31200306

May 7, 2019
UENR7997-01

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

When replacement parts are required for this

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

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200306 1
Table of Contents
Table of
Table of Contents Transmission.......................................... 43
Specifications Section Position Sensor (Transmission) ............. 45
Hydraulic Tank......................................... 3 Oil Filter.................................................. 46
Hydraulic Tank......................................... 5 Hydraulic Oil Cooler ............................... 48
Hydraulic Tank......................................... 6 Drive Shaft ............................................. 49
Piston Pump (Implement and Steering)... 7 Drive and Steering Axle (Front) ............. 50
Solenoid Valve (Pilot Selector) ................ 8 271 -6425 Drive and Steering
Main Control Valve (Implement) .............. 9 Axle Gp .............................................. 50
Frame .................................................... 11 271 -6426 Drive and Steering
Boom ..................................................... 12 Axle Gp .............................................. 52
Boom ..................................................... 13 Drive and Steering Axle (Front) ............. 54
Boom Cylinder ....................................... 14 271 -6427 Drive and Steering Axle Gp,
Boom Cylinder ....................................... 15 with Steering Sensor.......................... 54
Boom Cylinder ....................................... 16 Drive and Steering Axle (Rear) .............. 56
Load Control Valve (Boom Cylinder) 189-5717 Drive and Steering Axle Gp,
(Lock)..................................................... 17 with Steering Sensor.......................... 56
Compensating Cylinder ......................... 18 168-7443 Drive and Steering Axle Gp,
Compensating Cylinder ......................... 19 with Steering Sensor.......................... 57
Telescoping Cylinder ............................. 20 Drive and Steering Axle (Rear) .............. 58
Load Control Valve (Telescoping Cylinder) 231 -0710 Drive and Steering Axle Gp,
(Lock)..................................................... 21 without Steering Sensor..................... 58
Tilt Cylinder............................................ 22 231 -0709 Drive and Steering Axle Gp,
Tilt Cylinder............................................ 23 with Steering Sensor.......................... 59
Load Control Valve (Tilt Cylinder) (Lock)24 Differential and Bevel Gear Group ......... 60
Diverter Valve ........................................ 24 Differential and Bevel Gear Group ......... 61
Diverter Valve ........................................ 25 Axle Housing and Flange Group ............ 62
Towing Hitch .......................................... 26 Axle Housing and Flange Group ............ 62
Towing Hitch .......................................... 26 Final Drive Planetary Group................... 63
Towing Hitch .......................................... 27 Final Drive Planetary Group................... 64
Towing Hitch .......................................... 27 Axle Housing Group (Differential and Brake
Towing Hitch .......................................... 28 Cylinder)................................................. 65
Towing Hitch .......................................... 28 174-4642 Axle Housing Gp with a
Frame Leveling Cylinder........................ 29 Locking Differential ............................ 65
Frame Leveling Cylinder........................ 30 219-8780 Axle Housing Gp................ 67
Load Control Valve (Frame Leveling 219-8831 Axle Housing Gp with a
Cylinder) (Lock) ..................................... 31 Locking Differential ............................ 69
Control Valve (Stabilizer) ....................... 32 219-8842 Axle Housing Gp without a
Stabilizer Cylinder.................................. 33 Locking Differential ............................ 71
Stabilizer Cylinder.................................. 34 Axle Housing Group (Differential and Brake
Stabilizer Cylinder.................................. 35 Cylinder)................................................. 73
Load Control Valve (Stabilizer Cylinder) 253-4990 Axle Housing Gp with a
(Lock)..................................................... 36 Locking Differential ............................ 73
Axle Lock Cylinder ................................. 37 253-4985 Axle Housing Gp without a
Metering Pump (Steering) ..................... 38 Locking Differential ............................ 75
Solenoid Valve (Steering Mode Brake Cylinder (Master) ......................... 76
Selector) ................................................ 38 Parking Brake Control ............................ 77
Position Sensor (Steering)..................... 39 Parking Brake ........................................ 78
Position Sensor (Steering)..................... 39 Fender.................................................... 79
Flexible Coupling Drive.......................... 40 Wheel (Tire and Rim) ............................. 80
Transmission ......................................... 41 Fuel Tank ............................................... 81
2 31200306
Table of Contents

Fuel Tank ...............................................82

Engine Enclosure ...................................83
Engine and Transmission Mounting .......85
Air Cleaner .............................................86
Engine Oil Drain .....................................88
Muffler ....................................................89
Suction Fan ............................................90
Battery ....................................................91
Alternator................................................92
Coolant Lines Group ..............................93
Coolant Recovery Group........................94
Cab.........................................................96
Latch Adjustment ...............................96
Cab Mounting .........................................97
Cab Door ................................................98
Access Door .........................................100
Joystick Control ....................................101
Steering Wheel and Column ................102
Window Wiper and Wiper Motor...........103
Window Washer Tank ..........................104
Rear View Mirror ..................................105
Carriage Cylinder (Rotate) ...................105
Carriage Cylinder (Sideshift) ................106
Hydraulic Cylinder (Multipurpose
Bucket) .................................................107
Grapple Cylinder ..................................108
31200306 3
Specifications Section

Specifications Section
Hydraulic Tank

Illustration 1 g01076453

(1) Hydraulic filler cap

(2) The torque for the bolts for the oil level
indicator ...................................... 10 ± 1 Nm (88 ± 9 lb in)
Note: Remove nuts before assembly. The nuts are not
required.
(3) The torque for the bolt ............................. 2.25 ± 0.25 Nm
(20 ± 2 lb in)
(4) The torque for the drain plug .......................... 35 ± 5 Nm
(25 ± 3 lb ft)
(5) The torque for the bolts ........................... 2.25 ± 0.25 Nm
(20 ± 2 lb in)
4 31200306
Specifications Section

Illustration 2 g01076465

(6) The torque for the bolts for the hydraulic

tank.............................................. 30 ± 5 Nm (22 ± 3 lb ft)
(7) The torque for the bolts for the hydraulic
tank.............................................. 30 ± 5 Nm (22 ± 3 lb ft)
31200306 5
Specifications Section

Hydraulic Tank

Illustration 3 g01055813
203-1995 Fuel Tank Gp
(1) Hydraulic filler cap
(2) The torque for the bolts for the tube
assemblies .......................... 2.25 ± 0.25 Nm (20 ± 2 lb in)
(3) The torque for the drain plug ......................... 14 ± 1 Nm
(124 ±9 lb in)
6 31200306
Specifications Section

Hydraulic Tank

Illustration 5 g00862098
232-7695 Hydraulic Tank Gp
(1) Hydraulic filler cap
(2) The torque for the bolts for the oil level
indicator ...................................... 10 ± 1 Nm (88 ± 9 lb in)
(3) The torque for the bolts for the hydraulic
tank.............................................. 30 ± 5 Nm (22 ± 3 lb ft)
(4) The torque for the bolts for the tube
assemblies .......................... 2.25 ± 0.25 Nm (20 ± 2 lb in)
(5) The torque for the drain plug .......................... 35 ± 5 Nm
(25 ± 3 lb ft)
31200306 7
Specifications Section

Piston Pump (Implement and

Steering)

Illustration 6 g00937820

Pump type ......................................................... variable piston

The rotation of the shaft is counterclockwise when the rotation
of the shaft is viewed from the drive end.
Displacement of the pump.................... 45 cc/rev (2.75 in3/rev)
Pressure setting...................................... 31500 kPa (4570 psi)
Cut off pressure ...................................... 26000 kPa (3770 psi)
Margin pressure at full speed..................... 2200 kPa (320 psi)
Maximum case drain flow at port (T) ........................... 5 L/min
(1.32 US gpm)
The pump speed
LOW engine idle.....................................................1013 rpm
HIGH engine idle .................................................. 2515 rpm
(1) Torque setting for plug.......................... 190 Nm (140 lb ft)
(2) 223-8910 Valve As
(A) Pressure port
(S) Suction port
(X) LS pressure port
(T) Case Drain port
8 31200306
Specifications Section

Solenoid Valve (Pilot Selector)

Illustration 7 g00849505

Technical data
Maximum pressure ........................... 32000 kPa (4640 psi)
Oil flow at maximum pressure ............................ 25 L/min
(6.6 US gpm)
Voltage ....................................... 10.5 volts to 14 volts DC
Rated resistance...................................................................7.7Q
(1) Torque for fasteners . . . . . . . . . . . . . 4 ± 1 Nm (35 ± 9 lb in)
31200306 9
Specifications Section

Main Control Valve (Implement)

Illustration 8 g01134146
10 31200306
Specifications Section

Illustration 9 g01134171

(1) Load Signal port for Steering

(2) Control Valve for the Telescoping Cylinder
(3) Control Valve for the Auxiliary Function
(4) Control Valve for the Fork Cylinder
(5) Boom Cylinder Control Valve
(6) Torque for the locknut ....................20 ± 2 Nm (15 ± 1 lb ft)
(7) Torque for the valve....................... 55 ± 5 Nm (40 ± 5 lb ft)
(8) Torque for four nuts ................................. 35 Nm (25 lb ft)
(9) Oil Supply Port for Steering
(10) Relief Valve (Load sensing signal)
Pressure setting................................ 22800 kPa (3300 psi)
Torque for the relief valve........................ 45.0 ±4.5 Nm
(33.2 ± 3.3 lb ft)
(11) Torque for valve cap.................... 20 ± 2 Nm (15 ± 1 lb ft)
(12) Drain Port
(13) Torque for eight bolts ................. 3 ±0.3 Nm (27 ±3 lb in)
(14) Torque for eight bolts ................. 3 ±0.5 Nm (27 ±4 lb in)
31200306 11
Specifications Section

Frame

Illustration 10 g00998905

(1) Thickness of shim .....................................2 mm (0.08 inch)

(2) Thickness of shim ................................ 1.5 mm (0.06 inch)
(3) Thickness of shim ................................... 1 mm (0.04 inch)
(4) Thickness of shim ................................... 3 mm (0.12 inch)
Note: Use the shims in order to obtain a maximum gap of 1
mm (0.04 inch).
12 31200306
Specifications Section

Boom

Illustration 11 g01055968

(1) Use 4C-4030 Thread Lock Compound on

threads.
(2) Thickness of shims .............................. 1.5 mm (0.06 inch)
(3) Torque for the nuts on the chain .....................105 ± 5 Nm
(77 ± 4 lb ft)
(4) Torque for the nuts on the chain.......................70 ± 5 Nm
(52 ± 5 lb ft)
31200306 13
Specifications Section

Boom

Illustration 12 g01055968

(1) Use 4C-4030 Thread Lock Compound on

threads.
(2) Thickness of shims .............................. 1.5 mm (0.06 inch)
(3) Torque for the nuts on the chain..................... 130 ± 5 Nm
(95.88 ± 3.69 lb ft)
(4) Torque for the nuts on the chain ...................... 85 ± 5 Nm
(62.69 ± 3.69 lb ft)
14 31200306
Specifications Section

Boom Cylinder
Part No.: 253-3933

Illustration 16 g01170423

Cylinder stroke ..................................... 1951 mm (76.81 inch)

(1) Torque setting for self-locking
nut................................ 6500 ± 500 Nm (4795 ± 370 lb ft)
Lubricate the threads of the self-locking nut with clean grease.
(2) Diameter of piston ................................. 132.85 ± 0.03 mm
(5.2303 ±0.0012 inch)
(3) Bore of cylinder ..................................... 133.35 ± 0.08 mm
(5.250 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 101.55 ± 0.038 mm
(3.998 ±0.0015 inch)
(5) Bore of head .......................................... 101.93 ± 0.03 mm
(4.013 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7308 Sleeve Bearing
outside diameter................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter .................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
(9) 207-1738 Bearing
outside diameter............................. 104.993 ± 0.0075 mm
(4.1336 ±0.0003 inch)
Inside diameter ................................ 69.9930 ± 0.0075 mm
(2.7556 ± 0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 15
Specifications Section

Boom Cylinder
Part No.: 253-3964

Illustration 17 g01170423

Cylinder stroke ................................. 1832 mm (72.1258 inch)

(1) Torque setting for self-locking
nut ................................6500 ± 500 Nm (4795 ± 370 lb ft)
Lubricate the threads of the self-locking nut with clean grease.
(2) Diameter of piston ................................. 132.85 ± 0.03 mm
(5.230 ± 0.001 inch)
(3) Bore of cylinder ..................................... 133.35 ± 0.08 mm
(5.250 ± 0.003 inch)
(4) Diameter of piston rod ........................ 101.55 ± 0.038 mm
(3.998 ± 0.002 inch)
(5) Bore of head .......................................... 101.93 ± 0.03 mm
(4.013 ±0.001 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7308 Sleeve Bearing
outside diameter................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter.................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
(9) 207-1738 Bearing
outside diameter............................. 104.993 ± 0.0075 mm
(4.1336 ±0.0003 inch)
Inside diameter................................ 69.9930 ± 0.0075 mm
(2.7556 ± 0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
16 31200306
Specifications Section

Boom Cylinder
Part No.: 253-4258

Illustration 21 g01170707

Cylinder stroke ..................................... 1972 mm (77.64 inch)

(1) Torque setting for self-locking
nut................................ 6500 ± 500 Nm (4795 ± 370 lb ft)
Lubricate the threads of the self-locking nut with clean grease.
(2) Diameter of piston ................................... 154.5 ±0.03 mm
(6.083 ± 0.001 inch)
(3) Bore of cylinder .......................................... 155 ±0.08 mm
(6.102 ±0.003 inch)
(4) Diameter of piston rod ........................ 107.95 ± 0.038 mm
(4.248 ± 0.002 inch)
(5) Bore of head .......................................... 108.28 ± 0.03 mm
(4.263 ± 0.001 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 210-8897 Sleeve Bearing
outside diameter................................. 85.845 ± 0.025 mm
(3.3797 ±0.0010 inch)
Inside diameter................................... 70.315 ± 0.025 mm
(2.7683 ±0.0010 inch)
(9) 210-8374 Bearing
outside diameter............................. 119.9925 ± 0.0075 mm
(4.7241 ± 0.0003 inch)
Inside diameter............................... 79.9925 ± 0.0075 mm
(3.1493 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 17
Specifications Section

Load Control Valve (Boom

Cylinder) (Lock)

Illustration 22 g01170870
Load Control Valve (Boom Cylinder)

(1) Damper screw

The recommended torque for the mounting bolts is 23 ± 1 Nm
(204 ± 9 lb in).
18 31200306
Specifications Section

Compensating Cylinder
Part No.: 203-7847

Illustration 23 g01121416

Cylinder stroke ......................................... 344 mm (13.5 inch)

(1)Torque setting for bolt....................................850 ± 25 Nm
(625 ± 20 lb ft)
Lubricate the threads of the bolt with clean grease.
(2) Diameter of piston ..................................... 74.5 ± 0.03 mm
(2.9331 ±0.0012 inch)
(3) Bore of cylinder ............................................ 75 ± 0.08 mm
(2.9527 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 44.950 ± 0.038 mm
(1.7697 ±0.0015 inch)
(5) Bore of head ............................................ 45.33 ± 0.03 mm
(1.7846 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 193-3857 Bearing
Diameter......................................... 61.9935 ± 0.0065 mm
(2.4407 ± 0.0003 inch)
Bore .................................................... 39.994 ± 0.006 mm
(1.5746 ±0.0002 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 19
Specifications Section

Compensating Cylinder
Part No.: 207-5070

Illustration 24 g01121416

Cylinder stroke ......................................... 352 mm (13.9 inch)

(1) Torque setting for bolt .................................. 850 ± 25 Nm
(625 ± 20 lb ft)
Lubricate the threads of the bolt with clean grease.
(2) Diameter of piston ..................................... 74.5 ± 0.03 mm
(2.9331 ±0.0012 inch)
(3) Bore of cylinder ....................................... 90.00 ± 0.08 mm
(3.5433 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 44.950 ± 0.038 mm
(1.7697 ±0.0015 inch)
(5) Bore of head ............................................ 45.33 ± 0.03 mm
(1.7846 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7311 Bearing
Outside diameter ............................... 74.9935 ± 0.0065 mm
(2.9525 ± 0.0003inch)
Inside diameter ...................................... 49.994 ± .006 mm
(1.9683 ±0.0002 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
20 31200306
Specifications Section

Telescoping Cylinder
Part No.: 241-3160
Part No.: 241-3160

Illustration 26 g00842439

Cylinder stroke ..................................... 3570 mm (140.6 inch)

(1) Diameter of piston ................................. 99.55 ± 0.03 mm
(3.9193 ±0.0012 inch)
Torque setting for piston (1)........................... 1000 ± 100 Nm
(735 ± 75 lb ft)
Lubricate the threads of the piston with clean grease.
Apply sealant to the threads of the set screw (2).
(3) Bore of cylinder .......................................... 100 ±0.08 mm
(3.9370 ± 0.0031 inch)
(4) Diameter of piston rod ............................. 69.8 ± 0.038 mm
(2.7480 ±0.0015 inch)
(5) Bore of head ............................................ 70.13 ±0.03 mm
(2.7610 ±0.0012 inch)
(6) Torque setting of head . . . . . . . . . . . . . . . . . . . . . . . 6 0 0 ±1 3 0 N m
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to the wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
31200306 21
Specifications Section

Load Control Valve

(Telescoping Cylinder) (Lock)

Illustration 27 g01077337

(1) Damper screw

(2) Torque for four bolts.......................23 ± 1 N m ( 1 7 ±1 lb ft)
Pressure setting for the load control
valve ...................................................... 26000 kPa (3770 psi)
22 31200306
Specifications Section

Tilt Cylinder
Part No.: 203-7756

Illustration 28 g01171377

Cylinder stroke ................................... 327 mm (12.8740 inch)

(1) Torque setting for nut ...............................6500 ± 100 Nm
(4795 ± 75 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................... 124.5 ±0.03 mm
(4.9016 ±0.0012 inch)
(3) Bore of cylinder ....................................... 125.0 ±0.08 mm
(4.9213 ±0.0031 inch)
(4) Diameter of piston rod .......................... 74.95 ± 0.038 mm
(2.9508 ±0.0015 inch)
(5) Bore of head ............................................ 75.33 ± 0.03 mm
(2.9657 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 100 Nm
(445 ± 75 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 256-0181 Sleeve Bearing
Outside diameter................................ 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter .................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
(9) 193-3865 Bearing
Diameter......................................... 89.9925 ± 0.0075 mm
(3.5430 ± 0.0003 inch)
Bore ................................................ 59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
31200306 23
Specifications Section

Tilt Cylinder
Part No.: 211-1322

Illustration 30 g01171377

Cylinder stroke ......................................... 327 mm (12.9 inch)

(1) Torque setting for self-locking
nut ..................................6500 ± 100 Nm (4800 ± 75 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................... 149.5 ±0.03 mm
(5.89 ± 0.001 inch)
(3) Bore of cylinder ..................................... 150.00 ± 0.08 mm
(5.906 ± 0.003 inch)
(4) Diameter of piston rod .......................... 74.95 ± 0.038 mm
(2.950 ±0.0015 inch)
(5) Bore of head ............................................ 75.33 ± 0.03 mm
(2.966 ± 0.001 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 240-9962 Sleeve Bearing
Diameter............................................. 93.605 ± 0.025 mm
(3.6852 ±0.0010 inch)
Bore.................................................... 80.275 ± 0.025 mm
(3.1604 ±0.0010 inch)
(9) 210-8374 Bearing
Diameter ......................................... 119.9925 ± 0.0075 mm
(4.7241 ± 0.0003 inch)
Bore................................................ 79.9925 ±0.0075 mm
(3.1493 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
24 31200306
Specifications Section

Load Control Valve (Tilt Diverter Valve

Cylinder) (Lock)

Illustration 32 g00850222
Single Diverter Valve

Illustration 31 g00936419

(1) Installation torque .....................150 ± 8 Nm (110 ±6 lb ft)

Set pressure .......................................... 33000 kPa (4800 psi)
Pilot ratio......................................................................................... 4.2:1

Illustration 33 g00939703
Dual Diverter Valve
Technical Data
Maximum operating pressure.............................21000 kPa
(3045 psi)
Maximum flow ..................................90 L/min (25 US gpm)
(1) Torque for fastener......................... 8 ± 1 Nm (70 ± 9 lb in)
(2) Torque for cartridge ..................... 26 ± 1 Nm (20 ±1 lb ft)
(3) Torque for mounting bolts ................................ 14 ± 1 Nm
(10 ± 1 lb ft)
31200306 25
Specifications Section

Diverter Valve

Illustration 34 g01080341
Conversion kit for the diverter valve
(1) 226-6494 Diverter Valve (3) Components from original assembly
(2) 179-1867 Diverter Valve (4) Bolts from original assembly

Technical data
Maximum operating pressure ............................ 21000 kPa
(3045 psi)
Maximum flow ................................. 90 L/min (25 US gpm)
(3) Relocate the fittings. Torque for
fittings ..........................................80 ± 8 Nm (59 ± 6 lb ft)
(4) Relocate the bolts. Torque for bolts.....................13 ± 1 Nm
(115 ±9 lbin)
26 31200306
Specifications Section

Towing Hitch Towing Hitch

Part No.: 211-8359 Part No.: 211-8358

Illustration 35 g00943200 Illustration 36 g00943198

(1) 200-2141 Hitch Gp (1) 200-2142 Hitch Group

(2) Torque for Six Nuts ............................... 530±70Nm (2) Torque for Six Nuts ..................................... 530±70N-m
(390 ± 50 lb ft) (390 ± 50 lb ft)
31200306 27
Specifications Section

Towing Hitch Towing Hitch

Part No.: 211-8357 Part No.: 211-8356

Illustration 37 g00943195 Illustration 38 g00943109

(1) 200-2140 Hitch Group (1) Torque for Six Nuts .................................... 530±70N-m
(390 ± 50 lb ft)
(2) Torque for Six Nuts .............................. 530±70Nm
(390 ± 50 lb ft)
28 31200306
Specifications Section

Towing Hitch Towing Hitch

Part No.: 211-2381 Part No.: 211-9463

Illustration 39 g00941379 Illustration 40 g00943017

(1) Torque for Two Nuts .. ... ... .... ... ... ... ... ... .. 530±70Nm (1) Torque for Three Nuts .......................... 530±70Nm
(390 ± 50 lb ft) (390 ± 50 lb ft)
31200306 29
Specifications Section

Frame Leveling Cylinder

Part No.: 204-7813

Illustration 41 g01121213

Cylinder stroke ........................................... 168 mm (6.6 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................... 99.55 ± 0.03 mm
(3.9193 ±0.0012 inch)
(3) Bore of cylinder .......................................... 100 ±0.08 mm
(3.9370 ± 0.0031 inch)
(4) Diameter of piston rod ........................ 50.750 ± 0.038 mm
(1.9980 ±0.0015 inch)
(5) Bore of head ............................................ 51.13 ±0.03 mm
(2.0130 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 204-7311 Bearing
Outside diameter............................ 74.9935 ± 0.0065 mm
(2.9525 ± 0.0003 inch)
Inside diameter.................................... 49.988 ± 0.012 mm
(1.9680 ±0.0005 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
(9) 204-7310 Sleeve Bearing
Outside diameter................................. 60.195 ± 0.025 mm
(2.3699 ±0.0010 inch)
30 31200306
Specifications Section

Frame Leveling Cylinder

Part No.: 211-1327

Illustration 42 g01121139

Cylinder stroke ........................................... 168 mm (6.6 inch)

(1) Torque setting for self-locking
nut.................................... 1200 ± 120 Nm (885 ± 85 lb ft)
Lubricate the threads of the nut with clean grease.
(2) Diameter of piston ................................. 109.50 ± 0.03 mm
(4.3110 ±0.0012 inch)
(3) Bore of cylinder ...........................................110 ±0.08 mm
(4.3307 ± 0.0031 inch)
(4) Diameter of piston rod ............................. 44.4 ± 0.038 mm
(1.7480 ±0.0015 inch)
(5) Bore of head ............................................ 44.78 ± 0.03 mm
(1.7630 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 193-3865 Bearing
Diameter......................................... 89.9925 ± 0.0075 mm
(3.5430 ± 0.0003 inch)
Bore ................................................ 59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
(9) 204-7308 Sleeve Bearing
Outside diameter................................ 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Inside diameter .................................... .60.305 ±0.025 mm
(2.3742 ±0.0010 inch)
31200306 31
Specifications Section

Load Control Valve (Frame

Leveling Cylinder) (Lock)

Illustration 44 g00849768

(1) Pressure setting of valve .................. 35000 kPa (5075 psi)

(2) Torque for four mounting bolts.........................23 ± 1 Nm
(17 ± 1 lb ft)
(3) Pressure setting of valve .................. 35000 kPa (5075 psi)
(4) Installation torque for cartridge ........................45 ± 6 Nm
(33 ± 5 lb ft)
(5) Installation torque for fastener . . . . . . . . . . . . . . . . 5 ± 1 Nm
(44 ± 9 lb in)

i
32 31200306
Specifications Section

Control Valve (Stabilizer)

Illustration 46 g01164853

Maximum Operating pressure ................................. 23800 kPa

(3450 psi)
Temperature range ..................................... 43 °C to - 40 °C
(109 °Fto-32°F)
(1) Torque for the eight bolts.................................. 8 ± 1 Nm
(71 ± 9 lb in)
(2) Installation torque ........................ 50 ± 1 Nm (37 ± 1 lb ft)
(3) Installation torque .......................... 7 ± 1 Nm (62 ± 9 lb in)
(4) Four coils
Voltage ......................................................................... 12 VDC
Resistance .........................................................................5.2 Q
Wattage ................................................................... 27 W
(5) Coil
Voltage.......................................................................... 10 VDC
Resistance..............................................................................................................5 Q.
Wattage ....................................................................19.9 W
31200306 33
Specifications Section

Stabilizer Cylinder
Part No.: 207-2068

Illustration 47 g01171677

Cylinder stroke......................................... 450 mm (17.72 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston ................................... 124.5 ±0.03 mm
(4.9016 ±0.0012 inch)
(3) Bore of cylinder ..................................... 125.00 ± 0.08 mm
(4.9213 ±0.0031 inch)
(4) Diameter of piston rod ........................ 54.930 ± 0.038 mm
(2.1626 ±0.0015 inch)
(5) Bore of the head ...................................... 55.28 ± 0.03 mm
(2.1764 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8) 193-3865 Bearing
Diameter .............................................. 89.9925 ± 0.0075 mm
(3.5430 ± 0.0003 inch)
Bore...................................................... 59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
(9) 204-7308 Sleeve Bearing
Diameter............................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore ................................................... 60.305 ±0.025 mm
(2.3742 ±0.0010 inch)
34 31200306
Specifications Section

Stabilizer Cylinder
Part No.: 259-8723

Illustration 48 g01171746

Cylinder stroke......................................... 450 mm (17.72 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston .................................... 114.50 ± 0.03 mm
(4.508 ± 0.001 inch)
(3) Bore of cylinder ......................................115.00 ±0.08 mm
(4.528 ± 0.003 inch)
(4) Diameter of piston rod ........................ 54.930 ± 0.038 mm
(2.1626 ±0.0015 inch)
(5) Bore of the head ...................................... 55.28 ± 0.03 mm
(2.1764 ±0.0012 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8), (9) 204-7308 Sleeve Bearing
Diameter............................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore .................................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
31200306 35
Specifications Section

Stabilizer Cylinder
Part No.: 263-9955 S/N: SLG1300-Up

Illustration 50 g01165330

Cylinder stroke......................................... 450 mm (17.72 inch)

(1) Torque setting for self-locking
nut ................................. 1600 ± 160 Nm (1180 ± 120 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston ................................... 139.5 ±0.03 mm
(5.4921 ±0.0012 inch)
(3) Bore of cylinder .......................................... 140 ±0.08 mm
(5.5118 ±0.0031 inch)
(4) Diameter of piston rod .......................... 64.95 ± 0.038 mm
(2.5571 ±0.0015 inch)
(5) Bore of the head ...................................... 65.28 ± 0.03 mm
(2.5701 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 300 Nm
(440 ± 220 lb ft)
Lubricate the threads of the head (6) with clean grease.
Apply 4C-4032 Bearing Mount Compound to seal groove (7)
prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8) 210-8895 Bearing
Outside diameter.................................... 85.85 ± 0.01 mm
(3.380 ± 0.0004 inch)
Inside diameter................................... 70.315 ± 0.025 mm
(2.7683 ±0.0010 inch)
(9) 204-7308 Sleeve Bearing
Diameter............................................. 73.165 ± 0.025 mm
(2.8805 ±0.0010 inch)
Bore .................................................... 60.305 ± 0.025 mm
(2.3742 ±0.0010 inch)
36 31200306
Specifications Section

Load Control Valve (Stabilizer

Cylinder) (Lock)
Part No.: 204-6924
Part No.: 204-6924

Illustration 51 g00849802

(1) Pressure setting for the rod end of the

cylinder............................................ 10000 kPa (1450 psi)
(2) Pressure setting for the head end of the
cylinder ............................................. 35000 kPa (5075 psi)
Torque for four mounting bolts .............................. 23 ± 1 Nm
(17 ± 1 lb ft)
Maximum flow.....................................60 L/min (15.9 US gpm)
Maximum operating pressure................................... 35000 kPa
(5075 psi)
31200306 37
Specifications Section

Axle Lock Cylinder

Illustration 52 g01121364

Cylinder stroke............................................. 208 mm (8.2 inch)

(1) Torque setting for self-locking
nut ....................................1200 ± 120 Nm (885 ± 85 lb ft)
Lubricate the threads of self-locking nut (1) with clean grease.
(2) Diameter of piston ................................... 99.55 ± 0.03 mm
(3.9193 ±0.0012 inch)
(3) Bore of cylinder ...........................................110 ±0.08 mm
(4.3307 ± 0.0031 inch)
(4) Diameter of piston rod ......................... 44.400 ± 0.038 mm
(1.7480 ±0.0015 inch)
(5) Bore of the head ...................................... 44.78 ± 0.03 mm
(1.7630 ±0.0012 inch)
(6) Torque setting for the head ........................ 600 ± 130 Nm
(445 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all of the seals with the lubricant that is being
sealed.
(8) 193-3865 Bearing
Diameter. ........................................... 89.9925 ±0.0075 mm
(3.5430 ± 0.0003 inch)
Bore ..................................................59.9925 ±0.0075 mm
(2.3619 ±0.0003 inch)
Note: Secure the bearing with 185-3994 Bearing Mount
Compound.
38 31200306
Specifications Section

Metering Pump (Steering) Solenoid Valve (Steering Mode

Part No.: 233-6072 Selector)
Part No.: 237-4154

Illustration 56 g00930154
Illustration 53 g00927267
(1) Torque for the fastener ...................4 ± 1 Nm (35 ± 9 lb in)
Capacity per revolution................................ 250 cc (15.26 in3)
(2) Current at 12 VDC ..........................................................1.56A
(2) Resistance at 20 °C (68 °F) .............................................. 7.7Q
Maximum pressure ................................32000 kPa (4640 psi)

Illustration 54 g01094328

(1) Adjustment for the Relief pressure of the Steering Pressure

31200306 39
Specifications Section

Position Sensor (Steering) Position Sensor (Steering)

Part No.: 229-5075 Part No.: 198-7807 S/N: SLG1-Up

Illustration 57 g00926252 Illustration 58 g00926252

The switch is a magnetic position sensor. The switch is a magnetic position sensor.
Table 1 Table 2

Pin Circuit Color Pin Circuit Color

A (+) Bat Brown A Signal Black

B (-) Bat Blue B (+) Bat Brown

C Signal Black C (-) Bat Blue

Specifications for the position sensor Specifications for the position sensor
Maximum operating range of the sensor................. 7 mm Maximum operating range of the sensor................. 7 mm
(0.28 inch) (0.28 inch)
Nominal current draw ............................................. 800 mA Nominal current draw .............................................. 800 mA
Length of the cable................................ 250 mm (9.8 inch) Length of the cable ................................ 250 mm (9.8 inch)
40 31200306
Specifications Section

Flexible Coupling Drive

Illustration 59 g00998062

(1) Torque for the six bolts ..................55 ± 5 Nm (41 ± 4 lb ft)

(2) Apply 4C-5598 High Temperature Anti-Seize to
the pilot of the torque converter.
31200306 41
Specifications Section

Transmission
Part No.: 216-2273

Illustration 60 g01000938
42 31200306
Specifications Section

(1) Torque for the plug ..................... 24 ± 3.5 Nm (17 ± 3 lb ft)

(2) Torque for the 2 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(3) Torque for the bolt....................... 78 ± 10 Nm (57 ± 7 lb ft)
(4) Torque for the plugs .....................24 ± 3.5 Nm (17 ± 3 lb ft)
(5) Torque for the torque converter inlet relief
valve ........................................ 27 ± 3.5 Nm (20 ± 3 lb ft)
(6) Torque for the pressure regulator ................... 55 ± 9.5 Nm
(40 ± 7 lb ft)
(7) Torque for the sensor .................... 47 ± 7 Nm (35 ± 5 lb ft)
(8) Torque for the 4 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(9) Torque for the 7 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(10) Torque for the 6 bolts .................................. 55 ± 9.5 Nm
(40 ± 7 lb ft)
(11) Torque for the 2 bolts .................25 ±6 Nm (19 ±4 lb ft)
(12) Torque for the bolts ....................55 ± 9.5 Nm (40 ± 7 lb ft)
(13) Torque for the 3 bolts ................................. 25 ± 6.5 Nm
(18 ± 5 lb ft)
(14) Torque for the 2 bolts.................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(15) Torque for the sensor .................. 47 ±7 Nm (35 ± 5 lb ft)
(16) Torque for the 3 bolts ................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(17) Torque for the 2 bolts.................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(18) Torque for the bolt.................... 55 ± 9.5 Nm (40 ± 7 lb ft)
(19) Torque for the 2 bolts..................78 ± 10 Nm (58 ±7 lb ft)
(20) Torque for the plug....................24 ± 3.5 Nm (17 ± 3 lb ft)
(21) Torque for the 2 bolts ................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(22) Torque for the plug ................... 44 ± 10 Nm (32 ± 7 lb ft)
(23) Torque for the bolts ....................25 ± 6.5 Nm (18 ± 5 lb ft)
(24) Torque for the bolts.......................9± 1.5 N-m (6 ± 1 lb ft)
(25) Torque for the 3 modulating valves.............. .. 50 ± 5 Nm
(37 ± 4 lb ft)
31200306 43
Specifications Section

Transmission
Part No.: 216-2274

Illustration 61 g01007384
44 31200306
Specifications Section

(I) Torque for the plug.......................24 ± 3.5 Nm (17 ± 3 lb ft)

(2A) Torque for the valve ................. 50 ± 5.5 Nm (37 ± 4 lb ft)
(2B) Torque for the nuts ................................. 12.5 ± 1.5 Nm
(110 ± 13 lbin)
(3) Torque for the bolt....................... 78 ± 10 Nm (57 ± 7 lb ft)
(4) Torque fort he plug ..................... 24 ± 3.5 Nm (17 ± 3 lb ft)
(5) Torque for the torque converter inlet relief
valve ......................................... 27 ± 3.5 Nm (20 ± 3 lb ft)
(6) Torque for the pressure regulator ................... 55 ± 9.5 Nm
(40 ± 7 lb ft)
(7) Torque for the sensor ................... 47 ± 7 Nm (35 ± 5 lb ft)
(8) Torque for the 4 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(9) Torque for the 5 bolts ...................25 ± 6.5 Nm (18 ± 5 lb ft)
(10) Torque for the bolt ....................24 ± 3.5 Nm (17 ± 3 lb ft)
(II) Torque for the 4 bolts.................. 25 ±6 Nm (19 ±4 lb ft)
(12) Torque for the bolts ....................55 ± 9.5 Nm (40 ± 7 lb ft)
(13) Torque for the 3 bolts................................. 25 ± 6.5 Nm
(18 ± 45 lb ft)
(14) Torque for the 2 bolts ................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(15) Torque for the sensor....................47 ±7 Nm (35 ± 5 lb ft)
(16) Torque for the 9 bolts ..................................25 ± 6.5 Nm
(18 ± 5 lb ft)
(17) Torque for the bolt....................55 ± 9.5 Nm (40 ± 7 lb ft)
(18) Torque for the bolt....................55 ± 9.5 Nm (40 ± 7 lb ft)
(19) Torque for the bolt ................. 105 ±20 Nm (77 ± 15 lb ft)
(20) Torque for the plug ..................... 24 ± 3.5 Nm (17 ± 3 lb ft)
(21) Torque for the 4 bolts .................................. 25 ± 6.5 Nm
(18 ±5 lb ft)
(22) Torque for the plug....................44 ± 10 Nm (32 ± 7 lb ft)
(23) Torque for the bolt.....................78 ± 10 Nm (58 ± 7 lb ft)
(24) Torque for the bolts .....................8.5 ±1.5 Nm (6 ± 1 lb ft)
(25) Torque for the 2 bolts................................. 25 ± 6.5 Nm
(18 ± 45 lb ft)
(26) Torque for the 2 bolts................................... 25 ± 6.5 Nm
(18 ±5 lb ft)
(27) Torque for the bolt .....................25± 6.5 Nm (18 ± 5 lb ft)
31200306 45
Specifications Section

Position Sensor (Transmission)

Illustration 62 g00926041

The position sensor is a pulse width modulated sensor

(PWM).
Table 3

Pin Circuit Color

1 (+) Bat Red
2 (-) Bat Blue
3 PWM Yellow
4 Reserved White

Specifications for the position sensor

Operating range of the sensor ............................... 12 mm
(0.47 inch)
Operating range of the duty cycle .................... 10% to 90%
Sensors need to be spaced................... 100 mm (4.0 inch)
Minimum operating temperature ........................... -40 °C
(-40 °F)
Maximum operating temperature............................ 120 °C
(248 °F)
Torque for the two mounting bolts .................... 8 ± 1 Nm
(70 ± 9 lb in)
Regulated supply voltage .................................. 8 ± .4 VDC
Nominal current draw ............................... 7 mA at 8 VDC
46 31200306
Specifications Section

Oil Filter

Illustration 63 g00883006

(1) Torque for switch ........................ 5 ± 1 Nm (45 ± 10 lb in)

Pressure setting for the differential pressure switch
(1) ................................................................... 276 kPa (40 psi)
The differential pressure switch (1) is a normally open switch.
(2) 8C-3446 Fluid Sampling Valve
Bypass pressure setting for the filter 345 ± 34 kPa (50 ± 5 psi)
31200306 47
Specifications Section

Illustration 64 g01077798

(3) Torque for the bolts.......................30 ± 7 Nm (22 ± 5 lb ft)

48 31200306
Specifications Section

Hydraulic Oil Cooler

Illustration 65 g01165467

Pressure test the oil cooler:

• Pressurize the oil cooler assembly to a minimum of
586 kPa (85 psi).
• The oil cooler assembly is rejected if there is a
pressure drop of 1.4 kPa (0.2 psi) in three minutes.
Note: A mixture of a soap solution and a rust preventive can
aid in finding slow leaks in the castings, joints, and welds.
(1) Torque for the connector ................................30 ± 5 Nm
(22 ± 4 lb ft)
(A) Place the assembly so that the flat surface of the
first baffle is this position.
(B) The depth of the 205-3658 Baffle at each of the
ends................................. 5.5 ± 0.5 mm (0.22 ± 0.02 inch)
(C) The depth of the 205-3658 Baffle at each of the
ends................................. 1.5 ± 0.8 mm (0.06 ± 0.03 inch)
31200306 49
Specifications Section

Drive Shaft

Illustration 67 g00927112

(1) Replacement 117-9887 Spider and Bearing Kit

(A) Front drive shaft.................. 946 ± 36 mm (37.2 ± 1.4 inch)
(A) Rear drive shaft ......................................... 1097 ±36 mm
(43.2 ± 1.4 inch)
50 31200306
Specifications Section

Drive and Steering Axle (Front)

271 -6425 Drive and Steering Axle
Gp

Illustration 70 g01172126
31200306 51
Specifications Section

(1) Torque for four bolts ............................. 300 Nm (220 lb ft)

(2) Torque of the locknut for the steering
stop .................................................. 150 Nm (110 lb ft)
(2A) Torque of the locknut for the steering stop (not
shown)...................................................150 Nm (110 lb ft)
(3) Torque for three bolts .............................190 Nm (140 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(4) Torque of the purging screw for the
brake........................................................ 50 Nm (37 lb ft)
(4A) Torque of the purging screw for the brake (not
shown)..................................................... 50 Nm (37 lb ft)
(5) Torque for the plug.................................... 50 Nm (35 lb ft)
(5A) Torque for the plug (not shown) ........................ 50 Nm
(35 lb ft)
(6) Torque for tie rod nut ........................... 250 Nm (184 lb ft)
(7) Torque for four kingpin bolts .. 300 Nm (220 lb ft)
(8) Torque for locknut................................. 250 Nm (184 lb ft)
(9) Torque for the ball joint......................... 300 Nm (220 lb ft)
(10) Torque for breather .................................10 Nm (90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(11) Torque for thirteen axle housing bolts....................310 Nm
(230 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(13) Torque for two bolts ............................ 450 Nm (332 lb ft)
(14) Torque for two plugs (each carrier
assembly) ............................................... 25 Nm (20 lb ft)
(15) Torque for plug (each carrier
assembly) ............................................... 60 Nm (45 lb ft)
(16) 217-2895 Brake Disc for the 271-6425 Drive
and Steering Axle Gp
Thickness of disc....................................... 4.80 ± 0.05 mm
(0.189 ±0.002 inch)
Minimum allowable thickness .............................. 3.95 mm
(0.156 inch)
(16) 238-5291 Brake Disc for the 271-6426 Drive and
Steering Axle Gp
Thickness of disc...................................... 4.00 ± 0.05 mm
(0.158 ±0.002 inch)
Minimum allowable thickness .............................. 3.27 mm
(0.129 inch)
52 31200306
Specifications Section

271 -6426 Drive and Steering Axle

Gp

Illustration 71 g01173621
31200306 53
Specifications Section

(1) Torque for four bolts ............................. 300 Nm (220 lb ft)

(2) Torque of the locknut for the steering
stop .................................................. 150 Nm (110 lb ft)
(2A) Torque of the locknut for the steering stop (not
shown)...................................................150 Nm (110 lb ft)
(3) Torque for three bolts ............................ 300 Nm (220 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(4) Torque of the purging screw for the
brake.......................................................... 12 Nm (9 lb ft)
(4A) Torque of the purging screw for the brake (not
shown)....................................................... 12 N-m (9 lb ft)
(5) Torque for the plug.................................... 50 Nm (35 lb ft)
(5A) Torque for the plug (not shown) ........................ 50 Nm
(35 lb ft)
(6) Torque for tie rod nut............................ 280 Nm (206 lb ft)
(7) Torque for four kingpin bolts ...................300 Nm (220 lb ft)
(8) Torque for locknut................................. 350 Nm (260 lb ft)
(9) Torque for the ball joint......................... 550 Nm (405 lb ft)
(10) Torque for breather .................................10 Nm (90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(11) Torque for thirteen axle housing bolts....................310 Nm
(230 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(13) Torque for two bolts ........................... 450 Nm (332 lb ft)
(14) Torque for two plugs (each carrier
assembly) ............................................... 25 N-m (20 lb ft)
(15) Torque for plug (each carrier
assembly) ............................................... 60 N-m (45 lb ft)
(16) 238-5291 Brake Disc for the 271-6426 Drive
and Steering Axle Gp
Thickness of disc....................................... 4.00 ± 0.05 mm
(0.158 ±0.002 inch)
Minimum allowable thickness .............................. 3.27 mm
(0.129 inch)
54 31200306
Specifications Section

Drive and Steering Axle (Front)

271 -6427 Drive and Steering Axle
Gp, with Steering Sensor

Illustration 76 g01083281
31200306 55
Specifications Section

(1) Torque for four bolts ............................. 300 Nm (220 lb ft)

(2) Torque of the locknut for the steering
stop .................................................. 150 Nm (110 lb ft)
(2A) Torque of the locknut for the steering stop (not
shown)...................................................150 Nm (110 lb ft)
(3) Torque for breather and the vent ........................... 10 Nm
(90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(4) Torque for three bolts............................ 300 Nm (220 lb ft)
(5) Torque of the purging screw for the
brake .................................................... 12 Nm (105 lb in)
(5A) Torque of the purging screw for the brake (not
shown) ................................................. 12 Nm (105 lb in)
(6) Torque for the plug.................................... 50 Nm (35 lb ft)
(6A) Torque for the plug (not shown) ........................ 50 Nm
(35 lb ft)
(7) Torque for tie rod nut ........................... 280 Nm (205 lb ft)
(8) Torque for four kingpin bolts ............... .. 300 Nm (220 lb ft)
(9) Torque for locknut................................. 350 Nm (260 lb ft)
(10) Torque for the ball joint....................... 550 Nm (405 lb ft)
(11) Torque for seventeen axle housing
bolts ..................................................... 310 Nm (230 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(12) Torque for the plug.................................. 30 Nm (22 lb ft)
(12A) Torque for the plug (not shown)....................... 30 Nm
(22 lb ft)
(13) Torque for two bolts ................................ 23 Nm (20 lb ft)
(14) Torque for two bolts ................................ 23 Nm (20 lb ft)
(16) Torque for two plugs (each carrier
assembly) .............................................. 25 Nm (20 lb ft)
(17) Torque for plug (each carrier
assembly) .............................................. 60 Nm (45 lb ft)
56 31200306
Specifications Section

Drive and Steering Axle (Rear)

189-5717 Drive and Steering Axle
Gp, with Steering Sensor

Illustration 81 g00944836

(1) Torque for four bolts.............................. 300 Nm (220 lb ft) (7) Torque for locknut................................. 250 Nm (185 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to (8) Torque for the ball joint......................... 300 Nm (220 lb ft)
installing the bolts. (9) Torque for the plug ................................... 60 Nm (45 lb ft)
(2) Torque of the locknut for the steering (10) Torque for the plug.................................. 60 Nm (45 lb ft)
stop .................................................. 150 Nm (110 lb ft) (11) Torque for 10 bolts ............................. 169 Nm (125 lb ft)
(2A) Torque of the locknut for the steering stop (not Note: Apply Loctite 243 sealant to the threads prior to
shown)...................................................150 Nm (110 lb ft) installation of the bolts.
(3) Torque for breather................................... 10 Nm (90 lb in) (12) Torque for plug (each carrier
Install the breather so that the slot in the breather is parallel assembly) ............................................... 60 Nm (45 lb ft)
with the axle half shaft.
Note: Apply Loctite 243 sealant to the threads prior to
Note: Apply Loctite 243 sealant to the threads prior to installing the plugs.
installing the breather.
(4) Torque for three bolts .............................190 Nm (140 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to
installing the bolts.
(5) Torque for tie rod nut............................ 250 Nm (185 lb ft)
(6) Torque for four kingpin bolts....................300 Nm (220 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to
installing the bolts.
31200306 57
Specifications Section

168-7443 Drive and Steering Axle

Gp, with Steering Sensor

Illustration 82 g00944837

(1) Torque for four bolts ............................. 300 Nm (220 lb ft) (7) Torque for locknut................................. 350 Nm (260 lb ft)
(2) Torque of the locknut for the steering (8) Torque for the ball joint......................... 550 Nm (405 lb ft)
stop .................................................. 150 Nm (110 lb ft) (9) Torque for the plug ................................... 60 Nm (45 lb ft)
(2A) Torque of the locknut for the steering stop (not Note: Apply Loctite 243 sealant to the threads prior to
shown)...................................................150 Nm (110 lb ft) installing the plugs.
(3) Torque for breather ...................................10 Nm (90 lb in) (10) Torque for thirteen axle housing bolts ..................169 Nm
Install the breather so that the slot in the breather is parallel (125 lb ft)
with the axle half shaft. Note: Apply Loctite 243 sealant to the threads prior to
Note: Apply Loctite 243 sealant to the threads prior to installing the bolts.
installing the breather. (11) Torque for plug (each carrier
(4) Torque for three bolts ............................ 300 Nm (220 lb ft) assembly) ............................................... 25 Nm (20 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to (12) Torque for plug (each carrier
installing the bolts. assembly) ............................................... 60 Nm (45 lb ft)
(5) Torque for tie rod nut ........................... 280 Nm (205 lb ft) Note: Apply Loctite 243 sealant to the threads prior to
Note: Apply Loctite 243 sealant to the threads prior to installing the plugs.
installing the nut.
(6) Torque for four kingpin bolts ....................300 Nm (220 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to
installing the bolts.
58 31200306
Specifications Section

Drive and Steering Axle (Rear)

231 -0710 Drive and Steering Axle
Gp, without Steering Sensor

Illustration 83 g00944835

(1) Torque of the locknut for the steering (10) Torque for two plugs (one plug in each carrier
stop .......................................................150 Nm (110 lb ft) assembly) ............................................... 60 Nm (45 lb ft)

(1A) Torque of the locknut for the steering stop (not

shown)...................................................150 Nm (110 lb ft)
(2) Torque for the breather and for the vent ..................10 Nm
(88 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(3) Torque for locknut................................. 350 Nm (260 lb ft)
(4) Torque for the ball joint......................... 550 Nm (405 lb ft)
(5) Torque for three bolts ........................... 300 Nm (220 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the plugs.
(6) Torque for the plug ................................... 60 Nm (45 lb ft)
(7) Torque for four plugs (two plugs in each carrier
assembly) ............................................... 25 N-m (20 lb ft)
(8) Torque for plug.......................................... 60 Nm (45 lb ft)
(9) Torque for 13 bolts................................ 260 Nm (190 lb ft)
31200306 59
Specifications Section

231 -0709 Drive and Steering Axle

Gp, with Steering Sensor

Illustration 84 g00944836

(1) Torque for four bolts .............................. 300 Nm (220 lb ft) (11) Torque for 13 bolts .............................. 260 Nm (190 lb ft)
Note: Apply Loctite 243 sealant to the threads prior to (12) Torque for the 4 plugs (two plugs in each carrier
installing the bolts. assembly) ............................................... 25 N-m (18 lb ft)
(2) Torque of the locknut for the steering (13) Torque for two plugs (one plug in each carrier
stop .................................................. 150 Nm (110 lb ft) assembly) ............................................... 60 N-m (44 lb ft)

(2A) Torque of the locknut for the steering stop (not

shown)...................................................150 Nm (110 lb ft)
(3) Torque for breather and the vent ........................... 10 Nm
(90 lb in)
Install the breather so that the slot in the breather is parallel
with the axle half shaft.
(4) Torque for three bolts ............................ 300 Nm (220 lb ft)
Note: Apply Loctite 270 sealant to the threads prior to
installing the bolts.
(5) Torque for tie rod nut ........................... 280 Nm (206 lb ft)
(6) Torque for four kingpin bolts ...................300 Nm (220 lb ft)
(7) Torque for locknut................................. 350 Nm (258 lb ft)
(8) Torque for the ball joint......................... 550 Nm (405 lb ft)
(9) Torque for the plug ................................... 60 N-m (45 lb ft)
(10) Torque for the plug ................................. 60 N-m (45 lb ft)
60 31200306
Specifications Section

Differential and Bevel Gear

Group
Part No,: 219-8765

Illustration 85 g01176266

(1) Backlash ................................................... 0.18 to 0.32 mm Note: Apply Loctite 638 4C-9507 Retaining Compound to
(0.0071 to 0.0126 inch) the mounting surface of the bevel gear.
(2) Torque for four bolts ............................. 266 Nm (196 lb ft) Note: Apply Loctite 271 155-0695 Thread Lock Compound
(3) Before assembly, apply anti-seize compound to to the bolts (6).
the seal. (7) Torque the screw for the bearing ........................... 13 Nm
(4) Shims for the pinion (115 lb in)

209-7473 Shim .............................. 2.5 mm (0.0984 inch)

219-8751 Shim .............................. 2.6 mm (0.1024 inch)
219-8752 Shim .............................. 2.7 mm (0.1063 inch)
219-8753 Shim ................................ 2.8 mm (0.1102 inch)
219-8754 Shim ................................ 2.9 mm (0.1142 inch)
219-8755 Shim ................................ 3.0 mm (0.1181 inch)
219-8756 Shim .............................. 3.1 mm (0.1220 inch)
219-8757 Shim .............................. 3.2 mm (0.1260 inch)
219-8758 Shim .............................. 3.3 mm (0.1299 inch)
219-8759 Shim .............................. 3.4 mm (0.1339 inch)
(5) Torque for magnetic plug .......................... 60 Nm (44 lb ft)
(6) Torque for the twelve bolts........................ 85 Nm (63 lb ft)
31200306 61
Specifications Section

Differential and Bevel Gear

Group
Part No.: 226-4348

Illustration 86 g00941671 199-0688 Shim ................................ 2.9 mm (0.1142 inch)

199-0689 Shim ................................ 3.0 mm (0.1181 inch)
(1) Backlash ................................................... 0.18 to 0.23 mm
(0.0071 to 0.0091 inch) 199-0690 Shim .............................. 3.1 mm (0.1220 inch)

(2) Torque for four bolts .............................. 413 Nm (305 lb ft) 199-0691 Shim .............................. 3.2 mm (0.1260 inch)

Note: If nut (3) is loosened, both 199-0678 Washers 199-0692 Shim .............................. 3.3 mm (0.1299 inch)

(4) must be replaced with new washers. 199-0693 Shim .............................. 3.4 mm (0.1339 inch)

(5) Torque for magnetic plug .......................... 60 Nm (44 lb ft)

(6) Torque for the twelve bolts........................ 85 Nm (63 lb ft)
Note: Apply Loctite 638 4C-9507 Retaining Compound to
the mounting surface of the bevel gear.
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts (6).
(7) Torque the screw for the bearing ........................... 13 Nm
(115 lbin)
Shims for the pinion
199-0684 Shim .............................. 2.5 mm (0.0984 inch)
199-0685 Shim .............................. 2.6 mm (0.1024 inch)
199-0686 Shim .............................. 2.7 mm (0.1063 inch)
199-0687 Shim .................................2.8 mm (0.1102 inch)
62 31200306
Specifications Section

Axle Housing and Flange Group Axle Housing and Flange Group
Part No.: 229-5086, 229-5087 Part No.: 253-4986, 253-4987

Illustration 87 g01177555 Illustration 88 g01084006

(1) Torque for spanner nut...................... 1000 Nm (740 lb ft) (1) Torque for the 3 locking bolts on the tab................... 70 Nm
(52 lb ft)
(2) Torque for the three lock bolts.................. 70 Nm (52 lb ft)
(2) Torque for spanner nut .........................1100 Nm (810 lb ft)
Note: After the spanner nut is torqued and the tab does not
fit, rotate the nut in the direction of tightening until the tab fits.
31200306 63
Specifications Section

Final Drive Planetary Group

Part No.: 210-5924

Illustration 89 g00949246

(1) Assemble the three bearings so that the radius is facing in

the direction of the arrow.
64 31200306
Specifications Section

Final Drive Planetary Group

Part No.: 253-4989

Illustration 90 g01084036

(1) Assemble the three bearings so that the radius is facing in

the direction of the arrow.
31200306 65
Specifications Section

Axle Housing Group

(Differential and Brake
Cylinder)
Part No.: 174-4642, 219-8780

174-4642 Axle Housing Gp with a

Locking Differential

Illustration 91 g00948248
66 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts....................70 Nm (50 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash ......................................... 0.20 to 0.32 mm
(0.008 to 0.0126 inch)
Note: Stake the pinion nut after the bearing preload is set.
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
209-7473 Shim ................................ 2.5 mm (0.098 inch)
219-8751 Shim ................................ 2.6 mm (0.102 inch)
219-8752 Shim ................................ 2.7 mm (0.106 inch)
219-8753 Shim .................................. 2.8 mm (0.110 inch)
219-8754 Shim .................................. 2.9 mm (0.114 inch)
219-8755 Shim .................................. 3.0 mm (0.118 inch)
219-8756 Shim ................................ 3.1 mm (0.122 inch)
219-8757 Shim ................................ 3.2 mm (0.126 inch)
219-8758 Shim .................................. 3.3 mm (0.13 inch)
219-8759 Shim .................................. 3.4 mm (0.14 inch)
31200306 67
Specifications Section

219-8780 Axle Housing Gp

Illustration 92 g00948248
68 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts....................70 Nm (50 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash ......................................... 0.20 to 0.32 mm
(0.008 to 0.0126 inch)
Note: Stake the pinion nut after the bearing preload is set.
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
209-7473 Shim ................................ 2.5 mm (0.098 inch)
219-8751 Shim ................................ 2.6 mm (0.102 inch)
219-8752 Shim ................................ 2.7 mm (0.106 inch)
219-8753 Shim .................................. 2.8 mm (0.110 inch)
219-8754 Shim .................................. 2.9 mm (0.114 inch)
219-8755 Shim .................................. 3.0 mm (0.118 inch)
219-8756 Shim ................................ 3.1 mm (0.122 inch)
219-8757 Shim ................................ 3.2 mm (0.126 inch)
219-8758 Shim .................................. 3.3 mm (0.13 inch)
219-8759 Shim .................................. 3.4 mm (0.14 inch)
31200306 69
Specifications Section

219-8831 Axle Housing Gp with a

Locking Differential

Illustration 93 g00948256
70 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts .............................. 180 Nm
(135 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash .......................................... 0.20 ± 0.02 mm
(0.008 ± 0.001 inch)
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
199-0684 Shim ................................ 2.5 mm (0.098 inch)
199-0685 Shim ................................ 2.6 mm (0.102 inch)
199-0686 Shim ................................ 2.7 mm (0.106 inch)
199-0687 Shim .................................. 2.8 mm (0.110 inch)
199-0688 Shim .................................. 2.9 mm (0.114 inch)
199-0689 Shim .................................. 3.0 mm (0.118 inch)
199-0690 Shim ................................ 3.1 mm (0.122 inch)
199-0691 Shim ................................ 3.2 mm (0.126 inch)
199-0692 Shim .................................. 3.3 mm (0.13 inch)
199-0693 Shim .................................. 3.4 mm (0.14 inch)
31200306 71
Specifications Section

219-8842 Axle Housing Gp without a

Locking Differential

Illustration 94 g00948264
72 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Torque for the ring gear bolts .............................. 180 Nm
(135 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(5) Gear backlash .......................................... 0.20 ± 0.02 mm
(0.008 ± 0.001 inch)
Note: Stake the pinion nut after the bearing preload is set.
(6) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(7) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
Available shims for the pinion
199-0684 Shim ................................ 2.5 mm (0.098 inch)
199-0685 Shim ................................ 2.6 mm (0.102 inch)
199-0686 Shim ................................ 2.7 mm (0.106 inch)
199-0687 Shim .................................. 2.8 mm (0.110 inch)
199-0688 Shim ................................. 2.9 mm (0.114 inch)
199-0689 Shim .................................. 3.0 mm (0.118 inch)
199-0690 Shim ................................ 3.1 mm (0.122 inch)
199-0691 Shim ................................ 3.2 mm (0.126 inch)
199-0692 Shim .................................. 3.3 mm (0.13 inch)
199-0693 Shim .................................. 3.4 mm (0.14 inch)
31200306 73
Specifications Section

Axle Housing Group

(Differential and Brake
Cylinder)
Part No.: 253-4985, 253-4990

253-4990 Axle Housing Gp with a

Locking Differential

Illustration 95 g00948248
74 31200306
Specifications Section

(1) Bearing nut

(2) Brake cylinder assembly
(3) Apply Loctite 638 4C-9507 Retaining Compound
to the dowel pin. Each brake cylinder assembly
contains two dowel pins.
(4) Fork
(5) Torque for the ring gear bolts .............................. 180 Nm
(132 lb ft)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
(6) Gear backlash ........................................... 0.20 ± 0.02 mm
(0.008 ± 0.001 inch)
Note: Stake the pinion nut after the bearing preload is set.
(7) Torque for the bolts of the brake cylinder .................79 Nm
(60 lb ft)
(8) Torque of the lock screw for the bearing
nut .......................................................... 13 Nm (115 lb in)
31200306 75
Specifications Section

253-4985 Axle Housing Gp without a

Locking Differential

Illustration 96 g00948264

(1) Bearing nut (5) Gear backlash .......................................... 0.20 ± 0.02 mm

(2) Brake cylinder assembly (0.008 ± 0.001 inch)

(3) Apply Loctite 638 4C-9507 Retaining Compound Note: Stake the pinion nut after the bearing preload is set.
to the dowel pin. Each brake cylinder assembly (6) Torque for the bolts of the brake cylinder .................79 Nm
contains two dowel pins. (60 lb ft)
(4) Torque for the ring gear bolts .............................. 180 Nm (7) Torque of the lock screw for the bearing nut
(132 lb ft) ...............................................................13 Nm (115 lb in)
Note: Apply Loctite 271 155-0695 Thread Lock Compound
to the bolts.
76 31200306
Specifications Section

Brake Cylinder (Master)

Illustration 97 g00866817

(1) Minimum operating temperature............................ -30 °C

(-22 °F)
(2) Maximum operating temperature ................................... 100°C
(212 °F)
(3) Maximum working pressure............................... 10500 kPa
(1523 psi)
(4) Minimum burst pressure .................................... 31500 kPa
(4569 psi)
(5) Maximum oil pressure.......................................... 3550 kPa
(515 psi)
(6) Minimum rate of flow............................................. 10 L/min
(2.64 US gpm)
Note: This assembly is suitable for use with approved fluid.
The use of the improper fluid may cause damage to the seal
which can result in system failure.
31200306 77
Specifications Section

Parking Brake Control

Illustration 98 g00926862

(1) Torque for the terminal screws .................0.43 ± 0.02 Nm

(3.805 ± 0.177 lb in)
(2) Mounting screw torque ........................... 0.32 ± 0.02 Nm
(2.832 ± 0.177 lb in)
Note: Use 6V-8373 Screws for mounting the switch. Apply
4C-4030 Thread Lock Compound to the threads.
(3) Minimum range for the actuator......................... 13.49 mm
(0.531 inch)
(3) Maximum range for the actuator ........................ 27.74 mm
(1.092 inch)
(A) Dimension ......................... 120 + 4.0 mm (4.7 + 0.2 inch)
78 31200306
Specifications Section

Parking Brake

Illustration 99 g01083721

Adjust mounting bolt (4) and jam nut (2) in order to leave a
gap of 0.51 mm (0.020 inch) to 1.52 mm (0.060 inch) (1)
between jam nut (2) and sleeve (3).
(2) Tighten the jam nut against the mounting
surface of the axle housing. Torque for the jam
nut.............................................. 109 ± 7 Nm (80 ± 5 lb ft)
Tighten nut (5) to the following torque 14 ± 0.6 Nm (120 ± 5 lb
in). Back off nut (5) 4 to 6 flats for a final adjustment
(6) After nut (5) is correctly adjusted you should
tighten nut (6) against nut (5). Torque for nut
(6) ............................................. 68 ± 6.7 Nm (50 ± 5 lb ft)
31200306 79
Specifications Section

Fender

Illustration 100 g00996996

(1) Torque for 16 nuts that fasten fender assemblies

to the machine .................... 300 ±20 Nm (221 ± 15 lb ft)
Note: Apply 154-9731 Thread Lock Compound to the
threads.
80 31200306
Specifications Section

Wheel (Tire and Rim)

Illustration 101 g00997061

Clean the hardware and dry the hardware. Apply one drop of
lubrication oil to the threads.
(1) Torque of the 32 nuts ............................ 460±60Nm
(339 ± 44 lb ft)
31200306 81
Specifications Section

Fuel Tank
Part No.: 224-4783

Illustration 102 g01078161

(1) Torque for the six bolts............................. 2.25 ± 0.25 Nm

(20 ± 2 lb in)
(2) Torque for the plug . . . . . . . . . . . . . . . . 1 0 ± 5 N m ( 7 ± 4 lb ft)
82 31200306
Specifications Section

Fuel Tank
Part No.: 203-1995

Illustration 103 g01011074

(1) Torque for the six bolts .............................2.25 ± 0.25 Nm

(20 ± 2 lb in)
(2) Torque for the plug.................... 35.0 ± 7.5 Nm (26 ± 5 lb ft)
31200306 83
Specifications Section

Engine Enclosure

Illustration 104 g00998630

(1) Torque for the 8 screws ............................... 2.3 ± 0.3 Nm

(20 ± 2.2 lb in)
(2) Torque for the 4 nuts . . . . . . . . . . . . . . 6 ± 3 N m ( 4 ± 2 lb ft)
(3) Torque for the 8 bolts..................... 14 ± 3 Nm (10 ± 2 lb ft)
(4) Torque for connecting the gas spring to the
hood ............................................ 10 ± 1 Nm (89 ± 9 lb in)
Note: Apply 154-9731 Thread Lock Compound to threads on
both ends of the gas spring.
84 31200306
Specifications Section

Illustration 105 g00998765

(5) Torque for the bolt.............................................. 20 ± 6 Nm

(15 ± 4 lb ft)
Note: Apply 4C-4030 Thread Lock Compound to the bolt.
(6) Torque for the 4 bolts ......................................... 14 ± 3 Nm
(10± 2 lb ft)
Note: Apply 4C-4030 Thread Lock Compound to the bolts.
31200306 85
Specifications Section

Engine and Transmission

Mounting

Illustration 106 g00997919

(1) Torque for the two bolts . . . . . . . . . . . . . . . . . . . . . 2 2 0 ±2 0 N m

(162 ± 15 lb ft)
(2) Torque for the bolt.........................................775 ± 20 Nm
(572 ± 15 lb ft)
86 31200306
Specifications Section

Air Cleaner

Illustration 107 g01078304

(1) Torque for the bolt........................ 20 ±2 Nm (15 ± 1 lb ft)

(2) Torque for the nut ......................... 20 ±2 N-m (15 ± 1 lb ft)
31200306 87
Specifications Section

Illustration 108 g01078352

(3) Torque for the clamp...................... 5 ± 1 Nm (44 ± 9 lb in)

Illustration 109 g01166232

(4) Torque for the bracket............................... 2 Nm (1.5 lb ft)

88 31200306
Specifications Section

Engine Oil Drain

Illustration 110 g00997117

(1) Torque for shutoff valve ................ 40 ±5 Nm (30 ±4 lb ft)

(2) Length of hose ....................... 130 ± 5 mm (5.1 ± 0.2 inch)
31200306 89
Specifications Section

Muffler

Illustration 111 g01057347

(1) Torque for the three nuts . . . . . . . . . . . . . . . . . . . . . . 3 0 ± 7 N m

(22 ± 5 lb ft)
(2) Torque for the clamp ................................... 45 ±10 Nm
(33±7 lb ft)
Note: Refer to Illustration 111 in order to position the clamp.
90 31200306
Specifications Section

Suction Fan

Illustration 112 g00997794

(1) Torque for the three bolts............................. 10 ±2 Nm

(7.5 ± 1.5 lb ft)
31200306 91
Specifications Section

Battery

Illustration 114 g01166295

(1) Torque for the battery terminals .................... 7.2 ± 1.6 Nm

(5.31 ± 1.18 lb ft)
(2) Torque for cable at the starter....................... 26 ± 3.5 Nm
(19 ± 3 lb ft)
(3) Torque for the cables ...........................................8 ± 2 Nm
(6 ± 1.5 lb ft)
(4) Torque for cable at the alternator ..................... 8 ± 1 Nm
(77 ± 9 lb in)
(5) Torque of the disc at the large stud . . . . . . . . . . . . . 2 3 ± 4 N m
(17 ± 3 lb ft)
(6) Torque for the two nuts . . . . . . . . . . . . . . . . . . . . . . . 6 . 8 ± 1 . 4 N m
(60 ± 12 lb in)
92 31200306
Specifications Section

Alternator

Illustration 115 g01078644

Nominal Voltage .................................................................... 14 V

Nominal current at 6000 RPM ............................................105 A
Direction of rotation ................................................... Clockwise
Polarity ................................................................Negative earth
(1) Tighten terminal nut "W" to the following
torque.................................. 2.25 ± 0.25 Nm (20 ± 2 lb in)
(2) Tighten terminal nut "D+" to the following
torque.................................. 2.25 ± 0.25 Nm (20 ± 2 lb in)
(3) Tighten terminal nut "B+" to the following
torque.................................... 3.6 ± 0.08 Nm (32 ± 1 lb in)
31200306 93
Specifications Section

Coolant Lines Group

Illustration 116 g00997961

(1) Torque for the bolt ......................... 30 ± 7 Nm (22 ± 5 lb ft)

(2) Length of trim .......................... 200 ± 5 mm (7.9 ± 0.2 inch)
94 31200306
Specifications Section

Coolant Recovery Group

Illustration 117 g01166550

(1) Torque for the two bolts . . . . . . . . . . . . . . . . . . . . . . . 1 0 ± 2 N m

(89 ± 18 lb in)
(2) Torque for the two bolts . . . . . . . . . . . . . . . . . . . . . . 1 0 ± 2 N m
(89 ± 18 lb in)
(3) Specifications of the Tank
Pressure relief for the cap ...................... 100 kPa (15 psi)
Working pressure of the Tank .................... 150 kPa (22 psi)
Burst pressure of the Tank.......................000 kPa (145 psi)
Working temperature of tank .................... 110 °C (230 °F)
31200306 95
Specifications Section

Illustration 118 g01167691

(B) 50° ± 15°
(4) Apply a 8T-0065 Silicone Sealant to the Elbow. Tighten a
minimum of two complete threads. Align the elbow. Refer
to Illustration 118.
96 31200306
Specifications Section

Cab

Illustration 120 g01173739

(1) Use a urethane adhesive for bonding the glass. 4. Adjust the position of the clevis on the rod end
Note: Equally space rubber spacers in order to maintain the 5 so that the release lever is perpendicular to the
adhesive gap for bonding. B post.

(2) Tighten the knob hand tight.

Note: Apply 4C-4030 Thread Lock Compound.

Latch Adjustment
The Test with the Door Closed
1. Close the door. Check for interference
2. Locate the striker on the cab. The striker should
be centered in the jaws of the latch. The striker
should engage the jaws smoothly. The striker
should not guide the door upward. The striker
should not guide the door downward.
3. Check the latch when the door is closed.

Hold Open Latch Check

1. Open the door.
2. Locate the hold open striker on the door (upper).
Ensure that the striker is centered in the jaws of
the latch. Check that the striker engages the jaws
smoothly. Check that the striker does not guide
the door upward. Check that the striker does not
guide the door downward.
3. In order to regulate the force of activation for the
hold open latch, adjust the bumper on the door
(upper). The maximum force is 50 N (11 lb).
31200306 97
Specifications Section

Cab Mounting

Illustration 121 g00999337

(1) Torque for the 4 bolts........................... 450 Nm (332 lb ft)

98 31200306
Specifications Section

Cab Door

Illustration 124 g01168043

(1) Torque for the bolts ........................4 ± 1 Nm (35 ± 9 lb in)

(2) Tighten hand tight. Use 4C-4030 Thread Lock
Compound
(3) Length of seal....................... 955 ± 5 mm (37.6 ± 0.2 inch)
(4) Length of seal ....................... 821 ± 5 mm (32.3 ± 0.2 inch)
Note: Use a urethane adhesive for bonding the glass.
(5) Equally space the rubber spacers in order to
maintain the 5 adhesive gap for bonding.
31200306 99
Specifications Section

Illustration 125 g01168116

(6) Torque for the nut ........................ 4 ± 1 Nm (35 ± 9 lb in)

Note: Use a urethane adhesive for bonding the glass.
100 31200306
Specifications Section

Access Door

Illustration 126 g00999902

(1) Torque for the 4 nuts ......................6 ± 1 Nm (53 ± 9 lb in)

(2) Torque for the 4 nuts................ 15±3N m(11 ± 2 lb ft)
31200306 101
Specifications Section

Joystick Control

Illustration 127 g01124256

(1) Torque for the screws ............................. 1.92 ± 0.20 Nm

(17.00 ± 1.78 lb in)
102 31200306
Specifications Section

Steering Wheel and Column

Illustration 128 g00999390

(1) Torque for the nut ....................... 48 ± 5 Nm (35 ±4 lb ft)

(2) Torque for the nut and the bolt.................. 22.5 ±2.5 Nm
(17 ±2 lb ft)
31200306 103
Specifications Section

Window Wiper and Wiper Motor

Illustration 129 g00997368

(1) Torque for the nut ............... 23 ± 1 N m ( 1 7 ± 1 lb ft) (4) Length of hose........................ 163 ± 3 mm (6.4 ± 0.1 inch)
(2) Torque for the nut of the wiper motor . . . . 9 ± 1 Nm (5) Length of hose........................ 112 ±3 mm (4.4 ±0.1 inch)
(80 ± 9 lb in) (6) Length of hose .................... 2351 ± 5 mm (92.6 ± 0.2 inch)
(3) Torque for the nut ....................8 ± 0.5 Nm (66 ±4.4 lb in)
104 31200306
Specifications Section

Window Washer Tank

Illustration 130 g00999432

(1) Torque for the fitting....................... 8 ± 1 Nm (71 ± 9 lb in)

31200306 105
Specifications Section

Rear View Mirror

Illustration 131 g01079722

(1) Torque for the two bolts .................28 ± 7 Nm (20 ± 5 lb ft)

Carriage Cylinder (Rotate)

Illustration 132 g00999602

106 31200306
Specifications Section

Length of the stroke ................................... 123 mm (4.8 inch)

(1) Diameter of the rod .................................. 45 mm (1.8 inch)
(2) Bore of the cylinder................................ 80 mm (3.2 inch)7

Carriage Cylinder (Sideshift)

Illustration 133 g00999632

Cylinder stroke ............................................ 300 mm (11.8 inch)

(1) Torque setting for bolt..................................850 ± 25 Nm
(625 ± 20 lb ft)
Lubricate the threads of the bolt with clean grease.
(2A) Diameter of piston ............................... 75.69 ± 0.03 mm
(2.9799 ±0.0012 inch)
(2B) Bore of piston.............................. 26.97 mm (1.062 inch)
(3) Bore of cylinder.............................. 76.20 mm (3.000 inch)
(4) Diameter of piston rod ................ ..38.05 mm (1.4980 inch)
(5) Bore of head ........................................... 38.38 ± 0.03 mm
(1.511 ±0.001 inch)
(6) Torque setting for the head .........................600 ± 130 Nm
(440 ± 95 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 9T-4007 Bearing
Diameter............................................. .36.088 ±0.013 mm
(1.4208 ±0.0005 inch)
Bore.......................................................30.153 ±0.013 mm
(1.1871 ±0.0005 inch)
31200306 107
Specifications Section

Hydraulic Cylinder
(Multipurpose Bucket)

Illustration 134 g00999842

Cylinder stroke......................................... 260 mm (10.24 inch) Bore ................................................... 30.153 ±0.013 mm

(1) Torque setting for bolt ................................. 850 ± 25 Nm (1.1871 ±0.0005 inch)
(625 ± 20 lb ft)
Lubricate the threads of the nut with clean grease.
(2A) Diameter of piston................................ 75.69 ± 0.03 mm
(2.980 ± 0.001 inch)
(2B) Bore of piston.............................. 26.97 mm (1.062 inch)
(3) Bore of cylinder.................................. 76.2 mm (3.00 inch)
(4) Diameter of piston rod .................... 38.05 mm (1.498 inch)
(5) Bore of head ........................................... 38.38 ± 0.05 mm
(1.511 ±0.002 inch)
(6) Torque setting for the head ....................... 600 ± 130 Nm
(443 ± 96 lb ft)
Lubricate the threads of the head with clean grease.
Apply sealant to wiper seal groove (7) prior to assembly.
Note: Lubricate all seals with clean lubricant that is being
sealed.
(8) 9T-4007 Bearing
Diameter............................................. 36.088 ± 0.013 mm
(1.4208 ±0.0005 inch)
108 31200306
Specifications Section

Grapple Cylinder

Illustration 135 g01006744

(A) Open ................................................. 710 mm (28.0 inch)

(A) Closed................................................. 490 mm (19.3 inch)
(B) Diameter................................................. 85 mm (3.4 inch)
31200306 109
Index
Index
A E
Access Door..................................................................... 100 Engine and Transmission Mounting ................................... 85
Air Cleaner ......................................................................... 86 Engine Enclosure ............................................................... 83
Alternator............................................................................ 92 Engine Oil Drain ................................................................. 88
Axle Housing and Flange Group ........................................ 62
F
Axle Housing Group (Differential and Brake Cylinder)....... 65
174-4642 Axle Housing Gp with a Locking Differential. 65 Fender................................................................................ 79
219-8780 Axle Housing Gp........................................... 67 Final Drive Planetary Group............................................... 63
219-8831 Axle Housing Gp with a Locking Differential Final Drive Planetary Group............................................... 64
...................................................................................... 69 Flexible Coupling Drive ...................................................... 40
219-8842 Axle Housing Gp without a Locking Differential Frame................................................................................. 11
...................................................................................... 71 Frame Leveling Cylinder .............................................. 29, 30
253-4985 Axle Housing Gp without a Locking Differential Fuel Tank ........................................................................... 82
...................................................................................... 75
Fuel Tank ........................................................................... 81
253-4990 Axle Housing Gp with a Locking Differential
...................................................................................... 73 G
Axle Housing Group (Differential and Brake Cylinder)....... 73
Grapple Cylinder .............................................................. 108
Axle Lock Cylinder ............................................................. 37
H
B
Hydraulic Cylinder (Multipurpose Bucket) ........................ 107
Battery................................................................................ 91
Hydraulic Oil Cooler ........................................................... 48
Boom.................................................................................. 13
Hydraulic Tank ............................................................. 3, 5, 6
Boom Cylinder.............................................................. 15, 16
Boom Cylinder.................................................................... 14 I
Boom.................................................................................. 12 Important Safety Information.................................................ii
Brake Cylinder (Master) ..................................................... 76
J
C
Joystick Control................................................................ 101
Cab..................................................................................... 96
Latch Adjustment .......................................................... 96 L
Cab Door............................................................................ 98 Load Control Valve (Boom Cylinder) (Lock)....................... 17
Cab Mounting..................................................................... 97 Load Control Valve (Frame Leveling Cylinder) (Lock) ....... 31
Carriage Cylinder (Rotate) ............................................... 105 Load Control Valve (Stabilizer Cylinder) (Lock) ................. 36
Carriage Cylinder (Sideshift) ............................................ 106 Load Control Valve (Telescoping Cylinder) (Lock)............. 21
Compensating Cylinder...................................................... 18 Load Control Valve (Tilt Cylinder) (Lock) ........................... 24
Compensating Cylinder...................................................... 19
M
Control Valve (Stabilizer) ................................................... 32
Coolant Lines Group .......................................................... 93 Main Control Valve (Implement)........................................... 9
Coolant Recovery Group.................................................... 94 Metering Pump (Steering) .................................................. 38
Muffler ................................................................................ 89
D
O
Differential and Bevel Gear Group ............................... 60, 61
Diverter Valve..................................................................... 24 Oil Filter .............................................................................. 46
Diverter Valve..................................................................... 25 P
Drive and Steering Axle (Front).......................................... 50
Parking Brake..................................................................... 78
271 -6425 Drive and Steering Axle Gp ......................... 50
Parking Brake Control ........................................................ 77
271 -6426 Drive and Steering Axle Gp ......................... 52
Piston Pump (Implement and Steering) ............................... 7
271 -6427 Drive and Steering Axle Gp, with Steering
Sensor .......................................................................... 54 Position Sensor (Steering) ................................................. 39
Drive and Steering Axle (Front).......................................... 54 Position Sensor (Steering) ................................................. 39
Drive and Steering Axle (Rear) Position Sensor (Transmission) ......................................... 45
168-7443 Drive and Steering Axle Gp, with Steering R
Sensor .......................................................................... 57
189-5717 Drive and Steering Axle Gp, with Steering Rear View Mirror .............................................................. 105
Sensor .......................................................................... 56
S
231 -0709 Drive and Steering Axle Gp, with Steering
Sensor .......................................................................... 59 Solenoid Valve (Pilot Selector)............................................. 8
231 -0710 Drive and Steering Axle Gp, without Steering Solenoid Valve (Steering Mode Selector) .......................... 38
Sensor .......................................................................... 58 Specifications Section .......................................................... 3
Drive and Steering Axle (Rear) .................................... 56, 58 Stabilizer Cylinder .................................................. 33, 34, 35
Drive Shaft ......................................................................... 49 Steering Wheel and Column ............................................ 102
Suction Fan ........................................................................ 90
110 31200306
Index

T
Table of Contents................................................................. 1
Telescoping Cylinder.......................................................... 20
Tilt Cylinder .................................................................. 22, 23
Towing Hitch .......................................................... 26, 27, 28
Towing Hitch ................................................................ 27, 28
Transmission................................................................ 41, 43

W
Wheel (Tire and Rim) ......................................................... 80
Window Washer Tank ...................................................... 104
Window Wiper and Wiper Motor ...................................... 103
Manufactured by JLG under license from Caterpillar