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 Operator/Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.8 Hazard/Emergency Information Decal Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 26.6 & 30.7 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.5 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.7 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.4 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.5 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.6 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
5.6 Steering Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16

26.6/30.7 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 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Section 7
Engine: Deutz BF 4M 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.9 Engine Exhaust and Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.11 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.6 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.9 Front Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.10 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.11 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
Section 9 .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Wire Code and Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.5 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.6 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.7 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.8 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.9 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.10 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.11 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.12 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.13 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.14 Analyzer Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26

ii 26.6/30.7
Section Subject Page

Accident Prevention Tags

26.6/30.7 iii
Section Subject Page

iv 26.6/30.7
 Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Operator/Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.5.1 Safety Alert Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.8 Hazard/Emergency Information Decal Locations. . . . . . . . . . . . . . . . . . . . . . . . . 1.7

26.6/30.7 1.1
 Safety Practices

1.1 INTRODUCTION Many factors contribute to unsafe conditions: carelessness,

fatigue, overload, inattentiveness, unfamiliarity, even
Same Deutz Fahr-Italia S.p.A. (hereafter, SDFI) actively drugs and alcohol, among others. Although equipment
promotes safe practices in the use and maintenance of its damage can usually be repaired in a brief period of time,
products through training programs, instructional death and irreparable injury are permanent. For optimal
manuals and the pro-active efforts of all employees safety, encourage everyone to think, and to act, safely.
involved in engineering, design, manufacturing, Appropriate service methods and proper repair
marketing and service. procedures are essential for the safety of the individual
This manual is designed to provide service technicians doing the work, for the safety of the operator, and for the
with complete information on the maintenance and repair safe, reliable operation of the machine. All references to
of the 26.6 and 30.7 Telescopic Material Handler. the right side, left side, front and rear are given from the
Particular effort has been made to produce a manual to operator’s seat looking in a forward direction.
serve as a reference handbook for the experienced Provisions for supplementary information are made by
service technician, but also provides essential step-by- SDFI in the form of Service Bulletins, Service Campaigns,
step procedures for the professional development of the Service Training Schools, the SDFI website, other
less experienced person. Remember, even the best literature, and through updates to the manual itself.
manual in the world is no substitute for an appropriate Comments and suggestions for improvement are
education, skill development that comes through welcome and encouraged.
experience alone, safety, wise and judicious All information, illustrations and specifications contained
discernment, and ultimately, proper performance of in this manual are based on the latest product information
service procedures. available at the time of publication approval. SDFI
This service manual provides general directions for reserves the right to make changes and improvements to
accomplishing service and repair procedures with tested, its products, and to discontinue the manufacture of any
effective techniques. Following the procedures in this product, at its discretion at any time without public notice
manual will help assure safety and equipment reliability. or obligation.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.2 OPERATOR/SAFETY MANUAL
procedures, rules, codes, regulations and laws. Prior to
performing any maintenance on the machine, consider all The machine must be driven and operated as a
factors, circumstances and conditions which can have an consequence of, or when performing, service,
effect upon the safety of personnel and equipment, and maintenance and test procedures. The service technician
take appropriate action to ensure the safety of all must, therefore, thoroughly read, understand, and follow
involved. the appropriate Operator/Safety Manual.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency
during operation, maintenance, or testing. When additional
information is desired to satisfy a situation not covered
sufficiently, consult your local SDFI distributor.

1.2 26.6/30.7
 Safety Practices

1.3 TRAINING MECHANICS AS 1.4 ACCIDENT PREVENTION TAGS

OPERATORS
Because it is necessary to move the machine to service
or maintain the machine, it is necessary that all
mechanics are trained and certified as operators. A
mechanic trained in the proper operation of the machine
can better determine whether all functions are operating
correctly.
At the time of original purchase, the purchaser of this
machine was instructed by the seller on its proper use.
When this machine is to be serviced or maintained by
someone other than the purchaser, make certain that the
mechanic is trained, in accordance with the regulations
listed in the NOTICE below, and reads and understands
the Model 26.6/30.7 Telescopic Material Handler
Operator/Safety Manual before operating or maintaining
the machine.
NOTICE: It is the responsibility of the employer to provide
operator training. Successful completion and certification
of Safety Training for Rough Terrain Forklifts is required. MC0690

Operator Training Kits are available by calling the local

SDFI distributor. Before beginning any maintenance or service, place an
In addition, make sure that the mechanic has completed Accident Prevention Tag on both the starter key switch
a walk-around inspection of the machine, is familiar with and the steering wheel, stating that the vehicle should not
all decals and/or decal plates on the machine, and has be operated. Actual Accident Prevention Tags, which can
demonstrated the correct use of all controls. be punched out and used, are included as the last page
in this manual. Retain these Accident Prevention Tags for
reuse at a later date.

26.6/30.7 1.3
 Safety Practices

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

The following information provides general safety Following are general safety statements to consider before
instructions, including examples of hazard statements performing maintenance procedures on a machine.
with signal words, notification of hazards, methods to Additional statements related to specific tasks and
help avoid hazards, and the consequences of failing to procedures are located throughout this manual and are
follow the safety information. To avoid possible death or listed prior to any work instructions to provide safety
injury, carefully read and follow all safety messages. Fully information before the potential of a hazard occurs.
understand the potential causes of death and injury. For all safety messages, carefully read, understand and
In the event of an accident, know where to obtain medical follow the instructions before proceeding.
assistance and how to use a first-aid kit and fire
extinguisher/fire suppression system. Keep emergency 1.6.1 Personal Hazards
telephone numbers (fire department, ambulance, rescue
HAIR and CLOTHING: DO NOT wear loose clothing or
squad/paramedics, police department, etc.) nearby. If
jewelry. Tie up or restrain hair. Wear the correct safety
working alone, check with another person routinely to
equipment for the job (including, but not limited to: hard
help assure personal safety.
hat; safety shoes; safety glasses, goggles, or face shield;
The information in this manual does not replace any other heavy gloves; hearing protection; reflective clothing; wet-
safety rules or proper judgement. Governmental weather gear; respirator or filter mask).
authorities and employers also have their own sets of
EYE PROTECTION: Always wear appropriate eye
rules, codes, regulations and laws. Before starting work
protection when chiseling, grinding, sanding, welding,
at a site, check with the supervisor or safety coordinator
painting, repairing hydraulic systems, or checking, testing
and ask about the safety policy. Learn the safety
or charging the battery.
requirements in effect before operating, maintaining,
testing or servicing the machine. Safety depends on BREATHING PROTECTION: Wear respiratory protection
following safety requirements. when grinding or painting.
HEARING PROTECTION: Always wear hearing protection
1.5.1 Safety Alert Symbol in a high noise area.
The exclamation mark within a triangle is the Safety Alert FOOT PROTECTION: Wear protective footwear with
Symbol. This symbol is used to indicate a potential reinforced toe caps and slip-resistant soles.
personal injury hazard only. The symbol will not be LIFTING: NEVER lift a heavy object without the help of at
used to indicate property-damage-only hazards. least one assistant or a suitable sling and hoist.

MC0700

This symbol means “Attention! Become Alert! Your

Safety is Involved!” The symbol is used to attract
attention to safety hazards found on the machine safety
decals and throughout this manual.

1.4 26.6/30.7
 Safety Practices

1.6.2 Equipment Hazards 1.6.3 General Hazards

Operator/Safety Manual: Before operating the machine, SOLVENTS: Only use approved solvents, and solvents
carefully read, understand and follow the Operator/Safety that are known to be safe for use.
Manual. HOUSEKEEPING: Keep the work area and operator’s
OPERATIONAL PROTECTION: Before operating the cab clean, and remove all hazards (debris, oil, tools, etc.).
machine, or returning it for operational use, check that the FIRST AID: Immediately clean, dress and report all injuries
Operator’s Protective Structure is intact, undamaged, (cuts, abrasions, burns, etc.), no matter how minor the
unmodified and secure. injury may seem. Know the location of a First Aid Kit, and
LIFTING OF EQUIPMENT: Before using any lifting know how to use it.
equipment (chains, slings, brackets, hooks, etc.), verify CLEANLINESS: Wear eye protection, and clean all
that it is of the proper capacity, in good working order, and components with a high-pressure or steam cleaner
is properly attached. before attempting service.
NEVER stand or otherwise become positioned under a When removing hydraulic components, plug hose ends
suspended load or under raised equipment. The load or and connections to prevent excess leakage and
equipment could fall or tip. contamination. Place a suitable catch basin beneath the
DO NOT use a hoist, jack or jack stands only to support machine to capture fluid run-off.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load. A 1.6.4 Operational Hazards
hoist or jack failure can allow the equipment to tip or fall.
OPERATIONAL CONSIDERATIONS: Before operating
COMPRESSED AIR: Before and during the use of the machine, carefully read, understand and follow the
compressed air, wear eye protection and advise all other Operator/Safety Manual.
personnel in the work area that compressed air is about
ENGINE: Stop the engine before performing any service.
to be used.
DANGEROUS START: Place Accident Prevention Tags
HAND TOOLS: Always use the proper tool for the job;
on the ignition key switch and the steering wheel before
keep tools clean and in good working order, and use
attempting to perform any service or maintenance.
special service tools only as recommended.
Disconnect battery leads. Place a warning sign on a
machine that is dangerous to start, if leaving machine
unattended.
VENTILATION: Avoid prolonged engine operation in
enclosed areas without adequate ventilation.
RADIATOR CAP: Always wear steam-resistant, heat
protective gloves when opening the radiator cap. Cover
the cap with a clean, thick cloth and turn slowly to the first
stop to relieve pressure.
SOFT SURFACES AND SLOPES: NEVER work on a
machine that is parked on a soft surface or slope (inclined
ground or hills). The machine must be on a hard level
surface, with the wheels blocked when performing any
service. Obtain assistance, block all wheels, and add
supports if necessary before beginning any work.
SUPPORTS AND STRAPS: Install safe, stable supports,
slings or straps beneath or around a component or
structural member before beginning any work.

26.6/30.7 1.5
 Safety Practices

FLUID PRESSURE: Before loosening any hydraulic or 1.7 EMERGENCY EXIT REAR WINDOW
diesel fuel component, hose or tube, turn the engine
OFF. Wear heavy, protective gloves and eye protection. The rear window in the enclosed cab can be used as an
NEVER check for leaks using any part of your body; use emergency exit by removing the latch pin (1) located on
a piece of cardboard or wood instead. If injured, seek the window latch (2). Once the latch pin is removed, the
medical attention immediately. Diesel fluid leaking under window is free to swing open.
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause
1 1.

infection, gangrene and other serious personal injury. 2.

3.

Relieve all pressure before disconnecting any

component, part, line or hose. Slowly loosen parts and 1
9
7
9
0
1
4

allow release of residual pressure before removing any 2

part or component. Before starting the engine or applying OH1730
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
appropriate container and dispose of in accordance with
prevailing environmental regulations.
PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
manner, and make changes or repairs as indicated by the
test procedure to achieve the desired result.
LEAVING machine: Lower the attachment to the ground
before leaving the machine.
TIRE PRESSURE: Always keep tires inflated to the
proper pressure to help prevent dangerous travel and
load-handling situations. DO NOT over-inflate tires.

1.6 26.6/30.7
 Safety Practices

1.8 HAZARD/EMERGENCY clean.

INFORMATION DECAL LOCATIONS If a replacement decal is needed, refer to the Operator/
Safety Manual or parts manual for the latest part number
Locations of machine hazard and other emergency and ordering information, or, contact your local SDFI
information decals are shown on this page and the distributor.
following pages. As part of routine maintenance, check
that ALL hazard and emergency information decals on
the machine are present and readable. Keep all decals

1
1

2
3

View of Engine MAH0730

Compartment

1. 8005675 Keep Clear From Under Boom

2. 8005670 lnstruction and Safety Decal
3. 8006038 No Riders On Attachment
4. 8005869 Keep Hands Clear of Moving Parts

26.6/30.7 1.7
 Safety Practices

2 3
1

MAH09 40

1. 8005675 Keep Clear From Under Boom

2. 8008657 Keep Clear of Area Between Frame and Wheel
3. 8005671 Do Not Work Under Boom Without Securing Hoist Cylinder
4. 8006612 Keep Clear of Behind Machine

1.8 26.6/30.7
 Safety Practices

2
1

8005671

5 4 3

8005870

View of Rear
Window MAH0750

1. 8005673 Keep Clear of Power Lines

2. 8005671 Do Not Work Under Boom Without Securing Hoist Cylinder
3. 8005672 Read Operator Manual Before Operating Machine
4. 8005674 Keep Clear From Under Boom
5. 8008651 No Riders On Attachment
6. 8005670 Instruction and Safety Decal
7. 8005870 Emergency Exit

26.6/30.7 1.9
 Safety Practices

This Page Intentionally Left Blank

1.10 26.6/30.7
 Section 2
General Information and Specifications

PARAGRAPH TITLE PAGE

2.1 26.6 & 30.7 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.1 Service Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.2 The Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.3 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3.2 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4.1 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4.2 Machine Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4.3 Attachment Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4.4 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4.5 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2.7
2.4.6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4.7 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.4.8 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.4.9 Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.1 Axle (Differential Housing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.2 Axle Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.5 Brakes (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.7 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.7.1 8 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.7.2 50 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

26.6/30.7 2.1
 General Information and Specifications

2.1 26.6 & 30.7 COMPONENT

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

Cab
First Boom
Section

Second Boom
Section

Wheel/Tire
Assembly

Engine
Compartment
Axle MAH0360

2.2 26.6/30.7
 General Information and Specifications

2.2 INTRODUCTION The machine serial number plate (1) is located on the
right side in front of the engine compartment.
2.2.1 Service Methods
Appropriate service methods and proper repair
procedures are essential for safe, reliable operation of
this machine and the safety of the individual doing the work.
This Service Manual provides general direction for
accomplishing service and repair work with tested,
effective techniques. Following them will assure reliability.
There are many variations in procedures, techniques,
tools and parts for servicing machine, as well as work
skills. This manual cannot possibly anticipate all such
variations and provide advice or cautions for each one.
Accordingly, anyone who intends to depart from the
instructions in this Manual must first consider personal 1
safety and then machine integrity.
IMPORTANT: SDFI recommends the use of
environmentally sound waste storage and disposal
practices. NEVER drain fluids on the ground or into a
sewer or catch basin. Use suitable collection containers,
MAH0310
then store and/or dispose of waste products in an
approved and safe manner. Check and obey all Federal,
State and/or Local regulations regarding waste storage,
disposal and recycling. IMPORTANT: The replacement of any part on this
machine with any other than a SDFI authorized
2.2.2 The Operator & Safety Manual replacement part can adversely affect the performance,
durability, or safety of the machine, and will void the
The Operator & Safety Manual provides information you warranty. SDFI disclaims liability for any claims or
need to properly operate and maintain this machine. damages, whether regarding property damage, personal
IMPORTANT: Before you operate this machine, read injury or death arising out of the use of unauthorized
the manual completely and carefully, so that you will replacement parts.
understand the safety instructions and the operation of A warranty registration form must be filled out by the SDFI
the controls and safety equipment. You must comply distributor, signed by the purchaser and returned to SDFI
with all Danger, Warning and Caution notices. They are when the machine is sold and/or put into use.
for your benefit.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
2.2.3 Replacement Parts and Warranty
guarantee full warranty service, verify that the distributor
Information
has returned the business reply card of the warranty
For reference when ordering replacement parts or making registration form to SDFI.
service inquiries about the machine, the machine serial
number is required to help assure the provision of correct 2.2.4 Disclaimer
parts and information. Before ordering parts or initiating
SDFI reserves the right to make changes to and to add
service inquiries, make note of the serial number.
improvements upon its product at any time, without public
notice or obligation. SDFI also reserves the right to
discontinue manufacturing any product at its discretion at
any time.

26.6/30.7 2.3
 General Information and Specifications

2.3 TORQUES

2.3.1 Fasteners
All fasteners (nuts, bolts, washers, etc.) are equal to SAE
Grade 5 (PC8.8) and are plated, unless otherwise specified.

2.3.2 Bolts and Nuts

Unless otherwise specified, the following values apply for
nuts and bolts:

Size Class 8.8 Bolts Class 10.9 Bolts

mm Torque, Nm Torque, Nm Torque, Nm Torque, Nm Torque, Nm Torque, Nm

(Dry or Loctite (Lubricated) (Loctite 242 or (Dry or Loctite (Lubricated) (Loctite 242 or
263) 271) 263) 271)

3 1.3 1.0 1.4 1.9 1.4 2.1

3.5 2.1 1.6 2.3 3.0 2.2 3.3

4 3.1 2.3 3.4 4.4 3.3 4.8

5 6.2 4.6 6.8 8.9 6.6 9.7

6 11 7.9 12 15 11 17

7 18 13 19 25 19 28

8 25 19 28 37 27 40

10 50 38 55 72 54 79

12 88 66 97 126 95 139
14 140 105 154 200 150 220

16 219 164 241 313 235 344

18 301 226 331 430 323 473

20 426 320 469 610 458 671

22 581 436 639 832 624 915

24 737 553 811 1060 792 1170

27 1080 810 1130 1540 1160 1690

30 1460 1100 1530 2100 1570 2310

33 1990 1490 2090 2600 2140 2860

36 2560 1920 2690 3660 2750 4020

42 4090 3070 4290 5860 4400 6440

2.4 26.6/30.7
 General Information and Specifications

2.4 SPECIFICATIONS

2.4.1 Machine Dimensions

a. Models 26.6 & 30.7 (With Standard Tires)

Description 26.6 30.7

(A) Standard Tire 405/70-20 405/70-24
(B) Length from Carriage Face 4,364mm (171.8") 4,915mm (193.5")
(C) Width 2,050mm (80.7") 2,300mm (90.6")
(D) Height (Boom Lowered) 2,180mm (85.8") 2,354mm (92.7")
(E) Wheelbase 2,690mm (105.9") 2,900mm (114.2")
(F) Tread Center 1,633mm (64.3") 1,893mm (74.5")
(G) Ground Clearance 496mm (19.5") 439mm (17.3")
(H) Turning Radius, Over Tires (All-Wheel Steer) 3,9m (153.54") 4,4m (171.75")
(I) Turning Radius, at Forks (All-Wheel Steer) 5,1m (200") 5,4m (212")

F
C E

B
A

MAH0180

26.6/30.7 2.5
 General Information and Specifications

2.4.2 Machine Weights

Note: All weights are with quick switch, standard carriage and forks and standard tires.

Description 26.6 30.7

Curb Weight 6,060 kg (13,360 lb) 7,207 kg (15,888 lb)
Front Axle 3,270 kg (7,209 lb) 3,840 kg (8,466 lb)
Rear Axle 2,790 kg (6,151 lb) 3,366 kg (7,422 lb)
Total 6,060 kg (13,360 lb) 7,207 kg (15,888 lb)

2.4.3 Attachment Weights

Note: Attachments listed below are for all models, except where specified.

1170001 - Std 48" Carriage 218 kg (481 lb)

Std 48" Carriage with 45 x 125mm Forks 362 kg (798 lb), (pair)
2340029 - 45 x125mm Forks 72 kg (159 lb), (each)
2340030 - 50 x 100mm Forks 64,1 kg (141.3 lb), (each)
2700097 - Fork Hook - 4 Ton 34 kg (75 lb), (each)
0240063 - Truss Boom - 3.4m - 1000 kg 250 kg (551 lb), (each)
0240110 - Truss Boom - 3.6m - 650 kg 205 kg (452 lb), (each)
2340034 - Fork Extension - 2m 44,1 kg (97 lb), (each)
0930001 - Bucket 1.0m³ 370 kg (816 lb)
0930002 - Bucket 2.0m³ 650 kg (1433 lb)
0930003 - Bucket 4 in 1 - 1m³,(30.7) 819 kg (1806 lb)
1170002 - Side Shift Carriage 410,6 kg (905 lb)
0930006 - Bucket 4 in 1 -,6m³,(26.6) 681,8 kg (1503 lb)
0930004 - Bucket Manure - 1m³,(30.7) 705 kg (1554 lb)
0930005 - Bucket Manure, (26.6) 636,2 kg (1403 lb)

2.4.4 Performance Specifications

Note: Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable.

Travel Speed (Standard Tires, No Load) 26.6 & 30.7

Fwd/Rev 4/4 35 km/hr (21.7 mph)

2.6 26.6/30.7
 General Information and Specifications

2.4.5 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.)

26.6 30.7
Crowd Cylinder Extend 5.66 7.09
Crowd Cylinder Retract 4.51 5.59
Hoist Lift Retracted 5.87 8.05
Hoist Lower Retracted 3.79 5.55
Attachment Tilt - UP 2.48 4.30
Attachment Tilt - DOWN 1.97 3.32

2.4.6 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 600,44
Alternator 14V, 70 Amps
Starter 12V, 3,0 KW Type EV (Gear Reduction)

26.6/30.7 2.7
 General Information and Specifications

2.4.7 Engine Performance Specifications

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

Description 26.6 30.7

Engine Make/Model Deutz BF 4M 2012 Deutz BF 4M 2012
Low Idle 925 ±50 rpm 925 ±50 rpm
High Idle 2370 ±50 rpm 2370 ±50 rpm
Horsepower 85.8 BHP/ 64 kW 100.4 BHP/ 74.5 kW
@ 2200 rpm @ 2200 rpm
Fuel Delivery Fuel Injection Fuel Injection
Air Cleaner Dry Type, Replaceable Dry Type, Replaceable
Primary and Safety Primary and Safety
Elements Elements

2.4.8 Tires

Description 26.6 30.7

Wheel Lug Nut Torque 300 Nm (221 lb-ft) 300 Nm (221 lb-ft)
Standard Tire Size 405/70-20 MPT-01 405/70-24 MPT-01
Standard Tire Air Pressure (Minimum) 350 kPa (51 psi) 400 kPa (58 psi)
Optional Tires
Optional Tire Size 405/70-24 MPT-01 17,5-24 MPT-01
Optional Tire Air Pressure (Minimum) 400 kPa (58 psi) 220 kPa (32 psi)

2.4.9 Fork Ratings

All approved forks for this machine are marked with a
maximum load capacity rating. This rating is stamped on
the left edge of the fork (1), just below the fork pivot shaft
(2). The rating is based on a 500 mm (19.6") load center 3
(3).
This rating specifies the maximum load capacity that the
individual fork can safely carry at a maximum load center 1
of 500 mm (19.6").
Since forks are always used in multiples, the total rating
of any combination of forks is the sum of their rated
capacities. 2
Other than block forks, use all forks in matched pairs. Use
block forks in matched sets.
MZ0560

2.8 26.6/30.7
 General Information and Specifications

2.5 FLUIDS, LUBRICANTS AND c. Engine Coolant

CAPACITIES • 50/50 mix of Akros Farm Flu and water

2.5.1 Axle (Differential Housing) d. Engine Coolant Capacity

Capacity w/o Heater........................ ....15 liters (15.5 qt)
a. Axle Differential Housing Lubricants
• Akros Farm Flu 2.5.4 Fuel

b. Axle Differential Housing Capacity a. Diesel Fuel

26.6 • Standard #2 Diesel Fuel

Axle differential housing (front axle) ........8 liters (8.4 qt)
b. Fuel Tank Capacity
Axle differential housing (rear axle) .........5 liters (5.3 qt)
26.6.........................................................95 liters (25 gal)
30.7
30.7.......................................................102 liters (27 gal)
Axle differential housing (front axle) .....8,1 liters (8.5 qt)
Axle differential housing (rear axle) ......7,9 liters (8.3 qt) 2.5.5 Brakes (service)

2.5.2 Axle Wheel Ends a. Brake Fluid

• ATF
a. Axle Wheel End Lubricants
• Akros Farm Flu b. Master Cylinder Capacity
• DO NOT add additional friction modifier to fac- Capacity .......................................... ... 0,7 liters (0.7 qt)
tory-filled wheel ends. All wheel ends are factory-
filled by the manufacturer with oil. If a wheel end is 2.5.6 Hydraulic System
drained for service, it should be refilled with the
gear oil listed. a. Hydraulic Fluids
Note: DO NOT use synthetic oil without the expressed • Akros Multi FCT Tractor / Hydraulic Fluid
written consent of the manufacturer.
b. Hydraulic System Capacity
b. Axle Wheel End Capacity
26.6
The capacity listed below is for one wheel end
System Capacity ........................... ... 106 liters (28 gal)
26.6
Reservoir Capacity to FULL Mark ........ 65 liters (17 gal)
Axle wheel end (front axle) .................0,8 liters (0.84 qt)
30.7
Axle wheel end (rear axle)..................0,8 liters (0.84 qt)
System Capacity ........................... ... 133 liters (35 gal)
30.7
Reservoir Capacity to FULL Mark ........ 87 liters (23 gal)
Axle wheel end (front axle) .................0,65 liters (0.7 qt)
Axle wheel end (rear axle)..................0,65 liters (0.7 qt)

2.5.3 Engine

a. Engine Crankcase Oil

• Akros Turbo Engine Oil

b. Engine Crankcase Capacity

Capacity w/filter change ......................10 liters (10.6 qt)

26.6/30.7 2.9
 General Information and Specifications

2.6 MAINTENANCE SCHEDULES 2.6.2 50, 250 & 500 Hour Maintenance
Schedule
2.6.1 8 & 1st 50 Hour Maintenance Schedule

EVERY
50

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

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

Change Engine Check Axle Check Wheel Air Filter Check

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

1st
50 Check Boom
Bearing
Pads
LB/FT
(Nm
)

EVERY
Change
Axle Oil
Change Wheel
End Oil
Change Engine
Oil & Filter
Check Wheel
Lug Nut 500
Torque

LB/FT
(Nm)

Change Fuel Check Wheel

Filters Lug Nut
Torque
MAH0880
OAH0371

Note: In order to gain access to the engine fuel filter, the 2.6.3 1000 & 1500 Hour Maintenance
oil filter must be removed. It is best to replace both of Schedule
these filters at the same time.

EVERY
1000

Change Change Wheel

Axle Oil End Oil

EVERY
1500

Change Change Change Change

Engine Coolant Hydraulic Hydraulic Tank Brake Fluid
Fluid & Filters Breather
OAH0050

2.10 26.6/30.7
 General Information and Specifications

2.7 LUBRICATION SCHEDULES

2.7.1 8 Hour Lubrication Schedule

EVERY Akros Grease TLH

8

MAH0820

26.6/30.7 2.11
 General Information and Specifications

2.7.2 50 Hour Lubrication Schedule

EVERY
Akros Grease TLH
50

MAH0830

2.12 26.6/30.7
 Section 3
Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.2 Second Section Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.4 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.5 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.5.1 Disconnecting from an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.5.2 Connecting to an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.5.3 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.5.4 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

26.6/30.7 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.

Compensation
Cylinder

First
Boom
Section

Pivot Pin

Second
Boom
Section

Access Crowd
Panel Cylinder

Tilt
Cylinder
MAH0140

Quick
Switch

3.2 26.6/30.7
 Boom

3.2 BOOM SYSTEM - TWO SECTION 3.3 BOOM ASSEMBLY MAINTENANCE

BOOM
The boom assembly consists of the first and second
section booms and supporting hardware.
3.2.1 Boom System Description
IMPORTANT: Boom replacement must be completed in
The boom operates via an interchange among the sequence, one boom section at a time, as described in
electrical, hydraulic and mechanical systems. Components these instructions.
involved include the joystick, Tilt cylinder, Crowd cylinder,
Hoist cylinder, Compensation cylinder, electronic IMPORTANT: Before removing the boom, the carriage
sensors, various pivots, supporting hardware and other or any other attachment must be removed from the quick
components. attach.
Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.
After servicing the boom, perform the following:
1. Check wear pads. (Refer to the Operator & Safety
Manual.)
2. Apply grease at all lubrication points (grease fittings).
(Refer to the Operator & Safety Manual.)
3. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.

26.6/30.7 3.3
 Boom

3.3.1 Boom Removal

1. Remove any attachment from the quick attach
assembly. (Refer to Section 3.5.1, “Disconnecting
from an Attachment.”)

1
WARNING: Wear protective
footwear with reinforced toe caps and slip-
resistant soles. Failure to comply can result in 2
foot or other bodily injury from crushing,
slipping or falling. MAH0140

9. Remove the lock bolt and pivot pin (2) from rear of
WARNING: NEVER lift a heavy first boom section.
object without the help of at least one assistant 10. Lower the boom to a level position and place a
or a suitable sling and hoist. Failure to comply suitable support under the boom head. Reposition
can result in death or serious personal injury. the slings to each end of the boom.
2. Park the machine on a hard, level surface. Be sure 11. Lift the complete boom off machine and set on level
there is enough room in front of the machine to allow ground of supports being careful not to damage the
the boom sections to be removed. tubes on the side of the boom.
3. Set the quick switch assembly in a vertical position
3.3.2 Second Section Boom Removal
and set on a hard level surface. Remove lock bolt
and pin from rod end of tilt cylinder. Remove four self
locking bolts and covers from each side of the quick WARNING: Wear protective
switch assembly. Remove pivot pin from either side footwear with reinforced toe caps and slip
of quick switch and raise boom away. resistant soles. Failure to comply can result in
foot or other bodily injury from crushing,
4. Fully retract and raise the boom to access the rod
slipping or falling.
end pin of hoist cylinder. Place the travel select lever
in (N) NEUTRAL, engage the parking brake and shut
the engine OFF. Allow the hydraulic oil to cool before WARNING: NEVER lift a heavy
proceeding. object without the help of at least one assistant
5. Make sure the key is removed from the ignition and or a suitable sling and hoist. Failure to comply
the “DO NOT OPERATE” tag is placed in clear view can result in death or serious personal injury.
in the cab.
1. Set the complete boom on level ground and by
6. Disconnect the tilt, auxiliary and crowd hydraulic repositioning the slings turn boom over on to the top
hoses attached to the machine. Plug and cap the side. Set the complete boom on suitable stands to
hose ends to prevent dirt and debris from entering begin tear down.
the hydraulic system.
Note: With the complete boom setting upside down, the
Note: Tag or identify each hose to the corresponding second boom section, tilt cylinder and hoses are made
fitting it was removed from. more accessible. This also eliminates the need to
7. Remove the lock bolt and pin (1) from the rod end of remove the hose rack on the bottom of the boom.
the compensation cylinder on the first boom section. 2. At the boom head, attach a sling through rod end of
Rest the cylinder on the machine frame. tilt cylinder. Remove both hoses from tilt cylinder.
8. Support the front of the boom by placing a sling Plug the hose ends and cap the tilt cylinder fittings to
behind the boom head. Support the hoist cylinder prevent dirt and debris from entering the hydraulic
and remove the lock bolt and then the rod end pin. system. Remove the clip from barrel end of tilt
Lower the hoist cylinder onto the frame rails. cylinder pin. Remove the tilt cylinder pin and lift the
tilt cylinder out of the boomhead.
3. At the access panel on the bottom front of the boom,
unscrew the tilt and auxiliary hoses. Plug the hose

3.4 26.6/30.7
 Boom

ends to prevent dirt and debris from entering the 3.3.3 Second Section Boom Installation
hydraulic system.
Note: Tag or identify each hose to the corresponding WARNING: Wear protective
fitting it was removed from. footwear with reinforced toe caps and slip
resistant soles. Failure to comply can result in
4. Carefully pull the tilt, auxiliary and crowd hydraulic
foot or other bodily injury from crushing,
hoses (3) through the rear of the second boom
slipping or falling.
section.

WARNING: NEVER lift a heavy

object without the help of at least one assistant
or a suitable sling and hoist. Failure to comply
can result in death or serious personal injury.

1. Insert the crowd cylinder through the rear of the

second boom section and attach the pin and clip to
the rod end.
3 2. Install the bottom rear wear pads, washers and bolts
into the first boom section. Apply Loctite® #242 and
torque to 90 Nm (66 lb-ft). Install the bottom rear left
and right side wear pads, backing plate and bolts (do
not shim or tighten bolts). Install top rear wear pads,
backing plates and bolts (front bolts are drilled and
tapped for zerk fittings, do not shim or tighten bolts).
MAH0660
3. Grease the inside of the first boom section on areas
5. Remove the clip and pin from barrel end of the where the second boom section wear pads will slide.
crowd cylinder.
4. Using a suitable sling, balance the second boom
6. Pull the second section boom out 15 cm to 20 cm (6” section and carefully slide 1 m to 1.5 m (3’ to 4’) into
to 8”) to be able to loosen and remove all the bolts the front of the first boom section. Set the second
and remove all the wear pads, backing plates and boom section head onto suitable support and reset
shims from the front inside of the first section boom. sling under the boom head of the second section.
Tag each pad, backing plate, shim and bolts from Carefully slide the second section into the first
each location. section. Leave 15 cm to 20 cm (6” to 8”) of the
second section out to be able to install wear pads in
WARNING: NEVER weld or drill the front of the first boom section.
boom. The structural integrity of the boom will 5. With the sling still under the boom head, install the
be impaired if subjected to any repair involving top wear pads, washers and bolts in the front of the
welding or drilling. Failure to comply can result first boom section. Apply Loctite ® #242 and torque
in death or severe personal injury. to 90 Nm (66 lb-ft). Lower the second boom section
and install the bottom wear pads, backing plates,
7. Inspect the boom and welds. Consult the your local shims and bolts in the front of the first boom section.
SDFI distributor if structural damage is detected. Apply Loctite® #242 and torque to 90 Nm (66 lb-ft).
8. Inspect hoses, hardware, wear pads, mounting Install both left and right side front wear pads,
points and other components visible with the first backing plates, shims and bolts in the front of the
boom section. Replace any item if damaged. first boom section. Apply Loctite ® #242 and torque
9. Inspect all wear pads for wear. (Refer to Section to 90 Nm (66 lb-ft).
3.4.1, “Wear Pad Inspection.”) Note: Shim ALL side wear pads as needed to maintain
10. Remove the clip and pin from the rod end of the a minimum gap in the horizontal direction or a tight fit.
crowd cylinder and pull through the rear of the The number of shims can vary at each shim point.
second boom section.

26.6/30.7 3.5
 Boom

IMPORTANT: Light lubrication of the boom wear

surfaces with a factory authorized grease is
recommended to keep the boom wear surfaces
lubricated properly.
6. Tighten all rear wear pad bolts after ensuring the
minimum gap requirements have been met. Refer to
Section 3.4.1, “Wear Pad Inspection.”
7. Insert the pin and clip into the barrel end of the
crowd cylinder.
8. Slide the tilt and auxiliary hoses between the boom MAH0140
sections.
4. With the sling still in place, install the rod end of the
9. Remove the caps from the fittings on the tilt and
hoist cylinder, pin and lock bolt. Apply Loctite® #242
auxiliary hoses and attach to their appropriate
and torque to 90 Nm (66 lb-ft).
fittings on the tube ends.
Note: Raising the boom up or down with the sling may
3.3.4 Boom Installation be necessary so the boom, compensation and hoist
cylinder bores can be aligned for easier pin installation.
WARNING: Wear protective Note: Grease the boom pivot bore, compensation
footwear with reinforced toe caps and slip cylinder rod ends, hoist cylinder rod end and pins before
resistant soles. Failure to comply can result in installing.
foot or other bodily injury from crushing,
slipping or falling. 5. Remove the caps from the crowd cylinder fittings
and plugs from crowd cylinder hoses. Attach each
hose to the crowd cylinder fittings and tighten until
wrench-tight. Then tighten each hose firmly 1 to 1,5
WARNING: NEVER lift a heavy flats.
object without the help of at least one assistant 6. Remove the caps from both the tilt and auxiliary
or a suitable sling and hoist. Failure to comply hoses. Attach both sets to their appropriate tubes
can result in death or serious personal injury. until wrench-tight. Then tighten each hose firmly 1 to
1,5 flats.
IMPORTANT: Light lubrication of the boom wear
surfaces with a factory authorized grease is 7. Start the engine and operate all boom functions
recommended to keep the boom wear surfaces several times to bleed any air out of the hydraulic
lubricated properly. Light lubrication of the boom wear system. Check for leaks, and check the hydraulic
surfaces is also recommended when the machine is fluid level in the reservoir; add fluid if required.
stored, to help prevent rusting. 8. Clean up all debris, hydraulic fluid, etc., in, on, near
1. Park the machine on a hard, level surface. Make and around the machine.
sure that the park brake is set, key is removed from
the ignition and “DO NOT OPERATE” tag is placed
in clear view in the cab.
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
frame pivot bore with the boom assembly pivot bore.
Install boom pivot pin. Apply Loctite® #242 and
torque to 90 Nm (66 lb-ft).
3. With the sling still in place, reconnect the
compensation cylinder, pins and lock bolts. Apply
Loctite® #242 and torque to 90 Nm (66 lb-ft).

3.6 26.6/30.7
 Boom

3.4 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear
pads with metal inserts.
On the 26.6 and 30.7 a total of 16 wear pads are installed 6
on the outer boom.

3.4.1 Wear Pad Inspection

Inspect all wear pads (3) for wear. If the angle
indicators (4) 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.

MAH0870
4
4
Use shims (6) under the wear pads as required to maintain
a maximum gap of 1,5 mm (0.06") (7) between the wear
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”).
Shims are available in four thicknesses, 0,5mm (0.02'),
3 MA2070 1 mm (0.04”), 1,5mm (0.06”) and 2,0mm (0.08”).

3.4.2 Boom Wear Pad Replacement

7
When replacing a wear pad on the boom, replace both
wear pads on that side of the boom; e.g.: replace top front
left and top front right wear pads at the same time.
Usually, shimming will remain the same when installing
new wear pads. All wear pads are secured to the boom 6
using different capscrews and washers. When installing
new wear pads, apply Loctite® #242 to all wear pad
mounting capscrews and torque to 50 Nm (36 lb-ft).
Grease the new pads and surrounding area.
The boom wear pads (5) are mounted on the inside of the MU4080

first boom section and the outside of the second boom

section (6). 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 greaseis recommended
to keep the boom wear surfaces lubricated properly. Light
5 lubrication of the boom wear surfaces is also
recommended when the machine is stored, to help
prevent rusting.

MAH0300

26.6/30.7 3.7
 Boom

3.5 QUICK ATTACH ASSEMBLY 3.5.3 Quick Attach Removal

1. Remove the lock bolt holding the tilt cylinder rod end
This machine is equipped with a quick attach system for
pin to the quick switch assembly. Remove the tilt
easy attachment changes.
cylinder pin.
3.5.1 Disconnecting from an Attachment 2. Support the quick switch assembly. Remove the four
bolts and covers from each end of the quick switch
1. Park the machine on a hard, level surface. assembly. Remove the pin from the quick switch
2. Ground the attachment, place the travel select lever assembly from either side.
in the (N) NEUTRAL position and engage the 3. Inspect the above pin for nicks or surface corrosion.
parking brake. Use fine emery cloth to fix minor nicks or corrosion.
3. Extend the boom approximately 3,05 m (10 ft) and If damaged or if it cannot be repaired the pin must be
tilt the carriage backward. Shut the engine OFF. replaced.
Note: If removing a standard carriage with forks, spread
3.5.4 Quick Attach Installation
the forks apart on the carriage shaft. This will help give
the carriage better support to stand alone. 1. Assemble the quick attach to the boom head. Line
up the quick switch between the mounts on the
4. Lower the attachment to the ground in a level
boom head. The quick switch should be centered in
position. Tilt the attachment forward. This will rotate
the boom head.
the quick attach link back away from the attachment.
2. Coat the quick switch pivot pin with an anti-seize
5. Lower and then retract the boom until the
compound. Insert the quick switch pivot pin through
attachment pivot pins have disconnected from the
the quick switch and boom head. Replace the end
attachment.
covers and four bolts to each end of the quick
switch.
3.5.2 Connecting to an Attachment
3. Align the quick switch with the tilt cylinder rod end
1. Perform this procedure on a hard, level surface only. and insert the tilt cylinder pin. Align the tilt cylinder
Position the machine directly behind the attachment pin and screw in the locking bolt. Torque as required.
to be mounted.
2. Tilt the quick attach backward.
3. Extend the boom approximately 3,05 m (10 ft) and drive
the machine forward until the attachment pivot pins
are below and between the two hooks on the
attachment.
4. Raise the boom until the attachment pivot pins have
seated fully in the hooks on the attachment.
5. Tilt the attachment up slightly. The quick attach link
should be tight up against the rear of the attachment,
and the holes in the link and the attachment should
be aligned.

WARNING: DO NOT operate the

machine unless you are in the operator’s seat
with the seat belt fastened around you. Death or
serious injury could result if the seat belt is not
securely fastened.

6. Return to the cab, fasten the seat belt and resume

operation.

3.8 26.6/30.7
 Boom

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

Boom Troubleshooting

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. Crowd hydraulic system not 2. Refer to Section 8, “Hydraulic
operating properly. System.”
3. Faulty Crowd cylinder. 3. Repair cylinder (Refer to Section
8.11.4, “Cylinder Inspection.”)

2. Boom will not fully extend. 1. Crowd hydraulic system not 1. Refer to Section 8, “Hydraulic
operating properly. System.”

3. Boom shifts to right or left 1. Boom pivot pin improperly 1. Re-shim the boom to a maximum
when extending. shimmed. total gap of .10" (2.5 mm) with
shims distributed evenly on both
sides of the boom pivot pin.
2. Incorrect wear pad gap or 2. Shim wear pads to correct gap.
shimming, or wear pads Replace wear pads as needed.
excessively worn. 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 appropriate owners
manual for lubrication points.)
Replace worn pins as needed.
2. Worn bearing(s). 2. Replace bearing(s) and
lubricate at regular intervals
(Refer to appropriate owners
manual for lubrication points.)

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. Hoist hydraulic system not 2. Refer to Section 8, “Hydraulic
operating properly. System.”
3. Faulty Hoist cylinders. 3. Repair cylinder. (Refer to
Section 8.11.4, “Cylinder
Inspection.”)
4. Seized boom pivot pin bearing. 4. Replace bearing.

26.6/30.7 3.9
 Boom

Boom Troubleshooting (Continued)

Problem Cause Remedy

6. Rapid boom pad wear. 1. Incorrect wear pad gap. 5. Check wear pad gaps and
correct as needed. Refer to
Section 3.4.2, “Boom Wear Pad
Replacement.”
2. Rapid cycle times with heavy 6. Reduce cycle times.
loads.
3. Contaminated, corroded or 7. 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/ 8. 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 26.6/30.7
 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 Operator’s Cab Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.1 Steering Wheel, Column and Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.2 Steering Column/Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.3 Brake Pedal and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.4 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.5 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.6 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3.7 Windshield Washer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3.8 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

26.6/30.7 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.

Windshield
Wiper/Horn Lever

Transmission
Joystick
Travel and Gear
Selector Lever

Brake Fluid
Reservoir

Steering
Column Tilt
Adjustment

Heater Controls

Parking Brake MAH0150

MH3321

4.2 26.6/30.7
 Cab and Covers

4.3 CAB COMPONENTS

WARNING: DO NOT service the
machine without following all safety
precautions as outlined in the “Safety 4.3.1 Steering Wheel, Column and Shifter
Practices” section of this manual. Failure to
follow the safety practices may result in death a. Steering Wheel Removal
or serious injury. 1. Park the machine on a firm, level surface. Level the
machine, ground the attachment, place the travel
4.2 OPERATOR’S CAB select lever in the (N) NEUTRAL position, engage
the parking brake and shut the engine OFF.
4.2.1 Operator’s Cab Description 2. Place an Accident Prevention Tag on the ignition key
switch, stating that the machine should not be
The welded metal cab features a modular design, allowing operated.
for a relatively quick, simple exchange of the entire cab
and/or component parts. The cab is bolted directly to the 3. Disconnect the battery negative (-) cable or cables at
frame. the battery negative (-) terminal.

The operator’s cab is a protective structure. The cab itself 4. Carefully pry the center button (18) out of the
contains rollover protective and falling object protective steering wheel.
structures (ROPS/FOPS) for the operator. 5. Mark the steering wheel and shaft to ensure proper
installation. Remove the nut (19) securing the steering
WARNING: The protection offered wheel (20) to the splined steering column shaft.
by this ROPS/FOPS will be impaired if 6. Use a steering wheel puller to remove the steering
subjected to any modification or structural wheel (20) from the splined shaft.
damage, at which time replacement is
necessary.
18
20
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural
components requires cab replacement. The lives of the
operator and others are potentially at stake.
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
The cab contains the seat, operating controls, numerous
panels, steering and brake components, and more.
Covers and mirrors on the machine exist for safety,
protection and appearance. They are relatively simple to
remove and replace.

4.2.2 Serial Number Decal

The cab serial number decal is located inside the cab, MAH0430
19
under 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
b. Steering Wheel Installation
in a convenient location to use in cab correspondence.
1. Install the steering wheel (20) onto the splined
steering column shaft.
2. Secure the steering wheel with the nut (19).
3. Press the center button (18) onto the steering wheel.
4. Connect the battery negative (-) cable or cables.

26.6/30.7 4.3
 Cab and Covers

4.3.2 Steering Column/Valve Replacement

a. Steering Column and Valve Removal 1

2
1. Park the machine on a firm, level surface. Level the
machine, ground the carriage, place the travel select
lever in the (N) NEUTRAL position, engage the
parking brake and turn the engine OFF.
4
2. Place an Accident Prevention Tag on the ignition key
3
switch, stating that the machine should not be
operated.
3. Open the engine compartment. Allow the engine and
hydraulic fluid to cool.
4. Disconnect the battery negative (-) cable at the 5
battery negative (-) terminal.
5. Remove the steering wheel (1) and travel select
lever (2). MAH0610

6. Remove the steering column tilt knob (3).

9. Remove the two pivot bolts for the steering column
7. Remove the lower dash panel. and steering orbitrol valve.
8. Label, disconnect and cap the hydraulic hoses (4) 10. Pull the steering column assembly from the machine
connected to the steering orbitrol valve (5). cab.
11. Remove the four hex-flange capscrews connecting
WARNING: Hydraulic fluid leaking the orbitrol valve to the steering column.
under pressure can penetrate the skin, cause
infection, gangrene, and death or serious b. Steering Column and Valve Installation
personal injury. If injured, see a doctor
immediately. 1. Install the orbitrol valve onto the steering column.
Torque the four capscrews to 18 Nm (13 lb-ft).
Relieve all pressure before disconnecting any Position the steering valve in the cab, with the ports
component, part, line or hose. Slowly loosen pointing toward their original orientation.
parts and allow release of residual pressure
before removing any parts or component. 2. Secure the assembly with the two pivot bolts.
Note: ALWAYS use new o-rings when servicing the
machine.
WARNING: Wait for the hydraulic
fluid to cool before servicing any hydraulic 3. Install new o-rings into the fittings. Lubricate the o-
component. Hot hydraulic oil can cause severe rings with clean hydraulic oil.
burns. 4. Connect the previously labeled hydraulic hoses to
their appropriate ports.
5. Install the steering column tilt knob.
6. Install the steering wheel and travel select lever.
Refer to Section 4.3.1, “Steering Wheel, Column and
Shifter.”
7. Connect the battery negative (-) cable to the battery
negative (-) terminal.

4.4 26.6/30.7
 Cab and Covers

8. Carefully examine all connections one last time

before engine start-up. Rectify any faulty conditions.
2
WARNING: Hydraulic oil under
pressure can penetrate the skin and cause
severe personal injury. DO NOT use your hand
or any part of your body to check for hydraulic
leaks. When checking the hydraulic leaks, wear
safety glasses and gloves to help provide
protection from spraying hydraulic oil. Use a
piece of cardboard or paper to search for leaks. 1

9. Start the engine and check the operation of the

steering system. Check for hydraulic fluid leaks.
MAH0600
Check the hydraulic fluid level in the tank and add
fluid as required.
6. Remove the two capscrews (1) securing the brake
10. Install the lower dash panel. pedal to the inching valve.
c. Power Steering Test 7. Remove the circlip (2), flat washer, and the return
spring securing the service brake pedal to the cab.
Conduct a pressure check of the steering hydraulic
8. Remove the clip/pin from the brake plunger fork link.
circuits at the test port on the implement pump.
9. Remove the service brake pedal from the cab.
4.3.3 Brake Pedal and Valve
d. Service Brake Pedal Installation
a. Brake Valve Removal 1. Position the service brake pedal in its mounting
Refer to Section 8.10.2, a. “Service Brake Valve location within the cab.
Removal,” for removal information. 2. Install the brake pedal being careful to reposition the
brake plunger yoke. Install the return spring, washer and
b. Brake Valve Installation clip. Install clip/pin in brake plunger fork link.
Refer to Section 8.10.2, b. “Service Brake Valve 3. Adjust the brake pedal as needed.
Installation,” for installation information. 4. Install and secure the lower dash cover.
c. Service Brake Pedal Removal 5. Connect the battery negative (-) cable or cables to
the battery negative (-) terminal.
1. Park the machine on a firm, level surface. Level the
machine, ground the attachment, place the travel
select lever in the (N) NEUTRAL position, engage
the parking brake and shut the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Unlock and open the engine compartment. Allow the
engine and hydraulic fluid to cool.
4. Disconnect the battery negative (-) cable or cables at
the battery negative (-) terminal.
5. Remove the lower dash panel.

26.6/30.7 4.5
 Cab and Covers

4.3.4 Throttle Pedal Replacement c. Throttle Adjustment

1. From within the cab, lightly depress the accelerator
a. Throttle Pedal Removal
pedal (18) to the full-throttle position . As needed,
1. Park the machine on a firm, level surface. Level the adjust the limit-stop screw (19) until it touches the
machine, ground the attachment, place the travel pedal. Tighten the locknut (20).
select lever in the (N) NEUTRAL position, engage
the parking brake and shut the engine OFF.
2. Place an Accident Prevention Tag on both the 18
ignition key switch and steering wheel, stating that
the machine should not be operated.
19
3. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
20
4. Remove three capscrews, three lockwashers
securing the throttle pedal assembly to the cab floor.
5. Remove the hex jam nut and flat washer securing
the throttle cable to the throttle pedal assembly.
6. Remove the clip/pin from the fork link.
7. Remove the throttle pedal assembly from the cab.
MA01912

IMPORTANT: During the full throttle check:

• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep the transmission in (N) NEUTRAL.
2. Check the engine rpm at full throttle. If the rpm is not
2370 ±50 rpm, readjust the throttle limit-stop screw
at the throttle pedal within the cab.
MS0930
4.3.5 Joystick Assembly Replacement

b. Throttle Pedal Installation Joystick Assembly Removal

1. Install the hex jam nut and flat washer onto the end 1. Park the machine on a firm, level surface. Set the
of the throttle cable. Secure the cable to the throttle park brake, ground the carriage, place the travel
pedal. Secure with the cable clamp and two select lever in the (N) NEUTRAL position, engage
locknuts. the parking brake and turn the ignition OFF.
2. Align the throttle pedal assembly with its mount 2. Place an Accident Prevention Tag on both the
holes on the cab floor. ignition key switch and steering wheel, stating that
3. Install three capscrews securing the throttle pedal the machine should not be operated.
assembly to the cab floor. Torque the capscrews to 3. Disconnect the battery negative (-) cable or cables at
12 Nm (9 lb-ft). the battery negative (-) terminal.
4. Connect the battery negative (-) cable to the battery 4. Remove the two capscrews. Remove the bottom
negative (-) terminal. cover. Disconnect the electrical connections and
remove the four self-tapping screws from the bottom
of the joystick assembly.
5. Remove the joystick assembly.

4.6 26.6/30.7
 Cab and Covers

Joystick Assembly Installation 4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
1. Set the joystick assembly into the armrest support.
2. Install the four self-tapping screws. Connect the
electrical connections.
WARNING: The cooling system is
under pressure, and escaping coolant can
3. Reconnect the battery negative cable(s). cause severe burns and eye injury. To prevent
personal injury, NEVER remove the radiator
4. Test the boom joystick functions:
cap while the cooling system is hot. Wear
a. Move the joystick handle rearward, activating the safety glasses. Turn the radiator cap to the first
boom lift function. The boom should RISE. stop and allow pressure to escape before
b. Move the joystick handle forward, activating the removing the cap completely.
boom lower function. The boom should LOWER.
c. Move the joystick handle to the right, activating 5. Place a suitable container beneath the radiator drain
the boom tilt function. The boom should TILT plug or petcock. Slowly turn the radiator cap to the
DOWN. first stop, and allow any pressure to escape.
Remove the radiator cap.
d. Move the joystick handle to the left, activating the
boom tilt function. The boom should TILT UP. 6. Place a funnel at the base of the radiator to channel
e. Move the joystick rocker switch forward the drained coolant into the container. Open the
activating the boom extend function. The boom radiator drain plug or petcock and allow the coolant
should EXTEND. to drain. Replace the drain plug, or close the
f. Move the joystick rocker switch rearward petcock.
activating the boom retract function. The boom 7. Transfer the coolant to a container with a cover, and
should RETRACT. label as “Used Antifreeze.” Dispose of the used
Install the bottom cover and secure using two lens-head coolant at an approved recycling facility.
capscrews.
Note: Label all hoses to ensure correct installation.
4.3.6 Windshield Wiper Assembly 8. Remove the seat from the cab to expose the heater/
defroster element (1).
Refer to Section 9.11.1, “Windshield Wiper Motor,” for
removal and installation information. 9. Loosen the hose clamps and disconnect the two
heater hoses.
4.3.7 Windshield Washer Assembly
Refer to Section 9.11.3, “Windshield Washer Reservoir
and Pump,” for removal and installation information.

4.3.8 Heater/Defroster System

a. Heater Assembly Removal

1. Park the machine on a firm, level surface. Level the
machine, ground the attachment, place the travel
select lever in the (N) NEUTRAL position, engage
the parking brake and shut the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
1
3. Unlock and open the engine compartment. Allow the
engine and hydraulic fluid to cool. Draining the
cooling system while the engine block is hot can MAH0680
cause cracks in the engine block.
10. Remove the button-head capscrews, nuts and
lockwashers.

26.6/30.7 4.7
 Cab and Covers

11. Carefully pull out the heater assembly. Label and

disconnect the wiring harness connections at the
blower. WARNING: Wear protective
footwear with reinforced toe caps and slip-
12. Remove the heater assembly.
resistant soles. Failure to comply can result in
foot injury from falling objects or other bodily
b. Heater Assembly Installation
injury from slipping or falling.
For installation, reverse the removal procedure being
sure to follow all safety guidelines. Fill the cooling system
with a 50/50 mixture of Akros Farm Flu and water, WARNING: NEVER lift a heavy
allowing time for the coolant to fill the engine block. See object without the help of at least one assistant
Section 2.5, “Fluids, Lubricants and Capacities,” for or a suitable sling or hoist. Failure to comply
system capacities. can result in death or serious personal injury.

IMPORTANT: When the engine is initially started, run it IMPORTANT: Remove and label cab components as
briefly at low idle and check the machine for any visual needed before removing the cab from the machine.
sign of fluid leakage. STOP the engine immediately if Label, disconnect and cap hydraulic hoses. Transfer cab
any leakage is noted, and make any necessary repairs parts to the replacement cab after the replacement cab
before continuing. is securely mounted on the machine.
1. Park the machine on a firm, level surface. Allow
4.4 CAB REMOVAL
sufficient overhead and side clearance for cab
removal. Level the machine, ground the attachment,
WARNING: Risk of death or place the travel select lever in the (N) NEUTRAL
serious personal injury. NEVER modify, weld position, engage the parking brake and shut the
or drill the cab. engine OFF.
2. Unlock and open the engine compartment. Allow the
engine and hydraulic fluid to cool.
WARNING: The protection offered
by this ROPS/FOPS will be impaired if 3. Disconnect the battery negative (-) cable or cables at
subjected to any modification or structural the battery negative (-) terminal.
damage, at which time replacement is
necessary.
WARNING: Hot coolant can cause
IMPORTANT: To help ensure safety and optimum severe burns or eye injury. NEVER remove the
performance, replace the cab if it is damaged. Refer to radiator cap while the engine is hot. The
the appropriate parts manual for ordering information. cooling system is under pressure. Wear
Before performing any inspection, maintenance or protective clothing and safety glasses.
service operation, thoroughly clean the machine. DO
4. Place a suitable container beneath the radiator drain
NOT spray water or cleaning solution in, on, near or
plug. Slowly turn the radiator cap and allow any
around the operator’s dash panels and electrical
pressure to escape. Remove the drain plug.
components.
5. Place a funnel at the base of the radiator to channel
Inspect the cab, its welds and mounts. If modification,
the drained coolant into the container. Open the
damage, a cracked weld and/or fatigued metal is
radiator drain plug and allow the coolant to drain.
discovered, replace the cab. Contact your local SDFI
Replace the drain plug.
distributor with any questions about the suitability or
condition of a cab. 6. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.

4.8 26.6/30.7
 Cab and Covers

Bottom of Cab

MAH0950

MAH0700
13. Carefully begin to lift the cab. Stop and check that all
Note: Label all hoses to ensure correct installation. wiring, hydraulic hoses and fasteners are
disconnected or removed. Do not damage the fuel fill
7. Loosen the hose clamps, and disconnect the heater tube.
hoses from the engine.
14. When all wiring, hydraulic hoses and fasteners are
8. Disconnect the cab-to-wiring harness connectors. disconnected or removed, carefully and slowly lift
Note: Record the location, and label all cables to ensure the cab and remove it from the frame. Readjust the
correct installation. position of the sling as needed to help balance the
cab during removal.
9. Working underneath the cab, label and disconnect
15. When the cab is completely clear of the machine,
the hydraulic hoses at the cab fittings. Plug the
carefully lower it to the ground. Block up or support
hoses and cap the fittings.
the cab while it is being removed from the machine.
WARNING: Hydraulic fluid leaking 16. Inspect the condition of the fittings, clamps,
under pressure can penetrate the skin, cause hydraulic hoses, etc. Replace parts as indicated by
infection, gangrene, and death or serious their condition.
personal injury. If injured, see a doctor 17. Inspect and replace other machine parts that are
immediately. exposed with the cab removed. Repair or replace as
Relieve all pressure before disconnecting any required.
component, part, line or hose. Slowly loosen
parts and allow release of residual pressure
before removing any parts or component.

WARNING: Wait for the hydraulic

fluid to cool before servicing any hydraulic
component. Hot hydraulic oil can cause severe
burns.

10. Disconnect the throttle cable rod end at the throttle

lever extension bracket (1). Route the cable away
from the cab to prevent damage during removal.
11. Attach a sling with suitable lifting capacity through
the cab rails. Make sure the sling is centered to
ensure even lifting.
12. Remove the cab-to-frame bolts, washers and nuts.

26.6/30.7 4.9
 Cab and Covers

4.5 CAB INSTALLATION 8. Connect the heater hoses to the engine. Secure with
hose clamps.

WARNING: Wear protective

9. Install the cab-to-wiring harness connectors on side
of the cab.
footwear with reinforced toe caps and slip-
resistant soles. Failure to comply can result in 10. Fill the cooling system completely with a 50/50 mixture
foot injury from falling objects or other bodily of Akros Farm Flu and water, allowing time for the
injury from slipping or falling. coolant to fill the engine block. The cooling system
capacity is listed in Section 2.5, “Fluids, Lubricants
and Capacities.”
WARNING: NEVER lift a heavy
11. Connect the battery negative (-) cable to the battery
object without the help of at least one assistant
negative (-) terminal.
or a suitable sling or hoist. Failure to comply
can result in death or serious personal injury. 12. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
1. Block all four wheels to help prevent the machine faulty conditions.
from moving. Assure that there is sufficient overhead
and side clearance for cab installation. WARNING: Hydraulic oil leaking
2. Attach a sling with suitable lifting capacity through under pressure can penetrate the skin and
the cab rails. Make sure the sling is centered to cause severe personal injury. DO NOT use
ensure even lifting. your hand or any part of your body to check for
hydraulic leaks. When checking for hydraulic
3. Use a hoist or overhead crane and sling attached to
leaks, wear safety glasses and gloves to help
the cab. Carefully begin to align the cab with the
provide protection from spraying hydraulic oil.
mounting holes in the frame. Stop and check that
Use a piece of cardboard or paper to search for
wiring, hydraulic hoses, cables, etc., will not be
leaks.
pinched or damaged as the cab is positioned. Take
special note of the fuel fill tube as well. Readjust the 13. Start the engine and check the operation of all controls.
position of the sling as needed to help balance the Check for hydraulic fluid leaks. Check the hydraulic
cab during installation. fluid level in the tank and add fluid as required.
4. Install the cab-to-frame bolts, washers and nuts. IMPORTANT: When the engine is initially started, run it
Torque to 651 Nm (480 lb-ft). briefly at low idle and check the machine for any visual
sign of fluid leakage. STOP the engine immediately if
any leakage is noted, and make any necessary repairs
before continuing.
1

WARNING: The cooling system is

under pressure, and escaping coolant can
cause severe burns and eye injury. To prevent
personal injury, NEVER remove the radiator
cap while the cooling system is hot. Wear
safety glasses. Turn the radiator cap to the first
Bottom of Cab stop and allow pressure to escape before
removing the cap completely.

14. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
MAH0700
to bring the coolant to the proper level.
5. Connect the throttle cable rod end to the throttle
extension bracket (1) underneath the cab.
6. Reconnect the hydraulic hoses at the cab fittings.
7. Secure the throttle cable to the hydraulic hoses
using wire ties.

4.10 26.6/30.7
 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 Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5.7
5.3.7 Axle Internal Component Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.4.4 Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.4.5 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.4.6 Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.4.7 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.15
5.5.2 Wheel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
5.5.3 Wheel Inspection and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
5.5.4 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5.16
5.6 Steering Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.7.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16

26.6/30.7 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)

Steering
Cylinder
(Front)

Drive Shaft

Front Axle
Assembly
MAH0190

5.2 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

5.2 GENERAL INFORMATION 5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle,
Before performing any inspection, maintenance or
differential, brakes and wheel-end safety, repair,
service operation, thoroughly clean the unit. The axles
disassembly, reassembly, adjustment and
and drive shafts should be checked and repaired only by
troubleshooting information) are provided in the following
experienced service technicians who are aware of all
manuals.
safety instructions and particular component features.
Use suitable products to thoroughly clean all
Machine Carraro Axle SDFI P/N
disassembled mechanical parts to help prevent personal
Model
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts 26.6 CA FRONT
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners 141154 29.05:1
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. Always replace elastic locknuts and any 26.6 CA REAR 307.1128.3.6
damaged, worn, cracked, seized or otherwise improper 141155 14.308:1 (Language:
parts that could affect the safe and proper functioning of
30.7 CA FRONT Italian
the machine, axles and drive shafts.
139970 29.05:1 English)
5.3 AXLE ASSEMBLIES 30.7 CA REAR
141247 14.308:1
A 10-ply (or better) directional-tread tire, 405/70-20 MPT-
01 or optional 14 ply 405/70-24 MPT-01 Radial tire can be
used on the 26.6, and a 14 ply 405/70-24 MPT-01 or WARNING: DO NOT service the
optional 17,5-24 MPT-01 Radial, 14-ply (or better) machine without following all safety
directional-tread tire can be used on the 30.7. Tires are precautions as outlined in Section 1, “Safety
filled only with air when the machine is shipped from the Practices,” of this manual. Failure to follow the
factory. safety practices may result in death or serious
injury.
5.3.1 Axle Serial Number Plate
The axle serial number plate is located on the inside of 5.3.4 Axle Maintenance
the right yoke. Information on the serial number plate is CLEANING: Clean parts with machined or ground
required in correspondence regarding the axle. surfaces (such as gears, bearings and shafts) with
Supply information from the axle serial number plate emulsion cleaners or petroleum-based cleaners. DO
when communicating about an axle assembly or axle NOT steam clean internal components and the interior of
components. the planetary hub and axle housing. Water can cause
corrosion of critical parts. Rust contamination in the
5.3.2 Axle Specifications lubricant can cause gear and bearing failure. Remove old
General axle specifications are found in Section 2, gasket material from all surfaces.
“General Information and Specifications.” Axle DRYING: Use clean, lintless towels to dry components
(differential housing) fluid information is found in Section after cleaning. DO NOT dry bearings by spinning them
2.5.1, “Axle (Differential Housing).” Wheel end fluid with compressed air; this can damage mating surfaces
information is found in Section 2.5.2, “Axle Wheel Ends.” due to lack of lubrication. After drying, lightly coat
components with oil or a rust-preventive chemical to help
protect them from corrosion. If storing components for a
prolonged period, wrap them in wax paper.
PERIODIC OPERATION REQUIREMENT: Every two
weeks, drive the machine far enough to cause the drive-
train components to make several complete revolutions.
This will help ensure that internal components receive
lubrication to minimize deterioration caused by
environmental factors such as high humidity.

26.6/30.7 5.3
 Axles, Drive Shafts, Wheels and Tires

SUBMERSION: If the machine has been exposed to The front and rear axle assemblies differ in that the front
water deep enough to cover the hubs, disassemble the axle assembly is equipped with a parking brake
wheel ends and inspect for water damage and mechanism and a limited-slip feature; the rear axle has
contamination. If the carrier housing was submerged in neither. The following steps outline a typical axle removal
water, especially if the water level was above the vent procedure, suitable for either the front or the rear axle
tube (breather), drain the axle and inspect internal parts assembly.
for water damage and contamination. Before assembling Cleanliness is extremely important. Before attempting to
and refilling the unit with the specified lubricant(s), clean, remove the axle, thoroughly clean the machine. Avoid
examine and replace damaged parts as necessary. spraying water or cleaning solution on the stabilizer
Note: Use a suitable puller for bearing removal. Clean, solenoids and other electrical components. If using a
inspect and lubricate all bearings just prior to steam cleaner, seal all openings before steam cleaning.
reassembly. If replacement of a damaged bearing cup or IMPORTANT: Clear the work area of all debris,
cone is necessary, replace the cup and cone as a set. unnecessary personnel, etc. Allow sufficient space to
raise the machine and to remove the axle.
WARNING: Avoid prolonged 1. Park the machine on a firm, level surface, level the
engine operation in closed areas without machine, ground the attachment, place the travel
adequate ventilation. Failure to properly select lever in the (N) NEUTRAL position, engage
ventilate exhaust fumes can result in death or the parking brake, straighten all wheels and shut the
severe personal injury. engine OFF.
2. Place an Accident Prevention Tag on both the
WARNING: Escaping hydraulic ignition key switch and steering wheel, stating that
the machine should not be operated.
fluid under pressure can penetrate the skin,
causing death or serious injury. Before starting 3. Unlock and open the engine compartment cover.
the engine, tighten all hydraulic connections Allow the engine, transmission and hydraulic fluid to
and remove all tools from the machine. cool.
NEVER check for leaks using any part of the 4. Disconnect the battery negative (-) cable at the
human body; use a piece of cardboard or wood battery negative (-) terminal to prevent the engine
instead. Wear heavy, protective gloves and from starting accidentally.
eye protection.
5. If the axle will be disassembled after removal, the oil
will have to be drained. Loosen the breather to
5.3.5 Axle Removal release possible internal pressure, then tighten plug
with a torque wrench to 12 Nm (9 lb-ft).
WARNING: An improperly 6. Place a suitable receptacle under the axle drain plug
supported machine can fall, causing death or (1). Remove the drain plug and allow the axle oil to
severe personal injury. Safely raise and drain into the receptacle. Transfer the used axle oil
adequately support the machine so that it will into a suitable covered container, and label the
remain stable and in place before attempting to container as “Used Oil.” Dispose of used oil at an
remove an axle. approved recycling facility.

WARNING: Hot hydraulic fluid can

cause severe burns. Wait for the hydraulic fluid
to cool before servicing any hydraulic
component.

WARNING: Relieve hydraulic

1
pressure before servicing any hydraulic MAH0440

component. Escaping hydraulic fluid under

pressure can penetrate the skin, causing death 7. Label, disconnect and cap the steering and brake
or serious injury. lines at the axle. Wipe up any spilled oil.

5.4 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

8. Block the front and rear of both tires on the axle that Note: The wheel and tire assemblies must be re-installed
is not being removed. Ensure that the machine will later with the directional tread pattern “arrows” facing in
remain in place during axle removal before the direction of forward travel.
proceeding.
12. Remove the drive shaft assembly. (Refer to Section
9. Raise the machine using a suitable jack or hoist. 5.4.3, “Drive Shaft Removal.”)
Place suitable supports under both sides of the
13. Remove the capscrews, locknuts and axle plates
frame and lower the machine onto the supports.
securing the axle to the frame.
Ensure that the machine will remain in place during
axle removal. 14. Remove the axle from the machine using the jack,
hoist or overhead crane and sling supporting the
10. Support the axle that is being removed with a suitable
axle. DO NOT raise or otherwise disturb the
jack, hoist or overhead crane and sling. DO NOT
machine while removing the axle. Balance the axle
raise the axle or the machine.
and prevent it from tipping, turning or falling while
11. Mark and remove both wheel and tire assemblies removing it from beneath the machine. Place the
from the axle that is being removed. (Refer to axle on a suitable support or holding stand.
Section 5.5.1, “Removing Wheel and Tire Assembly
from Machine.”)

MAH0040

26.6/30.7 5.5
 Axles, Drive Shafts, Wheels and Tires

c. Axle Installation 12. Uncap and connect the steering and brake lines at
their axle fittings.
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake 13. Check the hydraulic reservoir oil level.
mechanism and limited-slip feature; the rear axle has
neither. The steps below outline a typical axle installation WARNING: Avoid prolonged
procedure, suitable for either the front or the rear axle engine operation in closed areas without
assembly. adequate ventilation. Failure to properly
1. Before proceeding, ensure that the machine will ventilate exhaust fumes can result in death or
remain in place during axle installation. Block the severe personal injury.
front and rear of both tires on the axle that is already
installed on the machine.
WARNING: Escaping hydraulic
2. If applicable, raise the machine using a suitable jack fluid under pressure can penetrate the skin,
or hoist. Place suitable supports beneath the frame causing death or serious injury. Before starting
and lower the machine onto the supports, allowing the engine, tighten all hydraulic connections
enough room for axle installation. Ensure that the and remove all tools from the machine.
machine will remain in place during axle installation. NEVER check for leaks using any part of the
3. Using a suitable jack, hoist or overhead crane and human body; use a piece of cardboard or wood
sling, remove the axle from its support or holding instead. Wear heavy, protective gloves and
stand. Balance the axle and prevent it from tipping, eye protection.
turning or falling while positioning it beneath the
machine. DO NOT raise or otherwise disturb the 14. Start the engine. Turn the steering wheel several
machine while installing the axle. Keep the axle times lock to lock and check the function of the
supported and balanced on the jack, hoist or brakes. Check for hydraulic leaks, and tighten or
overhead crane and sling throughout the installation repair as necessary.
procedure.
4. Position the axle under the frame, and align the pivot
pin bearings with the holes in the frame.
5. Install the axle with capscrews, locknuts and the axle
plates.
6. Install the drive shaft assemblies. (Refer to Section
5.4.7, “Drive Shaft Installation.”)
7. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transmission.
8. Install the wheel and tire assemblies. (Refer to
Section 5.5.4, “Installing Wheel and Tire Assembly
onto Machine.”)
9. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
10. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
and lower the machine to the ground.
11. Remove the blocks from the front and rear of both
tires on the other axle.

5.6 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

5.3.6 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. appropriate Operator/Safety
Manual.)
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 Universal Tractor Fluid.
(Refer to appropriate Operator/
Safety Manual.)
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 Universal Tractor Fluid.
(Refer to appropriate Operator/
Safety Manual.)
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.

26.6/30.7 5.7
 Axles, Drive Shafts, Wheels and Tires

5.3.6 Axle Assembly and Drive Shaft Troubleshooting

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 ZF
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.

5.8 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

5.3.6 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with Akros
Multi FCT Tractor / Hydraulic
Fluid. (Refer to appropriate
Operator/Safety Manual.)
2. Axle and/or wheel end housings 2. Drain axle and fill to correct
filled with incorrect oil or oil level with Akros Multi FCT
contaminated or oil level low. Tractor / Hydraulic Fluid. (Refer
to appropriate Operator/Safety
Manual.)

8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.11.7,
operating properly. “Steering 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 8.11.7,
operating properly. “Steering 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 appropriate Operator/
Safety Manual.)
2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.11.7,
operating properly. “Steering 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 appropriate Operator/
reduced. Safety Manual.)
2. Brake (hydraulic) system not 2. Refer to Section 8.11.7,
operating properly. “Steering Cylinders.”
3. Brake piston o-rings and seals 3. Replace o-rings and seals.
damaged (leaking).

26.6/30.7 5.9
 Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Internal Component

Troubleshooting
Note: The following conditions may be noticed when
inspecting parts during axle repair. Perform all remedies
that apply to the conditions noticed.

Problem Cause Remedy (See Note)

1. Differential ring gear teeth 1. Incorrect alignment of ring and • Replace ring and pinion gears.
broken on the heel of the pinion gears (excessive play). • Adjust ring and pinion alignment
tooth. 2. Incorrect pinion (input) shaft and bearing preload as described
bearing preload. in the D-S Repair Manuals.
2. Differential ring gear teeth 1. Incorrect alignment of ring and • Replace ring and pinions gears.
broken on the toe of the pinion gears (insufficient play). • Adjust ring and pinion alignment
tooth. 2. Incorrect pinion (input) shaft and bearing preload as described
bearing preload. in the D-S Repair Manuals.
3. Rapid differential ring and 1. Insufficient lubrication. • Replace ring and pinion gears.
pinion gear teeth wear. 2. Lubricant contaminated. • Drain axle and fill to correct level with
3. Incorrect lubricant. Akros Multi FCT Tractor / Hydraulic
Fluid. (Refer to appropriate Opera-
tor/Safety Manual.)
4. Differential ring and pinion 1. Insufficient lubrication. • Determine the cause of the prob-
gear teeth overheated. 2. Lubricant contaminated. lem and correct.

3. Incorrect lubricant or level. • Replace ring and pinions gears.

• Drain axle and fill to correct level
with Akros Multi FCT Tractor /
Hydraulic Fluid. (Refer to appropri-
ate Operator/Safety Manual.)

5. Gear teeth pitted. 1. Insufficient lubrication. • Determine the cause of the prob-
2. Lubricant contaminated. lem and correct.
3. Foreign objects in oil. • Replace gears.
• Drain axle and fill to correct level
with Akros Multi FCT Tractor /
Hydraulic Fluid. (Refer to appropri-
ate Operator/Safety Manual.)

6. Worn or pitted bearings. 1. Incorrect bearing preload. • Determine the cause of the prob-
2. Insufficient lubrication. lem and correct.

3. Lubricant contaminated. • Replace bearings.

• Adjust bearing preload as described
in the D-S Repair Manuals.
• Drain axle and fill to correct level
with Akros Multi FCT Tractor /
Hydraulic Fluid. (Refer to appropri-
ate Operator/Safety Manual.)

5.10 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

5.4 DRIVE SHAFTS

2
5.4.1 Drive Shaft Inspection and Service
Whenever servicing the machine, conduct a visual
inspection of the drive shaft and cross and bearing 1 3
assembly (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and 4
down time later. 5
Inspect area where the drive shaft flange yoke and slip
yoke mount to the drive shaft. Attempt to turn drive shaft
in both directions. Look for excessive looseness, missing
parts, cracks or other damage. Worn or damaged drive
shaft (1) and cross and bearing assembly may cause an 6
excessive amount of vibration or noise.
Individually inspect each cross (2) the needle bearings
and cap (4) for signs of wear or for missing parts. 7
8
Note: Replace the cross and bearings as a complete 9
assembly if any parts are worn or missing. If all parts of 2
the cross and bearing assemblies are in good condition, 10
pack the bearing caps with a premium grade of multi- 4
purpose wheel-bearing grease. Reattach the bearing
cap to the cross, assuring that all needle bearings are 5
present. Then, reassemble the cross and bearing 1. Yoke shaft (1) 6. Grease fitting (1)
assembly into the drive shaft yoke. 2. Cross (2) 7. Dust cap (1)
3. Yoke Flange (1) 8. Washer (1)
1. Replace the felt seal (9) if worn or damaged.
4. Needle bearings 9. Felt seal (1)
2. Replace the entire drive shaft assembly if any flange and cap (8) 10. Slip yoke (1)
yoke, slip yoke or drive shaft tube is severely dented 5. Snap ring (8) MA8910

or damaged.
3. Cross assemblies should flex and be free from
excessive binding. A slight amount of drag or
resistance is desirable on a new cross and bearing
assembly. Excessive looseness causes unbalance.

26.6/30.7 5.11
 Axles, Drive Shafts, Wheels and Tires

5.4.2 Drive Shaft Maintenance

To Front
Refer to the appropriate Operator/Safety Manual for 8 Axle
information regarding the lubrication of the grease fittings
on the drive shafts.

5.4.3 Drive Shaft Removal

IMPORTANT: To help ensure optimum performance,
the drive shaft assemblies are specially balanced as a
To Rear Axle 9
unit at the factory. When servicing any flange yoke, slip
yoke or drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the appropriate 10
parts manual for ordering information.
Note: The drive shaft assemblies are balanced MAH0450

assemblies. Mark the yoke and axle, transmission,

transfer case, and the shaft and slip yoke so that these
components can be returned to their original positions 5.4.4 Drive Shaft Disassembly
when reinstalled. Yokes at both ends of the drive shaft IMPORTANT: When servicing any flange yoke, slip
must be in the same plane to help prevent excessive yoke, or drive shaft tube, order a complete assembly if
vibration. components are bent or damaged. Refer to the
1. Level the machine, ground the carriage, place the appropriate Parts Manual for ordering information.
travel select lever in the (N) NEUTRAL position, 1. Use an approved, non-flammable cleaning fluid to
engage the parking switch and shut the engine OFF. thoroughly clean the drive shaft assembly with a
2. Place an Accident Prevention Tag on both the brush. Wipe dry before disassembling.
ignition key switch and steering wheel, stating that
the machine should not be operated. CAUTION: Avoid using excess force
when clamping the drive shaft in a vise. Apply
3. Unlock and open the engine compartment access
only enough force to hold the drive shaft
door. Allow the engine, transmission and hydraulic
securely. Excessive force can damage the
fluid to cool.
drive shaft, resulting in an unbalanced condition.
4. Disconnect the battery negative (-) ground cable at
the battery negative (-) terminal to prevent the 2. Place the drive shaft assembly in a bench vise.
engine from starting accidentally. 3. Use a pair of pliers to pinch the ends of the snap
5. The drive shaft assembly is a balanced assembly. rings (14) securing the cross (15) and bearing (16)
Mark the yoke and axle, transmission and the shaft assemblies to the yoke (17 or 18). Remove the snap
and slip yoke so that these components can be rings from their grooves in the yoke.
returned to their original positions when reinstalled. Note: If the snap rings fail to readily snap out of their
Yokes at both ends of the drive shaft must be in the grooves in the yokes, tap the end of the bearing cap
same plane to help prevent excessive vibration. lightly to help relieve pressure against the snap rings.
6. Remove the four capscrews (8) and four locknuts
securing the yoke flange (9) to the front axle flange.
7. Remove the four capscrews securing the flange yoke
to the rear axle flange.
8. Remove the drive shaft assembly (10).

5.12 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

2. Align the reference marks made previously on the

15 drive shaft and slip yoke.
17 3. Slide the slip yoke onto the splines of the drive shaft
and tighten the dust cap securely. DO NOT
overtighten or the cap will break.
16
4. Install the cross and bearing assembly into the yoke.
14 5. Secure the cross and bearing assembly into the yoke
with snap rings. Pinch each snap ring with a pliers
and insert them into their grooves in the yoke.
6. Apply grease to grease fitting.
5.4.7 Drive Shaft Installation
IMPORTANT: To help ensure optimum performance,
21 the drive shaft assemblies are specially balanced as a
unit at the factory. When servicing any flange yoke, slip
20 yoke or drive shaft tube, order a complete assembly if
19 components are bent or damaged. Refer to the
appropriate parts manual for ordering information.
15 18
1. Raise the drive shaft assembly into position. The
16 slip-yoke end of the drive shaft mounts toward the
14 MA8910
front axle. If reinstalling a drive shaft previously
removed, align the flange yokes according to the
4. Use a soft, round drive pin with a flat face alignment marks made during removal.
approximately 1/32" (0,8 mm) smaller than the hole
IMPORTANT: Yokes at both ends of the drive shaft
diameter in the yoke to drive on one end of the cross
must be in the same plane to help prevent excessive
and bearing assembly until the opposite bearing
vibration.
assembly comes out of the yoke.
2. Install the four capscrews and four locknuts securing
5. Turn the yoke over and tap on the exposed end of
the bearing crosses to the front axle. Loctite and
the cross until the opposite bearing assembly comes
torque the capscrews to 139 Nm (102 lb-ft).
out of the yoke.
3. Install the four capscrews securing the bearing
6. Remove the cross from the yoke.
crosses to the rear axle. Loctite and torque the
7. Repeat Steps 2 thru 6 to remove the cross and capscrews to 139 Nm (102 lb-ft).
bearing assembly on the other end of the drive shaft.
4. Connect the battery negative (-) ground cable at the
battery negative (-) terminal.
5.4.5 Drive Shaft Cleaning and Drying
5. The drive shaft assembly is a balanced assembly.
1. Disassemble and clean all parts using an approved Mark the yoke and axle, transmission and the shaft
cleaning fluid. Allow to dry. and slip yoke so that these components can be
2. Remove any burrs or rough spots from all machined returned to their original positions when reinstalled.
surfaces. Re-clean and dry as required. Yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
5.4.6 Drive Shaft Assembly
1. Install the dust cap (19), washer (20) and felt seal
(21) onto the splines of the drive shaft tube
assembly.
IMPORTANT: Ensure that the reference marks made
before removal on the drive shaft and slip yoke are
aligned. The drive shaft and yokes must be in the same
plane to help prevent excessive vibration.

26.6/30.7 5.13
 Axles, Drive Shafts, Wheels and Tires

5.5 WHEELS AND TIRES

8
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. 9

The Model 26.6 uses wheels with nominal dimensions of

405/70-20 and the Model 30.7 uses 405/70/24. For
optional tire dimensions, refer to Section 2.4.8, “Tires.”
Make sure the replacement tire is of the same size and
ply rating (star rating for radial tires) as all of the other
tires. A higher ply rating (star rating for radial tires) can be
used, but only when all four tires have the same ply
rating.
In standard configuration, the tires are filled with air only
when the machine leaves the factory. There is a foam fill
option available if the use of a tire-filling substance is
desired. Having tires filled has a positive effect on the
weight, stability and handling characteristics of the machine,
especially under load. SDFI does not recommend the use
of hydrofill as a tire-fill substance because of possible
environmental impact.
MAH0890
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this
produces a left or right tire and wheel assembly.
The wheel and tire assemblies must be installed with the
directional tread pattern “arrows” (8 and 9) facing in the
direction of forward travel.

5.14 26.6/30.7
 Axles, Drive Shafts, Wheels and Tires

5.5.1 Removing Wheel and Tire Assembly 5.5.2 Wheel Cleaning

from Machine
WARNING: Dirt and rust prevent
WARNING: Risk of death or the tire from seating properly on the wheel,
serious personal injury, if proper safety which could result in an explosive separation.
procedures are not followed. When removing Such explosions could result in death or
the wheel and tire assembly from the machine, severe personal injury to the tire installer and
follow the instructions in the “Wheel Removal to those in the area.
Instruction” box that follows:
Remove all rust, corrosion, dirt and other foreign material
from all metal surfaces. In particular, the bead area (tire-
to-wheel mounting surface) must be especially clean.
Wheel Removal Instructions:
• Position the machine on a flat, hard surface and 5.5.3 Wheel Inspection and Replacement
support the machine with approved jack stands
or suitable supports. WARNING: Damaged, modified,
• Use appropriate safety glasses, safety shoes repaired or mis-matched wheels and tires, or
and appropriate clothing and equipment. dirt and rust prevent the tire from seating
• DO NOT wear rings or jewelry. DO NOT wear properly on the wheel, which could result in an
hair or clothing that could become caught in explosive separation. Such explosions could
machinery or pinch points such as those cre- result in death or severe personal injury.
ated between the tire and the hub. • NEVER rework, heat, weld or braze a
wheel rim.
1. Park the machine on a firm, level surface. Level the • Clean and inspect the wheel rim before
machine, ground the attachment, place the travel installing a new tire. Verify that the wheel
select lever in the (N) NEUTRAL position, engage rim diameter exactly matches the tire
the parking switch, straighten all wheels and shut the rim diameter molded into the tire.
engine OFF.
• Inspect the inside of the tire for dirt, for-
2. Place an Accident Prevention Tag on both the eign material, loose cords, cuts, pene-
ignition key switch and steering wheel, stating that trating objects, and other damage. DO
the machine should not be operated. NOT use tires with irreparable damage.
3. Disconnect the battery negative (-) ground cable at
the battery negative (-) terminal, to prevent the Check all surfaces of the wheel for rust, corrosion,
engine from starting accidentally. cracks, bent flanges, deep marks or gouges. Replace a
damaged, worn or cracked wheel. NEVER rework, heat,
4. Loosen but DO NOT remove the lug nuts on the
weld or braze a wheel rim.
wheel and tire assembly to be removed.
Inspect the valve core and stem. Replace the entire valve
5. Place a suitable jack under the axle pad closest to
if either component is damaged.
the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
sufficient room to lower the machine onto the
support and to remove the wheel and tire assembly.
6. Lower the machine onto the support.
7. Remove lug nuts and lug washers in an alternating
pattern.
8. Remove the wheel and tire assembly from the
machine.

26.6/30.7 5.15
 Axles, Drive Shafts, Wheels and Tires

5.5.4 Installing Wheel and Tire Assembly

onto Machine
IMPORTANT: The wheel and tire assemblies must be
installed with the directional tread pattern “arrows” facing
in the direction of forward travel.

Tread “arrows” 30°

must point forward
MAH0860

5. Turn the wheel hub so the bars make an acute 30

degree angle.
6. Screw in or out the steering retainer bolt to meet the
stop on the shoulder of the axle beam. Torque the
locknut to 30 Nm (22 lb-ft). Repeat this step for the
remaining three retainer bolts being sure the wheel
hub is at an acute 30 degree angle.
7. Align the axle wheels as much as possible.
8. Position the steering sensor on the cylinder so that it
activates only when the wheel position corresponds
Install tires onto to their alignment.
wheels to rotate in
proper direction 5.7 BRAKES

MAH0460
5.7.1 Brake Disk Inspection.
1. Position wheel onto studs on wheel end of axle. Check the brake disks for wear every 1,000 hours of
operation or yearly.
2. Install wheel lug washers.
The service brakes can only be checked by performing a
3. Install lug nuts and tighten in an alternating pattern.
teardown of the axle. Refer to the appropriate Carraro
Torque to 583 to 637 Nm (430 to 470 lb-ft).
Repair Manual for complete teardown instructions.
The minimum tolerance for the brake disc gap is 4.10 mm
5.6 STEERING ADJUSTMENT (0.016").

5.6.1 Steering Angle Adjustment

1. Park the machine on a firm, level surface. Level the
machine, ground the attachment, place the travel
select lever in the (N) NEUTRAL position, engage
the parking switch, straighten all wheels and shut the
engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Disconnect the battery negative (-) ground cable at
the battery negative (-) terminal, to prevent the
engine from starting accidentally.
4. Use two bars and align one with the wheel hub and
one with the axle.

5.16 26.6/30.7
 Section 6
Transmission:

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3.1 Transmission General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3.2 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.2 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.4.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.4.4 After Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.4.5 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

26.6/30.7 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.

Hydrostatic
Transmission

Forward
Relief
Directional Valve
Valve

Reverse
Relief
MAH0250 Valve

6.2 26.6/30.7
 Transmission:

6.4.1 Transmission Removal

WARNING: DO NOT service the
machine without following all safety
precautions as outlined in Section 1, “Safety
WARNING: Risk of severe personal
injury. NEVER lift a transmission alone; enlist
Practices,” of this manual. Failure to follow the
the help of at least one assistant or use a
safety practices may result in death or serious
suitable hoist or overhead crane and sling.
injury.
1. Park the machine on a firm, level surface, fully
6.2 TRANSMISSION DESCRIPTION retract and raise the boom, place the travel select
lever in the (N) NEUTRAL position, turn rear wheels
Instructions in this section pertain mainly to general to give easier access to rear of engine compartment,
specifications, towing, maintenance information, and engage the parking switch and shut the engine OFF.
transmission removal and installation procedures. For 2. Place an Accident Prevention Tag on both the
internal transmission service instructions and detailed ignition key switch and steering wheel, stating that
specifications contact your local SDFI distributor for a copy
the machine should not be operated.
of the Rexroth Repair Manual (P/N 0.900.0389.9).
More information can be obtained from the serial number
plate directly mounted on the transmission. Information
WARNING: DO NOT get under a
raised boom unless the boom is blocked up.
specified on the serial number plate includes the ALWAYS block the boom before doing any
transmission model number, the transmission serial servicing that requires the boom to be up.
number and other data. Information on the serial number Unexpected lowering of the boom may cause
plate is required in correspondence regarding the death or serious injury.
transmission.

6.3 TRANSMISSION SPECIFICATIONS WARNING: Hot hydraulic fluid can

cause severe burns. Wait for hydraulic fluid to
cool before servicing any hydraulic component.
6.3.1 Transmission General Specifications
3. Unlock and open the engine compartment. Allow the
General transmission specifications are found in Section 2,
engine, transmission and hydraulic fluid to cool.
“General Information and Specifications.”
4. Disconnect the cables from the battery, starting with
6.3.2 Transmission Maintenance the negative (-) cable(s).

The transmission is a hydraulic component and requires 5. Remove battery from engine compartment,
the same maintenance as the hydraulic system. Refer to disconnect and remove battery tray.
Section 2.6, “Maintenance Schedules.” 6. Remove access panel in rear of engine
compartment.
6.4 TRANSMISSION REPLACEMENT 7. Remove belly pan of engine compartment.
8. Thoroughly clean the transmission and surrounding
Note: Contact your local SDFI distributor if internal
area, including all hoses and fittings, before
transmission repair is required during the warranty
proceeding.
period.
9. Drain the hydraulic oil reservoir. (Refer to the
IMPORTANT: To help ensure safety and optimum
appropriate Operator/Safety Manual for information
performance, replace the transmission if it is damaged.
concerning the hydraulic oil and filter change.
Refer to the appropriate parts manual for ordering
information. 10. Transfer the used hydraulic oil into a suitable,
covered container, and label the container as “Used
Cleanliness is of extreme importance. Before attempting Oil.” Dispose of used oil at an approved recycling
to remove the transmission, thoroughly clean the exterior facility. Clean and reinstall the drain plug.
of the transmission to help prevent dirt from entering
during the replacement process. Avoid spraying water or 11. Label and disconnect all hydraulic hoses attached to
cleaning solution onto or near the transmission shift transmission, cap all fittings and plug hoses to keep
solenoids and other electrical components. dirt & debris from entering hydraulic system.
12. Wipe up any spilled hydraulic and transmission oil.

26.6/30.7 6.3
 Transmission:

13. Vertically secure transmission with a lifting strap or 3. Remove the hoist or overhead crane and sling.
chain. Use a suitable hoist or overhead crane. 4. Reattach the previously labeled hoses to their
Operate the hoist or crane to remove slack from the appropriate ports.
chain, but DO NOT raise the transmission at this
time. 5. Fill hydraulic reservoir and bleed the system.

14. Remove the two Allen head bolts that attach the 6. Reinstall the battery tray.
transmission to the engine. 7. Replace battery into compartment and reconnect
battery cables to terminals, starting with the positive
WARNING: Risk of personal injury. (+) terminal.
The transmission may move while hoisting it 8. Reattach access panel to rear of engine
out of the chassis. Carefully move the compartment.
transmission and adjust the sling as needed.
Keep fingers, hands, legs and other body parts 6.4.4 After Transmission Replacement
clear of the transmission.
1. Check the hydraulic oil level and add oil as required.
15. Carefully remove the transmission from the 2. Install a new hydraulic filter.
machine. Avoid causing damage to the transmission
3. Wear suitable eye protection. When an overhauled
or surrounding parts.
or repaired transmission is installed, thoroughly
16. Lift the transmission clear of the machine, and lower clean the oil cooler lines to and from the transmission.
it onto suitable supports or secure it to a stand built
4. Drain and flush the entire system.
especially for transmission or engine service. Secure
the transmission so that it will not move or fall. 5. Disconnect and clean all transmission cooler hoses.
When possible, remove hydraulic lines from the
The transmission is now ready for inspection and/or
machine for cleaning.
further service.
6. Back flush the transmission oil cooler portion of the
6.4.2 Transmission Disassembly radiator or the oil cooler (located behind the radiator)
with oil and compressed air until all foreign material
The forward and reverse relief valves are the only parts is removed. Flushing in the direction of normal oil
of the transmission that can be serviced. DO NOT flow does not adequately clean the cooler. If needed,
completely disassemble the hydrostatic pump. The pump remove the radiator or oil cooler from the machine.
is preset and any unauthorized tampering will void the
warranty. Any repair to the pump must be done by an IMPORTANT: DO NOT use flushing compounds for
authorized repair dealer. cleaning purposes.
7. Reassemble all components and fill the hydraulic
6.4.3 Transmission Installation reservoir with clean, fresh oil. DO NOT overfill.
8. Run the engine for two minutes at idle to help prime the
WARNING: Risk of severe personal torque converter and the hydraulic oil lines.
injury. NEVER lift a transmission alone; enlist 9. Recheck the level of the fluid in the reservoir with the
the help of at least one assistant or use a engine running at idle.
suitable hoist or overhead crane and sling.
10. Add Universal Tractor Fluid as necessary to bring
the fluid level up until it reaches the FULL mark on
WARNING: The transmission must
the reservoir. Recheck the oil level when it reaches
operating temperature (83-94° C or 180-200° F).
be properly installed using fasteners of the
correct size and grade, and torqued to their 11. Recheck all drain plugs, lines, connections, etc., for
specified values. leaks, and tighten where necessary.

1. Use a lifting strap or chain attached to a hoist or

overhead crane to position the transmission within
the chassis.
2. Insert the two Allen head bolts that attach the
transmission to the engine. Torque to 210 Nm
(154 lb-ft)

6.4 26.6/30.7
 Transmission:

6.4.5 Towing a Disabled Machine After the machine has been towed to a secure location,
reactivate the parking brake.
Towing a disabled machine should only be attempted as
a last resort, after exhausting all other options. Make 1. Block all four wheels.
every effort to repair the machine, and move it under its
own power. WARNING: BLOCK ALL FOUR
Towing is only possible by using the "towing" feature built WHEELS. Failure to do so could result in
into the hydrostatic pump and disengaging the park brake death or serious injury from machine roll away.
on the front axle.
2. Using a torque wrench, alternately unscrew the
1. Securely block all four wheels. brake release bolts (1) outward in 1/2 turn
increments until the torque drops off sharply.
WARNING: BLOCK ALL FOUR 3. Again, alternately unscrew the bolts outward until
WHEELS. Failure to do so could result in you feel the bolts flange begin to contact against the
death or serious injury from machine roll away. special screw.
2. Locate the six brake release bolts (1) at the base of 4. Screw the bolts inward (clockwise) 1/4 turn.
the front axle. Mark a line on the socket so you can 5. The parking brake should now be reactivated and
accurately count the number of turns each bolt the front wheels locked.
makes as you perform the procedure.
6. Remove the blocks from the four tires.
3. Alternately screw the release bolts clockwise in 1/2
7. Verify that the parking brake works.
turn increments. Turn until resistance is felt.
4. Alternately screw the bolts clockwise 5 to 5 1/2 turns Note: If the parking brake does not work, check all
in 1/2 turn increments. activation operations step by step.

5. Carefully remove the blocking from each tire and tow

the machine to a secure location.
Note: This procedure does not alter any relief settings.

1
1

MAH0770

26.6/30.7 6.5
 Transmission:

This Page Intentionally Left Blank

6.6 26.6/30.7
 Section 7
Engine: Deutz BF 4M 2012

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5.1 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5.2 Gaskets and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5.3 Capscrews, Nuts and Metric Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.2 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7.6
7.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.8.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.8.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.9 Engine Exhaust and Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7.10
7.10.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.11 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.11.1 Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12

26.6/30.7 7.1
 Engine: Deutz BF 4M 2012

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, 7.1.2 Component Terminology
engine operation does not violate local regulations.
To understand the safety, operation and maintenance
IMPORTANT: These instructions cover only the routine information presented in this section, it is necessary that
maintenance, removal, installation and troubleshooting the operator/mechanic be familiar with the names and
of the engine. For assistance with comprehensive locations of the engine components. The following
engine diagnosis, repair and component replacement, illustration identifies the components that are referred to
contact your local Deutz AG Service partner. throughout this section.

7.2 26.6/30.7
 Engine: Deutz BF 4M 2012

Air Cleaner
Assembly

Coolant
Overflow
Tank

Primary Fuel
Filter

Engine Fan
Mount Shroud

Fan
Radiator/Oil
Cooler
Implement
Pump Oil Filter
Fuel Filter

Alternator
Thermostat

Starter

Hydrostatic
Transmission

MAH0230

26.6/30.7 7.3
 Engine: Deutz BF 4M 2012

7.2 SAFETY INFORMATION Cleaning

General Machine Operation WARNING: When using steam

cleaners and pressure washers, wear
protective glasses, gloves and clothing to help
WARNING: Before attempting to
prevent personal injury.
start the engine and/or operate the machine,
read the Operator/Safety Manual.
• Before operating the engine and/or the WARNING: NEVER use gasoline or
machine, install any engine guards that other flammable materials for cleaning parts.
were removed, and clear all personnel Use only approved cleaning solvents.
from the immediate area.
• Check that the brakes are fully functional. Engine Coolant (anti-freeze/anti-boil over)
• DO NOT exceed the stability limits of
the machine. WARNING: DO NOT remove the
radiator cap while the engine and coolant are
• Allow only ONE person to have control
hot. Hot coolant under pressure is dangerous
of the engine and the machine.
and can injure the eyes and cause severe burns.
• Cooling system corrosion inhibitors
Preparation
contain alkali (chemicals that break
down organic substances such as skin
WARNING: Wear protective and eye tissue), DO NOT swallow.
glasses and protective shoes. Avoid prolonged or repeated contact
• Verify that the work area is capable of with corrosion inhibitors. In case of skin
supporting the weight of the machine contact, immediately wash affected
and the torque created by any sus- area with soap and water. In case of
pended load. contact with eyes, immediately flood
eyes with large amounts of water for a
• DO NOT work on an engine or a machine
minimum of 15 minutes. Obtain medi-
that is supported ONLY by a hoist or lift
cal assistance immediately. Keep cor-
jacks. Use blocks or suitable stands.
rosion inhibitors out of the reach of
children.
Engine Operation
• DO NOT use salt water or other corro-
sive liquid in the cooling system.
WARNING: Operate the engine in a
well-ventilated area only. Assure that engine
Rotating Parts and Fan Blades
operation will not produce a concentration of
toxic emissions.
• DO NOT operate the engine in the
WARNING: Keep away from parts
which rotate; the fan blades can appear
presence of a fuel spill or gas leak.
invisible when the fan is rotating.
Such combustible vapors, when drawn
into the engine, can cause engine DO NOT pull or pry on the fan blades. This
over-acceleration, explosion, fire and practice will cause fan failure. Use only approved
extensive personal injury and property methods and tools for manually rotating the
damage. Before operating in any haz- engine.
ardous environment, consult a recog-
nized authority (such as the engine
distributor) on engine operation in haz-
ardous environments.
• DO NOT smoke or operate the engine
during refueling.

7.4 26.6/30.7
 Engine: Deutz BF 4M 2012

Battery Engine Repair

WARNING: Keep sparks and fires WARNING: Before beginning any

away from batteries. Batteries produce adjustments or repairs, place accident
hydrogen gas, which can explode and cause prevention tags in the operator’s compartment
severe personal injury and property damage. and on the controls, and disconnect the battery
Battery fluid can burn the skin and injure the negative cable.
eyes. If you come in contact with battery acid, • DO NOT operate, clean, lubricate or
flush the affected area with large amounts of adjust the engine without proper training.
water and obtain medical assistance immediately. • NEVER attempt to perform an adjust-
ment or repair that is not understood.
Engine Oil • Before servicing, relieve pressure in
fuel, oil, coolant and hydraulic lines.
WARNING: Engine oil can cause Obtain medical assistance immediately
skin disorders and other personal injury. Avoid if a high-pressure jet of fuel, oil, coolant
prolonged or repeated contact with both new or hydraulic fluid strikes the skin.
and used engine oil. • DO NOT permit loose clothing, hair,
etc., near moving parts.
Diesel Fuel • Keep away from parts which rotate; fan
blades can appear invisible when the
WARNING: Diesel fuel can cause fan is rotating.
skin irritation. Use gloves or protective hand • To help prevent burns, avoid contact
lotion when working on the fuel system. with components that remain hot after
power is turned off or disconnected.
• Some of the gaskets on the engine
contain asbestos. Breathing asbestos
dust is dangerous to health and may
cause severe bodily harm. Avoid creat-
ing dust and follow local directives for
handling and disposing of materials
that contain asbestos.

Parts

WARNING: When replacement is

necessary, ALWAYS use factory-approved
fasteners and parts.

7.3 ENGINE SERIAL NUMBER

The Deutz BF 4M 2012 serial number is stamped on the
side of the engine block underneath the implement pump
and oil filters. Information contained in the serial number
is required in correspondence with the engine
manufacturer.
Supply the engine serial number and/or data tag
information when communicating about an engine or
engine components.

26.6/30.7 7.5
 Engine: Deutz BF 4M 2012

7.4 SPECIFICATIONS AND 7.6 ENGINE COOLING SYSTEM

MAINTENANCE INFORMATION
7.6.1 Radiator Pressure Cap
For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General The cooling system is designed to use a radiator
Information and Specifications.” pressure cap to help prevent the coolant from boiling. In
addition, the pressure helps to eliminate the formation of
Note: Detailed Deutz engine service instructions steam pockets within the engine and ensures coolant
(covering disassembly, inspection, internal repair, circulation throughout all coolant passageways of the
assembly, adjustment and troubleshooting information) engine. For a 110° C (230° F) system, use a 95 kPa (13
are provided in the appropriate Deutz engine service psi) radiator cap. An incorrect or malfunctioning cap can
manual. result in the loss of coolant and a hot-running engine.

7.5 STANDARD PRACTICES 7.6.2 Radiator/Oil Cooler and Coolant

Heater Replacement
7.5.1 Cleanliness Before considering radiator or oil cooler replacement for
Cleanliness is very important during engine repair. other than obvious damage, conduct a cooling system
Contamination of the engine during repair will reduce the pressure test check the coolant specific gravity, coolant
life of an engine. Thoroughly clean the engine and engine level, fan belt tension and dash panel temperature
compartment area before attempting to service or repair indicator.
the engine. • If the engine runs hot, check the temperature of
DO NOT steam clean the following parts: the upper radiator hose.
• Electrical Components • If the hose is not hot, the thermostat may be
stuck in the closed position.
• Wiring
• If the engine has overheated, performance may
• Injectors
suffer, indicating other damage including a leaking
• Fuel Pump cylinder head gasket, cracked cylinder head or
• Belts and Hoses block, and/or other internal engine damage.
• Bearings
a. Radiator/Oil Cooler Removal
During reassembly and inspection, thoroughly clean all
parts, and, where present, remove burrs and scales. Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
7.5.2 Gaskets and O-rings 1. Level the machine, ground the attachment, place the
NEVER reuse a gasket or o-ring. Use new gaskets and o- travel select lever in NEUTRAL (N), engage the
rings. Thoroughly clean sealing surfaces before installing parking brake and shut off the engine.
a new gasket or o-ring. ALWAYS install new flat-faced o- 2. Remove the ignition key. Secure accident prevention
rings when servicing hydraulic fittings. tags to the steering wheel and ignition key switch.
Cover any open ports of high-precision components
(such as fuel system equipment) exposed by removal or WARNING: DO NOT attempt this
disassembly to help prevent the entry of foreign material. procedure when the engine is hot. Wait for the
engine, muffler, and tailpipes to cool down
7.5.3 Capscrews, Nuts and Metric Parts before proceeding. Failure to do so could
result in severe burns.
When replacing capscrews, ALWAYS use a capscrew of
the same size and strength (Grade) as the capscrew 3. Open the engine compartment and allow the engine,
being replaced. Incorrect capscrews can result in engine cooling system and hydraulic system to cool.
damage. Return capscrews removed from the engine to
4. Remove belly pan of engine compartment.
their original locations.
5. Thoroughly clean the engine and surrounding area,
Always replace used elastic locknuts with new elastic
including all hoses and fittings before proceeding.
locknuts.

7.6 26.6/30.7
 Engine: Deutz BF 4M 2012

6. Disconnect the cables from the battery, starting with b. Radiator/Oil Cooler Installation
the negative (-) cable(s).
For installation of the Radiator/Oil Cooler, reverse the
7. Slowly turn the radiator cap to the first stop and allow removal procedure. Refer to Section b, “Radiator/Oil
any pressure to escape. Remove the radiator cap. Cooler Installation.” After completed, run engine to
operating temperature. Visually check for leaks with the
engine running. Check the coolant level in the overflow
WARNING: Hot coolant can cause bottle and fill, or drain, as necessary.
severe burns or eye injury. NEVER remove the
radiator cap while the engine is hot. The cooling 7.7 ENGINE ELECTRICAL SYSTEM
system is under pressure. Wear protective
clothing and safety glasses. The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9, “.
8. Place a suitable container beneath the radiator Electrical System.”
petcock.
9. Place a funnel at the base of the radiator to channel 7.8 FUEL SYSTEM
the drained coolant into the container. Open the
radiator petcock and drain the coolant into the
funnel. Transfer the fluid into a properly labeled 7.8.1 Diesel Fuel
container. Dispose of properly if coolant needs to be Fuel represents a major portion of machine operating
replaced. Close the radiator petcock. costs and therefore must be used efficiently. ALWAYS
10. Disconnect hydraulic lines attached to radiator. use a premium brand of high-quality, clean diesel fuel.
Place a suitable container underneath the fittings. Low cost, inferior fuel can lead to poor performance and
Detach quickly and cap ends to minimize spilling of expensive engine repair.
fluid. Note: Use only diesel fuel designed for diesel engines.
11. Detach the fan safety shroud. Some heating fuels contain harmful chemicals that can
seriously affect engine efficiency and performance.

1 IMPORTANT: Due to the precise tolerances of diesel

injection systems, keep the fuel clean, and free of dirt
and water. Dirt and water in the fuel system can cause
severe damage to both the injection pump and the
injection nozzles. Use ASTM #2 diesel fuel with a
minimum Cetane rating of 40. #2 diesel fuel gives the
best economy and performance under most operating
conditions. Fuels with Cetane numbers higher than 40
2 may be needed in high altitudes or extremely low
ambient temperatures to help prevent misfiring and
excessive smoking.
MAH0290
Inform the owner/operator of the machine to use #2
12. Remove the two brackets (1) at the front of the diesel fuel, unless ambient temperatures are below 0° C
radiator attached to the frame. (32° F). When temperatures are below 0° C (32° F), a
13. Remove the bolts (2) and nuts that hold the radiator blend of #1 diesel and #2 diesel fuels (known as
to the engine compartment. “winterized” #2 diesel) may be used.
14. Carefully work the radiator out of the engine Note: #1 diesel fuel may be used, however, fuel
compartment, being sure not to damage any economy will be reduced.
surrounding components.
WARNING: DO NOT mix gasoline
or alcohol with diesel fuel. The mixture can
cause an explosion.

26.6/30.7 7.7
 Engine: Deutz BF 4M 2012

Use a low-sulfur content fuel with a cloud point (the c. Inspection

temperature at which wax crystals form in diesel fuel) at
Note: If a leak is suspected between the fuel and hydraulic
least 10° below the lowest expected fuel temperature.
oil tank, contact your local SDFI distributor.
The viscosity of the fuel must be kept above 1.3
centistrokes to provide adequate fuel system lubrication. 1. Inspect the fuel/hydraulic oil tank thoroughly for any
cracks, slices, leaks or other damage.
Note: When using diesel fuel with a sulfur content below
1.3 percent, the filter change interval must be reduced by 2. Plug all openings except one elbow fitting. Install the
75 hours. The use of fuel with a sulfur content above elbow fitting, and apply approximately 7-10 kPa
1.3 percent is not recommended. (1-1.5 psi) of air pressure through the elbow. Check
the tank for leaks by applying a soap solution to the
7.8.2 Fuel/Hydraulic Oil Tank exterior and look for bubbles to appear at the
cracked or damaged area.
a. Cleaning and Drying d. Disassembly and Assembly
If contaminated fuel, hydraulic oil or foreign material is in The fuel/hydraulic oil reservoir is a one piece-unit integral
the tank, the tank can usually be cleaned. to the chassis frame and cannot be disassembled.

b. If a leak is suspected between the fuel and hydraulic oil 7.8.3 After Fuel System Service
tank, contact your local SDFI distributor.
1. Drain and flush the fuel tank if it was contaminated.
To clean the fuel/hydraulic oil tank:
2. Vent air from the fuel system in accordance with the
1. Have a dry chemical (Class B) fire extinguisher near instructions found in the appropriate Operator/Safety
the work area. Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
WARNING: NEVER drain or store
fuel in an open container due to the possibility 7.9 ENGINE EXHAUST AND AIR
of explosion or fire. Discard the fuel in an
approved manner.
CLEANER SYSTEM

2. Depending on which side of the tank is contaminated

(fuel or hydraulic oil), remove the fuel or oil tank
WARNING: Exhaust fumes contain
carbon monoxide, a colorless, odorless gas
drain plug, and safely drain any fuel or hydraulic oil
which is fatal when inhaled in a confined area.
into a suitable container. Dispose of fuel or hydraulic
Avoid breathing exhaust fumes, and prevent
oil properly.
engine operation from becoming a cause of
3. Clean the fuel/hydraulic oil tank with a high-pressure toxic emissions. Exhaust system components
washer, or flush the tank with hot water for five reach high temperatures and can cause
minutes and drain the water. Dispose of severe burns. DO NOT come into contact with
contaminated water properly. hot exhaust system components.
4. For the fuel tank side, add a diesel fuel emulsifying
When the exhaust or air cleaner systems are removed be
agent to the tank. Refer to the manufacturer’s
sure to cover any open ports to prevent dirt and debris
instructions for the correct emulsifying agent-to-
from contaminating engine components.
water mixture ratio. Refill the tank with water, and
agitate the mixture for 10 minutes. Drain the tank
completely. Dispose of contaminated water properly. CAUTION: NEVER run the engine
with only the inner safety element installed.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.

7.8 26.6/30.7
 Engine: Deutz BF 4M 2012

7.10 ENGINE REPLACEMENT

3
7.10.1 Engine Removal 2

WARNING: To avoid severe burns,

DO NOT attempt to remove the engine when
the engine, cooling system and hydraulic
system are hot. Wait until all parts and systems
are cool before proceeding.

1. Level the machine, raise and support the boom,

place the travel select lever in NEUTRAL (N),
engage the parking brake and shut off the engine. 1

2. Secure accident prevention tags to the steering

wheel and ignition key switch.
MAH0620
3. Open the engine compartment and allow the engine,
cooling system and hydraulic system to cool. 17. Unbolt the relay distribution panel behind the engine.
Label any loose wire connections.
4. Remove belly pan of engine compartment.
18. Unplug the necessary harness plugs that go into the
5. Thoroughly clean the engine and surrounding area, cab.
including all hoses and fittings before proceeding.
19. Carefully pull wires through engine compartment
6. Disconnect the cables from the battery, starting with wall and place on engine.
the negative (-) cable(s).
20. Mark the location of the throttle cable (2) at the
7. Remove the engine compartment cover. engine throttle lever. Disconnect the throttle cable.
8. Remove battery from engine compartment, 21. Detach exhaust and air cleaner hoses from the
disconnect and remove battery tray. engine. Cover air inlets to protect from dirt & debris.
9. Drain hydraulic reservoir, expansion tank and 22. Remove air cleaner assembly from engine
radiator (Refer to the appropriate Operator/Safety compartment.
Manual for information concerning the hydraulic oil
and filter change). 23. Completely disconnect exhaust pipe.

10. Label and disconnect all hydraulic hoses attached to 24. Remove the 4 motor mount bolts that attach the
engine and radiator, cap all fittings and plug hoses to engine to the frame.
keep dirt & debris from entering hydraulic system. 25. Secure the engine with a lifting strap or chain from
11. Disconnect the fuel inlet (1) and return lines. Install a the appropriate lifting points (3). Use a suitable hoist
plug in the end of each line. or overhead crane.

12. Remove hydraulic and fuel filters, windshield washer 26. Carefully lift the engine from the machine. Avoid
fluid reservoir and filter bracket assembly. causing damage to the surrounding parts.

13. Remove radiator expansion tank. 27. Lift the engine clear of the machine, and lower it onto
suitable supports or stand. Secure the engine so that
14. Unbolt and remove the fan safety shroud. it will not move or fall.
15. Remove bolts securing the radiator and lift it clear of
engine compartment. Refer to section Section 7.6.2,
“Radiator/Oil Cooler and Coolant Heater
Replacement.”.
16. Remove the engine fan.

26.6/30.7 7.9
 Engine: Deutz BF 4M 2012

7.10.2 Engine Disassembly, Inspection and 12. Reattach all hydraulic hoses and fittings to the
Service engine and necessary hydraulic elements. Keep
hoses free of dirt & debris.
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Deutz BF 13. Refill the hydraulic reservoir (Refer to the
4M 2012 service manual. Several special engine service appropriate Operator/Safety Manual for information
tools are required to properly service the Deutz engine. concerning the hydraulic oil and filter change).
Contact your local Deutz AG Service partner for further
information.
Note: If the engine is being replaced, there may be external 2
components that will be required to be transferred from the
original engine to the replacement engine depending upon
who you purchase the new engine from and the
configuration of your replacement engine. Refer to the
appropriate Deutz user manual for detailed procedures that
cover the transfer of original engine components to the
replacement engine.

7.10.3 Engine Installation

1
Note: Refer to Section 2.3, “Torques,” for specific
fastener torque specifications.
1. Position engine in engine compartment being sure to MAH0620
line up the 4 motor mount holes. Torque to 80 Nm
(59 lb-ft). 14. Replace the battery tray and reconnect the battery
terminals, being sure to start with the positive (+)
2. Connect the exhaust pipe to the engine.
terminal.
3. Install the air cleaner assembly into the engine
15. Check that all hydraulic, electrical, cooling, fuel and
compartment and attach hose to air intake.
exhaust system connections are correct and
4. Reconnect throttle cable (2) onto the engine, if connected tightly.
necessary adjust for full travel.
16. Run engine to normal operating temperature then shut
5. Feed engine harness wires through the engine off the engine. While the engine is cooling, check for
compartment wall and plug into the ports located on leaks.
the side of the cab.
17. Allow the engine to cool. Check the radiator coolant
6. Reattach the relay distribution panel and connect level, and top off with a 50/50 mixture of Akros Farm
any loose wires. Flu and water. Replace the radiator cap.
7. Install the expansion tank bracket and secure the 18. Check for leaks from the engine, main hydraulic pump
expansion tank. and lines, transmission, hydraulic reservoir and fuel
8. Attach the engine fan. tank. Check the levels of all fluids and lubricants. Fill
as required.
9. Secure the radiator with the necessary bolts and
attach the fan safety shroud. Check that the fan top IMPORTANT: During the full throttle check:
clearance is adequate with regard to the radiator. • DO NOT operate any hydraulic function.
Refer to Section 7.6.2, “Radiator/Oil Cooler and
• DO NOT steer or apply any pressure to the
Coolant Heater Replacement.” Fill with a 50/50
steering wheel.
mixture of Akros Farm Flu and water.
• Keep the transmission in NEUTRAL (N).
10. Install the filter bracket assembly. Secure the
hydraulic and fuel filters and windshield washer fluid 19. Obtain and connect an appropriate engine analyzer
reservoir. or tachometer. Check the engine rpm at full throttle.
If the rpm is not 2600-2800 rpm, readjust the throttle
11. Connect the fuel inlet line to the fuel filter (1) and
limit-stop screw at the throttle pedal within the cab.
reconnect the return fuel line to the engine.

7.10 26.6/30.7
 Engine: Deutz BF 4M 2012

20. Purge the hydraulic system of air by operating all 7.11.2 Coupler Installation
boom functions through their entire range of motion
1. Attach the coupler (3) and flex plate (4) using the
several times. Check the hydraulic oil level.
necessary bolts. Torque to 210 Nm (155 lb-ft)
21. Check for proper operation of all components.
2. Bolt on the Flywheel Cover Plate (2) over the
22. Turn the engine OFF. coupler and flywheel. Torque bolts to 50 Nm (37 lb-
ft).
7.11 ENGINE COUPLER 3. Reattach the hydrostatic transmission (1). Follow all
guidelines in Section 6.4.3, “Transmission
7.11.1 Coupler Removal Installation.”
1. Remove Hydrostatic transmission. Refer to Section
6.4.1, “Transmission Removal.” Be sure to follow all
described safety guidelines.
2. After transmission (1) has been removed, take out
the 12 bolts that attach the Flywheel Cover Plate (2)
to the engine.
3. Pull off the Flywheel Cover Plate to expose the
coupler (3) and the flywheel.
4. Remove the necessary bolts to detach the coupler
and flex plate (4).

4 3
2

MAH0630

26.6/30.7 7.11
 Engine: Deutz BF 4M 2012

7.12 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

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 closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks

7.12 26.6/30.7
 Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4.1 Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4.2 Hose, Tube, Line and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5.2 Main Control Valve Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5.3 Charge Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5.4 Drive Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5.5 Steering Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5.6 Brake Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.6 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8.1 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8.2 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.9 Front Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.10 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.10.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.10.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8.10.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.10.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.10.5 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.11 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.11.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.11.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.11.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.11.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.11.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.11.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
8.11.7 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
8.11.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8.22

26.6/30.7 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

~
Crowd Cylinder

Compensation
~

Main Control Cylinder

Valve
Hoist Cylinder

Hydraulic
Filter

Main
Pump
MAH0240
Steering
Cylinder

8.2 26.6/30.7
 Hydraulic System

8.2 SAFETY INFORMATION

WARNING: DO NOT service the

WARNING: Before starting the
engine, verify that all hydraulic connections are
machine without following all safety
properly tightened. Escaping hydraulic fluid
precautions as outlined in Section 1, “Safety
under pressure can penetrate the skin causing
Practices,” of this manual. Failure to follow the
death or serious injury.
safety practices may result in death or serious
injury. A major cause of hydraulic component failure is contamination. Keeping
the hydraulic fluid as clean as possible will help avoid downtime and
repairs. Sand, grit and other contaminants can damage the finely
WARNING: Wait for hydraulic fluid machined surfaces within hydraulic components. If operating in an
to cool before servicing any hydraulic exceptionally dirty environment, change filters and inspect the fluid
component. Hot hydraulic fluid can cause more often. When servicing the system, cap or plug hydraulic fittings,
severe burns. hoses and tube assemblies. Plug all cylinder ports, valves and the
hydraulic reservoir, and pump openings until installation occurs. Protect
Petroleum-based hydraulic fluids are used in this machine. The
threads from contamination and damage. Some hydraulic functions are
temperature of hydraulic fluid increases during the operation of various
actuated by interfacing with electrical system components (switches,
hydraulic functions. A heated petroleum-based hydraulic fluid presents
solenoids and sensors). When the hydraulic system is not functioning
a fire hazard, especially when an ignition source is present. Hydraulic
properly, check the electrical aspect of the malfunctioning circuit also.
fluid has a flash point that ranges from 150-318° C (300-600° F) and an
auto-ignition temperature of 262-402° C (500-750° F). Accordingly,
periodically inspect all hydraulic system components, hoses, tubes, 8.3 SPECIFICATIONS
lines, fittings, etc. Carefully examine any deterioration and determine
Refer to Section 2.4, “Specifications,” for hydraulic system
whether any further use of the component would constitute a hazard. If
specifications.
in doubt, replace the component.

WARNING: Relieve hydraulic 8.4 HOSES, TUBE LINES, FITTINGS, ETC.

pressure before servicing any hydraulic
There are numerous hydraulic hoses, tubes, fittings, etc. used on this
component. Escaping hydraulic fluid under
machine. Periodically inspect all of these and carefully examine any
pressure can penetrate the skin causing death or
signs of wear, abrasion and/or deterioration. Determine whether any
serious injury.
further use of the component would constitute a hazard. If in doubt,
Operate the hydraulic controls after the engine has stopped to relieve replace the component.
trapped pressure.
8.4.1 Replacement Considerations
Note: Residual pressure may remain in hydraulic cylinders, hoses,
valve bodies, components, etc. If the hydraulic lines going to or coming Conditions including, but not limited to, the following are sufficient for
from a component are taut, slowly and cautiously relieve (“bleed off”) considering component replacement:
pressure. 1. Any evidence of hydraulic fluid leakage at the surface of a flexible
Whenever you disconnect a hydraulic line, coupler, fitting or other hose or its junction with the metal and couplings.
component, slowly and cautiously loosen the part involved. A hissing 2. Any blistering or abnormal deformation to the outer covering of a
sound or slow seepage of hydraulic fluid may occur in most cases. After hydraulic hose.
the hissing sound has ceased, continue removing the part. Any
3. Hydraulic oil leakage at any threaded or clamped joint that cannot
escaping oil should be directed into an appropriate container. Cap or
be eliminated by normal tightening or other recommended
otherwise block off the part to prevent further fluid seepage. Hydraulic
procedures.
system maintenance will, at times, require that the engine be operated.
Always follow safety precautions. 4. Evidence of excessive abrasion or scrubbing on the outer surface
of a hose, rigid tube, or hydraulic fitting. Modification must be
made to eliminate the interference of the elements in contact with
one another, or to otherwise protect the components from contact
with one another. Slightly moving a hose or adjusting a plastic tie
wrap may often be all that is necessary to eliminate interference;
evaluate each situation and proceed as required by the individual
circumstances.

26.6/30.7 8.3
 Hydraulic System

8.4.2 Hose, Tube, Line and Fitting Pressure Test Kit

Replacement The hydraulic pressure test kit is used to pressure test the
Before removing a hydraulic hose or component, always various hydraulic components in the hydraulic system. The
mark or otherwise label the related parts and the exact kit includes:
location of the hose or component to aid in proper • Gauges for testing high and low pressure circuits
reinstallation. Hydraulic fluid is a good cleaner and can
remove most liquid-ink type markings, so make sure the • Fittings, couplers and hoses
mark or label will remain intact. Alternative methods to using • Laminates of test diagrams and test procedures
markers include color-coded tie wraps, number-tag sets, • Durable carrying case
alpha-numeric stampings or markings, and suitably labeled
pieces of tape. Select an appropriate marking method for the Contact your local SDFI distributor for ordering information.
conditions and proceed accordingly. Part Description Approximate Price and
Number Weight Availability
NEVER replace a hydraulic hose or other component with a
0.900.0390.1 Hydraulic Pressure 10 lbs. Consult Factory
part not specifically designed for this machine. Use only Test Kit
factory approved parts for best performance and safety.
Removal and replacement of hoses, tube lines, fittings, etc. 8.5.1 Pressure Checks and Adjustments
usually involves straightforward procedures. When
removing a hydraulic hose or other component, be aware In general, follow the steps below whenever conducting
that o-rings are used throughout the hydraulic system. pressure checks and performing adjustments:
ALWAYS replace a used o-ring with a new part. 1. Park the machine on a firm, level surface. Engage the
Check all routing of hoses, wiring and tubing for sharp bends park brake, place the travel select lever in (N)
or interference with any rotating members. Install NEUTRAL, place the neutral lock lever in the (N)
appropriate protective devices such as tie wraps and conduit NEUTRAL LOCK position, level the boom and turn the
to help shield hoses from damage. All tube and hose clamps engine OFF.
must be tight. 2. Pressure tee fittings are conveniently located in each
hydraulic circuit. Install a pressure gauge capable of
8.5 HYDRAULIC PRESSURE DIAGNOSIS measuring at least 10% more pressure than that which
the circuit being checked operates under.
SDFI Parts Department has a kit available to use for
hydraulic system maintenance and troubleshooting: the WARNING: Avoid prolonged engine
SDFI Pressure Test Kit. The kit is in a durable polyethylene operation in closed areas with inadequate
carrying case for demanding field service conditions. ventilation. Failure to properly ventilate exhaust
fumes can result in death or serious injury.
3. Start the engine. Operate machine functions several
times to allow hydraulic oil to reach operating
temperature. The hydraulic oil temperature should be
between 38-49° C (100-120° F). If a temperature gauge
or thermometer is unavailable, the hydraulic oil reservoir
should be warm to the touch.
4. Fully depress the accelerator pedal as required. Place
and hold the joystick in the position needed to operate
the particular machine function being checked.
Continue holding the joystick in position until pressure
readings are taken.
5. Check the pressure gauge reading. It should read as
described in the appropriate section. If the reading is
not as specified, turn the engine OFF and check other
components in the system. Verify that all related
hydraulic components and electrical switches, sensors,
solenoids, etc. are operating correctly.

8.4 26.6/30.7
 Hydraulic System

6. As a last resort, adjust the appropriate relief valve, if 8.5.4 Drive Pressure Checking
applicable. Turning the adjustment screw clockwise
Attach a pressure gauge to the test fitting (9) on the
will increase the pressure; turning the screw
hydrostatic transmission to check the system pressure.
counterclockwise will decrease the pressure.
Check the drive pressure with the park brake on and the
Start the engine and check the pressure again. Turn the service brake off at full throttle. The pressure reading
engine OFF, operate the auxiliary hydraulic control lever should be 440 to 460 bar (6381 to 6671 psi).
(on units equipped with the optional auxiliary hydraulic
Do NOT adjust any relief settings. The unit is preset at the
system), then disconnect or remove the pressure gauge
factory and should not be tampered with. If the proper
from the machine.
pressure is not read, the unit may be defective.
8.5.2 Main Control Valve Pressure Checking
8.5.5 Steering Pressure Checking
Attach 345 bar (5000 psi) gauge to the test port (7) on the
Attach a pressure gauge to the test fitting (10) on the
main control valve port to check the system pressure.
appropriate hose of the implement pump. The pressure
The main control valve pressure should be 250 ± 5 bar
reading should be 180 bar (2610 psi) with the steering
(3600 psi) at full throttle.
wheel fully turned to one direction.
Do NOT adjust any relief settings. The unit is preset at the
7
factory and should not be tampered with. If the proper
pressure is not read, the unit may be defective.

10

MAH0120

MAH0850
8.5.3 Charge Pressure Checking
Attach a pressure gauge to the test port (8) on the 8.5.6 Brake Pressure Checking
hydrostatic transmission to check the system pressure.
The pressure should be between 25 to 28 bar (362 to 406 Attach a pressure gauge to the test fitting (11) on the
psi) with the engine at idle. brake valve in the cab to check system pressure. The
pressure reading should be 30 bar (435 psi) with the
Do NOT adjust any relief settings. The unit is preset at the brake pedal fully depressed.
factory and should not be tampered with. If the proper
pressure is not read, the unit may be defective. Do NOT adjust any relief settings. The unit is preset at the
factory and should not be tampered with. If the proper
pressure is not read, the unit may be defective.

9
11

MAH0030
MAH0780

26.6/30.7 8.5
 Hydraulic System

8.6 HYDRAULIC SCHEMATIC

RIGHT

REAR STEERING
CYLINDER
LEFT B
LEFT

FRONT STEERING
T

CYLINDER
T B
R L
P
H
RIGHT

L P
LS SEE SHEE
TRAILER
T C
P
K
P T

LS P EF

P
FL

INLET

O N

ITEM DESCRIPTION
A PUMP, DRIVE
B1 MOTOR, DRIVE - 266 LOW TORQUE
B2 MOTOR, DRIVE - 307 LOW TORQUE; 266 HIGH TORQUE
B3 MOTOR, DRIVE - 307 HIGH TORQUE
C PUMP, IMPLEMENT - WITH PRIORITY VALVE
D FILTER, CHARGE - REMOTE MOUNT
E VALVE, STEER SELECT
F VALVE, MAIN CONTROL
G VALVE, LOW RANGE
H VALVE, STEERING
J VALVE, FRONT/REAR AUX - OPTIONAL
K VALVE, PARK BRAKE
L VALVE, SERVICE BRAKE
M VALVE, 3 BAR CHECK - COOLER BYPASS
N COOLER, TRANSMISSION
O FILTER, MAIN RETURN - TANK MOUNT
P VALVE, 1ST/2ND FRONT AUX - OPTIONAL
Q VALVE, TRAILER BRAKES - OPTIONAL
R VALVE, BRAKE INCHING

8.6 26.6/30.7
 Hydraulic System

E
COMPENSATION
SEE SHEET 2 FOR
AUXILIARY OPTIONS TELESCOPAGE
CROWD

LEVAGE INCLINGISON
LIFT TILT

OUTILLAGE
AUX

EET 2 FOR
R BRAKE OPTION
F
B A B A B A B A PS
280 280 280 280

F P2B

PRIORITY
FLOW VALVE T4

250 T1
P1

UL

T2B T3B

TP

G
2

R
3 1

X3

D X1

X2

Ps Fa Fa1 Fe B
T2
T1
R B B
Mb

U T1
Vg min.

A
Ma
Vg max.
T2
X1 X2 G Mh S A

MAH0100

26.6/30.7 8.7
 Hydraulic System

8.6 Hydraulic Schematic (Continued)

Q
X TRAILER BRAKE
VALVE

L R

K B N P

LS P EF

PRIORITY
FLOW VALVE
TRAILER BRAKES

INLET

AUXILIARY OPTIONS FRONT AUX FRON

1ST 2ND 1ST

REAR AUX FRONT AUX REAR AUX P REAR AUX

J J J

B A
B A B A
280 280 280 280
280 280

OPTIONAL REAR OPTIONAL REAR AUX WITH OPTIONAL REAR AUX WITH
AUXILIARY MANUAL SECOND FRONT AUX ELECTRIC SECOND FRONT AUX

8.8 26.6/30.7
 Hydraulic System

F
B A B A B A B A PS
280 280 280 280

P2B

T4

250 T1
P1

UL

T2B T3B

TP

FRONT AUX FRONT AUX

1ST 2ND 1ST 2ND

P J

B A B A
ONT AUX 280 280 280 280
2ND

OPTIONAL SECOND OPTIONAL SECOND

FRONT AUXILIARY FRONT AUXILIARY
-MANUAL- -ELECTRIC-

MAH0110

26.6/30.7 8.9
 Hydraulic System

8.7 HYDRAULIC RESERVOIR 8.8.2 Pump Replacement

The hydraulic reservoir and fuel tank are part of the a. Pump Removal
frame. For this reason, neither tank can be removed. For
1. Park the machine on a firm, level surface, fully retract
cleaning instructions, see Section 7.8.2, “Fuel/Hydraulic
the boom, raise the boom, place the travel select
Oil Tank.”
lever in (N) NEUTRAL, engage the park brake and
Occasionally, fluid may seep, leak or be more forcefully shut the engine OFF.
expelled from the filter head when system pressure
2. Place an Accident Prevention Tag on both the
exceeds the rating of the filter head or breather. If the
ignition key switch and the steering wheel, stating
return filter becomes plugged, return hydraulic oil will
that the machine should not be operated.
bypass the filter when pressure reaches 1,7 bar (25 psi)
and return to the reservoir unfiltered.
WARNING: DO NOT get under a
Carefully examine fluid seepage or leaks from the raised boom unless the boom is blocked up.
hydraulic reservoir to determine the exact cause. Clean Always block the boom before doing any
the reservoir and note where any seepage occurs. servicing that requires the boom to be up.
Unexpected lowering of the boom may cause
DANGER: NEVER weld in, on, near or death or serious injury.
around the hydraulic reservoir. Hydraulic fluid and
fumes can cause the reservoir to explode. This 3. Temporarily block up or support the raised boom.
can result in death or serious personal injury.
WARNING: Hot hydraulic fluid can
Leaks from a cracked or damaged reservoir require that cause severe burns. Wait for hydraulic fluid to
the reservoir be flushed completely with water and cool before servicing any hydraulic component.
repaired by a certified welder using approved techniques.
If these conditions cannot be met, the reservoir must be 4. Unlock and open the engine compartment. Allow the
replaced in its entirety. Contact your local SDFI distributor hydraulic fluid to cool.
should reservoir welding be required.
WARNING: Escaping hydraulic
8.8 HYDRAULIC SYSTEM PUMP fluid under pressure can penetrate the skin,
causing death or serious injury. Relieve
hydraulic pressure before servicing any
8.8.1 Pump Failure Analysis hydraulic component.
The implement pump is the “heart” of the hydraulic 5. Drain the hydraulic oil reservoir. Refer to the
system, and whenever there is a problem in the system, appropriate Operator/Safety Manual, Hydraulic Oil
the pump often is blamed. However, implement pump and Filter Change.
failure is seldom due to failure of pump components.
Pump failure usually indicates another problem in the 6. Remove the belly pan.
hydraulic system. 7. Thoroughly clean the pump and surrounding area,
According to pump manufacturer statistics, 90-95 percent including all hoses and fittings before proceeding.
of pump failures are due to one or more of the following 8. Label and disconnect all hydraulic hoses attached to
causes: the pump, cap all fittings and plug hoses to keep dirt
• Aeration & debris from entering hydraulic system.
• Cavitation 9. Remove the two bolts that hold the pump in place.
• Contamination
• Excessive Heat
• Over-Pressurization
• Improper Fluid
In the event of pump failure, investigate further to
determine the cause of the problem.

8.10 26.6/30.7
 Hydraulic System

The pump must be renewed if:

1. The PFE coated bearings in the body and flange are
worn through revealing the bronze backing.
2. The gear side faces are scored.
3. There is a noticeable wear groove on the main shaft
where the shaft seal lips run.
4. The bronze balance plates are scored.
Note: It is not recommended that damaged gears/
bodies, flanges or balance plates are replaced
individually as this will not constitute a good repair.
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
Implement hydraulic oil.
MAH0270
Pump
e. Pump Assembly
Note: Before assembly, all parts must be perfectly clean
b. Pump Disassembly and lubricated with hydraulic fluid. Renew all seals using
hydraulic fluid as a lubricant.
1. Mark the position of the body and flange to ensure
correct reassembly 1. Fit the shaft seal mounting flange with the garter
spring facings into the pump and refit the circlip.
2. Remove the nuts and washers attaching the flange
to the body. If necessary, carefully separate with a 2. Fit the channel seals and back-up rings into grooves
soft faced hammer. on balance plate into bore. Ensure that the seals
remain in their groove and that the two small holes in
3. Remove the retaining circlip and shaft seal from the
the balance plate are to the low pressure side of the
flange.
pump.
4. Pull out the main shaft assembly. Mark the position
3. Insert the main shaft and drive gear into their original
of the drive gear and balance plate. Remove the
bores.
drive gear and balance plate.
4. Replace the second balance plate into its original
5. Discard all seals and clean off all sealant from the
position. Be sure the small holes are to the low
flange/body interface.
pressure side, fit the channel seal and back-up ring.
c. Pump Cleaning 5. Fit the o-ring into its groove in the mounting flange
and apply a small amount of Loctite® to the lower
Clean all pump components with a suitable cleaner such front face of the body.
as trichlorethylene.
6. Carefully fit the mounting plate in its original position.
d. Pump Inspection The drain hole in the rear face must be to the low
pressure side, DO NOT DAMAGE THE SEAL ON
Inspect internal pump components for wear, damage, THE SHAFT.
etc. If inner surfaces of the pump DO NOT display an
7. Fit washers and nuts to studs and torque to 88-95
ultra-smooth, polished finish, or are damaged in any way,
Nm (65-70 lb-ft).
replace the damaged part. Often, dirty hydraulic fluid
causes failure of internal pump seals and damage to the 8. Pour a small amount of clean hydraulic fluid into the
polished surfaces within the pump and other hydraulic inlet port and check that the shaft can be turned
system components. without undue force.
Inspect the o-ring groove and shaft seal recess in the
mounting flange. Be sure they are undamaged and free
from burrs.

26.6/30.7 8.11
 Hydraulic System

f. Pump Installation 8.9 FRONT DRIVE PUMP

1. Position pump in the mounting position.
For internal service instructions and detailed
Note: Use new o-rings where required. Never reuse o- specifications, contact your local SDFI distributor for a
rings. copy of the Rexroth Repair Manual (P/N 0.900.0390.0).
2. Use the two Allen head bolts to secure the pump into 1
place. Torque to 95 Nm (70 lb-ft).
3. Reconnect previously labeled hydraulic hoses to
their proper ports.
4. Fill the hydraulic reservoir with clean, filtered
hydraulic oil.
5. Prime the pump by filling the case drain port with fresh,
filtered hydraulic oil from a clean container before MAH0520
installing the case drain connector and hose.
6. Check all routing of hoses and tubing for sharp a. Front Drive Pump Removal
bends or interference with any rotating members. All 1. Park the machine on a firm, level surface, ground
tube and hose clamps must be tight. the attachment (if any), place the travel select lever
in (N) NEUTRAL, engage the park brake and shut
WARNING: Avoid prolonged engine the engine OFF.
operation in closed areas with inadequate
2. Place an Accident Prevention Tag on both the
ventilation. Failure to properly ventilate exhaust
ignition key switch and the steering wheel, stating
fumes can result in death or serious injury.
that the machine should not be operated.
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without WARNING: Hot hydraulic fluid can
moving the machine or operating any hydraulic cause severe burns. Wait for hydraulic fluid to
functions. cool before servicing any hydraulic component.
3. Open the engine cover. Allow the hydraulic fluid to
WARNING: Hydraulic oil leaking
cool.
under pressure can penetrate the skin and
cause severe personal injury. DO NOT use 4. Drain the hydraulic reservoir or place a vacuum on
your hand or any part of your body to check for the reservoir fill tube.
hydraulic leaks. When checking for hydraulic 5. Label and disconnect all hydraulic hoses attached to
leaks, wear safety glasses and gloves to help the pump, cap all fittings and plug hoses to keep dirt
provide protection from spraying hydraulic oil. & debris from entering hydraulic system.
Use a piece of cardboard or paper to search
6. Remove the four bolts attaching the pump to the
for leaks.
front axle.
8. Inspect for leaks and check all fluid levels.
b. Front Drive Pump Installation
Note: Check for leaks and repair as required before
continuing. 1. Install the pump onto the front axle. Torque the four
bolts to 200 Nm (146 lb-ft). Use only new seals.
g. Pump Test 2. Reconnect the previously labeled hydraulic hoses to
1. Perform a flow meter test on the pump. their appropriate locations.
2. Check the load sense. 3. Fill the pump with hydraulic fluid through the fill plug
(1) before starting the machine.
3. Check the system functions.

8.12 26.6/30.7
 Hydraulic System

8.10 VALVES AND MANIFOLDS 3. Temporarily block up or support the raised boom.

8.10.1 Main Control Valve

WARNING: Hot hydraulic fluid can
cause severe burns. Wait for hydraulic fluid to
The main control valve is mounted on the rear of the cool before servicing any hydraulic component.
machine behind the rear access panel.
4. Unlock and open the rear door. Allow the hydraulic
The main control valve assembly consists of various fluid to cool.
working sections with their own valve assemblies, each
providing a specific hydraulic function. The section
assemblies are the outlet, crowd, auxiliary, tilt, hoist and
WARNING: Escaping hydraulic
fluid under pressure can penetrate the skin,
load sense outlet sections. causing death or serious injury. Relieve
hydraulic pressure before servicing any
hydraulic component.
CROWD SECTION 5. With the engine OFF, operate all the hydraulic
AUXILIARY SECTION functions to relieve trapped pressure.
TILT SECTION
HOIST SECTION 6. Thoroughly clean the main control valve and
surrounding area, including all hoses and fittings,
before proceeding.
7. Place a suitable container to catch hydraulic fluid
drainage beneath the frame.
8. Label or otherwise mark and disconnect all the
FRONT OF MACHINE hydraulic hoses, tubes and control cables at the
main control valve.
9. Wipe up any hydraulic fluid spillage in, on, near and
MAH0120 around the machine and the work area.
10. Remove the four bolts securing the main control
Note: If the machine has auxiliary hydraulics installed,
valve to the frame bracket.
the auxiliary hydraulics section will have relief valves. If the
machine does not have auxiliary hydraulics installed, the
b. Main Control Valve Disassembly
relief valve ports will be plugged.
1. To disassemble the individual sections of the main
a. Main Control Valve Removal control valve, remove the nuts and from the end of
the tie rod. Pull the tie rods out through the sections.
1. Park the machine on a firm, level surface, fully
retract the boom, raise the boom, place the travel 2. Disassemble each section assembly as required.
select lever in (N) NEUTRAL, engage the park brake Some sections include a pre-adjusted relief valve that
and shut the engine OFF. regulates pressure in a specific circuit.
2. Place an Accident Prevention Tag on both the IMPORTANT: DO NOT adjust any of the relief valve
ignition key switch and the steering wheel, stating assemblies! Tampering with a relief valve will irrevocably
that the machine should not be operated. alter pressure in the affected circuit, requiring recalibration
or a new relief valve.
WARNING: DO NOT get under a
raised boom unless the boom is blocked up.
Always block the boom before doing any
servicing that requires the boom to be up.
Unexpected lowering of the boom may cause
death or serious injury.

26.6/30.7 8.13
 Hydraulic System

Assemble each Valve Section

Valve Section 1. Reassemble any check valves, compensator valves,

anti-cavitation valves or shock valves from individual
valve sections if equipped.
2. Install the control spool being careful not to nick or
Load Sense scratch the valve section bore or the control spool.
Section
3. Install the end caps on each end of the valve
section.

Assemble the Main Control Valve.

1. Place all three tie rods with the washers and nuts
through the end main control valve section.
2. Stand the end main control valve section on end.

MAH0720
3. Install proper o-rings and load sense shuttle on the
inner face of the end main control valve section.
Align the Crowd section over the three tie rods and
Disassemble each Valve Section
slide onto the end main control valve section.
1. Carefully separate the load sense outlet section from the 4. Using proper o-rings and load sense shuttle, repeat
crowd section. step three for the remaining sections.
2. Remove the o-rings from between the two sections. 5. Install the washers and nuts on the tie rods and
3. Carefully separate each remaining section being torque to 25 Nm (18.5 lb-ft).
careful not to lose the load sense shuttle ball.
4. Remove both end caps from each end of the valve f. Main Control Valve Installation
sections then remove each control spool. 1. Loosely install the four main control valve mounting
5. Remove any check valves, compensator valves, bolts through bracket on the rear of the machine.
anti-cavitation valves or shock valves from each 2. Install the main control valve onto the bracket,
individual valve section if equipped. aligning the bolts with the holes in the end sections
6. Keep all parts being removed from individual valve of the main control valve. Slide the main control
sections tagged and kept together. valve into position, and tighten the bolts.
3. Prime the main control valve by filling the inlet
c. Main Control Valve Parts Cleaning openings with fresh, filtered hydraulic oil from a
Clean all components with a suitable cleaner, such as clean container, before attaching the hoses.
trichlorethylene, before continuing. Blow dry. 4. Use new oiled o-rings as required. Reattach and
secure all hoses, clamps, etc. to the main control
d. Main Control Valve Parts Inspection valve.
Inspect all parts and internal passageways for wear, 5. Check the routing of all hoses, wiring and tubing for
damage, etc. If inner surfaces of any component DO NOT sharp bends or interference with any rotating
display an ultra-smooth, polished finish, or are damaged members, and install tie wraps and/or protective
in any way, replace the damaged part. Often, dirty conduit as required. Tighten all tube and hose
hydraulic fluid causes failure of internal seals, damage to clamps.
the polished surfaces within the component, and wear of
and/or harm to other parts. WARNING: Avoid prolonged engine
operation in closed areas with inadequate
e. Main Control Valve Assembly ventilation. Failure to properly ventilate exhaust
fumes can result in death or serious injury.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and 6. Start the engine and run at approximately one-third
operation. Lubricate seals and o-rings with clean to one-half throttle for about one minute without
hydraulic oil.

8.14 26.6/30.7
 Hydraulic System

moving the machine or operating any hydraulic 3. Allow the hydraulic fluid to cool.
functions.
WARNING: Escaping hydraulic
WARNING: Hydraulic oil leaking fluid under pressure can penetrate the skin,
under pressure can penetrate the skin and causing death or serious injury. Relieve
cause severe personal injury. DO NOT use hydraulic pressure before servicing any
your hand or any part of your body to check for hydraulic component.
hydraulic leaks. When checking for hydraulic
4. Remove the necessary dash panels. Refer to
leaks, wear safety glasses and gloves to help
Section 4.4, “Cab Removal.”
provide protection from spraying hydraulic oil.
Use a piece of cardboard or paper to search 5. Label or otherwise mark the hydraulic hoses
for leaks. connected to the service brake valve. Disconnect
and cap all hoses, fittings, etc.
7. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.

g. Main Control Valve Test

Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section MAH0030
8.5.2, “Main Control Valve Pressure Checking.”
6. Remove the bolts that mount the service brake valve
to the steering column support
8.10.2 Service Brake Valve
The service brake valve is at the base of the steering Note: DO NOT disassemble the service brake valve.
column support, concealed by the lower dash cover. The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
The service brakes themselves are part of the axles (the park
brake is part of the front axle only). Refer to Section 5, “Axles, b. Service Brake Valve Installation
Drive Shafts, Wheels and Tires,” for further information.
1. Install the service brake valve to the steering column
a. Service Brake Valve Removal support with the necessary hardware.

1. Park the machine on a firm, level surface, fully Note: ALWAYS replace seals, o-rings, gaskets, etc.,
retract all hydraulic cylinders, ground the attachment with new parts to help ensure proper sealing and
(if any), place the travel select lever in (N) operation. Lubricate seals and o-rings with clean
NEUTRAL, engage the park brake and shut the hydraulic oil.
engine OFF. 2. Use new oiled o-rings as required. Reattach and
2. Place an Accident Prevention Tag on both the secure all valves, hoses, clamps, etc.
ignition key switch and the steering wheel, stating 3. Check the routing of all hoses, and tubing for sharp
that the machine should not be operated. bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
WARNING: Hot hydraulic fluid can required. Tighten all tube and hose clamps.
cause severe burns. Wait for hydraulic fluid to
cool before servicing any hydraulic component. WARNING: Avoid prolonged engine
operation in closed areas with inadequate
ventilation. Failure to properly ventilate exhaust
fumes can result in death or serious injury.

26.6/30.7 8.15
 Hydraulic System

4. Start the engine and run at approximately one-third 2. Place an Accident Prevention Tag on both the
to one-half throttle for about one minute, without ignition key switch and the steering wheel, stating
moving the machine or operating any hydraulic that the machine should not be operated.
functions.
WARNING: Hot hydraulic fluid can
WARNING: Escaping hydraulic cause severe burns. Wait for hydraulic fluid to
fluid under pressure can penetrate the skin, cool before servicing any hydraulic component.
causing death or serious injury.
3. Open the engine cover. Allow the hydraulic fluid to
5. Inspect the service brake valve and connections for cool.
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF. WARNING: Escaping hydraulic fluid
Note: Check for leaks, and repair as required before under pressure can penetrate the skin, causing
continuing. Add hydraulic fluid to the reservoir as death or serious injury. Relieve hydraulic
needed. pressure before servicing any hydraulic
component.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools. 4. Loosen and remove the three bolts and washers
holding the park brake valve cover. Remove the
c. Brake Test cover.
The service brake is equipped with an automatic bleed 5. Label or otherwise mark the hydraulic hoses on each
feature. Run the machine for a few minutes. Then pump side and bottom of the park brake valve. Disconnect
the brake several times to force out any trapped air in the and cap all hoses, fittings, etc.
system. 6. Remove the two capscrews, and two lockwashers
mounting the park brake valve to the left side of the
8.10.3 Parking Brake seat base.
The park brake is secured with two capscrews and Note: DO NOT disassemble the park brake valve. The
lockwashers at the left side of the seat base. park brake valve is not serviceable and must be replaced
in its entirety, if defective.

b. Park Brake Valve Installation

1. Install the park brake valve with the two lockwashers
and two capscrews to mount the park brake valve to
the left side of the seat base.
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.
MZ0350
2. Use new oiled o-rings as required. Reattach and
secure the three hoses.
a. Park Brake Removal
3. Check the routing of all hoses for sharp bends or
1. Park the machine on a firm, level surface, fully interference with any rotating members, and install
retract all hydraulic cylinders, ground the attachment tie wraps and/or protective conduit as required.
(if any), place the travel select lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
WARNING: Avoid prolonged engine
operation in closed areas with inadequate
ventilation. Failure to properly ventilate exhaust
fumes can result in death or serious injury.
4. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without

8.16 26.6/30.7
 Hydraulic System

moving the machine or operating any hydraulic a. Steer Select Manifold and Valve Removal
functions. 1. Park the machine on a firm, level surface, fully
retract the boom, raise the boom, place the travel
WARNING: Escaping hydraulic fluid select lever in (N) NEUTRAL, engage the park brake
under pressure can penetrate the skin, causing and shut the engine OFF.
death or serious injury.
2. Place an Accident Prevention Tag on both the
5. Inspect the park brake valve and connections for ignition key switch and the steering wheel, stating
leaks, and check the level of the hydraulic fluid in the that the machine should not be operated.
reservoir. Shut the engine OFF.
Note: Check for leaks, and repair as required before WARNING: DO NOT get under a
continuing. Add hydraulic fluid to the reservoir as raised boom unless the boom is blocked up.
needed. Always block the boom before doing any
servicing that requires the boom to be up.
6. Wipe up any hydraulic fluid spillage in, on, near and Unexpected lowering of the boom may cause
around the machine, work area and tools. death or serious injury.

8.10.4 Steering Orbitrol Valve 3. Temporarily block up or support the raised boom.

Refer to Section 4.3.2, “Steering Column/Valve

Replacement,” for details.
WARNING: Hot hydraulic fluid can
cause severe burns. Wait for hydraulic fluid to
cool before servicing any hydraulic component.
8.10.5 Steer Select Valve
4. Allow the hydraulic fluid to cool.
The steer select valve is attached to a manifold mounted
on a mounting plate inside the frame near the front drive
motor. WARNING: Escaping hydraulic
fluid under pressure can penetrate the skin,
Verify the correct operation of the steer select valve causing death or serious injury. Relieve
solenoids before considering replacement of the valve. hydraulic pressure before servicing any
Refer to Section 9.13.3, “Steering.” The housing of the hydraulic component.
steer select valve is not serviceable and must be
replaced if defective. 5. Label or otherwise mark the hydraulic hoses in
relation to the steer select manifold. Disconnect and
cap all hoses, fittings, solenoid wire terminal leads,
etc.
6. Remove the capscrews that attach the manifold to
the frame.
7. Remove the steer select manifold with attached steer
select valve from the machine. Wipe up any
hydraulic fluid spillage in, on, near and around the
machine.

b. Steer Select Valve and Manifold Disassembly,

Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the capscrews. Discard the old o-rings.
3. Remove the solenoid valves and cartridges from the
steer select housing.
MAH0020
4. Clean all components with a suitable cleaner before
inspection.

26.6/30.7 8.17
 Hydraulic System

5. Inspect the solenoid cartridges for proper operation.

Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultra-
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 unit
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.
MAH0020
8. Attach the steer select valve to the manifold using
new, oiled o-rings and socket head capscrews. 4. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
c. Steer Select Manifold and Valve Installation machine or operating any hydraulic functions.
1. Attach the steer select manifold and valve to the
mounting plate on the frame using the socket head WARNING: Hydraulic oil leaking
capscrews. under pressure can penetrate the skin and
cause severe personal injury. DO NOT use
2. Connect the hydraulic hoses, fittings, solenoid wire your hand or any part of your body to check for
terminal leads, etc., to the steer select valve and hydraulic leaks. When checking for hydraulic
manifold. leaks, wear safety glasses and gloves to help
3. Check the routing of all hoses, wiring and tubing for provide protection from spraying hydraulic oil.
sharp bends or interference with any rotating Use a piece of cardboard or paper to search
members, and install tie wraps and/or protective for leaks.
conduit as required. Tighten all tube and hose clamps.
5. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.

WARNING: Avoid prolonged engine Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
operation in closed areas with inadequate
ventilation. Failure to properly ventilate exhaust 6. Wipe up any hydraulic fluid spillage in, on, near and
fumes can result in death or serious injury. around the machine, work area and tools.

d. Steering Test
1. Conduct a pressure check of the steering hydraulic
circuit at the test port on the implement pump.
2. Check each steering mode for proper function.

8.18 26.6/30.7
 Hydraulic System

8.11 HYDRAULIC CYLINDERS

1
8.11.1 General Cylinder Removal 2
Instructions
3
1. Remove any attachment from the machine. Park the
machine on a firm, level surface, allowing sufficient 4
workspace. Place the travel select lever in (N)
NEUTRAL, engage the park brake, shut the engine
OFF and chock the wheels.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.

WARNING: Hot hydraulic fluid can

1
cause severe burns. Wait for hydraulic fluid to
cool before servicing any hydraulic component.

3. Allow the hydraulic fluid to cool.

2 5
WARNING: Escaping hydraulic 6
fluid under pressure can penetrate the skin,
MAH0160
causing death or serious injury. Relieve
hydraulic pressure before servicing any
hydraulic component. 1. Barrel 4. Piston Head
2. Seals, Back-up 5. Rod
4. Label, disconnect and cap hydraulic hoses in rings and O-rings 6. Head Gland
relation to the cylinder. 3. Set screw
5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can
actually support the cylinder.
6. Remove the lock bolt and/or any retaining clips IMPORTANT: DO NOT tamper with or attempt to adjust
securing the cylinder pins. Remove the cylinder pins. the counterbalance valve cartridge. If adjustment is
necessary, replace the counterbalance valve with a new
7. Remove the cylinder. part.
8. Wipe up any hydraulic fluid spillage in, on, near or
4. Extend the rod (5) to allow access to the base of the
around the machine.
cylinder.
8.11.2 General Cylinder Disassembly IMPORTANT: Protect the finish on the rod at all times.
Damage to the surface of the rod can cause seal failure.
1. Clean the cylinder with a suitable cleaner before
5. Using a pin spanner wrench, unscrew the head
disassembly. Remove all dirt, debris and grease
gland (6) from the barrel (1). A considerable amount
from the cylinder.
of force will be necessary to remove the head gland.
2. Clamp the barrel end of the cylinder in a soft-jawed Carefully slide the head gland down along the rod
vise or other acceptable holding equipment if toward the rod eye end, away from the cylinder
possible. barrel.
IMPORTANT: Avoid using excessive force when IMPORTANT: When sliding the rod and piston assembly
clamping the cylinder in a vise. Apply only enough force out of the tube, prevent the threaded end of the tube
to hold the cylinder securely. Excessive force can from damaging the piston. Keep the rod centered within
damage the cylinder tube. the tube to help prevent binding.
3. If applicable, remove the counterbalance valve from 6. Carefully pull the rod assembly along with the head
the side of the cylinder barrel. gland out of the cylinder barrel.

26.6/30.7 8.19
 Hydraulic System

7. Fasten the rod end in a soft-jawed vise, and put a 2. Remove light scratches on the piston, rod or inner
padded support under and near the threaded end of surface of the tube with a 400-600 grit emery cloth.
the rod to help prevent damage to the rod. Use the emery cloth in a rotary motion to polish out
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
3. Check the piston rod assembly for run-out. If the rod
bond of the sealant between the piston and the rod
is bent, it must be replaced.
before the piston can be removed.
Some cylinder parts are sealed with a special organic 8.11.5 General Cylinder Assembly
sealant and locking compound. Before attempting to
1. Use the proper tools for specific installation tasks.
disassemble these parts, remove any accessible seals
Clean tools are required for assembly.
from the area of the bonded parts. Wipe off any hydraulic
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 Note: The Crowd cylinder has a spacer that MUST be
distorted or damaged. Apply sufficient torque for removal installed over the rod AFTER the head gland and
while the parts are still hot. The sealant often leaves a BEFORE the piston head.
white, powdery residue on threads and other parts, which
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
the rod (5) to prevent any damage to the rod.
9. Remove the piston head (4) from the rod (5) and
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
setscrew (3) in the piston head. Refer to Section
Note: The head gland bearing will need to be inspected 8.11.8, “Hydraulic Cylinder Torque Specifications,”
to determine if replacement is necessary. for tightening guidelines for the piston head and the
DO NOT attempt to salvage cylinder seals, sealing rings set 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.
8.11.3 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 IMPORTANT: When sliding the rod and piston assembly
ensure proper cylinder function. 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. 8.11.8, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the head gland.
8.11.4 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.

8.20 26.6/30.7
 Hydraulic System

7. Wipe up any hydraulic fluid spillage in, on, near and

around the machine, work area and tools.
1
2
8.11.7 Steering Cylinders
3 The steering cylinders are attached to each axle center
housing. The steer cylinders are covered in the
4 appropriate Carraro axle literature.

2 5
6
MAH0160

1. Barrel 4. Piston Head

2. Seals, Back-up 5. Rod
rings and O-rings 6. Head Gland
3. Set screw

8.11.6 General Cylinder Installation

1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Connect the hydraulic hoses in relation to the labels
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 Akros Multi FCT Tractor Fluid.
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
reservoir. Add hydraulic fluid if needed. Shut the
engine OFF.

26.6/30.7 8.21
 Hydraulic System

8.11.8 Hydraulic Cylinder Torque

Specifications

Description 26.6 30.7

All Cylinder Set Screws 20-25 Nm (15-18 lb-ft) 20-25 Nm (15-18 lb-ft)

Lift Cylinder
head gland 500-550 Nm (369-406 lb-ft) 700-750 Nm (516-553 lb-ft)
piston 2160-2210 Nm (1593-1630 lb-ft) 2630-2680 Nm (1940-1977 lb-ft)
Crowd Cylinder
head gland 300-350 Nm (221-258 lb-ft) 300-350 Nm (221-258 lb-ft)
piston 550-600 Nm (406-443 lb-ft) 550-600 Nm (406-443 lb-ft)
Tilt Cylinder
head gland 400-450 Nm (295-332 lb-ft) 700-750 Nm (516-553 lb-ft)
piston 1285-1335 Nm (948-985 lb-ft) 2630-2680 Nm (1940-1977 lb-ft)
Compensation Cylinder
head gland 400-450 Nm (295-332 lb-ft) 400-450 Nm (295-332 lb-ft)
piston 1115-1165 Nm (822-859 lb-ft) 115-1165 Nm (822-859 lb- ft)

8.22 26.6/30.7
 Section 9.
Electrical System

Contents

PARAGRAPH TITLE PAGE

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.2.2 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Wire Code and Color. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.5 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.5.1 Engine Compartment Relays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.6 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.6.1 Cab Roof Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.6.2 Cab Harness Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
9.6.3 Power Distribution Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
9.6.4 Front & Rear Chassis Harness, Battery, Boom Schematic . . . . . . . . . . . . 9.11
9.6.5 Engine Harness Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.7 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.7.1 Charge Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.7.2 Start Circuit Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.7.3 Drive Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.7.4 Constant Power Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.8 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.8.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.9 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.9.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.10 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.10.1 Load Moment Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.10.2 Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.10.3 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.11 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.11.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.11.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.11.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.12 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.12.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.13 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.13.1 Switch, Solenoid and Sender Maintenance . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.13.2 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.13.3 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.13.4 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9.24

26.6/30.7 9.1
 . Electrical System

9.13.5 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

9.14 Analyzer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.14.1 Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.14.2 Diagnostic Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28

9.2 26.6/30.7
 . Electrical System

9.1 ELECTRICAL 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 electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

Engine Compartment
Relays and Fuses

Power Distribution
Module

MAH0640

26.6/30.7 9.3
 . Electrical System

9.2 SERVICE WARNINGS

WARNING: Charge the battery in a
9.2.1 General well-ventilated area only. Always turn battery
chargers OFF before connecting to or
disconnecting from a battery.
CAUTION: DO NOT disconnect any
wiring without first stopping the engine, turning
all electrical switches to the OFF position and
disconnecting the battery ground (-) cable from CAUTION: DO NOT disconnect the
the battery. Failure to remove the negative (-) battery while the engine is running. This will
battery cable will result in damage to machine cause a voltage surge in the alternator
electronic systems. charging system that will immediately ruin
internal components.

CAUTION: DO NOT cause a short CAUTION: DO NOT connect a

circuit by connecting leads to incorrect battery into the system without checking for
terminals. Always identify a lead and its correct correct polarity and voltage.
terminal. A short circuit or wrong connection
creating reverse polarity will immediately and
permanently ruin internal components within
the electrical system. CAUTION: When doing welding
anywhere on the machine disconnect the wire
harness from the Engine Control Module
(ECM) on the engine.
CAUTION: DO NOT momentarily or
“flash” connect a terminal to check for current
flow. No matter how brief the contact, the
transistors may be ruined. 9.3 SPECIFICATIONS
Electrical system specifications are listed in Section 2,
9.2.2 Battery
“General Information and Specifications.”

WARNING: All lead-acid batteries

generate hydrogen gas, which is highly
flammable. If ignited by a spark or flame, the
gas may explode violently, causing spraying of
acid, fragmentation of the battery and possible
severe personal injuries, particularly to the
eyes. Wear safety glasses when working near
the battery.

WARNING: Avoid battery acid.

Battery acid can cause chemical burns or other
serious injury. In case of contact with battery
acid, flush area immediately with water.

9.4 26.6/30.7
 . Electrical System

9.4 WIRE CODE AND COLOR 9.5 FUSES AND RELAYS

The chart below indicates the wire code abbreviation and
color as used on the electrical schematics.
9.5.1 Engine Compartment Relays and
Fuses
Wire Code Color There are two relays and one buss bar located inside the
engine compartment, mounted on a bracket behind the
BLK Black
engine. The relays control the starter (1) and engine
BLU Blue preheat (2).
BRN Brown
DK BLU Dark Blue
DK GRN Dark Green
1
GRN Green
GRY Gray
LT BLU Light Blue
LT GRN Light Green
ORG Orange 2
PNK Pink
PUR Purple MAH0480

RED Red
TAN Tan
YEL Yellow
VIO Violet
WHT White

26.6/30.7 9.5
 . Electrical System

9.5.2 Power Distribution Module

F1 F8 F22

F2 F9 F23
K1 K5 K9
F3 F10 F24

F4 F11 F25

F5 F12 F26

F6 F13 F27 K2 K6 K10

F7 F14 F28

F15 F29

F16 F30 K3 K7 K11

F17 F31

F18 F32

F19 F33
K4 K8 K12
F20 F34

F21

MAH0490

Fuse/Relay Function Amp Rating

F1 Right Headlight High 7.5
F2 Right Headlight Low 7.5
F3 Left Headlight High 7.5
F4 Left Headlight Low 7.5
F5 Radio 10
F6 Radio Bat 5
F7 Front Wiper 20
F8 Heater Fan 20
F9 Aux Pwr Socket 15
F10 Air Suspension Seat 10
F11 Ignition 1 10
F12 Left Park/Side Lights 7.5

9.6 26.6/30.7
 . Electrical System

F13 Right Park/Side Lights 7.5

F14 Front Worklights 15
F15 Rear Worklights 15
F16 Boom Lights 15
F17 Beacon/Aux 15
F18 Reserved Switch 15
F19 Reserved Bat 15
F20 Reserved Ignition 10
F21 PCB Bat 10
F22 Ignition 2 15
F23 LMI/Joystick 10
F24 PCB Ignition 15
F25 Rear Wiper 20
F26 Flasher Pwr 15
F27 Key Bat 15
F28 Brake Lights 15
F29 A/C Compressor 7.5
F30 Driving Lights Bat 1 20
F31 Driving Lights Bat 2 20
F32 Shift/Steer 15
F33 Engine Heater Control 7.5
F34 Fuel Solenoid/Cold Start 10

K1 Ignition Pwr 4
K2 Reverse Travel
K3 Start
K4 Front Wiper
K5 Flasher
K6 Ignition Pwr 1
K7 Ignition Pwr 2
K8 Ignition Pwr 3
K9 Work Lights
K10 Boom Lights
K11 Rear Wiper
K12 Heater Fan

26.6/30.7 9.7
 . Electrical System

9.6 ELECTRICAL SYSTEM SCHEMATICS

9.6.1 Cab Roof Schematic

Note: For more detailed schematics, contact your local
SDFI distributor.

RT FRT LT FRT RT REAR LT REAR BEACON

WKLIGHT WKLIGHT WKLIGHT WKLIGHT LIGHT
(OPT) (OPT) (OPT) (OPT) (OPT)

X31 X30 X29 X28 X27

1 2 1 2 1 2 1 2 1 2
X33
1
2
FRT WKLTS

FRT WKLTS

RR WKLTS

RR WKLTS
3

GND10

GND10

GND27
BCN LT
GND9

GND9

RADIO BAT
4
5
6
RADIO IGN
7
GND21
RADIO 8
(OPT)
X34
1
2
SX-
3
SX+
4
DX-
5
DX+
6
7
8

RIGHT DX+
1
DX DX-
SPEAKERS 2
(OPT)
SX+
LEFT 1
SX-
SX 2

X35
53A R WIPE IGN
1
REAR WIPER 31 GND2
2
MOTOR M 53
3
R WIPE
31B R WIPE PK
4

X37
BRK LT PWR
DOME 1
LIGHT GND21
2
BRK LT PWR
FRT WKLTS

RR WKLTS
RADIO BAT

R WIPE IGN
RADIO IGN
R WIPE PK

EMPTY
GND21

GND10

GND27
R WIPE

BCN LT
GND2

GND9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
PINS 4-7=2.5MM, ALL OTHERS=1.0MM
CAB ROOF HARNESS
X43
TO CAB HARNESS

MAH0060

9.8 26.6/30.7
 9.6.2

26.6/30.7
X26 X24
S20 S1 S2 S3 S4 S5 PINS 4-7=2.5MM, ALL OTHERS=1.0MM IND LAMPS JLG ANALYZER S6 S7 S8 S9 S21 X25 X23 F/R AUX HYD SELECT ALL 1.0 MM WIRES
JOYSTICK LOCKOUT A/C TO DASHBOARD TO CAB ROOF HARNESS SIREN
REAR WIPER DRIVING LIGHTS FRT WORK LIGHTS REAR WORK LIGHTS L1 DIAGNOSTIC BEACON LIGHT BOOM LIGHTS RESERVED 1/2 AUX HYD SELECT LMI OVERRIDE (OPT) SPEEDO SWITCH (OPT) AMP MATE-N-LOK 1-480706-0
X11 L2 (BUZZER) SPARE ALL 1.0 MM WIRES
SWITCH SWITCH (OPT) SWITCH SWITCH SWITCH (OPT) SWITCH (OPT) X43 LMI O/R TRAILER AMP 350780-1 SWITCH (OPT) SWITCH (OPT) SWITCH SWITCH (OPT) SWITCH (OPT) AMP SOCKETS 350550-1
CAB HARNESS CAB HARNESS S10 DEUTSCH DRC16-40S
AMP 350690-1 CONN J2
7 9 12 15 19 1 13 2 4 6 18 20 11 14 10 17 5 8 3 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 CONN J1
1 2 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
S - + S +
3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 PCBGND 40 GND
5 6 2 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 1 2 3 4 5 6 7 8 9 EMPTY 39 BAT
7 8 7 8 7 8 7 8 7 8 1 2 1 2 7 8 7 8 7 8 7 8 7 8 7 8 PCB IGN 38 IGN
EMPTY 37
1 9 10 2 3 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2 1 9 10 2
8042 (18991 & After)

JMP
JMP
EMPTY

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
DIODE 36

GND2
GND9
GND8
SIREN

EMPTY

GND21
GND10
GND27
MODULE 2 EMPTY

R WIPE
SPEEDO

BCN LT
GND 24

ANAL TX
35

ANAL RX

R WIPE
R WIPE
ANAL GND

RR WKLTS
ANAL PWR

RADIO IGN

GND8

R WASH
RADIO BAT
FRT WKLTS
IGN SGN 1
IGN SGN 1

ALT W
R WIPE PK
R WIPE IGN
X45

HYD LT
ALT D+

STR AW
STR 2W
BRK LT PWR
GND8
GND8
34 CAN TERM

FUEL GA

R WIPE PK
PBRK LT
RESD SW OUT

R WIPE IGN
STR CRB
BCN/AUX PWR
REAR AUX HYD

TRAILER

GND8
GND8
GND8
GND8
GND8
GND8
GND8
GND8
GND8
GND8
GND8
GND8

HYD PUMP

IGN SGN 1
LMI O/R

ENG OIL LT

STR PWR
LT PARK LT
EMPTY

H FAN C
PREHEAT LT

RT PARK LT
IGN SGN 1A
120

ENG H2O LT
IGN SGN 1B

ENG H2O GA

FLASHER OUT
33

LMI O/R
PCB IGN

LEFT HI BEAM
RESD SW

LT PARK LT
LT BAT 1
LT BAT 2
RR WKLTS

HDLT PWR
BOOM LTS

AC TEMP SW
FRT WKLTS

IGN SGN 1
LT PARK LT
LT PARK LT
LT PARK LT
LT PARK LT
LT PARK LT
LT PARK LT
LT PARK LT
LT PARK LT
1 2 3 4 5 6 7 8 9 10 ...

PARK LT SW

SHFT/STR PWR
32 CAN TERM

RESD SW OUT

RR WKLT PWR
BOOM LT PWR

FRT WKLT PWR

BCN LT
AUX HYD 1/2
EMPTY

BCN/AUX PWR
BCN/AUX PWR
31
EMPTY 30
EMPTY 29
AUX2 28 DO/PWM
EMPTY 27
LIFT UP 26 DO/PWM
X36 LIFT DN 25 DO/PWM JLG
AUX 1 AUX OUT PWR TILT DN 24 DO/PWM P/C BOARD
POWER 2 GND6 TILT UP 23 DO/PWM (REF 0610164)
SOCKET TELE IN 22 DO/PWM
X38 TELE OUT
AIR SEAT PWR 21 DO/PWM
AIR RIDE 1 STR PWR
SEAT GND7 20 DI
M 2 EMPTY
(OPT) 19
LMI CUTOUT 18 DI
X42 EMPTY
EMPTY 17
15 EMPTY
SIREN 16
14 EMPTY
ENG H20 LT 15
13 EMPTY
SIREN 14
12 (SHIELD)
ENG OIL LT 13 SHIELD
11 CANL
EMPTY 12 CAN LO
10 CANH
EMPTY 11 CAN HI
9 LMI O/R
EMPTY 10 DI
DIODE 8 EMPTY
Cab Harness Schematic

MODULE 1 EMPTY 9
7 AUX1
IGN SGN 1 8 DO/PWM
6 PCB IGN
IGN SGN 1B 7 IGN
5 EMPTY
PBRK LT 6
4 PCB IGN
STRT INTLK 5 IGN
3 ANAL TX
IGN SGN 1 4 ANAL TX
2 ANAL RX
IGN SGN 1A 3 ANAL RX
1 ANAL PWR 2 ANAL PWR
A/C AC TEMP SW ANAL GND
TEMP 1 1 ANAL GND
AC TEMP OUT
SENSOR 2
(OPT) 3 GND5 X22
X32 LMI CELL1 1 LOAD CELL
LMI CELL2 2 LOAD CELL
TO
POWER LOAD MOMENT
LMI CUTOUT 1 SGN OUT INDICATOR
DISTRIBUTION
LMI/JOY PWR 2 IGN
MODULE
GND1 3 GND
IN CAB
EMPTY 4
ALL 4.O MM WIRES X21
H (RED)
CAB HARNESS (RED) RT TURN
G R
X44 (DEUTSCH (RED) FLSH PWR
F 30
HD34-18-8PE) (RED) LT TURN
E L
TO BAT POSITIVE (BLK) FLASHER IN
D 49
AND NEGATIVE (BLK) FLASHER IN HAZARD
C 30B
ON ENGINE (BLK) FLASHER OUT SWITCH
B 49A
(BLK) IGN SGN 2 S11
A 15
LT PARK LT 58
CAB HARNESS BOOM LTS
1 GND3
X09 GND19 31
DEUTSCH DT04-4P-L012 2
TO OPT BOOM LT/ 3 AUX HYD 1/2
2. AUX HYD GND20 S16A
4 HORN
ALL 1.O MM WIRES 1 HORN
H FAN MED FLSH PWR 2
H FAN HI HDLT PWR 5 DIMMER
LO BEAM SGN 3 LO HI FLASH
HEATER FAN M H HI BEAM SGN
SWITCH H FAN PWR 6
L B F WASH
SEE SHT 2 FOR 4
C WASH TURN SIGNAL
OPT WIRING S16B
F WIPE L AND WIPER
S17 2
H FAN C RT TURN LEVER
7
WIPER S16
H FAN LO LT TURN TURN
6
X39 EMPTY L R
BRAKE LTS 5 BAR BRK LTS 4 I L H I L H
PRESSURE FLASHER OUT 5
SWITCH
BRK LT PWR
IGN SGN 2 1
F WIPE HS 8
X40
HEATER 1 H FAN HI F WIPE HS 3
BLOWER MOTOR GND5
2
3 1 H FAN MED KEY BAT 1 30 BAT
M 3 1
4 2 H FAN LO KEY BAT 1 30 BAT
4 2
EMPTY 3 17 HEAT
X41
1 GND4 EMPTY 4 17 HEAT
0
EMPTY 1
FRONT 2 KEY IGN 1 15 IGN 2
F WIPE H 5 3
WIPER MOTOR
M 3 KEY IGN 1 15 IGN KEY
F WIPE L 6
4 KEY STRT 50A STRT 0 SWITCH
F WIPE PK 7 1
5 EMPTY 19 HEAT 2 S15
8 3
EMPTY 9 19 HEAT
EMPTY 10 EMPTY
PARK BRAKE GND3
ON 2
SWITCH SHFT/STR PWR
OFF
A S14
S18 STRT INTLK STR CRB CRB
1 B STEER
STR 2W C 2W MODE
STR AW D SWITCH
EMPTY AW
E
N EMPTY F
R F FWD
4 UNUSED SWITCH CONT AUX HYD
3 NEUT
(RIGHT) SWITCH (LEFT) (OPT)
FNR/GEAR 5 REV
1ST GEAR S12 'T' 'S' S13
SHIFTER 6
1 1 2 1 2
2 EMPTY
S19 2 3 4 3 4
1 SHFT/STR PWR
5 6 5 6
7 8 7 8

9 10 9 10

VCC
CANL

1300
GND1
CANH

F1
680
LMI/JOY PWR

F2 ITT AJ3
1 PWR JOYSTICK X20
2 GND 1939 CAN

REV

FWD
NEUT

AUX2
AUX1
GND1
GND2
GND3
GND4
GND5
GND6
GND7
GND8
GND9

HORN
ALT W

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY

GND11
GND12
GND13
GND22
GND14
GND15
GND16
GND17
GND18
GND23
GND10
GND11
GND12
GND13
GND14
GND15
GND16
GND17
GND18
GND19
GND20
GND21
GND22
GND23
GND24
GND27

HYD LT
ALT D+
TRAILER

STR AW
TILT UP
TILT DN

TELE IN

SPEEDO
LIFT UP
LIFT DN

F WASH
R WASH
3 CAN H

LT TURN
LT TURN
LT TURN
PCBGND

FUEL GA

RT TURN
RT TURN
REV OUT
REV OUT
RT TURN
REV OUT

BRK LTS
BRK LTS
PCB IGN

RESD SW

STR CRB
STRT RLY
STRT RLY

TELE OUT
LT BAT 1
LT BAT 2
KEY STRT

120

FUEL SOL
FUEL SOL

F WIPE H

1ST GEAR
KEY PLUG
KEY PLUG
KEY PLUG
KEY PLUG
KEY PLUG
KEY PLUG

RADIO IGN
FLSH PWR

LMI CELL1
LMI CELL2
RADIO BAT

HYD PUMP
KEY IGN 1

F WIPE PK
F WIPE HS

IGN SGN 1
IGN SGN 2
IGN SGN 1

AC PSI SW
AC PSI SW
STRT INTLK

KEY BAT 1

HTR CNTRL
HTR CNTRL

ENG OIL LT
R WIPE IGN
FLASHER IN

LT PARK LT
LT PARK LT
LT PARK LT
LT PARK LT

H FAN PWR

PREHEAT LT

RT PARK LT
RT PARK LT
RT PARK LT
RT PARK LT
PARK LT SW

ENG H2O LT

ENG H2O GA
BRK LT PWR
LMI/JOY PWR
FLASHER OUT

4 CAN L
HI BEAM SGN

AC TEMP OUT
AUX OUT PWR

LEFT HI BEAM
LEFT HI BEAM
RR WKLT PWR

AIR SEAT PWR

LO BEAM SGN

BOOM LT PWR

LEFT LO BEAM
LEFT LO BEAM
BCN/AUX PWR

FRT WKLT PWR

REAR AUX HYD

SHFT/STR PWR

RIGHT HI BEAM
RIGHT HI BEAM

RIGHT LO BEAM
RIGHT LO BEAM

5
ITT (STD) JOYSTICK
6 FUNCTIONS
X AXIS-TILT UP/DN
Y AXIS-LIFT UP/DN
1 2 3 4 5 6 7 8 9 10 11 12 A B C D E F G H J K L M N O P Q R S T U V W X A B C D E F G H J K L M N O P Q R S T U V W X 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 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 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 KNURL-TELE IN/OUT
ALL 1.0 MM WIRES IN THIS CONNECTOR ALL 1.0 MM WIRES IN THIS CONNECTOR ALL 1.0 MM WIRES IN THIS CONNECTOR ALL 1.0 MM WIRES IN THIS CONNECTOR PINS 1-11,15=1.0 MM. PINS 12-14=2.5 MM. PINS 1-6, 9-15=1.0 MM. PINS 7-8=2.5 MM. PINS 1-7, 9-15=1.0 MM. PIN 8=2.5 MM. ALL 1.0 MM WIRES IN THIS CONNECTOR PINS 1,3,6-10,11-15=1.0 MM. PINS 2,4-5=2.5 MM. ALL 1.0 MM WIRES IN THIS CONNECTOR BUTTON 1-UNUSED
24-31 EMPTY BUTTON 2-UNUSED
CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS BUTTON 3-UNUSED

MAH0050
X10 X08 X07 X06 X05 X04 X03 X00 X02 X01 BUTTON 4-AUX HYD
DEUTSCH DT04-12PA-L012 DEUTSCH HD34-24-23SE DEUTSCH HD34-24-23PE DEUTSCH HD34-24-31PE AMP MATE-N-LOK PLUG W/ PINS AMP MATE-N-LOK PLUG W/ PINS AMP MATE-N-LOK PLUG W/ PINS AMP MATE-N-LOK PLUG W/ PINS AMP MATE-N-LOK PLUG W/ PINS AMP MATE-N-LOK PLUG W/ PINS ENABLE
TO OPTIONAL TRAILER HARNESS TO FRONT CHASSIS HARNESS TO ENGINE HARNESS TO REAR CHASSIS HARNESS TO POWER DIST. MODULE TO POWER DIST. MODULE TO POWER DIST. MODULE TO POWER DIST. MODULE TO POWER DIST. MODULE TO POWER DIST. MODULE

NOTE: S12 AND S13 WIRING AND CONNECTORS ARE PROVIDED WITH ITT JOYSTICK
. Electrical System

9.9
9.10
9.6.3
TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS
X05 X04 X03 X00 X02 X01
BATTERY BATTERY
NEGATIVE POSITIVE POWER DISTRIBUTION MODULE POWER DISTRIBUTION MODULE POWER DISTRIBUTION MODULE POWER DISTRIBUTION MODULE POWER DISTRIBUTION MODULE POWER DISTRIBUTION MODULE

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

4mm
4mm
4mm
4mm

REV
NEUT
GND1
GND2
GND3
GND4
GND5
GND6
GND7
GND8
GND9

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
GND10
GND11
GND12
GND13
GND14
GND15
GND16
GND17
GND18
GND19
GND20
GND21
GND22
GND23
GND24
GND25
GND26
GND27

PCBGND

REV OUT
TRAILER
RESD SW
PCB BAT
PCB IGN

KEY PLUG
STRT RLY
F WIPE H
KEY PLUG
LT BAT 1
LT BAT 2
FUEL SOL
KEY PLUG
FLSH PWR
RESD BAT
RESD IGN
KEY PLUG
KEY STRT
KEY PLUG
KEY PLUG

RADIO IGN
RADIO BAT
AC PSI SW
F WIPE PK
H FAN PWR
HTR CNTRL
IGN SGN 2
F WIPE HS
IGN SGN 1
KEY BAT 1
KEY IGN 1

LT PARK LT
RT PARK LT
BRK LT PWR
PARK LT SW
R WIPE IGN
FLASHER IN
STRT INTLK
4mm-RED

AC TEMP OUT
AUX OUT PWR
RR WKLT PWR
BOOM LT PWR
BCN/AUX PWR
LMI/JOY PWR
LO BEAM SGN
HI BEAM SGN
FLASHER OUT

LEFT HI BEAM
LEFT LO BEAM
AIR SEAT PWR
FRT WKLT PWR
SHFT/STR PWR

RIGHT HI BEAM
RIGHT LO BEAM
4mm-RED
4mm-RED
4mm-RED

1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm
1mm

2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
RT HEADLIGHT HIGH
7.5 F1
. Electrical System

RT HEADLIGHT LOW
7.5 F2
85
86 LT HEADLIGHT HIGH
K1 IGN 7.5 F3
PWR 4 87 4mm
RELAY 30 4mm LT HEADLIGHT LOW
7.5 F4
87a
RADIO
10 F5
85
RADIO BAT
86 5 F6
K2 REVERSE
TRAVEL 87
FRONT WIPER
RELAY 30 20 F7
87a
HEATER FAN
20 F8

85 AUX PWR SOCKET

D1 6A/400V 15 F9
86
K3 START
INTLK 87 AIR SUSPENSION SEAT
10 F10
RELAY 30
87a IGNITION 1
10 F11

LEFT PARK/SIDE LIGHTS

85 7.5 F12
86
K4 FRONT RIGHT PARK/SIDE LIGHTS
WIPER 87 7.5 F13
RELAY 30 4mm
FRONT WORKLIGHTS
87a 15 F14

REAR WORKLIGHTS
15 F15
49
49a
BOOM LIGHTS
K5 FLASHER 15 F16
31
C2
BEACON/AUX1.2.
15 F17

RESERVED SWITCH
15 F18
85
Power Distribution Module Schematic

86 RESERVED BAT
IGN 15 F19
K6 PWR 1 87 4mm
RELAY 30 4mm RESERVED IGN
10 F20
87a
PCB BAT
10 F21
85
IGNITION 2
86 15 F22
IGN
K7 PWR 2 87 4mm
LMI/JOYSTICK
RELAY 30 4mm 10 F23
87a
PCB IGN
15 F24

85 REAR WIPER
20 F25
86
IGN
K8 PWR 3 87 4mm FLASHER PWR
15 F26
RELAY 30 4mm
87a KEY BAT
15 F27

BRAKE LIGHTS
85 15 F28
86
K9 WORK A/C COMPRESSOR
LIGHTS 87 4mm 7.5 F29
RELAY 30 4mm
87a DRIVING LIGHTS BAT 1
20 F30

DRIVING LIGHTS BAT 2

85 20 F31
86
K10 BOOM SHIFT/STEER
LIGHTS 87 4mm 15 F32
RELAY 30 4mm
ENG HEATER CONTROL
87a 7.5 F33

FUEL SOL/COLD START

10 F34
85
86
K11 REAR
WIPER 87
RELAY 30 4mm
87a

85
86
K12 HEATER
FAN 87
RELAY 30 4mm
87a

1mm

1mm
4mm
4mm
4mm
4mm
2.5mm
1mm
4mm
1mm
1mm

BATTERY POSITIVE (+)

DESIGN LOAD: 80 AMPS CONTINUOUS

BATTERY NEGATIVE (-)

MAH0070

26.6/30.7
 9.6.4

26.6/30.7
25mm BLK
LICENSE REVERSE FUEL TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS
LEFT REAR DRIVING LIGHT RIGHT REAR DRIVING LIGHT DEUTSCH HD36-24-31SE DEUTSCH DT06-12SA DEUTSCH DT06-4S DEUTSCH HD36-24-23PE CAB
LIGHT ALARM SNDR
X06 X10 X09 X08 FRAME
TAIL BACK TURN STOP TAIL BACK TURN STOP REAR CHASSIS HARNESS OPTIONAL TRAILER HARNESS OPTIONAL BOOM LT/ 2. AUX HYD FRONT CHASSIS HARNESS
ALL 1.0 MM WIRES IN THIS CONNECTOR
24-31 EMPTY ALL 1.0 MM WIRES IN THIS CONNECTOR ALL 1.0 MM WIRES ALL 1.0 MM WIRES IN THIS CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 A B C D E F G H J K L M N O P Q R S T U V W X

CHASSIS
FRAME

1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 1 2 3

AUX2
AUX1
HORN

EMPTY
GND16
GND17
GND18
GND23
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
GND19
GND20
EMPTY
EMPTY
EMPTY
EMPTY
GND11
GND12
GND13
EMPTY
GND22

SPEEDO
STR AW

REV OUT
BRK LTS
TELE IN
RT TURN
LT TURN
LIFT UP
LIFT DN
TILT UP
TILT DN
FUEL GA
LT TURN
RT TURN
BRK LTS
RT TURN
LT TURN
STR CRB

TELE OUT
BOOM LTS
1ST GEAR

LMI CELL1
LMI CELL2
IGN SGN 1

LT PARK LT
RT PARK LT
RT PARK LT
LT PARK LT
LT PARK LT
RT PARK LT

AUX HYD 1/2

REAR AUX HYD

LEFT LO BEAM
LEFT HI BEAM
RIGHT LO BEAM
RIGHT HI BEAM
HORN

GND18
EMPTY
EMPTY
GND17
EMPTY
EMPTY
GND16
GND16
GND16
EMPTY

REV OUT
LT TURN
BRK LTS
REV OUT
RT TURN
BRK LTS
REV OUT
FUEL GA
HORN

LT PARK LT
RT PARK LT
RT PARK LT
GND22

STR AW 1 ALL WHEEL

GND22 2 STEER
MODE
STR CRB 1 VALVE
GND22 2 CRAB

REAR LMI CELL1

AXLE 1
LMI CELL2
LOAD 2
CELL

EMPTY 1 EMPTY
1 1 218 2 AUX HYD 1/2
2ND AUX 2 300 EMPTY
HYD CONN 2 3
3 GND GND20
SEL VLV 3 4
ON BOOM (GRN) 4 EMPTY 5 EMPTY
(OPT) EMPTY EMPTY GND EMPTY
5 6

135 1 BOOM LTS

GND 2 GND19
LOW
BOOM EMPTY 1
LIGHTS LEFT LO BEAM
(OPT) 2
135 LEFT HI BEAM LEFT
3 HIGH
FRONT
GND LT PARK LT 4 DRIVING
LT TURN 5 LIGHT
SIDE
GND12 6

TURN

LOW
EMPTY 1
RIGHT LO BEAM 2
RIGHT HI BEAM RIGHT
3 HIGH
FRONT
RT PARK LT 4 DRIVING
RT TURN 5 LIGHT
SIDE
GND11 6
50mm RED
POSITIVE CABLE
TO STARTER SOLENOID TURN

BATTERY DISCONNECT
SWITCH (OPT)

50mm BLK 50mm BLK NEGATIVE CABLE

Front & Rear Chassis Harness, Battery, Boom Schematic

TO STARTER (BODY)

+ -
12 VDC
BATTERY
CHASSIS GROUND

AUX1
AUX2

GND23
GND23
GND23
GND23
GND23
GND23
GND23
GND23
GND16
GND13
GND13

SPEEDO

LIFT UP
LIFT DN
TELE IN
TILT UP
TILT DN

TELE OUT
1ST GEAR

IGN SGN 1

REAR AUX HYD

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 1 2
RED
GRN
BLK

LIFT LIFT TELE TELE TILT TILT AUX AUX + S -

UP DN IN OUT UP DN 1 2

REAR SPEEDO TWO

CONTROL VALVE AUX SENSOR SPEED

MAH0080
(OPT)
. Electrical System

9.11
9.12
9.6.5
HYDROSTATIC AC PRESSURE AC COMPRESSOR TO CAB HARNESS TO CAB HARNESS
DRIVE PUMP SWITCH (OPT) CLUTCH (OPT) X07 X44
DEUTSCH HD36-24-23SE DEUTSCH HD36-18-8SE
FWD REV POSITIVE CABLE
ENGINE HARNESS POWER/GND HARNESS
TO BATTERY +
ALL 1.0 MM WIRES IN THIS CONNECTOR ALL 4.0 MM WIRES IN THIS CONNECTOR
M A B C D E F G H J K L M N O P Q R S T U V W X A B C D E F G H
NEGATIVE CABLE
TO BATTERY DISCONNECT
1 2 1 2 OR BATTERY -

50mm (BLK)

FWD

ALT W
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
GND14
GND15
(BRN)
(BRN)
(BRN)
(BRN)
(RED)
(RED)
(RED)
(RED)

HYD LT
R WASH
F WASH
ALT D+
REV OUT

HYD PUMP
STRT RLY
FUEL SOL
CAB GND 4

AC PSI SW
HTR CNTRL

ENG OIL LT
ENG H2O GA
PREHEAT LT
ENG H2O LT
CAB GND 3

AC COMP
AC COMP

FWD
AC PSI SW

GND15
GND15
CAB GND 2

REV OUT
CAB GND 1
STARTER

50mm (RED)

CAB PWR 4 (RED)

M
CAB PWR 3 (RED)
CAB PWR 2 (RED)
CAB PWR 1 (RED)
16mm (RED) PREHEAT PWR
. Electrical System

16mm (RED) ALT BAT

6mm STRT SOL

30
6mm (RED) STRT PWR
STARTER
6mm STRT SOL 87
RELAY
STRT RLY 86
GND14 85

ALTERNATOR
16mm (RED) ALT BAT
Engine Harness Schematic

B+
ALT W W
ALT D+
G
D+

ENG OIL LT 1 ENGINE OIL

PLUGGED PRESSURE
2 SWITCH

ENG H20 GA 2
ENG H20 LT 1 CLT TEMP
SENDER

118 C COOLANT
TEMP
SWITCH

GND14 1 EXCESS
STRT RLY START FUEL
2 SOLENOID

GND15 1
PLUGGED 2
HTR CNTRL 3
STRT RLY 4 ENGINE
PREHEAT LT 5 GLOWPLUGS
CONTROL

30
16mm (RED) PREHEAT RLY 8
16mm (RED) PREHEAT 9 87

FUEL SOL
SHUTDOWN
GND14 SOLENOID

6mm (RED) STRT PWR

16mm (RED) PREHEAT PWR
ENGINE
50 HEATER
FUSE
50A
16mm (RED) PREHEAT RLY SLO BLO

HYD PUMP 10 BAR

STEERING
GND14 PRESSURE
SWITCH

16mm (RED) PREHEAT

ENGINE
GLOWPLUGS

HYD LT 1.2 BAR HYD FILTER

1
GND15 PRESSURE
2 SWITCH

F WASH FRONT

MAH0090
GND15 M W/WASHER
PUMP
REAR
R WASH W/WASHER
GND15 M PUMP
(OPT)

26.6/30.7
 . Electrical System

9.7 CIRCUIT BREAKDOWNS

9.7.1 Charge Circuit Breakdown

ENGINE HARNESS

POSITIVE CABLE
TO BATTERY +

NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -

50mm (BLK)

STARTER

50mm (RED)
M
16mm (RED) ALT BAT

16mm (RED) ALT BAT

ALT W ALTERNATOR

ALT D+

TO CAB HARNESS
X07

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

CAB HARNESS
X07
DEUTSCH HD36-24-23SE
ENGINE HARNESS
ALL 1.0 MM WIRES IN THIS CONNECTOR
ALT D+
ALT W

TO DASH BOARD
X11

7 9 12 15 19 1 13 2 4 6 18 20 11 14 10 17 5 8 3 16

DASH BOARD
X11
ALT D+

TACH
ALT W

BATTERY

TO IGN SGN B

+ - S
ALT W

MAH0790

26.6/30.7 9.13
 . Electrical System

9.7.2 Start Circuit Breakdown

CAB HARNESS
ALL 1.0 MM WIRES IN THIS CONNECTOR
FNR/GEAR PARK BRAKE
KEY
SHIFTER
SWITCH SWITCH
S19
S15 S18

N
KEY BAT 1 1 30 BAT R F
KEY BAT 1 30 BAT 4
2 ON 2 GND 3
17 HEAT 3
3
17 HEAT 5 OFF STRT INTLK
4 0 1
1 1 6
KEY IGN 1 5 15 IGN 2 2
2
3
KEY IGN 1 6 15 IGN 1
KEY STRT 7 50A STRT 0
1
8 19 HEAT 2
NEUT

9 19 HEAT
10 EMPTY

STRT RLY
STRT INTLK
KEY BAT 1

KEY IGN 1
KEY STRT

CAB HARNESS
X00
NEUT

TO POWER DIST. MODULE

CAB HARNESS
X05 TO ENGINE HARNESS

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

TO CAB HARNESS TO CAB HARNESS

CAB HARNESS
POWER DISTRIBUTION MODULE X00
X05 X07

STRT RLY
BATTERY POSITIVE (+)
POSITIVE CABLE
TO BATTERY +
STRT RLY

30
NEGATIVE CABLE
STRT PWR TO BATTERY DISCONNECT
85 STARTER
86 STRT SOL 87
RELAY OR BATTERY -
IGN
PWR 4 87 STRT RLY 86 50mm (BLK)
RELAY 30 GND 14 85
87a

85 GND 15
1
86 NEUT 85 2 STARTER
IGN
PWR 1 87 STRT INTLK 86 START 3

M
INTLK STRT RLY ENGINE 50mm (RED)
RELAY 30 STRT RLY 87 4
RELAY 5 GLOWPLUGS
87a KEY STRT 30 CONTROL
87a
PREHEAT RLY 30
8
85 87
9
86
IGN 87
PWR 2 PREHEAT TO ENGINE
RELAY 30 GLOWPLUGS
87a
PREHEAT PWR

STRT SOL

85 GND 14 EXCESS
1
86 STRT RLY START FUEL
2
IGN SOLENOID
87
PWR 3
RELAY 30
87a

STRT PWR
BATTERY NEGATIVE (-)

PREHEAT PWR
ENGINE
HEATER FUSE
50A
SLO BLO

PREHEAT RLY

PREHEAT PWR

STRT SOL

ENGINE HARNESS

MAH0810

9.14 26.6/30.7
 . Electrical System

9.7.3 Drive Circuit Breakdown

CAB HARNESS POWER DISTRIBUTION MODULE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
N
R F FWD 85
4
3
NEUT REV 86
REV REVERSE
FNR/GEAR 5 REV OUT 87 TRAVEL
SHIFTER
1 6
30
RELAY
2
S19 2
SHFT/STR PWR 87a
1

F32
SHFT/STEER 85
REV OUT REV OUT 86
IGN
REV REV 87 PWR 3
30
RELAY
CAB HARNESS TO CAB HARNESS 87a
X05 X05

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

85
NEUT NEUT 86 START
INTLK
SHFT/STR PWR SHFT/STR PWR 87 RELAY
30
87a
REV OUT
FWD

REV OUT

TO BATTERY POSITIVE (+)

CAB HARNESS TO CAB HARNESS

X00 X00
CAB HARNESS CAB HARNESS
X07 X06

A B C D E F G H J K L M N O P Q R S T U V W X 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

TO CAB HARNESS TO CAB HARNESS

X07 X06

REVERSE
LEFT REAR DRIVING LIGHT RIGHT REAR DRIVING LIGHT
ALARM
TAIL BACK TURN STOP TAIL BACK TURN STOP
2
REV REV OUT
HYDROSTATIC 1
DRIVE PUMP 2
FWD FWD
1

1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2
REV OUT

REV OUT

REV OUT
GND18

GND17

GND16

ENGINE HARNESS REAR CHASSIS HARNESS

MAH0800

26.6/30.7 9.15
 . Electrical System

9.7.4 Constant Power Circuit Breakdown

ENGINE HARNESS

POSITIVE CABLE
TO BATTERY +

STARTER

CAB PWR 4
M
CAB PWR 3
CAB PWR 2
CAB PWR 1
PREHEAT PWR
ALT BAT

ALTERNATOR
30 1 ENGINE
STRT PWR
B+ 2 50 HEATER
STARTER
FUSE
87
RELAY W G 3
50A
86 D+ 4 ENGINE
85 GLOWPLUGS SLO BLO
5
CONTROL

30
ALT BAT
8
9 87

STRT PWR
PREHEAT PWR

PREHEAT RELAY
TO CAB HARNESS
X44
DEUTSCH HD36-18-8SE
POWER/GND HARNESS
ALL 4.0 MM WIRES IN THIS CONNECTOR

A B C D E F G H

CAB HARNESS
X44
K1 K4 K6 K7 K8 K9 K10 K11 K12

IGN FRONT IGN IGN IGN WORK BOOM REAR HEATER

PWR 4 WIPER PWR 1 PWR 2 PWR 3 LIGHTS LIGHTS WIPER FAN
RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY
85
86
87

30

85
86
87

30

85
86
87

30

85
86
87

30

85
86
87

30

85
86
87

30

85
86
87

30

85
86
87

30

85
86
87

30
87a

87a

87a

87a

87a

87a

87a

87a

87a
HEATER FAN
BATTERY POSITIVE (+)

F30 DRIVING LIGHTS BAT 1

F31 DRIVING LIGHTS BAT 2
F27 KEY BAT
F21 PCB BAT
F25 REAR WIPER
F19 RESERVED BAT
F9 AUX PWR SOCKET

F8 HEATER FAN

F7 FRONT WIPER
F6 RADIO BAT
F26 FLASHER PWR
AUX OUT PWR

LT BAT 1
LT BAT 2

KEY BAT 1
PCB BAT

RESERVED BAT
FLSHPWR
RADIO BAT

TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS

X05 X04 X03 X00
POWER DISTRIBUTION MODULE

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

CAB HARNESS CAB HARNESS CAB HARNESS

EMPTY

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

KEY BAT 1

X05 X04 X03

AUX OUT PWR

X00
LT BAT 1
LT BAT 2

FLSH PWR
AUX
RADIO (OPT) POWER
SOCKET R
X36 30
L
1 S3 49 HAZARD 1 30 BAT
30 BAT
2 DRIVING LIGHTS 30B SWITCH 2
17 HEAT
SWITCH 49A S11 3
4 17 HEAT
15 0
KEY
1 2 3 4 5 6 7 8
1
15 IGN
1 2 58 5 2
3 SWITCH
15 IGN
31 6 S15
3 4 7 50A STRT 0
1
8 19 HEAT 2
5 6 3

9 19 HEAT
7 8 S16A
10 EMPTY
1 HORN

2
1 9 10 2
5 DIMMER
CAB ROOF HARNESS TO CAB ROOF HARNESS 3 LO HI FLASH

X43 X43 6
4
TURN SIGNAL
WASH AND WIPER
S16B
2
LEVER
7
S16
WIPER
6 TURN

4 L R I L H I L H

5
1
8
CAB ROOF HARNESS CAB HARNESS 3

MAH0840

9.16 26.6/30.7
 . Electrical System

9.8 ENGINE START CIRCUIT 3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
9.8.1 Starter battery state of charge and battery condition first,
The starter (1) is located on the left side of the engine (the then check the cables and cable connections.
left side of the machine) underneath a heat shield 4. For additional information on the starting circuit,
attached to the flywheel. refer to Section 9.6.4, “Front & Rear Chassis
Harness, Battery, Boom Schematic.”

c. Starter Removal

1 Remove the starter only if it fails. To remove the starter:

1. Unlock and open the engine compartment.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the bolts that secure the starter heat shield.
Disconnect the shield.
4. Remove the wires from the solenoid stud. Remove
the red, positive (+) battery cable from the starter.
MAH0210 Label and disconnect the wire from the starter
solenoid housing stud. Record how the wires are
a. Testing the Starter on the Engine installed to ensure correct installation later.

If the starter does not engage when the ignition key 5. Loosen, but DO NOT remove, the fasteners
switch is turned, check the following: securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
1. The main fuse may be blown, requiring replacement. fall if not supported.
Check for the cause of the blown fuse.
6. Support the starter and remove the fasteners
2. There may be a defect in the ignition key switch, securing the starter to the engine. Remove the
ignition wiring or starter solenoid. negative (-) ground cable from its starter mounting
3. Check battery condition. Clean the battery posts and bolt.
the connectors at each end of the battery cables. 7. Remove the starter (1) from the machine.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring. d. Starter Cleaning and Drying
5. Check all connections at the starter solenoid, key 1. While the starter is being removed, wipe away any
switch and wiring harness plugs. Clean and tighten grease or dirt that has accumulated around the
all connections. starter mounting opening.
6. If the starter still does not operate after these checks 2. If reinstalling the starter, clean the exterior of the
have been performed, check the starting circuit. starter with an approved solvent. DO NOT submerse
the starter or allow the solvent to contact the starter
b. Starter Circuit Checks bushings.
1. Check wires and connections for looseness, 3. Dry the starter with a clean, lint-free cloth.
corrosion, damage, etc.
2. If a “whirring” noise is heard but the engine does not e. Starter Periodic Maintenance
turn over, the starter is spinning but not engaging the A starter requires no routine maintenance beyond the
flywheel. The starter drive or solenoid that pushes occasional inspection of the electrical connections, which
the drive forward to engage the flywheel may be must be clean and tight. The starter is not serviceable;
defective. Missing or damaged teeth on the flywheel replace a defective starter with a new unit.
can also prevent the starter from cranking the
engine.

26.6/30.7 9.17
 . 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. Unlock and open the engine compartment.
fasteners. Torque fasteners to 43 Nm (32 lb-ft). 2. Disconnect the positive (+) and negative (-) battery
2. Connect the positive (+) battery cable to the upper cables at the battery terminals.
solenoid stud. Install the wires to the upper solenoid 3. Label and disconnect the wires attached to the
stud, and secure with lockwasher and nut. Torque alternator.
nuts to 43 Nm (32 lb-ft).
Note: Record how the alternator is installed to ensure
3. Connect the wire to the solenoid mounting stud.
correct installation later.
4. Connect the negative (-) battery cable to the
negative (-) battery terminal. 4. Loosen the top mounting bolt, but don’t remove it at
this time. This will allow the alternator to swivel
during belt removal.
9.9 CHARGING CIRCUIT
Before using a battery charger, an attempt can be made
to recharge the battery by jump-starting the machine.
(Refer to the appropriate Operator/Safety Manual.) Allow
the engine to run, which will enable the alternator to
charge the battery.

WARNING: DO NOT charge a

frozen battery. A frozen battery may explode
and cause serious personal injury. Allow the
battery to thaw before “jump-starting” the
machine or connecting a battery charger.

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
MAH0220
connections, and verify that they are in good
condition.
5. Loosen the belt tensioning adjustment bolt at the
3. Check the fan belt condition and tension. bottom of the alternator to loosen the fan drive belt.
4. Verify that the alternator mounting hardware is tight. 6. Remove the fan drive belt from the alternator.
5. Run the engine and check the alternator for noise. A 7. Remove the lower mounting capscrew securing the
loose drive pulley, loose mounting hardware, worn or alternator to the lower mounting hole on the engine.
dirty internal alternator bearings, a defective stator
or defective diodes can cause noise. Replace a worn 8. While supporting the alternator with one hand,
or defective alternator. remove the upper mounting hardware from the
upper alternator mount. Remove the alternator from
the machine.

b. Alternator Installation
1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the
upper mounting hardware through the alternator
mount. DO NOT tighten completely at this time.

9.18 26.6/30.7
 . Electrical System

2. Align the lower alternator mount hole with the lower 9.10.2 Back-up Alarm
mounting bracket on the engine, and insert the lower
The back-up alarm is located at the rear of the machine.
mounting capscrew. Be sure to leave enough room
to attach the drive belt. When the transmission shift control switch (travel select
lever) is shifted to the (R) REVERSE position, the back-
3. Attach the fan drive belt to the alternator.
up alarm will automatically sound.
4. Adjust the lower belt tensioning bolt to remove
Place the travel select lever in (R) REVERSE to test the
excessive slack from the drive belt. Check for proper
back-up alarm. The back-up alarm must not sound when
fan belt deflection. (Refer to the appropriate
the travel select lever is in (N) NEUTRAL or (F)
Operator/Safety Manual.)
FORWARD. Also, with the ignition key switch in the RUN
5. Reattach the previously labeled electrical wires to position, the back-up alarm will sound when the travel
the alternator. select lever is shifted into the (R) REVERSE position.
6. Connect the positive (+) and negative (-) battery
cables to the battery terminals. a. Disassembly
DO NOT disassemble the back-up alarm. Replace a
9.10 ELECTRICAL SYSTEM defective or faulty alarm with a new part.
COMPONENTS
b. Inspection and Replacement
9.10.1 Load Moment Indicator Inspect the wiring harness connector and alarm terminals
The Load Moment Indicator provides a visual indication for continuity and shorting. Test the alarm by turning the
for forward stability limitations. ignition key switch to the RUN position and shifting the
travel select lever into the REVERSE position. The alarm
• All five LED’s will light (three green, yellow & red) should sound.
and the warning buzzer sounds as the machine
reaches its forward stability limitations. Replace a defective or faulty alarm with a new part.

• The red LED is illuminated when the machine has

reached its forward stability limitations.
• Overload Protection Function (optional). When the
red LED is illuminated the automatic overload
protection function is activated. Boom extension and
lower functions are disabled.
Test the LMI at the beginning of each work shift.
1. Fully retract and level the boom, with no load. Do
not raise the boom during this test.
2. Level frame using level in cab.
3. Press the test button on the LMI display. This will
cause all LEDs to flash on and an audible warning to
sound. This indicates that the system is functioning
properly. If the test gives a different result, the
system is not functioning properly and the machine
must be removed from service and repaired before
continued operation.

26.6/30.7 9.19
 . Electrical System

9.10.3 Instrument Cluster 9.11 WINDOW WIPER/WASHER

9.11.1 Windshield Wiper Motor

15
10 20
a. Removal
25
5
Note: It may be necessary to remove several hydraulic
30
0 RPM X 100
hoses from under the dash in order to remove and install
000000 h
the wiper motor housing.
1. Disconnect the negative (-) battery cable at the
MAH0170 negative (-) battery terminal.
2. Remove the lower access panel below the
a. Removal/Installation instrument panel.
3. Disconnect the right side defroster hose from dash
CAUTION: Static electricity can panel hose connector.
cause damage to the operator’s instrument
4. Disconnect the cab harness connectors from the
cluster. Avoid any manner of touching (hands,
wiper motor.
tools, etc.) the printed circuit boards and
terminals. Disconnect the negative (-) battery
cable at its battery terminal before beginning
this procedure. Failure to comply can result in
damage to the operator’s instrument cluster
and malfunction of the instruments and
indicator lights.

1. Disconnect the negative (-) battery cable at the

negative (-) battery terminal.
2. Slide the instrument cluster out of the operator
console.
3. Disconnect the wiring harnesses.
For installation, reverse the removal procedure. MAH0910

5. Remove the linkage attached to the wiper motor.

6. Loosen and remove the four bolts holding the wiper
motor to the mounting bracket.
Note: Retain all hardware removed from the wiper
assembly for possible reuse on the replacement motor
housing.
7. Remove the motor from the inside of the cab.

b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.

c. Inspection and Replacement

Inspect the motor terminals for continuity. Replace motor
if continuity is not found.

9.20 26.6/30.7
 . Electrical System

d. Installation and Testing

1. Install all required hardware to the motor assembly.
2. Align motor with the mounting holes and bolt the
motor to the mounting bracket.
3. Connect the wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with the flat on the
motor shaft to ensure wiper stroke covers window area,
MAH0920
and it does not swipe past the glass area.
3. Install the wiper arm onto the wiper motor shaft.
4. Connect the cab harness connectors to windshield
wiper motor connectors. 4. Connect the negative (-) battery cable to the negative
(-) battery terminal.
5. Connect the negative (-) battery cable to the negative
(-) battery terminal. 5. Turn ignition key switch to the RUN position and turn
the rear wiper switch to the ON position. Ensure
6. Turn ignition key switch to the RUN position, and
wiper stays on the window through a full stroke. Turn
operate windshield wiper in both LOW and HIGH
the rear wiper switch to the OFF position.
speeds to ensure proper operation and that correct
wiper travel is achieved. 6. Engage the washer switch and ensure washer fluid
is sprayed on the rear window. Turn the ignition key
7. Install right side defroster hose to the dash panel
switch to the OFF position.
hose connector.
8. If previously removed, install hydraulic hoses under 9.11.3 Windshield Washer Reservoir and
the dash. Pump
9. Install the lower dash panel. The windshield washer motor and reservoir is a unit and
cannot be serviced separately.
9.11.2 Rear Window Wiper Motor
a. Removal
a. Removal
1. Disconnect the negative (-) battery cable at the
1. Disconnect the negative (-) battery cable at the negative (-) battery terminal.
negative (-) battery terminal.
2. Remove the nuts and the lockwashers from the
2. Remove the wiper arm from the wiper motor shaft. washer mounting studs.
3. Remove the nut on the wiper motor shaft and on the 3. Pull the washer reservoir out and away from the
wiper motor. mounting studs.
4. From inside the cab, pull the wiper motor away from 4. Rotate the washer reservoir, label and remove the
the rear window. cab harness connectors from the washer reservoir
5. Label and disconnect the cab harness connectors connectors.
from the wiper motor. 5. Remove the windshield washer hoses from the
reservoir.
b. Disassembly
DO NOT disassemble the motor. The motor is not b. Disassembly
serviceable. Replace motor if found to be defective. DO NOT disassemble the pumps. The pump is not
serviceable. Replace pumps if found to be defective.
c. Installation and Testing
1. Hold wiper motor up toward cab rear window and c. Cleaning and Drying
install the cab harness connectors. Without submerging the pumps, clean the pumps and
2. With the help of an assistant, insert the wiper motor reservoir with an approved solvent and dry with a clean,
through the roof hole and have the assistant thread lint-free cloth.
the hex nuts onto the wiper motor shaft and the
wiper motor. Insure that the motor housing is facing
the front of the cab.
26.6/30.7 9.21
 . Electrical System

d. Inspection and Replacement 7. Remove the hex locknut from the suspect control
shaft.
Inspect the electrical terminals for continuity.
8. Remove the control from the panel.
e. Installation and Testing
b. Disassembly
1. Connect the windshield washer hoses to the
reservoir. DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
2. Connect the cab wiring harness connectors to the
found to be defective.
reservoir connectors.
3. Install the reservoir tank onto the mounting studs. c. Cleaning and Drying
4. Install the lockwashers and nuts and secure. Without submerging the variable speed fan control, clean
5. Fill the washer fluid reservoir with washer fluid. the control with an approved solvent and dry with a clean,
6. Connect the negative (-) battery cable to the negative lint-free cloth
(-) battery terminal.
d. Installation and Testing
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed 1. Check that the variable speed fan control is in the
on both the windshield and rear glass. OFF position.
2. If installing the temperature control, attach the
9.12 CAB HEATER AND FAN control cable (not shown) to the back of the control.
3. Insert the control shaft through the panel, ensuring
9.12.1 Cab Heater Controls that the knob is in the VERTICAL position.
Note: If the suspect component is found to be within the 4. Install the hex locknut on the shaft and tighten.
heater box, the heater box must be removed as a 5. Connect the cab harness connector to the variable
complete unit and replaced. For additional information speed fan control.
on the removal and installation of the heater box, refer to
6. Install the screws and backing locknuts securing the
Section 4.3.8, a. “Heater Assembly Removal.”
control panel to the dash panel.
The cab heater controls are located to the right of the 7. Install the setscrew, securing the knob to the control.
seat. The control panel consists of a variable speed fan
control knob and a temperature control knob. 8. Install the right side control panel screws.
9. Connect the negative (-) battery cable to the negative
a. Cab Heater Controls Removal (-) battery terminal.
Note: After determining which control knob is not
functioning, remove only the suspect control knob. In
order to remove either knob, the cab heater and fan
control panel must be removed from the dash panel.
1. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
2. Remove the setscrew from the variable speed fan
control knob or temperature control knob.
3. Remove the right side control panel screws.
4. Remove the screws and backing locknuts from the
cab heater and fan control panel.
5. Pull the control panel out from the dash panel, and if
removing variable speed fan control, remove the cab
harness connector.
6. If removing the temperature control knob, disconnect
the cable connector and remove control knob.

9.22 26.6/30.7
 . Electrical System

9.13 SWITCHES, SOLENOIDS AND a. Inspection and Replacement

SENDERS To determine the proper operation of the ignition key
switch, using the following charts, test the wires on the
9.13.1 Switch, Solenoid and Sender back of the switch for continuity with an ohmmeter.
Maintenance Test the ignition key switch for continuity, by checking
from the ignition (#30) wires to each of the following wires
a. Removal in each switch position. Continuity (X) should be present
1. Disconnect the negative (-) battery cable(s). as indicated in the following chart:

2. Carefully remove the component from it’s mounting Switch Position

position. Test from #30 wires to: OFF RUN START
3. Disconnect and label wires to the wiring harness. #50A Wire X
#15 Wires X X
b. Disassembly
DO NOT disassemble the component. They are not b. Transmission Neutral Start Feature
serviceable. Replace the component if found to be
defective. The transmission neutral start feature is a safety feature
designed to prevent the engine from starting with the
c. Inspection and Replacement transmission in (F) FORWARD or (R) REVERSE.
Shifting into (N) NEUTRAL activates the neutral start
Inspect all terminals for continuity. If necessary, connect
feature.
terminals to a 12V DC source and ground. Energize and
check for defects. If found to be defective, replace the Test the neutral start circuit as follows:
component. • The starter MUST NOT operate with the travel
select lever in (F) FORWARD or (R) REVERSE.
d. Installation
• The starter MUST NOT operate when the park
1. Connect the component to the previously labeled brake is OFF (disengaged).
wiring harness. • The starter MUST operate with the travel select
2. Reposition and secure the component back into lever in (N) NEUTRAL.
position. If the starter fails to turn the engine with the travel select
3. Reconnect the negative (-) battery cable(s). lever in (N) NEUTRAL and the ignition key switch is in
4. Test all functions of the replaced component. the START position, refer to Section 9.6.4, “Front & Rear
Chassis Harness, Battery, Boom Schematic.” The
NEUTRAL position contacts in the travel select lever are
9.13.2 Ignition Key Switch
non-repairable. Replace the travel select lever if
If the key binds in the switch, check the key for defects defective.
and the switch for foreign objects. Clean or remove foreign
material from the key as required. Check that the key is
not bent or excessively worn; replace a bent or worn key
with a new key.
Apply powdered graphite to the key, and insert and
withdraw the key from the switch several times to
distribute the graphite into the switch-lock mechanism.
During freezing temperatures, if the ignition key switch
fails to turn, or does not allow the key to be inserted,
warm the switch with a heat gun (blow-dryer), or use
liquid lock deicer to help evaporate frozen moisture from
within the switch.
IMPORTANT: Only use graphite or a liquid lock deicer
within the switch. Replace a defective switch.

26.6/30.7 9.23
 . Electrical System

9.13.3 Steering Crab-Steer Mode

Stop the machine before changing steering modes. A
light on the instrumental panel will indicate the steering
mode selected.

All-Wheel Steer

OAH0250

The following conditions must be met:

1. Front wheels must steer in the direction that the

OAH0230 steering wheel is turned.
The following conditions must be met: 2. Rear wheels must steer in the direction that the
steering wheel is turned.
1. Front wheels must steer in the direction that the
steering wheel is turned.
2. Rear wheels must steer in the opposite direction
9.13.4 Fuel Level Indicator and Fuel Level
from which the steering wheel is turned.
Sender

a. Fuel Level Indicator Testing

Front-Wheel Steer Mode
1. The fuel level sender wiring harness leads can be
accessed from the top of the fuel tank. Disconnect
the fuel level sender wiring harness leads. With the
help of an assistant, touch both harness leads
together.
2. From the operator’s cab, have the assistant turn the
ignition key switch to the RUN position. DO NOT
start the engine. Observe the fuel level indicator
OAH0240
needle on the operator’s instrument cluster.
The following conditions must be met: 3. Turn the ignition key switch to the OFF position. The
fuel level indicator needle should return to the
1. The front wheels must steer in the direction that the EMPTY position.
steering wheel is turned.
2. Rear wheels must remain in a fixed FORWARD b. Fuel Level Circuit Tests
position and not move. If the fuel level indicator is suspected of giving a false
reading, perform the following checks:
1. If the fuel level indicator needle does not move,
check the fuel tank for fuel.
2. Check for loose or defective wiring, faulty ground
connections or corrosion on the fuel tank sender and
wiring lead.
3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level
sender.

9.24 26.6/30.7
 . Electrical System

4. If the fuel level indicator does not move and a faulty

or defective fuel level sender in the fuel tank has
been ruled out and in addition, wiring and
connectors have been checked and ruled out, the
fuel level indicator is defective and must be
replaced.
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key
switch and from the fuel level sender on the fuel tank
through the wiring in the cab.
7. Check the fuel level sender. The resistance of the
fuel level sender is 31 ohms for a full tank of fuel,
101 ohms for 1/2 tank and 255 ohms for an empty
tank. A defective fuel level sender in the fuel tank
may also prevent the fuel level indicator from
moving.

9.13.5 Hourmeter
The hourmeter is a non-repairable instrument that
records hours of machine engine operation in tenth of an
hour increments and is located in the instrument cluster.
The hourmeter is an analog device, similar to an
odometer, and will display 99,999.9 hours before
resetting to zero.
If trouble is suspected, time the hourmeter for six minutes
to verify that a tenth of an hour has been recorded.
The hourmeter is built into the instrument cluster and
cannot be repaired. If the hourmeter is suspect, replace
the instrument cluster.

26.6/30.7 9.25
 . Electrical System

9.14 ANALYZER TROUBLESHOOTING message shall be EVERYTHING OK when no fault is

present. Help Messages larger than the Analyzer display
are scrolled in a marquee-style fashion and repeated.
9.14.1 Fault Messages The Help Messages are prioritized to the Help Message
The following help messages are retained in Logged indicating faults present in the system, the LED on the
Help, which can be accessed by pressing the ENTER key PCB flashes out all fault codes from highest to lowest
while viewing the current Help message. The Help priority. The table below defines fault messages

Help Message Flash Code Fault Condition Action

SYSTEM VOLTS LOW 2-1 System voltage at If occurrence lasts for more than 3.2
pin J1-38<10 volts seconds then disable all outputs. The
fault shall be cleared upon all 3 axes of
the joystick being set to neutral (X and
Y and Knurl) and S4 becomes open.
SYSTEM VOLTS HIGH 2-2 System voltage at If occurrence lasts for more than 3.2
pin J1-38>15 volts seconds then disable all outputs. The
fault shall be cleared upon all 3 axes of
the joystick being set to neutral (X and
Y and Knurl) and S4 becomes open.

JOYSTICK FAULT 3-1 Joystick Fault Disable all functions. The fault shall be
latched and only reset upon power
down of the controller.

SYSTEM LOCKED OUT 3-2 Joystick X, Y, or Knurl Disable all functions. The fault shall be
CENTER JOYSTICK axes not in neutral at cleared upon all 3 axes of the joystick
system startup or S4 on being set to neutral (X and Y and Knurl)
the joystick closed and S4 becomes open.

TELE OUT OPEN FAULT 4-1 Open on pin J1-21 None. Fault shall be latched and only
reset upon power down of the
controller.

TELE IN OPEN FAULT 4-2 Open on pin J1-22 None. Fault shall be latched and only
reset upon power down of the
controller.

TILT UP OPEN FAULT 4-3 Open on pin J1-23 None. Fault shall be latched and only
reset upon power down of the
controller.

TILT DOWN OPEN 4-4 Open on pin J1-24 None. Fault shall be latched and only
FAULT reset upon power down of the
controller.

LIFT DOWN OPEN 4-5 Open on pin J1-25 None. Fault shall be latched and only
FAULT reset upon power down of the
controller.

LIFT UP OPEN FAULT 4-6 Open on pin J1-26 None. Fault shall be latched and only
reset upon power down of the
controller.

9.26 26.6/30.7
 . Electrical System

AUX HYD 1 OPEN FAULT 4-8 Open on pin J1-8 None. Fault shall be latched and only
reset upon power down of the
controller.

AUX HYD 2 OPEN FAULT 4-7 Open on pin J1-28 None. Fault shall be latched and only
reset upon power down of the
controller.
TELE OUT SHORT 5-1 Short to plus on pin J1-21 Disable Telescope Out output. Fault
FAULT shall be latched and only reset upon
power down of the controller.

TELE IN SHORT FAULT 5-2 Short to plus on pin J1-22 Disable Telescope In and Telescope
Out outputs. Fault shall be latched and
only reset upon power down of the
controller.

TILT UP SHORT FAULT 5-3 Short to plus on pin J1-23 Disable Tilt Up and Tilt Down outputs.
Fault shall be latched and only reset
upon power down of the controller.

TILT DOWN SHORT 5-4 Short to plus on pin J1-24 Disable Tilt Down output. Fault shall be
FAULT latched and only reset upon power
down of the controller.

LIFT DOWN SHORT 5-5 Short to plus on pin J1-25 Disable Lift Down and Lift Up outputs.
FAULT Fault shall be latched and only reset
upon power down of the controller.

LIFT UP SHORT FAULT 5-6 Short to plus on pin J1-26 Disable Lift Up output. Fault shall be
latched and only reset upon power
down of the controller.

AUX HYD 1 SHORT 5-8 Short to plus on pin J1-8 Disable Aux Hyd 1 output. Fault shall
FAULT be latched and only reset upon power
down of the controller.

AUX HYD 2 SHORT 5-7 Short to plus on pin J1-28 Disable Aux Hyd 2 output. Fault shall
FAULT be latched and only reset upon power
down of the controller.

CAN COMMUNICATION 6-6 Open circuit, short to plus, Disable all outputs. The fault shall be
or short to minus on pins cleared upon all 3 axes of the joystick
J1-11 or J1-12 being set to neutral (X and Y and Knurl)
and S4 becomes open.

EEPROM FAULT 9-9 eeprom None. Fault shall be latched and only
reset upon power down of the
controller.

26.6/30.7 9.27
 . Electrical System

9.14.2 Diagnostic Help Messages

The table below lists Diagnostic Help Messages that the
Control System communicates to the Analyzer.

Diagnostics Submenu Parameter Parameter Value Description

(Displayed on Analyzer (Displayed (Displayed on Analyzer
1st Line) on Analyzer 2nd Line)
2nd Line)

GROUND INPUT: JYSTK ON/OFF Display status of joystick lockout

LOCK

LMI ON/OFF Displays status of LMI Cutout

CUTOUT

LMI ON/OFF Displays status of LMI Override

OVERRIDE

GROUND OUTPUT: TELE IN/OUT XXX% Displays telescope switch direction &
demand.

LIFT UP/DOWN XXX% Displays lift direction & demand

FORK TILT UP/DOWN XXX% Displays fork lift direction & demand

AUX HYD XXX% Displays whether Auxiliary Hydraulics 1

1 OR 2 or 2 is active and demand percentage.

JOYSTICK: X POSITION ±XXX% Displays position in percentage for this

axis

X NEUTRL IN NEUTRAL, Indicates whether joystick is in neutral

NOT NEUTRAL, position for this axis
ERROR

Y POSITION ±XXX% Displays position in percentage for this

axis

Y NEUTRL IN NEUTRAL, Indicates whether joystick is in neutral

NOT NEUTRAL, position for this axis
ERROR

AR ±XXX% Displays position in percentage for the

analog rocker

AR NEUTRL IN NEUTRAL, Indicates whether analog rocker is in

NOT NEUTRAL, neutral position
ERROR

S1 ON/OFF Displays status of S1 pushbutton

S2 ON/OFF Displays status of S2 pushbutton

S3 ON/OFF Displays status of S3 pushbutton

S4 ON/OFF Displays status of S4 pushbutton

F1 ON/OFF Displays status of F1 pushbutton

9.28 26.6/30.7
 . Electrical System

SYSTEM: GM XX.XV Ground module battery voltage

BATTERY

DATALOG: ON XXXXhXXm Displays total controller on (power) time

LIFT XXXXhXXm Displays total controller lift operation
time

FORK TILT XXXXhXXm Displays total controller fork tilt

operation time

TELE XXXXhXXm Displays total controller telescope

operation time
AUX HYD XXXXhXXm Displays total auxiliary hydraulics 1 and
1/2 2 operation time

MAX VOLTS XX.XV Displays maximum measured battery

voltage

RENTAL XXXXhXXm Displays total controller operation time.

NOTE: can be reset
ERASE Not available at password level 2.
RENTAL? ENTER resets rental data log time to
zero

VERSION: GM SW PX.X Displays ground module software

version

GM HW REV XXXX Displays ground module hardware

version

GM SN XXXXXX Displays ground module serial number

JYSTK SW XX.X Displays joystick software version

ANALYZER VX.XXXX Displays Analyzer software version

26.6/30.7 9.29
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By Personal computing Technical Publications Dep.
 307. 1127. 3. 6

11 - 2005