystick.

1. Retract quick switch device to provide clearance. 3. Connect the quick-disconnect fittings.
Check to be sure lock pin (4) and retainer pin (5) is 4. Start the engine.
out.
2. Align attachment pin (6) with recess in 3.5.4 Quick Switch Removal
attachment (7). Raise boom slightly to engage 1. Support the quick switch assembly. Remove the lock
attachment pin in recess. bolt (9) holding the tilt cylinder rod end to the quick
3. Engage quick switch device. switch assembly. Remove the tilt cylinder pin.
4. Shut off engine. Exit cab and insert lick pin and 2. Support the quick switch assembly. Remove the four
secure with retainer pin. bolts and covers (10) from each end of the quick
switch assembly. Remove the pin from the quick
5. If attachment is equipped, connect auxiliary
switch assembly from either side.
hydraulic hoses. See Section 3.5.3, “Connecting
with a Quick Switch to a Hydraulic Operated 3. Inspect the above pin for nicks or surface corrosion.
Attachment.” Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired, the pin must
3.5.2 Connecting with a Hydraulic Quick be replaced.
Switch Device
3.5.5 Quick Switch Installation
1. Retract quick switch device to provide clearance.
Check to be sure lock pin is disengaged. 1. Assemble the quick switch to the boom head. Line
up the quick switch between the mounts on the
2. Align attachment pin (6) with recess in
boom head. The quick switch should be centered in
attachment (7). Raise boom slightly to engage
the boom head.
attachment pin in recess.
2. Coat the quick switch pivot pin with an anti-seize
3. Engage quick switch device.
compound. Insert the quick switch pivot pin through
4. Press the button (8) and at the same time, move the the quick switch and boom head. Replace the end
joystick to engage or to disengage the quick switch covers and four bolts (10) to each end of the quick
device. switch.
3. Align the quick switch with the tilt cylinder rod end
8
and insert the tilt cylinder pin. Align the tilt cylinder
pin and screw in the locking bolt (9). Torque as
required.
7

MAH0980 6

5. Raise the boom to eye level and visually check that

the quick switch pin protrudes through the hole. If
the pin does not protrude through the hole, place the 10

attachment on the ground and return to step 2.

9
6. If attachment is equipped, connect auxiliary
hydraulic hoses. See Section 3.5.3, “Connecting
with a Quick Switch to a Hydraulic Operated
Attachment.” 4
5

40.8, 40.9 3.7

 Boom

3.6 FORKS
Forks should be cleaned and inspected prior to being attached
to carriage. If the following criteria is not met, forks must be
removed from service immediately.
Daily Inspection
1. Inspect forks (4) for cracks, paying special attention
to heel (5) and mounting tubes (6).
2. Inspect forks for broken or bent tips (7) and twisted
blades (8) and shanks (9).
Yearly Inspection
1. Straightness of the upper face of blade (8) and the
front face of shank (9) should not exceed 0.5 percent
of the length of blade or height of shank.
2. Angle (10) between upper face of blade and front
face of shank should not exceed 93 degrees.
3. Thickness of blade (13) and shank (14) should not
be reduced to 90 percent of original thickness.
4. Ensure fork length (12) is adequate for intended
loads.
5. Fork markings should be legible, re-stamp if
required.
6. Compare fork tips (11) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent
of the length of the blade (13).

6
9

10 7
8

5
4
14

13 11

12 MH6460

3.8 40.8, 40.9

 Boom

3.7 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.

Problem Cause Remedy

1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract tube(s) and/or connections or tube(s), tighten connections.
leaking.

2. Extend/retract hydraulic system 2. Refer to Section 8, “Hydraulic

not operating properly. System.”

3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section

8.9.4, “Cylinder Inspection.”
2. Boom will not fully extend. 1. Extend/retract hydraulic system 1. Refer to Section 8, “Hydraulic
not operating properly. System.”

3. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.4.2, “Boom
Wear Pad Replacement.”

4. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.

and/or wear. Refer to Section 2.6,
“Lubrication Schedules.”
Replace worn pins as needed.

2. Worn bearing(s). 2. Replace bearing(s) and

lubricate at regular intervals
Refer to Section 2.6,
“Lubrication Schedules.”

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.

2. Lift/lower hydraulic system not 2. Refer to Section 8, “Hydraulic

operating properly. System.”

3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.9.4, “Cylinder Inspection.”

4. Seized boom pivot pin bearing. 4. Replace bearing.

40.8, 40.9 3.9

 Boom

Problem Cause Remedy

6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.4.2, “Boom Wear Pad
Replacement.”

2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.

3. Contaminated, corroded or 3. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).

4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.

7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”

3.10 40.8, 40.9

 Section 4
Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.2 Service Brake Pedal and Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.3 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.4 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.5 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.6 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.7 Windshield Washer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.8 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.9 Cab Heater/Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

40.8, 40.9 4.1

 Cab and Covers

4.1 OPERATOR’S CAB AND COVERS

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.

LOAD STABILITY
INDICATOR

HEATER & AC
CONTROLS
DISPLAY
PANEL

TRANSMISSION
CONTROL LEVER

BRAKE FLUID
RESERVOIR JOYSTICK

SERVICE BRAKE
PEDAL

ACCELERATOR
PEDAL

PARKING BRAKE MZ3030

LEVER

4.2 40.8, 40.9

 Cab and Covers

Note: DO NOT disassemble the orbitrol valve. The

orbitrol valve is not serviceable and must be replaced in

WARNING its entirety, if defective.

DO NOT service the machine without following all

safety precautions as outlined in the “Safety
Practices” section of this manual. Failure to follow the 2

safety practices may result in death or serious injury. 4

4.2 OPERATOR’S CAB

4.2.1 Serial Number Decal

The cab serial number decal is located inside the cab, 3
behind the seat. Information specified on the serial
number plate includes the cab model number, the cab
serial number and other data. Write this information down
in a convenient location to use in cab correspondence.
1
4.3 CAB COMPONENTS MZ2000

4.3.1 Steering Column and Orbitrol Valve b. Orbitrol Valve Installation

1. Install the steering valve and steering column to their
a. Orbitrol Valve Removal original orientation on the steering bracket with four
1. Park the machine on a firm, level surface, level the hex-flange capscrews and four lockwashers.
machine, fully retract the boom, lower the boom, 2. Install the accessory control lever and transmission
place the transmission control lever in control lever and connect the harness connector,
(N) NEUTRAL, engage the park brake and shut the install the steering wheel assembly. Torque the
engine OFF. steering wheel nut to 40 Nm (29.5 lb-ft).
2. Place a Do Not Operate Tag on both the ignition key Note: ALWAYS use new o-rings when servicing the
switch and steering wheel, stating that the machine machine.
should not be operated.
3. Install new o-rings into the fittings. Lubricate the o-
3. Open the engine cover. Allow the system fluids to rings with clean hydraulic oil.
cool.
4. Uncap and connect the previously labeled hoses to
4. Disconnect the battery negative (-) cable at the the appropriate ports.
battery negative (-) terminal.
5. Install the steering adjustment lever.
5. Remove the lower dash panel.
6. Connect the battery negative (-) cable to the battery
6. Remove the steering adjustment lever. negative (-) terminal.
7. Label, disconnect and cap the hydraulic hoses 7. Start the engine and check the operation of steering
attached to the steering valve (1). Cap all fittings to system. Check for hydraulic fluid leaks. Check the
prevent dirt & debris from entering the hydraulic hydraulic fluid level in the tank and add fluid as
system. required. Wipe up any spilled oil.
8. Remove the steering wheel (2), disconnect and 8. Install the lower dash panel.
remove the accessory control lever (3) and
transmission control lever (4). 9. Close and secure the engine cover.
9. Support the steering valve, and remove the four hex- c. Power Steering Test
head capscrews and four lockwashers.
Conduct a pressure check of the steering hydraulic
10. Remove the steering assembly from the dash panel.
circuits at the main control valve. Refer to Section 8.4.1,
“Hydraulic Pressures.”
40.8, 40.9 4.3
 Cab and Covers

4.3.2 Service Brake Pedal and Valve 4. Install and secure the lower dash cover.
5. Connect the battery negative (-) cable to the battery
a. Service Brake Valve negative (-) terminal.
Refer to Section 8.8.2, “Service Brake Valve,” for removal 6. Close and secure the engine cover.
and installation information.
4.3.3 Throttle Pedal Replacement
b. Service Brake Pedal Removal
1. Park the machine on a firm, level surface, level the a. Throttle Pedal Removal
machine, fully retract the boom, lower the boom, 1. Park the machine on a firm, level surface, level the
place the transmission control lever in machine, fully retract the boom, lower the boom,
(N) NEUTRAL, engage the park brake and shut the place the transmission control lever in
engine OFF. (N) NEUTRAL, engage the park brake and shut the
2. Place a Do Not Operate Tag on both the ignition key engine OFF.
switch and steering wheel, stating that the machine 2. Place a Do Not Operate Tag on both the ignition key
should not be operated. switch and steering wheel, stating that the machine
3. Open the engine cover. Allow the system fluids to should not be operated.
cool. 3. Open the engine cover. Allow the engine to cool.
4. Disconnect the battery negative (-) cable at the 4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal. battery negative (-) terminal.
5. Remove the lower dash panel. 5. Remove the lower dash panel.
6. Remove the throttle pedal return spring (6).

5
7. Disconnect the throttle control cable (7) from the
throttle lever.
8. Remove the retaining ring from the throttle pedal
pivot pin. Slide the throttle pedal, bushings and
washers off the pivot pin.
9. Remove the throttle pedal assembly from the cab.
10. If a new throttle cable is required, remove the cable
connector from the engine. Route the cable through
the bottom of the cab and remove from the machine.
Note the routing path for installation.

MZ1960

6. Remove the circlip, flat washer, bushing and the

return spring securing the service brake pedal to the 7
cab.
7. Remove the clip/pin from the brake plunger fork link.
8. Remove the service brake pedal (5) from the cab.
6
c. Service Brake Pedal Installation
1. Position the service brake pedal in its mounting
location within the cab.
2. Install the brake pedal being careful to reposition the
brake plunger yoke. Install the return spring, washer, MZ1970

bushing and clip. Install clip/pin in brake plunger fork link.

3. Adjust the brake pedal as needed.

4.4 40.8, 40.9

 Cab and Covers

b. Throttle Pedal Installation

1. If required, install a new throttle cable to the engine
connection and route cable to cab following the 9
previous routing path.
2. Slide the throttle pedal, bushings and washers onto
the throttle pedal pivot pin. Secure with retaining
ring.
3. Connect the throttle control cable to the throttle
lever.
8
4. Install the throttle pedal return spring.
5. Connect the battery negative (-) cable to the battery
negative (-) terminal.
MZ2030
c. Throttle Adjustment
3. Open the engine cover. Allow the engine to cool.
1. Adjust the distance on each end of the throttle cable
from the locknut to the connector end. The distance 4. Disconnect the battery negative (-) cable at the
from the connector to the locknut in the cab should battery negative (-) terminal.
be 129 mm (5 in). In the engine compartment, the 5. Remove the capscrews securing the bottom cover
distance should be 234 mm (9.2 in). (8). Disconnect the electrical connections and
remove the four self-tapping screws from the bottom
Note: These measurements are to be used as starting
of the joystick assembly.
points. If further adjustment is required, the distance may
need to be altered. 6. Remove the joystick assembly (9).

2. From within the cab, check the engine rpm at low b. Joystick Assembly Installation
idle. If the rpm is not 925 ±50 rpm, readjust the
throttle cable adjustments. 1. Set the joystick assembly into the armrest support.
3. Check the engine rpm at full throttle. If the rpm is not 2. Install the four self-tapping screws. Connect the
2340 ±50 rpm, adjust the rubber-stop screw on the electrical connections.
throttle pedal or the throttle cable adjustments. 3. Connect the battery negative (-) cable to the battery
IMPORTANT: During the full throttle check: negative (-) terminal.
• DO NOT operate any hydraulic function. 4. Test the boom joystick functions:
• DO NOT steer or apply any pressure to the a. Move the joystick handle rearward, activating the
steering wheel. boom lift function. The boom should RISE.
• Keep the transmission in (N) NEUTRAL. b. Move the joystick handle forward, activating the
boom lower function. The boom should LOWER.
4. Close and secure the engine cover.
c. Move the joystick handle to the right, activating
the boom extend function. The boom should
4.3.4 Joystick Assembly Replacement EXTEND.
d. Move the joystick handle to the left, activating the
a. Joystick Assembly Removal
boom retract function. The boom should
1. Park the machine on a firm, level surface, level the RETRACT.
machine, fully retract the boom, lower the boom, e. Move the joystick rocker switch forward
place the transmission control lever in activating the boom extend function. The boom
(N) NEUTRAL, engage the park brake and shut the should EXTEND.
engine OFF. 5. Install the bottom cover.
2. Place a Do Not Operate Tag on both the ignition key 6. Close and secure the engine cover.
switch and steering wheel, stating that the machine
should not be operated.

40.8, 40.9 4.5

 Cab and Covers

4.3.5 Parking Brake b. Park Brake Installation

1. Install the park brake cable on the front axle.
2. Route the park brake cable using the previous
routing path.
3. Feed the cable end through the bottom of the cab.
4. Secure the park brake lever to the mounting plate
using the pre-existing mounting hardware.
2
5. Secure the park brake cable to the park brake lever
with the pre-existing pin.
6. Connect the park brake electrical connector switch.
7. Test the park brake for proper functionality.
8. With the park brake applied, check the display panel
1 for the proper indicator light.
MZ1490
9. Reinstall the cover around the park brake lever.
a. Park Brake Removal 10. Unblock the wheels.

1. Park the machine on a firm, level surface, level the 4.3.6 Windshield Wiper Assembly
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) Refer to Section 9.11.1, “Windshield Wiper Motor,” for
NEUTRAL, engage the park brake and shut the removal and installation information.
engine OFF.
4.3.7 Windshield Washer Assembly
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the Refer to Section 9.11.3, “Windshield Washer Reservoir
machine should not be operated. and Pump,” for removal and installation information.
3. Block the wheels.
4.3.8 Heater/Defroster System
4. Remove the cover from around the park brake lever.
5. Disconnect the park brake electrical connector a. Heater Assembly Removal
switch.
1. Park the machine on a firm, level surface, level the
6. Remove the pin attached to the park brake cable (1) machine, fully retract the boom, lower the boom,
from the park brake lever (2). place the transmission control lever in
7. Remove the bolts holding the park brake lever to the (N) NEUTRAL, engage the park brake and shut the
mounting plate. engine OFF.
8. Loosen the nuts securing the park brake cable to the 2. Place a Do Not Operate Tag on both the ignition key
mounting plate. switch and the steering wheel, stating that the
machine should not be operated.
9. Feed the cable end through the bottom of the cab.
3. Open the engine cover. Allow the system fluids to
10. If necessary, remove the cable clamp from under the
cool.
cab.
4. Disconnect the battery negative (-) cable from the
Note: Record the routing of the park brake cable for battery negative (-) terminal.
later installation.
5. Remove the belly pan.
11. Remove the cable mounting hardware on the front
6. Slowly turn the radiator cap to the first stop and allow
axle to free the park brake cable.
any pressure to escape. Remove the radiator cap.
7. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug and slowly remove to allow the coolant to
drain. Transfer the coolant into a suitable, covered
container and label as "Used Coolant". Dispose of

4.6 40.8, 40.9

 Cab and Covers

the used coolant at an approved recycling facility. b. Heater Assembly Installation

Clean and reinstall the drain plug.
1. Lower the heater assembly into the cab to its original
8. Remove the cab bottom and heater shield (5). orientation. Secure with the previously used
9. Remove the cab floor mat to gain access to the hardware.
heater assembly mounting bolts. 2. Connect the wiring harness connections to the
blower.
3. Connect the previously labeled hoses to the heater.
Secure with hose clamps.
4. Fill the cooling system completely with a 50/50
mixture of ethylene glycol and water, allowing time
for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.4, “Fluids,
Lubricants and Capacities.”
5. Connect the battery negative (-) cable to the battery
negative (-) terminal.
6. Start the engine and run at low idle. Check for any
visual signs of fluid leakage. STOP the engine
immediately if any leakage is noted, and make any
5 necessary repairs before continuing.
MZ2050 7. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
Note: Label all hoses to ensure correct installation. to bring the coolant to the proper level.
10. Loosen the hose clamps and disconnect the heater 8. Replace the cab bottom and heater shield.
hoses (6).
9. Replace the belly pan.
11. Remove the heat duct hoses (7) from the back side
10. Close and secure the engine cover.
of the heating unit assembly.
12. Label and disconnect the electrical connectors 4.3.9 Cab Heater/Air Conditioning Controls
attached to the heater assembly.
13. Remove the heater assembly mounting bolts. a. Cab Heater Controls Removal
14. Carefully lift the heater assembly and remove from
the cab. 9

7
8
8

MAM0310

1. Park the machine on a firm, level surface, level the

machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
6
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
MZ2040 machine should not be operated.

40.8, 40.9 4.7

 Cab and Covers

3. Open the engine cover. Allow the system fluids to 4.4 CAB REMOVAL
cool.
4. Disconnect the battery negative (-) cable from the IMPORTANT: To help ensure safety and optimum
battery negative (-) terminal. performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
5. Remove the plastic side cover in the cab to gain
access to the control cables and electronics. If Before performing any inspection, maintenance or
necessary, remove the seat for more accessibility. service operation, thoroughly clean the machine. DO
NOT spray water or cleaning solution in, on, near or
6. Label and disconnect the control cables (8) attached around the operator’s dash panels and electrical
to the control knob mechanisms. components.
7. Label and disconnect the electrical connectors Inspect the cab, its welds and mounts. If modification,
attached to the control box. damage, a cracked weld and/or fatigued metal is
8. Depress the side clips (9) and push the control box discovered, replace the cab. Contact your local authorized
through the dash panel. service distributor with any questions about the suitability
or condition of a cab.
b. Disassembly IMPORTANT: Remove and label cab components as
DO NOT disassemble the cab heater and fan controls. needed before removing the cab from the machine.
The controls are not serviceable. Replace controls if Label, disconnect and cap hydraulic hoses. Transfer cab
found to be defective. parts to the replacement cab after the replacement cab
is securely mounted on the machine.
c. Installation and Testing 1. Park the machine on a firm, level surface, level the
1. Install the control box into the dash panel until the machine. Allow sufficient overhead and side
side clips firmly hold the box. clearance for cab removal. Fully retract the boom,
lower the boom, place the transmission control lever
2. Connect the previously labeled electrical connectors in (N) NEUTRAL, engage the park brake and shut
to the appropriate locations. the engine OFF.
3. Connect the previously labeled control cables to the 2. Block the wheels.
appropriate control knob mechanisms.
3. Open the engine cover. Allow the system fluids to
4. Connect the battery negative (-) cable to the battery cool.
negative (-) terminal.
4. Disconnect the battery negative (-) cable from the
5. Turn the ignition key to the ON position and check battery negative (-) terminal.
the control functions.
5. Remove the belly pan.
6. Start the machine and allow engine to warm to
operating temperature. Check heat control at 6. Drain the engine radiator. Refer to Section 7.4.3,
different levels. “Radiator/Oil Cooler and Coolant Heater
Replacement.”
7. Install the plastic side cover. If necessary, install the
seat. 7. Working under the cab, remove the cab bottom
shield.
8. Close and secure the engine cover.
8. Label, disconnect and cap the heater hoses.
9. Remove the lens-head screws in the cab and
remove the console panel below the right side
window to access the wire harness connections, the
right rear side panel and the left rear cup holder
panel to access the two rear cab mount bolts. Also
remove the rubber floor mat to access the front two
cab mount bolts.
10. Disconnect the cab-to-wiring harness connectors at
the circuit board. Push the harness connectors
through the opening at the right front corner of the
cab.

4.8 40.8, 40.9

 Cab and Covers

11. Remove the park brake cover. Disconnect the park

brake switch connector and park brake cable.
12. Working under the cab, label, disconnect and cap
the hydraulic hoses at the cab fittings. Plug the
hoses and cap the fittings.
13. Disconnect the throttle cable from the throttle pedal
lever. Push the throttle cable through the bottom of
the cab.
14. Install two lifting eye bolts with a suitable lifting
capacity in the existing threaded holes (1) at the top
corners of the windshield.

2
MZ0640

17. Remove the mirrors and all other cab components

as needed, if not previously removed.
18. Use a hoist or overhead crane and sling attached to
the cab, carefully begin to lift the cab. Stop and
check that all wiring, hydraulic hoses and fasteners
are disconnected or removed.
19. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift
the cab and remove it from the frame.
20. When the cab is completely clear of the machine,
MZ0660
carefully lower it to the ground. Block up or support
15. Secure the cab with a hoist or overhead crane and the cab so that it does not move or fall over. Assure
sling. Do not lift the cab at this time. that no personnel enter the cab while it is being
16. Remove the four cab-to-frame bolts (2), flat washers removed from the machine.
and nuts. 21. Inspect the condition of the fittings, clamps,
hydraulic hoses, etc. Replace parts as indicated by
their condition.
22. Inspect and replace other machine parts that are
exposed with the cab removed. Repair or replace as
required.

40.8, 40.9 4.9

 Cab and Covers

4.5 CAB INSTALLATION 16. Connect the battery negative (-) cable to the battery
negative (-) terminal.
1. Block all four wheels to help prevent the machine 17. Start the engine and check the operation of all
from moving. Assure that there is sufficient overhead controls. Check for hydraulic leaks. Check the
and side clearance for cab installation. hydraulic fluid level in the tank and add fluid as
2. Attach a sling with suitable lifting capacity through required.
the previously installed eye bolts on top of the cab. IMPORTANT: When the engine is initially started, run it
3. Using a hoist or overhead crane and sling attached briefly at low idle and check the machine for any visual
to the two lifting eyes, carefully begin to align the cab sign of fluid leakage. STOP the engine immediately if
with the mounting holes in the frame. Stop and any leakage is noted, and make any necessary repairs
check that wiring, hydraulic hoses, cables, etc., will before continuing.
not be pinched or damaged as the cab is positioned. 18. Wait for the engine to cool and check the coolant
Readjust the position of the sling as needed to help level. Add coolant to the overflow bottle as required
balance the cab during installation. to bring the coolant to the proper level.
4. Install the four bolts through the cab/frame mounts 19. Reinstall engine belly pan.
and install the four washers and nuts. Remove the
sling and both lifting eye bolts. Tighten and torque 20. Reinstall the cab bottom shield.
the four mounting bolts to 150 Nm (110 lb-ft). 21. Close and secure the engine cover.
5. Uncap and connect the previously labeled heater 22. Unblock the wheels.
hoses to the heater assembly.
6. Uncap and connect the previously labeled air
conditioner lines (if equipped) to the heater
assembly.
7. Route the park brake cable back into the cab.
Secure the park brake cable to the park brake lever
with the pre-existing pin. Connect the previously
labeled electrical connector to the park brake lever.
8. Connect the throttle cable to the throttle pedal lever.
Adjust the throttle as required.
9. Route any hydraulic hoses through the opening at
the right front corner of the cab.
10. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
11. Connect the previously labeled windshield wiper
fluid lines to the appropriate locations.
12. Route the wiring harness connectors through the
opening at the right front corner of the cab and up
into the side console.
13. Connect the previously labeled cab-to-wiring
harness connectors.
14. Install the right side console panel, the right rear side
panel, the left rear cup holder panel and the rubber
floor mat.
15. Fill the cooling system completely with a 50/50
mixture of ethylene glycol and water, allowing time
for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.4, “Fluids,
Lubricants and Capacities.”

4.10 40.8, 40.9

 Section 5
Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.3 Axle Internal Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5.6
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.10
5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5.11
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.7.1 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

40.8, 40.9 5.1

 Axles, Drive Shafts, Wheels and Tires

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.

REAR AXLE
ASSEMBLY
STEERING
CYLINDER
(REAR)

TRANSMISSION
DROP BOX

STEERING
CYLINDER
(FRONT)

DRIVE SHAFTS

MZ1510

FRONT
AXLE
ASSEMBLY

5.2 40.8, 40.9

 Axles, Drive Shafts, Wheels and Tires

5.2 GENERAL INFORMATION 5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle,
IMPORTANT: To help ensure optimum performance,
differential, brakes and wheel-end safety, repair,
the drive shaft assemblies are specially balanced as a
disassembly, reassembly, adjustment and
unit at the factory. When servicing any flange yoke, slip
troubleshooting information) are provided in the Dana
yoke or drive shaft tube, order a complete assembly if
Spicer Maintenance and Repair Manual (P/N
components are bent of damaged. Refer to the
0.900.1168.9).
appropriate parts manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The axles
and drive shafts should be checked and repaired only by WARNING
experienced service technicians who are aware of all DO NOT service the machine without following all
safety instructions and particular component features. safety precautions as outlined in Section 1, “Safety
Use suitable products to thoroughly clean all Practices,” of this manual. Failure to follow the safety
disassembled mechanical parts to help prevent personal practices may result in death or serious injury.
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts 5.3.4 Axle Maintenance
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
(nuts, bolts, washers, etc.) as they are subject to major CLEANING: Clean parts with machined or ground
stress and wear. Always replace elastic locknuts and any surfaces (such as gears, bearings and shafts) with
damaged, worn, cracked, seized or otherwise improper emulsion cleaners or petroleum-based cleaners. DO
parts that could affect the safe and proper functioning of NOT steam clean internal components and the interior of
the machine, axles and drive shafts. the planetary hub and axle housing. Water can cause
corrosion of critical parts. Rust contamination in the
5.3 AXLE ASSEMBLIES lubricant ca n cause gear and bearing failure. Remove
old gasket material from all surfaces.
DRYING: Use clean, lintless towels to dry components
5.3.1 Axle Serial Number Plate after cleaning. DO NOT dry bearings by spinning them
The front and rear axle serial number plate is located on with compressed air; this can damage mating surfaces
a mounting pad on the front side of the center section of due to lack of lubrication. After drying, lightly coat
each axle. Information on the serial number plate is components with oil or a rust-preventive chemical to help
required in correspondence regarding the axle. protect them from corrosion. If storing components for a
Supply information from the axle serial number plate prolonged period, wrap them in wax paper.
when communicating about an axle assembly or axle PERIODIC OPERATION REQUIREMENT: Every two
components. weeks, drive the machine far enough to cause the drive-
train components to make several complete revolutions.
5.3.2 Axle Specifications This will help ensure that internal components receive
General axle specifications are found in Section 2.4, lubrication to minimize deterioration caused by
“Fluids, Lubricants and Capacities.” environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to
water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
tube (breather), drain the axle and inspect internal parts
for water damage and contamination. Before assembling
and refilling the unit with the specified lubricant(s), clean,
examine and replace damaged parts as necessary.
Note: Use a suitable puller for bearing removal. Clean,
inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or
cone is necessary, replace the cup and cone as a set.

40.8, 40.9 5.3

 Axles, Drive Shafts, Wheels and Tires

5.3.5 Axle Removal

The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid 2
spraying water or cleaning solution on the outrigger MZ1520
solenoids and other electrical components. If using a
steam cleaner, seal all openings before steam cleaning. 7. Label, disconnect and cap the steering and brake
lines at the axle. Wipe up any spilled oil.
IMPORTANT: Clear the work area of all debris,
unnecessary personnel, etc. Allow sufficient space to 8. Block the front and rear of both tires on the axle that
raise the machine and to remove the axle. is not being removed. Ensure that the machine will
remain in place during axle removal before
1. Park the machine on a firm, level surface, level the proceeding.
machine, fully retract the boom, lower the boom,
place the transmission control lever in 9. Raise the machine using a suitable jack or hoist.
(N) NEUTRAL, engage the park brake and shut the Place suitable supports under both sides of the
engine OFF. frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
2. Place a Do Not Operate Tag on both the ignition key axle removal.
switch and steering wheel, stating that the machine
should not be operated. 10. Support the axle that is being removed with a suitable
jack, hoist or overhead crane and sling. DO NOT
3. Open the engine cover. Allow the system fluids to raise the axle or the machine.
cool.
11. Mark and remove both wheel and tire assemblies
4. Disconnect the battery negative (-) cable at the from the axle that is being removed. Refer to Section
battery negative (-) terminal. 5.5.1, “Removing Wheel and Tire Assembly from
5. Remove the fender assemblies. Machine.”
6. If the axle will be disassembled after removal, place 12. Remove the drive shaft assembly. Refer to Section
a suitable receptacle under the axle (1) and wheel 5.4.3, “Drive Shaft Removal.”
hubs drain plugs (2). Remove the drain plugs and 13. On the front axle, remove the hardware securing the
allow the axle oil to drain into the receptacle. sway cylinder or bar. Tap the mount pin out, and
Transfer the used axle oil into a suitable covered move the cylinder or bar to prevent it from interfering
container, and label the container as "Used Oil". with axle removal.
Dispose of used oil at an approved recycling facility.
14. Remove the park brake cable from the front axle.
15. Remove the bolts and locknuts securing the axle to
the frame.
16. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
machine while removing the axle. Balance the axle
MZ1030
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
1

5.4 40.8, 40.9

 Axles, Drive Shafts, Wheels and Tires

5.3.6 Axle Installation

3
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and limited-slip feature; the rear axle has
neither. The steps below outline a typical axle installation
procedure, suitable for either the front or the rear axle
assembly.
1. Before proceeding, ensure that the machine will
remain in place during axle installation. Block the MZ1030
front and rear of both tires on the axle that is already
4
installed on the machine.
2. If applicable, raise the machine using a suitable jack 11. Rotate wheel hubs 90 degrees so the drain plug
or hoist. Place suitable supports beneath the frame becomes the fill plug. Refer to Section 2.4, “Fluids,
and lower the machine onto the supports, allowing Lubricants and Capacities,” for proper oil and
enough room for axle installation. Ensure that the capacities.
machine will remain in place during axle installation. 12. Install the wheel and tire assemblies. Refer to
3. Using a suitable jack, hoist or overhead crane and Section 5.5.2, “Installing Wheel and Tire Assembly
sling, remove the axle from its support or holding onto Machine.”
stand. Balance the axle and prevent it from tipping, Note: Be sure the directional tread pattern "arrows" of
turning or falling while positioning it beneath the the tires are facing in the direction of forward travel.
machine. DO NOT raise or otherwise disturb the
machine while installing the axle. Keep the axle 13. Carefully remove the jack, hoist or overhead crane
supported and balanced on the jack, hoist or and sling supporting the axle.
overhead crane and sling throughout the installation 14. Carefully raise the machine using a suitable jack or
procedure. hoist. Remove the supports from beneath the frame
4. Position the axle under the frame, and align the axle and lower the machine to the ground.
housing with the holes in the frame. Note: ALWAYS use new o-rings when servicing the
5. Install the axle bolts and nuts. Tighten and torque the machine.
axle nuts to 550-600 Nm (406-443 lb-ft). 15. Install new o-rings into the fittings. Lubricate the
6. Move the cylinder or bar into position on the front o-rings with clean hydraulic oil.
axle anchor (if necessary). Install the mount pin. 16. Uncap and connect the steering and brake lines at
7. Apply a multi-purpose grease through the self- their axle fittings.
tapping lube fitting to lubricate the self-align bearing 17. Install the park brake on the front axle.
and the cylinder-mount pin (if required).
18. If reinstalling the front axle, the hydraulic brake
8. Install the drive shaft assemblies. Refer to Section circuit will need to be bled. Refer to Section 8.8.3,
5.4.5, “Drive Shaft Installation.” “Brake Test.”
9. If reinstalling an axle previously removed from the 19. Check the hydraulic reservoir oil level.
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If 20. Install the fender assemblies.
installing a new axle, note the position of the 21. Unblock the wheels.
driveshaft yoke at the transmission. Align the 22. Start the engine. Turn the steering wheel several
driveshaft yoke on the axle in the same plane as the times lock to lock, operate the frame tilt function
yoke on the transmission. several times in both directions and check the
10. Tighten the axle oil drain plug, loosen and remove function of the brakes. Check for hydraulic leaks,
the axle oil fill plug (3). Fill the axle through the axle and tighten or repair as necessary.
fill plug until the oil level is even with the oil check
23. Close and secure the engine cover.
level plugs (4). Refer to Section 2.4, “Fluids,
Lubricants and Capacities,” for proper oil and
capacities.

40.8, 40.9 5.5

 Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.4, “Fluids, Lubricants
and Capacities.”

2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with DF UTTO Tractor Hydraulic
Fluid ISO 46. Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”

3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by
bearing preload. adding or removing shims as
needed.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end
housings and fill to correct level
with DF UTTO Tractor Hydraulic
Fluid ISO 46. Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”

8. Axle housing damaged. 8. Replace damaged parts.

2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal

traveling. damaged. joints as needed.

2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.

3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.

2. Drive shaft universal joint(s) 2. Repair or replace universal

worn or damaged. joints as needed.

3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as

unbalanced. needed.

5.6 40.8, 40.9

 Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged tighten plugs to 130 Nm
axle housings). or missing. (96 lb-ft).

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or 3. Replace seal and/or joint

missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or
damaged or missing and/or input shaft. Adjust ring and
worn or damaged pinion (input) pinion alignment and bearing
shaft sealing surfaces. preload as described in the
Dana Repair Manuals.

5. Axle casing to brake housing 5. Replace o-rings and seals.

and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.

6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews to 390 Nm
(288 lb-ft).

7. Differential and/or axle 7. Replace housing(s) as needed.

housing(s) damaged.

5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 130 Nm
(96 lb-ft).

2. O-ring between hub and 2. Replace o-ring.

housing (planet carrier)
damaged or missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint
and/or worn or damaged shaft shaft.
sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

55 Nm (41 lb-ft).

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.
cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.

3. Piston rod seal worn or 3. Replace piston rod seal.

damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

40.8, 40.9 5.7

 Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with DF
UTTO Tractor Hydraulic Fluid
ISO 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”

2. Axle and/or wheel end housings 2. Drain axle and fill to correct
filled with incorrect oil or oil level with DF UTTO Tractor
contaminated or oil level low. Hydraulic Fluid ISO 46. Refer
toSection 2.4, “Fluids,
Lubricants and Capacities.”

3. Dragging park brake. 3. Adjust park brake cable as

needed.

8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.9.8, “Steering
operating properly. Cylinders.”

2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.

3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.

9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.9.8, “Steering
operating properly. Cylinders.”

2. Steering cylinder leaking 2. Repair or replace steering

internally. cylinder as needed.

10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 5.6, “Brakes.”
2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.9.8, “Steering
operating properly. Cylinders.”

2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 5.6, “Brakes.”
reduced.
2. Brake (hydraulic) system not 2. Refer to Section 8.8.3, “Brake
operating properly. Test.”

3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).

5.8 40.8, 40.9

 Axles, Drive Shafts, Wheels and Tires

5.4 DRIVE SHAFTS returned to their original positions when reinstalled.

Yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
5.4.1 Drive Shaft Inspection and Service
7. Remove the four capscrews and two straps securing
Whenever servicing the machine, conduct a visual the bearing cross to the transmission output shaft
inspection of the drive shaft and cross and bearing flange.
assembly (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and 8. Remove the four capscrews and two straps securing
down time later. the bearing crosses to the axle.

Inspect area where the drive shaft flange yoke and slip 9. Remove the front drive shaft assembly.
yoke mount to the drive shaft. Attempt to turn drive shaft 10. Repeat the above procedure for the rear drive shaft.
in both directions. Look for excessive looseness, missing
parts, cracks or other damage. Worn or damaged drive To Transmission
shaft and cross and bearing assembly may cause an
excessive amount of vibration or noise.

5.4.2 Drive Shaft Maintenance

Refer to Section 2.6, “Lubrication Schedules,” for
information regarding the lubrication of the grease fittings
on the drive shafts.

5.4.3 Drive Shaft Removal To Axle

IMPORTANT: To help ensure optimum performance,

the drive shaft assemblies are specially balanced as a
unit at the factory. When servicing any flange yoke, slip
yoke or drive shaft tube, order a complete assembly if 5.4.4 Drive Shaft Cleaning and Drying
components are bent or damaged. Refer to the appropriate 1. Disassemble and clean all parts using an approved
parts manual for ordering information. cleaning fluid. Allow to dry.
Note: The drive shaft assemblies are balanced 2. Remove any burrs or rough spots from all machined
assemblies. Mark the yoke and axle, transmission, surfaces. Re-clean and dry as required.
transfer case, and the shaft and slip yoke so that these
components can be returned to their original positions 5.4.5 Drive Shaft Installation
when reinstalled. Yokes at both ends of the drive shaft IMPORTANT: To help ensure optimum performance,
must be in the same plane to help prevent excessive the drive shaft assemblies are specially balanced as a
vibration. unit at the factory. When servicing any flange yoke, slip
1. Park the machine on a firm, level surface, level the yoke or drive shaft tube, order a complete assembly if
machine, fully retract the boom, lower the boom, components are bent or damaged. Refer to the
place the transmission control lever in appropriate parts manual for ordering information.
(N) NEUTRAL, engage the park brake and shut the 1. Raise the drive shaft assembly into position. The
engine OFF. slip-yoke end of the drive shaft mounts toward the
2. Place a Do Not Operate Tag on both the ignition key axle. If reinstalling a drive shaft previously removed,
switch and steering wheel, stating that the machine align the flange yokes according to the alignment
should not be operated. marks made during removal.
3. Open the engine cover. Allow the engine to cool. 2. Install the four capscrews and two straps securing
the bearing crosses to the transmission. Torque the
4. Disconnect the battery negative (-) cable at the capscrews to 38 Nm (28 lb-ft).
battery negative (-) terminal.
3. Install the four capscrews and two straps securing
5. Block the wheels. the bearing crosses to the axle. Torque the
6. The drive shaft assembly is a balanced assembly. capscrews to 38 Nm (28 lb-ft).
Mark the yoke and axle, transmission and the shaft 4. Repeat the above procedure on the rear drive shaft.
and slip yoke so that these components can be
40.8, 40.9 5.9
 Axles, Drive Shafts, Wheels and Tires

5. Connect the battery negative (-) cable at the battery

4
negative (-) terminal.
6. Unblock the wheels.
7. Close and secure the engine cover.

5.5 WHEELS AND TIRES

WARNING
Risk of death or serious personal injury. Mismatched
tire sizes, ply ratings or mixing of tire types (radial
tires with bias-ply tires) may compromise machine
stability and may cause machine to tip over.

SDF recommends a replacement tire to be the same size,

ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using a SDF approved replacement tire, SDF
recommends that replacement tires have the following
characteristics:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than
original.
MAH0890
• Wheel diameter, width and offset dimensions equal
to the original.
5.5.1 Removing Wheel and Tire Assembly
• Approved for the application by the tire manufacturer from Machine
(including inflation pressure and maximum tire load).
1. Park the machine on a firm, level surface, level the
The rims installed have been designed for stability machine, fully retract the boom, lower the boom,
requirements which consist of track width, tire pressure place the transmission control lever in
and load capacity. Size changes such as rim width, (N) NEUTRAL, engage the park brake and shut the
center piece location, larger or smaller diameter, etc., engine OFF.
without written factory recommendations, may result in
2. Place a Do Not Operate Tag on both the ignition key
unsafe condition regarding stability.
switch and steering wheel, stating that the machine
The tires are filled with air only when the machine leaves should not be operated.
the factory. SDF does not recommend the use of hydrofill
3. Loosen, but DO NOT remove the lug nuts on the
as a tire-fill substance because of possible environmental
wheel and tire assembly to be removed.
impact.
4. Place a suitable jack under the axle pad closest to
Large-bore valve stems are used to help expedite tire
the wheel being removed. Raise the machine and
inflation and deflation. An inner tube may be used if a tire
position a suitable support beneath the axle. Allow
does not provide an airtight seal. Check tire inflation
sufficient room to lower the machine onto the
pressures when the tires are cold. When mounting a tire
support and to remove the wheel and tire assembly.
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this 5. Lower the machine onto the support.
produces a left or right tire and wheel assembly. 6. Remove lug nuts and lug washers in an alternating
The wheel and tire assemblies must be installed with the pattern.
directional tread pattern “arrows” (4) facing in the 7. Remove the wheel and tire assembly from the
direction of forward travel. machine.

5.10 40.8, 40.9

 Axles, Drive Shafts, Wheels and Tires

5.5.2 Installing Wheel and Tire Assembly 5.6 BRAKES

onto Machine
IMPORTANT: The wheel and tire assemblies must be 5.6.1 Brake Disk Inspection.
installed with the directional tread pattern “arrows” facing
in the direction of forward travel. a. Front and Rear Axles

WARNING
BLOCK ALL FOUR WHEELS. Failure to do so could
result in death or serious injury from machine roll-
away.

1. Block all four wheels to help prevent the machine

from moving after the parking brake is disabled.
2. Remove the oil-level plug (7) on each side of the
axle.
3. Have an assistant sit in the cab and apply the
brakes, keeping pressure applied.
4. Using a feeler gauge, check the gap between the
brake discs. If the gap is less than 4,5 mm (0.18"),
replace the brake discs.
Note: If the brake discs are worn beyond their
tolerance, the brake disc must be replaced on both sides
of the axle at the same time.

Mh3300

1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
4. Tighten lug nuts in an alternating pattern as
indicated in figure. Torque to 575 Nm (424 lb-ft).

3 5
1 7

10 9
4,5 mm
8 2
6 4

OY1220

5. Remove machine from supports.

40.8, 40.9 5.11

 Axles, Drive Shafts, Wheels and Tires

MZ1030

5. Repeat steps 3 and 4 for the other side of the axle.

6. Fill the axle through the axle fill plug (6) until the oil
level is even with the oil check level plugs (7). Refer
to Section 2.4, “Fluids, Lubricants and Capacities,”
for proper oil and capacities.

5.7 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as
a last resort, after exhausting all other options. Make
every effort to repair the machine, and move it under its
own power, before using the emergency towing
procedures outlined below.

5.7.1 Towing
1. Secure the machine to a suitable towing vehicle.
2. Release the park brake and set the transmission
control lever in (N) NEUTRAL.
3. Tow the machine to a suitable repair facility.
4. After towing is complete, engage the park brake.

5.12 40.8, 40.9

 Section 6
Transmission:

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

40.8, 40.9 6.1

 Transmission:

6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.

TORQUE CONVERTOR
DIPSTICK AND FILL TUBE

OIL FILTER
OUTPUT SHAFT
(FRONT)

BREATHER

OUTPUT SHAFT
(REAR)
BREATHER

DROP BOX OIL LEVEL

SIGHT GAUGE

MZ0670
TRANSMISSION DROP BOX
SHIFT SOLENOIDS
FLEX PLATE ASSEMBLY

6.2 40.8, 40.9

 Transmission:

6.4.2 Transmission Maintenance Schedule

Complete transmission maintenance information is
WARNING located in the appropriate Operation & Safety Manual.
DO NOT service the machine without following all • At ten hour intervals, check the transmission oil
safety precautions as outlined in Section 1, “Safety level. Refer to the appropriate Operation & Safety
Practices,” of this manual. Failure to follow the safety Manual.
practices may result in death or serious injury. • When the machine completes it’s first 50 hours of
use, change the transmission filter. Change the filter
6.2 TRANSMISSION DESCRIPTION only; DO NOT change the transmission oil at the first
50 hour maintenance level. Refer to the appropriate
Instructions in this section pertain mainly to general Operation & Safety Manual.
specifications, towing, maintenance information, and • At 1,000 hour intervals, change the transmission oil
transmission removal and installation procedures. For and filter. Refer to the appropriate Operation &
internal transmission service instructions and detailed Safety Manual.
specifications contact your local authorized service Periodically, depending on operating conditions and
distributor for a copy of the Dana Spicer Repair Manual other factors, back flush the transmission oil cooler,
(P/N 0.900.1168.9). which is located in or behind the radiator. ALWAYS back
flush the transmission oil cooler after removing the
6.3 TRANSMISSION SERIAL NUMBER transmission for repair or replacement.

The transmission serial number plate is located on the The transmission oil cooler outlet hose, routed to the
front of the transmission case below the convertor lower oil cooler fitting, is located on the top of the
housing. Information specified on the serial number plate transmission. The transmission oil cooler inlet hose,
includes the transmission model number, the routed to the upper oil cooler fitting, is located on the top
transmission serial number and other data. Information of the transmission Refer to Section 7.4, “Engine Cooling
on the serial number plate is required in correspondence System.”
regarding the transmission. Disconnect and back flush the oil cooler portion of the
radiator or the oil cooler with oil and compressed air until
6.4 TRANSMISSION SPECIFICATIONS all foreign material is removed. If necessary, remove the
radiator or oil cooler from the machine, and clean the oil
cooler circuit using oil, compressed air and steam.
6.4.1 Transmission Maintenance
IMPORTANT: DO NOT use flushing compounds for
Cleanliness is of extreme importance. Before attempting cleaning purposes.
any repairs, thoroughly clean the exterior of the
transmission to help prevent dirt from entering while 6.5 TRANSMISSION REPLACEMENT
performing maintenance checks and procedures.
Section 2.5, “Maintenance Schedules.” provides a Note: Contact the SDF Service Department if internal
suggested maintenance schedule with references to transmission repair is required during the warranty
pertinent procedures and instructions in this manual. To period.
help prevent transmission problems before they occur,
IMPORTANT: To help ensure safety and optimum
follow the maintenance schedule.
performance, replace the transmission if it is damaged.
Note: Lubrication and Maintenance chart decals are Refer to the appropriate Parts Manual for ordering
located inside the rear door of the machine or in the cab. information.
These decals contain a general maintenance schedule Cleanliness is of extreme importance. Before attempting
that should be followed to maintain the machine in good to remove the transmission, thoroughly clean the exterior
operating condition. Refer to Section 2.6, “Lubrication of the transmission to help prevent dirt from entering
Schedules.” The same schedule information is during the replacement process. Avoid spraying water or
presented in the appropriate Operation & Safety Manual, cleaning solution onto or near the transmission shift
with a detailed account of how to perform the solenoids and other electrical components.
procedures.

40.8, 40.9 6.3

 Transmission:

6.5.1 Transmission Removal 10. Remove the drive shafts. Refer to Section 5.4.3,
“Drive Shaft Removal.”

WARNING 11. Remove the air cleaner unit and intake tubes.
12. Remove the hydraulic pump. Refer to Section 8.7.3,
Risk of severe personal injury. NEVER lift a “Pump Replacement.”
transmission alone; enlist the help of at least one 13. Label and disconnect the transmission temperature
assistant or use a suitable hoist or overhead crane switch connector and shift solenoid wiring harness
and sling. connectors.
1. Park the machine on a firm, level surface, level the 14. Label, disconnect and cap the transmission oil
machine, fully retract the boom, lower the boom, cooler inlet and outlet hoses at the transmission. The
place the transmission control lever in the transmission oil cooler outlet hose, routed to the
(N) NEUTRAL, engage the park brake and shut the lower radiator fitting, is located on the top of the
engine OFF. transmission. the transmission oil cooler inlet hose,
2. Place a Do Not Operate Tag on both the ignition key routed to the upper radiator fitting, is located on top
switch and steering wheel, stating that the machine of the transmission.
should not be operated. 15. Remove the access plug from the side of the engine
3. Open the engine cover. Allow the engine to cool. bell housing. This will allow access to remove the
eight bolts holding the flex plate to the engine
4. Remove the engine cover to allow easier access to
flywheel.
the transmission.
16. Turn the engine over slowly by hand and align each
5. Remove the belly pan from under engine.
of the eight flex plate bolts to be accessed. Remove
6. Disconnect the (+) positive and (-) negative battery them one at a time.
cables and remove the battery.
17. Wipe up any spilled hydraulic and transmission oil.
7. Thoroughly clean the transmission and surrounding
18. Connect a lifting strap or chain to the lifting eye at
area, including all hoses and fittings, before
the top of the transmission, and to a suitable hoist or
proceeding.
overhead crane. Operate the hoist or crane to
8. Place a suitable receptacle under the transmission remove slack from the chain, but DO NOT raise the
drain plug (1). Remove the transmission drain plug transmission at this time.
and allow the transmission oil to drain into the
19. Place blocks under the rear of engine for support
receptacle. Repeat drain procedure with the drop
BEFORE transmission mounts are removed.
box (2).
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the ten bolts and washers holding the
transmission to the engine.
23. Remove the four capscrews and four lockwashers
securing each rear transmission mount to the
1
transmission.
24. Remove the two transmission mounts from the
MZ1380
2 machine.
25. Inspect the rubber mounts. Replace the mounts if
9. Transfer the used transmission oil into a suitable,
damaged.
covered container, and label the container "Used
Oil". Dispose of used oil at an approved recycling 26. Carefully remove the transmission from the
facility. Clean and reinstall the transmission drain machine. Avoid causing damage to the transmission
plug. or surrounding parts.

6.4 40.8, 40.9

 Transmission:

27. Lift the transmission clear of the machine, and lower 6.5.3 Transmission Installation
it onto suitable supports or secure it to a stand built
1. Install both the rear transmission mounts on the
especially for transmission or engine service. Secure
transmission. Torque capscrews to 120 Nm
the transmission so that it will not move or fall.
(88 lb-ft).
28. Remove any external transmission components as
2. Install guide studs near the top of the bell housing
required, including the transmission temperature
holes and in the flex plate.
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings. 3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
29. Remove the transmission oil filter (3) and dispose of
and position the transmission within the chassis.
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount. 4. Align the torque convertor, align the transmission
bolt holes with the guide studs in the bell housing
3 and flex plate. Install the eight bolts and washers
and torque to 63 Nm (46 lb-ft). Remove the
alignment studs and install and torque the last two
transmission mount bolts and torque to 63 Nm
(46 lb-ft).
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite® 242 threadlock to the transmission
mount bolts and torque to 210 Nm (155 lb-ft).
6. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Install
them one at a time. Torque to 35-39 Nm (26-29 lb-ft).
Replace access plug.
7. Remove the hoist or overhead crane and sling.
8. Connect the transmission temperature switch
MZ0680 connector and shift solenoid wiring harness
30. If transmission oil is suspected of contamination or connectors.
torque convertor is damaged, remove the convertor 9. Secure the wiring harness to the transmission
and flex plate from the transmission. housing.
31. Remove the six bolts and washers holding the 10. Uncap and connect the transmission oil cooler inlet
convertor to the flex plate. and outlet hoses at the transmission.
11. Install the hydraulic pump. Refer to Section 8.7.3,
6.5.2 Transmission Inspection and Internal
“Pump Replacement.”
Repair
12. Install the transmission-to-axle drive shafts. Refer to
If replacing the entire transmission, transfer the
Section 5.4.5, “Drive Shaft Installation.”
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a 13. Install air cleaner and tubing.
new transmission. 14. Clean the transmission oil filter mounting surface.
Detailed internal service instructions are provided in the 15. Apply a thin film of clean DF UTTO Tractor Hydraulic
Dana Spicer Repair Manual, which can be obtained by Fluid ISO
contacting your local SDF Distributor. Grade 46 to the new transmission filter gasket.
Install the new filter and torque to 27-34 Nm
(20-25 lb-ft).
16. Transmission oil may be added through the dipstick
tube. Remove the dipstick and add approximately
11,4 liters (3 Gallons) of DF UTTO Tractor Hydraulic
Fluid ISO
Grade 46. Check the oil level by taking intermittent

40.8, 40.9 6.5

 Transmission:

dipstick readings as outlined in the appropriate 9. Reassemble all components and fill the transmission
Operation & Safety Manual. DO NOT overfill. with clean, fresh DF UTTO Tractor Hydraulic Fluid
Reinstall the dipstick when finished. ISO Grade 46 through the dipstick tube opening (4).
17. Install the belly pan under the engine. Remove the dipstick and fill with approximately 11
liters
18. Install the engine cover. (2.5 gallons) of DF UTTO Tractor Hydraulic Fluid
19. Install the battery and reconnect the positive (+) and ISO Grade 46. Check the level by taking intermittent
negative (-) cables. dipstick readings as outlined in the appropriate
20. Close and secure the engine cover. Operation & Safety Manual. DO NOT overfill.
Reinstall the dipstick when finished.
6.5.4 After Transmission Service or
Replacement
Refer to the Dana Spicer Transmission Repair Manual 4
which can be obtained by calling your local SDF
Distributor.
In General:
1. Check the transmission oil level and add oil as
required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke capscrews.
4. Wear suitable eye protection. When an overhauled
or repaired transmission is installed, thoroughly
clean the oil cooler lines to and from the
transmission.
5. Drain and flush the entire system.
MZ0680
6. Disconnect and clean all transmission cooler hoses.
When possible, remove transmission lines from the 10. Run the engine for two minutes at idle to help prime
machine for cleaning. the torque convertor and the transmission oil lines.
7. Thoroughly clean transmission filter screens and 11. Recheck the level of the fluid in the transmission
cases, and replace transmission filter elements. with the engine running at idle.
12. Add DF UTTO Tractor Hydraulic Fluid ISO Grade 46
as necessary to bring the fluid level up until it
reaches the FULL mark on the dipstick. Recheck the
CAUTION oil level when it reaches operating temperature 83-
94°C (180-200°F).
DO NOT exceed 11,4 bar (165 psi) when back
flushing the oil cooler. Applying too much pressure 13. Recheck all drain plugs, lines, connections, etc. for
may damage the oil cooler/radiator. leaks, and tighten where necessary.

8. Back flush the transmission oil cooler portion of the

radiator or the oil cooler (located behind the radiator)
with oil and compressed air until all foreign material
is removed. Flushing in the direction of normal oil
flow does not adequately clean the cooler. If needed,
remove the radiator or oil cooler from the machine.
IMPORTANT: DO NOT use flushing compounds for
cleaning purposes.

6.6 40.8, 40.9

 Transmission:

6.6 TROUBLESHOOTING The transmission should be checked, serviced and

repaired only by experienced service technicians who are
This section provides an easy reference guide covering aware of all safety instructions and particular component
the most common problems that may occur during features.
operation of the transmission.
Note: Contact the SDF Service Department if internal
transmission repair is required during the warranty
period.

Problem Cause Remedy

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with DF UTTO Tractor Hydraulic
Fluid ISO
Grade 46. (Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”)

2. Transmission control lever not 2. Refer to Section 9.6.1, “Cab

functioning properly and/or a Harness Electrical Schematic.”
fault in the wiring
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.

3. Transmission valve body 3. Refer to Section 9.6.1, “Cab

solenoids not functioning Harness Electrical Schematic.”
properly.

4. Pilot-operated shift valves not 4. Clean the valve spool and

operating properly. housing. Replace return spring
as needed.

5. Pump output pressure low. 5. Refer to Section 6.6,

“Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.

7. Clutch discs worn or damaged. 7. Replace clutch discs.

8. Coupling shafts or gear teeth 8. Replace couplings.

damaged.

40.8, 40.9 6.7

 Transmission:

Problem Cause Remedy

2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with DF UTTO Tractor Hydraulic
Fluid ISO
Grade 46. (Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”)

2. Transmission filled with 2. Drain transmission and fill to

incorrect oil, or oil correct level with DF UTTO
contaminated. Tractor Hydraulic Fluid ISO
Grade 46. (Refer Section 2.4,
“Fluids, Lubricants and
Capacities.”)

3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.

4. Central shaft damaged. 4. Replace central shaft.

5. Pump worn or damaged. 5. Repair or replace pump

assembly.

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with DF UTTO Tractor Hydraulic
Fluid ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.

3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.

piston o-rings.

4. Pressure reducing valve stuck 4. Clean the valve spool and

open. housing.

6.8 40.8, 40.9

 Transmission:

Problem Cause Remedy

4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5, “Hydraulic
Schematics.”

2. Low engine rpm causes 2. Adjust the engine rpm to

converter stall. specifications. Refer to Dana-
Spicer Service Manual.

3. Pump output pressure is low. 3. Refer to Section 6.6,

“Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.

5. Transmission overheating. 5. Refer to Section 6.6,

“Troubleshooting,” Problem 5.
“Transmission overheating (oil
above 120° C (248° F)).”

5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level

(oil above 120° C (248° F)). with DF UTTO Tractor Hydraulic
Fluid ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”

2. Clogged radiator. 2. Remove debris from the

radiator.

3. Transmission filled with 3. Drain transmission and fill to

incorrect oil, or oil correct level with DF UTTO
contaminated. Tractor Hydraulic Fluid ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”

4. Excessive “roading.” 4. Stop and idle the engine.

5. Restriction in oil cooler hoses. 5. Replace cooler hoses.

6. Pump worn or damaged. 6. Repair or replace pump

assembly.

7. Engine thermostat stuck. 7. Replace engine thermostat.

Refer to Section 7.4.2,
“Thermostat Replacement.”

40.8, 40.9 6.9

 Transmission:

Problem Cause Remedy

6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, “Fluids, Lubricants
and Capacities.”

2. Transmission filled with 2. Drain transmission and fill to

incorrect oil. correct level with DF UTTO
Tractor Hydraulic Fluid ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”

3. Incorrect clutch engagement. 3. Refer to Section 9.13.1,

“Transmission Solenoid Valves.”
4. Internal damage. 4. Repair or replace parts as
needed.

5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).

Refer to Section 6.5.1,
“Transmission Removal.”

6. Loose diaphragm (flex plate) 6. Tighten capscrews.

mounting capscrews.

6.10 40.8, 40.9

 Transmission:

Problem Cause Remedy

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.” Replace o-rings as
needed and tighten plugs to
130 Nm (96 lb-ft).

2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and

damaged or missing. tighten plug to 35 Nm (26 lb-ft).

3. Hose fittings loose. 3. Tighten fittings.

4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten
(possible valve body gaskets capscrews to 9,5 Nm (7 lb-ft).
damaged or missing and/or
mounting capscrews not tight).

5. Housing capscrews loose. 5. Tighten capscrews to 46 Nm

(34 lb-ft).

6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten

pump-to-housing o-rings capscrews to 115 Nm (85 lb-ft).
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell 7. Replace converter and/or input
(possible converter leak and/or shaft seal.
input shaft seal damage).

8. Oil leaking at output shaft 8. Replace output shaft seal.

(output shaft seal damaged).

9. Housing damaged. 9. Replace housing as needed.

40.8, 40.9 6.11

 Transmission:

6.12 40.8, 40.9

 Section 7
Engine: Perkins 1104-42 & 1104-42T

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7.5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7.10
7.9.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.10 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.10.1 Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.10.2 Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

40.8, 40.9 7.1

 Engine: Perkins 1104-42 & 1104-42T

7.1 INTRODUCTION A gradual running-in (break-in) of a new engine is not

necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
7.1.1 Disclaimer and Scope temperature is at least 60° C (140° F). Extended light-
These instructions are written for worldwide use. In load operation during the early life of the engine is not
territories where legal requirements govern engine smoke recommended. DO NOT run the engine at high, no-load
emission, noise, safety factors, etc., apply all instructions, speeds. DO NOT apply an overload to the engine.
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
IMPORTANT: These instructions cover only the routine
maintenance, removal, installation and troubleshooting
of the engine. For assistance with comprehensive
engine diagnosis, repair and component replacement,
contact your local Perkins Service partner.

7.2 40.8, 40.9

 Engine: Perkins 1104-42 & 1104-42T

7.1.2 Component Terminology

To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.

FUEL INJECTION
PUMP

FUEL FILTER

OIL FILTER

THERMOSTAT

ALTERNATOR

TURBOCHARGER

STARTER

MZ0070

40.8, 40.9 7.3

 Engine: Perkins 1104-42 & 1104-42T

7.2 ENGINE SERIAL NUMBER a. Thermostat Removal

1. Park the machine on a firm, level surface, level the
The Perkins serial number is stamped on a plate which is
machine, fully retract the boom, lower the boom,
secured to the engine block, near the fuel injector pump.
place the transmission control lever in
Information contained in the serial number is required in
(N) NEUTRAL, engage the park brake and shut the
correspondence with the engine manufacturer.
engine OFF.

7.3 SPECIFICATIONS AND 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
MAINTENANCE INFORMATION should not be operated.
For engine, coolant and oil specifications, and 3. Open the engine cover. Allow the system fluids to
maintenance information, refer to Section 2, “General cool.
Information and Specifications.” 4. Disconnect the battery negative (-) cable from the
Note: These instructions cover only the routine battery negative (-) terminal.
maintenance, removal, installation and troubleshooting 5. Slowly turn the radiator cap to the first stop and allow
of the engine. Refer to your local Perkins Engine any pressure to escape. Remove the radiator cap.
Distributor for assistance with comprehensive engine 6. Place a funnel at the base of the radiator to channel
diagnosis, repair and component replacement. the drained coolant into the container. Loosen the
drain plug and slowly remove to allow the coolant to
7.4 ENGINE COOLING SYSTEM drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
7.4.1 Radiator Pressure Cap replaced. Replace the radiator drain plug.

For a 99° C (210° F) system, use a 90 kPa (13 psi) 1

radiator cap. An incorrect or malfunctioning cap can
result in the loss of coolant and a hot-running engine.

7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If the engine seems to take a long time to warm up,
the thermostat may be stuck in the open position
and requires replacement.
• If the engine runs hot, check the temperature of the
upper radiator hose.
• If the hose is not hot, the thermostat may be stuck in
the closed position.
MZ2180
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking 7. Remove the two capscrews securing the thermostat
cylinder head gasket, cracked cylinder head or housing (1) to the engine.
block, and/or other internal engine damage. 8. Remove the thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let
any debris into the thermostat opening.
IMPORTANT: ALWAYS use the correct thermostat and
install a new gasket. NEVER operate the engine without
a thermostat, or engine damage will result.

7.4 40.8, 40.9

 Engine: Perkins 1104-42 & 1104-42T

b. Thermostat Installation
1. Install the engine thermostat, thermostat gasket and 6
thermostat housing. Secure with the two capscrews.
Torque to 24 Nm (18 lb-ft).
4
2. Connect the battery negative (-) cable to the battery
negative (-) terminal.
7
3. Open the radiator cap, and fill the radiator 8
completely with a 50/50 mixture of ethylene glycol
and water. Replace and tighten the radiator cap. Add
coolant to the overflow bottle until the bottle is 1/4 to
1/2 full. This overfilling will compensate for any air
trapped in the cooling system.
4. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain, 2

as necessary.
5. Close and secure the engine cover.
7

3
7.4.3 Radiator/Oil Cooler and Coolant
Heater Replacement 5
MZ2070
Before considering radiator or oil cooler replacement for
other than obvious damage, conduct a cooling system 6. Remove the coolant overflow bottle (2).
pressure test check the coolant specific gravity, coolant 7. Remove the radiator fan shroud (3) and the engine
level, fan belt tension and dash panel temperature belly pan.
indicator. 8. Slowly turn the radiator cap to the first stop and allow
• If the engine runs hot, check the temperature of any pressure to escape. Remove the radiator cap.
the upper radiator hose. 9. Place a suitable container beneath the radiator drain
• If the hose is not hot, the thermostat may be plug.
stuck in the closed position. 10. Place a funnel at the base of the radiator to channel
• If the engine has overheated, performance may the drained coolant into the container. Loosen the
suffer, indicating other damage including a leaking drain plug and slowly remove to allow the coolant to
cylinder head gasket, cracked cylinder head or drain. Transfer the coolant into a properly labeled
block, and/or other internal engine damage. container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
a. Radiator/Oil Cooler Removal 11. Loosen the radiator clamp on the top (4) and bottom
1. Park the machine on a firm, level surface, level the (5) radiator hoses. Work the hoses off the radiator.
machine, fully retract the boom, lower the boom, Position the hoses out of the way to allow radiator
place the transmission control lever in removal, or remove the hoses from the engine.
(N) NEUTRAL, engage the park brake and shut the Inspect the hoses, and replace if necessary.
engine OFF. 12. Disconnect and plug the oil cooler top (6) and
2. Place a Do Not Operate Tag on both the ignition key bottom hoses (7) and cap the fittings on the oil
switch and steering wheel, stating that the machine cooler. Inspect the hoses, and replace if necessary.
should not be operated. 13. Label, disconnect and cap the air conditioner hoses
3. Open the engine cover. Allow the system fluids to (8) (if equipped).
cool. 14. Remove the four nuts and four washers from the
4. Disconnect the battery negative (-) cable from the radiator mounts.
battery negative (-) terminal. 15. Remove the air conditioner condenser (if equipped)
5. Remove the engine cover to ease removal of from the radiator assembly.
radiator/oil cooler.
40.8, 40.9 7.5
 Engine: Perkins 1104-42 & 1104-42T

16. Carefully lift the radiator/oil cooler out of the engine 7.6 FUEL SYSTEM
bay.
Note: If applicable the radiator can be removed with the 7.6.1 Diesel Fuel
radiator frame. Remove the five bolts holding the
Fuel represents a major portion of machine operating
radiator frame to the machine frame and remove the
costs and therefore must be used efficiently. ALWAYS
radiator and radiator frame as one unit.
use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
b. Radiator/Oil Cooler Installation
expensive engine repair.
1. Install the isolator mounts to the bottom of the
Note: Use only diesel fuel designed for diesel engines.
radiator. Insert radiator through the machine frame
Some heating fuels contain harmful chemicals that can
mounts and install the washers and new locknuts.
seriously affect engine efficiency and performance.
2. Install the air conditioner condenser (if equipped) to
the radiator assembly. IMPORTANT: Due to the precise tolerances of diesel
injection systems, keep the fuel clean, and free of dirt
3. At the top of the radiator, install the isolator mounts. and water. Dirt and water in the fuel system can cause
Install the washers and new locknuts on the back severe damage to both the injection pump and the
side of the weldment. injection nozzles. Use ASTM #2 diesel fuel with a
4. Be sure the engine fan has clearance in regard to minimum Cetane rating of 40. #2 diesel fuel gives the
the radiator. Install the radiator fan shroud. best economy and performance under most operating
5. Uncap and connect the previously labeled oil cooler conditions. Fuels with Cetane numbers higher than 40
top (6) and bottom (7) hoses to their appropriate may be needed in high altitudes or extremely low
locations. ambient temperatures to help prevent misfiring and
excessive smoking.
6. Uncap and connect the previously labeled radiator
top (4) and bottom (5) hoses to their appropriate Inform the owner/operator of the machine to use #2
locations. diesel fuel, unless ambient temperatures are below 0° C
(32° F). When temperatures are below 0° C (32° F), a
7. Uncap and connect the previously labeled air blend of #1 diesel and #2 diesel fuels (known as
conditioner hoses (8) (if equipped) to their “winterized” #2 diesel) may be used.
appropriate locations.
Note: #1 diesel fuel may be used, however, fuel
8. Open the radiator cap and fill the radiator completely
with a 50/50 mixture of ethylene glycol and water. economy will be reduced.
Replace and tighten the radiator cap. Add coolant to Use a low-sulfur content fuel with a cloud point (the
the overflow bottle until the bottle is 1/4 to 1/2 full. temperature at which wax crystals form in diesel fuel) at
This overfilling will compensate for any air trapped in least 10° below the lowest expected fuel temperature.
the cooling system. The viscosity of the fuel must be kept above 1.3
9. Connect the battery negative (-) cable to the battery centistrokes to provide adequate fuel system lubrication.
negative (-) terminal. Note: When using diesel fuel with a sulfur content below
10. Run the engine to operating temperature. Visually 1.3 percent, the filter change interval must be reduced by
check for leaks with the engine running. Check the 75 hours. The use of fuel with a sulfur content above
coolant level in the overflow bottle and fill, or drain as 1.3 percent is not recommended.
necessary.
11. Install the engine cover.
12. Install the belly pan.
13. Close and secure the engine cover.

7.5 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9,
“Electrical System.”

7.6 40.8, 40.9

 Engine: Perkins 1104-42 & 1104-42T

6. Remove fuel tank drain plug (9), and drain fuel into
an approved and suitable container. Dispose of fuel
properly. Reinstall the fuel tank drain plug and torque
to 26 Nm (19 lb-ft).
7. Loosen and remove the strap over the fuel tank and
disconnect the fuel hoses from the tank.
10
8. Disconnect fuel level sender (10) electrical
connectors from the fuel level sender.
9. Remove screws securing fuel sender to the tank.
Remove fuel sender from tank.
10. Lift the empty fuel tank from between the frame rails.

b. Disassembly
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed
and reused on the new replacement tank.

c. Cleaning and Drying

If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned.
9
MZ2690
Note: If a leak is suspected in the fuel tank, contact your
local SDF distributor.
7.6.2 Fuel Tank
To clean the fuel tank:
Note: The fuel tank is a one piece unit. It is located at
the rear of the machine, between the frame. If it is 1. Have a dry chemical (Class B) fire extinguisher near
determined that the fuel tank must be removed, the fuel the work area.
must be drained before tank removal. Always dispose of 2. Remove the fuel or oil tank drain plug, and safely
fuel properly. drain any fuel into a suitable container. Dispose of
fuel properly.
a. Fuel Tank Removal 3. Clean the fuel tank with a high-pressure washer, or
1. Park the machine on a firm, level surface, level the flush the tank with hot water for five minutes and
machine, raise the boom to access the fuel tank, drain the water. Dispose of contaminated water
place the transmission control lever in properly.
(N) NEUTRAL, engage the park brake and shut the 4. Add a diesel fuel emulsifying agent to the tank. Refer
engine OFF. to the manufacturer’s instructions for the correct
2. Place a Do Not Operate Tag on both the ignition key emulsifying agent-to-water mixture ratio. Refill the
switch and steering wheel, stating that the machine tank with water, and agitate the mixture for 10
should not be operated. minutes. Drain the tank completely. Dispose of
contaminated water properly.
3. Open the engine cover. Allow the engine to cool.
5. Refill the fuel tank with water until it overflows.
4. Remove the boom. Refer to Section 3.3.1, Completely flush the tank with water. Empty the fuel
“Assembled Boom Removal.” tank, and allow it to dry completely.
5. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for
use on the replacement tank.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area.
40.8, 40.9 7.7
 Engine: Perkins 1104-42 & 1104-42T

d. Assembly 7.7 ENGINE EXHAUST SYSTEM

The fuel level indicator can be removed and reused on
the new replacement tank. Dispose of the old tank 7.7.1 Exhaust System Removal
according to local regulations concerning hazardous
1. Park the machine on a firm, level surface, level the
materials disposal.
machine, fully retract the boom, lower the boom,
place the transmission control lever in
e. Inspection
(N) NEUTRAL, engage the park brake and shut the
Note: If a leak is suspected in the fuel tank, contact your engine OFF.
local SDF distributor. 2. Place a Do Not Operate Tag on both the ignition key
1. Inspect the fuel tank thoroughly for any cracks, switch and steering wheel, stating that the machine
slices, leaks or other damage. should not be operated.
2. Plug all openings except one elbow fitting. Install the 3. Open the engine cover. Allow the engine to cool.
elbow fitting, and apply approximately 7-10 kPa 4. Disconnect the battery negative (-) cable from the
(1-1.5 psi) of air pressure through the elbow. Check battery negative (-) terminal.
the tank for leaks by applying a soap solution to the
exterior and look for bubbles to appear at the 5. Remove the belly pan.
cracked or damaged area. 6. Loosen and remove the mounting hardware for the
exhaust pipe at the exhaust manifold. Replace the
f. Fuel Tank Installation hardware if damaged.
1. Set fuel tank between frame rails. 7. Disconnect and remove the clamp attaching the
exhaust pipe to the frame.
2. Install the fuel tank strap over the fuel tank.
8. Disconnect and remove the clamp connecting the
3. Install the fuel sender with new gasket into the fuel
muffler to the exhaust pipe.
tank and secure with screws. Tighten to 5 Nm
(3.6 lb-ft). DO NOT overtighten. 9. Disconnect and remove the clamp connecting the
tail pipe to the muffler and remove the tail pipe.
4. Connect the fuel hoses to the tank. Secure with
clamps and tighten to 25 Nm (18 lb-ft). 10. Loosen and remove the two bolts at the front and
one bolt at the rear of the muffler, and remove the
5. Install the wire harness connections to the fuel
muffler.
sender.
6. Fill the fuel tank according to specifications. Refer to
Section 2.4, “Fluids, Lubricants and Capacities.”
7. Check fuel tank for leaks.
8. Install the boom. Refer to Section 3.3.4, “Assembled
Boom Installation.”
9. Connect the battery negative (-) cable to the battery
negative (-) terminal. MZ0110

10. Close and secure the engine cover.

7.7.2 Exhaust System Installation
7.6.3 After Fuel System Service Note: Keep all clamps loosened until entire exhaust
1. Drain and flush the fuel tank if it was contaminated. system is in place.
2. Replace all engine fuel filters and check fuel/water 1. Install the exhaust pipe with a new seal to the
separator. exhaust manifold.
3. Vent air from the fuel system in accordance with the 2. Install the exhaust pipe clamp under the engine.
instructions found in the appropriate Operation & 3. Install the muffler to the exhaust pipe and bolt the
Safety Manual. muffler to the side of the frame.
4. Fill the fuel tank with fresh, clean diesel fuel as required. 4. Install the clamp securing the muffler to the exhaust
pipe.

7.8 40.8, 40.9

 Engine: Perkins 1104-42 & 1104-42T

5. Install the clamp securing the muffler to the tail pipe.

6. Adjust the muffler, exhaust and tail pipes for proper
clearance then tighten all clamps.
7. Connect the battery negative (-) cable to the battery
negative (-) terminal.
11
8. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
9. Install the belly pan. 12

10. Close and secure the engine cover.

7.8 AIR CLEANER ASSEMBLY

CAUTION MZ2010

NEVER run the engine with only the inner safety 7.8.2 Air Cleaner Assembly Installation
element installed. Note: Apply Loctite® 242 threadlock to the capscrew
IMPORTANT: Refer to the appropriate Operation & threads before installation.
Safety Manual for the correct element change 1. With the air cleaner assembly attached, install the air
procedure. cleaner mounting bracket using capscrews and ripp
nuts.
7.8.1 Air Cleaner Assembly Removal
2. Place the loosened clamp over the air intake boot,
1. Park the machine on a firm, level surface, level the and install boot on the air cleaner assembly.
machine, fully retract the boom, lower the boom, 3. Place the loosened clamp over the air outlet elbow
place the transmission control lever in and install elbow on the air cleaner assembly.
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 4. Connect low pressure indicator wire connection.
2. Place a Do Not Operate Tag on both the ignition key 5. Adjust and tighten both clamps before starting the
switch and steering wheel, stating that the machine machine.
should not be operated. 6. Connect the battery negative (-) cable at the battery
3. Open the engine cover. Allow the engine to cool. negative (-) terminal.

4. Disconnect the battery negative (-) cable at the 7. Close and secure the engine cover.
battery negative (-) terminal.
7.9 ENGINE REPLACEMENT
5. Disconnect the low pressure indicator wire
connection on the air cleaner.
6. Remove the clamp securing the air intake boot (11) 7.9.1 Engine Removal
to the air cleaner assembly. Lift the air intake boot off 1. Park the machine on a firm, level surface, level the
the air cleaner. machine, fully retract the boom, lower the boom,
7. Remove the clamp securing the air outlet elbow (12). place the transmission control lever in
Lift the air outlet elbow off the air cleaner. (N) NEUTRAL, engage the park brake and shut the
engine OFF.
8. Remove the two capscrews and ripp nuts securing
the air cleaner mounting bracket to the air cleaner 2. Place a Do Not Operate Tag on both the ignition key
mounting plate. Remove the air cleaner assembly. switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Disconnect the (+) positive and (-) negative battery
cables and remove the battery.

40.8, 40.9 7.9

 Engine: Perkins 1104-42 & 1104-42T

5. Remove the engine cover, radiator guard plate and 17. Remove the air cleaner assembly. Refer to Section
the engine belly pan. 7.8.1, “Air Cleaner Assembly Removal.”
6. Drain and remove the radiator assembly. Refer to 18. Remove the access plug from side of the engine bell
Section 7.4.3, “Radiator/Oil Cooler and Coolant housing. This will allow access to remove the eight
Heater Replacement.” bolts holding the flex plate to the engine flywheel.
7. Remove the heater hoses attached to the engine. 19. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Remove
Note: The engine harness is routed and attached to the
them one at a time.
engine using hold-down clamps and plastic wire ties at
various places on the engine. Before removing engine, 20. Secure the engine with a lifting strap or chain from
ensure that the harness has been completely separated the appropriate lifting points. Use a suitable hoist or
(disconnected) from the engine. Move the harness clear overhead crane.
of the engine, and with the help of an observer, ensure 21. At the rear right engine mount (14), remove the bolt
that engine clears the harness during removal. and washer. Repeat for the rear left engine mount.
8. Label and disconnect all wire harness connections
on the engine.
9. Unbolt and remove the hood latch plate. Mark the
plate to help with hood adjustment when being
reinstalled.
10. Unbolt the return hydraulic oil filter plate and leave in
place.
11. Disconnect and cap the fuel inlet line at the fuel filter
head.
12. Disconnect and cap the fuel return line from the fuel
filter head. 14

13. Mark the location of the throttle cable (13) at the

throttle cable mount. Loosen jam nuts and remove.
MZ2170

22. Place a support or jack under the transmission to

hold the transmission in place while engine is being
removed.
23. Remove the ten bolts holding the transmission to the
13 engine. Slightly lift and pull the engine out of the
machine. Have an assistant ensure that the engine
clears all frame components during removal.
24. Place engine on a flat, level surface.

7.9.2 Engine Disassembly, Inspection and

Service
MZ0940 Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Perkins
14. Disconnect the throttle cable at the engine throttle
service manual. Several special engine service tools are
lever.
required to properly service the engine. Contact your local
15. Remove the exhaust pipe from the exhaust Perkins Service partner for further information.
manifold. Refer to Section 7.7.1, “Exhaust System
Note: If the engine is being replaced, there may be external
Removal.”
components that will be required to be transferred from the
16. Loosen the clamps on the sleeve reducer at the original engine to the replacement engine depending upon
engine and on the air suction pipe. who you purchase the new engine from and the
configuration of your replacement engine. Refer to the
appropriate Perkins user manual for detailed procedures

7.10 40.8, 40.9

 Engine: Perkins 1104-42 & 1104-42T

that cover the transfer of original engine components to the 16. Connect all the labeled wire harness connections on
replacement engine. the engine.
17. Install the hood latch plate. Align the mark on the
7.9.3 Engine Installation plate to help with hood adjustment.
1. Attach a lifting chain to the front and rear engine lift 18. Secure the return hydraulic oil filter plate to the
brackets, and lift engine clear of the ground. frame.
Note: Apply Loctite® 242 threadlock to the engine 19. Install both heater hoses to the engine and tighten
mount bracket capscrew threads before installation. clamps.
2. Inspect the front engine mounting bracket isolator. 20. Install the complete radiator assembly. Refer to
Replace isolator if cracked or worn. Section 7.4.3, “Radiator/Oil Cooler and Coolant
Heater Replacement.”
3. Install two guide studs in the bell housing holes.
21. Install the hose clamp on the bottom radiator hose
4. Lift the engine and slowly push and lower into the
and work onto the engine. Tighten the clamp.
engine bay. Have an assistant ensure that the
engine clears all frame, hose and harness 22. Install the hose clamp on the top radiator hose and
components during engine installation. Position work onto the engine. Tighten the clamp.
engine brackets over the front frame mounts. 23. Connect the transmission inlet and outlet hoses on
5. Push the engine towards the transmission aligning the oil cooler. Install the clamp holding the top
the guide studs and the torque converter shaft with transmission cooler hose and the three bolts holding
the corresponding holes. the fan screen.
6. Push the engine against the transmission and install 24. Install the engine cover and adjust.
eight of the ten bolts and washers. Remove both 25. Install the battery and reconnect the (+) positive and
guide studs and replace with the remaining two bolts (-) negative cables.
and washers. Tighten bolts.
26. Open the radiator cap and fill the radiator completely
7. Torque the transmission bolts to 63 Nm (46 lb-ft) with a 50/50 mixture of ethylene glycol and water.
AFTER engine is lowered and secured with the front Replace and tighten the radiator cap. Add coolant to
motor mount bolts installed and torqued. the overflow bottle until the bottle is 1/4 to 1/2 full.
8. Remove the support from under the transmission This overfilling will compensate for any air trapped in
and lower the engine the remainder of the way onto the cooling system.
the frame. Align the motor mount holes and install 27. Check that all hydraulic system, electrical system,
the bolts. Apply Loctite® 242 threadlock to the motor cooling system, fuel system and exhaust system
mount bolts and torque to 210 Nm (155 lb-ft). connections are correct and connected tightly.
9. Turn the engine over slowly by hand and align each 28. From within the cab, lightly depress the throttle pedal
of the eight flex plate bolts through the access plug to full-throttle position. As needed, adjust the limit-
in the bell housing. Install them one at a time. DO stop screw until it touches the pedal. Tighten the
NOT fully tighten until all of the capscrews and locknut to 13,6-14,1 Nm (120-125 lb-in).
locknuts are in place. Torque to 35-39 Nm
Note: Have an assistant stand by with a Class B fire
(26-29 lb-ft). Replace access plug.
extinguisher.
10. Install the exhaust pipe. Refer to Section 7.7.2,
“Exhaust System Installation.” 29. Start the engine and run to normal operating
temperature then shut off the engine. While the
11. Install the complete air cleaner assembly. Refer to engine is cooling, check for leaks.
Section 7.8.2, “Air Cleaner Assembly Installation.”
30. Allow the engine to cool. Check the radiator coolant
12. Install and tighten the jam nuts on the throttle cable level, and top off with a 50/50 mixture of ethylene
at the throttle cable mount. glycol and water. Replace the radiator cap.
13. Connect the throttle cable at the engine throttle 31. Check for leaks from the engine, main hydraulic
lever. pump and lines, transmission, hydraulic reservoir
14. Connect the fuel inlet line to the fuel filter head. and fuel tank. Check the levels of all fluids and
15. Connect the fuel return line to the fuel filter head. lubricants. Fill as required.

40.8, 40.9 7.11

 Engine: Perkins 1104-42 & 1104-42T

IMPORTANT: During the full throttle check: 7.10.2 Drive Plate Installation
• DO NOT operate any hydraulic function. 1. Install the three new drive plates on the torque
• DO NOT steer or apply any pressure to the converter and torque the six bolts with lock washers
steering wheel. to 35-39 Nm (26-29 lb-ft).
• Keep the transmission in (N) NEUTRAL. 2. Mount the drive plate/converter assembly to the
transmission.
32. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle. 3. Refer to Section 6.5.3, “Transmission Installation,” or
If the rpm is not 2340 ±50 rpm, readjust the throttle Section 7.9.3, “Engine Installation,” for the
limit-stop screw at the throttle pedal within the cab. remainder of the installation.
33. Purge the hydraulic system of air by operating all 4. Connect the battery negative (-) cable to the battery
boom functions through their entire range of motion negative (-) terminal.
several times. Check the hydraulic oil level. 5. Close and secure the engine cover.
34. Check for proper operation of all components.
35. Turn the engine off.
36. Install the engine belly pan.
15
37. Close and secure the engine cover.

7.10 ENGINE DRIVE PLATE

7.10.1 Drive Plate Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the MZ0580

engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Disconnect the battery negative (-) cable from the
battery negative (-) terminal.
Note: In order to remove the engine drive plates, the
engine and transmission must be separated.
5. Refer to Section 6.5.1, “Transmission Removal,” or
Section 7.9.1, “Engine Removal.”
6. Remove the eight bolts holding the drive plates (15)
to the flywheel.
7. With the drive plates and torque convertor removed,
loosen and remove the six bolts and six lock
washers holding the three drive plates to the torque
converter.
8. Replace all three drive plates if damaged

7.12 40.8, 40.9

 Engine: Perkins 1104-42 & 1104-42T

7.11 TROUBLESHOOTING

Trouble Possible Causes (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
Key to Possible Causes

40.8, 40.9 7.13

 Engine: Perkins 1104-42 & 1104-42T

Trouble Possible Causes (see key, below)

1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking 62. Turbo lubricating oil seal leak
20. Poor compression closed 63. Induction system leaks
42. Broken relief valve spring

This Page Intentionally Left Blank

7.14 40.8, 40.9

 Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.1 Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.2 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.8.3 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.8.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.5 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.6 Leveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8.9 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.9.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.9.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.9.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.9.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.9.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.9.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.9.7 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.9.8 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.9.9 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8.20

40.8, 40.9 8.1

 Hydraulic System

8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

TILT CYLINDER

LIFT/LOWER
CYLINDER

EXTEND/RETRACT
CYLINDER
(INSIDE BOOM)

MZ3050

STEERING
CYLINDER
HYDRAULIC FLUID COMPENSATION
RESERVOIR CYLINDER

HYDRAULIC
FILTER

MAIN PUMP

MAIN CONTROL
VALVE

MZ2700
ENGINE COMPARTMENT
(ENGINE REMOVED FOR CLARITY)

8.2 40.8, 40.9

 Hydraulic System

8.2 SAFETY INFORMATION 8.3 HYDRAULIC PRESSURE DIAGNOSIS

Kits are available to use for hydraulic system
WARNING maintenance and troubleshooting. The kits are contained
in a durable polyethylene carrying case for demanding
DO NOT service the machine without following all field service conditions.
safety precautions as outlined in Section 1, “Safety The hydraulic pressure test kit is used to pressure test the
Practices,” of this manual. Failure to follow the safety various hydraulic components in the hydraulic system.
practices may result in death or serious injury.
The kit includes:
Petroleum-based hydraulic fluids are used in this • Gauges for testing high and low pressure circuits
machine. The temperature of hydraulic fluid increases
during the operation of various hydraulic functions. A • Fittings, couplers and hoses
heated petroleum-based hydraulic fluid presents a fire • Durable carrying case
hazard, especially when an ignition source is present. A flowmeter test kit is used to pinpoint hydraulic system
Accordingly, periodically inspect all hydraulic system faults. It includes a flowmeter with load valve, magnetic
components, hoses, tubes, lines, fittings, etc. Carefully base, photo tachometer head and flex arm. The kit
examine any deterioration and determine whether any features:
further use of the component would constitute a hazard. • Bi-directional for unrestricted connection and
If in doubt, replace the component. simplified testing
Whenever you disconnect a hydraulic line, coupler, fitting • Internal by-pass to protect system and tester
or other component, slowly and cautiously loosen the part from over-pressure
involved. A hissing sound or slow seepage of hydraulic
fluid may occur in most cases. After the hissing sound • Measures up to 60 GPM and 6000 psi
has ceased, continue removing the part. Any escaping oil • Durable carrying case
should be directed into an appropriate container. Cap or Contact your local authorized service distributor for
otherwise block off the part to prevent further fluid ordering information.
seepage.
Part Description Approximate Price and
Hydraulic system maintenance will, at times, require that Number Weight Availability
the engine be operated. Always follow safety 70000652 Hydraulic Pressure Test Kit 10 lbs. Consult Factory
precautions.
70000101 Digital Hydraulic Pressure 7 lbs. Consult Factory
A major cause of hydraulic component failure is Test Kit
contamination. Keeping the hydraulic fluid as clean as 1321107 Hydraulic Flowmeter Kit 28 lbs. Consult Factory
possible will help avoid downtime and repairs. Sand, grit
and other contaminants can damage the finely machined
surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
inspect the fluid more often. When servicing the system,
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir,
and pump openings until installation occurs. Protect
threads from contamination and damage.
Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
properly, check the electrical aspect of the malfunctioning
circuit also.

40.8, 40.9 8.3

 Hydraulic System

8.4 HYDRAULIC CIRCUITS 8.4.1 Hydraulic Pressures

This section covers the hydraulic circuits and includes a. Checking Pressures
listings for all hydraulic function pressures, where and
1. Start the machine and warm the hydraulic system to
how to check those pressures.
operating temperature.
Electrical and hydraulic functions are often related. Verify
2. Shut off the machine and install a digital or a 345 bar
that the electrical components of the circuit are
(5000 psi) gauge to the appropriate test port.
functioning properly whenever troubleshooting the
hydraulic circuit. 3. Start the machine, run the engine and follow
procedures in Section 8.4.1, c. “Pressure
Always check the following before beginning to
Specifications.”
troubleshoot a circuit that is not functioning correctly.
1. Check the hydraulic oil level in the reservoir. Oil level b. Adjusting Hydraulic Pressure
should be at the middle of the sight glass with all
cylinders retracted. 1. Shut the machine off. Remove the cap on the relief
(if necessary).
2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, 2. Start the machine and loosen the jam nut on the
etc. relief. Turn the relief clockwise to increase pressure
or counter-clockwise to decrease pressure. Set to
3. Check for air in the hydraulic system. Erratic the correct pressure.
machine performance and/or spongy cylinder
operation are signs of air in the hydraulic system. 3. Tighten the jam nut and recheck the pressure at full
throttle. If the reading is within specification, shut the
If air in the hydraulic system is suspected, you will machine off, install the safety cap and remove the
hear air leakage when hydraulic fittings are loosened gauge from the test port.
and see air bubbles in the hydraulic fluid. 4. If the proper pressure cannot be set, use the
accompanying hydraulic schematic and/or the
Loose fittings, faulty o-rings or seals, trapped oil, electrical schematic to help troubleshoot and correct
leaks, system opened for service, etc., can cause air the problem.
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.

8.4 40.8, 40.9

 Hydraulic System

c. Pressure Specifications

Hydraulic Test Port Procedure Adjustment Pressure Range

Circuit Location
Implement M Connect gauge to M port, run engine at low idle, 1 250 ±5 Bar
bottom out boom retract function. Hold over relief (3626 ±73 psi)
and check pressure.
Pilot Pr Connect gauge to Pr port, run engine at low idle, 2 30 ±2 Bar
bottom out boom retract function. Hold over relief (435 ±29 psi)
and check pressure.

M 2

Pr

1
MZ2320

40.8, 40.9 8.5

8.6
BOOM TILT

8.5
LIFT
CYLINDER TELESCOPING CYLINDER VALVE
140/70 COMPENSATION
8M-140/90 CYLINDER GP DIVERTOR
9M,12M,13M-160/90 12/13M CLYINDERS
90/60
HY QUICK CONNECT
90/45 STABILIZERS LEVELING
110/63 OPTION (ATTACHMENT)
(LEFT) (RIGHT)
125/60 125/60
M C2 M1 C1
M C2 M1 C1 C2
M C2 M1 C1 C3

1
1 C1 C4
1
2
2

V2 V1 P1 P2
V2 V1
V2 V1

B4 A4

LS
LS1 D B1 A1 B2 A2 B3 A3 B4 A4

6
TPr A B A B A B

P
9
9
DLS P2
11

10
Pr

3-4
Hydraulic System

LS

Ø0.6
2

S
Ø1.5

1
P1

Ø1.0 15

T
30 bar VALVE LEVELING STABILIZERS

230
M bar
HYDRAULIC SCHEMATICS

T2
T1 A T T B A T T B A T
280 280 280
STEERING
280 280
bar bar bar bar bar SELECT VALVE

SX14NGE SAE MAIN CONTROL VALVE

A B

7
L R
240 240
bar bar

P
LS
T
A10VO60DFR1 PUMP
60cc/REV, CLOCKWISE ROTATION
180
0.97:1 DRIVE RATIO bar
POR = 280 bar
HYDRAULIC OIL DIFF = 17 bar
RETURN FILTER STDBY = 20 bar
P T
CYLINDER

CYLINDER
REAR STEERING

FRONT STEERING STEERING VALVE

IN (ORBITAL)
X2 X1
5 bar
13 MICRON NC SWITCH

1.40
bar B

1.70 bar
B

OUT SERVICE BRAKE

RESERVOIR

SERVICE
S L1
BRAKE
L VALVE

REAR AXLE

FRONT AXLE

TANK TANK TANK TANK TANK TANK TANK TANK

PORT PORT PORT PORT PORT PORT PORT PORT

MZ2290
FILTER SUCTION 6 4 5 3 2 1
RETURN

40.8, 40.9
40.8, 40.9
LEVELING
100/50
8.5 Hydraulic Schematics (Continued)

BOOM
TELESCOPING
CYLINDER LS A B
8M/9M
100/60

TPr

P
P2
Pr
M C2 M1 C1 Ø0.7
LS Ø1.0
T
2
4
1
3

30 bar
V2 V1

A2 T2

B2

MZ3060
Hydraulic System

8.7
 Hydraulic System

8.6 HYDRAULIC RESERVOIR 8.6.2 Hydraulic Oil Reservoir Filling

1. Be sure reservoir is clean and free of all debris.
The hydraulic reservoir is a one piece unit. It is located
under the rear of the machine cab. Occasionally, fluid 2. Install a new hydraulic oil filter.
may seep, leak or be more forcefully expelled from the 3. Fill the reservoir with DF UTTO Tractor Hydraulic
breather when system pressure exceeds the rating of the Fluid ISO Grade 46 oil. Refer to Section 2.4, “Fluids,
filter head or breather. If the return filter becomes Lubricants and Capacities.”
plugged, the return hydraulic oil will bypass the filter when
pressure reaches 1,7 bar (25 psi) and return to the 8.6.3 Hydraulic Oil Reservoir Removal/
reservoir unfiltered. Installation
Carefully examine fluid seepage or leaks from the If it is determined that the hydraulic oil reservoir must be
hydraulic reservoir to determine the exact cause. Clean removed, the hydraulic oil must be drained before the
the reservoir and note where any seepage occurs. reservoir is removed. Always dispose of hydraulic oil
properly.

a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
MZ0130
3. Open the engine cover. Allow the system fluids to
cool.
8.6.1 Hydraulic Oil Reservoir Draining
4. Disconnect the battery negative (-) cable from the
1. Park the machine on a firm, level surface, level the battery negative (-) terminal.
machine, fully retract the boom, lower the boom,
5. Drain the hydraulic oil reservoir. Refer to Section
place the transmission control lever in
8.6.1, “Hydraulic Oil Reservoir Draining.”
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 6. Loosen the clamps and remove and cap the suction
and return hoses on the hydraulic oil reservoir.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the 7. Plug and cap the fittings on the hydraulic oil
machine should not be operated. reservoir.
3. Open the engine cover. Allow the system fluids to 8. Support the hydraulic oil reservoir from the bottom
cool. and remove the six bolts, washers and nuts.
4. Disconnect the battery negative (-) cable from the 9. Carefully lower the reservoir to the ground.
battery negative (-) terminal.
b. Disassembly
5. Open the filler cap on the hydraulic oil reservoir.
Remove the drain plug at the bottom of the hydraulic The hydraulic oil reservoir is a one-piece unit and cannot
oil reservoir. be disassembled. The hydraulic oil level sight-glass and
6. Transfer the used hydraulic oil into a suitable, hydraulic oil filler cap can be removed and reused on the
covered container, and label as "Used Oil". Dispose new replacement reservoir. Dispose of the old reservoir
of used oil at an approved recycling facility. Clean according to local regulations concerning hazardous
and reinstall the drain plug. materials disposal.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.

8.8 40.8, 40.9

 Hydraulic System

c. Cleaning and Drying 8.7 HYDRAULIC SYSTEM PUMP

If contaminated hydraulic oil or foreign material is in the
tank, the tank can usually be cleaned. 8.7.1 Pump Description
To clean the hydraulic oil reservoir: For internal service instructions contact your local
1. Have a dry chemical (Class B) fire extinguisher near authorized service distributor.
the work area.
2. Clean the hydraulic oil reservoir with a high-pressure 8.7.2 Pump Failure Analysis
washer, or flush the tank with hot water for five The implement pump (1) is the “heart” of the hydraulic
minutes and drain the water. Dispose of system, and whenever there is a problem in the system,
contaminated water properly. the pump often is blamed. However, implement pump
failure is seldom due to failure of pump components.
d. Inspection Pump failure usually indicates another problem in the
hydraulic system.
Note: If a leak is suspected in the hydraulic oil reservoir,
contact SDF Service Department. According to pump manufacturer statistics, 90-95 percent
of pump failures are due to one or more of the following
1. Inspect the hydraulic oil reservoir thoroughly for any causes:
cracks, slices, leaks or other damage.
• Aeration
2. With the hydraulic oil reservoir removed from the
• Cavitation
machine, plug all openings except one elbow fitting.
• Contamination
Install the elbow fitting, and apply approximately
0,06-0,10 bar (1-1.5 psi) of air pressure through the • Excessive Heat
elbow. Check the reservoir for leaks by applying a • Over-Pressurization
soap solution to the exterior and look for bubbles to • Improper Fluid
appear at the cracked or damaged area. In the event of pump failure, investigate further to
determine the cause of the problem.
e. Reservoir Installation
1. Lift the hydraulic oil reservoir into place and install
the six bolts, washers and nuts. 1

2. Uncap and connect the suction hose and return

hose. Tighten both clamps.
3. Uncap and connect the four small return hoses to
the fittings on the hydraulic oil reservoir.
4. Install the hydraulic fluid level sight-glass using
special designed and drilled capscrews and gaskets.
MZ1950
5. Install hydraulic filter neck components and secure.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8. Connect the battery negative (-) cable to the battery
negative (-) terminal.
9. Close and secure the engine cover.

40.8, 40.9 8.9

 Hydraulic System

8.7.3 Pump Replacement b. Pump Installation

1. While the pump is still on the bench, install all
a. Pump Removal
fittings, except the outlet hose fitting, orienting them
1. Park the machine on a firm, level surface, level the as noted during removal.
machine, fully retract the boom, lower the boom, 2. Apply Loctite® 573 on the metal seal of the pump
place the transmission control lever in (N) NEUTRAL, and place into position on the transmission. Align the
engage the park brake and shut the engine OFF. pump shaft with the internal transmission gear, so
2. Place a Do Not Operate Tag on both the ignition key that the machined teeth mesh together.
switch and the steering wheel, stating that the 3. Align the bolt holes with the pump mount holes.
machine should not be operated. Secure the pump to the transmission with the bolts
3. Open the engine cover. Allow the system fluids to and washers. Torque to 115 Nm (85 lb-ft).
cool. 4. If necessary, slide the T-bolt band clamp onto the
4. Disconnect the battery negative (-) cable from the pump inlet hose. Secure the hoses to the hydraulic
battery negative (-) terminal. reservoir outlet connection with the T-bolt band
5. Thoroughly clean the pump and surrounding area, clamp.
including all hoses and fittings before proceeding. 5. Place a new oiled o-ring into position over the pump
opening. Secure the inlet hose with two flange
Note: Cap all hoses as you remove them to prevent
halves, lockwashers and bolts.
unnecessary fluid spillage.
6. Connect the load sense line to the fitting.
6. Remove the bolts and lockwashers securing the
flange halves to the pump. Remove the inlet hose 7. Place a new, oiled o-ring into position over the pump
and o-ring. opening. Secure the outlet hose with two flange
halves, lockwashers and bolts.
Note: Before removing any fittings from the pump, note
8. Prime the pump by filling the case drain port with
their orientation to ensure correct installation.
fresh, filtered hydraulic oil from a clean container
7. Remove the bolts and lockwashers securing the before installing the case drain connector and
flange halves to the pump. Remove the outlet hose hoses.
and o-ring. 9. Check all routing of hoses and tubing for sharp
8. Disconnect the case drain hose from the fitting. bends or interference with any rotating members. All
Disconnect the load sense line. tube and hose clamps must be tight.
9. Remove the bolts and lockwashers securing the 10. Start the engine and run at approximately one-third
pump to the transmission. Remove the gasket to one-half throttle for about one minute without
located between the transmission and the pump. moving the machine or operating any hydraulic
Wipe up any hydraulic oil spillage. functions.
Note: DO NOT disassemble the implement pump. The 11. Inspect for leaks and check all fluid levels. The
pump is pre-set from the manufacturer. Any adjustments hydraulic reservoir oil level must be to the middle of
or repairs performed by anyone other than an authorized the sight gauge.
dealer could void the warranty.
12. Connect the battery negative (-) cable to the battery
negative (-) terminal.
13. Close and secure the engine cover.

c. Pump Test
Refer to Section 8.4.1, “Hydraulic Pressures.”

8.10 40.8, 40.9

 Hydraulic System

8.8 VALVES AND MANIFOLDS 8. Support the valve and remove the four bolts
securing the main control valve bracket to the frame.
8.8.1 Main Control Valve 9. Remove the main control valve and bracket from the
frame and remove the four bolts holding the
The main control valve is mounted on the side rail in the mounting bracket to the valve.
engine compartment.
b. Main Control Valve Disassembly
3 4 5 6
1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the
tie rods. Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
IMPORTANT: DO NOT adjust any of the relief valve
assemblies. Tampering with a relief valve will irrevocably
alter pressure in the affected circuit, requiring recalibration
or a new relief valve.

MZ2080

The main control valve assembly consists of working

sections with their own valve assemblies, each providing
a specific hydraulic function. Those functions are: 7
lift/lower (3), extend/retract (4), tilt (5) and auxiliary (6).

a. Main Control Valve Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
MAM0100
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the Disassemble each Valve Section
machine should not be operated. 1. Carefully separate the load sense outlet section (7) from
3. Open the engine cover. Allow the system fluids to the next section.
cool. 2. Remove the o-rings from between the two sections.
4. Thoroughly clean the main control valve and 3. Carefully separate each remaining section.
surrounding area, including all hoses and fittings,
before proceeding. 4. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual
5. Place a suitable container to catch hydraulic fluid valve section if equipped.
drainage beneath the frame.
5. Keep all parts being removed from individual valve
6. Label, disconnect and cap all the hydraulic hoses, sections tagged and kept together.
tubes and wires at the main control valve. Slowly
turn hose fittings to allow any trapped pressure in c. Main Control Valve Parts Cleaning
the hydraulic system to escape.
Clean all components with a suitable cleaner, such as
7. Wipe up any hydraulic fluid spillage in, on, near and
triclorethylene, before continuing. Blow dry.
around the machine and the work area.

40.8, 40.9 8.11

 Hydraulic System

d. Main Control Valve Parts Inspection f. Main Control Valve Installation

Inspect all parts and internal passageways for wear, 1. Loosely install the four main control valve mounting
damage, etc. If inner surfaces of any component DO NOT bolts through bracket on the inside rail of the engine
display an ultra-smooth, polished finish, or are damaged bay.
in any way, replace the damaged part. Often, dirty 2. Install the main control valve onto the bracket,
hydraulic fluid causes failure of internal seals, damage to aligning the bolts with the holes in the end sections
the polished surfaces within the component, and wear of of the main control valve. Slide the main control
and/or harm to other parts. valve into position, and tighten the bolts.

e. Main Control Valve Assembly 3. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a
Note: ALWAYS replace seals, o-rings, gaskets, etc., clean container, before attaching the hoses.
with new parts to help ensure proper sealing and
4. Use new oiled o-rings as required. Uncap and
operation. Lubricate seals and o-rings with clean
connect all hoses, clamps, etc. to the main control
hydraulic oil.
valve.
Assemble each Valve Section 5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
1. Reassemble any check valves, compensator valves, members, and install tie wraps and/or protective
anti-cavitation valves or shock valves from each conduit as required. Tighten all tube and hose
individual valve sections if equipped. clamps.
2. Install the end caps on each end of the valve 6. Connect the battery negative (-) cable to the battery
section. negative (-) terminal.

Assemble the Main Control Valve. 7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
1. Place all three tie rods with the nuts through the end moving the machine or operating any hydraulic
main control valve section. functions.
2. Stand the end main control valve section on end. 8. Inspect for leaks and check the level of the hydraulic
3. Install the proper o-rings and load sense shuttle on fluid in the reservoir. Shut the engine OFF.
the inner face of the end main control valve section. 9. Wipe up any hydraulic fluid spillage in, on, near and
Align the next valve section over the three tie rods around the machine, work area and tools.
and slide onto the end main control valve section.
10. Close and secure the engine cover.
4. Using the proper o-rings and load sense shuttle,
repeat step three for the remaining valve sections g. Main Control Valve Test
and lastly the inlet end valve section.
Conduct a pressure check of the hydraulic system in its
5. Install the nuts on the tie rods. entirety. Adjust pressure(s) as required. Refer to Section
8.4.1, “Hydraulic Pressures.”

MAM0100

8.12 40.8, 40.9

 Hydraulic System

8.8.2 Service Brake Valve 1. Install the service brake valve with the lockwashers
and capscrews to mount the brake valve to the
The service brake valve is at the base of the steering
steering column support.
column support, concealed by the lower dash cover.
2. Align the yoke on the brake valve with the brake
The service brakes themselves are part of the axles (the park
pedal arm. Insert the pin and clip into place being
brake is part of the front axle only). Refer to Section 5, “Axles,
sure there is a small amount of play between the
Drive Shafts, Wheels and Tires,” for further information.
pedal and the brake plunger.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
3. Use new oiled o-rings as required. Reattach and
secure all valves, hoses, clamps, etc.
4. Check the routing of all hoses, and tubing for sharp
bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
8 5. Connect the battery negative (-) cable to the battery
negative (-) terminal.
MZ1980
6. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
a. Service Brake Valve Removal
moving the machine or operating any hydraulic
1. Park the machine on a firm, level surface, level the functions.
machine, fully retract the boom, lower the boom, 7. Bleed air from the brake circuit. Refer to Section
place the transmission control lever in 8.8.3, “Brake Test.”
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 8. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
2. Place a Do Not Operate Tag on both the ignition key reservoir. Shut the engine OFF.
switch and the steering wheel, stating that the
machine should not be operated. Note: Check for leaks, and repair as required before
continuing. Add hydraulic fluid to the reservoir as
3. Open the engine cover. Allow the system fluids to
needed.
cool.
4. Disconnect the battery negative (-) cable from the 9. Close and secure the engine cover.
battery negative (-) terminal.
8.8.3 Brake Test
5. Remove the necessary dash panels.
Carefully bleed the brake lines as soon as the brake valve
6. Label, disconnect and cap all hydraulic hoses and
is installed in the machine. Air in the system will not allow
fittings on the service brake valve (8).
the brakes to apply properly. Work with an assistant to
7. Disconnect the pin holding the yoke to the brake perform this procedure.
pedal arm.
1. Place the transmission control lever in (N)
8. Remove the capscrews and lockwashers mounting NEUTRAL, engage the park brake, and start the
the service brake valve to the steering column engine.
support.
2. Remove the plastic cap from the front brake bleeder.
Note: DO NOT disassemble the service brake valve. Attach one end of a length of transparent tubing over
The service brake valve is not serviceable and must be the brake bleeder. Place the other end of this tubing
replaced in its entirety, if defective. in a suitable transparent container that is partially
filled with hydraulic oil. The end of the tubing must
b. Service Brake Valve Installation be below the oil level in the container.

40.8, 40.9 8.13

 Hydraulic System

3. DO NOT open the brake bleeder without holding the 6. Disconnect all wire terminal leads attached to the
tubing firmly on the bleeder. There is a pressure at steering select valve.
the brakes. Carefully open the bleeder with a 7. Remove the two bolts holding the steer select valve
wrench. Have the assistant depress the brake pedal. to the mounting plate on the frame.
Close the brake bleeder when air bubbles no longer
appear in the oil. Release the brake pedal. remove
the tubing from the brake bleeder.
4. Repeat Steps 2 and 3 for the remaining brake
bleeders.
5. Install a vacuum pump on the brake reservoir and
remove the remainder of the trapped air from the
brake system.
6. Check brake fluid level and add if necessary using
ATF fluid.
7. Conduct a pressure and function check of the
service brake. Refer to Section 8.3, “Hydraulic
Pressure Diagnosis.”

8.8.4 Steering Orbitrol Valve 9

Refer to Section 4.3.1, “Steering Column and Orbitrol

Valve,” for details. MZ0380

8.8.5 Steer Select Valve 8. Remove the steer select manifold with the attached
steer select valve (9) from the machine. Wipe up any
The machine can be used in the front-wheel, four-wheel
hydraulic fluid spillage in, on, near and around the
or crab steering mode. The steer select valve controls the
machine.
direction of hydraulic fluid flow to the steering cylinder
mounted on each axle. The steer select valve is attached
b. Steer Select Valve and Manifold Disassembly,
to a mounting plate inside the frame near the left front
Cleaning, Inspection and Assembly
corner of the cab.
Verify the correct operation of the steer select valve 1. Place the steer select assembly on a suitable work
solenoids before considering replacement of the valve. surface.
The housing of the steer select valve is not serviceable 2. Separate the steer select valve from the manifold by
and must be replaced if defective. removing the four socket head capscrews. Discard
the four o-rings.
a. Steer Select Manifold and Valve Removal 3. Remove the solenoid valves and cartridges from the
1. Park the machine on a firm, level surface, fully steer select housing.
retract the boom, lower the boom, place the 4. Clean all components with a suitable cleaner before
transmission control lever in (N) NEUTRAL, engage inspection.
the park brake and shut the engine OFF.
5. Inspect the solenoid cartridges for proper operation.
2. Place a Do Not Operate Tag on both the ignition key Check by shifting the spool to ensure that it is
switch and the steering wheel, stating that the functioning properly. Check that the spring is intact.
machine should not be operated. Inspect the cartridge interior for contamination.
3. Open the engine cover. Allow the system fluids to
cool.
4. Disconnect the battery negative (-) cable from the
battery negative (-) terminal.
5. Label, disconnect and cap all hydraulic hoses and
fittings connected to the steering select valve.

8.14 40.8, 40.9

 Hydraulic System

6. Inspect internal passageways of the steer select 8.8.6 Leveling Valve

manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultra- 1
smooth, polished finish, or components are
damaged in any way, replace the manifold or
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
surfaces within the secondary function manifold.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
MZ2280
four new, oiled o-rings and the four socket head
capscrews.
a. Leveling Valve Removal
c. Steer Select Manifold and Valve Installation 1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
1. Install the steer select valve to the mounting plate
transmission control lever in (N) NEUTRAL, engage
under the left side of the frame using the previously
the park brake and shut the engine OFF.
used hardware.
2. Place a Do Not Operate Tag on both the ignition key
2. Uncap and connect the previously labeled hydraulic
switch and the steering wheel, stating that the
hoses and fittings to the steer select valve.
machine should not be operated.
3. Connect all previously labeled wire terminal leads to
3. Open the engine cover. Allow the system fluids to
the steer select valve.
cool.
4. Check the routing of all hoses, wiring and tubing for
4. Disconnect the battery negative (-) cable from the
sharp bends or interference with any rotating
battery negative (-) terminal.
members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps. 5. Label, disconnect and cap all hydraulic hoses (1)
and fittings connected to the leveling valve.
5. Connect the battery negative (-) cable to the battery
negative (-) terminal. 6. Disconnect all wire terminal leads attached to the
leveling valve.
6. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the 7. Remove the bolts holding the leveling valve to the
machine or operating any hydraulic functions. engine compartment.
7. Inspect for leaks and check the level of the hydraulic 8. Remove the leveling valve from the machine. Wipe
fluid in the reservoir. up any hydraulic fluid spillage in, on, near and
around the machine.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed. b. Leveling Valve Disassembly
8. Check each steering mode for proper function. 1. To disassemble the individual sections of the
9. Wipe up any hydraulic fluid spillage in, on, near and leveling valve, remove the nuts from one end of the
around the machine, work area and tools. tie rods. Pull the tie rods out through the sections.
10. Close and secure the engine cover. 2. Disassemble each section assembly as required.
Disassemble each Valve Section
1. Carefully separate the cover plate from the next
section.
2. Remove the o-rings from between the two sections.

40.8, 40.9 8.15

 Hydraulic System

3. Carefully separate each remaining section. f. Leveling Valve Installation

4. Remove any coils (2) or retainers (3) from the 1. Install the leveling valve into the engine
individual valve section. compartment and secure with the previously used
hardware.
2
3 2. Prime the leveling valve by filling the inlet openings
with fresh, filtered hydraulic oil from a clean
container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and
connect all hoses, clamps, etc. to the leveling valve.
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
MZ2410
clamps.
5. Connect the battery negative (-) cable to the battery
5. Keep all parts being removed from individual valve negative (-) terminal.
sections tagged and kept together. 6. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
c. Leveling Valve Parts Cleaning moving the machine or operating any hydraulic
Clean all components with a suitable cleaner, such as functions.
triclorethylene, before continuing. Blow dry. 7. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
d. Leveling Valve Parts Inspection
8. Wipe up any hydraulic fluid spillage in, on, near and
Inspect all parts and internal passageways for wear, around the machine, work area and tools.
damage, etc. If inner surfaces of any component DO NOT 9. Close and secure the engine cover.
display an ultra-smooth, polished finish, or are damaged
in any way, replace the damaged part. Often, dirty
hydraulic fluid causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
and/or harm to other parts.

e. Leveling Valve Assembly

Note: ALWAYS replace seals, o-rings, etc., with new
parts to help ensure proper sealing and operation.
Lubricate seals and o-rings with clean hydraulic oil.
Assemble each Valve Section
1. Reassemble any coils or retainers from each
individual valve section.
Assemble the Leveling Valve
1. Place all three tie rods with the nuts through the end
valve section.
2. Stand the end valve section on end.
3. Install the proper o-rings on the inner face of the
valve section. Align the next valve section over the
three tie rods and slide onto the end valve section.
4. Using the proper o-rings, repeat step three for the
remaining valve sections and lastly the cover plate.
5. Install the nuts on the tie rods.
8.16 40.8, 40.9
 Hydraulic System

8.9 HYDRAULIC CYLINDERS to hold the cylinder securely. Excessive force can
damage the cylinder tube.
8.9.1 General Cylinder Removal 3. If applicable, remove the counterbalance valve from
Instructions the side of the cylinder barrel.

1. Remove any attachment from the machine. Park the IMPORTANT: DO NOT tamper with or attempt to adjust
machine on a firm, level surface, allowing sufficient the counterbalance valve cartridge. If adjustment is
workspace. Level the machine, place the transmission necessary, replace the counterbalance valve with a new
control lever in (N) NEUTRAL, engage the park brake, part.
shut the engine OFF and block the wheels. 4. Extend the rod (5) to allow access to the base of the
2. Place a Do Not Operate Tag on both the ignition key cylinder.
switch and the steering wheel, stating that the IMPORTANT: Protect the finish on the rod at all times.
machine should not be operated. Damage to the surface of the rod can cause seal failure.
3. Open the engine cover. Allow the system fluids to 5. Using a pin spanner wrench, unscrew the head
cool. gland (6) from the barrel (1). A considerable amount
4. Relieve any trapped pressure in the hydraulic of force will be necessary to remove the head gland.
system by using the handle or wrench (located in the Carefully slide the head gland down along the rod
toolbox) and move the double nut on the side of the toward the rod eye end, away from the cylinder
actuator module on the valve section back and forth. barrel.

5. Label, disconnect and cap hydraulic hoses and IMPORTANT: When sliding the rod and piston assembly
cylinder ports in relation to the cylinder. out of the tube, prevent the threaded end of the tube
from damaging the piston. Keep the rod centered within
6. Attach a suitable sling to an appropriate lifting device the tube to help prevent binding.
to the cylinder. Make sure the device used can
actually support the cylinder.
1
7. Remove the lock bolt and/or any retaining clips 2
securing the cylinder pins. Remove the cylinder pins.
8. Remove the cylinder. 3

9. Wipe up any hydraulic fluid spillage in, on, near or

4
around the machine.

8.9.2 General Cylinder Disassembly

1. Clean the cylinder with a suitable cleaner before
disassembly. Remove all dirt, debris and grease
from the cylinder.
2. Clamp the barrel end of the cylinder in a soft-jawed
vise or other acceptable holding equipment if
1
possible.

WARNING 2 5
Significant pressure may be trapped inside the
6
cylinder. Exercise caution when removing a
counterbalance valve or a pilot-operated check valve MAH0160

from a cylinder. Escaping hydraulic fluid under

pressure can penetrate the skin, causing death or
6. Carefully pull the rod assembly along with the head
serious injury.
gland out of the cylinder barrel.
IMPORTANT: Avoid using excessive force when 7. Fasten the rod end in a soft-jawed vise, and put a
clamping the cylinder in a vise. Apply only enough force padded support under and near the threaded end of
the rod to help prevent damage to the rod.

40.8, 40.9 8.17

 Hydraulic System

8. Remove the set screw (3) from the piston (4). and blend the scratch(es) into the surrounding
surface.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod 3. Check the piston rod assembly for run-out. If the rod
before the piston can be removed. is bent, it must be replaced.

Some cylinder parts are sealed with a special organic 8.9.5 General Cylinder Assembly
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals 1. Use the proper tools for specific installation tasks.
from the area of the bonded parts. Wipe off any hydraulic Clean tools are required for assembly.
oil, then heat the part(s) uniformly to break the bond. A 2. Install new seals, back-up rings and o-rings (2) on
temperature of 149-204° C (300-400° F) will destroy the the piston (4) and the head gland (6).
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal Note: The extend/retract cylinder has a spacer that
while the parts are still hot. The sealant often leaves a MUST be installed over the rod AFTER the head gland
white, powdery residue on threads and other parts, which and BEFORE the piston head.
must be removed by brushing with a soft brass wire brush 3. Fasten the rod eye in a soft-jawed vise, and place a
prior to reassembly. padded support under and near the threaded end of
9. Remove the piston head (4) from the rod (5) and the rod (5) to prevent any damage to the rod.
carefully slide the head gland (6) off the end of the IMPORTANT: Protect the finish on the rod at all times.
rod. Damage to the surface of the rod can cause seal failure.
10. Remove all seals, back-up rings and o-rings (2) from 4. Lubricate and slide the head gland (6) over the
the piston head and all seals, back-up rings and o- cylinder rod (5). Install the piston head (4) on to the
rings from the head gland. end of the cylinder rod. Loctite and install the
Note: The head gland bearing will need to be inspected setscrew (3) in the piston head. Refer to Section
to determine if replacement is necessary. 8.9.9, “Hydraulic Cylinder Torque Specifications,” for
tightening guidelines for the piston head and the set
DO NOT attempt to salvage cylinder seals, sealing rings screw.
or o-rings. ALWAYS use a new, complete seal kit when
IMPORTANT: Avoid using excessive force when
rebuilding hydraulic components. Consult the parts
clamping the cylinder barrel in a vise. Apply only enough
catalog for ordering information.
force to hold the cylinder barrel securely. Excessive
force can damage the cylinder barrel.
8.9.3 Cylinder Cleaning Instructions
5. Place the cylinder barrel (1) in a soft-jawed vise or
1. Discard all seals, back-up rings and o-rings. Replace other acceptable holding equipment if possible.
with new items from complete seal kits to help
ensure proper cylinder function. IMPORTANT: When sliding the rod and piston assembly
into the cylinder barrel, prevent the threaded end of the
2. Clean all metal parts with an approved cleaning cylinder barrel from damaging the piston head. Keep the
solvent such as trichlorethylene. Carefully clean cylinder rod centered within the barrel to prevent binding.
cavities, grooves, threads, etc.
6. Carefully insert the cylinder rod assembly into the
Note: If a white powdery residue is present on threads tube.
and parts, it can be removed. Clean the residue away
7. Screw the head gland (6) into the cylinder barrel (1)
with a soft brass wire brush prior to reassembly, and
and tighten with a spanner wrench. Refer to Section
wipe with loctite cleaner before reinstallation.
8.9.9, “Hydraulic Cylinder Torque Specifications,” for
tightening guidelines for the head gland.
8.9.4 Cylinder Inspection
8. If applicable, thread the new counterbalance valve
1. Inspect internal surfaces and all parts for wear, into the block on the cylinder barrel.
damage, etc. If the inner surface of the tube does not
display a smooth finish, or is scored or damaged in
any way, replace the tube.
2. Remove light scratches on the piston, rod or inner
surface of the tube with a 400-600 grit emery cloth.
Use the emery cloth in a rotary motion to polish out

8.18 40.8, 40.9

 Hydraulic System

8.9.6 General Cylinder Installation 8.9.8 Steering Cylinders

1. Grease the bushings at the ends of the hydraulic The steering cylinders (7) are attached to each axle
cylinder. Using an appropriate sling, lift the cylinder center housing. The steer cylinders are covered in the
into it’s mounting position. appropriate manufacturer’s axle literature.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Connect the hydraulic hoses in relation to the labels 7
or markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary, fill to full
mark with DF UTTO Tractor Hydraulic Fluid ISO
Grade 46.
5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
6. Inspect for leaks and check level of hydraulic fluid in
Axle Center Section
reservoir. Add hydraulic fluid if needed. Shut the
engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.

8.9.7 Cylinder Pressure Checking

Attach a 345 bar (5000 psi) gauge to the test port on the
main control valve to check the system pressure.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
individual circuit. Activate the circuit and if pressure is
obtained, turn the main relief counter clockwise one half
turn. Recheck the main relief setting and adjust if
necessary.

40.8, 40.9 8.19

 Hydraulic System

8.9.9 Hydraulic Cylinder Torque Specifications

a. Lift/Lower Cylinder

Machine Piston Head Set Screw

40.8 2550-2600 Nm 775-825 Nm 20-25 Nm
(1881-1917 lb-ft) (571-608 lb-ft) (15-19 lb-ft)
40.9 2490-2540 Nm 950-1000 Nm 20-25 Nm
1837-1873 lb-ft) (701-738 lb-ft) (15-19 lb-ft)

b. Extend/Retract Cylinder

Machine Piston Head Plug Set Screw

40.8 & 40.9 1290-1340 Nm 400-450 Nm N/A 20-25 Nm
(951-988 lb-ft) (295-332 lb-ft) (15-19 lb-ft)

c. Tilt Cylinder

Piston Head Set Screw

2850-2900 Nm (2102-2139 lb-ft) 775-825 Nm (572-608 lb-ft) 20-25 Nm (15-19 lb-ft)

d. Compensation Cylinder

Piston Head Set Screw

850-900 Nm (627-664 lb-ft) 380-430 Nm (280-317 lb-ft) 20-25 Nm (15-19 lb-ft)

e. Sway Cylinder

Piston Head Set Screw

1050-1100 Nm (774-811 lb-ft) 400-450 Nm (295-332 lb-ft) 20-25 Nm (15-19 lb-ft)

8.20 40.8, 40.9

 Section 9
Electrical System

Contents

PARAGRAPH TITLE PAGE

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.3 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3.1 Operator Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3.2 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.3.3 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.4 Operator Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.4.1 Resetting the Anti theft Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.4.2 Hardware Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.4.3 Confirm Machine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.4.4 Review Service History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.4.5 Set Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.4.6 Cabin Joystick Telescope: X-Axis/Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.2 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.3 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.6 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
9.6.1 Cab Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
9.6.2 Cabin Roof Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.6.3 Power Distribution Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.6.4 Chassis & Boom Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.6.5 Engine Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.7 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.7.1 Constant Power Circuit from Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.7.2 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.8 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.8.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.9 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.9.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.10 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.10.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.10.2 Load Stability Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.10.3 Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.11 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.11.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.11.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.11.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

40.8, 40.9 9.1

 Electrical System

9.12 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24

9.12.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.13 Switches, Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.13.1 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.13.2 Transmission Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.13.3 Transmission Mounted Speed Sensor (if equipped) . . . . . . . . . . . . . . . . . 9.26
9.13.4 Engine Coolant Temperature Sender/Switch . . . . . . . . . . . . . . . . . . . . . . 9.26
9.13.5 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.13.6 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.13.7 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.13.8 Boom Retracted Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.14 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
9.14.1 Indicator Cross Reference Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
9.14.2 Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

9.2 40.8, 40.9

 Electrical System

9.1 ELECTRICAL COMPONENT 9.2 SPECIFICATIONS

TERMINOLOGY
Electrical system specifications are listed in Section 2,
To understand the safety, operation, and service “General Information and Specifications.”
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

LOAD
STABILITY
INDICATOR JOYSTICK

POWER
DISTRIBUTION
DISPLAY BOARD
PANEL
TRANSMISSION
SOLENOID VALVES

ALTERNATOR
UGM
CONTROLLER

STARTER

BATTERY

MZ2370

MZ2380
IGNITION KEY
SWITCH

BOOM ANGLE
SENSOR

LOAD STABILITY
SENSOR
(ON AXLE)

MZ3070

8.

40.8, 40.9 9.3

 Electrical System

9.3 SOFTWARE LEVEL 2 ACCESSIBILITY

The following parameters can be altered in the 2nd level of access to the machine’s software.

9.3.1 Operator Tools

Function Description
Change Anti Theft Allows the owner to change the Anti Theft Code
Code
Perform Hardware Allows the owner to restore machine data (anti theft code, engine hours, machine
Exchange personalities, etc.) in the event that the machine controller or display/cluster gauge has
been replaced
Confirm Machine Allows the owner to turn off the Service Required Warning lamp when service is
Service performed
Review Service History Allows the owner to see the last 15 times the Service Required Warning lamp was reset
Set Service Interval Allows the owner to modify the default service interval of 100 hours
Cabin Joystick Allows the owner to change/swap operation of the joystick Telescope and Fork Tilt
Telescope: X-Axis/ functions.
Roller NOTE: This change requires the installation of a new joystick operation decal in the cab.
Contact your local authorized distributor.

9.4 40.8, 40.9

 Electrical System

9.3.2 Personalities

Function Description Range Default Value

Main Lift Allows the owner to adjust the Max Lift Up & Max Lift 900-2500 mA 1550 mA
Down function speeds
Soft Lift Allows the owner to adjust the derate value when the 0-90% 40%
boom enters the soft lift zone
Telescope Allows the owner to adjust the Max Tele In & Max Tele Out 900-2500 mA 1550 mA
function speeds
Fork Tilt Allows the owner to adjust the Max Fork Tilt Up & Max 900-2500 mA 1200 mA
Fork Tilt Down function speeds
Frame Allows the owner to adjust the Max Frame Level Left & 1000-2500 mA 1000 mA
Level Max Frame Level Right function speeds
Aux. Allows the owner to adjust the Accel, Decel, and Max 1100-2500 mA 1550 mA
Function 1 Function A & Max Function B function speeds
Aux. Allows the owner to adjust the Accel, Decel, and Max 1100-2500 mA 1550 mA
Function 2 Function A & Max Function B function speeds
Aux. Allows the owner to adjust the Max Momentary Aux A & 0-1800 mA 1100 mA
Momentary Max Momentary Aux B function speeds
Bucket Allows the owner to adjust the Max Bucket Up & Max 1200-2500 mA 1550 mA
Mode Bucket Down function speeds

9.3.3 Calibrations

Function Description
Boom Angle Allows the owner to calibrate the boom angle sensor if it is replaced. Refer to Section 9.13.7,
“Boom Angle Sensor.”

40.8, 40.9 9.5

 Electrical System

9.4 OPERATOR TOOLS 9.4.3 Confirm Machine Service

To log the machine service into the software:
9.4.1 Resetting the Anti theft Code 1. Turn the engine to the ON position.
To reset the anti theft code: 2. Press the "C" and "OK" buttons on the dash
1. Turn the engine to the ON position. simultaneously to enter the analyzer mode.
2. Press the "C" and "OK" buttons on the dash 3. Scroll to "Access level code". Enter the code
simultaneously to enter the analyzer mode. "33271" to go into access level 2.
3. Scroll to "Access level code". Enter the code 4. Scroll to and select the "Operator Tools" screen.
"33271" to go into access level 2. 5. Scroll to and select the "Confirm Machine Service"
4. Scroll to and select the "Operator Tools" screen. screen.
5. Scroll to and select the "Change Anti Theft Code" 6. If service is complete, press ENTER for YES.
screen. Otherwise, press ESC for NO.
6. Enter the current anti theft code.
9.4.4 Review Service History
Note: If a machine does not have an anti theft code set,
To view the last 15 machine service instances:
the default code is "00000".
1. Turn the engine to the ON position.
7. Enter the new code.
2. Press the "C" and "OK" buttons on the dash
simultaneously to enter the analyzer mode.
9.4.2 Hardware Exchange
3. Scroll to "Access level code". Enter the code
After the replacement of either the display or UGM
"33271" to go into access level 2.
(Controller) the machine software will indicate a
Hardware Exchange fault. To correct this fault: 4. Scroll to and select the "Operator Tools" screen.
1. Turn the engine to the ON position. 5. Scroll to and select the "Review Service History"
screen.
2. Press the "C" and "OK" buttons on the dash
simultaneously to enter the analyzer mode. 6. Scroll through the screens to view the last 15 times
the machine was serviced.
3. Scroll to "Access level code". Enter the code
"33271" to go into access level 2.
9.4.5 Set Service Interval
4. Scroll to and select the "Operator Tools" screen.
To set the machine recommended service interval:
5. Scroll to and select the "Perform Hardware
Exchange" screen. 1. Turn the engine to the ON position.

6. Scroll to and select the proper screen for hardware 2. Press the "C" and "OK" buttons on the dash
exchange. The screen will show either simultaneously to enter the analyzer mode.
"DISPLAY -> UGM" or "UGM -> DISPLAY". The new 3. Scroll to "Access level code". Enter the code
component should be listed second. "33271" to go into access level 2.
4. Scroll to and select the "Operator Tools" screen.
5. Scroll to and select the "Set Service Interval" screen.
6. Enter a new service interval.

9.6 40.8, 40.9

 Electrical System

9.4.6 Cabin Joystick Telescope: X-Axis/ 9.5 FUSES AND RELAYS

Roller
To change the joystick telescope function on the joystick: 9.5.1 Cab
1. Turn the engine to the ON position. For access to the fuse and relay panel, remove the
2. Press the "C" and "OK" buttons on the dash screw (1) securing the right side console access
simultaneously to enter the analyzer mode. panel (2) to the cab. The fuses and sealed 12-volt relays
are mounted under the right side console access panel.
3. Scroll to "Access level code". Enter the code
The fuse and relay panels are part of the cab harness.
"33271" to go into access level 2.
4. Scroll to and select the "Operator Tools" screen.
5. Scroll to and select the "Cabin Joystick Telescope"
screen.
6. Select either X-AXIS or ROLLER.
Note: When changing the joystick function, ensure the 1

correct joystick operation decal is installed. Contact your 2

local authorized distributor.

MZ1990

9.5.2 Engine Compartment

The fuse and relay bar is located on the frame directly
above the engine. The fuse and relay bar contains the
glow plug fuse (3), glow plug relay (4) and starter
relay (5). To remove the relays from inside the engine
compartment, remove the mounting screws and washers.

3
4
5

MZ2100

40.8, 40.9 9.7

 Electrical System

9.5.3 Power Distribution Board

MZ2090

Fuse/Relay Function Amp Rating

F1 Rt. Headlight Low 7.5
F2 Rear Wiper 15
F3 Rt. Headlight High 7.5
F4 Lt. Headlight Low 7.5
F5 Lt. Headlight High 7.5
F6 Fan 20
F7 Front Wiper 25
F8 A/C 7.5
F9 Key 2 15
F10 Key 1 15
F11 Radio 10
F12 Lights Bat 1 15
F13 Lights Bat 2 15
F14 Lt. Marker Lights 7.5
F15 Boom Worklights 15

9.8 40.8, 40.9

 Electrical System

F16 Brake Lights 15

F17 Front Worklights 15
F18 Flasher 15
F19 Rt. Marker Lights 7.5
F20 Beacon 15
F21 Rear Worklights 15
F22 Controller 25
F23 Display/Joystick 10
F24 Fuel 15
F25 Socket 15
F26 Seat 15
F27 Key Bat 15
F28 Spare Bat 15
F29 Shift/Steer 15
F30 Spare Key 15
K1 Reverse Travel
K2 1/2 Aux
K3 Flasher
K4 Ign Power 1
K5 Ign Power 2
K6 Work Lights
K7 Ign Power 3
K8 Fuel
K9 Fuel Enable

40.8, 40.9 9.9

 Electrical System

9.6 ELECTRICAL SYSTEM SCHEMATICS

For more detailed schematics, contact your local authorized service distributor.

9.6.1 Cab Harness Electrical Schematic

ENGINE POD HARNESS ENGINE POD HARNESS CONTROL SIGNAL CONTROL SIGNAL CONTROL SIGNAL

AMP 796288-1 AMP 796276-1 AMP 776286-1 AMP 776273-1 AMP 776164-2
X3 X4 J12-BLACK J3-BLACK J1-NATURAL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

PLUGGED
PLUGGED
CAN2H
CAN2L

TRANS TEMP/GB RANGE

ENG OIL

FRONT MTR RETURN

HS VEH SPD
PS VEH SPD

CAN2 SHIELD
TRANS TEMP/GB RANGE

FRONT MOTOR
GLOWPLUGS

GLOWPLUGS
CLUTCH LOCK

STAB RETURN
TELE RETURN

TELE RETURN
AUX RETURN

BM RETRACT

AUX RETURN

QUICK CONN
HYD QC OFF
LIFT RETURN

LIFT RETURN
TILT RETURN

TILT RETURN
HS VEH SPD
PS VEH SPD
PLUGGED

PLUGGED
PLUGGED

PLUGGED

PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED

PLUGGED

PLUGGED

PLUGGED
PLUGGED

PLUGGED

PLUGGED
PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED

PLUGGED

PLUGGED
ENG GND1
ENG GND2
ENG GND3
ENG GND4

APU RELAY
ENG SPD +

ENG SPD +

ANG GND
FUEL PMP
ENG TMP

TELE OUT

ENG TMP
STAB SPD
HYD FLTR

REV OUT
TRANS R

STRT RLY
TRANS S

TRANS S
R WASH

STR RTN
FUEL VLV

TRANS F
TRANS 2
TRANS 1

TRANS 1

TRANS 2
F WASH

PLAT ON
AC OUT

STR 2W
ENG OIL

AIR FLTR

AIR FLTR
STR PSI
KEY 1B

TELE IN
LIFT DN
LIFT UP
TILT DN
ALT D+

ALT D+
TILT UP

AUX 1
AUX 2

RX
TX
(0.75)
(0.75)
LTF MKR LT

(0.75)
S1 6 5 4 7
APU ENABLE

(1.5)
(1.5)
(1.5)

(1.5)
SWITCH
COBO 16.600.021
(PLATFORM ONLY)
COBO 17.638.100
(0.75) (0.75)
3 2 1 8 SW LT GND
(0.75) (0.75)
KEY 1B

(0.75)
APU ENABLE

(0.75) (0.75)

(0.75)
2
EMERG STOP S2 S2
SWITCH
(PLATFORM ONLY)
KEY BAT A (2.5)
1

(1.5) KEY 2A
(1.5) FLASH 49
(1.5) FLASH BAT
S3 KEY 1A
6 5 4 7

HAZARD
COBO 16.600.021
SWITCH
COBO 16.623.100
SW LT GND
3 2 1 8
(1.5) LT TURN
(1.5) FLASH 49A
(1.5) RT TURN

(0.75)
LTF MRK LT
S25 7
HYD QUICK CONNECT
SWITCH
COBO 16.600.021
(OPTION)
COBO 17.638.100

3 2 1 8 SW LT GND
HYD QC OFF
KEY 1B
HYD QC ON

R WASH
S4 LTF MRK LT
6 5 7

REAR WIPER
COBO 16.600.021
SWITCH
COBO 16.643.100

3 2 1 8 SW LT GND
R WIPE PK
R WIPE SW
R WIPE
LTF MRK LT
S5 7
CLUTCH LOCK
SWITCH COBO 16.600.021
(POWERSHIFT ONLY)
COBO 13.608.100

3 2 8 SW LT GND
KEY 1B
CLUTCH LOCK
LTF MRK LT
S6 7
FRT/REAR AUX HYD
SWITCH COBO 16.600.021
(OPTION)
COBO 13.608.100

3 2 8 SW LT GND
KEY 1D
F/R AUX
LTF MRK LT
S7 7
FRAME LEVEL
SWITCH COBO 16.600.021
(SOME MODELS)
COBO 17.608.100
3 2 1 8 SW LT GND
LEVEL R
KEY 1B
LEVEL L
LTF MRK LT
S8 7
BEACON LIGHT
SWITCH COBO 16.600.021
(OPTION)
COBO 13.608.100

3 2 8 SW LT GND
BCN PWR
BCN LT
LTF MRK LT (1.5)
S9 7
BOOM WKLIGHTS
SWITCH COBO 16.600.021
(OPTION)
COBO 13.608.100
3 2 8 SW LT GND
BM WKLT PWR (1.5)
BM LTS (1.5) (1.5)
LTF MRK LT
S10 7
REAR WKLIGHTS
SWITCH COBO 16.600.021
(OPTION)
COBO 13.608.100

3 2 8 SW LT GND
RR WKLT PWR (1.5)
RR WKLTS (1.5)
LTF MRK LT
S11 7
(1.5)

FRONT WKLIGHTS
SWITCH COBO 16.600.021
(OPTION)
COBO 13.608.100

3 2 8 SW LT GND
FT WKLT PWR (1.5)
FT WKLTS (1.5)
DR LTS (1.5)
LTS BAT 2 (1.5)
KEY 1A
S12 6 5 7
DRIVING LIGHTS
SWITCH COBO 16.600.021
COBO 16.633.100

3 2 8 SW LT GND
LTS BAT 1 (1.5)
MKR LTS (1.5)

S13 AMP 280232-0

A/C FAN C (1.5)
1
SWITCH AC TEMP (1.5)
(OPTION) 2
AMP 280232-0

X8 COBO XE0802658
EMPTY
1
AUX POWER SOCKET (1.5)
SOCKET 2
SCKT GND (1.5)
COBO 4120.0583 3
AMP 180923-0
X9
AIR RIDE SEAT
1
SEAT M SEAT GND
(OPTION) 2

S14 AMP 180907-0

A/C TEMP AC TEMP (1.5)
SWITCH 1
AC IN (1.5)
(OPTION) 2
AMP 626062-0 (x2)
2 SW LT GND
S15.L1
LTF MRK LT
1
HVAC CNTRL AMP 280232-0 (X5) FAN L (1.5)
PANEL S15
BACKLIGHT 1 FAN M (1.5)
FAN
SWITCH B FAN H (1.5)
2 L
S15.L2 FAN B (1.5)
AMP 626062-0 (x2) M
C
H

FAN C (1.5)

X10 AMP 282088-1

BRAKE KEY 1B
1
PEDAL BRK LT SW (1.5)
SWITCH 2
BRK LTS (1.5)
COBO 15.0167.0000.02 3
CLUTCH
(1.5)

4
X11 AMP 180900-0
FAN H (1.5)
HEATER 1
FAN GND (1.5)
(1.5)

FAN MOTOR 2
M FAN M (1.5) (1.5) (1.5)
3 1 3
4 2 FAN L (1.5) (1.5) (1.5)
4
X12 FRAMATOME FFH05102BKT
FWIPE GND (1.5)
1
(1.0)
(1.0)

EMPTY
(1.5)
(1.5)

2
FRONT F WIPE H (1.5)
3
WIPER MOTOR M F WIPE L (1.5)
4
F WIPE P (1.5)
5

DEUTSCH DT06-2S
PARK BRAKE KEY 1B
1
SWITCH OFF X13 P BRK
2
FMDI (NC=ON)
ON
X13B AMP 282087-1
KEY 1B
1
P BRK
2
LOW PLUGGED
3

LEFT DEUTSCH DT06-6S

HIGH X15
FRONT LTFLT GND (1.5)
DRIVING 1
LT LO BEAM
LIGHT 2
(SOME MODELS) SIDE LT HI BEAM
3
COBO 05.0895.0000 LTF MRK LT
(1.0)
(1.0)

4
LT TURN (1.0)
TURN 5
PLUGGED PACKARD 12033769
6 (1.5) REV OUT
REVERSE
AMP 1-480706-0
10 ALARM
X14 F10 FUSE/CAP
FWD PWR KEY 1B (PACKARD)
1
NEUT F FWD (1.5) REV OUT 10A
2
REV N NEUT
3 PACKARD 12033731 (CAP)
SHIFTER REV
I R
SWITCH 4
(GEAR SELECTION WILL II I GEAR 1
5
VARY BETWEEN MODELS) II GEAR 2
6
(4 SPD) COBO 01.0810.0000 III III GEAR 3
(1.5)
(1.5)

(1.5)
(1.5)
(1.5)
(1.5)
(1.5)
(1.5)

(1.5)
(1.5)

(1.5)
(1.5)
(1.5)

(1.5)

(1.5)
(1.5)
(1.5)
(1.5)

7
(0.75)

(0.75)

(0.75)
(0.75)

(0.75)
(0.75)

ALTERNATE 2 SPD SHIFTER

IV IV GEAR 4
(1.0)
(1.0)

SHOWN BELOW 8
FRONT MTR RETURN

nc EMPTY
9
FRONT MOTOR
STAB RETURN

FRT REAR AUX

BM RETRACT

CAN2 SHIELD
STR CRB VLV

HORN OUT

RT LO BEAM

PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED

RCH GND5

RTR MRK LT

RCH GND2
RCH GND3
RCH GND4
STR AW VLV

RT STAB DN

LT LO BEAM

RTF MRK LT

FCH GND1
FCH GND2
FCH GND3
FCH GND4
FCH GND5

RR WKLTS
RT STAB UP

R WIPE SW
R STR POS

ANG GND
LTR MRK LT
RT HI BEAM
F STR POS

LT STAB DN

LTF MRK LT
STAB SPD
LEV RT VLV

LT STAB UP

LMI SHIELD

FT WKLTS
R WIPE PK
REV OUT
LT HI BEAM

RF GND1

RF GND2

RF GND3

RF GND4

RF GND5
RT TURN

RT TURN

KEY BAT A
LEV LT VLV

BM ANG
FUEL LVL

EMPTY
LT TURN

LT TURN

BRK LTS
CAN2H

CAN2L

R WIPE
KEY 1C

BM LTS

RADIO
KEY 2B

BCN LT
LMI S+

KEY 2
LMI S-

FWD PWR
1
NEUT F
2
REV N
SHIFTER 3
I R
SWITCH 4
(GEAR SELECTION WILL II I
5
VARY BETWEEN MODELS) II 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
6
(2 SPD) COBO 01.0809.0000
7 X1 X2 X0

MZ2610
8 AMP 796287-1 AMP 796188-1 AMP 1-480711-0
nc
9 FRONT CHASSIS HARNESS REAR CHASSIS HARNESS CAB ROOF HARNESS

9.10 40.8, 40.9

 Electrical System

9.6.1 Cab Harness Electrical Schematic (Continued)

8042 (18991 & After)

1/2 AUX HYD CONT AUX HYD

CONTROL SIGNAL CONTROL SIGNAL CONTROL SIGNAL CONTROL PWR/GND PLATFORM BOOM PLATFORM STAB/ERS SWITCH (RIGHT) SWITCH (LEFT)

AMP 776164-4 AMP 776164-5 AMP 776164-1 MOLEX 42816-0412 AMP 796207-1 AMP 788159-2 COBO 13.605.100 COBO 17.635.100
S16 S17
J2-GRAY J4-BLUE J7-BLACK J8 X6 X7 'T' 'S'
COBO 16.600.021 COBO 16.600.021
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 3 3

2 2

QUICK CONN
QUICK CONN
8 7 8 7

FUNC EN SW
GND MODE

CAN2 SHIELD
P CTRL PWR
PLAT MODE
PLAT MODE

PLAT MODE
P CTRL GND

PLUGGED

PLUGGED

PLUGGED
PERS GND
APU RELAY
DUMP VLV
BM EXT LIM
CAN1 SHIELD

KEY PLAT

ST DEPL 2
ST DEPL 1
PLAT ON
JYSTK LOCK IND

CLUTCH LOCK

CAN2H

KEY IGN
LMI CANCEL IND
FRT REAR AUX

CAN2L

KEY 2C
FUNC EN SW
APU ENABLE

1/2 AUX
1/2 AUX
GND MODE
STR CRB VLV

CAN1 TERM

JYSTK LOCK

CAN1 TERM
BUCKET IND
HORN OUT

STR CRB IND

HYD QC ON
LMI CANCEL
PLUGGED

PLUGGED

PLUGGED

PLUGGED
PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED

PLUGGED
PLUGGED

PLUGGED

PLUGGED
PLUGGED

PLUGGED
PLUGGED

PLUGGED
PLUGGED

PLUGGED

PLUGGED
PLUGGED

PLUGGED

PLUGGED

PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
STR AW VLV

RT STAB DN

STR AW IND
RT STAB UP

STR 2W IND

R STR POS
DUMP VLV

PREHEAT
FUEL SGN

BM EXT LIM
LT STAB DN

F STR POS
ACT 1/2 AUX

TELE OUT
LEV RT VLV

LT STAB UP

KEY STRT
HYD FLTR

BUCKET

CLUTCH
STRT RLY

TRANS R

STR CRB
LEV LT VLV

TRANS F

BM ANG

ST DEPL 1
ST DEPL 2
FUEL LVL

STR AW

CAN1H
LEVEL R
LMI OUT

KEY IGN
GEAR 2

GEAR 1
GEAR 3
GEAR 4

CAN1L
LEVEL L

F/R AUX
TELE IN

NEUT
LIFT DN
LIFT UP

TILT DN

P BRK

ALT D+

FWD
TILT UP
AUX 1

AUX 2

REV

G CTRL PWR

G CTRL PWR
G CTRL GND
G CTRL GND

P CTRL PWR
P CTRL GND
(0.75)

(0.75)
(0.75)

(0.75)
(0.75)
(0.75)
(1.0)
(1.0)
(1.5)

(2.5)

(1.0)
(1.0)
(2.5)
(1.0)
(1.0)
(2.5)

(2.5)

(1.5)
VCC
1300
F1
680
DEUTSCH DTM04-6P
F2
JYSTK + BLUE
1N5400
3A 50V

(1.5)

1 PWR
(1.5)

INSTR GND BLACK ITT AJ3

2 GND JOYSTICK
(1.5) (0.75) CAN1H BROWN
3 CANH
(0.75) CAN1L WHITE 12O
(1.5) (1.5) (2.5) 4 CANL
PLUGGED ITT AJ3
(1.5) 5
SW LT GND SAE 1939 CAN
6

(1.5)
(1.5)
X16

(2.5)
(2.5)
(2.5)
(2.5)
(2.5)
(2.5)
(1.5)

AMP 1-480710-0
X17
(1.5) F WIPER 15
1
(1.5) F WIPE L J
2
(1.5) F WIPE H 53
3
(1.5) F WIPE P 53a
4
(1.5) FLASH 49A 49a
5
(1.5) LT TURN L
6
(1.5) RT TURN R COBO
7
HORN OUT H TURN/
8
FLASH BAT 30 WIPER
9 SWITCH
(1.5) LO BEAM 56b
10 COBO
(1.5) (1.5) F WASH 53c
11 01.0811.0000
(1.5) DR LTS 56
12
(1.5) (1.5) (1.5) HI BEAM 56a
13
EMPTY
14
EMPTY
15

(0.75)
(0.75)
(0.75)
(0.75)
(0.75)
(0.75)

(0.75)
(0.75)
(0.75)
COBO 14.156.004
OR EQUIV
X18
(2.5) (2.5) KEY BAT A
30
(1.5) KEY BAT A
30 0P
(1.5) (1.5) (1.5) KEY IGN 1
15 2
(1.5) KEY IGN
15 3

(1.5)
(1.0)
(1.0)

(1.5)
(2.5) (2.5) KEY PLAT
(1.5) (1.5) (1.5) 58 0P
(1.5) KEY PLAT 1
58
2
COBO

(1.5)
COBO 14.156.005
X19 OR EQUIV 3 KEY
PREHEAT
19 0P SWITCH
PREHEAT A 1 COBO
19
2 14.0322.0000.12
PREHEAT A
17 3
EMPTY
17
0P
KEY STRT 1
50
EMPTY 2
50
3
(1.0)

X20 AMP 770680-1

PLUGGED
1 RS232 TX
PLUGGED
2 RS232 RX
PLUGGED
3 CAL 1
PLUGGED
4 CAL 2
INSTR GND
5 GND
(0.75) LMI SHIELD
6 GND
PLUGGED
7 GND
(0.75) LMI S+
8 SENSOR +
PLUGGED
(1.5) (1.0) 9 SYS ENABLE
PLUGGED
10 STAB ACTIVATED COBO
PLUGGED
11 LOW INTENSITY LOAD MOMENT
(1.5)

PLUGGED
12 EXT BUZZER DISPLAY
PLUGGED
13 NC
PLUGGED
14 NC
PLUGGED
15 SENSOR +
PLUGGED
16 PLATFORM
LMI +
17 PWR
PLUGGED
18 PWR
PLUGGED
19 90% CUTOUT
LMI OUT
20 100% CUTOUT
PLUGGED
21 NC
(0.75) LMI S-
22 SENSOR -
PLUGGED
23 NC

X21 AMP 1-640525-0

EMPTY
10 CAN1H 2
EMPTY
15 CAN1L 2
EMPTY
17 CAN1 SHIELD 2
(0.75) CAN1H
9 CAN1H 1
(0.75) CAN1L
14 CAN1L 1
EMPTY
16 CAN1 SHIELD 1
KEY LT
6 KEYPAD BACKLT
EMPTY
24 KEYPAD UBAT
EMPTY COBO
2
SIREN GND GAGE
3 BUZZER GND CLUSTER
EMPTY
7 AND
EMPTY DISPLAY
8
(1.0) RT TURN
11 RT TURN

EMPTY
18 +30 VBAT
EMPTY
19 KEYPAD GND
(1.5)

FLASH C2
22 TRLR TURN
(1.0) LT TURN
13 LT TURN
(1.0) HI BEAM
20 HI BEAM
(1.5)

INSTR GND
12 GND
DISPL +
5 +15 VBAT
D CLEAR
21 CLEAR
D UP
23 UP ARROW
D DN
1 DN ARROW
D OK
4 OK
(1.5)

(2.5)
(2.5)

X22 AMP 1-640524

(1.5)
(1.5)

(1.5)
(1.5)

INSTR GND -
1
D CLEAR
5 CLEAR
D UP
4 UP ARROW
D DN
3 DN ARROW
D OK
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)

2 OK
(1.5) BUCKET IND
20
BUCKET
13 BUCKET
(1.5)

JYSTK LOCK IND

18
JYSTK LOCK
11 JOYSTICK COBO
LMI CANCEL IND KEYPAD
19
LMI CANCEL
12 LMI CANCEL
(2.5)

STR AW IND
14
(1.5) STR AW
8 AW STEER
STR 2W IND
16
STR 2W
10 2W STEER
STR CRB IND
15
STR CRB
9 CRAB STEER
(2.5)

KEYPAD + +
7
KEY LT
6 BACKLIGHT
(1.5)
FWIPE GND (1.5)
LTFLT GND (1.5)

ENG GND3 (1.5)

ENG GND4 (1.5)

FCH GND2 (1.5)

FCH GND3 (1.5)

RCH GND2 (1.5)

RCH GND2 (1.5)
RCH GND3 (1.5)
RCH GND4 (1.5)

(1.5)
(1.5)
SCKT GND (1.5)

EMPTY
17
EMPTY
G CTRL GND
G CTRL GND
RELAY GND

ENG GND1
ENG GND2

RCH GND5
SW LT GND
FCH GND1

FCH GND4

FCH GND5
SEAT GND

PLAT MODE

PLAT MODE

PLAT MODE
FAN GND

RF GND1
RF GND2
RF GND3
RF GND4
RF GND5

INSTR GND

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY

IGNITION

IGNITION

IGNITION

IGNITION

IGNITION

IGNITION
KEY IGN

KEY IGN

KEY IGN

X5 AMP 280232-0
STR PSI 10 BAR STEERING
1
STR RTN PRESSURE
2 SWITCH
AMP 280232-0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12
XK XL XM XP X122 AMP 280232-0

AMP 1-480710-0 AMP 1-480710-0 AMP 1-480704-0 AMP 1-480708-0 DISPLAY + CONT
1
SIREN GND - SIREN
PCB PCB PCB PCB 2 BUZZER
PULSE
AMP 280232-0
(1.5)
(1.5)
(1.5)

(1.5)
(1.5)
(1.5)

(1.5)
(1.5)
(1.5)
(1.5)

(1.5)

(2.5)
(2.5)

(2.5)
(1.5)

(1.5)
(1.5)
(1.5)

(1.5)
(1.5)

(1.5)
(1.5)

(1.5)

(1.5)

(1.5)

BM WKLT PWR
RR WKLT PWR
FT WKLT PWR

FUNC EN SW
RT LO BEAM

1/2 AUX PWR

1/2 AUX PWR

G CTRL PWR
G CTRL PWR
LT LO BEAM

RTF MRK LT

RTR MRK LT

RELAY GND
RT HI BEAM

ACT 1/2 AUX

LTF MRK LT

LTR MRK LT
LT HI BEAM

R WIPE SW

FLASH BAT

FLASH 49A

INTLK GND

INTLK GND

DUMP VLV
BRK LT SW

DUMP VLV
PERS GND

STAB SPD
STAB SPD
LTS BAT 1
LTS BAT 2

KEY BAT A
FUEL SGN

FUEL PMP
KEYPAD +
FLASH C2

BCN PWR
FLASH 49

FUEL VLV
LO BEAM
F WIPER

IGNITION
MKR LTS

KEY IGN
HI BEAM

SOCKET
AC OUT

JYSTK +
KEY 1D

KEY 1C

KEY 2C

EMPTY
KEY 1A
KEY 1B

KEY 2A
KEY 2B

EMPTY
EMPTY

EMPTY
EMPTY
EMPTY

EMPTY

EMPTY

DISPL +

1/2 AUX
EMPTY
RADIO

EMPTY
EMPTY

EMPTY
EMPTY

EMPTY
EMPTY

EMPTY
EMPTY

EMPTY

EMPTY
FAN B
KEY 2

AC IN

SEAT
LMI +
RX
TX

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 1 2 3 4 5 6

XC XD XF XG XH X123A X123B
AMP 1-480708-0 AMP 1-480710-0 AMP 1-480710-0 AMP 1-480710-0 AMP 1-480710-0 AMP 1-480705-0 AMP 1-480704-0

PCB PCB PCB PCB PCB PLATFORM CAB PLATFORM CAB

PCB PWR
PCB PWR
PCB PWR
PCB PWR
PCB PWR
PCB PWR
PCB PWR
PCB PWR

PCB GND
PCB GND
PCB GND
PCB GND

PCB GND
PCB GND
PCB GND
PCB GND
EMPTY

EMPTY
EMPTY

4 3 2 1 1 2 3 4 5 1 2 3 4 5 6 4 3 2 1

XA1 XA XB XB1

MZ2620
DEUTSCH DTP04-4P MOLEX 42816-0512 MOLEX 42816-0612 DEUTSCH DTP06-4S

PCB PWR PCB PWR PCB GND PCB GND

40.8, 40.9 9.11

9.12
9.6.2
COBO
05.0698.0000
RT FRT LT FRT RT REAR LT REAR
WKLIGHT WKLIGHT WKLIGHT WKLIGHT
(OPT) (OPT) (OPT) (OPT)

A B A B A B A B
X29 X30 X31 X32 X29, X30, X31, X32: PACKARD 12124819
Electrical System

RF GND5
AMP 962189-1 AUX POWER
X23 SOCKET
EMPTY
1 COBO
BEACON

RF GND3
RF GND3
RF GND4
RF GND4
EMPTY 25.0051.0100 BCN LT

FT WKLTS
FT WKLTS
RR WKLTS
RR WKLTS
2 AMP 180907-0 X33 LIGHT
EMPTY BCN LT
3 1 (OPT)
KEY BAT A RF GND5
4 2 COBO
EMPTY 35.406.000
5
EMPTY
6
RADIO
7

(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
RF GND1
8
RADIO
X24AMP 962191-1
(OPT)
Cabin Roof Electrical Schematic

EMPTY

(1.5)
1

(1.5)
EMPTY
2

(1.5)
SX-

(1.5)
3
SX+
4
DX-
5
DX+
6
EMPTY
7
EMPTY
8
X25
DX+ HEAT SHRINK OVER 4.8mm FASTON
DX 1 +
DX- AMP 626062-0 (OVER 2.8mm FASTON)
SPEAKERS 2 -
SX- AMP 626062-0 (OVER 2.8mm FASTON)
(OPT) 2 -
SX SX+ HEAT SHRINK OVER 4.8mm FASTON
1 +
X26 AMP 180900
X27
53A R WIPE SW
1
REAR WIPER 31 RF GND2
2
MOTOR M 53 R WIPE
3
31B R WIPE PK
4

DOME X28
KEY 2 AMP 280232-0
LIGHT 1
RF GND1 AMP 280232-0
COBO 10.104.000 2

(1.5)
(1.5)
(1.5)
(1.5)

RADIO
KEY 2
EMPTY

R WIPE
BCN LT

RF GND1
RF GND2
RF GND3
RF GND4
RF GND5

FT WKLTS
RR WKLTS

KEY BAT A
R WIPE PK
R WIPE SW

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

X0
AMP 1-480710-0
CAB HARNESS

MZ2630

40.8, 40.9
9.13 40.8, 40.9
MZ2640
XQ
AMP 350780-1

DIAGNOSTIC
CONNECTOR
1

4
3
2

KEY 1
KEY 1
KEY 1
KEY 1
KEY 1
KEY 2
XC

KEY 2
AMP 350433-1

KEY 2
KEY 2
KEY 2
TX
RX
1 2 3 4 5 6 7 8 9 10 11 12

LIGHTS BAT 1
XA

LIGHTS BAT 2
RADIO
MOLEX 42819-5212
1 2 3 4 5

LEFT HI BEAM
BAT POSITIVE

LEFT LO BEAM
EMPTY
FRONT WIPER
AC OUT
XD

AC IN
AMP 350434-1

RIGHT HI BEAM
RIGHT LO BEAM
LT MARK LT
RT MARK LT
FAN
REAR WIPER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

LO BEAM IN
MRK LT IN
RT MARK LT
LT MARK LT
EMPTY
FLASHER
FLASHER 49
XF

FLASHER 49A
XB

FLASHER C2
AMP 350765-4

MOLEX 42819-6212

BRAKE LIGHTS
1 2 3 4 5 6

FRT WKLIGHTS
BAT NEGATIVE

REAR WKLIGHTS
BOOM WKLIGHTS
BEACON
HI BEAM IN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CONTROLLER
CONTROLLER
EMPTY
EMPTY
DISPLAY
KEYPAD
LMI
JOYSTICK
XG

EMPTY
AMP 350434-1

EMPTY
FUEL SGN
1/2 AUX 87
FUEL PUMP
EMPTY
EMPTY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

EMPTY
SPARE BAT
SPARE KEY
KEY BAT
KEY SGN IN
FUEL VALVE
1/2 AUX 30
EMPTY
XH

1/2 AUX 86
AMP 350765-4

GND
EMPTY
SEAT
SOCKET
GND
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

GND
GND
GND
GND
GND
GND
GND
GND
XK
AMP 350434-1

GND
GND
GND
GND
GND
GND
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

GND
GND
GND
GND
GND
GND
GND
GND
XL

GND
AMP 350765-4

GND
GND
GND
GND
GND
GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

D8
D9
D10
XM

D11
AMP 350762-4

D12
D13
1 2 3 4 5 6

D2
D3
D4
XP

D5
AMP 350764-4

D6
D7
1 2 3 4 5 6 7 8 9 10 11 12
Power Distribution Electrical Schematic 9.6.3
Electrical System
9.14
9.6.4
BOOM RIGHT RIGHT LEFT LEFT MAIN HYDRAULIC RIGHT LEFT
EXTEND LIMIT STABILIZER PAD STABILIZER ARM STABILIZER PAD STABILIZER ARM MAIN PRESSURE STABILIZER PAD RIGHT LEFT STABILIZER ARM
PROXIMITY PRESSURE PROXIMITY PROXIMITY PRESSURE HYDRAULIC REDUCING VALVE PRESSURE STABILIZER ARM STABILIZER PAD PRESSURE
SWITCH SWITCH SWITCH SWITCH SWITCH DUMP/BLOCK SWITCH PROXIMITY PROXIMITY SWITCH
LICENSE REVERSE FUEL (OPTION ON
CABLE HARNESS PLATFORM, 1/2 AUX, EXT (AUSTRALIA PLATFORM ONLY) (13M PLATFORM ONLY) (PLATFORM ONLY) (PLATFORM ONLY) (13M PLATFORM ONLY) VALVE (17M ONLY) SWITCH SWITCH (17M ONLY)
LIGHT ALARM SNDR PLATFORM ONLY-
1001092136 QUICK JLG 80363166 JLG 4360606 JLG 4000017 JLG 4000017 JLG 4360606 (PLATFORM ONLY) JLG 4360661 JLG 4000017 JLG 4000017 JLG 4360661
LEFT REAR DRIVING LIGHT RIGHT REAR DRIVING LIGHT COBO ECCO COBO CONNECT AUSTRALIA)

02.482.000 575-JLG2 29.211.000

(FOR Q CONN, SEE BELOW)
VIBRA-ACTIVE VIBRA-ACTIVE

TAIL BACK TURN STOP TAIL BACK TURN STOP

OIL CONTROL VALVE

1/2 AUX QUICK CONN

RED
BLK
BLU
RED
BLK
BLU

BRN
BLU
BLK
BRN
BLU
BLK

RED
BLK
BLU
RED
BLK
BLU

BRN
BLU
BLK
BRN
BLU
BLK
BRN
BLU
BLK
LEFT LEFT RIGHT RIGHT FRAME FRAME
X123 X124 SPEED
DEUTSCH DT06-2S
STAB STAB STAB STAB LEVEL LEVEL
DEUTSCH DT06-2S CNTRL
UP DN UP DN RIGHT LEFT
1 2 1 2 A B C A B C A B C
A B C A B C A B C A B C A B C A B C
PACKARD 12015793 DEUTSCH DT06-3S AMP 282087-1 AMP 282087-1 DEUTSCH DT06-3S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-3S AMP 282087-1 AMP 282087-1 DEUTSCH DT06-3S

1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 1 2 1 2 X111 X105 X106 X107 X108 X109 X114 X105 X106 X107 X108
BOOM HEAD

1/2 AUX
X74 X75
AMP 0-967650-1
X76 AMP
X77
AMP
X78

PWR
GND
AMP 0-967650-1 AMP 280543-0
X125

P CTRL GND
QUICK CONN
P CTRL GND
280543-0 282080-1
DEUTSCH HD34-24-21SE
1 2 1 2 1 2 1 2 1 2 1 2 1 2

PLUG
PLUG

PLUG
PLUG
A B C D E F G H J K L M N P R S T U V W X

KEY 2C
KEY 2C
DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S

KEY 2C
KEY 2C
KEY IGN
PERS GND
PERS GND

PERS GND
PERS GND
DUMP VLV
PERS GND
PERS GND
LT PRX DN
RT PRX DN
ST DEPL 2
LT PRX DN
ST DEPL 1
RT PRX DN

LT PRX DN
RT PRX DN
ST DEPL 2
LT PRX DN
ST DEPL 1
RT PRX DN

BM EXT LIM
X91 X92 X93 X94 X95 X96 X97

REV OUT
LT TURN
BRK LTS
PLUGGED
PLUGGED
REV OUT
RT TURN
BRK LTS
PLUGGED
PLUGGED
REV OUT

RCH GND2
RCH GND2
RCH GND2
RCH GND2
FUEL LVL
RCH GND5

LTR MRK LT
RTR MRK LT
RTR MRK LT
CAN2H
CAN2L
WHITE (1.5)
BROWN (1.5)
Electrical System

(1.5)
(1.0)
(1.0)
(1.0)
(1.0)
(1.5)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
(1.0)
PLUGGED
PLUGGED
PLAT ON
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
WHITE (1.5)
FCH GND5
FCH GND5
FCH GND4
FCH GND4
FCH GND4
FCH GND4
STAB SPD

BROWN (1.5)

KEY PLAT
GND MODE
LT STAB UP
LT STAB DN
RT STAB UP
RT STAB DN
LEV RT VLV
LEV LT VLV
STAB RETURN

PLAT MODE

P CTRL PWR
P CTRL GND
FUNC EN SW
120

CAN2 SHIELD
CABIN
Ohm FRAME
(50.0)

(1.5)
AMP 282105-1

(.75)
1 2 3 X104

RED (1.0)

WHITE (2.5)
WHITE (2.5)
AMP 282087-1

BROWN (2.5)
WHITE (1.0)
WHITE (2.5)
WHITE (1.0)
WHITE (1.0)
WHITE (1.0)
BLACK (1.0)

WHITE (1.0)
WHITE (1.0)
WHITE (1.0)

(1.5)
(1.0)
(1.5)
(1.5)
KEY 2C
PERS GND
PETERS 853431 (OR EQUIV)
REAR

BM EXT LIM
X80
AXLE
KEY 2B
1 HORN
PROXIMITY NC COBO AV.31.0076.41
2
SWITCH RCH GND5 AMP 280232-0
(OPTION) 3 X98
HORN OUT

CAN2H
CAN2L
CAN2 SHIELD

PLUGGED
P CTRL PWR
PLUGGED
P CTRL GND
PLAT MODE
PLAT ON
KEY PLAT
FUNC EN SW
GND MODE
1/2 AUX
1/2 AUX
PLUGGED
QUICK CONN
QUICK CONN
PLUGGED
PLUGGED
PLUGGED
PLUGGED
R STR POS
4
DEUTSCH DT06-2S
REAR AXLE
X81 DEUTSCH HD36-24-21PE
LMI S- (0.75)
LOAD CELL 1 A B C D E F G H J K L M N P R S T U V W X
LMI S+ (0.75) X113
COBO 2 DEUTSCH HD34-24-21SE-072 CHASSIS
FRAME
DEUTSCH DT06-2S
AMP 282087-1 X99
X82 STR AW VLV ALL WHEEL
BOOM ANG GND 1
1 FCH GND5
ANGLE KEY 2B 2 STEER SELECT

CAN2H
CAN2L
SENSOR 2 VALVE
BM ANG STR CRB VLV

PLUGGED
PLUGGED
PLAT ON
1/2 AUX
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
ELOBAU 424A07B090B 3 1 OIL CONTROLS

KEY PLAT
GND MODE

PLAT MODE
1/2 AUX A
FCH GND5 CRAB
2

P CTRL PWR
P CTRL GND
FUNC EN SW
QUICK CONN
CAN2 SHIELD
DEUTSCH DT06-2S

QUICK CONN A
X100
PETERS 853431 (OR EQUIV)
X101
KEY 1C FRONT
BOOM AMP 282105-1 AMP 282087-1
1
PACKARD 12015793 X83 NC AXLE
RETRACTED X84 2
PROXIMITY BRN PWR PWR KEY 2B FCH GND1 PROXIMITY
A 1 3
SWITCH BLU GND GND RCH GND5 SWITCH
B 2 F STR POS
(PLATFORM AND OPTION) 4
BLK BM RETRACT BM RETRACT BM RETRACT
JLG 80363166 C 3 AUXILIARY

RED

BLUE

BROWN
BLACK

YELLOW
SHIELD
POWER

ORANGE
NO CONNECTOR REQUIRED

RED (12AWG)
UNIT

RED/BLACK
BLUE/BLACK
DEUTSCH DT06-6S

BLACK (12AWG)
RELAY LOW

ORANGE/BLACK
X102

ORANGE (12AWG)
FRT/REAR DEUTSCH DT06-2S (PLATFORM ONLY)
(1.5) FCH GND2
X85 1

BLACK/WHITE (12AWG)
AUX HYD FRT REAR AUX JLG 3740067 RT LO BEAM
(1.5) 2
SEL VLV 1 RT HI BEAM HIGH RIGHT
RCH GND3 (1.5) 3 FRONT
AT REAR 2 RTF MKR LT
(OPTION) 4 DRIVING
RT TURN LIGHT
5 SIDE

30
87
86
COBO

(1.5)
PACKARD 12124819 AMP 282104-1 AMP 282080-1
X110 PLUGGED
X88 X87 6 05.0894.0000
BM LTS (1.0) (1.5) BM LTS BM LTS (1.5)
A 1 TURN
GND (1.0) (1.5) GND RCH GND3 (1.5) (1.5)
BOOM B 2

CAN2H
CAN2L
CAN2 SHIELD

PLUGGED
P CTRL PWR
PLUGGED
P CTRL GND
PLAT MODE
PLAT ON
KEY PLAT
FUNC EN SW
GND MODE
1/2 AUX
1/2 AUX A
PLUGGED
QUICK CONN
QUICK CONN A
PLUGGED
PLUGGED
PLUGGED
PLUGGED
8mm RING
8mm RING
5mm RING
LIGHTS
(OPTION) PACKARD 12124819
X89
COBO BM LTS DEUTSCH HD34-24-21PE-072

(1.5)
(1.0)
05.0698.0000 A
GND (1.0) X112 A B C D E F G H J K L M N P R S T U V W X DEUTSCH DT06-6S
B DEUTSCH HD36-24-21SE-072 X103 LOW
(1.5) FCH GND3
1 LEFT

(25.0)
(25.0)
LT LO BEAM FRONT
2

APU RELAY
LT HI BEAM HIGH DRIVING
DEUTSCH DT06-6S
3
LTF MKR LT LIGHT
X86 4 (SOME MODELS)
ANG GND (25.0) LT TURN
1 5 SIDE COBO
BOOM ANGLE KEY 2B X121 PLUGGED 05.0895.0000

CAN2H
CAN2L
2 6
Chassis & Boom Electrical Schematic

SENSOR, 90 DEG

PLUGGED
PLUGGED
PLAT ON
1/2 AUX
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED

KEY PLAT
GND MODE
PLUGGED FRT MOTOR RETURN

PLAT MODE
1/2 AUX A
HALL EFFECT 3

P CTRL PWR
P CTRL GND
FUNC EN SW
QUICK CONN
2

CAN2 SHIELD

QUICK CONN A
(PLATFORM ONLY)
PLUGGED FRT MOTOR TURN
4 M 1
ELOBAU CAN2L (0.75)
5
424CS09001 CAN2H (0.75)
6

AMP 280232-0 (X6)

120 Ohm KEY 1C

(1.0)
(1.0)
(1.0)
(1.0)
(1.5)
X90
LT TURN
RT TURN
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED

KEY 2C
HORN OUT
STAB SPD
FCH GND1
FCH GND2 (1.5)
FCH GND3 (1.5)
FCH GND4
FCH GND5

LT TURN (1.5) (1.5)

PLUGGED
PLUGGED
PLUGGED
F STR POS

PLUGGED
PLUGGED

PERS GND
STR AW VLV
LEV LT VLV
LEV RT VLV
RT STAB UP
RT STAB DN
LT STAB UP
LT STAB DN
LT HI BEAM
LT LO BEAM
RT HI BEAM
RT LO BEAM
LTF MRK LT
RTF MRK LT
1

ST DEPL 2
ST DEPL 1
TRAILER/

STR CRB VLV

STAB RETURN
FRONT MOTOR

(25.0)
(25.0)
EMPTY
FRONT MTR RETURN

TOWING 2
PLUG RCH GND4 (1.5) (1.5) 8mm RING 8mm RING
3
(OPTION) RT TURN (1.5) (1.5)
4

RED
(ISO 1724:2003 E)

BLUE

BROWN
BLACK
RTR MRK LT (1.5) (1.5) POSITIVE

YELLOW
ORANGE
SHIELD
COBO 5 - + 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
(50.0) CABLE

RED/BLACK
BRK LTS (1.5) (1.5)

BLUE/BLACK
25.044.100

RED (12AWG)
6 TO STARTER X7

ORANGE/BLACK
X1

BLACK (12AWG)
25.022.105 LTR MRK LT (1.5) (1.5)

ORANGE (12AWG)
7 SOLENOID
AMP 788157-2 AMP 796288-1

BLACK/WHITE (12AWG)

(1.5)
CABIN HARNESS CABIN HARNESS

(0.75)

(0.75)

(1.5)
(1.5)
(1.5)
(1.5)

(0.75)
(0.75)
BATTERY DISCONNECT
SWITCH (OPTION)
M
AUXILIARY
SPECIAL BATTERY 10mm RING (25.0)
CABLE IF POWER

CAN2H
CAN2L
PLATFORM WITH UNIT

PLAT ON
1/2 AUX
PLUGGED
PLUGGED
50.0 AND 25.O

CAN2H (0.75)
CAN2L (0.75)
GND MODE
KEY PLAT
NEGATIVE CABLE

BM ANG
LMI S+
LMI S-
BM LTS
KEY 2B
1/2 AUX A
PLAT MODE
(50.0) (50.0) MOTOR

KEY 2C

REV OUT (1.5)

LT TURN
RT TURN
BRK LTS
ANG GND
CABLES CRIMPED

P CTRL PWR
FUNC EN SW
P CTRL GND
QUICK CONN

FUEL LVL
RCH GND5
RCH GND2 (1.5)
RCH GND3 (1.5)
RCH GND4 (1.5)
KEY IGN
PLUGGED

CAN2 SHIELD
DUMP VLV
PERS GND
TO STARTER

R STR POS
QUICK CONN A
INTO ONE TOP

ST DEPL 2
ST DEPL 1
APU RELAY
JLG 3600422

RTR MRK LT (1.5)

LTR MRK LT (1.5)
LMI SHIELD
BM RETRACT
BM EXT LIM

CAN2 SHIELD
POST TERMINAL (BODY)

FRT REAR AUX

(PLATFORM ONLY)
+ -
12 VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 BATTERY
X6 X7
X2 AMP 796203-1
AMP 796291-1 AMP 788157-2
CABIN HARNESS CABIN HARNESS CHASSIS GROUND
CABIN HARNESS

CABLE HARNESS Q CONN, 1/2 AUX, EXT

1001092137
(FOR PLATFORM, SEE ABOVE) QUICK
CONNECT

1/2 AUX QUICK CONN

X123 X124
DEUTSCH DT06-2S DEUTSCH DT06-2S

1/2 AUX
P CTRL GND
QUICK CONN
P CTRL GND

WHITE (1.5)
BROWN (1.5)
WHITE (1.5)
BROWN (1.5)

BROWN (2.5)
WHITE (1.0)
WHITE (1.0)
WHITE (1.0)
WHITE (1.0)
PLUGGED
PLUGGED
PLUGGED

PLUGGED
PLUGGED
PLUGGED
P CTRL GND
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
1/2 AUX
1/2 AUX
PLUGGED
QUICK CONN
QUICK CONN
PLUGGED
PLUGGED
PLUGGED
PLUGGED
DEUTSCH HD36-24-21PE

A B C D E F G H J K L M N P R S T U V W X X113

MZ2650

40.8, 40.9
 9.6.5

40.8, 40.9
CABIN HARNESS CABIN HARNESS
AC PRESSURE AC COMPRESSOR PCB PWR PCB GND
SWITCH (OPT) CLUTCH (OPT) AMP 796274-1 AMP 796287-1 DEUTSCH DTP06-4S DEUTSCH DTP04-4P
X4 X3 XA1 XB1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 1 2 3 4 1 2 3 4
C
AC PUMP

MZ2660
1 2 1

PCB PWR
PCB PWR
PCB PWR
PCB PWR
PCB GND
PCB GND
PCB GND
PCB GND
X34 X35

AUX 1
AUX 2
F WASH
R WASH
KEY 1B
AC OUT
ALT D+
AMP 180907-0 AMP 60799-4

TILT UP
TILT DN
LIFT UP
LIFT DN
TELE IN
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
ENG TMP
ENG OIL
PLUGGED
TRANS 2
TRANS 1
TRANS F
TRANS R
TRANS S
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED

TELE OUT
FUEL VLV
AIR FLTR
ENG GND1
ENG GND2
HYD FLTR
FUEL PMP
STRT RLY

ENG SPD +
GLOWPLUGS

AUX RETURN
PS VEH SPD
TRANS TEMP

TILT RETURN
LIFT RETURN
TELE RETURN
AC OUT

(4.0)
(4.0)
(4.0)
(4.0)
(4.0)
(4.0)
(4.0)
(4.0)

(1.5) ENG GND3

(1.5) ENG GND4

AC OUT
AC PUMP
AC PUMP
(1.5)

POSITIVE CABLE
TO BATTERY +

NEGATIVE CABLE
TO FRAME
(BATTERY -)
PCB GND
PCB GND
PCB GND
PCB GND

(4.0)
(4.0)
(4.0)
(4.0)

(50.0)
G

STARTER
RIN
m

(50.0)
E 8m
ON

PCB PWR (4.0)

PCB PWR (4.0) X37
PCB PWR (4.0) ONE
8mm
X36
M
RING
PCB PWR (4.0)

STRT PWR (6.0) RING

PHEAT PWR (10.0) ONE 8mm
G G
RIN
ALT BAT (6.0) E 8mm m RIN X38
ON 6m
ALT BAT (6.0)
STRT SOL (6.0) X39
30
STRT PWR (6.0) 5mm RING
STARTER
STRT SOL (6.0) 5mm RING 87
RELAY
STRT RLY AMP 280232-0 86 (BOSCH 75A)
ENG GND2 AMP 280232-0 85

ALT BAT (6.0) ALTERNATOR

ALT BAT (6.0) ONE 6mm RING
B+ X40
W G
ALT D+ 5mm RING
D+

DEUT. DT06-2S
X41
ENG OIL ENGINE OIL
1
PLUGGED PRESSURE
2 SWITCH

AMP 282189-1
X42
ENG TMP COBO U2M02B004
1
PLUGGED CLT TEMP
Engine Harness Electrical Schematic

2
SENDER

107 C COOLANT
TEMP
SWITCH

AMP 280232-0
X43
FUEL VLV COLD START
TEMP
SWITCH

AMP 282189-1
X44

(1.5)
FUEL VLV FUEL
1
(1.0) (1.0) ENG GND4 VALVE
2 (TURBO)
AMP 280232-0 (x2)
X45

(1.0)
AIR FLTR AIR FILTER
ENG GND2 RESTRICTION
SWITCH

(10.0) PHEAT PWR 5mm RING

GLOWPLUGS
50
X46 FUSE
(1.0) (1.5) (1.5) SLO-BLO 50A
(10.0) PHEAT RLY 5mm RING
(LITTELFUSE)

X47 30
(10.0) PHEAT RLY 5mm RING
GLOWPLUGS

(1.0)
(1.0)
(10.0) PHEAT 5mm RING 87
RELAY
GLOWPLUGS AMP 280232-0 86
(BOSCH 75A)
ENG GND1 AMP 280232-0 85
DEUTSCH DTHD06-1-8S
X48
(10.0) PHEAT
1 ENGINE
GLOWPLUGS

DEUTSCH DT06-2S
X49
FUEL PMP
1
(1.0) ENG GND4 FUEL
2 M PUMP

AMP 282080-1
X73 3 BAR
HYD FLTR HYD FILTER
1
ENG GND2 PRESSURE
2 SWITCH

AMP 180907-0 ENG GND1

X50
F WASH FRONT
1
ENG GND1 W/WASHER
2 M PUMP
F WASH
AMP 180907-0 ENG GND1
X51
R WASH REAR
1
ENG GND1 W/WASHER
2 M PUMP
R WASH

DEUTSCH DT06-3S
X126
ENG SPD+ WHT/SIGNAL
1 ENGINE
KEY 1B RED/VCC
2 SPEED
ENG GND1 BLK/GND SENSOR
3

(1.0)
(1.0)
(1.0)
KEY 1B

TRANS 2
TRANS 1
TRANS F
TRANS R
TRANS S

ENG GND3
ENG GND3
ENG GND3
ENG GND2
ENG GND2
PS VEH SPD
TRANS TEMP
AMP 282189-1 AMP 282189-1 AMP 282189-1 AMP 282189-1 AMP 282189-1 AMP 282080-1 AMP 280232-0
(SOME MODELS) (SOME MODELS) (SOME MODELS) (SOME MODELS) (SOME MODELS) (SOME MODELS) (SOME MODELS)

X63 X64 X62 X61 X60 X59 X58

1
1 2 1 2 1 2 1 2 1 2 1 2

AUX 1
AUX 2

LIFT UP
LIFT DN
TELE IN
TILT UP
TILT DN

TELE OUT
AUX RETURN
AUX RETURN

LIFT RETURN
LIFT RETURN
TELE RETURN
TELE RETURN
TILT RETURN
TILT RETURN
DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S DEUTSCH DT06-2S

X72 X71 X70 X69 X68 X67 X66 X65

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 2 1 F R S
TURBINE OIL
SPEED TEMPERATURE
SENSOR SWITCH

LIFT LIFT TELE TELE TILT TILT AUX AUX POWERSHIFT

UP DN IN OUT UP DN 1 2
TRANSMISSION
REXROTH CONTROL VALVE
Electrical System

9.15
 Electrical System

9.7 CIRCUIT BREAKDOWNS

9.7.1 Constant Power Circuit from Battery

POWER CONTROL BOARD

SOCKET
FLASHER
LIGHTS BAT 1
LIGHTS BAT 2

KEY BAT
SPARE BAT
XF XH
XA XD

5 4 3 2 1 1 2 6 2 4 13

PCB PWR
XA

SOCKET
KEY BAT
EMPTY
LIGHTS BAT 1
LIGHTS BAT 2

HAZARD
SWITCH
X8
S3 1
1 2
3 6
DRIVING LIGHTS
SWITCH 2 5 1
EMERG STOP
S12 1 4 FLASH BAT SWITCH AUX POWER
3 6 8 7 (PLATFORM ONLY)
SOCKET
2
2 5
FLASH BAT

X18
KEY BAT A
30
KEY BAT A
8 7 30 0P
1
15 2
X17
15 3
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
58 0P
1
58
2
3
56a

53c
56b

49a
53a

KEY
56

30

53

15
H
R
L

19 0P SWITCH
19 1
2
17 3
17
TURN/ 0P
WIPER 50 1
SWITCH 2
50
3
PCB PWR
PCB PWR
PCB PWR
PCB PWR

PCB PWR XA1 CAB HARNESS

1 2 3 4

XA1 30
AUXILIARY
PCB PWR
PCB PWR
PCB PWR
PCB PWR

POWER
87
UNIT
86 RELAY
(PLATFORM ONLY)

X110

+ -
12 VDC
BATTERY
STARTER

PCB PWR
PCB PWR
PCB PWR X36
M
PCB PWR

STRT PWR
PHEAT PWR
ALT BAT X38
ALT BAT
30
STRT PWR
STARTER
87
RELAY
86
85

ALT BAT ALTERNATOR

ALT BAT B+ X40
PHEAT PWR W G
D+
50 GLOWPLUGS
X46
FUSE
PHEAT RLY
X47 30
PHEAT RLY
87 GLOWPLUGS
86 RELAY
ENGINE HARNESS 85

MZ2260

9.16 40.8, 40.9

 Electrical System

9.7.2 Start Circuit

POWER CONTROL BOARD CAB UGM

CONN. CONN. CONN. CONN. CONN. CONN. CONN. CONN. CONN.

XC XF XG XH XP J1 J2 J4 J7

3 10 13 4 5 6 7 8 9 10 11 12 12 4 4 5 6 8 16 20 30 3

STRT RLY
BRK LT SW

APU ENABLE
GLOWPLUGS

CLUTCH LOCK

PREHEAT
CLUTCH

KEY IGN
NEUT
P BRK

KEY STRT
KEY 1B

FUEL PMP

IGNITION

IGNITION

IGNITION
IGNITION

KEY IGN

KEY IGN

KEY IGN
FUEL VLV
KEY BAT A

S1 7

APU ENABLE 3 2 1 8
SWITCH KEY 1B
(PLATFORM ONLY)
APU

S5 7
CLUTCH LOCK
SWITCH
(POWERSHIFT ONLY)

3 2 8
KEY 1B
CLUTCH

X10
1
KEY 1B
BRAKE BRK LT
2 EMERG STOP
PEDAL
SWITCH 3 SWITCH
CLUTCH (PLATFORM ONLY)
4 X18
2 KEY BAT A
30
1 KEY BAT A
30 0P
1 KEY 1B 1
PARK BRAKE X13 KEY IGN
OFF 2 P BRK 15 2
SWITCH KEY IGN
ON 15 3
X13B
KEY 1B 58 0P
1
P BRK 1
2 58
2
3 3 KEY
PREHEAT
X14 19 0P SWITCH
KEY 1B PREHEAT A 1
FWD PWR
1 19
2
STRT RLY

NEUT F PREHEAT A
2 17
REV N NEUT 3
SHIFTER 3
17
SWITCH
I R
4 0P
KEY STRT
II I
5 50 1
II 2
6 50
III III
7
3
FUEL PMP
IV IV
8
nc
9 FUEL VLV GLOWPLUGS

CAB HARNESS

8 20 36 37

ENGINE HARNESS CONN.

FUEL PMP
GLOWPLUGS
FUEL VLV

STRT RLY

X3
+ -
12 VDC
BATTERY
STARTER

GLOWPLUGS
50
PHEAT PWR
FUEL VLV
X43
COLD START
TEMP
M
FUSE X46
SWITCH

PHEAT RLY STRT PWR

X47 PHEAT PWR

30 PHEAT RLY X44 ALT BAT X38
GLOWPLUGS FUEL VLV FUEL
87 PHEAT 1 ALT BAT
RELAY VALVE
86 GLOWPLUGS 2 (TURBO) 30
FUEL PMP

STRT PWR
85 STARTER
87
X48 X49 RELAY
PHEAT STRT RLY 86
1 1
ENGINE
GLOWPLUGS 2 M FUEL
PUMP
85

ALT BAT ALTERNATOR

ALT BAT B+ X40
W G
D+

MZ2270

40.8, 40.9 9.17

 Electrical System

9.8 ENGINE START CIRCUIT defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
9.8.1 Starter
3. If the starter only “clicks” it may indicate that the
The starter (1) is located on the left side of the engine (the battery is discharged, or that there is a loose or
right side of the machine). corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit,
refer to Section 9.7.2, “Start Circuit.”

c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Open the engine cover. Allow the engine to cool.
2. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
3. Remove the wires from the solenoid stud. Remove
the positive (+) battery cable from the starter. Label
and disconnect the wire from the starter solenoid
1 housing stud. Record how the wires are installed to
ensure correct installation later.

MZ0150
4. Loosen, but DO NOT remove the three fasteners
securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
a. Testing the Starter on the Engine
fall if not supported.
If the starter does not engage when the ignition key 5. Support the starter and remove the fasteners
switch is turned, check the following: securing the starter to the engine. Remove the
1. The main fuse may be blown, requiring replacement. negative (-) ground cable from its starter mounting
Check for the cause of the blown fuse. bolt.
2. There may be a defect in the ignition key switch, 6. Remove the starter from the machine.
ignition wiring or starter solenoid.
3. Check battery condition. Clean the battery posts and d. Starter Cleaning and Drying
the connectors at each end of the battery cables. 1. While the starter is being removed, wipe away any
4. Check for broken wiring and damaged insulation on grease or dirt that has accumulated around the
the wiring. Replace all broken or damaged wiring. starter mounting opening.
5. Check all connections at the starter solenoid, key 2. If reinstalling the starter, clean the exterior of the
switch and wiring harness plugs. Clean and tighten starter with an approved solvent. DO NOT submerse
all connections. the starter or allow the solvent to contact the starter
bushings.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit. 3. Dry the starter with a clean, lint-free cloth.

b. Starter Circuit Checks e. Starter Periodic Maintenance

1. Check wires and connections for looseness, A starter requires no routine maintenance beyond the
corrosion, damage, etc. occasional inspection of the electrical connections, which
must be clean and tight. The starter is not serviceable;
2. If a “whirring” noise is heard but the engine does not
replace a defective starter with a new unit.
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
the drive forward to engage the flywheel may be

9.18 40.8, 40.9

 Electrical System

f. Starter Installation 9.9.1 Alternator

1. Position the starter in its mounting opening on the
a. Alternator Removal
flywheel housing. Position the ground cable over the
correct starter mounting bolt. Secure the starter with 1. Park the machine on a firm, level surface, level the
fasteners. Torque fasteners to 43 Nm (32 lb-ft). machine, fully retract the boom, lower the boom,
2. Connect the positive (+) battery cable to the upper place the transmission control lever in (N)
solenoid stud. Install the wires to the upper solenoid NEUTRAL, engage the park brake and shut the
stud, and secure with lockwasher and nut. Torque engine OFF.
nuts to 43 Nm (32 lb-ft). 2. Place a Do Not Operate Tag on both the ignition key
3. Connect the wire to the solenoid mounting stud. switch and the steering wheel, stating that the
machine should not be operated.
4. Connect the battery negative (-) cable to the battery
negative (-) terminal. 3. Open the engine cover. Allow the engine to cool.
5. Close and secure the engine cover. 4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
9.9 CHARGING CIRCUIT 5. Loosen both alternator (2) mounting bolts and pivot
alternator in.
Before using a battery charger, an attempt can be made 6. With the fan belt now being loose, remove the belt
to recharge the battery by jump-starting the machine. from the engine.
(Refer to the appropriate Operation & Safety Manual.)
Allow the engine to run, which will enable the alternator to
charge the battery.
If the engine alternator charging warning indicator
illuminates, perform the following checks:
1. Check the all battery cable connections at the
battery, and verify that they are clean and tight.
2. Check the external alternator wiring and
connections, and verify that they are in good 2
condition.
3. Check the fan belt condition and tension.
4. Verify that the alternator mounting hardware is tight.
5. Run the engine and check the alternator for noise. A
loose drive pulley, loose mounting hardware, worn or
dirty internal alternator bearings, a defective stator
or defective diodes can cause noise. Replace a worn
or defective alternator. MZ0150

Note: Record how the alternator is installed to ensure

correct installation later.
7. Label and disconnect the wire leads attached to the
alternator.
8. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
9. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.

40.8, 40.9 9.19

 Electrical System

b. Alternator Installation 9.10.2 Load Stability Sensor

1. Position the alternator and align with the upper The LSI sensor (3) is bolted on the top right of the rear
alternator mount on the engine bracket. Insert the axle.
upper mounting hardware through the alternator
mount. DO NOT tighten completely at this time. 3
2. Align the lower alternator mount hole with the lower
mounting bracket on the engine. Insert the lower
mounting capscrew. DO NOT tighten completely at
this time.
3. Install the fan belt, adjust the alternator for proper
belt tension and belt alignment. Tighten the lower
capscrew and upper capscrew securely.
4. Connect the previously labeled wire leads.
5. Connect the battery negative (-) cable to the battery
negative (-) terminal.
a. Load Stability Sensor Removal
6. Close and secure the engine cover.
1. Park the machine on a firm, level surface, level the
9.10 ELECTRICAL SYSTEM machine, fully retract the boom, lower the boom,
COMPONENTS place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
9.10.1 Load Stability Indicator
2. Place a Do Not Operate Tag on both the ignition key
The Load Stability Indicator provides a visual indication switch and the steering wheel, stating that the
for forward stability limitations. machine should not be operated.
• All six LED’s will light (green, yellow & red) and the 3. Open the engine cover. Allow the engine to cool.
warning buzzer sounds as the machine reaches its 4. Disconnect the battery negative (-) cable at the
forward stability limitations. battery negative (-) terminal.
• The 2nd red LED is illuminated when the machine 5. Disconnect the LSI electrical connector.
has reached its forward stability limitations.
6. Loosen and remove the two bolts holding the LSI
• Overload Protection Function. When the 2nd red assembly to the rear axle.
LED is illuminated the automatic overload protection
function is activated. Boom extension and lower 7. Remove the sensor assembly.
functions are disabled.
b. Load Stability Sensor Installation
Test the LSI at the beginning of each work shift.
1. Fully retract and level the boom, with no load. Do not 1. Clean the bare metal with a degreasing solution and
raise the boom during this test. allow to dry.

2. Level frame using level in cab. 2. Apply a thin film of Loctite® 638 adhesive to the flat
metal surface of the transducer, ensuring the
3. Press the test button on the LSI display. This will adhesive is spread evenly over the entire surface.
cause all LEDs to flash on and an audible warning to
sound. This indicates that the system is functioning 3. Fit the transducer, ensuring the lead exits in the
properly. If the test gives a different result, the corner direction. If the existing bolts are not
system is not functioning properly and the machine available, use M10 x 40mm bolts with a minimum
must be removed from service and repaired before tensile strength of 10.9. Two washers are used.
continued operation. Note: It is important to prevent distortion of the sensor
Note: The Load Stability Indicator is NOT a serviceable element, therefore tighten the bolts alternately a small
item. The Load Stability Indicator must be inspected and/ amount at a time, until a value of 70 Nm (50 lb-ft) is
or replaced by a qualified dealer or a SDF technician. achieved.

9.20 40.8, 40.9

 Electrical System

4. Leave the machine undisturbed for a minimum of 2 the buzzer will sound for 2 seconds, the green led
hours before moving. DO NOT lift any load for a will be turned off, and the top red led will be on
minimum of 12 hours. constant.
5. The transducer and area around it can be painted 2 4. Position the machine (using weight on the
hours after installation. attachment) such that the rear axle weight in the
6. Recheck the bolt torque of 70 Nm (50 lb-ft) after 12 following table is achieved.
hours of curing.
Model Weight on Rear Axle
7. Plug the electrical connector into the sensor
assembly. 40.8 1000 kg (2204 lb)
8. Connect the battery negative (-) cable to the battery 40.9 1100 kg (2425 lb)
negative (-) terminal.
9. Close and secure the engine cover. 5. Press the TEST button on the LSI display and
release. The top red led should flash for
c. Load Stability Sensor Calibration approximately 8 seconds while the calibration point
To calibrate the LSI, certain conditions must be met: is read. Following a successful calibration of the
second point, the buzzer will be on constant, the red
• The sensor must be mounted according to assembly led will be turned off, and the green power led will be
instructions at least 12 hours before calibration. on constant.
• The machine control system must be powered on for 6. Turn the ignition key to OFF. LSI is now calibrated.
at least 10 minutes before calibration.
• The calibration shall be conducted with the standard 9.10.3 Back-up Alarm
carriage and forks attached for the machine and
The back-up alarm is located at the rear of the machine.
weights as necessary.
When the transmission shift control switch (transmission
• If the machine is equipped with stabilizers, they shall
control lever) is shifted to the (R) REVERSE position, the
remain up for the calibration procedure.
back-up alarm will automatically sound.
• The machine must be on a level surface with the Place the transmission control lever in (R) REVERSE to
wheels steered straight and park brake off, with
test the back-up alarm. The back-up alarm must not
straight driving over a distance of at least 2 meters
being the last movement before entering a sound when the transmission control lever is in (N)
calibration point. NEUTRAL or (F) FORWARD. Also, with the ignition key
switch in the RUN position, the back-up alarm will sound
• The calibration must be completed within 30 minutes when the transmission control lever is shifted into the (R)
after starting procedure. REVERSE position.
Calibration Procedure:
1. With ignition key in OFF position, press and hold a. Disassembly
TEST button on LSI display and turn ignition key to DO NOT disassemble the back-up alarm. Replace a
engine START position. Release the ignition key defective or faulty alarm with a new part.
when engine start is achieved, but continue to hold
TEST button on LSI display until the led power b. Inspection and Replacement
indicator on LSI display begins to flash (approx. 2
seconds). Release TEST key within 2 seconds of Inspect the wiring harness connector and alarm terminals
power led flashing. for continuity and shorting. Test the alarm by turning the
ignition key switch to the RUN position and shifting the
2. The lower green led of the scale should be on transmission control lever into the REVERSE position.
constant. Position the machine with empty The alarm should sound.
attachment with boom level and fully retracted, forks
level (not contacting ground). Replace a defective or faulty alarm with a new part.
3. Press the TEST button on the LSI display and
release. The lower green led should flash for approx
8 seconds while the calibration point is read.
Following a successful calibration of the first point,

40.8, 40.9 9.21

 Electrical System

9.11 WINDOW WIPER/WASHER b. Disassembly

DO NOT disassemble the motor. The motor is not
9.11.1 Windshield Wiper Motor serviceable. Replace motor if found to be defective.

a. Removal c. Inspection and Replacement

Note: It may be necessary to remove several hydraulic Inspect the motor terminals for continuity. Replace motor
hoses from under the dash in order to remove and install if continuity is not found.
the wiper motor housing.
d. Installation and Testing
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, 1. Install all required hardware to the motor assembly.
place the transmission control lever in (N) 2. Align motor with the mounting holes and bolt the
NEUTRAL, engage the park brake and shut the motor to the mounting bracket.
engine OFF.
3. Connect the wiper linkage to the wiper motor shaft.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the Note: Align the wiper linkage arm with the flat on the
machine should not be operated. motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
3. Open the engine cover. Allow the engine to cool.
4. Connect the cab harness connectors to windshield
4. Disconnect the battery negative (-) cable at the
wiper motor connectors.
battery negative (-) terminal.
5. Connect the battery negative (-) cable to the battery
5. Remove the lower dash panel.
negative (-) terminal.
6. Disconnect the right side defroster hose from dash
6. Turn ignition key switch to the RUN position, and
panel hose connector.
operate windshield wiper in both LOW and HIGH
IMPORTANT: DO NOT start the engine with the hoses speeds to ensure proper operation and that correct
not connected to their proper fittings. wiper travel is achieved.
7. Disconnect the cab harness connectors from the 7. Install right side defroster hose to the dash panel
wiper motor. hose connector.
8. If previously removed, install hydraulic hoses under
the dash.
9. Install the lower dash panel.
10. Close and secure the engine cover.

4 9.11.2 Rear Window Wiper Motor

a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
MAH0910
NEUTRAL, engage the park brake and shut the
engine OFF.
8. Remove the linkage attached to the wiper motor (4).
2. Place a Do Not Operate Tag on both the ignition key
9. Loosen and remove the four bolts holding the wiper
switch and the steering wheel, stating that the
motor to the mounting bracket.
machine should not be operated.
Note: Retain all hardware removed from the wiper 3. Open the engine cover. Allow the engine to cool.
assembly for possible reuse on the replacement motor
housing. 4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
10. Remove the motor from the inside of the cab.
5. Remove the wiper arm from the wiper motor (5)
shaft.

9.22 40.8, 40.9

 Electrical System

6. Remove the nut on the wiper motor shaft and on the 9.11.3 Windshield Washer Reservoir and
wiper motor. Pump
7. From inside the cab, pull the wiper motor away from The windshield washer motor and reservoir is located in
the rear window. the engine compartment as a unit and cannot be serviced
8. Pull the cab headliner down in the rear right corner. separately.
Label and disconnect the cab harness connectors
from the wiper motor. a. Removal
1. Park the machine on a firm, level surface, level the
b. Disassembly machine, fully retract the boom, lower the boom,
DO NOT disassemble the motor. The motor is not place the transmission control lever in (N)
serviceable. Replace motor if found to be defective. NEUTRAL, engage the park brake and shut the
engine OFF.
c. Installation and Testing 2. Place a Do Not Operate Tag on both the ignition key
1. Hold wiper motor up toward cab rear window and switch and the steering wheel, stating that the
install the cab harness connectors. Refit the machine should not be operated.
headliner. 3. Open the engine cover. Allow the engine to cool.
2. With the help of an assistant, insert the wiper motor 4. Disconnect the battery negative (-) cable at the
through the roof hole and have the assistant thread battery negative (-) terminal.
the hex nuts onto the wiper motor shaft and the 5. Remove the nuts and the lockwashers from the
wiper motor. Ensure that the motor housing is facing washer mounting studs.
the front of the cab.
6. Pull the washer reservoir (6) out and away from the
5 mounting studs.

6
MAH0920

3. Install the wiper arm onto the wiper motor shaft.

4. Connect the battery negative (-) cable to the
battery negative (-) terminal.
5. Turn ignition key switch to the RUN position and turn
the rear wiper switch to the ON position. Ensure
wiper stays on the window through a full stroke. Turn
the rear wiper switch to the OFF position.
6. Engage the washer switch and ensure washer fluid MZ2110
is sprayed on the rear window. Turn the ignition key
switch to the OFF position. 7. Rotate the washer reservoir, label and remove the
7. Close and secure the engine cover. cab harness connectors from the washer reservoir
connectors.
8. Remove the windshield washer hoses from the
reservoir.

40.8, 40.9 9.23

 Electrical System

b. Disassembly place the transmission control lever in (N)

NEUTRAL, engage the park brake and shut the
DO NOT disassemble the pumps. The pump is not
engine OFF.
serviceable. Replace pumps if found to be defective.
2. Place a Do Not Operate Tag on both the ignition key
c. Cleaning and Drying switch and the steering wheel, stating that the
machine should not be operated.
Without submerging the pumps, clean the pumps and
reservoir with an approved solvent and dry with a clean, 3. Open the engine cover. Allow the engine to cool.
lint-free cloth. 4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
d. Inspection and Replacement 5. Remove the four screws (7) from the cab heater and
Inspect the electrical terminals for continuity. fan control panel.
6. Pull the control panel out from the dash panel and
e. Installation and Testing disconnect the variable speed fan control cab
1. Connect the windshield washer hoses to the harness connector and disconnect the temperature
reservoir. cable.
2. Connect the cab wiring harness connectors to the 7. Remove the control from the panel.
reservoir connectors.
b. Disassembly
3. Install the reservoir tank onto the mounting studs.
DO NOT disassemble the cab heater and fan controls.
4. Install the lockwashers and nuts and secure.
The controls are not serviceable. Replace controls if
5. Fill the washer fluid reservoir with washer fluid. found to be defective.
6. Connect the battery negative (-) cable to the battery
negative (-) terminal. c. Installation and Testing
7. Turn the ignition key switch to the RUN position and 1. Check that the variable speed fan control is in the
press the washer switches. Verify that fluid is OFF position.
sprayed on both the windshield and rear glass. 2. Install the temperature control cable to the back of
8. Close and secure the engine cover. the control.
3. Install the hex locknut on the shaft and tighten.
4. Connect the cab harness connector to the variable
speed fan control.
9.12 CAB HEATER AND FAN 5. Install the screws securing the control panel to the
dash panel.
9.12.1 Cab Heater Controls 6. Connect the battery negative (-) cable to the battery
Note: If the suspect component is found to be within the negative (-) terminal.
heater box, the heater box must be removed as a 7. Turn the ignition key to the ON position and check
complete unit and replaced. For additional information the fan speeds. If further repair is needed, refer to
on the removal and installation of the heater box, refer to Section 9.6, “Electrical System Schematics.”
Section 4.3.8, “Heater/Defroster System.” 8. Start the machine and allow engine to reach
operating temperature. Check heat control at
different levels.
9. Close and secure the engine cover.
7
MZ2160

a. Cab Heater Controls Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,

9.24 40.8, 40.9

 Electrical System

9.13 SWITCHES, SOLENOIDS, SENSORS 9.13.2 Transmission Temperature Switch

AND SENDERS The transmission temperature switch (9) is located at the
bottom right side of the transmission housing.
9.13.1 Transmission Solenoid Valves

9 MZ2150

a. Transmission Temperature Switch Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
8
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
MZ0650
2. Place a Do Not Operate Tag on both the ignition key
If the transmission is not shifting properly, the switch and the steering wheel, stating that the
transmission control lever, wiring harness or transmission machine should not be operated.
shift solenoids (8) should be checked in order to 3. Open the engine cover. Allow the engine to cool.
determine which component is defective. Specific
information to determine which travel position and 4. Disconnect the battery negative (-) cable at the
corresponding component is not responding can be battery negative (-) terminal.
found in the detailed transmission service instructions are 5. Unplug the transmission temperature switch
provided in the Dana-Spicer T12000 Transmission connector from the wiring harness connector.
Repair Manual, P/N 0.900.1168.9 and can be obtained by 6. The switch is threaded into the transmission
calling your local SDF service distributor. housing. Remove the switch.
The transmission should be checked, serviced and
repaired only by experienced service technicians who are b. Transmission Temperature Switch Inspection
aware of all safety instructions and particular component and Replacement
features.
Inspect the switch and the wiring harness connector
Note: Contact the SDF Service Department if internal terminals for continuity. Replace a defective or faulty
transmission repair is required during the warranty switch with a new part.
period.
c. Transmission Temperature Switch Installation
and Testing
1. Thread the transmission temperature switch into the
transmission housing snugly, then connect the
switch connector to the wiring harness connector.
2. Connect the battery negative (-) cable to the battery
negative (-) terminal.
3. Check for proper fluid level.

40.8, 40.9 9.25

 Electrical System

4. Start the engine, allow it to reach operating c. Transmission Mounted Speed Sensor Installation
temperature and observe the operator’s display and Testing
cluster for warning indication. If the sender is not
1. Install new o-ring on speed sensor, install sensor in
defective, the problem could be elsewhere; possibly
transmission, install clamp on sensor, bolt down
in a shorted wire, damaged transmission, improper
clamp, turn arrow on sensor 45 degrees from clamp
or low fluid, etc.
bolt and torque to 8-10 Nm (70-88 lb-in).
5. Close and secure the engine cover.
2. Connect the sensor plug to the wire harness.
9.13.3 Transmission Mounted Speed Sensor 3. Connect the battery negative (-) cable to the battery
(if equipped) negative (-) terminal.

The transmission speed sensor (10) is located at the left 4. Close and secure the engine cover.
side of the transmission below the transmission filter.
d. Transmission Mounted Speed Sensor Calibration
A SDF Analyzer (2901443) is required to perform this
calibration. There is also an embedded SDF Analyzer in
the cab display. To access the SDF Analyzer, press and
hold the C and OK buttons on the keypad simultaneously
10 until the SDF Analyzer Help Menu screen appears on the
display.
1. Go to the Access Level menu and enter a password
of 33271.

MZ2120
2. Go to the Calibrations menu, select Vehicle Speed
and press the Enter button (OK button on the
embedded Analyzer).
a. Transmission Mounted Speed Sensor Removal
3. Follow the instructions on the Analyzer. The
1. Park the machine on a firm, level surface, level the machine must be driven over a 50 meter straight line
machine, fully retract the boom, lower the boom, course.
place the transmission control lever in (N)
• The machine cab be driven in any gear and at
NEUTRAL, engage the park brake and shut the
any speed.
engine OFF.
• The Analyzer will prompt the operator to press
2. Place a Do Not Operate Tag on both the ignition key
Enter or OK when starting the 50 meter drive.
switch and the steering wheel, stating that the
machine should not be operated. • Drive the machine 50 meters and stop. When the
50 meter point is reached, press the Enter or OK
3. Open the engine cover. Allow the engine to cool.
button as appropriate.
4. Disconnect the battery negative (-) cable at the
4. If the calibration fails, check the Help menu for
battery negative (-) terminal.
possible faults.
5. Unplug the speed sensor connector from the wiring
harness connector. 9.13.4 Engine Coolant Temperature Sender/
6. Loosen the screw holding the clamp and remove the Switch
sensor, clamp and o-ring. The engine coolant temperature sender/switch is located
by the alternator.
b. Transmission Mounted Speed Sensor Inspection
and Replacement a. Engine Coolant Temperature Sender/Switch
Inspect the sensor and the wiring harness connector Removal
terminals for continuity. Replace a defective or faulty 1. Park the machine on a firm, level surface, level the
sensor with a new part. machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.

9.26 40.8, 40.9

 Electrical System

2. Place a Do Not Operate Tag on both the ignition key 5. Remove the lower dash panel.
switch and the steering wheel, stating that the 6. Remove the hex nut securing the ignition key switch
machine should not be operated. to the dash.
3. Open the engine cover. Allow the engine to cool. 7. Reach up and under the dash to work the ignition
4. Disconnect the battery negative (-) cable at the switch and wiring out of the mounting hole.
battery negative (-) terminal. 8. Disconnect the ignition switch connectors from the
5. Unplug the engine coolant temperature sender/ cab harness connectors, and remove the switch
switch connector from the wiring harness connector. from the machine.
6. The sender/switch is threaded into the engine block.
Remove the sender. b. Disassembly
DO NOT disassemble the ignition key switch. Replace a
b. Engine Coolant Temperature Sender/Switch defective switch with a new part.
Inspection and Replacement
Inspect the sender/switch and the wiring harness c. Inspection and Replacement
connector terminals for continuity. Replace a defective or To determine the proper operation of the ignition key
faulty sender/switch with a new part. switch, using the following chart, test the wires on the
back of the switch for continuity with an ohmmeter.
c. Engine Coolant Temperature Sender/Switch 0
Installation and Testing P I

1. Thread the engine coolant temperature sender into II

the engine block snugly, then connect the sender/
switch connector to the wiring harness connector. III
2. Connect the battery negative (-) cable to the battery
MZ2130
negative (-) terminal.
3. Check for proper coolant level.
4. Start the engine, allow it to reach operating
temperature and observe the operator’s instrument
cluster for warning indication. If the sender/switch is
not defective, the problem could be elsewhere;
possibly in a shorted wire, improper-running engine,
improper or low coolant, obstructed or faulty radiator,
coolant pump, loose fan belt, defective instrument
MZ2140
display, etc.
Test the ignition key switch for continuity, by checking
5. Close and secure the engine cover.
from the power (#30) wire to each of the following wires
in each switch position. Continuity should be present as
9.13.5 Ignition Key Switch indicated in the following chart:
a. Ignition Key Switch Removal Switch Position Test for Continuity Between
Wire #30 and wires:
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, P #58
place the transmission control lever in (N) I #15
NEUTRAL, engage the park brake and shut the
II #15 & #19
engine OFF.
III #15, #17 & #50
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the If all connections do not show proper continuity, replace
machine should not be operated. the ignition switch.
3. Open the engine cover. Allow the engine to cool.
4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
40.8, 40.9 9.27
 Electrical System

d. Ignition Key Switch Installation fuel level indicator is defective and must be
replaced.
1. Connect the ignition key switch to the cab harness
connectors. 5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
2. Reach up and under the dash to work the ignition
key switch into the ignition key switch mounting hole 6. Check for broken, shorted, frayed, disconnected or
on the dash. damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key
3. Secure the ignition key switch with the previously
switch and from the fuel level sender on the fuel tank
used hex nut.
through the wiring in the cab.
4. Install the lower dash panel.
7. Check the fuel level sender. The resistance of the
5. Connect the battery negative (-) cable to the battery fuel level sender is <7 ohms for a full tank of fuel,
negative (-) terminal. 108-128 ohms for 1/2 tank and 315-345 ohms for an
6. Close and secure the engine cover. empty tank. A defective fuel level sender in the fuel
tank may also prevent the fuel level indicator from
9.13.6 Fuel Level Indicator and Fuel Level moving.
Sender
9.13.7 Boom Angle Sensor
a. Fuel Level Indicator Testing The boom angle sensor (11) is located at the top left
1. The fuel level sender wiring harness leads can be inside rear of the machine.
accessed from the top of the fuel tank. Disconnect IMPORTANT: After installation, the sensor will need to
the fuel level sender wiring harness leads. With the be calibrated by an authorized service technician.
help of an assistant, touch both harness leads
together. a. Boom Angle Sensor Removal
2. From the operator’s cab, have the assistant turn the 1. Park the machine on a firm, level surface, level the
ignition key switch to the RUN position. DO NOT machine, fully retract the boom, lower the boom,
start the engine. Observe the fuel level indicator place the transmission control lever in (N)
needle on the operator’s instrument cluster. When NEUTRAL, engage the park brake and shut the
the two wires are shorted, a full tank should be engine OFF.
shown on the fuel gauge.
2. Place a Do Not Operate Tag on both the ignition key
3. Turn the ignition key switch to the OFF position. The switch and the steering wheel, stating that the
fuel level indicator needle should return to the machine should not be operated.
EMPTY position.
3. Open the engine cover. Allow the engine to cool.
b. Fuel Level Circuit Tests 4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
If the fuel level indicator is suspected of giving a false
reading, perform the following checks: 5. Disconnect the boom angle sensor electrical
connector.
1. If the fuel level indicator needle does not move,
check the fuel tank for fuel. 6. If equipped, remove the safety spring (12).
2. Check for loose or defective wiring, faulty ground 7. Loosen and remove the nut holding the rod
connections or corrosion on the fuel tank sender and assembly to the sensor arm.
wiring lead. 8. Loosen and remove the two bolts holding the sensor
3. If the fuel level indicator needle does not move after to the sensor seat.
the ignition key switch is turned to the RUN position, 9. Remove the sensor assembly.
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level b. Boom Angle Sensor Inspection and Replacement
sender.
Inspect the sensor and the wiring harness connector
4. If the fuel level indicator does not move and a faulty terminals for continuity. Replace a defective or faulty
or defective fuel level sender in the fuel tank has sensor with a new sensor.
been ruled out and in addition, wiring and
connectors have been checked and ruled out, the
9.28 40.8, 40.9
 Electrical System

9.13.8 Boom Retracted Sensor

12
The boom retracted sensor (14) is located at the rear of
11 the boom.

a. Boom Retracted Sensor Removal

1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
13 NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
14
MZ2540

c. Boom Angle Sensor Installation

1. Install the sensor assembly to the sensor seat and
tighten both bolts.
2. Install the rod end to the sensor arm and tighten nut.
MZ2570
3. If equipped, install the safety spring (12).
3. Open the engine cover. Allow the engine to cool.
4. Measure and set rod length (13) to 212 ±0,5 mm.
4. Disconnect the battery negative (-) cable at the
5. Plug the electrical connector into the sensor
battery negative (-) terminal.
assembly.
5. Disconnect the boom retracted sensor electrical
IMPORTANT: At this point, the boom angle sensor will
connector.
need to be calibrated by an authorized service
technician. 6. Remove the two bolts securing the boom retracted
sensor bracket to the boom.
6. Connect the battery negative (-) cable to the battery
negative (-) terminal. 7. Remove the boom retracted sensor from the sensor
bracket.
7. Close and secure the engine cover.
b. Boom Retracted Sensor Inspection and
Replacement
Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sensor with a new sensor.

40.8, 40.9 9.29

 Electrical System

c. Boom Retracted Sensor Installation 9.14 FAULT CODES

1. Mount the boom retracted sensor to the boom with
Active faults and fault memory will be displayed at the
the previously used hardware.
operator level of access. Active faults will also be
2. Install the sensor into the sensor bracket. Adjust the displayed as a blink code at the controller on-board LED.
sensor to 5 ± 0,5 mm from the rear of the second The 16 previous faults are logged in fault memory, which
boom section. Tighten the sensor locknut. can be accessed by choosing ENTER while viewing
active fault messages.

9.14.1 Indicator Cross Reference Table

Indicator # Assignment
1 = Machine System Distress
2 = Engine Fault Warning
5 ±0,5 mm MZ2580
3 = Engine Fault Critical
3. Plug the electrical connector into the sensor
assembly. 4 = Machine Locked

4. Connect the battery negative (-) cable to the battery 5 = Service

negative (-) terminal. 6 = Hydraulic Filter Restriction
5. Close and secure the engine cover. 7 = Air Filter Restriction
8 = Low Steer Pressure
9 = Low Engine Oil Pressure
10 = Battery Low or Not Charging
11 = High Transmission Oil Temperature
12 = High Engine Coolant Temperature
13 = Low Fuel Level
14 = Platform Overloaded
15 = Stabilizers Not Deployed (Platform)
16 = Chassis Not Level
Note: Fault codes listed in the table above are for all
machine configurations. Your machine model &
configuration will determine which indicators and codes
will be active.

9.30 40.8, 40.9

 Electrical System

9.14.2 Fault Code Table

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

HELP COMMENT 00XXX - - - -

EVERYTHING OK 1 - - The system detects no problems -

exist.

POWER UP 21XXX - - - -

POWER CYCLE 211 - - Power was cycled ON. -

FUNCTION 214 1 Ignore and inhibit all function If both J7-15 of the UGM and J7-8 Power cycled.
ENABLE INPUTS - requests from the platform station. of the platform module are
INVALID SIGNAL Output J2-19 Function Enable simultaneously HIGH or LOW for a
STATES Relay of the platform module will be period of 1 second after the
deactivated. Function Enable Relay power-up
check have been successfully
Output J2-26 Engage Starter will be
completed or J7-15 is HIGH and
deactivated and inhibited from the
J7-8 is LOW after the Function
platform.
Enable Relay power-up check
have been successfully completed
and the PLATFORM STATION is
active and a valid PLATFORM
MODE exists.

JOYSTICK AXES 215 1 Ignore command signals from the At system power-up, if the one of A CAN
NOT IN NEUTRAL joystick regarding the X axis and Y the two axes are not in the neutral message is
POSITION AT axis. position, the UGM will report and received
POWER UP log a "JOYSTICK AXES NOT IN indicating the
NEUTRAL POSITION AT X axis and Y
POWER-UP" fault. axis are in the
neutral
position.

JOYSTICK ROLLER 216 1 Ignore command signals from the At system power-up, if the roller is A CAN
NOT IN NEUTRAL joystick regarding the roller. not in the neutral position. message is
POSITION AT received
POWER UP indicating the
roller is in the
neutral
position.

JOYSTICK S1 217 1 Ignore command signals from the At system power-up, if the S1 A CAN
BUTTON ACTIVE joystick S1 button that was active button is activated. message is
AT POWER UP during the power-up. received
indicating the
joystick S1
button is not
activated.

JOYSTICK S2 218 1 Ignore command signals from the At system power-up, if the S2 A CAN
BUTTON ACTIVE joystick S2 button that was active button is activated. message is
AT POWER UP during the power-up. received
indicating the
joystick S2
button is not
activated.

40.8, 40.9 9.31

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

JOYSTICK S3 219 1 Ignore command signals from the At system power-up, if the S3 A CAN
BUTTON ACTIVE joystick S3 button that was active button is activated. message is
AT POWER UP during the power-up. received
indicating the
joystick S3
button is not
activated.

JOYSTICK S4 2110 1 Ignore command signals from the At system power-up, if the S4 A CAN
BUTTON ACTIVE joystick S4 button that was active button is activated. message is
AT POWER UP during the power-up. received
indicating the
joystick S4
button is not
activated.

ENGINE START 2111 1 The engine start signal will be If a LOW on J1-14 of the platform Power cycled.
PREVENTED - ignored. module and the PLATFORM
PLATFORM START J2-26 Engage Starter will be STATION is active at system
SWITCH HIGH AT deactivated and inhibited. power up.
POWER UP

PLATFORM 2112 1 Ignore platform rotate left function If the PLATFORM STATION is The input goes
ROTATE LEFT request. active and a platform is configured LOW for a
PREVENTED - as ENABLED and a platform is period of at
INPUT HIGH AT detected as attached and a HIGH least 1 second.
POWER UP is detected at the platform station
on the platform rotate left input at
system power up.

PLATFORM 2113 1 Ignore platform rotate right function If the PLATFORM STATION is The input goes
ROTATE RIGHT request. active and a platform is configured LOW for a
PREVENTED - as ENABLED and a platform is period of at
INPUT HIGH AT detected as attached and a HIGH least 1 second.
POWER UP is detected at the platform station
on the platform rotate right input at
system power up.

PLATFORM LEVEL 2114 1 Ignore platform level up function If the PLATFORM STATION is The input goes
UP PREVENTED - request. active and a platform is configured LOW for a
INPUT HIGH AT as ENABLED and a platform is period of at
POWER UP detected as attached and a HIGH least 1 second.
is detected at the platform station
on the platform level up input at
system power up.

PLATFORM LEVEL 2115 1 Ignore platform level down function If the PLATFORM STATION is The input goes
DOWN request. active and a platform is configured LOW for a
PREVENTED - as ENABLED and a platform is period of at
INPUT HIGH AT detected as attached and a HIGH least 1 second.
POWER UP is detected at the platform station
on the platform level down input at
system power up.

APU SWITCH 2116 1 Still allow APU function request. If a platform is configured as The input goes
INPUT INVALID - If J7-4 Boom Angle reading is less ENABLED and the UGM detects LOW for a
INPUT HIGH AT than 10° and the J3-8 Boom J4-16 Auxiliary Power Unit (APU) period of at
POWER UP Retracted input is HIGH, cutout the Enable is HIGH or the platform least 1 second.
Main Lift Up and Telescope Out module input J1-15 APU Enable is
functions. HIGH at system power up.

9.32 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

PLATFORM 2117 1 Ignore platform lift and telescope If the PLATFORM STATION is Joystick is
JOYSTICK NOT IN function requests from the platform active and a platform is configured detected to be
NEUTRAL joystick. as ENABLED and a platform is in neutral
POSITION AT detected as attached and the position.
POWER UP platform joystick is not detected to
be in the neutral position at system
power up.

ENGINE PRE-HEAT 2118 1 Ignore engine pre-heat function If the UGM detects J4-20 Engine The input goes
PREVENTED - request. Pre-Heat or the platform module LOW for a
INPUT HIGH AT input J1-23 Engine Pre-heat is period of at
POWER UP HIGH at system power up. least 1 second.
Also occurs if the ignition key is
moved to "Engine Preheat" or
"Engine Start" position BEFORE
the system controller completes
powerup.

FRAME LEVEL 2119 1 Deactivate and inhibit J2-5 Frame If J4-17 Frame Leveling Right is Power cycled.
RIGHT INPUT - Level Right Valve. HIGH at power up.
INVALID SIGNAL Deactivate and inhibit J2-7 Frame
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve as it relates to frame leveling
functions only.

FRAME LEVEL 2120 1 Deactivate and inhibit J2-5 Frame If J4-9 Frame Leveling Left is Power cycled.
LEFT INPUT - Level Right Valve. HIGH at power up.
INVALID SIGNAL Deactivate and inhibit J2-7 Frame
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve as it relates to frame leveling
functions only.

QUICK CONNECT 2121 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature Power cycled.
INPUT - INVALID Quick Connect Valve. is configured in the MACHINE
SIGNAL Ignore hydraulic quick connect SETUP menu and J7-35 Hydraulic
function requests. Quick Connect ON is HIGH at
power up or J3-10 Hydraulic Quick
Deactivate output J2-9 Auxiliary
Connect OFF is LOW at power up
Function-A Valve until the cabin’s
or J7-35 matches the state of input
joystick is in the neutral position and
J3-10 for 0.5 seconds.
the S4 switch is OFF and J1-23 is
confirmed to be deactivated.
Deactivate output J2-20 Auxiliary
Function-B Valve until the cabin’s
joystick is in the neutral position and
the S4 switch is OFF and J1-23 is
confirmed to be deactivated.

CONTINUOUS 2122 1 Inhibit operation of the Continuous The UGM has detected the The input goes
AUXILIARY Auxiliary Hydraulics feature/logic. Continuous Auxiliary Hydraulics LOW for a
HYDRAULICS switch is HIGH at system power period of at
SWITCH HIGH AT up. least 1 second.
POWER UP

40.8, 40.9 9.33

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

JOYSTICK 2123 1 Ignore command signals from At system power-up, if the left A CAN
TRIGGER SWITCH joystick trigger switch that was roller of the joystick trigger switch message is
ACTIVE AT POWER active during the power up. is activated on CAT models only. received
UP indicating the
joystick trigger
switch is not
activated.

JOYSTICK LEFT 2124 1 Ignore command signals from the At system power-up, if the left Latch fault until
ROLLER NOT IN joystick regarding the left roller roller of the joystick is in the neutral a joystick CAN
THE NEUTRAL position on CAT models only. message is
POSITION AT received
POWER UP indicating the
roller is in the
neutral position

JOYSTICK RIGHT 2125 1 Ignore command signals from the At system power-up, if the right Latch fault unit
ROLLER NOT IN joystick regarding the right roller. roller of the joystick is in the neutral a joystick CAN
THE NEUTRAL position on CAT models only. message is
POSITION AT received
POWER UP indicating the
roller is in the
neutral position

PLATFORM 22XXX - - - -
CONTROLS

PLATFORM LEVEL 2225 1 Not acknowledge either platform If the UGM receives CAN2 Power cycled.
- CONFLICTING level function request messages. messages that indicate both J1-9
INPUT SIGNALS and J1-10 inputs to the platform
controller are HIGH together.

PLATFORM 2226 1 Not acknowledge either platform If the UGM receives CAN2 Power cycled.
ROTATE - rotate function request messages. messages that indicate both J1-7
CONFLICTING and J1-8 inputs to the platform
INPUT SIGNALS controller are HIGH together.

FUNCTION 2227 1 The requested function will be If the PLATFORM STATION is The hydraulic
ENABLE ignored. active and a platform is configured function
INTERLOCK - as ENABLED and a platform is request is no
ENABLE SWITCH detected as attached and a longer active.
NOT SELECTED hydraulic function request is detect
FIRST at the platform station before the
function enable signal was
received.

FUNCTION 2228 1 Turn OFF the functions enabled If the PLATFORM STATION is The function
ENABLE indicator at the platform station. active and a platform is configured enable switch
INTERLOCK - NOT Ignore all function requests from the as ENABLED and a platform is is released.
SELECTED IN TIME platform station while the detected as attached and if a
FUNCTIONS ENABLED state is function request is not received
active. within the 7 second period from the
time the FUNCTION ENABLE
state is activated.

ENGINE START 2229 1 The engine start signal will be When the PLATFORM STATION is The function
PREVENTED - ignored. active and the engine start signal is enable switch
FUNCTION J2-26 Engage Starter will be detected at the platform and the is released.
ENABLE SWITCH deactivated and inhibited. UGM detects the function enable
ENGAGED switch is engaged.

9.34 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

PLATFORM 2230 1 Hydraulic functions (Lift and The platform module detects the Power cycle.
JOYSTICK - OUT Telescope) associated to the dual- input voltage for dual-axis joystick
OF RANGE HIGH axis platform joystick are inhibited. is out of range on the high side and
reports the issue to the UGM.

PLATFORM 2231 1 Hydraulic functions (Lift and The platform module detects Power cycle.
JOYSTICK - Telescope) associated to the dual- center tap dual-axis joystick
CENTER TAP BAD axis platform joystick are inhibited. voltage is out of range and reports
the issue to the UGM.

FUNCTION 2233 1 Deactivate and inhibit platform J7-4 Function Enable Integrity Power cycle.
ENABLE RELAY - module output J2-19 Function Signal does not change states
INVALID SIGNAL Enable Relay. from HIGH to LOW during the
Deactivate and inhibit UGM output power-up test sequence.
J2-26 Engage Starter.
Suppress the "FUNCTION ENABLE
INPUTS - INVALID SIGNAL
STATES" fault.

GROUND 23XXX - - - -
CONTROLS

PLATFORM 2311 1 The UGM will also disregard all If the PLATFORM ATTACHED Power cycled.
OPTION NOT commands from the platform option has not been configured in
CONFIGURED station. the MACHINE SETUP menu and a
The UGM will use the platform platform attached state is detected
attached response curves. or the UGM detects a HIGH on J7-
1 or J7-2.

STABILIZERS NOT 2312 1 The UGM will ignore all stabilizer If the S1 button on the cabin’s The S1 button
CONFIGURED function requests from the joystick. joystick is activated and the on the cabin
STABILIZERS option has not been joystick is
configured in the MACHINE released.
SETUP menu.

FRAME LEVEL NOT 2313 1 The UGM will ignore all frame level If J4-17 Frame Leveling Right or J4-17 or J4-9
CONFIGURED function requests on UGM inputs J4-9 Frame Leveling Left inputs goes LOW.
J4-17 and J4-9. are HIGH and the FRAME LEVEL
option has not been configured in
the MACHINE SETUP menu.

OPERATING 2314 1 The directional symbol "N" will be If J7-3 Ground Mode and J7-2 Power cycled.
STATION displayed in the operator’s cabin Platform Mode both are HIGH
SELECTION display LCD. during operation.
INVALID The transmission will be
commanded to neutral and drive
will not be permitted.
Immediately deactivate and inhibit
all hydraulic function operation.

40.8, 40.9 9.35

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

OPERATING MODE 2315 1, 15 J2-26 Engage Starter output will be The PLATFORM STATION is J7-7 and J7-20
INTERLOCK - deactivated and engine start will not active and one or both inputs J7-7 become HIGH.
STABILIZERS NOT be permitted if the PLATFORM and J7-20 are LOW.
DEPLOYED STATION is active and CABIN
MODE was the last valid operating
mode.
Changeover to PLATFORM MODE
will not be permitted. If PLATFORM
MODE is already the valid
operating state, then inhibit the Lift
function until the Boom Retracted
switch is HIGH. Once the Boom
Retracted switch is HIGH, the UGM
will permit the Lift Down Function to
operate and inhibit the Telescope
Out function. Once the UGM
detects the boom angle is below
10°, the Telescope Out function will
be permitted and the Lift function
permitted up to a boom angle of
10°.

OPERATING MODE 2316 1 J2-26 Engage Starter output will be The PLATFORM STATION is The UGM
INTERLOCK - deactivated and engine start will not active and the UGM has not detects the
PLATFORM NOT be permitted if the PLATFORM detected the platform electrically platform as
ATTACHED STATION is active and CABIN attached. electrically
MODE was the last valid operating attached.
mode.
Changeover to PLATFORM MODE
will not be permitted. If PLATFORM
MODE is the last valid operating
mode, the UGM will assume the
platform is attached.

OPERATING MODE 2317 1, 16 J2-26 Engage Starter output will be The PLATFORM STATION is The UGM
INTERLOCK - deactivated and engine start will not active and the UGM has detected detects the
CHASSIS NOT be permitted if the PLATFORM the machine’s chassis is not machine’s
LEVEL STATION is active and CABIN sufficiently level for platform chassis tilt
MODE was the last valid operating operation. level is within
mode. range.
Changeover to PLATFORM MODE
will not be permitted. If PLATFORM
MODE is already the valid
operating state, then inhibit the Lift
function until the Boom Retracted
switch is HIGH. Once the Boom
Retracted switch is HIGH, the UGM
will permit the Lift Down Function to
operate and inhibit the Telescope
Out function. Once the UGM
detects the boom angle is below
10°, the Telescope Out function will
be permitted and the Lift function
permitted up to a boom angle of
10°.

9.36 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

OPERATING MODE 2318 1 J2-26 Engage Starter output will be CABIN MODE was the last valid The UGM has
INTERLOCK - deactivated and engine start will not operating mode and the detected the
BOOM ANGLE TOO be permitted if the PLATFORM PLATFORM STATION is currently boom angle is
HIGH STATION is active and CABIN active and the UGM has detected = 10°.
MODE was the last valid operating the boom angle is > 10°.
mode. PLATFORM MODE was the last
Changeover to PLATFORM MODE valid operating mode and the
will not be permitted. CABIN STATION is currently active
Changeover to CABIN MODE will and the UGM has detected the
not be permitted. boom angle is > 10°.

OPERATING MODE 2319 1 J2-26 Engage Starter output will be CABIN MODE was the last valid The UGM has
INTERLOCK - deactivated and engine start will not operating mode and the detected J3-8
BOOM NOT FULLY be permitted if the PLATFORM PLATFORM STATION is currently Boom
RETRACTED STATION is active and CABIN active and the UGM has detected Retracted is
MODE was the last valid operating J3-8 Boom Retracted is LOW. HIGH.
mode. PLATFORM MODE was the last
Changeover to PLATFORM MODE valid operating mode and the
will not be permitted. CABIN STATION is currently active
Changeover to CABIN MODE will and the UGM has detected J3-8
not be permitted. Boom Retracted is LOW.

OPERATING MODE 2320 1 J2-26 Engage Starter output will be The PLATFORM STATION or J4-5 Park
INTERLOCK - PARK deactivated and engine start will not CABIN STATION is active and the Brake is HIGH
BRAKE NOT SET be permitted if the PLATFORM UGM has detected J4-5 Park (set).
STATION. Brake is LOW (not set) during a
Changeover to PLATFORM MODE MODE changeover situation.
will not be permitted.

ERRATIC 2321 1 The platform will be considered The UGM detects three signal Power cycled.
PLATFORM attached. transitions on J1-21 within a 5
ATTACHED SIGNAL Display the platform attached second period.
screen on the cabin’s LCD.

CONFLICTING 2322 1 Deactivate and inhibit J2-5 Frame J4-17 Frame Leveling Right and Power cycled.
FRAME LEVEL Level Right Valve. J4-9 Frame Leveling Left inputs
SIGNALS Deactivate and inhibit J2-7 Frame are both HIGH simultaneously.
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve as it relates to frame leveling
functions only.

CABIN JOYSTICK - 2323 1 X-axis function requests will be The cabin joystick detects a fault Power cycled.
X AXIS FAULT ignored by the UGM. on the X-axis of the joystick.

CABIN JOYSTICK - 2324 1 Y-axis function requests will be The cabin joystick detects a fault Power cycled.
Y AXIS FAULT ignored by the UGM. on the Y-axis of the joystick.

CABIN JOYSTICK - 2325 1 Roller function requests will be The cabin joystick detects a fault Power cycled.
ROLLER FAULT ignored by the UGM. with the roller on the joystick.

CABIN JOYSTICK - 2326 1 S1 button function requests will be The cabin joystick detects a fault Power cycled.
S1 BUTTON FAULT ignored by the UGM. with the S1 button on the joystick.

CABIN JOYSTICK - 2327 1 S2 button function requests will be The cabin joystick detects a fault Power cycled.
S2 BUTTON FAULT ignored by the UGM. with the S2 button on the joystick.

CABIN JOYSTICK - 2328 1 S3 button function requests will be The cabin joystick detects a fault Power cycled.
S3 BUTTON FAULT ignored by the UGM. with the S3 button on the joystick.

40.8, 40.9 9.37

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CABIN JOYSTICK - 2329 1 S4 button function requests will be The cabin joystick detects a fault Power cycled.
S4 BUTTON FAULT ignored by the UGM. with the S4 button on the joystick.

CABIN JOYSTICK - 2330 1 S switch function requests will be The cabin joystick detects a fault Power cycled.
S SWITCH FAULT ignored by the UGM. with the S switch.

CABIN JOYSTICK - 2331 1 T switch function requests will be The cabin joystick detects a fault Power cycled.
T SWITCH FAULT ignored by the UGM. with the T switch.

HYDRAULIC 2332 1, 6 N/A J2-24 Hydraulic Filter Restriction J2-24

FILTER input is HIGH for a period of 3 Hydraulic Filter
RESTRICTION seconds or more or 10 seconds if Restriction
detected at system power up. input is LOW
for 1 second.

ALL WHEEL STEER 2333 1 Not recognize any steer mode J4-35 All Wheel Steer input is Power cycled.
INPUT - INVALID requests on input J4-35 All Wheel HIGH at power up or for a period of
SIGNAL Steer. 7 seconds or longer.
Flash the All-Wheel Steer Mode
Indicator at a frequency of 5 Hz.

CRAB STEER 2334 1 Not recognize any steer mode J4-34 Crab Steer input is HIGH at Power cycled.
INPUT - INVALID requests on input J4-34 Crab Steer. power up or for a period of 7
SIGNAL Flash the Crab Steer Mode seconds or longer.
Indicator at a frequency of 5 Hz.

JOYSTICK LOCK 2335 1 Deactivate the Joystick Lock J7-11 Joystick Lock input is HIGH Power cycled.
INPUT - INVALID feature if the CABIN STATION is at power up or for a period of 7
SIGNAL active. seconds or longer.
Activate J4-1 Joystick Function
Indicator to flash at a frequency of 5
Hz.

LOAD STABILITY 2336 1 Disregard a HIGH on input J4-33. J4-33 Load Stability Shutoff input is Power cycled.
SHUTOFF INPUT - If the CABIN STATION is active, HIGH at power up or for a period of
INVALID SIGNAL monitor and immediately react to 40 seconds or longer.
the signal at J4-10; otherwise,
disregard the signal at J4-10.
If the CABIN STATION is active,
flash J4-26 Load Stability Shutoff
Indicator at a frequency of 5Hz;
otherwise, activate J4-26.
If the CABIN STATION is active, set
the Load Stability Shutoff state to
active; otherwise, set the Load
Stability Shutoff state to inactive.

BUCKET MODE 2337 1 Discard the fork tilt response curves J4-19 Bucket Mode input is HIGH Power cycled.
INPUT - INVALID for bucket mode. at power up or for a period of 7
SIGNAL Activate J4-13 Bucket Mode seconds or longer.
Indicator to flash at a frequency of 5
Hz.
Apply the proper fork tilt response
curves for the new active mode
when the cabin’s joystick X and Y
and roller axes are in neutral.

9.38 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

2-WHEEL STEER 2338 1 Not recognize any steer mode J3-9 2-Wheel Steer input is HIGH Power cycled.
INPUT - INVALID requests on input J3-9 2-Wheel at power up or for a period of 7
SIGNAL Steer. seconds or longer.
Flash the 2-Wheel Steer Mode
Indicator at a frequency of 5 Hz.

KEYPAD OK 2339 1 Disregard all signal changes until The UGM detects the keypad OK Power cycled.
BUTTON - INVALID switch state transitions to LOW. button is HIGH at power up or for a
SIGNAL period of 7 seconds or longer.

KEYPAD CANCEL 2340 1 Disregard all signal changes until The UGM detects the keypad Power cycled.
BUTTON - INVALID switch state transitions to LOW. CANCEL button is HIGH at power
SIGNAL up or for a period of 7 seconds or
longer.

KEYPAD UP 2341 1 Disregard all signal changes until The UGM detects the keypad UP Power cycled.
BUTTON - INVALID switch state transitions to LOW. button is HIGH at power up or for a
SIGNAL period of 7 seconds or longer.

KEYPAD DOWN 2342 1 Disregard all signal changes until The UGM detects the keypad Power cycled.
BUTTON - INVALID switch state transitions to LOW. DOWN button is HIGH at power up
SIGNAL or for a period of 7 seconds or
longer.

BOOM ANGLE 2343 1 Assign a fixed boom angle value of The UGM detects no calibration A valid boom
SENSOR - NOT 99°, as other functions will then fault has been completed. angle sensor
CALIBRATED to safe conditions. calibration is
Display the fixed boom angle value completed.
of ’99’ on the operator’s cabin
display.
Derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.

BOOM ANGLE 2344 1 Display the fixed boom angle value During operation or calibration, the Power cycled.
SENSOR - OUT OF of ’99’ on the operator’s cabin UGM detects a value at this input
RANGE HIGH display. of more than 4.4V.
Temporarily assign a fixed boom
angle value of 99°.
If a calibration is in progress, fail
boom angle sensor calibration
("CALIBRATION: SENSOR
FAULT").
Derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.

40.8, 40.9 9.39

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

BOOM ANGLE 2345 1 Display the fixed boom angle value During operation or calibration, the Power cycled.
SENSOR - OUT OF of ’99’ on the operator’s cabin UGM detects a value at this input
RANGE LOW display. of less than 0.6V.
Temporarily assign a fixed boom
angle value of 99°.
If a calibration is in progress, fail
boom angle sensor calibration
("CALIBRATION: SENSOR
FAULT").
Derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.

BOOM ANGLE 2346 1 Display the fixed boom angle value J2-11 Main Lift Up Valve or J2-22 Power cycled.
SENSOR - NOT of ’99’ on the operator’s cabin Main Lift Down Valve are active
RESPONDING display. operating at a current of at least
Temporarily assign a fixed boom 900 mA for a period = 4 seconds
angle value of 99°. with an ENGINE RUNNING
condition and no appreciable
Disallow boom angle sensor
change set at 0.5 degrees
calibration ("BOOM ANGLE:
(adjustable in Constant Data) in
CALIBRATION FAIL").
the value at this input. (Note, this
Derate the MAX LIFT UP in the fault will not be report during boom
PERSONALITIES menu screen by angle sensor calibration.)
the LIFT UP DERATE value in the
Constant Data tables.

9.40 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

SYSTEM 2347 1 Deactivate and inhibit all joystick The UGM has detected one of the Joystick inputs
INTERLOCK - SET functionality. following conditions: are in the
JOYSTICK INPUTS The hydraulic quick connect switch neutral
TO NEUTRAL is activated when any of the other position.
auxiliary hydraulics functions is
active.
If the joystick roller and/or X-axis
and/or Y-axis are not in the neutral
or centered position when the
hydraulic quick connect switch is
released.
When the hydraulic quick connect
switch is activated and the S4
button activation is not the next
detected operator action.
If the joystick roller and/or X-axis
and/or Y-axis are not in the neutral
or centered position when the ’S’
switch activation cause the
Auxiliary Hydraulics Release
feature to engage.
If the Auxiliary Hydraulics Release
feature is active and the platform
becomes detected as attached.
When the hydraulic quick connect
switch is activated and the S4
button activated, but then
released.
When the Quick Connect feature is
active and the S4 button is
released.
If the platform is detected as
attached with bucket mode active.
If the roller and/or X-axis and/or Y-
axis are not in the neutral or
centered position or one of the S1-
S4 buttons are engaged and the
Joystick Lock feature is enabled.
The S4 button is engaged when
the joystick roller and/or X-axis
and/or Y-axis are not in the neutral
or centered position.
The Auxiliary Hydraulics Release
feature will suppress this fault
when active.

ENGINE START 2348 1 N/A If a HIGH is detected on J4-8 J4-8 Engine

INPUT - INVALID Engine Start and an ENGINE Start goes
SIGNAL RUNNING condition has existed LOW for 1
for 7 seconds second.

LIFT ANGLE 2349 1 N/A A MODEL configuration of 4017 is Inputs J7-7

DERATED - selected and the stabilizers are not and J7-20
STABILIZERS NOT deployed and a platform is not indicate the
DEPLOYED attached and a valid Lift function is stabilizers are
engaged and a boom angle sensor deployed.
reading equals the 4017-ANGLE
LIMIT parameter.

40.8, 40.9 9.41

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CABIN JOYSTICK - 2350 1 Left roller function requests will be The CAT cabin joystick detects a Power cycled.
LEFT ROLLER ignored by the UGM. fault with the left roller on the
FAULT joystick

CABIN JOYSTICK - 2351 1 Right roller function requests will be The CAT cabin joystick detects a Power cycled.
RIGHT ROLLER ignored by the UGM. fault with the right roller on the
FAULT joystick

CABIN JOYSTICK - 2352 1 Trigger switch requests will be The CAT cabin joystick detects a Power cycled.
TRIGGER SWITCH ignored by the UGM. fault with the trigger switch on the
FAULT joystick.

BOOM ANGLE 2353 1 Display the fixed boom angle value The UGM or platform module has Power cycled.
SENSOR - of “99” on the operator’s cabin detected one of the following
INTERNAL display. internal failures of the CAN based
FAILURE Temporarily assign a fixed boom boom angle sensor:
angle value of 99°. A difference of more than 7 counts
Disallow boom angle sensor (~2.5°) for 1 second between the 2
calibration (“BOOM ANGLE: angle readings.
CALIBRATION FAIL”). A CAN bus message indicating a
Ignore all hydraulic function boom angle value out of range of
requests from the platform module. the calibration, i.e. more than 250
counts.
Deactivate and inhibit the Lift Up
output if the platform is detected as
attached or PLATFORM MODE is
the current active mode; otherwise,
derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data Tables

OPERATING 2354 1 J2-26 Engage Starter output will be The platform module has detected J1-1 of the
INTERLOCK - deactivated and engine start will not J1-1 of the platform module is platform
ATTACHMENT be permitted if the PLATFORM LOW and the PLATFORM module goes
COUPLING PIN STATION is active and CABIN STATION is active and a platform HIGH for a
NOT ENGAGED MODE was the last valid operating is detected as attached and CAN period of 3
mode. communications exist between the seconds.
Changeover to PLATFORM MODE UGM and platform module.
will not be permitted.
If the PLATFORM MODE is the
valid operating mode, Lift and
Telescope functions will be derated
to the LIFT UP DERATE and TELE
DERATE values in Constant Data.

FUNCTION 25XXX - - - -
PREVENTED

MODEL CHANGED 259 1 Deactivate and inhibit all hydraulic The MODEL selection on the Power cycled.
- HYDRAULICS function operation. Analyzer was changed from its
SUSPENDED - J2-26 Engage Starter output will be previous setting.
CYCLE EMS deactivated and engine start will not
be permitted.

FUNCTIONS 2520 1 Deactivate and inhibit all hydraulic The Constant Data code version is Proper
LOCKED OUT - function operation. not up to date / compatible with the Constant
CONSTANT DATA J2-26 Engage Starter output will be current machine Application code. Version is
VERSION deactivated and engine start will not loaded and
IMPROPER be permitted. power is
cycled.

9.42 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

ENGINE START 2525 1 J2-26 Engage Starter output will be The CABIN STATION is active and J4-5 Park
PREVENTED - deactivated and engine start will not J4-8 Engine Start input is HIGH Brake is HIGH
PARK BRAKE NOT be permitted. and J4-5 Park Brake is LOW (not (set).
SET set).

BOOM EXTENDED 2526 1 N/A J7-8 Boom Extension Limit input is Power cycled.
SWITCH - LOW, the feature is enabled in the
CONFLICTING MACHINE SETUP menu, and the
STATE J3-8 Boom Retracted input is
HIGH.

EXCESSIVE BOOM 2527 1 Not activate outputs J2-9 Auxiliary If hydraulic quick connect feature J7-35
ANGLE FOR Function-A Valve or J2-20 Auxiliary is configured in the MACHINE Hydraulic
HYDRAULIC QUICK Function-B Valve. SETUP menu and the boom angle Quick Connect
CONNECT sensor reading is > 10° and the ON is LOW
OPERATION boom angle sensor has and J3-10
successfully completed a Hydraulic
calibration and a hydraulic quick Quick Connect
connect function request is OFF is HIGH.
detected.

PLATFORM 2528 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature J7-35
ATTACHED - Quick Connect. is configured in the MACHINE Hydraulic
HYDRAULIC QUICK Ignore auxiliary hydraulic requests SETUP menu and the platform Quick Connect
CONNECT when the S4 button is engaged on attached conditions have been met ON is LOW
CUTOUT the cabin’s joystick. and J7-35 is HIGH and J3-10 is and J3-10
LOW and the CABIN STATION is Hydraulic
active. Quick Connect
OFF is HIGH.

ENGINE START 2529 1 J2-26 Engage Starter output is If the drive direction signal is not in Shift lever is in
PREVENTED - inhibited. neutral (i.e. - J7-22 Forward = neutral
SHIFT LEVER NOT HIGH and/or J4-18 Reverse = position.
IN NEUTRAL HIGH).

PLATFORM 2533 1 Report the condition to the UGM. The platform option is configured The UGM and
ATTACHED ANGLE Deactivate platform module output and a platform is detected as platform
LIMIT EXCEEDED J2-19 Function Enable Relay attached and the platform module module
(which deactivates the dump valve) is detecting the “PLATFORM confirm the
with any Main Lift Up hydraulic ATTACHED BOOM ANGLE boom angle
request from the platform station. OVERSHOOT POINT” has been sensor reading
reached and faults 2343, 2353 and is less than the
The UGM will inhibit activation of
6621 are not active. “PLATFORM
J2-11 Main Lift Up Valve
ATTACHED
BOOM ANGLE
CUTOUT
POINT” for at
least 1 second.

UGM OUTPUT 33XXX - - - -

DRIVERS

MAIN LIFT UP 33181 1 Deactivate output J2-11 Main Lift The UGM detects an open circuit Power cycled.
VALVE - OPEN Up Valve. at this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag
to determine if this fault condition is
the reason for the fault.

40.8, 40.9 9.43

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

MAIN LIFT VALVES 33182 1 Deactivate output J2-11 Main Lift The UGM detects a short to battery Power cycled.
- SHORT TO Up Valve. at this output.
BATTERY Deactivate output J2-22 Main Lift
Down Valve.
Decouple/disable current feedback
input J3-2 Lift Return (Disables Lift
Up and Down).

MAIN LIFT UP 33183 1 Deactivate output J2-11 Main Lift The UGM detects a short to Power cycled.
VALVE - SHORT TO Up Valve. ground at this output or the UGM
GROUND Decouple/disable current feedback detects a CURRENT FEEDBACK
input J3-2 Lift Return (Disables Lift LOST condition and sets an
Up and Down). internal flag to determine if this
fault condition is the reason for the
fault.

MAIN LIFT DOWN 33184 1 Deactivate output J2-22 Main Lift The UGM detects an open circuit Power cycled.
VALVE - OPEN Down Valve. at this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag
to determine if this fault condition is
the reason for the fault.

MAIN LIFT DOWN 33185 1 Deactivate output J2-22 Main Lift The UGM detects a short to Power cycled.
VALVE - SHORT TO Down Valve. ground at this output or the UGM
GROUND Decouple/disable current feedback detects a CURRENT FEEDBACK
input J3-2 Lift Return (Disables Lift LOST condition and sets an
Up and Down). internal flag to determine if this
fault condition is the reason for the
fault.

MAIN TELESCOPE 33186 1 Deactivate output J2-35 Main The UGM detects an open circuit Power cycled.
OUT VALVE - OPEN Telescope Out Valve. at this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag
to determine if this fault condition is
the reason why.

MAIN TELESCOPE 33187 1 Deactivate output J2-35 Main The UGM detects a short to battery Power cycled.
VALVES - SHORT Telescope Out Valve. at this output.
TO BATTERY Deactivate output J2-34 Main
Telescope In Valve.
Decouple/disable current feedback
input J3-4 Telescope Return
(Disables Telescope Out and In).

MAIN TELESCOPE 33188 1 Deactivate output J2-35 Main The UGM detects a short to Power cycled.
OUT VALVE - Telescope Out Valve. ground at this output or the UGM
SHORT TO Decouple/disable current feedback detects a CURRENT FEEDBACK
GROUND input J3-4 Telescope Return LOST condition and sets an
(Disables Telescope Out and In). internal flag to determine if this
fault condition is the reason for the
fault.

MAIN TELESCOPE 33189 1 Deactivate output J2-34 Main The UGM detects an open circuit Power cycled.
IN VALVE - OPEN Telescope In Valve. at this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag
to determine if this fault condition is
the reason for the fault.

9.44 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

MAIN TELESCOPE 33190 1 Deactivate output J2-34 Main The UGM detects a short to Power cycled.
IN VALVE - SHORT Telescope In Valve. ground at this output or the UGM
TO GROUND Decouple/disable current feedback detects a CURRENT FEEDBACK
input J3-4 Telescope Return LOST condition and sets an
(Disables Telescope Out and In). internal flag to determine if this
fault condition is the reason for the
fault.

FORK TILT UP 33191 1 Deactivate output J2-8 Fork Tilt Up The UGM detects an open circuit Power cycled.
VALVE - OPEN Valve. at this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag
to determine if this fault condition is
the reason for the fault.

FORK TILT VALVES 33192 1 Deactivate output J2-8 Fork Tilt Up The UGM detects a short to battery Power cycled.
- SHORT TO Valve. at this output.
BATTERY Deactivate output J2-19 Fork Tilt
Down Valve.
Decouple/disable current feedback
input J3-6 Tilt Return (Disables Fork
Tilt Up and Down).

FORK TILT UP 33193 1 Deactivate output J2-8 Fork Tilt Up The UGM detects a short to Power cycled.
VALVE - SHORT TO Valve. ground at this output or the UGM
GROUND Decouple/disable current feedback detects a CURRENT FEEDBACK
input J3-6 Tilt Return (Disables Fork LOST condition and sets an
Tilt Up and Down). internal flag to determine if this
fault condition is the reason for the
fault.

FORK TILT DOWN 33194 1 Deactivate output J2-19 Fork Tilt The UGM detects an open circuit Power cycled.
VALVE - OPEN Down Valve. at this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag
to determine if this fault condition is
the reason for the fault.

FORK TILT DOWN 33195 1 Deactivate output J2-19 Fork Tilt The UGM detects a short to Power cycled.
VALVE - SHORT TO Down Valve. ground at this output or the UGM
GROUND Decouple/disable current feedback detects a CURRENT FEEDBACK
input J3-6 Tilt Return (Disables Fork LOST condition and sets an
Tilt Up and Down). internal flag to determine if this
fault condition is the reason for the
fault.

AUXILIARY 33196 1 Deactivate output J2-9 Auxiliary The UGM detects an open circuit Power cycled.
FUNCTION-A Function-A Valve. at this output or the UGM detects a
VALVE - OPEN Deactivate and inhibit the CURRENT FEEDBACK LOST
CIRCUIT Continuous Auxiliary Hydraulics condition and sets an internal flag
feature. to determine if this fault condition is
the reason for the fault.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.

40.8, 40.9 9.45

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

AUXILIARY 33197 1 Deactivate output J2-9 Auxiliary The UGM detects a short to battery Power cycled.
FUNCTION-A/B Function-A Valve. at this output.
VALVES - SHORT Decouple/disable current feedback
TO BATTERY input J3-14 Aux Return (Disables
Auxiliary Function-A and
Function-B).
Deactivate and inhibit the
Continuous Auxiliary Hydraulics
feature.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.

AUXILIARY 33198 1 Deactivate output J2-9 Auxiliary The UGM detects a short to Power cycled.
FUNCTION-A Function-A Valve. ground at this output or the UGM
VALVE - SHORT TO Decouple/disable current feedback detects a CURRENT FEEDBACK
GROUND input J3-14 Aux Return (Disables LOST condition and sets an
Auxiliary Function-A and internal flag to determine if this
Function-B). fault condition is the reason for the
fault.
Deactivate and inhibit the
Continuous Auxiliary Hydraulics
feature.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.

AUXILIARY 33199 1 Deactivate output J2-20 Auxiliary The UGM detects an open circuit Power cycled.
FUNCTION-B Function-B Valve. at this output or the UGM detects a
VALVE - OPEN Deactivate and inhibit the CURRENT FEEDBACK LOST
CIRCUIT Continuous Auxiliary Hydraulics condition and sets an internal flag
feature. to determine if this fault condition is
the reason for the fault.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.

AUXILIARY 33200 1 Deactivate output J2-20 Auxiliary The UGM detects a short to Power cycled.
FUNCTION-B Function-B Valve. ground at this output or the UGM
VALVE - SHORT TO Decouple/disable current feedback detects a CURRENT FEEDBACK
GROUND input J3-14 Aux Return (Disables LOST condition and sets an
Auxiliary Function-A and internal flag to determine if this
Function-B). fault condition is the reason for the
fault.
Deactivate and inhibit the
Continuous Auxiliary Hydraulics
feature.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.

STABILIZER/ 33201 1 Deactivate output J1-3 Stabilizer The UGM detects an open circuit Power cycled.
FRAME LEVEL and Frame Level Speed Valve. at this output or the UGM detects a
SPEED VALVE - CURRENT FEEDBACK LOST
OPEN CIRCUIT condition and sets an internal flag
to determine if this fault condition is
the reason for the fault.

STABILIZER/ 33202 1 Deactivate output J1-3 Stabilizer The UGM detects a short to battery Power cycled.
FRAME LEVEL and Frame Level Speed Valve. at this output.
SPEED VALVE - Decouple/disable current feedback
SHORT TO input J3-5 Stabilizer - Frame Level
BATTERY Return (Disables Stabilizers and
Frame Leveling functions).

9.46 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

STABILIZER/ 33203 1 Deactivate output J1-3 Stabilizer The UGM detects a short to Power cycled.
FRAME LEVEL and Frame Level Speed Valve. ground at this output or the UGM
SPEED VALVE - Decouple/disable current feedback detects a CURRENT FEEDBACK
SHORT TO input J3-5 Stabilizer - Frame Level LOST condition and sets an
GROUND Return (Disables Stabilizers and internal flag to determine if this
Frame Leveling functions). fault condition is the reason for the
fault.

HYDRAULIC QUICK 33204 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature Power cycled.
CONNECT SELECT Quick Connect Select. is configured in the MACHINE
- OPEN CIRCUIT SETUP menu and the UGM
detects an open circuit at this
output.

HYDRAULIC QUICK 33205 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature Power cycled.
CONNECT SELECT Quick Connect Select. is configured in the MACHINE
- SHORT TO Deactivate output J2-9 Auxiliary SETUP menu and the UGM
BATTERY Function-A Valve. detects a short to battery at this
output.
Deactivate output J2-20 Auxiliary
Function-B Valve.

HYDRAULIC QUICK 33206 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature Power cycled.
CONNECT SELECT Quick Connect Select. is configured in the MACHINE
- SHORT TO Deactivate output J2-9 Auxiliary SETUP menu and the UGM
GROUND Function-A Valve. detects a short to ground at this
output.
Deactivate output J2-20 Auxiliary
Function-B Valve.

HORN - OPEN 33207 1 Deactivate output J2-2 Horn. The UGM detects an open circuit Power cycled.
CIRCUIT at this output.

HORN - SHORT TO 33208 1 Deactivate output J2-2 Horn. The UGM detects a short to battery Power cycled.
BATTERY at this output.

HORN - SHORT TO 33209 1 Deactivate output J2-2 Horn. The UGM detects a short to Power cycled.
GROUND ground at this output.

REVERSE ALARM 33210 1 Deactivate output J1-1 Reverse The UGM detects an open circuit Power cycled.
AND LIGHTS - Alarm and Lights. at this output.
OPEN CIRCUIT

REVERSE ALARM 33211 1 Deactivate output J1-1 Reverse The UGM detects a short to battery Power cycled.
AND LIGHTS - Alarm and Lights. at this output.
SHORT TO
BATTERY

REVERSE ALARM 33212 1 Deactivate output J1-1 Reverse The UGM detects a short to Power cycled.
AND LIGHTS - Alarm and Lights. ground at this output.
SHORT TO
GROUND

DUMP VALVE - 33213 1 Deactivate output J2-13 Dump The platform option is configured Power cycled.
OPEN CIRCUIT Valve. and the UGM detects an open
circuit at this output.

40.8, 40.9 9.47

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

DUMP VALVE - 33214 1 Deactivate output J2-13 Dump The platform option is configured Power cycled.
SHORT TO Valve. and the UGM detects a short to
BATTERY Deactivate output J2-3 Right battery at this output.
Stabilizer Up Valve.
Deactivate output J2-5 Frame Level
Right Valve.
Deactivate output J2-7 Frame Level
Left Valve.
Deactivate output J2-8 Fork Tilt Up
Valve.
Deactivate output J2-9 Auxiliary
Function-A Valve.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-11 Main Lift
Up Valve.
Deactivate output J2-15 Right
Stabilizer Down Valve.
Deactivate output J2-19 Fork Tilt
Down Valve.
Deactivate output J2-20 Auxiliary
Function-B Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate output J2-22 Main Lift
Down Valve.
Deactivate output J2-34 Main
Telescope In Valve.
Deactivate output J2-35 Main
Telescope Out Valve.
Deactivate output J1-3 Stabilizer
and Frame Level Speed Valve.

DUMP VALVE - 33215 1 Deactivate output J2-13 Dump The platform option is configured Power cycled.
SHORT TO Valve. and the UGM detects a short to
GROUND ground at this output.

AUXILIARY 33216 1 Deactivate output J2-1 Auxiliary The CAT brand is configured for Power cycled.
FUNCTION Function Select. the UGM and the UGM detects an
SELECT - OPEN open circuit at this output.
CIRCUIT

AUXILIARY 33217 1 Deactivate output J2-1 Auxiliary The CAT brand is configured for Power cycled.
FUNCTION Function Select. the UGM and the UGM detects a
SELECT - SHORT Deactivate output J2-9 Auxiliary short to battery at this output.
TO BATTERY Function-A Valve.
Deactivate output J2-20 Auxiliary
Function-B Valve.

AUXILIARY 33218 1 Deactivate output J2-1 Auxiliary The CAT brand is configured for Power cycled.
FUNCTION Function Select. the UGM and the UGM detects a
SELECT - SHORT Deactivate output J2-9 Auxiliary short to ground at this output.
TO GROUND Function-A Valve.
Deactivate output J2-20 Auxiliary
Function-B Valve.

9.48 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

AUXILIARY 33219 1 Deactivate output J2-1 Auxiliary The SDF brand is configured for Power cycled.
ELECTRICS - OPEN Electrics. the UGM and the UGM detects an
CIRCUIT open circuit at this output.

AUXILIARY 33220 1 Deactivate output J2-1 Auxiliary The SDF brand is configured for Power cycled.
ELECTRICS - Electrics. the UGM and the UGM detects a
SHORT TO short to battery at this output.
BATTERY

AUXILIARY 33221 1 Deactivate output J2-1 Auxiliary The SDF brand is configured for Power cycled.
ELECTRICS - Electrics. the UGM and the UGM detects a
SHORT TO short to ground at this output.
GROUND

LEFT STABILIZER 33222 1 Deactivate output J2-15 Right The stabilizers are configured in Power cycled.
DOWN VALVE - Stabilizer Down Valve. the MACHINE SETUP menu and
OPEN CIRCUIT Deactivate output J2-21 Left the UGM detects an open circuit at
Stabilizer Down Valve. this output.

LEFT STABILIZER 33223 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
DOWN VALVE - Stabilizer Up Valve. the MACHINE SETUP menu and
SHORT TO Deactivate output J2-15 Right the UGM detects a short to battery
BATTERY Stabilizer Down Valve. at this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output J1-3
(Frame Leveling and Stabilizers will
be cutout).

LEFT STABILIZER 33224 1 Deactivate output J2-15 Right The stabilizers are configured in Power cycled.
DOWN VALVE - Stabilizer Down Valve. the MACHINE SETUP menu and
SHORT TO Deactivate output J2-21 Left the UGM detects a short to ground
GROUND Stabilizer Down Valve. at this output.

LEFT STABILIZER 33225 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
UP VALVE - OPEN Stabilizer Up Valve. the MACHINE SETUP menu and
CIRCUIT Deactivate output J2-15 Right the UGM detects an open circuit at
Stabilizer Down Valve. this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.

LEFT STABILIZER 33226 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
UP VALVE - SHORT Stabilizer Up Valve. the MACHINE SETUP menu and
TO BATTERY Deactivate output J2-15 Right the UGM detects a short to battery
Stabilizer Down Valve. at this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output J1-3
(Frame Leveling and Stabilizers will
be cutout).

40.8, 40.9 9.49

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

LEFT STABILIZER 33227 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
UP VALVE - SHORT Stabilizer Up Valve. the MACHINE SETUP menu and
TO GROUND Deactivate output J2-15 Right the UGM detects a short to ground
Stabilizer Down Valve. at this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.

RIGHT STABILIZER 33228 1 Deactivate output J2-15 Right The stabilizers are configured in Power cycled.
DOWN VALVE - Stabilizer Down Valve. the MACHINE SETUP menu and
OPEN CIRCUIT Deactivate output J2-21 Left the UGM detects an open circuit at
Stabilizer Down Valve. this output.

RIGHT STABILIZER 33229 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
DOWN VALVE - Stabilizer Up Valve. the MACHINE SETUP menu and
SHORT TO Deactivate output J2-15 Right the UGM detects a short to battery
BATTERY Stabilizer Down Valve. at this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output J1-3
(Frame Leveling and Stabilizers will
be cutout).

RIGHT STABILIZER 33230 1 Deactivate output J2-15 Right The stabilizers are configured in Power cycled.
DOWN VALVE - Stabilizer Down Valve. the MACHINE SETUP menu and
SHORT TO Deactivate output J2-21 Left the UGM detects a short to ground
GROUND Stabilizer Down Valve. at this output.

RIGHT STABILIZER 33231 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
UP VALVE - OPEN Stabilizer Up Valve. the MACHINE SETUP menu and
CIRCUIT Deactivate output J2-15 Right the UGM detects an open circuit at
Stabilizer Down Valve. this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.

RIGHT STABILIZER 33232 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
UP VALVE - SHORT Stabilizer Up Valve. the MACHINE SETUP menu and
TO BATTERY Deactivate output J2-15 Right the UGM detects a short to battery
Stabilizer Down Valve. at this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output J1-3
(Frame Leveling and Stabilizers will
be cutout).

9.50 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

RIGHT STABILIZER 33233 1 Deactivate output J2-3 Right The stabilizers are configured in Power cycled.
UP VALVE - SHORT Stabilizer Up Valve. the MACHINE SETUP menu and
TO GROUND Deactivate output J2-15 Right the UGM detects a short to ground
Stabilizer Down Valve. at this output.

Deactivate output J2-10 Left

Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.

FRAME LEVEL 33234 1 Deactivate output J2-7. Frame leveling is configured in the Power cycled.
LEFT VALVE - MACHINE SETUP menu and the
OPEN CIRCUIT UGM detects an open circuit at this
output.

FRAME LEVEL 33235 1 Deactivate output J2-7. Frame leveling is configured in the Power cycled.
LEFT VALVE - Deactivate and inhibit output J1-3 MACHINE SETUP menu and the
SHORT TO Frame Leveling and Stabilizers UGM detects a short to battery at
BATTERY Speed Valve. this output.

FRAME LEVEL 33236 1 Deactivate output J2-7. Frame leveling is configured in the Power cycled.
LEFT VALVE - MACHINE SETUP menu and the
SHORT TO UGM detects a short to ground at
GROUND this output.

FRAME LEVEL 33237 1 Deactivate output J2-5. Frame leveling is configured in the Power cycled.
RIGHT VALVE - MACHINE SETUP menu and the
OPEN CIRCUIT UGM detects an open circuit at this
output.

FRAME LEVEL 33238 1 Deactivate output J2-5. Frame leveling is configured in the Power cycled.
RIGHT VALVE - Deactivate and inhibit output J1-3 MACHINE SETUP menu and the
SHORT TO Frame Leveling and Stabilizers UGM detects a short to battery at
BATTERY Speed Valve. this output.

FRAME LEVEL 33239 1 Deactivate output J2-5. Frame leveling is configured in the Power cycled.
RIGHT VALVE - MACHINE SETUP menu and the
SHORT TO UGM detects a short to ground at
GROUND this output.

TRANSMISSION C 33240 1 Deactivate output J1-10 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission C Control Coil (Gear of POWERSHIFT is configured
CIRCUIT will not be available for selection). and a GEAR SELECTION of 4F/
3rd, 2nd, and 1st will be the only 3R is configured and the UGM
available gear selections. detects an open circuit at this
output.
Flash the "Gear Selection" symbol
on the LCD of the cabin’s display.

TRANSMISSION C 33241 1 Deactivate output J1-10 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission C Control Coil. of POWERSHIFT is configured
BATTERY Flash the "Gear Selection" symbol and a GEAR SELECTION of 4F/
on the LCD of the cabin’s display. 3R is configured and the UGM
detects a short to battery at this
output.

TRANSMISSION C 33242 1 Deactivate output J1-10 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission C Control Coil. of POWERSHIFT is configured
GROUND 3rd, 2nd, and 1st will be the only and a GEAR SELECTION of 4F/
available gear selections. 3R is configured and the UGM
detects a short to ground at this
Flash the "Gear Selection" symbol output.
on the LCD of the cabin’s display.

40.8, 40.9 9.51

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

TRANSMISSION B 33243 1 Deactivate output J2-32 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission B Control Coil. of POWERSHIFT is configured
CIRCUIT Flash the "Gear Selection" and the and the UGM detects an open
"Drive Direction" symbols on the circuit at this output.
LCD of the cabin’s display.

TRANSMISSION B 33244 1 Deactivate output J2-32 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission B Control Coil. of POWERSHIFT is configured
BATTERY Flash the "Gear Selection" and the and the UGM detects a short to
"Drive Direction" symbols on the battery at this output.
LCD of the cabin’s display.

TRANSMISSION B 33245 1 Deactivate output J2-32 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission B Control Coil. of POWERSHIFT is configured
GROUND Flash the "Gear Selection" and the and the UGM detects a short to
"Drive Direction" symbols on the ground at this output.
LCD of the cabin’s display.

TRANSMISSION 33246 1 Deactivate output J2-32 A TRANSMISSION configuration Power cycled.

REVERSE COIL - Transmission Reverse Coil. of HYDROSTATIC is configured
OPEN CIRCUIT Flash the "Gear Selection" and the and the UGM detects an open
"Drive Direction" symbols on the circuit at this output.
LCD of the cabin’s display.

TRANSMISSION 33247 1 Deactivate output J2-32 A TRANSMISSION configuration Power cycled.

REVERSE COIL - Transmission Reverse Coil. of HYDROSTATIC is configured
SHORT TO Flash the "Gear Selection" and the and the UGM detects a short to
BATTERY "Drive Direction" symbols on the battery at this output.
LCD of the cabin’s display.

TRANSMISSION 33248 1 Deactivate output J2-32 A TRANSMISSION configuration Power cycled.

REVERSE COIL - Transmission Reverse Coil. of HYDROSTATIC is configured
SHORT TO Flash the "Gear Selection" and the and the UGM detects a short to
GROUND "Drive Direction" symbols on the ground at this output.
LCD of the cabin’s display.

TRANSMISSION A 33249 1 Deactivate output J2-33 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission A Control Coil. of POWERSHIFT is configured
CIRCUIT Flash the "Gear Selection" and the and the UGM detects an open
"Drive Direction" symbols on the circuit at this output.
LCD of the cabin’s display.

TRANSMISSION A 33250 1 Deactivate output J2-33 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission A Control Coil. of POWERSHIFT is configured
BATTERY Flash the "Gear Selection" and the and the UGM detects a short to
"Drive Direction" symbols on the battery at this output.
LCD of the cabin’s display.

TRANSMISSION A 33251 1 Deactivate output J2-33 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission A Control Coil. of POWERSHIFT is configured
GROUND Flash the "Gear Selection" and the and the UGM detects a short to
"Drive Direction" symbols on the ground at this output.
LCD of the cabin’s display.

TRANSMISSION 33252 1 Deactivate output J2-33 A TRANSMISSION configuration Power cycled.

FORWARD COIL - Transmission Forward Coil. of HYDROSTATIC is configured
OPEN CIRCUIT Flash the "Gear Selection" and the and the UGM detects an open
"Drive Direction" symbols on the circuit at this output.
LCD of the cabin’s display.

9.52 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

TRANSMISSION 33253 1 Deactivate output J2-33 A TRANSMISSION configuration Power cycled.

FORWARD COIL - Transmission Forward Coil. of HYDROSTATIC is configured
SHORT TO Flash the "Gear Selection" and the and the UGM detects a short to
BATTERY "Drive Direction" symbols on the battery at this output.
LCD of the cabin’s display.

TRANSMISSION 33254 1 Deactivate output J2-33 A TRANSMISSION configuration Power cycled.

FORWARD COIL - Transmission Forward Coil. of HYDROSTATIC is configured
SHORT TO Flash the "Gear Selection" and the and the UGM detects a short to
GROUND "Drive Direction" symbols on the ground at this output.
LCD of the cabin’s display.

TRANSMISSION E 33255 1 Deactivate output J1-7 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission E Control Coil (Gear of POWERSHIFT is configured
CIRCUIT will not be available for selection). and the UGM detects an open
3rd and 4th will be the only circuit at this output.
available gear selections.
Flash the "Gear Selection" symbol
on the LCD of the cabin’s display.

TRANSMISSION E 33256 1 Deactivate output J1-7 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission E Control Coil. of POWERSHIFT is configured
BATTERY Flash the "Gear Selection" symbol and the UGM detects a short to
on the LCD of the cabin’s display. battery at this output.

TRANSMISSION E 33257 1 Deactivate output J1-7 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission E Control Coil. of POWERSHIFT is configured
GROUND 3rd and 4th will be the only and the UGM detects a short to
available gear selections. ground at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

TRANSMISSION 1 33258 1 Deactivate output J1-7 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission 1 Coil. of HYDROSTATIC is configured
CIRCUIT Maintain the last valid gear and the UGM detects an open
selection. circuit at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

TRANSMISSION 1 33259 1 Deactivate output J1-7 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission 1 Coil. of HYDROSTATIC is configured
BATTERY Deactivate and inhibit activation of and the UGM detects a short to
J1-20 Transmission 2 Coil. battery at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

TRANSMISSION 1 33260 1 Deactivate output J1-7 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission 1 Coil. of HYDROSTATIC is configured
GROUND Deactivate and inhibit activation of and the UGM detects a short to
J1-20 Transmission 2 Coil. ground at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

40.8, 40.9 9.53

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

TRANSMISSION D 33261 1 Deactivate output J1-20 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission D Control Coil (Gear of POWERSHIFT is configured
CIRCUIT will not be available for selection). and the UGM detects an open
2nd, 3rd, and 4th will be the only circuit at this output.
available gear selections.
Flash the "Gear Selection" symbol
on the LCD of the cabin’s display.

TRANSMISSION D 33262 1 Deactivate output J1-20 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission D Control Coil. of POWERSHIFT is configured
BATTERY Flash the "Gear Selection" symbol and the UGM detects a short to
on the LCD of the cabin’s display. battery at this output.

TRANSMISSION D 33263 1 Deactivate output J1-20 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission D Control Coil. of POWERSHIFT is configured
GROUND 2nd, 3rd, and 4th will be the only and the UGM detects a short to
available gear selections. ground at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

TRANSMISSION 2 33264 1 Deactivate output J1-20 A TRANSMISSION configuration Power cycled.

COIL - OPEN Transmission 2 Coil. of HYDROSTATIC is configured
CIRCUIT Deactivate and inhibit activation of and the UGM detects an open
J1-7 Transmission 1 Coil. circuit at this output.

Maintain the last valid gear

selection.
Flash the "Gear Selection" symbol
on the LCD of the cabin’s display.

TRANSMISSION 2 33265 1 Deactivate output J1-20 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission 2 Coil. of HYDROSTATIC is configured
BATTERY Deactivate and inhibit activation of and the UGM detects a short to
J1-7 Transmission 1 Coil. battery at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

TRANSMISSION 2 33266 1 Deactivate output J1-20 A TRANSMISSION configuration Power cycled.

COIL - SHORT TO Transmission 2 Coil. of HYDROSTATIC is configured
GROUND Deactivate and inhibit activation of and the UGM detects a short to
J1-7 Transmission 1 Coil. ground at this output.

Flash the "Gear Selection" symbol

on the LCD of the cabin’s display.

ENGINE FUEL 33267 1 Deactivate output J2-31 Engine The UGM detects an open circuit Power cycled.
RELAY - OPEN Fuel Relay. at this output.
CIRCUIT Deactivate and inhibit output J2-26
Engage Starter.

ENGINE FUEL 33268 1 Deactivate output J2-31 Engine The UGM detects a short to battery Power cycled.
RELAY - SHORT TO Fuel Relay. at this output.
BATTERY Deactivate and inhibit output J2-26
Engage Starter.

ENGINE FUEL 33269 1 Deactivate output J2-31 Engine The UGM detects a short to Power cycled.
RELAY - SHORT TO Fuel Relay. ground at this output.
GROUND Deactivate and inhibit output J2-26
Engage Starter.

9.54 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CRAB STEER 33270 1 Deactivate output J2-16 Crab Steer The UGM detects an open circuit Power cycled.
VALVE - OPEN Valve. at this output.
CIRCUIT Try to complete any pending steer
mode changes.
Display the "Steer Valve Failure"
screen on the LCD of the cabin’s
display.

CRAB STEER 33271 1 Deactivate output J2-16 Crab Steer The UGM detects a short to battery Power cycled.
VALVE - SHORT TO Valve. at this output.
BATTERY Try to complete any pending steer
mode changes and prohibit any
new steer mode requests.
Display the "Steer Valve Failure"
screen on the LCD of the cabin’s
display.

CRAB STEER 33272 1 Deactivate output J2-16 Crab Steer The UGM detects a short to Power cycled.
VALVE - SHORT TO Valve. ground at this output.
GROUND Try to complete any pending steer
mode changes.
Display the "Steer Valve Failure"
screen on the LCD of the cabin’s
display.

ALL WHEEL STEER 33273 1 Deactivate output J2-4 All Wheel The UGM detects an open circuit Power cycled.
VALVE - OPEN Steer Valve. at this output.
CIRCUIT Try to complete any pending steer
mode changes.
Display the "Steer Valve Failure"
screen on the LCD of the cabin’s
display.

ALL WHEEL STEER 33274 1 Deactivate output J2-4 All Wheel The UGM detects a short to battery Power cycled.
VALVE - SHORT TO Steer Valve. at this output.
BATTERY Try to complete any pending steer
mode changes and prohibit any
new steer mode requests.
Display the "Steer Valve Failure"
screen on the LCD of the cabin’s
display.

ALL WHEEL STEER 33275 1 Deactivate output J2-4 All Wheel The UGM detects a short to Power cycled.
VALVE - SHORT TO Steer Valve. ground at this output.
GROUND Try to complete any pending steer
mode changes.
Display the "Steer Valve Failure"
screen on the LCD of the cabin’s
display.

APU PUMP RELAY - 33276 1 Inhibit operation of J1-13 APU The platform option is configured Power cycled.
OPEN CIRCUIT Pump Relay. and the UGM detects an open
circuit at this output.

APU PUMP RELAY - 33277 1 Inhibit operation of J1-13 APU The platform option is configured Power cycled.
SHORT TO Pump Relay. and the UGM detects a short to
BATTERY battery at this output.

40.8, 40.9 9.55

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

APU PUMP RELAY - 33278 1 Inhibit operation of J1-13 APU The platform option is configured Power cycled.
SHORT TO Pump Relay. and the UGM detects a short to
GROUND ground at this output.

GLOWPLUGS - 33279 1 Deactivate output J1-12 Glow- The UGM detects an open circuit Power cycled.
OPEN CIRCUIT plugs. at this output.

GLOWPLUGS - 33280 1 Deactivate output J1-12 Glow- The UGM detects a short to battery Power cycled.
SHORT TO plugs. at this output.
BATTERY

GLOWPLUGS - 33281 1 Deactivate output J1-12 Glow- The UGM detects a short to Power cycled.
SHORT TO plugs. ground at this output.
GROUND

ENGAGE STARTER 33282 1 Deactivate output J2-26 Engage The UGM detects an open circuit Power cycled.
OUTPUT - OPEN Starter. at this output.
CIRCUIT

ENGAGE STARTER 33283 1 Deactivate output J2-26 Engage The UGM detects a short to battery Power cycled.
OUTPUT - SHORT Starter. at this output.
TO BATTERY Activate output J2-31 Fuel Enable
Signal.

ENGAGE STARTER 33284 1 Deactivate output J2-26 Engage The UGM detects a short to Power cycled.
OUTPUT - SHORT Starter. ground at this output.
TO GROUND

ALTERNATOR 33285 1, 2, 10 J1-32 Alternator Excitation output J1-32-Alternator Excite (and thus Power cycled.
EXCITATION LINE - will be deactivated. J4-7 Alternator D+) is HIGH for a
SHORT TO period of 2 seconds or more and
BATTERY an ENGINE STOPPED state is
detected.

FRONT MOTOR - 33286 1 N/A The UGM detects the actual Power cycled.
CURRENT current has deviated more than
FEEDBACK 250 mA from the commanded
READING TOO current for more than 1 second.
LOW

LIFT - CURRENT 33287 1 Do not detect or report the BOOM The UGM detects the actual Power cycled.
FEEDBACK ANGLE SENSOR - NOT current has deviated more than
READING TOO RESPONDING fault. 250 mA from the commanded
LOW current for more than 1 second.

TELESCOPE - 33288 1 N/A The UGM detects the actual Power cycled.
CURRENT current has deviated more than
FEEDBACK 250 mA from the commanded
READING TOO current for more than 1 second.
LOW

STABILIZERS/ 33289 1 N/A The UGM detects the actual Power cycled.
FRAME LEVEL - current has deviated more than
CURRENT 250 mA from the commanded
FEEDBACK current for more than 1 second.
READING TOO
LOW

FORK TILT - 33290 1 N/A The UGM detects the actual Power cycled.
CURRENT current has deviated more than
FEEDBACK 250 mA from the commanded
READING TOO current for more than 1 second.
LOW

9.56 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

AUXILIARY 33291 1 N/A The UGM detects the actual Power cycled.
HYDRAULICS - current has deviated more than
CURRENT 250 mA from the commanded
FEEDBACK current for more than 1 second.
READING TOO
LOW

FRONT MOTOR 33292 1 Deactivate output J1-6 Front Motor The UGM detects an open circuit Power cycled.
SWIVEL ANGLE - Swivel. at this output.
OPEN CIRCUIT

FRONT MOTOR 33293 1 Deactivate output J1-6 Front Motor The UGM detects a short to battery Power cycled.
SWIVEL ANGLE - Swivel. at this output.
SHORT TO
BATTERY

FRONT MOTOR 33294 1 Deactivate output J1-6 Front Motor The UGM detects a short to Power cycled.
SWIVEL ANGLE - Swivel. ground at this output.
SHORT TO
GROUND

REAR AUXILIARY 33326 1 Deactivate output J2-23 Rear If the rear auxiliary hydraulics Power cycled.
HYDRAULICS Auxiliary Hydraulics Valve feature is configured in the
VALVE - OPEN MACHINE SETUP menu and the
CIRCUIT UGM detects an open circuit at this
output.

REAR AUXILIARY 33327 1 Deactivate output J2-23 Rear If the rear auxiliary hydraulics Power cycled.
HYDRAULICS Auxiliary Hydraulics Valve. feature is configured in the
VALVE - SHORT TO Deactivate output J2-9 Auxiliary MACHINE SETUP menu and the
BATTERY Function-A Valve. UGM detects a short to battery at
this output.
Deactivate output J2-20 Auxiliary
Function-B Valve.

REAR AUXILIARY 33328 1 Deactivate output J2-23 Rear If the rear auxiliary hydraulics Power cycled.
HYDRAULICS Auxiliary Hydraulics Valve. feature is configured in the
VALVE - SHORT TO Deactivate output J2-9 Auxiliary MACHINE SETUP menu and the
GROUND Function-A Valve until input J7-23 is UGM detects a short to battery at
LOW. this output.

Deactivate output J2-20 Auxiliary

Function-B Valve until input J7-23 is
LOW.

ENGINE 43XXX - - - -

ENGINE TROUBLE 437 1, 2, 3* (ECM will determine the proper The ECM detects a fault condition Power cycled
CODE: (SPN):(FMI) action to take.) (not defined in this SRD).
* - The UGM will illuminate just the
engine warning fault indicator if the
DM1 message indicates a warning
or derate condition. The UGM will
illuminate the engine warning and
engine critical fault indicators if the
DM1 message indicates a critical
(shutdown) condition. In the event a
transfer protocol message is
received with multiple faults, a fault
indicating a critical (shutdown) fault
will receive priority when the UGM
determines what indicators to turn
ON.

40.8, 40.9 9.57

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

WRONG ENGINE 4314 1, 2 J2-26 Engage Starter will be The ENGINE CONTROL Power cycled.
SELECTED - ECM deactivated and inhibited. configuration is MECHANICAL and
DETECTED the UGM detects CAN messages
from an ECM.

HIGH ENGINE 4316 1, 2, 12 (For ECM controlled engines, the MECHANICAL: The engine MECHANCIAL
COOLANT ECM may also derate the engine.) coolant temperature reaches The engine
TEMPERATURE 113°C or more for a period of at coolant
WARNING least 10 seconds and an ENGINE temperature
RUNNING state exists. reaches
110°C.
ELECTRONIC: The ECM detects ELECTRONIC:
the engine coolant temperature The ECM no
has reached 113°C or more, the longer
ECM will transmit a J1939 CAN transmits the
bus DM1 message, or use the condition as an
J1939 Transfer Protocol in the active fault.
event multiple engine faults exist,
on CAN1 to communicate an
engine coolant temperature
warning (SPN:FMI 110:15 or
110:16).

HIGH ENGINE 4317 1, 2, 3, 12 (For ECM controlled engines, the MECHANCIAL: The engine MECHANCIAL
COOLANT ECM may also derate the engine.) coolant temperature reaches : The engine
TEMPERATURE 118°C or more for a period of at coolant
CRITICAL least 10 seconds and an ENGINE temperature
RUNNING state exists. reaches
115°C.
ELECTRONIC: The engine coolant ELECTRONIC:
temperature reaches 118°C or The ECM no
more, the ECM will transmit a longer
J1939 CAN bus DM1 message, or transmits the
use the J1939 Transfer Protocol in condition as an
the event multiple engine faults active fault.
exist, on CAN1 to communicate an
engine coolant temperature critical
(SPN:FMI 110:0).

LOW ENGINE OIL 4318 1, 2, 9 N/A The ECM detects the engine oil Power cycled.
PRESSURE pressure is getting low, the ECM
WARNING will transmit a J1939 CAN bus
DM1 message, or use the J1939
Transfer Protocol in the event
multiple engine faults exist, on
CAN1 to communicate low engine
oil pressure (SPN:FMI 100:17 or
100:18).

9.58 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

LOW ENGINE OIL 4319 1, 2, 3, 9 N/A MECHANICAL: The UGM detects Power cycled.
PRESSURE input J12-8 Engine Oil Pressure is
CRITICAL LOW for 1 second and an ENGINE
RUNNING state exists for a period
of 5 seconds.
ELECTRONIC: The engine oil
pressure reaches its critical low oil
pressure value, which is based on
engine speed, the ECM will
transmit a J1939 CAN bus DM1
message, or use the J1939
Transfer Protocol in the event
multiple engine faults exist, on
CAN1 at a rate of 1 second to
communicate low engine oil
pressure (SPN:FMI 100:1).

ALTERNATOR 4320 1, 2, 10 N/A J4-7 Alternator D+ is LOW and an J4-7 Alternator

CHARGING ENGINE RUNNING state exists for D+ is
FAILURE a period of 3 seconds or more. continuously
HIGH for a
period of 3
seconds.

AIR FILTER 4321 1, 2, 7 N/A J1-34 Air Filter Restriction input is J1-34 Air Filter
RESTRICTION LOW and an ENGINE RUNNING Restriction
state exists for a period of 3 input is HIGH
seconds or more or 10 seconds for 1 second.
after a system power up.

LOSS OF ENGINE 4322 1, 2 Deactivate J2-26 Engage Starter. MECHANICAL: J4-7 Alternator D+ Power cycled.
SPEED SIGNAL Ignore the above-mentioned is HIGH and J12-8 is HIGH and no
interlock for disabling the impulses are received at J1-16
Continuous Auxiliary Hydraulics Engine Speed.
function when engine speed is ELECTRONIC: The TCM or ECM
< 600 RPM. will report the fault using J1939
Ignore the prevent engine stall CAN protocol to the UGM.
logic.

CONFLICTING 4324 1,2 N/A J4-8 Engine Start has been Power cycled.
OPERATING changed during the active power
ENGINE STATE cycle, and ENGINE STOPPED
condition exists, and one of the
three ENGINE RUNNING
conditions is true.

BATTERY SUPPLY 44XXX - - - -

BATTERY 441 1 Inhibit all output drivers. The UGM has detected the battery Power cycled.
VOLTAGE TOO voltage is at or below 9V. (Replace/fix
LOW - SYSTEM battery.)
SHUTDOWN

BATTERY 442 1 Inhibit all output drivers. The UGM has detected the battery Power cycled.
VOLTAGE TOO voltage is at or above 16V. (Fix supply
HIGH - SYSTEM voltage.)
SHUTDOWN

LSS BATTERY 443 1 UGM assumes a platform The LSS module detects its supply Power cycled.
VOLTAGE TOO overloaded condition. voltage is too high and reports the (Fix supply
HIGH issue to the UGM. voltage.)

40.8, 40.9 9.59

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

LSS BATTERY 444 1 UGM assumes a platform The LSS module detects its supply Power cycled.
VOLTAGE TOO overloaded condition. voltage is too low and reports the (Replace/fix
LOW issue to the UGM. battery.)

BATTERY 445 1 J1-12 Glow-plugs will be inhibited. The UGM has detected the battery The UGM
VOLTAGE LOW voltage below 11V for a period of 3 detects the
seconds or more and an ENGINE battery voltage
RUNNING state exists. higher than
11V for a
period of 10
seconds or
power cycled.

REFERENCE 447 1 Inhibit all hydraulic functions The UGM has detected its Power cycled.
VOLTAGE OUT OF reference voltage is too high or
RANGE - GROUND low.

TRANSMISSION & 46XXX - - - -

DRIVE SYSTEM

HIGH 461 1, 11 N/A UGM input J3-11 Transmission Oil Power cycled.
TRANSMISSION Temperature is LOW when a
OIL TRANSMISSION configuration of
TEMPERATURE POWERSHIFT or
CRITICAL POWERSYNCRO is selected.

CONFLICTING 462 1 Command an ’N’ in the cabin’s A HIGH signal is detected on more Only input J4-4
DRIVE DIRECTION display. than one of drive direction inputs Neutral is
SIGNALS Broadcast the TC1 J1939 CAN (J4-4 Neutral / J7-22 Forward / J4- HIGH.
message on CAN1 to command the 18 Reverse) at the same time for a
TCM to the neutral gear selection if period of 1 second or more.
MODELS: TH406, TH407, TH414,
TH417, TH515 are configured.
Deactivate and inhibit output J2-33
Transmission Forward.
Deactivate and inhibit output J2-32
Transmission Reverse.
Deactivate and inhibit output J1-1
Reversing Alarm and Lights.

DRIVE DIRECTION 463 1 Command an ’N’ in the cabin’s J4-4 Neutral and J7-22 Forward Only input J4-4
SIGNAL LOST display. and J4-18 Reverse are Neutral is
Broadcast the TC1 J1939 CAN simultaneously LOW for a period of HIGH.
message on CAN1 to command the 1 second or more
TCM to the neutral gear selection if
MODELS: TH406, TH407, TH414,
TH417, TH515 are configured.
Deactivate and inhibit output J2-33
Transmission Forward.
Deactivate and inhibit output J2-32
Transmission Reverse.
Deactivate and inhibit output J1-1
Reversing Alarm and Lights.

9.60 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CONFLICTING 464 1 Maintain the output of the last valid If more than one of the gear J4-5 Park
GEAR SELECTION gear selected or 3rd Gear if the fault selection inputs, J4-21 1st Gear / Brake is HIGH
SIGNALS is present at startup for J4-11 2nd Gear / J4-22 3rd Gear / and issue
POWERSHIFT and J4-23 4th Gear, are HIGH cleared or
POWERSYNCRO transmissions or simultaneously for a period of 1 power cycled.
2nd Gear if the fault is present at second.
startup for a HYDROSTATIC
transmission. Transmission drive
direction signals will still be
acknowledged in this case.
Flash last valid gear selection or
flash 3rd Gear if the fault is present
at startup for POWERSHIFT and
POWERSYNCRO transmissions or
2nd Gear if the fault is present at
startup for a HYDROSTATIC
transmission on the LCD of the
cabin’s display.

GEAR SELECTION 465 1 Maintain the output of the last valid If J4-21 1st Gear and J4-11 2nd J4-5 Park
SIGNAL LOST gear selected or 3rd Gear if the fault Gear and J4-22 3rd Gear and J4- Brake is HIGH
is present at startup for 23 4th Gear are simultaneously and issue
POWERSHIFT and LOW for a period of 1 second or cleared or
POWERSYNCRO transmissions or more. power cycled.
2nd Gear if the fault is present at
startup for a HYDROSTATIC
transmission. Transmission drive
direction signals will still be
acknowledged in this case.
Flash last valid gear selection or
flash 3rd Gear if the fault is present
at startup for POWERSHIFT and
POWERSYNCRO transmissions or
2nd Gear if the fault is present at
startup for a HYDROSTATIC
transmission on the LCD of the
cabin’s display.

40.8, 40.9 9.61

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

INVALID 466 1 Deactivate output J1-20 J4-22 3rd Gear or J4-23 4th Gear The
TRANSMISSION Transmission D / 2 Coil. are LOW and a TRANSMISSION configuration is
CONFIGURATION Deactivate output J1-7 selection of HYDROSTATIC is corrected and
Transmission E / 1 Coil. configured. power is
cycled.
Deactivate output J2-33
Transmission A / Forward Coil.
Deactivate output J2-32
Transmission B / Reverse Coil.
Deactivate output J1-10
Transmission C Coil.
Deactivate output J2-5 Frame
Leveling Right Valve.
Deactivate output J2-7 Frame
Leveling Left Valve.
Deactivate output J2-3 Right
Stabilizer Up Valve.
Deactivate output J2-15 Right
Stabilizer Down Valve.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate output J2-13 Dump
Valve.
Deactivate output J1-3 Stabilizer
and Frame Level Speed Valve.
Deactivate output J2-11 Main Lift
Up Valve.
Deactivate output J2-22 Main Lift
Down Valve.
Deactivate output J2-35 Main
Telescope Out Valve.
Deactivate output J2-34 Main
Telescope In Valve.
Deactivate output J2-8 Fork Tilt Up
Valve.
Deactivate output J2-19 Fork Tilt
Down Valve.
Deactivate output J2-9 Auxiliary
Hydraulics 1 Valve.
Deactivate output J2-20 Auxiliary
Hydraulics 2 Valve.

TRANSMISSION 467 1 (TCM will determine the proper The TCM detects a fault condition Power cycled
TROUBLE CODE: action to take.) (not defined in this SRD).
(SPN):(FMI) Flash the current drive direction and
gear selection on the cabin’s
display.

9.62 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

VEHICLE SPEED 468 1 Broadcast a proprietary B CAN VEHICLE SPEED is configured in Power cycled.
SENSOR - NOT message on CAN1 to display a the MACHINE SETUP menu and
RESPONDING value of ’99’ on the cabin’s LCD the transmission is not in neutral
display. and the service brake is not
Disable the drive direction interlock engaged and the park brake is not
and allow drive direction to be engaged and Engine RPM is =
changed at any point in time. 1200 RPM and no VEHICLE
SPEED signal is measured for a
period 3 seconds or more.

COMMUNICATIONS 66XXX - - - -

CANBUS FAILURE - 662 1 Disregard any CAN messages with The PLATFORM OPTION is Power cycled.
PLATFORM the platform module source configured as ENABLED and a
MODULE addresses. platform is detected as attached
and the UGM does not detect the
platform module on the CAN bus
for a period of > 250msec.

CANBUS FAILURE - 663 1, 14 Deactivate and inhibit the Lift Up The PLATFORM STATION is Power cycled.
LOAD SENSING output. active and the PLATFORM
SYSTEM MODULE Deactivate and inhibit the Lift Down OPTION is configured as
output. ENABLED and a platform is
detected as attached and a
Deactivate and inhibit the
MARKET selection of CE or
Telescope Out output.
AUSTRALIA is configured and the
Deactivate and inhibit the UGM does not detect the platform
Telescope In output. module on the CAN bus.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
Disregard any CAN messages with
platform module source addresses.

CANBUS FAILURE - 666 1, 3 Deactivate and inhibit output J2-26 The ENGINE CONTROL menu is Power cycled.
ENGINE Engage Starter. configured as ELECTRONIC and
CONTROLLER the UGM does not detect the ECM
on the CAN bus.

CANBUS FAILURE - 6613 1 N/A The UGM detects more than 500 Power cycled.
EXCESSIVE Bus Off or more than 500 Bus
CANBUS ERRORS Passive conditions during a power
cycle or the UGM detects more
than 22 Bus Off or more than 22
Bus Passive conditions during a
period of 1 second.

40.8, 40.9 9.63

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CANBUS FAILURE - 6616 1 Only transmit messages that keep The UGM does not detect the TCM Power cycled.
TRANSMISSION the transmission in neutral. on the CAN bus when a
CONTROLLER POWERSYNCRO transmission is
configured and an ENGINE
STOPPED or ENGINE RUNNING
state exists for a period of one
second.

CANBUS FAILURE - 6617 1 Disregard any CAN messages with The UGM does not detect the Power cycled.
CABIN JOYSTICK the cabin joystick source cabin’s joystick on the CAN bus for
addresses. a period of > 250msec.
Deactivate and inhibit all hydraulic
functions.

CANBUS FAILURE - 6618 1 - The UGM does not detect the Power cycled.
CABIN DISPLAY cabin’s display on the CAN bus.

CANBUS FAILURE - 6619 1 N/A The UGM has detected an Power cycled.
UNKNOWN unknown module reporting a DM1
TROUBLE CODE or transfer protocol message.

CANBUS FAILURE - 6621 1 Display the fixed boom angle value The UGM or platform module has Power cycled.
BOOM ANGLE of “99” on the operator’s cabin lost communications with the
SENSOR display. Boom Angle Sensor.
Temporarily assign a fixed boom
angle value of 99°.
Disallow boom angle sensor
calibration (“BOOM ANGLE:
CALIBRATION FAIL”).
Ignore any hydraulic function
requests from the platform station.
Deactivate and inhibit the Lift Up
output if the platform is detected as
attached or PLATFORM MODE is
the current active mode; otherwise,
derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.

TILT SENSOR 81XXX - - - -

CHASSIS TILT 813 1 The UGM will not permit The PLAFORM OPTION is Successful tilt
SENSOR NOT PLATFORM MODE operation. configured as ENABLED and the calibration has
CALIBRATED UGM detects its on-board tilt been
sensor has not been calibrated. completed.

CHASSIS TILT 814 1 The UGM will not permit The PLAFORM OPTION is Power cycle.
SENSOR OUT OF PLATFORM MODE operation. configured as ENABLED and the (Replace
RANGE UGM detects the tilt sensor board)
reading is more than 19° for 4
seconds.

CHASSIS TILT 815 1 The UGM will not permit The PLATFORM OPTION is Power cycle.
SENSOR PLATFORM MODE operation. configured as ENABLED and the (Replace
DISAGREEMENT UGM detects the machine is board)
driving and a 3° difference
between tilt sensor for 5 seconds
or the UGM detects the machine is
not driving and a 1° difference
between tilt sensor for 2 seconds.

9.64 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

PLATFORM LOAD 82XXX - - - -

SENSE

LSS CELL #1 821 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active
Deactivate and inhibit the Lift Down and the PLATFORM OPTION is
output. ENABLED and a platform is
detected as attached and the LSS
Deactivate and inhibit the
module is reporting a error with
Telescope Out output.
regard to load cell #1.
Deactivate and inhibit the
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

LSS CELL #2 822 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active
Deactivate and inhibit the Lift Down and the PLATFORM OPTION is
output. ENABLED and a platform is
detected as attached and the LSS
Deactivate and inhibit the
module is reporting a error with
Telescope Out output.
regard to load cell #2.
Deactivate and inhibit the
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

40.8, 40.9 9.65

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

LSS CELL #3 823 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active
Deactivate and inhibit the Lift Down and the PLATFORM OPTION is
output. ENABLED and a platform is
detected as attached and the LSS
Deactivate and inhibit the
module is reporting a error with
Telescope Out output.
regard to load cell #3.
Deactivate and inhibit the
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.Deactivate and
inhibit the Platform Rotate Right
output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

LSS CELL #4 824 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active
Deactivate and inhibit the Lift Down and the PLATFORM OPTION is
output. ENABLED and a platform is
detected as attached and the LSS
Deactivate and inhibit the
module is reporting a error with
Telescope Out output.
regard to load cell #4.
Deactivate and inhibit the
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

9.66 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

LSS HAS NOT 825 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the A valid
BEEN CALIBRATED output. PLATFORM STATION is active calibration of
Deactivate and inhibit the Lift Down and the PLATFORM OPTION is the LSS
output. ENABLED and a platform is module is
detected as attached and the LSS completed.
Deactivate and inhibit the
module calibration has not been
Telescope Out output.
completed.
Deactivate and inhibit the
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

FUNCTIONS 829 1, 14 Deactivate and inhibit the Lift Up When the UGM or platform module When a rated
CUTOUT - output. detects an overloaded platform load of less
PLATFORM Deactivate and inhibit the Lift Down condition at 110% rated load and than 110% is
OVERLOADED output. the PLATFORM STATION is detected for a
selected and a platform is detected period of at
Deactivate and inhibit the
as attached and the LOAD least 2
Telescope Out output.
SENSING menu screen is seconds and
Deactivate and inhibit the configured as PLATFORM the platform
Telescope In output. CUTOUT. function
Deactivate and inhibit the Platform enable switch
Rotate Left output. is not
engaged.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

STEERING 86XXX - - - -

LOW STEERING 8638 1, 8 N/A J1-35 Steering Pressure is HIGH Until steer
PRESSURE for a period of 3 seconds or more pressure is re-
and an ENGINE RUNNING state established
must be detected for at least 5 (i.e. J1-35 is
seconds. LOW for a
period of 3
seconds).

<<< HARDWARE 99XXX - - - -

>>>

40.8, 40.9 9.67

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

LSS WATCHDOG 991 1 · Power cycle.

RESET (Replace
board)

LSS EEPROM 992 1 · Power cycle.

ERROR (Replace
board)

LSS INTERNAL 993 1 · Power cycle.

ERROR - PIN (Replace
EXCITATION board)

LSS INTERNAL 994 1 · Power cycle.

ERROR - DRDY (Replace
MISSING FROM board)
A/D

EEPROM FAILURE 998 1 Suspend all hydraulic function, The UGM has detected an Power cycle.
- CHECK ALL engine, and transmission operation. anomaly in EEPROM. (Replace
SETTINGS board)

FUNCTION 9910 1 Suspend all hydraulic function, The UGM has detected the Reprogram
LOCKED OUT - engine, and transmission operation platform module software major board and
PLATFORM from platform station only. (CABIN revision # is not compatible. power cycle.
MODULE STATION operation is permitted.) (Replace
SOFTWARE board)
VERSION
IMPROPER

FUNCTION 9911 1 Suspend all hydraulic function, The UGM has detected the LSS Reprogram
LOCKED OUT - LSS engine, and transmission operation module software major revision # board and
MODULE from platform station only. (CABIN is not compatible. power cycle.
SOFTWARE STATION operation is permitted.) (Replace
VERSION board)
IMPROPER

CHASSIS TILT 9915 1 The UGM will not permit The PLATFORM OPTION is Power cycle.
SENSOR NOT GAIN PLATFORM MODE operation. configured as ENABLED and the (Replace
CALIBRATED UGM detects the tilt gain values board)
necessary for calculating chassis
have been lost.

GROUND MODULE 9921 1 Suspend all hydraulics. The UGM detects an internal Power cycle.
FAILURE - HIGH hardware failure on J2-1, J2-13,
SIDE DRIVER and/or J1-23.
CUTOUT FAULTY

FUNCTIONS 9924 1 The UGM will not permit engine The UGM detects the MACHINE The MACHINE
LOCKED OUT - start. SETUP menu has never been SETUP menu
MACHINE NOT The UGM will not permit any entered, which is noted by the has been
CONFIGURED hydraulic function operation. MODEL menu screen being accessed and
configured to power is
"????????????????" (i.e. it is the cycled.
first time the board was powered
ON).

CURRENT 9944 1 The UGM will not permit engine The UGM has detected the current Power cycle.
FEEDBACK GAINS start. feedback gain calibrations have (Replace
OUT OF RANGE The UGM will not permit any been lost. board)
hydraulic function operation.

9.68 40.8, 40.9

 Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CURRENT 9945 1 The UGM will not permit engine The UGM has detected the current Power cycle.
FEEDBACK start. feedback calibration checksum is (Replace
CALIBRATION The UGM will not permit any incorrect. board)
CHECKSUM hydraulic function operation.
INCORRECT

CABIN DISPLAY 9946 1 N/A The UGM was not able to write/ Power cycle.
EEPROM WRITE reprogram the cabin display’s
FAILURE EEPROM.

HARDWARE 9947 1 Enter analyzer mode and take the The UGM has detected a data Complete a
EXCHANGE user directly to the "PERFORM mismatch between itself and the hardware
REQUIRED HARDWARE EXCHANGE?" menu. cabin’s display. exchange and
cycle power.

PLATFORM 9948 1 The UGM will not permit engine The platform module has detected Power cycle.
MODULE start from the platform. the cleaning current FET has
HARDWARE The UGM will not permit any failed.
FAILURE hydraulic function operation from
the platform.

MACHINE 9949 1 Suspend all hydraulic function, The UGM has detected an Use analyzer
CONFIGURATION engine, and transmission operation. anomaly in the EEPROM. and correct
OUT OF RANGE - parameter that
CHECK ALL is out of range.
SETTINGS

CABIN JOYSTICK - 9976 1 The UGM will not permit any The ITT cabin joystick reports a Power cycle.
INTERNAL hydraulic function operation. internal problem on the
FAILURE Operational Mode byte that is not a
hex value of 1, 2, 8, or 20.
(Reference ITT SRD)

LSS CORRUPT 9971 1 Deactivate and inhibit the Lift Up At power-up or immediately Power cycle
EEPROM output. thereafter, the platform module will
Deactivate and inhibit the Lift Down check the consistency of the
output. redundantly stored Platform
Unloaded Weight and the Platform
Deactivate and inhibit the
Maximum Allowed Load values.
Telescope Out output.
Deactivate and inhibit the
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.

EEPROM VALUE - 9978 1 Suspend all hydraulic function and The UGM has detected an Use analyzer
OUT OF RANGE engine operation, and command anomaly in the EEPROM. and correct
the transmission to neutral. parameter that
is out of range.

40.8, 40.9 9.69

 Electrical System

This Page Intentionally Left Blank

9.70 40.8, 40.9

 Der Nachdruck des Textes und der Abbildungen ist, auch auszugsweise, verboten.

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Der zeitliche Unterschied zwischen der Aktualisierung der Druckschriften und der Durchführung technischer Verände-
rungen (die ständig vorgenommen werden, um immer hochwertigere Erzeugnisse auf den Markt zu bringen) erfordern
aus Gründen der Korrektheit des Hinweises, dass die in dieser Ausgabe enthaltenen Daten jederzeit geändert werden
können und deshalb unverbindlich sind.

Le temps qui s’écoule entre la mise à jour en impression et les modifications techniques (ces dernières changeant con-
tinuellement afin d’offrir aux utilisateurs des produits toujours plus qualifiés) nous oblige a vous signaler que les donné-
es de la présente publication pourraient être susceptibles de variations. Elles sont données sans engagement de notre
part.

Because of the possible time lag between the introduction of technical modifications (an on-going process the aim of
which is to offer products which are being continually improved) and the latest update of the manual, we must point out,
for the sake of correctness,that the data contained in this edition are liable to change at any time and are therefore not
binding.

La differenza tra i tempi di aggiornamento in stampa e i tempi delle modifiche tecniche (variando queste ultime conti-
nuamente, ciò al fine di offrire prodotti sempre più qualificati) impongono di dichiarare, per correttezza, che i dati conte-
nuti nella presente edizione sono suscettibili di variazione in qualsiasi momento e che quindi non sono impegnativi.

La diferencia entre los tiempos necesarios para poner al dia la impresiòn y los tiempos de las modificaciones tècnicas
(las que se verifican continuamente, con el objeto de ofrecer productos cada vez màs calificados) nos imponen decla-
rar, por corrección, que los datos contenidos en la presente ediciòn estàn sujetos a variaciones en cualquier momento
y que portanto no son obligativos.

A diferença entre os tempos necessãrrios para actualizar a impressão e os tempos das modificacões técnicas (que se
verificam continuamente, a fim de oferecer um produto cada vez mais qualificado), obrigam-nos a declarar, que os da-
dos contidos neste manuel são susceptiveis de variacão em qualquer momento e que portanto não são vinculatórios.
NOTA
NOTA

12 - 2008 cod. 307.1143.3.6

By Personal computing Technical Publications Dep.
 307. 1143. 3. 6
12 - 2008