FUEL HOSE REPLACEMENTFigure 2. Upper Access Plate and Retaining Hardware on Rear of Machine.Figure 4. Center Access Cover and Retaining Hardware on Rear of Machine.Figure 5. Fuel Tank Cap on Rear of Machine.Figure 6. Fuel Tank Drain on Rear of Machine.Figure 7. Fuel Tank Cap on Rear of Machine.Figure 8. Fuel Tank Drain Hardware on Rear of Machine.Figure 9. Fuel Hose and Connector on Rear of Machine.Figure 10. Fuel Hose, Connector, and Check Valve Behind Left Rear Access Door.Figure 11. Fuel Hose Clamp Behind Left Rear Access Door.Figure 13. Fuel Hose Retaining Hardware on Side of Hydraulic Tank.Figure 15. Fuel Hose Retaining Hardware Underneath Cab Floor.Figure 17. Fuel Hose Retaining Hardware on Flywheel Housing.Figure 19. Fuel Hose Retaining Hardware Underneath Fuel Filter.Figure 20. Fuel Hose Retaining Hardware Underneath Oil Filter.Figure 21. Fuel Hose Connector and Retaining Hardware Near Front of Engine.FUEL HOSE REPLACEMENT - ContinuedFigure 22. Fuel Hose Connector and Hardware Near Filter Base.FUEL HOSE REPLACEMENT - ContinuedFUEL HOSE REPLACEMENT - ContinuedFigure 23. Arctic Kit Heater and Main Fuel Shutoff.FUEL HOSE REPLACEMENT - ContinuedFigure 24. Arctic Kit Heater and Main Fuel Shutoff.Figure 25. Fuel Hose Connector and Hardware Near Filter Base.Figure 26. Fuel Hose Connector and Retaining Hardware Near Front of Engine.Figure 27. Fuel Hose Retaining Hardware Underneath Oil Filter.Figure 28. Fuel Hose Retaining Hardware Underneath Fuel Filter.Figure 29. Left Front Access Door and Panel.Figure 31. Fuel Hose Retaining Hardware Underneath Cab Floor.Figure 33. Fuel Hose Retaining Hardware Above Hydraulic Tank.Figure 35. Fuel Hose Retaining Hardware on Side of Hydraulic Tank Near Rear of Machine.Figure 37. Fuel Hose, Connector, and Check Valve Behind Left Rear Access Door.Figure 38. Fuel Hose and Connector on Rear of Machine.Figure 39. Fuel Tank Drain Hardware on Rear of Machine.Figure 40. Center Access Cover and Retaining Hardware on Rear of Machine.Figure 42. Upper Access Plate and Retaining Hardware on Rear of Machine.FUEL HOSE REPLACEMENTFUEL TANK REPLACEMENTFigure 1. Fuel Tank Cap on Rear of Machine.Figure 2. Fuel Tank Drain on Rear of Machine.Figure 3. Washer Tank Filler, Bracket, and Retaining Hardware Behind Right Rear Access Door.Figure 4. Fuel Hose and Connector Behind Left Rear Access Door.Figure 5. Fuel Hose and Connector on Rear of Machine.Figure 6. Fuel Level Sender, Chassis Harness, Fuel Tank, and Retaining Hardware.Figure 7. Fuel Tank Cap and Baffle.Figure 9. Fuel Level Sender and Retaining Hardware.Figure 10. Drain Valve.Figure 12. Fuel Outlet Connector.Figure 14. Fuel Outlet Check Valve.Figure 16. Fuel Return Connector.Figure 18. Fuel Level Sender and Retaining Hardware.Figure 19. Fuel Strainer.Figure 21. Fuel Level Sender, Chassis Harness, Fuel Tank, and Retaining Hardware.Figure 22. Fuel Hose and Connector on Rear of Machine.Figure 24. Washer Tank Filler, Bracket, and Retaining Hardware Behind Right Rear Access Door.FUEL LEVEL SENDER REPLACEMENTFigure 1. Fuel Tank Cap on Rear of Machine.Figure 2. Fuel Tank Drain on Rear of Machine.Figure 3. Fuel Tank Cap on Rear of Machine.Figure 4. Fuel Level Sender and Retaining Hardware.Figure 5. Fuel Level Sender and Retaining Hardware.HYDRAULIC TANK HOSE REPLACEMENTHYDRAULIC TANK HOSE REPLACEMENT - ContinuedFigure 1. Hydraulic Tank Fill Hose.Figure 2. Hydraulic Tank Vent Hose.Figure 3. Hydraulic Tank Fill Hose.Figure 4. Access Door.HYDRAULIC TANK OIL TEMPERATURE SENSOR REPLACEMENTHYDRAULIC TANK OIL TEMPERATURE SENSOR REPLACEMENT - ContinuedFigure 1. Temperature Sensor.RADIATOR GUARD SERVICEFigure 1. Access Cover, Latch, Lock, and Retaining Hardware.Figure 3. Radiator Guard Hardware.Figure 4. Radiator Guard Hardware.Figure 5. Radiator Guard Hardware.Figure 6. Radiator Guard Hardware.Figure 7. Access Cover, Latch, Lock, and Retaining Hardware.RADIATOR GRILL SERVICEFigure 1. Upper Radiator Grill and Retaining Hardware.Figure 2. Latch Assembly and Upper Radiator Grill.Figure 3. Access Cover, Brackets, and Upper Radiator Grill.Figure 4. Lower Radiator Grill and Retaining Hardware.Figure 5. Latch Assembly and Lower Radiator Grill.Figure 6. Bumpers and Lower Radiator Grill.Figure 7. Latch Assembly and Lower Radiator Grill.Figure 8. Lower Radiator Grill and Retaining Hardware.Figure 9. Access Cover, Brackets, and Upper Radiator Grill.Figure 10. Latch Assembly and Upper Radiator Grill.Figure 11. Upper Radiator Grill and Retaining Hardware.RADIATOR ACCESS DOOR SERVICEFigure 2. Strut Retaining Hardware.Figure 3. Hinges and Retaining Hardware.Figure 4. Hinges and Retaining Hardware.Figure 6. Radiator Access Door Hardware.Figure 7. Radiator Access Door Hardware.Figure 8. Strut and Retaining Hardware.Figure 9. Hinges and Retaining Hardware.Figure 10. Positioning Radiator Access Door on Machine.Figure 11. Strut Retaining Hardware.Figure 13. Radiator Access Door.RIGHT ENGINE ACCESS PANEL REPLACEMENTFigure 1. Right Side Panel Bracket.Figure 2. Right Side Panel and Retaining Hardware.RIGHT ENGINE ACCESS PANEL REPLACEMENT - ContinuedRIGHT ENGINE ACCESS DOOR REPLACEMENTFigure 1. Right Front Access Door, Access Cover, and Retaining Hardware.RIGHT ENGINE ACCESS DOOR REPLACEMENT - ContinuedLEFT ENGINE ACCESS PANEL REPLACEMENTFigure 1. Left Side Panel Bracket.Figure 2. Left Side Panel and Retaining Hardware.Figure 3. Left Side Panel Bracket.LEFT ENGINE ACCESS DOOR REPLACEMENTFigure 1. Left Engine Access Door, Hinge, Seals, and Latch.Figure 2. Left Front Access Door and Lock Assembly.Figure 3. Left Engine Access Door, Hinge, Seals, and Latch.HOOD REPLACEMENTFigure 2. Chassis Harness Retaining Hardware.Figure 4. Hood and Retaining Hardware.HOOD REPLACEMENT - ContinuedFigure 5. Hood and Retaining Hardware.Figure 6. Air Cleaner, Bracket, and Retaining Hardware.Figure 8. Exhaust Pipe and Clamp.DEBRIS GUARD REPLACEMENTFigure 1. Angle and Tilt Hose Guard.DEBRIS GUARD REPLACEMENT - ContinuedHOOD SUPPORT REPLACEMENTFigure 1. Chassis and Engine Harness and Retaining Hardware at Top of Hood Support.Figure 2. Hood Support and Retaining Hardware.Figure 3. Chassis and Engine Harness Retainers Below Ether Aid.Figure 4. Chassis and Engine Harness Retainers Behind Hood Support.Figure 5. Hood Support, Brackets, and Retaining Hardware.Figure 6. Chassis and Engine Harness Retainers Behind Hood Support.Figure 7. Chassis and Engine Harness Retainers Below Ether Aid.Figure 8. Hood Support and Retaining Hardware.HOOD SUPPORT REPLACEMENT - ContinuedFigure 9. Right Side Mounting Bracket.Figure 10. Chassis and Engine Harness and Retaining Hardware at Top of Hood Support.LOCKOUT SWITCH ACCESS PANEL REPLACEMENTFigure 1. Lockout Switch Access Panel, Hinge, and Retaining Hardware.LOCKOUT SWITCH ACCESS PANEL REPLACEMENT - ContinuedRIGHT REAR ACCESS PANEL REPLACEMENTFigure 2. Lockwasher and Lockout Switch.Figure 4. Arctic Kit Heater Battery Cable.Figure 5. Right Rear Access Panel Retaining Hardware.Figure 7. Right Rear Access Panel Bracket.Figure 8. Right Rear Access Panel and Retaining Hardware.Figure 9. Retaining Hardware.Figure 10. Weld Boss.Figure 11. Right Rear Access Panel and Retaining Hardware.Figure 13. Right Rear Access Panel Retaining Hardware.Figure 15. Arctic Kit Heater Battery Cable.Figure 16. Battery Disconnect Switch and Retaining Hardware.Figure 18. Lockout Switch and Guard.RIGHT REAR ACCESS COVER REPLACEMENTFigure 1. Right Rear Access Cover and Retaining Hardware.LEFT REAR ACCESS DOOR REPLACEMENTFigure 2. Striker Plate.Figure 3. Left Rear Access Door and Retaining Hardware.Figure 4. Left Rear Access Door and Retaining Hardware.Figure 5. Striker Plate.Figure 6. Door Latch Assembly.LEFT REAR ACCESS PANEL REPLACEMENTFigure 2. Access Panel Nuts.Figure 4. Access Panel Bolts at Mounting Flange.Figure 5. Left Rear Access Panel.Figure 6. Access Panel Bolts at Mounting Flange.Figure 7. Gap Strip.Figure 9. Access Panel Nuts.FUEL TANK GUARD AND ACCESS COVER REPLACEMENT (WITH RIPPER)Figure 2. Center Access Cover and Retaining Hardware on Rear of Machine.Figure 4. Left Access Cover and Retaining Hardware on Rear of Machine.Figure 6. Fuel Tank Guard Retaining Hardware Behind Left Rear Access.Figure 8. Retaining Hardware on Rear of Machine.Figure 9. Fuel Tank Guard and Retaining Hardware on Rear of Machine.Figure 10. Retaining Hardware on Rear of Machine.Figure 11. Fuel Tank Guard Retaining Hardware on Rear of Machine.Figure 13. Fuel Tank Guard Retaining Hardware Behind Right Rear Access.Figure 15. Upper Access Cover and Retaining Hardware on Rear of Machine.Figure 17. Lower Access Cover and Retaining Hardware on Rear of Machine.FUEL TANK GUARD AND ACCESS COVER REPLACEMENT (WITH WINCH)Figure 1. Left, Center, Upper, and Lower Access Covers and Retaining Hardware on Rear of Machine.Figure 2. Center Access Cover, Plate, and Retaining Hardware.Figure 4. Fuel Tank Guard Retaining Hardware Behind Left Rear Access.Figure 6. Retaining Hardware on Rear of Machine.Figure 7. Fuel Tank Guard and Retaining Hardware on Rear of Machine.Figure 8. Retaining Hardware on Rear of Machine.Figure 9. Fuel Tank Guard Retaining Hardware on Rear of Machine.Figure 11. Fuel Tank Guard Retaining Hardware Behind Right Rear Access.Figure 13. Left, Center, Upper, and Lower Access Covers and Retaining Hardware on Rear of Machine.ACCESS COVERS INSTALLATION CONTINUEDVALVE BANK 4 SERVICE (WITH RIPPER)Figure 2. Rear Top Plates.Figure 4. Outlet Manifold Hoses.Figure 5. Electrical Connectors.Figure 6. Valve Bank Lines.Figure 7. Valve Bank Assembly.Figure 8. Outlet Manifold.Figure 9. Ripper Control Valve.Figure 10. Valve Solenoid Cover.Figure 12. Blade Angle Control Valve.Figure 13. Valve Solenoid Cover.Figure 15. Blade Tilt Control Valve.Figure 16. Valve Solenoid Cover.Figure 18. Blade Lift Control Valve.Figure 19. Valve Solenoid Cover.Figure 21. Inlet Manifold.Figure 22. Solenoids.Figure 23. Valve Solenoid Cover.Figure 24. Blade Lift Control Valve.Figure 26. Valve Solenoid Cover.Figure 27. Blade Tilt Control Valve.Figure 29. Valve Solenoid Cover.Figure 30. Blade Angle Control Valve.Figure 31. Solenoids.Figure 32. Valve Solenoid Cover.Figure 33. Ripper Control Valve.Figure 34. Outlet Manifold.Figure 35. Valve Bank Assembly.Figure 36. Valve Bank Lines.Figure 37. Electrical Connectors.Figure 38. Outlet Manifold Hoses.Figure 39. Hydraulic Tank Supply Hoses.Figure 41. Bottom Rear Plate.VALVE BANK 3 SERVICE (WITH WINCH)Figure 1. Hydraulic Tank Supply Hoses.Figure 2. Outlet Manifold Hoses.Figure 3. Valve Bank Lines.Figure 4. Powertrain Diagnostic Line.Figure 5. Valve Bank Assembly.Figure 6. Outlet Manifold.Figure 7. Blade Angle Control Valve.Figure 8. Valve Solenoid Cover.Figure 10. Blade Tilt Control Valve.Figure 11. Valve Solenoid Cover.Figure 13. Blade Lift Control Valve.Figure 14. Valve Solenoid Cover.Figure 16. Inlet Manifold.Figure 17. Solenoids.Figure 18. Valve Solenoid Cover.Figure 19. Blade Lift Control Valve.Figure 20. Solenoids.Figure 22. Blade Tilt Control Valve.Figure 23. Solenoids.Figure 25. Blade Angle Control Valve.Figure 26. Outlet Manifold.Figure 27. Valve Bank Assembly.Figure 28. Powertrain Diagnostic Line.Figure 29. Valve Bank Lines.Figure 30. Electrical Connectors.Figure 31. Hydraulic Tank Supply Hoses.DEMAND FAN MANIFOLD REPLACEMENTDEMAND FAN MANIFOLD REPLACEMENT - ContinuedFigure 1. Demand Fan Manifold.Figure 2. Demand Fan Manifold and Fittings.DEMAND FAN MANIFOLD REPLACEMENT - ContinuedFigure 3. Demand Fan Manifold.DEMAND FAN MANIFOLD SOLENOID VALVE REPLACEMENTFigure 1. Demand Fan Manifold.Figure 2. Solenoid Valve.Figure 3. Demand Fan Manifold.MAIN AND ALTERNATOR CIRCUIT BREAKER REPLACEMENTFigure 2. Fuse Panel Side Cover.Figure 3. Cable Connection Outside Panel.Figure 5. Panel Electrical Bracket.Figure 7. Circuit Breaker Mounting.Figure 8. Strip Connection to Circuit Breaker.Figure 9. Circuit Breaker Mounting.Figure 10. Cable Connection Inside Panel.Figure 11. Panel Electrical Bracket.Figure 13. Cable Connection Outside Panel.Figure 14. Fuse Panel Side Cover.MAIN AND ALTERNATOR CIRCUIT BREAKER REPLACEMENT - ContinuedFUSE BLOCK AND CIRCUIT BREAKER PANEL WIRING HARNESS REPLACEMENTFigure 2. Fuse Panel Side Cover.Figure 3. Harness Tiedown Straps.Figure 4. Cable Connection Inside Panel.Figure 5. Circuit Breaker Mounting.Figure 6. Plug Backing Plate.Figure 8. Harness Tiedown Straps.Figure 10. Magnetic Switch Cables.CLEANING AND INSPECTIONFigure 11. Magnetic Switch Mounting.Figure 13. Right Rear Access Panel.Figure 15. Circuit Breaker Mounting.Figure 16. Cable Connection Inside Panel.Figure 17. Harness Tiedown Straps.Figure 18. Fuse Panel Side Cover.FUSE BLOCK AND CIRCUIT BREAKER PANEL WIRING HARNESS REPLACEMENT - ContinuedA/C CONDENSER ASSEMBLY SERVICEFigure 1. Lift Guide.Figure 2. A/C Condenser Cover Grille.Figure 3. A/C Condenser Cover.Figure 4. A/C Condenser Hose Connections and Hose Retainer.Figure 5. A/C Hoses, O-rings, Receiver Dryer, and Retaining Hardware on Condenser Assembly.Figure 6. Left Side Bracket and Retaining Hardware.Figure 7. Right Side Bracket and Retaining Hardware.Figure 8. A/C Condenser.Figure 9. Mounting Bracket.Figure 10. Relays, Retaining Hardware, and Wiring Harness on Condenser Assembly.Figure 11. Fans and Retaining Hardware on Condenser Assembly.Figure 13. Relays, Retaining Hardware, and Wiring Harness on Condenser Assembly.Figure 14. A/C Condenser Bracket.Figure 15. A/C Condenser.Figure 16. Right Side Bracket and Retaining Hardware.Figure 17. Left Side Bracket and Retaining Hardware.Figure 18. A/C Hoses, O-rings, Receiver Dryer, and Retaining Hardware on Condenser Assembly.Figure 19. A/C Condenser Hose Connections and Hose Retainer.Figure 20. A/C Condenser Cover.Figure 22. Lift Guide.A/C THERMOSTATIC SWITCH REPLACEMENTFigure 2. Filter Housing.Figure 3. Filter Housing.Figure 4. Filter Housing.Figure 5. Filter Housing.Figure 6. Filter.A/C COMPRESSOR PRESSURE SENSOR REPLACEMENTFigure 1. Compressor Pressure Sensor.A/C COMPRESSOR PRESSURE SENSOR REPLACEMENT - ContinuedFRONT FLOOR PLATE REPLACEMENTFigure 2. Floor Mat.Figure 4. Bottom Floor Plate.Figure 5. Top Floor Plate.Figure 7. Foot Rest.REAR FLOOR PLATE REPLACEMENTFigure 2. Top Floor Plate.Figure 3. Bottom Floor Plate.Figure 4. Bottom Floor Plate.Figure 6. Floor Mat.FRONT WIPER MOTOR, WIPER ARM, AND WIPER BLADE REPLACEMENTFigure 1. Light Guard.Figure 2. Front Wiper Motor Arms and Fasteners.Figure 3. Front Wiper Motor Mounting Fasteners.Figure 5. Front Wiper Motor Connector.Figure 6. Front Wiper Motor Connector.Figure 7. Cab Mirror and Headliner.Figure 9. Front Wiper Motor Arms and Fasteners.Figure 10. Light Guard.REAR WIPER MOTOR, WIPER ARM, AND WIPER BLADE REPLACEMENTFigure 2. Rear Wiper Arm.Figure 4. Rear Speakers.Figure 6. Rear Wiper Motor.Figure 7. Rear Speakers.Figure 9. Rear Wiper Arm.REAR WIPER MOTOR, WIPER ARM, AND WIPER BLADE REPLACEMENT - ContinuedDOOR WIPER MOTOR, WIPER ARM, AND WIPER BLADE REPLACEMENTFigure 1. Door Wiper Motor Arm and Fasteners.Figure 2. Door Wiper Motor Mounting Fasteners.Figure 4. Door Wiper Motor Connector.Figure 5. Door Wiper Motor Connector.Figure 7. Door Wiper Motor Cover.Figure 8. Door Wiper Motor Arm and Fasteners.CAB GLASS REPLACEMENTFigure 1. Left Side Glass.CAB GLASS REPLACEMENT - ContinuedRIFLE BRACKET REPLACEMENTFigure 2. Lower Rifle Bracket.Figure 3. Upper Rifle Bracket.CAB TRIM REPLACEMENTFigure 1. Cab Rear Mat.Figure 2. Cab Front Mat.Figure 4. Heater, A/C Control Electrical Connectors.Figure 5. Heater, A/C Duct Hose.Figure 6. Control Panel - Front.Figure 8. Control Panel Electrical Connectors - Front.Figure 9. Control Panel Electrical Connectors - Rear.Figure 10. Right Console.Figure 11. Left B-Pillar.Figure 12. Right B-Pillar.Figure 13. Left C-Pillar.Figure 14. Right C-Pillar.Figure 15. Heater, A/C Duct Hose.Figure 16. Messenger.Figure 17. Heater, A/C Duct Hose.Figure 18. Right C-Pillar.Figure 19. Left C-Pillar.Figure 20. Right B-Pillar.Figure 21. Left B-Pillar.Figure 22. Right Console.Figure 24. Control Panel Electrical Connectors - Front.Figure 25. Control Panel - Rear.Figure 27. Heater, A/C Duct Hose.Figure 29. Heater, A/C Control and Console Mounting Bolts.Figure 31. Cab Rear Mat.CAB FAN AND BRACKET REPLACEMENTFigure 2. Bracket.Figure 3. Cab Fan.CAB FAN RESISTOR REPLACEMENTFigure 1. Cab Fan Resistor.CAB FAN RESISTOR REPLACEMENT - ContinuedMESSENGER REPLACEMENTFigure 1. Messenger Mounting.POWER CONVERTER REPLACEMENTFigure 2. Power Converter.WINCH OPERATION CONTROL HANDLE REPLACEMENTFigure 2. Winch Operation Electrical Connectors.Figure 3. Winch Control Handle Panel Components.Figure 4. Winch Control Handle Panel Components.Figure 5. Winch Operation Electrical Connectors.Figure 6. Winch Operation Control Handle Panel.RIPPER OPERATION CONTROL HANDLE REPLACEMENTFigure 1. Ripper Operation Control Handle Panel.CLEANING AND INSPECTIONHEADLINER REPLACEMENTFigure 2. Cab Mirror and Headliner.Figure 3. Rear Speakers.DASH PANEL REPLACEMENTFigure 2. Lower Dash Panel.Figure 4. Upper Dash Panel.Figure 5. Rear Dash Panel.Figure 6. Upper Vent.Figure 8. Level.Figure 10. Level Mounting.Figure 11. Upper Vent.Figure 13. Upper Dash Panel.Figure 15. Lower Dash Panel.INSTRUMENT CLUSTER REPLACEMENTFigure 1. Instrument Cluster.CLEANING AND INSPECTIONIGNITION SWITCH REPLACEMENTFigure 2. Ignition Switch Connection.Figure 3. Ignition Switch.WASHER BOTTLE REPLACEMENTFigure 1. Washer Bottle Connector.Figure 2. Washer Bottle Hold-Down Bracket.Figure 3. Washer Wiring Harness.Figure 4. Washer Pumps.Figure 5. Washer Bottle Rear Bracket.Figure 7. Washer Pumps.Figure 8. Washer Wiring Harness.Figure 9. Washer Bottle Hold-Down Bracket.Figure 10. Washer Bottle Connector.FRONT WASHER HOSE REPLACEMENTFigure 2. Front Wiper Hose.Figure 3. Front Hose Connector.Figure 4. Hose Routing on Roof.Figure 5. Front Hose Routing on Rear Pillar.Figure 6. Hose Routing through Right Console.Figure 7. Hose Routing through Battery Compartment.Figure 8. Front Hose Routing on Washer Bottle.Figure 9. Front Hose Routing on Washer Bottle.Figure 10. Hose Routing through Battery Compartment.Figure 11. Hose Routing through Right Console.Figure 12. Front Hose Routing on Rear Pillar.Figure 13. Hose Routing on Roof.Figure 14. Front Hose Connector.Figure 15. Front Wiper Hose.Figure 16. Light Guard.REAR WASHER HOSE REPLACEMENTFigure 2. Rear Hose Connector.Figure 3. Rear Hose Routing on Rear Pillar.Figure 4. Rear Hose Routing through Right Console.Figure 5. Rear Hose Routing through Battery Compartment.Figure 6. Rear Hose Routing on Washer Bottle.Figure 7. Rear Hose Routing through Battery Compartment.Figure 8. Rear Hose Routing through Right Console.Figure 9. Rear Hose Routing on Rear Pillar.Figure 10. Rear Hose Connector.Figure 11. Rear Hose Nozzle Connection.RIGHT DOOR WASHER HOSE REPLACEMENTFigure 1. Door Wiper Motor Nozzle.Figure 2. Door Wiper Motor Cover.Figure 3. Door Wiper Connector.Figure 4. Door Grommet.Figure 6. Hose in Door Routing.Figure 7. Hose in Battery Compartment.Figure 8. Hose Routing through Battery Compartment.Figure 9. Hose Routing on Washer Bottle.Figure 10. Hose Routing through Battery Compartment.Figure 11. Hose in Battery Compartment.Figure 12. Hose in Door Routing.Figure 13. Door Hinge Plate.Figure 14. Door Grommet.Figure 15. Door Wiper Connector.Figure 16. Door Wiper Motor Cover.Figure 17. Door Wiper Motor Nozzle.LEFT DOOR WASHER HOSE REPLACEMENTFigure 1. Door Wiper Nozzle.Figure 2. Door Wiper Motor Cover.Figure 3. Door Wiper Connector.Figure 5. Door Hinge Plate.Figure 6. Hose Below Floor Routing.Figure 8. Hose in Battery Compartment.Figure 9. Hose Routing through Battery Compartment.Figure 10. Hose Routing on Washer Bottle.Figure 11. Hose Routing on Washer Bottle.Figure 12. Hose Routing through Battery Compartment.Figure 13. Hose in Battery Compartment.Figure 14. Washer Hose and Tiedown Strap.Figure 15. Hose Below Floor Routing.Figure 16. Door Hinge Plate.Figure 17. Door Grommet.Figure 18. Door Wiper Connector.Figure 19. Door Wiper Motor Cover.Figure 20. Door Wiper Nozzle.LOWER CAB WIRING HARNESS REPLACEMENTFigure 1. Foot Rests, Floor Mat and Brake Pedal Cover Plate.Figure 2. Lower Dash Cab Wire Harness Connectors.Figure 4. Fire Extinguisher.Figure 6. Fuse Panel Side Cover.Figure 8. Cab Wiring Harness, Ground Wire Bolt - Right Side.Figure 10. Cab Wiring Harness Tiedown Straps - Rear Pillar.Figure 11. Cab Harness Connector.Figure 12. Cab Wiring Harness - Rear Right.Figure 14. Cab Wiring Harness - Rear Center.Figure 16. 24V to 12V Power Converter.Figure 18. Cab Wiring Harness Main Connector.Figure 20. Ground Wires.Figure 22. Cab Wiring Harness.Figure 23. Ground Wires.Figure 24. A/C Connectors.Figure 26. Cab Wiring Harness - Left Floor.Figure 28. Cab Wiring Harness - Left Side.Figure 30. Cab Wiring Harness - Rear Left.Figure 32. Cab Harness Connector.Figure 33. Cab Wiring Harness Tiedown Straps - Rear Pillar.Figure 34. Cab Wiring Harness Tiedown Strap - Right Rear.Figure 36. Fuse Block Harness Connector.Figure 38. Fire Extinguisher Bracket and Fuse Panel Front Cover.Figure 40. Cab Wiring Harness - Right Floor.Figure 42. Foot Rests, Floor Mat, and Brake Pedal Cover Plate.UPPER CAB WIRING HARNESS REPLACEMENTFigure 2. Front Cab Flood Lights Wiring Harness.Figure 4. Cab Roof Plate and Lift Bar.Figure 5. A/C Condenser Cover.Figure 6. Rear Cab Flood Light Wiring Harness Connector.Figure 7. Rear Cab Lights Wiring Harness - Left Side.Figure 8. Rear Cab Lights Wiring Harness - Right Side.Figure 9. A/C Condenser Fan Wiring Harness.Figure 10. A/C Condenser Quick Disconnect at Back of Cab.Figure 11. A/C Condenser Mounting Bracket at Back of Cab Left Side.Figure 12. A/C Condenser Mounting Bracket at Back of Cab Right Side.Figure 13. Upper and Lower Cab Harness Connector.Figure 14. Cab Wiring Harness - Rear.Figure 15. Cab Fan and Interior Light Connections.Figure 16. Cab Wiring Harness - Front.Figure 17. Cab Fan and Interior Light Connections.Figure 18. Cab Wiring Harness - Rear.Figure 19. Upper and Lower Cab Harness Connector.Figure 20. A/C Condenser Mounting Bracket at Back of Cab Right Side.Figure 21. A/C Condenser Mounting Bracket at Back of Cab Left Side.Figure 22. A/C Condenser Quick Disconnect at Back of Cab.Figure 23. A/C Condenser Fan Wiring Harness.Figure 24. Rear Cab Lights Wiring Harness - Right Side.Figure 25. Rear Cab Lights Wiring Harness - Left Side.Figure 26. Rear Cab Flood Light Wiring Harness Connector.Figure 27. A/C Condenser Cover.Figure 28. Cab Roof Plate and Lift Bar.Figure 29. Cab Flood Lights Wiring Harness and Grommet.Figure 31. Brush Guard and Cover.INSULATION FOAM REPLACEMENTFigure 2. Right Side Panel Insulation Foam.SURFACE PREPARATIONFigure 3. Fuse Panel Cover Insulation Foam.Figure 4. Right Side Panel Insulation Foam.OPERATOR PLATFORM REPLACEMENTFigure 1. Wiring Harness Bracket and Support Bracket.Figure 2. Hydraulic Filter Bracket.Figure 3. Hydraulic Service Port Bracket.Figure 4. Support Bracket.Figure 5. Operator Platform.OPERATOR PLATFORM REPLACEMENT - ContinuedFigure 6. Support Bracket.Figure 7. Hydraulic Service Port Bracket.Figure 8. Wiring Harness Bracket and Support Bracket.Figure 9. Hydraulic Filter Bracket.CAB REPLACEMENTFigure 1. Harness Connectors and Retaining Hardware Above Hydraulic Filters.Figure 2. Positive Battery Cables.Figure 3. Ground Strap.Figure 5. Cab Floor Plate Harness Connection.Figure 6. Plenum Connections.Figure 8. Left Front Cab Mount Cover.Figure 9. Left Front Cab Mount.Figure 10. Left Rear Cab Mount.CAB REPLACEMENT - ContinuedFigure 11. Left Rear Cab Mount.Figure 12. Left Front Cab Mount.Figure 13. Left Front Cab Mount Cover.Figure 14. Wiring Harness Clamp.Figure 16. Cab Floor Plate Harness Connection.Figure 17. Washer Reservoir Hoses.Figure 19. Positive Battery Cables.Figure 20. Harness Connectors and Retaining Hardware Above Hydraulic Filters.CAB ROOF PLATE REPLACEMENTFigure 1. Cab Roof Plate.CAB ROOF PLATE REPLACEMENT - ContinuedCAB MOUNT REPLACEMENTFigure 1. Left Front Cab Mount Cover.Figure 2. Left Front Cab Mount.Figure 3. Left Front Cab Mount.Figure 4. Left Front Cab Mount Cover.SEAT ASSEMBLY SERVICEFigure 2. Harness Clips.Figure 3. Seat Harness Connections.Figure 4. Left Support.Figure 5. Right Support.Figure 7. Seat.Figure 8. Seat Belt Retractor.Figure 10. Seat Back Cushion.Figure 12. Operator Present Harness.Figure 13. Seat Pan.Figure 14. Recliner Shaft Stop.Figure 15. Recliner Shaft.Figure 17. Seat Adjuster.Figure 19. Nuts, Bolts, and Clips.Figure 20. Nuts, Bolts, and Clips.Figure 22. Seat Adjuster.Figure 23. Cable End.Figure 24. Recliner Shaft.Figure 25. Recliner Shaft Stop.Figure 26. Recliner Spacer Shaft Adjustment.Figure 27. Seat Pan.Figure 28. Operator Present Harness.Figure 29. Seat Cushion.Figure 32. Seat Belt Retractor.Figure 33. Seat.Figure 34. Right Support.Figure 35. Left Support.Figure 36. Seat Harness Connections.Figure 37. Harness Clips.Figure 39. BII Box.SEAT WIRING HARNESS REPLACEMENTFigure 2. Seat Harness Connectors.Figure 3. Right Joystick Cover - Lower.Figure 5. Right Joystick Harness Connectors.Figure 6. Left Joystick Cover - Lower.Figure 8. Left Joystick Harness Connectors.Figure 9. Left Wiring Harness Tiedown Straps.Figure 10. Left Joystick Harness Connectors.Figure 11. Left Joystick Connector Tiedown Straps.Figure 13. Left Joystick Cover - Lower.Figure 15. Right Joystick Harness Connectors.Figure 16. Right Joystick Cover - Lower.Figure 17. Seat Harness Connectors.Figure 18. Seat Harness Clips.LEFT JOYSTICK SUPPORT SERVICEFigure 2. Joystick Connector Tiedown Straps.Figure 4. Wiring Harness Tiedown Straps.Figure 5. Joystick Control Support Assembly Mounting Bolts.Figure 6. Joystick Control Support Cover.Figure 8. Joystick Control Mounting Bolt.Figure 10. Joystick Cushion and Cover.Figure 12. Joystick Bracket.Figure 14. Joystick Control Support Wrist Pad.Figure 16. Joystick Adjustment Lever and Bolt.Figure 18. Joystick Control Mounting Plate.Figure 20. Support Arm, Housing, and Pin.Figure 22. Support Housing Plugs.Figure 23. Support Housing Seals and Bearings.Figure 24. Support Housing Plugs.Figure 26. Support Arm, Housing, and Pin.Figure 28. Joystick Control Mounting Plate.Figure 30. Joystick Adjustment Lever and Bolt.Figure 32. Joystick Control Support Wrist Pad.Figure 34. Joystick Bracket.Figure 36. Joystick Cushion and Cover.Figure 38. Joystick Control Mounting Bolt.Figure 40. Joystick Control Support Cover.Figure 42. Joystick Harness Connectors.Figure 44. Wiring Harness Tiedown Straps.LEFT JOYSTICK SUPPORT SERVICE - ContinuedRIGHT JOYSTICK SUPPORT SERVICEFigure 2. Wiring Harness Tiedown Straps.Figure 3. Joystick Harness Connectors.Figure 4. Joystick Control Support Assembly Mounting Bolts.Figure 5. Joystick Control Support Cover.Figure 7. Joystick Control Mounting Bolt.Figure 9. Joystick Cushion and Cover.Figure 11. Joystick Bracket.Figure 13. Joystick Control Support Wrist Pad.Figure 15. Joystick Adjustment Lever and Bolt.Figure 17. Joystick Control Mounting Plate.Figure 19. Support Arm, Housing, and Pin.Figure 21. Support Housing Plugs.Figure 22. Support Housing Seals and Bearings.Figure 23. Support Housing Plugs.Figure 25. Support Arm, Housing, and Pin.Figure 27. Joystick Control Mounting Plate.Figure 28. Adjustment Rods and Pin.Figure 29. Joystick Adjustment Lever and Bolt.Figure 31. Joystick Control Support Wrist Pad.Figure 33. Joystick Bracket.Figure 35. Joystick Cushion and Cover.Figure 37. Joystick Control Mounting Bolt.Figure 39. Joystick Control Support Cover.Figure 40. Joystick Control Support Assembly Mounting Bolts.Figure 41. Wiring Harness Tiedown Straps.Figure 42. Joystick Harness Connectors.Figure 43. Joystick Cover - Lower.LEFT JOYSTICK CONTROL REPLACEMENTFigure 2. Joystick Harness Connectors.Figure 3. Joystick Sensor.Figure 5. Joystick Handle, Boot, and Sensor.Figure 6. Joystick Handle and Boot.Figure 7. Joystick Sensor.Figure 8. Joystick Harness Connectors.LEFT JOYSTICK CONTROL REPLACEMENT - ContinuedRIGHT JOYSTICK CONTROL REPLACEMENTFigure 2. Joystick Harness Connectors.Figure 3. Joystick Sensor.Figure 4. Joystick Handle and Boot.Figure 5. Joystick Handle, Boot, and Sensor.Figure 6. Joystick Handle, Boot, and Sensor.Figure 7. Joystick Handle and Boot.Figure 8. Joystick Sensor.Figure 9. Joystick Harness Connectors.Figure 10. Joystick Cover - Lower.SEAT AIR SUSPENSION REPLACEMENTFigure 1. Seat Air Suspension Mounting.Figure 2. Floor Spacers.Figure 3. Seat Air Suspension Mounting.SERVICE BRAKE CONTROL SERVICEFigure 1. Brake Pedal Cover Plate.Figure 2. Lower Dash Cab Wiring Harness Connector.Figure 3. Brake Pedal Position Sensor.Figure 5. Brake Pedal Limit Switch and Spring.Figure 6. Brake Pedal Link and Mounting Bolts.Figure 8. Brake Pedal Shaft Components.Figure 10. Brake Pedal Plunger Assembly.Figure 12. Brake Pedal Bearings.Figure 13. Brake Pedal Limit Switch Spring.Figure 15. Brake Pedal and Shaft.Figure 17. Brake Pedal Pivot Shaft Locknut.Figure 18. Brake Pedal Link and Mounting Bolts.Figure 19. Brake Pedal Limit Switch and Spring.Figure 20. Position Sensor O-Ring.Figure 22. Brake Pedal Plunger Adjustment.Figure 23. Limit Switch Adjustment.Figure 24. Lower Dash Cab Wiring Harness Connectors.Figure 25. Brake Pedal Cover Plate.SERVICE BRAKE POSITION SENSOR REPLACEMENTFigure 2. Position Sensor O-ring.Figure 3. Brake Pedal Position Sensor.SERVICE BRAKE LIMIT SWITCH REPLACEMENTFigure 1. Brake Pedal Limit Switch and Spring.Figure 2. Brake Pedal Plunger Adjustment.Figure 3. Limit Switch Adjustment.Figure 4. Brake Pedal Limit Switch and Spring.AIR CONDITIONER ASSEMBLY SERVICEFigure 1. Hydraulic Oil Filler Tube and Retaining Hardware Below A/C Heater AssemblyFigure 2. Bracket and Retaining Hardware Below A/C Heater Assembly.Figure 3. Diagnostic Lines, Bracket, and Retaining Hardware Below A/C Heater Assembly.Figure 4. Harness Connectors, Upper Heater Hose, Duct, and Clamps on A/C Heater Assembly.Figure 5. A/C Line, Orifice Tube, and O-rings on A/C Heater Assembly.Figure 6. Connector Hose, Heater Core, and Clamp on Bottom of A/C Heater Assembly.Figure 7. Ground Wire.Figure 9. Duct and Retaining Hardware on Left Side of A/C Heater Assembly.Figure 10. Filter, Plate, Case, and Retaining Hardware.Figure 11. Evaporator Temperature Sensor and Retaining Hardware.Figure 12. Plate and Retaining Hardware.Figure 13. Side Plate, Evaporator, and Retaining Hardware.Figure 15. Wiring Harness, Actuator, and Retaining Hardware.Figure 17. Heater Core and Grommet.Figure 18. Heater Valve, Hose, and Clamps.Figure 19. Blower Motor and Retaining Hardware.Figure 20. Blower Motor Resister and Wiring Harness.Figure 21. Wiring Harness and Duct Hose Connector.Figure 22. Wiring Harness and Duct Hose Connector.Figure 23. Blower Motor Resistor and Wiring Harness.Figure 24. Blower Motor and Retaining Hardware.Figure 25. Heater Valve, Hose, and Clamps.Figure 26. Heater Core and Grommet.Figure 28. Wiring Harness, Actuator, and Retaining Hardware.Figure 30. Side Plate, Evaporator, and Retaining Hardware.Figure 32. Evaporator Temperature Sensor and Retaining Hardware.Figure 33. Filter, Plate, Case, and Retaining Hardware.Figure 34. Duct and Retaining Hardware on Left Side of A/C Heater Assembly.Figure 35. Ground Wire.Figure 36. Bracket, Duct, Wiring Harness, and Retaining Hardware On and Above A/C Heater Assembly.Figure 37. Connector Hose, Heater Core, and Clamp on Bottom of A/C Heater Assembly.Figure 38. A/C Line, Orifice Tube, and O-rings on A/C Heater Assembly.Figure 39. Harness Connectors, Upper Heater Hose, Duct, and Clamps on A/C Heater Assembly.Figure 40. Diagnostic Lines, Bracket, and Retaining Hardware Below A/C Heater Assembly.Figure 42. Hydraulic Oil Filler Tube and Retaining Hardware Below A/C Heater Assembly.AIR DUCT REPLACEMENTFigure 1. Air Duct and Retaining Hardware.AIR DUCT REPLACEMENT - ContinuedHEATER HOSE REPLACEMENTFigure 2. Heater Hose, Elbow, and Clamp on Front Housing.Figure 3. Heater Hose Retaining Hardware Near Left Front of Engine.Figure 4. Heater Hose Retaining Hardware on Left Side of Engine.Figure 5. Heater Hose Retaining Hardware Near Starter.Figure 6. Heater Hose Retaining Hardware Above Starter and On Flywheel Housing.Figure 8. Heater Hose, Elbow, and Clamp on Right Rear of Engine.Figure 9. Left Rear Access Door.Figure 11. Diagnostic Lines, Bracket, and Retaining Hardware in Left Rear Access.Figure 12. Heater Hoses and Clamps in Left Rear Access.Figure 13. Heater Hose Retaining Hardware Behind A/C Heater Assembly.Figure 14. Heater Hose Retaining Hardware Near HVAC Duct.Figure 15. Heater Hoses, Clamps, Shutoff Valves, and Bracket Underneath Front Floor Plate.Figure 16. Heater Hoses, Clamps, Shutoff Valves, and Bracket Underneath Front Floor Plate.Figure 17. Heater Hose Retaining Hardware Near HVAC Duct.Figure 18. Heater Hose Retaining Hardware Behind A/C Heater Assembly.Figure 19. Heater Hoses and Clamps in Left Rear Access.Figure 20. Diagnostic Lines, Bracket, and Retaining Hardware in Left Rear Access.Figure 22. Left Rear Access Door.Figure 24. Arctic Kit Heater, Water Inlet Hose and Fittings.Figure 26. Heater Hose Retaining Hardware Near Starter.Figure 27. Heater Hose Retaining Hardware on Left Side of Engine.Figure 28. Heater Hose Retaining Hardware Near Left Front of Engine.Figure 29. Heater Hose, Elbow, and Clamp on Front Housing.Figure 30. Left Front Access Door and Plate.A/C HOSE AND BRACKET REPLACEMENTA/C HOSE REMOVALFigure 1. A/C Hoses on Right Side of Engine.Figure 2. Accumulator and Retaining Hardware on Right Side of Engine.Figure 3. A/C Hose Retaining Hardware Behind Right Side of Engine.A/C HOSE REMOVAL CONTINUEDFigure 4. A/C Hoses, Fittings, and Bracket Underneath Front Cab Floor Plates.Figure 5. A/C Hose Retaining Hardware Near HVAC Duct.Figure 6. A/C Hose Retaining Hardware Behind A/C Heater Assembly.Figure 8. A/C Hose, Orifice Tube, O-ring and Retaining Hardware on A/C Heater Assembly.Figure 9. Orifice Tube, O-ring, and Retaining Hardware.Figure 10. A/C Hose Retaining Hardware Below Right Side of A/C Heater Assembly and Above Fuel Tank.Figure 11. A/C Hoses, Fittings and Bracket on Rear of Machine.Figure 12. Cover and Retaining Hardware on Top of Machine.Figure 13. A/C Hoses, O-rings and Retaining Hardware on Condenser Assembly.A/C HOSE AND BRACKET REPLACEMENT - ContinuedFigure 14. A/C Hoses, O-rings, Receiver Dryer and Retaining Hardware on Condenser Assembly.Figure 15. A/C Hoses, Fittings, Heater Hoses, and Bracket Underneath Front Cab Floor Plates.A/C BRACKET INSTALLATIONFigure 16. A/C Hoses, O-rings, and Retaining Hardware on Condenser Assembly.Figure 17. A/C Hoses, O-rings, Receiver Dryer and Retaining Hardware on Condenser Assembly.Figure 18. Cover and Retaining Hardware on Top of Machine.Figure 19. A/C Hoses, Fittings and Bracket on Rear of Machine.Figure 20. A/C Hose Retaining Hardware Below Right Side of A/C Heater Assembly and Above Fuel Tank.Figure 21. Orifice Tube, O-ring, and Retaining Hardware.Figure 22. A/C Hose, Orifice Tube, O-ring and Retaining Hardware on A/C Heater Assembly.Figure 23. Left Rear Access Door.Figure 25. A/C Hose Retaining Hardware Near HVAC Duct.Figure 26. A/C Hoses, Fittings, and Bracket Underneath Front Cab Floor Plates.Figure 27. A/C Hose Retaining Hardware Behind Right Side of Engine.Figure 28. Accumulator and Retaining Hardware on Right Side of Engine.A/C HOSE AND BRACKET REPLACEMENT - ContinuedFigure 29. A/C Hoses on Right Side of Engine.A/C HOSE AND BRACKET REPLACEMENT - ContinuedA/C LINE REPLACEMENTFigure 1. A/C Line, O-ring and Retaining Hardware.Figure 2. Low Pressure Switch, O-rings, A/C Lines, and Retaining Hardware.A/C LINE REPLACEMENT - ContinuedFigure 3. Low Pressure Switch, O-rings, A/C Lines, and Retaining Hardware.Figure 4. A/C Line, O-ring, and Retaining Hardware.A/C LINE REPLACEMENT - ContinuedA/C LOW PRESSURE SENSOR REPLACEMENTFigure 1. A/C Low Pressure Sensor.A/C LOW PRESSURE SENSOR REPLACEMENT - ContinuedA/C TEMPERATURE SENSOR REPLACEMENTFigure 1. A/C Temperature Sensor.A/C TEMPERATURE SENSOR REPLACEMENT - ContinuedRECIRCULATION CABIN AIR FILTER REPLACEMENTFigure 1. Air Filter Cover.Figure 3. Air Filter Element.Figure 4. Air Filter Cover.FRESH AIR FILTER REPLACEMENTFigure 1. Cabin Fresh Air Filter.A/C SYSTEM SERVICEA/C SYSTEM SERVICE - ContinuedFigure 1. Recovery Hook-Up.A/C SYSTEM SERVICE - ContinuedFigure 2. Evacuation Hook-Up.A/C SYSTEM SERVICE - ContinuedFigure 3. Charging Hook-Up.DOOR ASSEMBLY SERVICEFigure 1. Door Hinge Cover Plate - Lower.Figure 3. Door Wiper Harness and Washer Fluid Hose.Figure 4. Cab Door and Mounting Bolts.Figure 5. Door Seal Gasket.Figure 6. Door Access Cover.Figure 7. Door Wiper Harness and Hose.Figure 8. Door Washer Nozzle and Hose.Figure 9. Door Hardware Cover Plate.Figure 10. Door Handle and Components.Figure 11. Door Lock Components.Figure 13. Door Latch Components.Figure 15. Door Pull Handle.Figure 16. Door Bump Stop.Figure 17. Door Glass and Frame.Figure 18. Applying Glass Primer.Figure 19. Door Glass Seal Adhesive.Figure 20. Door Glass.Figure 21. Door Bump Stop.Figure 22. Door Pull Handle.Figure 23. Door Handle Clevis.Figure 25. Door Handle and Gasket.Figure 27. Door Handle and Components.Figure 28. Door Handle Adjustment.Figure 29. Clevis Rod Length Adjustment.Figure 30. Clevis Rod Spring Pin.Figure 32. Door Wiper Harness and Hose Grommets.Figure 33. Door Wiper Harness and Wiper Hose.Figure 34. Door Access Cover.Figure 35. Door Washer Nozzle and Hose.Figure 36. Cab Door and Mounting Bolts.Figure 37. Door Wiper Harness and Washer Fluid Hose.Figure 39. Door Hinge Cover Plate - Lower.CAB FRONT FLOOD LAMP SERVICEFigure 2. Cab Front Flood Lamp.Figure 3. Flood Lamp Mounting Bracket.Figure 4. Flood Lamp.Figure 5. Flood Lamp Components.Figure 6. Flood Lamp.Figure 7. Flood Lamp Mounting Bracket.Figure 8. Cab Front Flood Lamp.Figure 9. Brush Guard.CAB REAR FLOOD LAMP SERVICEFigure 1. Cab Rear Flood Lamp.Figure 2. Flood Lamp Grid and Mounting Bracket.Figure 3. Flood Lamp Bracket Assembly.Figure 4. Flood Lamp Mounting Bracket.Figure 5. Flood Lamp.Figure 6. Flood Lamp Components.Figure 7. Flood Lamp Components.Figure 8. Flood Lamp.Figure 9. Flood Lamp Mounting Bracket.Figure 10. Flood Lamp Bracket Assembly.Figure 11. Flood Lamp Grid and Mounting Bracket.Figure 12. Cab Rear Flood Lamp.BULLDOZER FINE GRADING HOSE REPLACEMENTFigure 1. Fine Grading Hoses.Figure 2. Fine Grading Hoses.BULLDOZER ANGLE AND TILT HOSE REPLACEMENTBULLDOZER ANGLE AND TILT HOSE REPLACEMENT - ContinuedFigure 1. Hydraulic and Lubrication Hoses.Figure 2. Hydraulic and Lubrication Hoses.BULLDOZER ANGLE AND TILT HOSE REPLACEMENT - ContinuedBULLDOZER LIFT CYLINDER SERVICEBULLDOZER LIFT CYLINDER SERVICE - ContinuedFigure 1. Fine Grading Hoses, Lift Cylinder, and Retaining Hardware.BULLDOZER LIFT CYLINDER SERVICE - ContinuedFigure 2. Lift Cylinder, Head, Rod, Bearings, and Internal Components.BULLDOZER LIFT CYLINDER SERVICE - ContinuedFigure 3. Lift Cylinder, Head, Rod, Bearings, and Internal Components.BULLDOZER LIFT CYLINDER SERVICE - ContinuedFigure 4. Fine Grading Hoses, Lift Cylinder, and Retaining Hardware.BULLDOZER TILT CYLINDER SERVICEFigure 1. Tilt Cylinder, Guard, and Retaining Hardware.Figure 2. Hydraulic Hoses.Figure 4. Tilt Cylinder and Retaining Hardware.Figure 5. Tilt Cylinder, Head, Rod, Bearings, and Internal Components.Figure 6. Tilt Cylinder, Head, Rod, Bearings, and Internal Components.BULLDOZER TILT CYLINDER SERVICE - ContinuedFigure 7. Tilt Cylinder and Retaining Hardware.Figure 8. Hydraulic Hoses Clamp Brackets.Figure 9. Hydraulic Hoses.Figure 10. Tilt Cylinder, Guard, and Retaining Hardware.BULLDOZER ANGLE CYLINDER SERVICEBULLDOZER ANGLE CYLINDER SERVICE - ContinuedFigure 1. Angle Cylinder, Bracket, Lubrication Hose, and Retaining Hardware.Figure 3. Angle Cylinder Retaining Hardware on Blade.Figure 4. Angle Cylinder, Retaining Hardware, and Lubrication Hose.BULLDOZER ANGLE CYLINDER SERVICE - ContinuedFigure 5. Angle Cylinder, Head, Rod, Bearings, and Internal Components.BULLDOZER ANGLE CYLINDER SERVICE - ContinuedFigure 6. Angle Cylinder, Head, Rod, Bearings, and Internal Components.Figure 7. Angle Cylinder, Retaining Hardware, and Lubrication Hose.Figure 8. Angle Cylinder Retaining Hardware on Blade.Figure 10. Angle Cylinder, Bracket, Lubrication Hose, and Retaining Hardware.BLADE EDGE REPLACEMENTFigure 1. Blade, Cutting Edges, Bit Ends, and Retaining Hardware.Figure 2. Blade, Cutting Edges, Bit Ends, and Retaining Hardware.CYLINDER AND HOSE DEBRIS GUARD AND BRACKET REPLACEMENTFigure 1. Tilt Cylinder, Guard, Angle Cylinder, Bracket, and Retaining Hardware.Figure 2. Bracket and Lubrication Hose.Figure 3. Guards, Bracket, and Retaining Hardware.Figure 4. Bracket and Lubrication Hose.Figure 5. Guards, Bracket, and Retaining Hardware.Figure 6. Bracket and Lubrication Hose.CYLINDER AND HOSE DEBRIS GUARD AND BRACKET REPLACEMENT - ContinuedWINCH ASSEMBLY REPLACEMENTCYLINDER AND HOSE DEBRIS GUARD AND BRACKET REPLACEMENT - ContinuedFigure 1. Winch Harness, Hoses, and O-rings.Figure 3. Attaching Lifting Device on Winch.Figure 4. Lower Winch Mounting Bolts.Figure 6. Upper Right Winch Mounting Bolts.Figure 8. Winch Assembly Supported on Ground.Figure 9. Left Debris Guard and Retaining Hardware.Figure 11. Upper Winch Mounting Bracket and Retaining Hardware.Figure 13. Lower Winch Mounting Bracket and Retaining Hardware.Figure 14. Winch, Motor Assembly, Hoses, and O-rings.Figure 15. Winch, Motor Assembly, Hoses, and O-rings.Figure 16. Lower Winch Mounting Bracket and Retaining Hardware.Figure 17. Upper Debris Guard and Retaining Hardware.Figure 18. Upper Winch Mounting Bracket and Retaining Hardware.Figure 19. Attaching Lifting Device on Winch.Figure 20. Winch Mounting Bolts.Figure 21. Installing Winch With Lifting Device.Figure 22. Winch Harness, Hoses, and O-rings.Figure 23. Upper Left Winch Mounting Bolts.Figure 24. Upper Right Winch Mounting Bolts.Figure 25. Lower Winch Mounting Bolts.Figure 26. Winch Mounting Bolts.Figure 27. Right Debris Guard and Retaining Hardware.Figure 29. Upper Right Bolt and Washer on Plate.WINCH MANIFOLD BLOCK SERVICEFigure 1. Plate and Retaining Hardware on Right Side of Winch.Figure 2. Winch Manifold, Fittings, O-rings, and Retaining Hardware.Figure 3. Winch Manifold, Solenoids, O-rings, and Retaining Hardware.Figure 4. Winch Manifold, Solenoids, O-rings, and Retaining Hardware.Figure 5. Winch Manifold, Fittings, O-rings, and Retaining Hardware.Figure 6. Plate and Retaining Hardware on Right Side of Winch.WINCH PISTON PUMP SERVICEFigure 1. Hoses on Hydrostatic Drive Motors.Figure 2. Harness, Solenoid, Hoses, and Retaining Hardware on Winch Piston Pump.Figure 3. Harness, Solenoid, Lines, and Hoses on Winch Piston Pump.Figure 4. Winch Piston Pump and Retaining Hardware.Figure 5. Sensor, Fittings, and O-rings on Winch Piston Pump.Figure 6. Sensor, Fittings, and O-rings on Winch Piston Pump.Figure 7. Winch Piston Pump and Retaining Hardware.Figure 8. Harness, Solenoid, Lines, and Hoses on Winch Piston Pump.Figure 9. Harness, Solenoid, Hoses, and Retaining Hardware on Winch Piston Pump.Figure 10. Hoses on Hydrostatic Drive Motors.WINCH CABLE REPLACEMENTFigure 1. Winch Cable and Retaining Hardware.Figure 2. Winch Cable, Hook, Clevis, Latch, and Retaining Hardware.CLEANING AND INSPECTIONFigure 3. Winch Cable, Hook, Clevis, Latch, and Retaining Hardware.Figure 4. Winch Cable and Retaining Hardware.WINCH CABLE REPLACEMENT - ContinuedRIPPER TOOTH REPLACEMENTFigure 1. Ripper Tooth Assembly.RIPPER TOOTH REPLACEMENT - ContinuedRIPPER CYLINDER SERVICERIPPER CYLINDER SERVICE - ContinuedFigure 1. Ripper Lift Cylinder Hydraulic Line - Rear.Figure 2. Ripper Lift Cylinder Hydraulic Line - Front.Figure 3. Ripper Hydraulic Hose Fittings.Figure 5. Ripper Lift Cylinder Trunnion Bearing Attachment Bolts.Figure 6. Ripper Lift Cylinder Trunnion Bearing.Figure 7. Ripper Lift Cylinder.Figure 9. Ripper Lift Cylinder Head and Rod Components.RIPPER CYLINDER SERVICE - ContinuedFigure 10. Ripper Lift Cylinder Head and Rod Components.Figure 12. Ripper Lift Cylinder.Figure 13. Ripper Lift Cylinder Trunnion Bearing.Figure 15. Ripper Lift Cylinder Attachment - Front.Figure 16. Ripper Hydraulic Line Fittings.Figure 17. Ripper Lift Cylinder Hydraulic Line - Front.Figure 18. Ripper Lift Cylinder Hydraulic Line - Rear.ARCTIC KIT TROUBLESHOOTING INTRODUCTIONARCTIC KIT TROUBLESHOOTING SYMPTOM INDEXARCTIC KIT TROUBLESHOOTING PROCEDURESFigure 1. Intake Port and Exhaust Tube.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer Figure 2. Intake Port and Exhaust Tube.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.Table 1. Arctic Kit Troubleshooting Procedures for the D6K Dozer - Continued.ARCTIC HEATER FUEL FLOW TESTPREPARING FOR TESTFigure 1. Measuring Fuel Flow.ARCTIC KIT BATTERY BOX REPLACEMENTARCTIC KIT BATTERY BOX REPLACEMENT - ContinuedFigure 1. Battery Box.Figure 3. Bracket and Mounting Assemblies.ARCTIC KIT BATTERY BOX REPLACEMENT - ContinuedFigure 4. Battery Tray.ARCTIC KIT BATTERY BOX REPLACEMENT - ContinuedFigure 5. Battery Box.ARCTIC KIT BATTERY CABLE REPLACEMENTARCTIC KIT BATTERY CABLE REPLACEMENT - ContinuedFigure 2. Arctic Battery Negative Terminal Cover Removal.Figure 4. Arctic Battery Box Cover Removal (Upper).Figure 6. Negative Arctic Battery Terminal Removal (Right Battery).Figure 7. Positive Arctic Battery Terminal Removal (Right Battery).Figure 8. Positive Arctic Battery Terminal Removal (Right Battery).Figure 9. Arctic Battery Positive Terminal Cover Removal.Figure 11. Arctic Battery Cable Clamps Removal at Fuel Filter Housing.Figure 12. Arctic Battery Cable Clamps Removal Inside of Battery/Fuel Filter Compartment.Figure 13. Arctic Battery Cable Clamps Removal Back of Battery/Fuel Filter Compartment.Figure 14. Arctic Battery Cable Clamps Removal in Upper Arctic Battery Box.Figure 15. Arctic Battery Cables and Grommets.ARCTIC KIT BATTERY CABLE REPLACEMENT - ContinuedFigure 16. Arctic Battery Cable Clamps Installation in Upper Arctic Battery Box.Figure 17. Arctic Battery Cable Clamps Installation Back of Battery/Fuel Filter Compartment.Figure 18. Arctic Battery Cable Clamps Installation Inside of Battery/Fuel Filter Compartment.Figure 19. Arctic Battery Cable Clamps Installation at Fuel Filter Housing.Figure 20. Arctic Battery Positive Terminal Installation.Figure 22. Positive Arctic Battery Terminal Installation (Left Battery).Figure 23. Positive Arctic Battery Terminal Installation (Right Battery).Figure 24. Negative Arctic Battery Terminal Removal (Right Battery).Figure 25. Negative Arctic Battery Jumper Terminal Installation.Figure 26. Arctic Battery Box Cover Installation (Upper).Figure 28. Arctic Battery Negative Terminal Cover Installation.ARCTIC HEATER SWITCH AND HEATER HARNESS REPLACEMENTFigure 1. Arctic Heater Harness.Figure 2. Harness Routing Left Side.Figure 4. Right Console.Figure 5. Arctic Heater Switch and Guard.Figure 6. Arctic Heater Switch and Guard.Figure 8. Harness Routing Right Side.Figure 10. Arctic Heater Harness.ARCTIC HEATER SWITCH AND HEATER HARNESS REPLACEMENT - ContinuedARCTIC HEATER AND BRACKET REPLACEMENTFigure 2. Arctic Heater Attachments.Figure 3. Hose.Figure 4. Arctic Heater and Deflector.Figure 5. Mounting Bracket.Figure 6. Mounting Bracket and Attachments.Figure 7. Mounting Bracket and Attachments.Figure 8. Mounting Bracket.Figure 10. Arctic Heater and Deflector.Figure 11. Arctic Heater Attachments.Figure 12. Fuel Shutoff Valve.ARCTIC KIT HEATER HOSE AND FITTING REPLACEMENTFigure 1. Exhaust Tube.Figure 2. Arctic Kit Heater Outlet Hose and Tee.Figure 3. Radiator Tee, Fittings, and Hose.Figure 5. Water Outlet Hose.Figure 6. Water Outlet Hose Clamp.Figure 7. Water Inlet Hose Routing.Figure 8. Water Inlet Hose and Fittings.ARCTIC KIT HEATER HOSE AND FITTING REPLACEMENT - ContinuedFigure 9. Water Inlet Hose Routing.Figure 10. Water Outlet Hose.Figure 11. Water Outlet Hose Clamp.Figure 12. Hose from Radiator Routing.Figure 13. Radiator Tee, Fittings, and Hose.Figure 14. Water Outlet Tee and Fittings.Figure 15. Arctic Kit Heater Outlet Hose and Tee.Figure 16. Exhaust Tube.ARCTIC KIT HEATER HOSE AND FITTING REPLACEMENT - ContinuedARCTIC KIT FUEL METERING PUMP, HOSE, AND FITTING REPLACEMENTFigure 1. Fuel Shutoff Valve.Figure 2. Fuel Metering Pump.Figure 3. Arctic Kit Heater Fuel Supply Hose and Shutoff Valve.Figure 4. Fuel Supply Hose Routing.Figure 5. Fuel Supply Hose Routing.Figure 6. Arctic Kit Heater Fuel Supply Hose and Shutoff Valve.Figure 7. Fuel Metering Pump.Figure 8. Fuel Shutoff Valve.USING JACK STANDS TO SUPPORT MACHINEFigure 1. Rear Support.Figure 2. Front Support.Figure 3. Rear Support.Figure 4. Front Support.MECHANICAL GENERAL MAINTENANCE INSTRUCTIONSMECHANICAL GENERAL MAINTENANCE INSTRUCTIONS - ContinuedRELIEVING HYDRAULIC SYSTEM PRESSURECLEANING INSTRUCTIONSCLEANING INSTRUCTIONS CONTINUEDExternal Engine Cleaning.Oil Seals and Flexible Hoses.INSPECTION INSTRUCTIONSREPAIR INSTRUCTIONSBushings and Bushing-Type Bearings.TAGGING INSTRUCTIONSFLUID DISPOSALELECTRICAL GENERAL MAINTENANCE INSTRUCTIONSInspect Connectors for Moisture and CorrosionPerform a Pull Test on Each Wire Terminal ConnectionWIRING HARNESS OPEN CIRCUIT TESTFigure 1. Splicing Wires.HEAT-SHRINKABLE TUBING (ELECTRICAL INSULATING SLEEVING)Figure 3. Military Connector Repair.Figure 4. Weatherproof Connector - Female.Figure 5. Female Terminal.Figure 6. Weatherproof Connector - Female.Figure 7. Weatherproof Connector - Male.Figure 9. Weatherproof Connector - Male.MULTIMETER USAGERELAY INSPECTION AND TESTINGCIRCUIT BREAKER INSPECTION AND TESTINGPREPARATION FOR TRANSPORTFigure 1. Dozer Shown Loaded on M870 Trailer Before Component Removal.Figure 2. Tie Down Locations.PREPARATION FOR CONUS RAIL TRANSPORTFigure 3. Lift Points.PREPARATION FOR MARINE TRANSPORTFigure 5. Tie Down Locations.PREPARATION FOR AIR TRANSPORTFigure 6. Tie Down Locations.Figure 8. Dozer Blade Retainers.Figure 9. Retaining Arm Installation.Figure 10. Hinge Cover Plates.Figure 11. Door Electrical Connector and Washer Hose.Figure 12. Door Hinge Bolts.Figure 13. Door Shipping Brackets.Figure 14. Air Conditioning Hose Connections.Figure 15. Washer Fluid Hoses and Electrical Connectors.Figure 16. Windshield Flange Bolts.Figure 18. Cab Corner Bolts.Figure 19. Slings and Lifting Device Attached to Cab.Figure 20. Headrest Removal.Figure 21. Exhaust Stack Removal.Figure 22. Headrest Installation.Figure 23. Slings and Lifting Device Attached to Cab.Figure 24. Cab Corner Bolts.Figure 26. Washer Fluid Hoses and Electrical Connector.Figure 27. Air Conditioning Hose Connections.Figure 28. Door Shipping Brackets.Figure 29. Door Installation.Figure 30. Electrical and Washer Hose Connections.Figure 31. Hinge Cover Plates.Figure 32. Stowing Door Shipping Brackets.Figure 33. Bolt Removal - Center Belly Plates.Figure 34. Installing Load Support T-bolts.Figure 35. Securing T-bolts.Figure 36. Bolt Installation - Center Belly Plates.Highway and OCONUS Rail TransportFigure 37. Data Plate for Shipping the D6K Dozer with Winch.Figure 38. Data Plate for Shipping the D6K Dozer with Ripper.TORQUE LIMITSFigure 1. Extension Measurement.Figure 4. Measuring a Bolt.Table 1. Torque Limits - SAE Standard Fasteners.Table 2. Torque Limits - Metric Fasteners.Table 3. 37-Degree Flare Fitting.Table 4. Straight Thread with O-ring.Table 6. O-ring Face Seal End.Table 8. Pipe Fitting.SCHEMATICS INDEXSCHEMATICS INDEX - ContinuedCHAPTER 6. SUPPORTING INFORMATIONREFERENCESREFERENCES - ContinuedMAINTENANCE ALLOCATION CHART (MAC) INTRODUCTIONMAINTENANCE FUNCTIONSEXPLANATION OF COLUMNS IN THE MACEXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTSTable 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 1 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 2 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 3 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 4 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 5 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 6 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 7 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 8 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 9 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 10 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 11 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 12 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 13 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 14 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 15 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 16 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 17 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 18 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 19 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 20 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 21 of 22).Table 1. Maintenance Allocation Chart (MAC) for D6K Dozer with Winch and D6K Dozer with Ripper (Sheet 22 of 22).Table 2. Tools and Test Equipment for the D6K Dozer with Winch and D6K Dozer with Ripper.Table 2. Tools and Test Equipment for the D6K Dozer with Winch and D6K Dozer with Ripper - Continued.Table 2. Tools and Test Equipment for the D6K Dozer with Winch and D6K Dozer with Ripper - Continued.Table 2. Tools and Test Equipment for the D6K Dozer with Winch and D6K Dozer with Ripper - Continued.EXPENDABLE AND DURABLE ITEMS LISTTable 1. Expendable and Durable Items for the D6K Dozer with Winch and D6K Dozer with Ripper.Table 1. Expendable and Durable Items for the D6K Dozer with Winch and D6K Dozer with Ripper - Continued.Table 1. Expendable and Durable Items for the D6K Dozer with Winch and D6K Dozer with Ripper - Continued.Table 1. Expendable and Durable Items for the D6K Dozer with Winch and D6K Dozer with Ripper - Continued.SPECIAL/FABRICATED TOOLSFigure 1. Hydraulic Pressure Test Hose and Gauge.INDEXINDEX - CONTINUEDINDEX - CONTINUEDINDEX - CONTINUEDINDEX - CONTINUEDFO-1. Map 1.FO-2. MapFO-3. Sheet 1.FO-4. Sheet 2.FO-5. Sheet 3.FO-6. Sheet 4.FO-7. Sheet 5.FO-8. Sheet 6.FO-9. Sheet 7.FO-10. Sheet 8.FO-11. Sheet 9.FO-12. Sheet 10.FO-13. Sheet 11.FO-14. Sheet 12.FO-15. Sheet 13.FO-16. Sheet 14.FO-17. Sheet 15.FO-18. Sheet 16.FO-19. Sheet 17.FO-20. Sheet 18.FO-21. Sheet 19.FO-22. Sheet 20.FO-23. Sheet 21.FO-24. Sheet 22.FO-25. Sheet 23.FO-26. Sheet 24.FO-27. Sheet 25.FO-28. Sheet 26.FO-29. Sheet 27.FO-30. Sheet 28.FO-31. Sheet 29.FO-32. Sheet 30.FO-33. Sheet 31.FO-34. Sheet 32.FO-35. Sheet 33.FO-36. Sheet 34.FO-37. Sheet 35.FO-38. Sheet 36.FO-39. Sheet 37.FO-40. Sheet 38.FO-41. Sheet 39.FO-42. Sheet 40.FO-43. Sheet 41.FO-44. Sheet 42.FO-45. Sheet 43.FO-46. Sheet 44.FO-47. Sheet 45.FO-48. Sheet 46.FO-49. Sheet 47.