Case 721F Tier 4 Wheel Loader SERVICE MANUAL- PDF DOWNLOAD by www.heydownloads.com

1 - GENERAL INFORMATION 2 - ENGINE 4 - ELECTRICAL SYSTEM

721F Tier 4 Wheel Loader

SERVICE MANUAL

Part number 84487558 1st edition English April 2011

1001 Section 1001 GENERAL TORQUE SPECIFICATIONS

1001-2

TABLE OF CONTENTS TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6

1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

Size

PoundInches

Newton metres

Size

PoundFeet

Newton metres

1/4 inch

108 to 132

12 to 15

7/16 inch

70 to 84

95 to 114

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

3/8 inch

420 to 504

48 to 57

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

Newton metres

3/4 inch

380 to 456

515 to 618

Size

PoundFeet

7/8 inch

600 to 720

814 to 976

7/16 inch

54 to 64

73 to 87

1.0 inch

900 to 1080

1220 to 1465

1/2 inch

80 to 96

109 to 130

1-1/8 inch

1280 to 1440

1736 to 1953

9/16 inch

110 to 132

149 to 179

1-1/4 inch

1820 to 2000

2468 to 2712

5/8 inch

150 to 180

203 to 244

1-3/8 inch

2380 to 2720

3227 to 3688

3/4 inch

270 to 324

366 to 439

1-1/2 inch

3160 to 3560

4285 to 4827

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

NOTE: Use thick nuts with Grade 8 bolts.

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.

Grade 8.8 Bolts, Nuts, and Studs 8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs 10.9

Size

PoundInches

Newton metres

36 to 48

4 to 5

84 to 96

9 to 11

132 to 156

15 to 18

324 to 384

37 to 43

PoundFeet

Newton metres

24 to 36

3 to 4

Size

60 to 72

7 to 8

M10

54 to 64

73 to 87

96 to 108

11 to 12

M12

93 to 112

125 to 150

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

1/4 inch 6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch 6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch 7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch 7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch 9.5 mm

9/16-18

120 to 300

14 to 34

3/8 inch 9.5 mm

9/16-18

300 to 480

34 to 54

1/2 inch 12.7 mm

3/4-16

180 to 504

20 to 57

1/2 inch 12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch 15.9 mm

7/8-14

300 to 696

34 to 79 Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

3/4 inch 19.0 mm

1-1/16-12

40 to 80

54 to 108

3/4 inch 19.0 mm

1-1/16-12

80 to 128

108 to 174

7/8 inch 22.2 mm

1-3/16-12

60 to 100

81 to 135

7/8 inch 22.2 mm

1-3/16-12

100 to 160

136 to 216

1.0 inch 25.4 mm

1-5/16-12

75 to 117

102 to 158

1.0 inch 25.4 mm

1-5/16-12

117 to 187

159 to 253

1-1/4 inch 31.8 mm

1-5/8-12

125 to 165

169 to 223

1-1/4 inch 31.8 mm

1-5/8-12

165 to 264

224 to 357

1-1/2 inch 38.1 mm

1-7/8-12

210 to 250

285 to 338

1-1/2 inch 38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts PoundInches

Newton metres

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS O-ring Boss End Fitting or Lock Nut

O-ring Face Seal End Nom. SAE Dash Size

Tube OD

Thread Size

PoundInches

Newton metres

Thread Size

PoundInches

Newton metres

-4

1/4 inch 6.4 mm

9/16-18

120 to 144

14 to 16

7/16-20

204 to 240

23 to 27

-6

3/8 inch 9.5 mm

11/16-16

216 to 240

24 to 27

9/16-18

300 to 360

34 to 41

-8

1/2 inch 12.7 mm

13/16-16

384 to 480

43 to 54

3/4-16

540 to 600

61 to 68

Thread Size

PoundFeet

Newton metres

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

-10

Nom. SAE Dash Size

5/8 inch 15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread Size

PoundFeet

Newton metres

1-3/16-12

95 to 100

129 to 136

-12

3/4 inch 19.0 mm

1-3/16-12

65 to 80

90 to 110

1-5/16-12

115 to 125

156 to 169

-14

7/8 inch 22.2 mm

1-3/16-12

65 to 80

90 to 110

1-5/8-12

150 to 160

203 to 217

-16

1.0 inch 25.4 mm

1-7/16-12

92 to 105

125 to 140

1-7/8-12

190 to 200

258 to 271

-20

1-1/4 inch 31.8 mm

1-11/16-12

125 to 140

170 to 190

-24

1-1/2 inch 38.1 mm

2-12

150 to 180

200 to 254

FLUIDS AND LUBRICANTS

1002

Section 1002

1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is Selective Catalytic Reduction (SCR)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selective Catalytic Reduction (SCR) - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 5 5 5 6 8 9 11

1002-3

CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ....................................................................................... 13.25 liters (14 U.S. quarts) Total system capacity ................................................................................................... 15.1 liters (16 U.S. quarts) Type of oil ...................................... Case AKCELA No. 1 engine oil - see engine oil recommendations on page 4 Engine Cooling System Capacity........................................................................................................................ 28.4 liters (30 U.S. quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ................................................................................................................... 253 liters (66.8 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 Hydraulic System Hydraulic Reservoir Refill Capacity .............................................................................90.8 liters (24 U.S. Gallons) Total System Capacity............................................................................................... 177.8 liters (47 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ................................................................................. 34 litres (35.9 U.S. quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Standard Front ............................................................................................................ 35 litres (37 U.S. Quarts) Standard Rear.......................................................................................................... 23 litres (24.3 U.S. Quarts) Optional Front ............................................................................................................. 35 litres (37 U.S. Quarts) Optional Rear.............................................................................................................. 35 litres (27 U.S. Quarts) Type of Lubricant ............................................................................................................................. Case Nexplore DEF (Diesel Exhaust Fluid) Total Capacity ..........................................................................................................59.8 litres (15.8 U.S. Gallons) NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil. Brake System Type of Fluid (Same as Hydraulic System)................................................................ Case AKCELA Hy-Tran Ultra®

1002-4

ENGINE OIL RECOMMENDATIONS Case AKCELA No. 1 Engine oil is recommended for use in your Case engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions. If Case AKCELA No. 1 Multi-Viscosity Oil is not available, use only oil meeting API engine oil service category CH-4 (preferred) or CG-4. S e e t h e c h a r t b e l ow fo r recommended viscosity at ambient air temperature ranges.

RH99K130

NOTE: Do not put performance additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case AKCELA lubricants.

BD03A102

BC02N250

1002-5

TRANSMISSION TEMPERATURE CHART

BC04F193

DIESEL FUEL SYSTEM Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption. In very cold temperatures, a mixture of No. 1 and No. 2 diesel fuels is temporarily permitted. See the following Note. NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will restrict the fuel filter and cause the engine to lose power or not start.

Fuel Storage If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel. Keep the fuel storage tank outside and keep the fuel as cool as possible. Remove water from the storage container at regular periods of time. Fill the fuel tank at the end of the daily operating period to prevent condensation in the fuel tank.

The diesel fuel used in this machine must meet the specifications as shown below in, “Specifications for Acceptable No. 2 Diesel Fuel”, or “Specification D975-81” of the American Society for Testing and Materials.

Specifications for Acceptable No. 2 Diesel Fuel API gravity, minimum ............................................................................................................................................. 34 Flash point, minimum ............................................................................................................................60°C (140°F) Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F) Viscosity, at 38°C (100°F) Centistokes ......................................................................................................................................... 2.0 to 4.3 Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum ..................................................................................................... 0.05%

1002-6

What is Selective Catalytic Reduction (SCR)? The main components of the SCR system include the SCR catalyst, the Diesel Exhaust Fluid (DEF)/ AdBlue® injection unit, the DEF/AdBlue® tank, and the DEF/AdBlue® dosing control unit.

How does Selective Catalytic Reduction (SCR) work? During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue® solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue® solution. During cold engine operation at low engine coolant and ambient air temperatures, water vapor will be visible from the exhaust when the engine operates. This water vapor will resemble steam or light white smoke and will dissipate as the engine and machine components warm and is considered normal. NOTE: After engine shutdown, the SCR system will perform a purge cycle, which permits the supply module to continue to run for up to 70 seconds. This is to be considered normal and requires no action from the operator.

What is Diesel Exhaust Fluid (DEF)/AdBlue®? DEF/AdBlue® is a non-toxic aqueous urea solution ( 3 2 .5 % ) w i th a s l i g h t a m m o n i a o d o r u s ed to chemically reduce NOx emissions from heavy-duty diesel powered vehicles. DEF/AdBlue® is neither explosive nor harmful to the environment and is classified under the minimum-risk category of transpor table fluids. DEF/AdBlue® quality is defined by ISO 22241-1. The American Petroleum Institute (API®) has a voluntary certification program for DEF/AdBlue®. To ensure DEF/ AdBlue® satisfies the requirements of ISO 22241. DEF/AdBlue®. API Diesel Exhaust Fluid Certification Mark is a registered trademark of API in the United States and or other countries.

Storage, handling, and transport NOTICE: Storage temperatures above 30 °C (86 °F) greatly reduce the shelf life of DEF/AdBlue®. DEF/AdBlue® has a typical shelf life of 6-12 months. Refer to the SHELF LIFE table below. In order for DEF/AdBlue® to remain in a usable condition, storage requirements need to be met.

• Store between -11 °C (12 °F) and 30 °C (86 °F). • Use only an approved DEF/AdBlue® container. .

• Keep container tightly closed. • Keep container in a cool, well-ventilated area. • Keep away from heat and direct sunlight. Thawing • The machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue®. The machine will still function until the DEF/AdBlue® begins to flow. The SCR system will then function normally. • Do not heat DEF/AdBlue® for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life. NOTICE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue®. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue® mixture will lessen its ability to perform correctly and may cause damage to the SCR components. Handling and supply of additives, if any. • Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, imper vious gloves are recommended. Follow the precautions listed in the SAFETY INFORMATION chapter when handling any service fluid. • No additives are required. NOTICE: Contaminated DEF/AdBlue® can affect the performance of your machine. Follow all instructions in this manual when handling DEF/AdBlue®.

Shelf life Constant ambient storage temperature and minimum shelf life Less than or equal to 10 °C (50 °F) 36 months Less than or equal to 25 °C (77 °F) ¹ 18 months Less than or equal to 30 °C (86 °F) 12 months Less than or equal to 35 °C (95 °F) 6 months Greater than 35 °C (95 °F) -² ¹ To prevent decomposition of DEF/AdBlue®, prolonged transportation or storage above 25 °C (77 °F) should be avoided. ² Significant loss of shelf life: check every batch before use. See your [Brand] dealer for more information on testing.

1002-7 NOTE: The main factors taken into account to define the shelf life in the previous figures are the ambient storage temperature and the initial alkalinity of DEF/AdBlue®. The difference in evaporation between vented and non-vented storage containers is an additional factor. NOTE: The information in this table is for reference only and has been provided by the International Organization for Standardization, Document number ISO 22241-3 Diesel engines - NOx reduction agent AUS 32 - Part 3: Handling, transportation and storage. Disposal • Dispose of DEF/AdBlue® and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal. For machines sold in California CNH must warrant the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owner’s manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owner’s manual for other warranty information. The diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, and other emission-related assemblies.

Glossary Acronym Definition DEF

Diesel Exhaust Fluid

ISO

International Organization for Standardization

MSDS

Material Safety Data Sheet

NOx

Nitrogen Oxide

PPE

Pe r s o n a l Equipment

Protective

SCR

Selective Reduction

Catalytic

ULSD

Ultra Low Sulfur Diesel

1002-8

SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS Requirements

●

The operator must maintain appropriate DEF/AdBlue® levels at all times. The SCR system is compatible with up to 7% bio-diesel fuel.

Impurities are not entering the DEF/AdBlue® tank. The standardized DEF/AdBlue® nozzle matches the filler neck diameter.

●

The DEF/AdBlue® tank is not overfilled, as the DEF/AdBlue® pump will stop when the DEF/AdBlue® tank is full.

●

DEF/AdBlue® is not pumped in the fuel tank, as the DEF/AdBlue® nozzle cannot pump when the magnet is not sensed.

Diesel Exhaust Fluid (DEF)/AdBlue® refilling The DEF/AdBlue® tank cap (1) can be identified by the “blue” color of the cap. A fitting under the cap prevents the insertion of a diesel fill nozzle. NOTE: If any DEF/AdBlue® spills or contacts any surface other than the storage tanks, immediately clean the affected surface with clear water. DEF/AdBlue® will cause corrosion on painted and unpainted metallic surfaces, and may distort some plastic and rubber components. It i s r e c o m m e n d e d t h at D E F /A d B l u e ® f i l l i n g equipment should be used having a fill nozzle/pump with the correct length and diameter, triggered by the magnet in the tank filler neck and with overfill flow cut out. This will ensure that: ●

The screen in the filler neck will not be damaged.

NOTICE: Refilling with a funnel is not recommended as this may lead to damage of the screen in the filler neck. NOTE: The information above has been provided by the International Organization for Standardization (ISO), Document number ISO 22241-4 Diesel engines - NOx reduction agent AUS 32 - Part 4: Refilling interface.

Diesel Exhaust Fluid (DEF)/AdBlue® consumption NOTE: DEF/AdBlue® consumption is highly dependent on engine loads, humidity levels, DEF/AdBlue® fluid concentration, and engine speed.

1002-9

MAINTENANCE SCHEDULE

Variable Periodic (*)

Radiator Coolant Level

Tires

Hydraulic Filter

Alternator, AC, Drive Belt

Air cleaner

Bleed Fuel Filter of Condensation

Clean SCR system DEF tank filter

Fire extinguisher

Check Engine Oil Level

Check Engine Coolant Level

Check Transmission Oil Level

Check Hydraulic Oil Level

Every 10 Hours 1

Every 50 Hours 4

First 100 Hours

Every 500 Hours

* *

Grease Bucket Mounting Fittings

Grease machine and attachments

Change Engine Oil and Filters

100

Replace Fuel Filters

100

Change Hydraulic Filter

100

Change Oil in Axles

100

Check wheel torque

Clean in-line DEF supply filter

Lubricate The Steering Cylinder Pivots - Rod And Closed End (4 Fittings)

100

Grease Front Drive Shaft Support Bearing

100

Lubricate Loader Lift & Cylinder Pivots (10) Z-bar

100

Lubricate Loader Lift & Cylinder Pivots (18) XT

100

Check Cab Air Filter

Check Tire Pressure & Wheel Torque

Check Drive Belt

Trans Clutch Calibration (See Section 6002)

Check Axle Oil Level

500

Check Battery Electrolyte Level

500

Change Engine Oil and Filter

Check ROPS

Drain Fuel Tank Condensation & Water Separator

Replace Fuel Filter

100 100

250 4

250 250

250

1000

500 500 500 500

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

5&6

Every 100 Hours 9

Every 250 Hours

SERVICE POINTS

CHECK

ITEM NUMBER

SERVICE INTERVAL

Initial Service

FREQUENCY IN HOURS

1002-10

Every 1000 Hours

Every 1500 Hours

Every 2000 Hours

Every 3000 Hours Every 6000 Hours

Replace Hydraulic Oil filter

1000

Grease Articulation Fittings

Change crankcase filter

Replace Drive Belt

Replace Cab Air Filter

Change Transmission Oil and Filter

Check Injector Calibration

Check Valve Adjustment (Engine Manual)

1000

Trans Clutch Calibration (See Section 6002)

1000

Change Front & Rear Axle Oil

1500

Change Transmission Oil and Filter

1500

Clean in-line DEF filter

Change Hydraulic Oil

2000

Change Coolant

2000

Replace Engine Air Cleaner

Lubricate cab and door

Valve Clearance (Engine Manual)

Replace DEF supply module filter

Engine Injectors (Engine Manual)

6000

Fuel Pump (Engine Manual)

6000

1000 1000

1000

1000 1000 1000

2000 2000 2000 3000

6000

1002-11

MAINTENANCE POINTS

84397762

See your Operators manual for maintenance of safety related items and for detailed information of the ser vice items on this char t. Operators and service manuals are available for this machine from your dealer.

If you operate the machine in severe conditions, lubricate and service the machine more frequently.

1002-12

METRIC CONVERSION CHART

1003

Section 1003

1003-2

TABLE OF CONTENTS CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1003-3

CONVERSION FACTORS Metric to U.S. MULTIPLY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

Force:

newton newton

3.596 942 0.224 809

ounce force pound force

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C +32

degree F

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969

cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial)

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

gallon/min. (US liquid) gallon/min. (Imperial)

1003-4

U.S. to Metric MULTIPLY

TO OBTAIN

Area:

square foot acre

0.092 903 0.404 686

square meter hectare

Force:

ounce force pound force

0.278 014 4.448 222

newton newton

Length:

inch foot mile

25.4 * 0.304 8 * 1.609 344 *

millimeter meter kilometer

Mass:

pound ounce

0.453 592 28.35

kilogram gram

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Power:

horsepower

0.745 700

kilowatt

Pressure:

lbs/sq. in. lbs/sq. in. lbs/sq. in.

6.894 757 0.069 0.070 303

kilopascal bar kg/sq. cm

Temperature:

degree F

1.8 F - 32

degree C

Torque:

pound/inch pound/foot

0.112 985 1.355 818

newton meter newton meter

Velocity:

miles/hr.

1.609 344 *

kilometer/hr.

Volume:

cubic inch cubic foot cubic yard ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US) gallons (Imperial)

16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

Volume/Time:

gallon/min.

3.785 412

litre/min.

* = exact

Section 2000

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 10 18 18 20

2000-3

ENGINE Removal

STEP 5

STEP 1

BD02N160

Park machine on a level surface and lower bucket to ground. Put articulation lock in LOCKED position.

Put a 28.4 liter (30 U.S. quart) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

STEP 2

STEP 6

BD03A040

Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

STEP 3 Slowly loosen the filler cap for hydraulic reservoir to release air pressure in hydraulic reservoir.

STEP 4 BD02N160

Put a 15.1 liter (16 U.S. quart) container below engine oil drain. Remove cap and drain oil into container. Install cap after oil has drained. NOTE: After draining oil disconnect drain hose from frame for removal with engine.

BD06F108

The master and hood raise switch are located by the battery box. Raise the hood with the hood lift motor. Put master disconnect switch in OFF position. Remove both batte r y cove rs and disconn ec t batteries from the machine.

2000-4

STEP 7

STEP 10

BD03A231

BD06F109

Double up a nylon lifting strap (1) and slide through the exhaust stack (2) on the hood.

Tag and disconnect hood wiring harness connector from rear chassis wiring harness connector.

STEP 8

STEP 11

1 BD03A230

BD03A227

Place a solid steel bar through the strap, raise the hood and release tension on the lifting motor.

STEP 9 2

BD03A226

BD03A228

Remove the pin from the top of the lifting motor.

Remove mount bolt (1) and backup alarm wiring harness clamp from cooler housing. Have another person balance the hood and remove the hood hinge mounting bolts (2) from the cooler frame.

2000-5

STEP 12

STEP 15

BD03A232

BD06F110

Carefully raise and remove hood from loader. Lower hood onto suitable platform and disconnect lifting equipment.

Loosen clamps on turbocharger and air cleaner, remove the intake hose.

STEP 16 STEP 13

BD06F110 BD03A224

Tag and disconnect engine wiring harness connector from air filter restriction switch.

Loosen the clamp on the turbocharger for the after cooler inlet hose.

STEP 17 STEP 14

BD03A115 BD03A225

Loosen clamp on air cleaner intake hose and remove the crankcase ventilation hose.

Loosen the clamp on the after cooler and remove the after cooler inlet hose from the machine.

2000-6

STEP 18

STEP 21

BD06F111

BD06F112

Loosen the clamp on the intake manifold for the after cooler output hose.

Remove the air cleaner and muffler from the bracket.

STEP 22

STEP 19

BD06F113 BD03A118

Loosen the clamp on the after cooler and remove the after cooler outlet hose from the machine.

STEP 20

BD06F114

Remove the four mounting bolts from the belt cover, remove the cover. NOTE: After removing the belt cover remove the cover mounting brackets from the machine frame. BD06F110

Loosen the exhaust clamp from the turbocharger.

2000-7

STEP 23

STEP 26

BD06F115

BD06F118

Remove the drive belt from the engine.

Tag and disconnect the wiring from the alternator.

STEP 24

STEP 27

BD06F116

BD06F119

Loosen clamps and remove lower cooler hose from the engine.

Remove bolt securing wiring harness clamp to engine.

STEP 25

STEP 28 1

1 2

BD06F117

BD06F120

If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness connectors from air compressor clutch connector (1). Remove the thre e m oun tin g b olts (2) for the compressor and set the compressor on the left battery cover.

Remove bolt securing wiring harness clamp (1) to the engine. Remove ground wires (2) from the engine.

2000-8

STEP 29

STEP 32

1 3

BD06F121

Tag and remove the wires from the starter solenoid (3), remove the ground cable (2), and ground strap (1) from the starter.

BD06F111

Tag and remove the grid heater cable.

STEP 33

NOTE: Move the starter cables away from the engine, move the wiring harness away from the engine.

STEP 30

BD03A142

Disconnect the wiring harness from the EDC 7 controller. NOTE: Lifting up on the lever will release the connector from the controller. BD06F146

Disconnect the engine coolant vent hose and root to the rear of the engine.

STEP 34

STEP 31 3 2 1

BD06F123

Remove the fuel line from the top of the EDC 7 controller, plug the line and cap the fitting. BD06F122

Remove the radiator hose (1) from the rear of the engine, remove the heater hose from the rear of the engine (2), remove the clamp bolts and clamps (3) from the bell housing.

2000-9

STEP 35

STEP 38

BD06F127

BD06F124

Tag and disconnect the fuel filter heater wires (1), disconnect the fuel line (2) from the fuel filter head, plug the line and cap the fitting.

Remove the lower cover for the drive shaft.

STEP 39

STEP 36

BD03A172

BD06F125

Remove bolt and clamp.

Remove the drive shaft bolts from the flywheel. Move the drive shaft clear of the flywheel.

STEP 40

STEP 37

Connect suitable lifting equipment to engine lifting brackets. Take up all slack in lifting equipment. Remove the engine mounting bolts and lift the engine enough to gain access to the drain hose, pull the drain hose with the engine.

STEP 41 Slowly raise engine from rear chassis. Be sure all h a r n e s s c o n n e c t i o n s a n d h o s e s h ave b e e n disconnected and are clear of the engine. Remove engine from machine.

BD06F126

Connect and turn on vacuum pump to hydraulic reservoir. Tag and remove the hydraulic lines from the brake system pump, plug the lines and cap the fittings.

2000-10

Installation

1 2

2 3

4 5 6

6 7

7 8

4 5 6 7 BS03B035

1. ENGINE MOUNT BOLT 2. WASHER

3. INSOLATOR UPPER 4. INSOLATOR LOWER

STEP 42

5. WASHER 6. WASHER

7. NUT 8. REMOTE OIL DRAIN HOSE

STEP 47

If engine rubber isolators require replacement, remove and discard isolators (3 and 4). Install new rubber isolator (4), then rubber isolator (3).

STEP 43 Slowly raise engine and move into position over rear chassis. Be sure all harness connections and hoses are out of the way then lower engine. Put washer (5) between front rubber isolator (4) and chassis. Install washer (2), bolt (1), washer (6), and nut (7) in engine isolators. Lower engine into position. BD03A172

STEP 44 Tighten engine mounting bolts to a torque of 244 to 298 Nm (180 to 220 lb-ft).

STEP 45 Disconnect lifting equipment from engine lifting brackets.

STEP 46 Connect engine oil drain hose to frame bracket.

At front of engine, position drive shaft on engine coupling. Install six bolts to secure drive shaft to engine coupling. Tighten the six bolts to a torque of 53 to 62 Nm (39 to 46 lb-ft).

2000-11

STEP 48

STEP 51

BD06F127

Install the lower cover for the drive shaft.

BD06F124

Remove cap from fitting and plug from the hose, connect fuel line (2). Connect fuel filter heater wires (1). Remove and discard tag.

STEP 49

STEP 52

BD06F126

Connect and turn on vacuum pump to the hydraulic reservoir. Remove caps from fittings and plugs from hoses. Connect hoses to brake pump following tags installed during removal. Remove and discard tags. Turn off and disconnect vacuum pump from hydraulic reservoir.

BD06F123

Remove cap from fitting and plug from the hose, connect fuel line to EDC 7.

STEP 53

STEP 50

BD03A142

Connect wiring harness to EDC 7 controller. BD06F125

Install bolt and clamp for fuel return hose.

NOTE: Start the connector on the EDC 7 with lever straight out from EDC 7. Use lever to pull connector into position.

2000-12

STEP 54

STEP 57

1 2

BD06F111

BD06F121

Connect grid heater cable to grid heater. Remove and discard tag.

Install the wires to the starter solenoid (3), install the ground cable (2), and ground strap (1) to the starter. Remove and discard tags.

STEP 55 STEP 58 3

1 2 2

BD06F122

Install the heater hose (2) to the rear of the engine, mount the clamps (3), install the radiator hose (1).

STEP 56

BD06F120

Install bolt securing wiring harness (1) clamp to the engine. Install ground wires (2) to the engine.

STEP 59

BD06F146

Connect the engine coolant vent hose.

BD06F119

Install bolt securing wiring harness clamp to engine.

2000-13

STEP 60

STEP 63

BD06F118

Connect the wiring to the alternator. Remove and discard tags.

BD06F115

Install the drive belt.

STEP 64 STEP 61 1 2

BD06F113 BD06F117

If loader is equipped with air conditioning, mount the compressor using the three mounting bolts (2), connect the engine wiring harness connectors to air compressor clutch connector (1). Remove and discard tags.

STEP 62

BD06F114

Install the cover mounting brackets to the machine frame. Install the belt cover, install the four mounting bolts for the belt cover.

BD06F116

Install lower cooler hose to the engine and tighten the clamps to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

2000-14

STEP 65

STEP 68

BD06F112

BD06F111

Place the muffler and air cleaner on the bracket. Install mounting bolts in air cleaner and tighten, install the mounting bolts in the muffler and leave loose at this time.

Tighten the clamp on the intake manifold for the after cooler output hose.

STEP 69

STEP 66

BD03A115

BD06F110

Install and tighten the exhaust clamp on the turbocharger, tighten the muffler mounting bolts.

Place the after cooler inlet hose on the machine. Tighten the clamp on the after cooler.

STEP 70

STEP 67

BD06F110

BD03A118

Place the after cooler outlet hose on the machine. Tighten the clamp on the after cooler.

Tighten the clamp on the turbocharger for the after cooler inlet hose.

2000-15

STEP 71

STEP 74

BD06F110

Install the intake hose and tighten the clamps on turbocharger and air cleaner.

STEP 72

BD03A232

Carefully raise and place hood over loader. NOTE: Refer to step 7 and 8 of removal for lifting procedure.

STEP 75

BD03A225

Install the crankcase ventilation hose and tighten the clamp on air cleaner intake hose.

BD03A227

STEP 73

BD03A226

BD03A224

Connect engine wiring harness connector to air filter restriction switch. Remove and discard tag.

Have another person balance the hood, install the hood hinge mounting bolts (2) to the cooler frame. Install mount bolt (1) and backup alarm wiring harness clamp to cooler housing.

2000-16

STEP 76

STEP 78

1 BD03A228

BD03A221

Install the pin from the top of the lifting motor, lower and remove lifting equipment.

NOTE: If hood strut is not adjusted properly the hood will be damaged. When a hood is removed and replaced an initial adjustment on the strut is necessary. Adjust between the top of the lift motor adjusting jam nut (1) to the top of the threads (2) to 20 mm (X). With the motor down to its lowest point take a measurement between the left hand side hood bumper and the counter weight, record this measurement (Y). Use the following table to adjust the strut (X).

STEP 77

Hood Adjustment Table Y X (MM) (MM)

BD06F109

Connect hood wiring harness connector to rear chassis wiring harness connector. Remove and discard tag.

Y X (MM) (MM)

2000-17

STEP 79

STEP 85

BD02N160

BD06F108

Check and make sure that drain caps are tight.

Lower the hood with the hood lift motor.

STEP 80

STEP 86

Install a new oil filter on engine. Fill engine with 13.25 liters (14 U.S. quarts) of Case AKCELA Engine Oil (SAE 15W-40).

Put articulation lock in OPERATING position.

STEP 81 If hydraulic reservoir was drained, fill reservoir with 90.8 liters (24.0 U.S. gallons) of Case AKCELA Hy-Tran Ultra® fluid.

STEP 82 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 28.4 liters (30.0 U.S. quarts). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 83 Connect the batteries, install battery covers, put master disconnect switch in ON position.

STEP 84 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wat er. Wh en the coo lan t is at o pe ra ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

2000-18

RADIATOR Removal

STEP 5

STEP 1 Park loader on level surface and lower bucket to ground. Apply parking brake and shut down engine.

STEP 2

BD06F128

Remove bolt and washer securing LH fender. Remove LH fender.

STEP 6 BD03A040

Put articulation lock in LOCKED position.

STEP 3 Put master disconnect switch in OFF position.

STEP 4

BD02N160

Put a 28.4 liter (30.0 U.S. quart) container below radiator drain. Remove radiator cap then remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

STEP 7 BD03A120

Have another person raise and hold the side panel up into the raised position. Remove the two mounting screws for the side panel, remove the panel. NOTE: Photo is of the oil cooler side of the machine, the procedure is the same.

BD03A109

Release catch and tilt air conditioning condenser core up to gain access to upper radiator hose.

2000-19

STEP 8

STEP 11

1 2

BD03A108

BD03A106

Loosen the upper radiator hose clamps, remove the hose.

Remove screws and install lifting eyes (1). Attach suitable lifting equipment to lifting eyes. Remove four mounting bolts (2), remove radiator from machine.

STEP 9

BD06F129

Loose and remove the lower radiator hose from the radiator.

STEP 10

BD03A113

Disconnect overflow hose from radiator. Disconnect connector from coolant level sender.

2000-20

Installation

STEP 15

STEP 12 Move radiator into position above cooling frame. Carefully lower radiator while guiding it into position in cooling frame.

STEP 13

1 BD06F129

At bottom of radiator, install bottom radiator hose. Position and tighten two hose clamps to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 16 BD03A106

Install four lock washers and bolts (2) to secure ra d i a t o r t o c o o li n g f ra m e. D i s c o n n e c t l i f t i n g equipment from lifting eyes. Remove lifting eyes and install screws (1).

STEP 14

BD03A108

At top of cooling system frame, install hose. Position hose clamps and tighten to a torque of 10.1 to 11.3 Nm (90 to 100 lb-inch).

STEP 17

BD03A113

Connect connector to coolant level sender, connect overflow hose to radiator.

BD06F130

When installing fender make sure it is behind the fender mounting bolt.

2000-21

STEP 18

STEP 21

BD06F131

Align the whole in the fender on the bolt.

BD03A120

Have another person raise and hold the side panel up into position. Apply Loctite 242 to the threads, install the two mounting screws for the side panel and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5 pound-inches).

STEP 19

NOTE: Photo is of the oil cooler side of the machine, the procedure is the same.

STEP 22

BD06F132

Align the slots in the fender with the tabs on the body of the machine.

STEP 20 BD02N160

Check that coolant drain cap is tight.

STEP 23 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 28.4 liters (30.0 U.S. quarts). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir. DSC00105.TIF

Push the fender towards the front of the machine and secure it using washer and bolt.

2000-22

STEP 24 Put master disconnect switch in ON position.

STEP 25 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol an d wate r. Wh en the coo lan t is at o pe ra ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir.

WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

STEP 26 Put articulation lock in OPERATING position.

STALL TEST

2002

Section 2002

2002-2

TABLE OF CONTENTS 721F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 6 6 6 7 8 8 8 8 8 9 9

2002-3

721F SPECIFICATIONS Engine with 4 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2185 rpm C. Converter Stall ............................................................................................................................2000 to 2040 rpm D. Hydraulic Stall .............................................................................................................................2028 to 2108 rpm E. Converter & Hydraulic Stall .........................................................................................................1537 to 1617 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F) Engine with 5 Speed Transmission A. Low idle ..........................................................................................................................................870 to 930 rpm Alternate low idle .................................................................................................................................570 to 630 rpm Alternate Accelerated Idle ...............................................................................................................1170 to 1230 rpm B. Maximum No Load RPM .............................................................................................................2100 to 2185 rpm C. Converter Stall ............................................................................................................................1785 to 1825 rpm D. Hydraulic Stall .............................................................................................................................1890 to 1970 rpm E. Converter & Hydraulic Stall .........................................................................................................1423 to 1503 rpm Temperature of the torque converter oil....................................................................... 82° to 104° C (180° to 220° F) Temperature of the hydraulic oil....................................................................................... 54° to 57°C (129° to 134°F)

NOTE: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode with transmission in manual mode and in 3rd gear.

STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.

2002-4

INSTRUMENT CLUSTER DISPLAYS 1. With the engine running, press the up or down key and scroll through the information screens and trip screens. The following sequence is using the down key only. NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

BD06F027

4. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, engine oil temperature in either Fahrenheit or Celsius, as well as oil pressure. BD06F188

2. From the driving screen push the down arrow, as shown.

BD06F184

BD06F183

3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, and fuel level.

5. Push the down button again for the Info 3 screen. T h i s s c r e e n d i s p l ay s t h e t e m p e ra t u r e i n Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil.

2002-5

BD06F169

6. Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

BD06F170

7. By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.

2002-6

PROCEDURE TO HEAT THE OIL Torque Converter

Hydraulic System

1. Sit in the seat.

1. Apply the parking brake.

2. Start the engine and run the engine at low idle.

2. Start the engine and run at full throttle.

3. To measure the oil temperature with the instrument cluster:

A. Press the up or down arrow key.

B. Stop at the info screen with the temperatures that need to be monitored.

B. Stop at the info screen with the temperatures that need to be monitored are on.

4. Place the declutch switch in the OFF position. 5. Place the automatic switch in the manual mode position. Push down and hold the brake pedal for the remainder of this procedure. 6. Release the parking brake. 7. Move the transmission control lever to Forward and turn the transmission control lever to 3rd gear. 8. Increase the engine speed to full throttle and run the engine at this speed for 30 seconds. 9. Decrease the engine speed to low idle and move the transmission control lever to the Neutral position for 15 seconds. 10. Repeat steps 7, 8, and 9 until the temperature of the torque converter oil is 82° to 104°C (180° to 220°F).

4. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height. 5. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).

2002-7

POWER MODE SELECTION 1. After the oil temperatures have been raised to operating temperatures the power mode must be set to “Auto”.

3. Use down arrow to scroll through the menu’s. 4. High light Power Mode and press the enter key. 5. Power Mode Menu A. Max - Maximum power possible B. Standard - Standard operation C. Auto - Will cycle between Max and Standard D. Eco - Limited power for economy 6. High light Auto mode and press the enter key. 7. Press the escape key to return to the normal driving screen.

BD06H038

2. Press and hold the confirmation “enter” button for two seconds to arrive at the above ser vice screen.

2002-8

PERFORMING STALL TESTS Test No. 1 - Torque Converter and Hydraulic Stall Together 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. Run engine at low idle. Push the clutch cutout switch to OFF. Put the transmission in manual mode. Push down and hold the brake pedal for the remainder of this procedure.

Test No. 2 - Torque Converter Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. Run the engine at low idle. 5. Push down and hold the brake pedal for the remainder of this test. 6. Turn the transmission control lever to third gear.

5. Turn the transmission control lever to third gear.

7. Increase the engine speed to full throttle.

6. Increase the engine speed to full throttle.

8. Check the engine speed.

7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms.

9. Decrease the engine speed to low idle.

NOTE: The stall speed must be read while the lift arms are in motion.

10. Place the transmission in neutral and apply the parking brake. 11. Stop the engine.

8. Check the engine speed. 9. Release the bucket control lever. 10. Decrease the engine speed to low idle. 11. Lower the bucket to the ground, place the transmission in neutral and apply the parking brake. 12. Stop the engine.

Understanding the Results of Test No. 1 1. If the engine speed was as specified, the engine, torque converter, transmission and hydraulic system are probably good. 2. If the engine speed was not as specified, do Test No. 2 and 3.

Understanding the Results of Test No. 2 1. If the engine speed was as specified, the engine, torque converter and transmission are probably good. 2. If the engine speed was more than specified, the problem can be in the torque converter or the t r a n s m i s s i o n . S e e S e c t i o n 6 0 0 2 fo r troubleshooting information. 3. If the engine speed was less than specified, do Test No. 3.

2002-9

Test No. 3 - Hydraulic Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Increase the engine speed to full throttle. 4. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. NOTE: The stall speed must be read while the lift arms are in motion. 5. Check the engine speed. 6. Release the bucket control lever. 7. Decrease the engine speed to low idle. 8. Lower the bucket to the ground. 9. Stop the engine.

Understanding the Results of Test No. 3 1. If the engine speed was as specified, the engine and hydraulic system are good. 2. If the engine speed was more or less than specified the main relieef setting may be too low or too high. See Section 8002 for troubleshooting information. 3. If the engine speed was less than specified in all tests, the engine is probably the cause.

2002-10

AFTER COOLER

2003

Section 2003

2003-2

TABLE OF CONTENTS TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 6 6

2003-3

TROUBLESHOOTING AFTER COOLER STEP 1 Park machine on level ground, lower the bucket. Put transmission in neutral, apply the parking brake. Turn off engine.

STEP 2 Raise hood. Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 3 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. If the pressure difference is greater than 60 mbar (0.87 psi), inspect cooler components for damaged or missing parts.

BD03A118

Inspect the after cooler outlet flex hose for leaks or holes and insure that the clamps are tight.

STEP 6

STEP 4

BD03A119 BD03A116

Inspect the turbocharger flex hose for leaks or holes and insure that the clamps are tight.

Inspect the intake manifold flex hose for leaks or holes and insure that the clamps are tight.

STEP 7

STEP 5

BD03A109 BD03A115

Inspect the after cooler inlet flex hose for leaks or holes and insure that the clamps are tight.

Visually inspect top of after cooler for damage or leaks NOTE: If the leak source has not been located, remove and test the after cooler.

2003-4

AFTERCOOLER REMOVAL Removal

STEP 4

STEP 1

BD03A118

Loosen clamps and remove air cooler outlet hose. BD03A116

Loosen clamps and remove turbocharger outlet components.

STEP 5

STEP 2

BD03112

BD03A115

Raise air conditioning/air cooler cover. Support cover with appropriate lifting device. Remove cover support latch.

Loosen clamps and remove air cooler inlet hose.

STEP 6

STEP 3

BD03A111 BD03A119

Loosen clamps and remove Intake hose.

Remove three cover mounting bolts and lift cover off.

2003-5

STEP 7

STEP 10

BD03A109

Unlatch air conditioning condenser clamp.

BD03A113

Remove two bolts, one from each side of the after cooler mounting frame.

STEP 8 STEP 11 L i f t a i r c o o l e r a n d f ra m e f r o m m a c h i n e w i t h appropriate lifting devise.

STEP 12

BD03A107

Rotate air conditioning condenser up and remove the two retaining bolts, one on each side. Move the air conditioning condenser back away from the air cooler

STEP 9

BD03A111

Remove four bolts that mount air cooler in the air cooler frame. Remove air cooler from frame.

BD03A117

Remove the two bolts at the rear of the after cooler mounting frame.

2003-6

Leak Test

Installation STEP 1

BD03A111 BS03B028

Check the core for leaks by closing off the outlet tube and attaching regulated air pressure 550kPa (80psi) to the inlet tube. Submerge the cooler in water and watch for air leakage. NOTE: If leakage is detected replace the after cooler.

Install after cooler in its frame. Install four mounting bolts. Support after cooler with appropriate lifting device. Install the after cooler and frame in the machine.

STEP 2

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

Install two bolts at the rear of the after cooler mounting frame.

2003-7

STEP 4

STEP 7

BD03A107

BD03A116

Position air conditioner condenser and install mounting bolts. Rotate the condenser down and latch.

Install air cooler inlet hose. Tighten clamps at turbocharger outlet.

STEP 8 STEP 5

BD03A115 BD03112

Support cover with appropriate lifting device. Raise air conditioning/air cooler cover over machine. Install cover support latch.

Tighten clamps at air cooler inlet.

STEP 9

STEP 6

BD03A119

Install air cooler outlet hose and tighten clamps at engine intake. BD03A111

Install three cover mounting bolts.

2003-8

STEP 10

STEP 11 Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 12 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. confirm that the pressure difference is less than 60 mBar (0.87 psi).

BD03A118

Tighten clamps at air cooler outlet.

Section 2010

2010

ENGINE INTAKE AIR FILTRATION

2010-2

TABLE OF CONTENTS Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-cleaner Disassembly & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5

2010-3

AIR FILTRATION Pre-cleaner Disassembly & Reassembly

STEP 3

STEP 1

IMG_1682.AI.TIF

Disassemble and remove precleaner from machine. 721F-8469.PNG

Access pre-cleaner located on top of engine compartment hood.

STEP 4

STEP 2

IMG_1680.AI.TIF

Empty debris and clean wipe precleaner with a damp clean cloth. Reassemble/install unit on machine.

IMG_1683.AI.TIF

Loosen wing nut.

2010-4

Primary/Secondary Fillter Element Disassembly

STEP 3

STEP 1 1

IMG_0115.PNGD

Release all clips securing air filter element housing cover. 721F-8469.PNG

Raise engine compartment hood using controls located behind access cover (1). Air filter housing/element (2) is located in main engine compartment on left hand side of engine.

STEP 4

STEP 2

IMG_0142.PNG

Remove cover from air filter element housing.

STEP 5 IMG_0099.PNG

Turn master electric switch “off”.

IMG_0143A.PNG

Remove primary filter element by lifting up on handle

2010-5

STEP 6

STEP 2

IMG_0144A.PNG

IMG_0143A.PNG

Remove secondary filter element from right side of housing. Remove debris from inside filter element housing before installing new filter elements.

Install new primary filter element by sliding it down into housing.

NOTE: Do not clean the seconday filter element. It must be replaced if damaged or clogged.

NOTE: Make sure primary and secondary filter elements form an effective seal.

STEP 3

Primary/Secondary Element Reassembly STEP 1

IMG_0142.PNG

Install housing cover.

STEP 4 IMG_0144A.PNG

Install new secondary filter element by inserting it into positioning slot. NOTE: Make sure filter element is firmly seated into housing.

721F-8508.PNG

Lock clips to secure filter housing cover. NOTE: If cover does not fit properly, recheck filter element installation. Cover will be difficult to install if filter elements are not properly installed.

2010-6

STEP 5

IMG_0099.PNG

Turn master electric power switch “on”. Clear any fault codes. Start machine and confirm problem has been corrected.

Section 2020

2020

SCR SYSTEM SENSORS

2020-2

TABLE OF CONTENTS SCR System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOx Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 6 7 9

2020-3

SCR SYSTEM SENSORS Upstream Exhaust Temperature Sensor Removal NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 3 1

STEP 1

IMG_0912.TIF

Locate exhaust temperature sensor (1) on exhaust system before the catalyst (2). 721F-8469.PNG

STEP 4

Raise the hood using controls located behind the access cover.

STEP 2

IMG_1507.TIF

Loosen hex nut on sensor. IMG_0099.PNG

Turn master electric switch to the “off” position.

2020-4

Upstream Exhaust Temperature Sensor Reinstall

STEP 5

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

IMG_1510.JPG

Remove temperature sensor from exhaust system.

STEP 6 IMG_1510.TIF

Install temperature sensor into exhaust pipe.

STEP 2

IMG_1514.TIF

Remove wire ties securing wire harness to support brackets. Unplug sensor from machine wiring harness and remove it.

IMG_1507.TIF

Secure sensor into exhaust pipe. Sensor torque 40 to 50 Nm (30 to 36 lb ft.). Reconnect sensor to wire harness and secure harness to support brackets using new wire ties.

2020-5

STEP 3

STEP 2

IMG_0099.PNG

Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.

IMG_0099.PNG

Turn master electric switch to the “off” position.

STEP 3

Downstream Exhaust Temperature Sensor Removal

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

IMG_1465.TIF

Locate the exhaust temperature sensor (1) on exhaust system after catalyst (2).

STEP 4 721F-8469.PNG

Raise the hood using controls located behind the access panel.

GRAPHIC_ID

Loosen hex nut and remove sensor from exhaust system.

2020-6

Downstream Exhaust Temperature Sensor Reinstall

STEP 5

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

IMG_1524.TIF

Loosen hex nut and remove P-clamp securing sensor wiring harness to catalyst mounting support bracket. Remove any wire ties securing wiring harness to machine.

STEP 6

IMG_1518.TIF

Install temperature sensor into exhaust system. Secure sensor by tightening hex nut. Sensor torque 40 to 50 Nm (30 to 36 lb ft.).

STEP 2

1528.TIF

Disconnect sensor from wiring harness.

STEP 7 IMG_1524.TIF

Install hex nut and P-clamp holding sensor wiring harness to catalyst mounting support bracket.

GRAPHIC_ID

R e m o ve s e n s o r a n d w i r i n g h a r n e s s a s o n e component from machine.

2020-7

NOx Sensor Removal

STEP 3

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

IMG_1528.TIF

Reconnect sensor to machine wiring harness.

STEP 4

721F-8469.PNG

Raise the hood using controls located behind the access cover.

STEP 2

IMG_0099.PNG

Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected. IMG_0099.PNG

Turn master electric switch to the “off” position.

2020-8

STEP 3

STEP 5

IMG_1465.TIF

Locate NOx sensor (1) on exhaust system down stream of catalyst (2).

IMG_1535.TIF

Loosen hex nut on NOx sensor.

STEP 6 STEP 4 2 1

IMG_1536.TIF IMG_1524.TIF

Loosen hex nut and remove P-clamp (1) holding sensor wiring harness to catalyst mounting support bracket (2).

Remove NOx sensor from exhaust system.

STEP 7 1

IMG_1539.TIF

Locate NOx sensor module (1) on the backside of the SCR catalyst mounting support bracket (2).

2020-9

NOx Sensor Reinstall

STEP 8

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

IMG_1585.TIF

Disconnect NOx sensor module from machine wiring harness.

STEP 9 IMG_1536.TIF

Install NOx sensor into exhaust system.

STEP 2

IMG_1584.TIF

Remove hex bolts securing NOx sensor module to mounting support bracket and remove module.

STEP 10

IMG_1535.TIF

Secure NOx sensor with hex nut. Sensor torque 40 to 60 Nm (30 to 44 lb ft.)

IMG_1544.TIF

Remove wire ties securing NOx sensor wiring harness to machine and remove sensor.

2020-10

STEP 3

STEP 5

IMG_1584.TIF

IMG_1524.TIF

Install NOx sensor module and secure it to mounting support bracket using hex bolts. NOx sensor module torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.).

Secure NOx sensor wire harness with P-clip (1) to catalyst mounting support bracket (2) using hex bolts. Secure wire harness with wire ties where appropriate.

STEP 4 STEP 6

IMG_0099.PNG IMG_1585.TIF

Reconnect machine wiring harness to NOx sensor module.

Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.

Section 2030

2030

SCR CATALYST

2030-2

TABLE OF CONTENTS SCR Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2030-3

SCR CATALYST Removal

STEP 3

NOTE: Do not use impact wrenches on the exhaust system unless sensors are removed.

STEP 1

IMG_0912.TIF

Locate the SCR catalyst (1) and the upstream exhaust gas temperature sensor (2). 721F-8469.PNG

Raise the hood using controls located behind the access cover.

STEP 4

STEP 2

IMG_1507.TIF IMG_0099.PNG

Turn the master electric switch to the “off” position.

Loosen hex nut on sensor.

2030-4

STEP 5

STEP 7

IMG_1510.TIF

Remove upstream exhaust gas temperature sensor.

IMG_1518.TIF

Loosen hex nut and remove downstream exhaust temperature sensor.

STEP 6 STEP 8 1

IMG_1465.TIF

Locate the downstream NOx sensor (1) and exhaust gas temperature sensor (2) after the SCR catalyst.

IMG_1535.TIF

Loosen hex nut on NOx sensor.

STEP 9

IMG_1536.TIF

Remove NOX sensor from exhaust system.

2030-5

STEP 10

STEP 12

IMG_1555.TIF

IMG_1552.TIF

Attach a suitable lifting device and lift strap to the SCR catalyst.

Remove hex bolts from mounting support brackets at front of SCR catalyst.

STEP 11

STEP 13

IMG_1549.TIF

IMG_1560.TIF

Remove clamp, gasket and gasket alignment sleeve at SCR catalyst and mixing pipe connection. Discard clamp and gasket.

Remove hex bolts that secure mounting support bracket to the rear of the SCR catalyst.

NOTE: Gasket alignment sleeve may be attached to mixing pipe. Gasket and clamp should be replaced every time the connection is disassembled.

2030-6

Installation

STEP 14

NOTE: Do not use impact wrenches on the exhaust system unless sensors are removed.

STEP 1

IMG_1560.TIF

Lift SCR catalyst from machine.

STEP 15 IMG_1571.TIF

Attach mounting support bracket to front of SCR catalyst.

STEP 2

IMG_1571.TIF

Remove mounting support bracket from front of SCR catalyst. IMG_1567.TIF

Attach a suitable lifting device and lift strap to the SCR catalyst. Move SCR catalyst into position within the wheel loader.

2030-7

STEP 3

STEP 5

IMG_1560.TIF

IMG_1549.TIF

Install hex bolts into SCR catalyst through rear mounting support bracket.

Install new gasket and clamp on connection between SCR catalyst and mixing pipe. Clamp torque 6 Nm (53 lb in.). Tighten all hex bolts to secure SCR catalyst to mounting support brackets.

NOTE: Leave hex bolts loose until final positioning of SCR catalyst is completed.

NOTE: Gasket and clamp should be replaced every time connection is disassembled. The gasket alignment sleeve press fits into mixing pipe or muffler, whichever fits better.

STEP 4

NOTE: It might be necessary to loosen the turbo clamp, brackets and U-bolts to gain proper alignment of components.

STEP 6

IMG_1552.TIF

Install hex bolts into front mounting support brackets. NOTE: Leave hex bolts loose until final positioning of SCR catalyst is obtained.

IMG_1536.TIF

Install NOx sensor into exhaust pipe downstream of SCR catalyst. Sensor torque 40 to 60 Nm (30 to 44 lb ft.).

2030-8

STEP 7

STEP 9

IMG_0099.PNG

IMG_1518.TIF

Install downstream exhaust gas temperature sensor into exhaust pipe after SCR catalyst. Sensor torque 40 to 50 Nm (30 to 36 lb ft.).

STEP 8

IMG_1507.TIF

Install upstream exhaust gas temperature sensor into mixing pipe upstream of SCR catalyst. Sensor torque 40 to 50 Nm (30 to 36 lb ft.).

Turn the master electric switch to the “on” position. Clear any fault code. Start machine and check for exhaust leaks. Confirm problem has been corrected.

Section 2040

2040

ENGINE INTAKE TEMPERATURE/HUMIDITY SENSOR

2000-2

TABLE OF CONTENTS Intake Temperature/Humidity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2040-3

INTAKE TEMPERATURE/HUMIDITY SENSOR Removal

STEP 3

STEP 1

IMG_1643.TIF

721F-8469.PNG

Raise the engine compartment hood using controls located behind the access cover.

STEP 2

Locate the intake temperature/humidity sensor on air intake pipe between the air filter housing and turbocharger.

STEP 4

IMG_0099.PNG

Turn the master electric switch to the “off” position. IMG_1645.TIF

Disconnect wiring harness plug.

2040-4

Installation

STEP 5

STEP 1

IMG_1646.TIF

Remove hex bolts. IMG_1648.TIF

STEP 6

Remove plug covering hole in intake pipe. Insert sensor.

STEP 2

IMG_1648.TIF

Remove sensor. NOTE: Cover hole in the intake pipe to prevent debris from entering the system.

IMG_1646.TIF

Secure sensor with hex bolts.

2040-5

STEP 3

IMG_1645.TIF

Reconnect wiring harness plug.

STEP 4

IMG_0099.PNG

Turn master electric switch “on”. Clear any fault code. Start machine and confirm that problem has been corrected.

2040-6

Section 2050

2050

DEF/ADBLUE HEATER CONTROL VALVE

2050-2

TABLE OF CONTENTS DEF/ADBLUE Heater Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2050-3

DEF/ADBLUE HEATER CONTROL VALVE Removal

STEP 3

STEP 1

IMG_1693.TIF

721F-8469.PNG

Raise the hood using controls located behind the access cover.

STEP 2

Place a suitable container below radiator drain located behind access cover. Remove radiator cap. Remove drain cap and drain engine coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area prior to draining the system.

STEP 4

IMG_0099.PNG

Turn master electric switch to the “off” position.

IMG_0945.TIF

Locate DEF/AdBlue Heater Control valve next to the DNOx Supply Module on the right hand side of the engine.

2050-4

STEP 5

STEP 7

IMG_1477.TIF

IMG_1484.TIF

Disconnect the machine wiring harness from the DEF/AdBlue heater control valve.

Remove hex bolts securing heater control valve to mounting support bracket.

STEP 6

STEP 8

IMG_1479.TIF

Using a small flat blade screw driver, pull up on the fitting retaining clip and disconnect the coolant inlet/outlet lines from the heater control valve.

1486.TIF

Remove heater control valve from machine.

2050-5

Installation

STEP 3

STEP 1

IMG_0099.PNG

IMG_1484.TIF

Position DEF/AdBlue heater control valve on the mounting support bracket and secure it with hex bolts.

STEP 2

IMG_1477.TIF

Reconnect coolant inlet/outlet lines and wiring harness. Refill engine cooling system.

Turn master electric switch to the “on” position. Clear any fault code. Start the machine and check for engine coolant leaks. Confirm that problem has been corrected.

2050-6

Section 2060

2060

DEF/ADBLUE DNOx SUPPLY MODULE

2060-2

TABLE OF CONTENTS DEF/ADBLUE DNOx Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2060-3

DEF/ADBLUE DNOX SUPPLY MODULE Removal

STEP 3

STEP 1

721F-8490.PNG

721F-8469.PNG

Raise the hood using controls located behind the access cover.

Open the grill located above the radiator/charge air cooler/oil cooler/hydraulic cooler package located just behind the cab.

STEP 4

STEP 2

IMG_0099.PNG

Turn the master electric switch to the “off” position.

IMG_1592.TIF

Raise the right hand side engine compartment side panel of the machine.

2060-4

STEP 5

STEP 7

IMG_1594.TIF

IMG_1607.TIF

Remove thumb screw securing the right hand side inner fender panel.

Mark supply and return line connection locations for reference during reassembly.

STEP 6

STEP 8

IMG_1598.TIF

Remove right hand side inner fender panel.

GRAPHIC_ID

Disconnect DEF/AdBlue supply and return lines from underneath DNOx supply module. NOTE: To disconnect fittings, squirt water into the fitting connection to lubricate the O-ring. Squeeze the locking tabs together while slightly pushing the fitting ends together and then pulling them apart. If the fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be used. NOTE: Use compressed air and water to clean debris from supply and return line connections.

2060-5

STEP 9

STEP 11

IMG_1615.TIF

Remove hex bolts securing the DNOx supply module to the mounting support bracket.

IMG_1626.TIF

Remove DNOx supply module from the machine.

Installation

STEP 10 1

STEP 1 2 1

IMG_1634.TIF

Par tially remove DNOx supply module from its mounting support bracket to gain access to the wiring harness (1). Open the lever (2) and disconnect wiring harness from DNOx supply module.

GRAPHIC_ID

Position the DNOx supply module on its mounting support bracket. Connect wiring harness to back of supply module. Be sure the lever (1) is fully engaged and the plug (2) is fully seated.

2060-6

STEP 2

STEP 4

IMG_1615.TIF

IMG_1600.TIF

Fit the DNOx supply module into mounting support bracket and secure with hex bolts.

Check wire harness and supply lines for proper positioning.

STEP 3

NOTE: Make sure wire harness and supply lines do not contact anything that would cause damage.

STEP 5

IMG_1640.TIF

Reconnect supply and return lines underneath DNOx control module. To connect, push the two fitting ends together until an audible snap is heard. NOTE: Test fitting connections to be sure they are secure. Match supply and return markings to ensure correct connections are made.

IMG_0099.PNG

Turn master switch to “on” position. Clear any fault codes. Start engine. Check for fluid leaks at connections. Confirm problem has been corrected.

2060-7

STEP 6

IMG_1598.TIF

Reinstall inner fender panel and secure using thumbscrew.

STEP 7

IMG_1592.TIF

Lower right hand side engine compartment side panel of machine. Lowe r gr ill located above radiator/charge air cooler/oil cooler/hydraulic cooler package located just behind cab. Close engine compartment hood.

2060-8

Section 2070

2070

DEF/ADBLUE DOSING INJECTOR

2070-2

TABLE OF CONTENTS DEF/Adblue Dosing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2070-3

DEF/ADBLUE DOSING INJECTOR Removal

STEP 3

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.

STEP 1

WHL011MM.PNG

Clean dirt and debris from around engine air intake pipe connections and DEF/AdBlue dosing injector.

721F-8469.PNG

Raise the hood using controls located behind the access cover.

NOTE: The dosing injector is located in the exhaust system upstream from the SCR catalyst and downstream of the turbocharger.

STEP 4

STEP 2 1

WHL010MM.PNG IMG_0099.PNG

Turn master electric switch “off”.

Remove intake pipe (1) connecting turbocharger and charge air cooler. Remove intake pipe (2) connecting air filter housing inlet and support bracket. NOTE: Cover openings to prevent debris entering system.

2070-4

STEP 5

STEP 7 1

WHL026MM.PNG

WHL021MM.PNG

Remove engine coolant line hold down bracket (1) for easier access to dosing injector (2).

Mark location of DEF/AdBlue supply and return lines fo r r e fe r e n c e d u r i n g r e a s s e m b l y. R e m o ve DEF/AdBlue supply and return lines. Cap lines to prevent debris from entering the system

NOTE: Mark location and routing of coolant lines for reference during reassembly.

NOTE: To separate connections, squirt water into fittings to lubricate O-rings. Squeeze fitting locking tabs slightly and push fitting together then pull it apart. If fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be applied.

STEP 6

STEP 8

WHL001MM.PNG

Disconnect dosing injector wiring harness.

WHL023MM.PNG

Remove bolts securing dosing injector into mixing pipe.

2070-5

Installation

STEP 9

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.

STEP 1

WHL025MM.PNG

Remove dosing injector. Cover opening to prevent debris from entering exhaust system.

STEP 10 WHL025MM.PNG

Remove cover from exhaust system and install dosing injector. NOTE: Use markings made during disassembly to determined proper positioning.

STEP 2

WHL027MM.PNG

Inspect dosing injector and service or replace as recommended.

WHL023MM.PNG

Secure dosing injector to exhaust pipe. Torque screws to 7 +/- 0.5 Nm (62 +/- 4 lb in.).

2070-6

STEP 3

STEP 5 1

WHL022MM.PNG

WHL011MM.PNG

Connect DEF/AdBlue supply and return lines and wiring harness to dosing injector.

Remove covers from air intake pipe openings. Install air intake pipe (1) connecting air filter housing inlet and suppor t bracket. Install air intake pipe (2) connecting turbocharger inlet side and charge air cooler.

NOTE: Use marks made during disassembly to determine proper positioning.

STEP 4

STEP 6

WHL026MM.PNG

Secure engine coolant line hold down bracket.

IMG_0099.PNG

Turn master electric switch to “on”. Clear any fault code. Start machine. Check for leaks at DEF/AdBlue, exhaust and intake system connections. Confirm problem has been corrected.

Section 2080

2080

DEF/ADBLUE SUPPLY TANK

2080-2

TABLE OF CONTENTS DEF/AdBlue Supply Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2080-3

DEF/ADBLUE SUPPLY TANK Removal

STEP 3

STEP 1

IMG_1693.TIF

721F-8469.PNG

Raise the hood using controls located behind the access cover.

STEP 2

Place a suitable container below radiator drain located beneath the access cover at rear left hand side of machine. Remove radiator cap. Remove drain cap. Drain coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area.

STEP 4

IMG_0099.PNG

Turn master electric switch “off”.

WHL024MM.PNG

Loosen hex bolts and remove access cover below supply tank to gain access to the drain. NOTE: Use compressed air and water, to clean debris from around drain plug area.

2080-4

STEP 5

STEP 7

WHL029MM.PNG

Place a suitable container below DEF/AdBlue supply tank drain plug. Remove filler neck cap from supply tank. Loosen drain plug and drain DEF/AdBlue. Install drain plug and access cover after DEF/AdBlue has drained.

Remove filler neck/screen assembly and O-ring from supply ta nk by pullin g upwa rd while twisting assembly left and right.

STEP 6

STEP 8

PICT106.TIF

Remove bolts securing filler neck screen assembly. NOTE: Place a plug in filler neck hole to prevent loose screws from entering the supply tank.

PICT109.TIF

WHL002MM.PNG

Remove hex bolts and panel to access supply tank.

2080-5

STEP 9

STEP 11

WHL005MM.PNG

WHL007MM.PNG

Remove rubber boot cover from liquid level/temp sensor sending unit wires, DEF/AdBlue and engine coolant supply lines. Mark wire and hose connection positions.

Pull wire and hose harness up and off to the side out of the way.

NOTE: Use compressed air and water to clean debris from top of DEF/AdBlue supply tank around liquid level/temp sensor sending unit area.

NOTE: Plug all lines to prevent debris from entering the system.

STEP 12

STEP 10

WHL008MM.PNG

WHL006MM.PNG

Unplug wiring harness. Disconnect engine coolant lines and DEF/AdBlue lines by pushing coupling together, squeezing tabs and then pulling connection apart.

Mark location of pickup unit within tank before removal. Twist DEF/AdBlue level temperature sensor unit counter clockwise to loosen it from tank.

2080-6

Installation

STEP 13

STEP 1

WHL009MM.PNG

Lift DEF/AdBlue level/temp sensor unit out of tank. NOTE: Cover tank opening to prevent debris from entering it.

STEP 14

IMG_0910.TIF

Install DEF/AdBlue supply tank into the machine frame cradle and secure it using hex bolts and upper support mounting bracket.

STEP 2

WHL012MM.JPG

Remove hex bolts from mounting support bracket above tank and from bottom of tank. Lift tank up and out of its cradle in the wheel loader frame. WHL009MM.PNG

Lower DEF/AdBlue level temp sensor and pick-up unit into tank.

2080-7

STEP 3

STEP 6

WHL008MM.PNG

Use reference marks from disassembly procedure to position DEF/AdBlue level temp sensor and pick-up unit. Secure by turning it clockwise.

WHL002MM.PNG

Replace access panel and secure using hex bolts.

STEP 7

STEP 4

WHL006MM.PNG

PICT119.TIF

Remove plugs from all lines. Reconnect DEF/AdBlue supply/return and purge lines, engine coolant supply/ return lines and liquid level gage sensor wiring harness. To connect, push connections together all the way, and then pull back to lock.

Reinstall the O-ring onto the DEF/AdBlue supply tank with the radius surface facing upward. NOTE: Lubricate O-ring with petroleum jelly.

STEP 8

STEP 5

WHL005MM.PNG

Replace rubber boot protective cover.

PICT109.TIF

Reinstall filler neck assembly onto supply tank.

2080-8

STEP 9

PICT106.TIF

Secure filler neck assembly using Torx bolts. Refill DEF/AdBlue storage tank and engine cooling system.

STEP 10

IMG_0099.PNG

Turn master electric power switch to “on” position. Clear any fault codes. Start machine and check for DEF/AdBlue and coolant leaks. Confirm that the problem has been corrected.

Section 2090

2090

DEF/ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR/PICK-UP AND HEATER

2090-2

TABLE OF CONTENTS DEF ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2090-3

DEF ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER Removal

STEP 3

STEP 1

IMG_1693.TIF

721F-8469.PNG

Raise the hood using controls located behind the access cover.

STEP 2

Place a suitable container below the radiator drain under the access cover at the left rear of the machine. Remove radiator cap. Remove drain cap and drain engine coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area before draining system.

STEP 4

IMG_0099.PNG

Turn master electric switch to “off” position.

WHL002MM.PNG

Loosen hex bolts and remove cover on right rear of machine to access DEF/AdBLue supply tank.

2090-4

STEP 5

STEP 7

2 1

WHL003MM.PNG

WHL006MM.PNG

Use compressed air or water to clean dirt and debris from DEF/AdBlue supply tank around filler cap/neck (1) and level/temp sensor pickup heater element (2).

Unplug wiring harness. Disconnect engine coolant lines and DEF/AdBlue lines. Disconnect the lines by pushing coupling together all the way to unlock. Squeeze tabs and pull coupling apar t to break connections.

STEP 6

STEP 8

WHL005MM.PNG

Remove rubber cover from DEF/AdBlue level/temp sensor pickup heater wires and supply/return lines. Mark hose and wire connection positioning.

WHL007MM.PNG

Move wiring harness, engine coolant/DEF/AdBlue supply/return and purge line harness off to the side. Plug all lines to prevent debris from entering the system.

2090-5

Installation

STEP 9

STEP 1

WHL008MM.PNG

Mark positioning of the DEF/AdBlue level temp sensor pickup heater unit within thank. Turn unit counter clockwise to loosen it from tank. WHL009MM.PNG

STEP 10

Insert the DEF/AdBlue tank level/temp sensor pickup heater unit into the supply tank.

STEP 2

WHL009MM.PNG

Lift the DEF/AdBlue level/temp sensor pickup heater unit out of tank. Cover the tank opening to prevent debris from entering.

WHL008MM.PNG

Twist DEF/AdBlue tank level/temp sensor pick up heater unit clockwise to secure it to the tank. NOTE: Use markings made during disassembly to position unit correctly in the tank.

2090-6

STEP 3

STEP 5

WHL006MM.PNG

IMG_0099.PNG

Remove plugs from all lines. Reconnect DEF/AdBlue purge and supply/return lines. Reconnect engine coolant supply/return lines. Reconnect liquid level and temperature sensor wiring har ness. Push connections together all the way and then pull back to lock.

Turn master electric switch to the “on” position. Clear any fault codes. Start the machine and check for engine coolant and DEF/AdBlue leaks. Confirm that problem has been corrected.

STEP 6

STEP 4

721F-8490.PNG

WHL003MM.PNG

Replace protective rubber boot cover. Refill engine cooling system. Turn master electric switch “on”. Erase fault code. Star t machine and check for coolant or DEF/AdBlue leaks. Confirm problem has been corrected.

Replace tank access cover and secure with hex bolts.

Section 2100

2100

DEF/ADBLUE SUPPLY FILTERS

2100-2

TABLE OF CONTENTS DEF/adblue supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 6 7 8

2100-3

DEF/ADBLUE SUPPLY FILTERS Removal Supply Tank Filler Neck Screen

STEP 3

STEP 1

IMG_0099.PNG

Turn off master electric switch to the “off” position.

721F-8490.PNG

STEP 4

Locate the DEF/AdBlue supply tank on the right hand side of the machine beneath an access cover.

STEP 2

PICT101.TIF

Open access cover and remove filler cap from filler neck of supply tank. 721F-8469.PNG

Raise the hood using controls located behind the access cover.

NOTE: Use compressed air and water, to clean debris from around filler cap/neck area.

2100-4

STEP 5

STEP 7

PICT106.TIF

WHL018MM.PNG

Remove bolts securing filler cap/neck screen assembly.

Remove plug from filler neck. Rinse screen with water to remove accumulated debris. Reinstall plug into filler hole.

NOTE: Place a stopper into filler neck hole to prevent loose screws and debris from entering supply tank.

STEP 6

NOTE: If the screen is damaged replace it. To replace, remove bolts and separate filler neck from screen. Attach new screen to filler neck and secure with bolts.

Installation Supply Tank Filler Neck Screen STEP 1

2 PICT109.TIF

Remove filler cap/neck screen assembly and O-ring. Pull upwards while twisting assembly left and right. NOTE: Cap opening of supply tank to prevent debris from entering tank. PICT119.TIF

Reinstall O-ring (1) onto supply tank (2) with radius surface facing upward. NOTE: Lubricate O-ring with petroleum jelly.

2100-5

Removal Supply Line Screen

STEP 2

STEP 1 1

PICT122.TIF

Reinstall filler cap/neck screen assembly (1) into supply tank (2).

STEP 3

721F-8490.PNG

DEF/AdBlue supply line screen is located under the engine hood on the right side of engine at rear of machine.

STEP 2

PICT106.TIF

Secure assembly with bolts and remove stopper from filler neck hole. Reinstall supply tank filler neck cap.

STEP 4

721F-8469.PNG

Raise the hood using controls located behind the access cover.

STEP 3

IMG_0099.PNG

Close side cover concealing supply tank. Turn master electr ic switch to “on” position. Lower engine compartment hood.

IMG_0099.PNG

Turn master electric switch to “off” position.

2100-6

STEP 4

STEP 6 2

921F-9194.PNG

IMG_2007.PNG

Locate supply line filter screen housing within supply line between supply tank (1) and DNOx supply module (2) mounted on right hand side of engine.

Remove filter screen from housing with needle nose pliers. Rinse filter screen with water to remove accumulated debris.

NOTE: Use compressed air and water to clean debris from around screen assembly.

NOTE: If filter screen is damaged, replace it.

Installation Supply Line Screen

STEP 5

STEP 1

WHL013MM.PNG

To open fitting, push fitting together, squeeze locking tabs slightly, and then pull apart. NOTE: Squirt water into fitting connection to lubricate O-ring. If fitting will not release, but is free to rotate, O-ring is likely stuck and additional water should be used to free connection.

IMG_2007.PNG

Install filter screen into supply line filter housing.

STEP 2

NOTE: Use a suitable container to catch any fluid discharged during hose and filter disassembly.

WHL013MM.PNG

Reconnect supply line coupling.

2100-7

STEP 3

STEP 2

IMG_0099.PNG

721F-8469.PNG

Turn master electric switch to “on” position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.

Raise the hood using controls located behind the access cover.

STEP 3

Removal DNOx Supply Module Filter STEP 1

IMG_0099.PNG

Turn master electric switch to the “off” position.

STEP 4 721F-8490.PNG

The DEF/AdBlue Supply filter is located inside the DNOx supply module under the hood on the right side of the engine at the rear of the machine.

1 2

921F-9194.PNG

Locate the DNOx supply module (1). The filter element assembly (2) is located on the underside of the module. NOTE: Clean dirt and debris from filter element housing using compressed air and water.

2100-8

STEP 5

STEP 7

WHL015MM.PNG

WHL014MM.PNG

Squirt water into fitting connections to lubricate O-r ings. Disconnect fittings by pushing them together. Then squeeze locking tabs and pull fitting down and off.

Remove filter element (1) from housing (2) by turing it counter clockwise. Discard filter element following local environmental and waste regulations.

NOTE: If the fitting will not release, but is free to rotate, the O-ring is likely stuck and lubrication of the O-ring should be repeated.

Installation DNOx Supply Module Filter STEP 1

STEP 6

2 1

WHL014MM.PNG IMG_2001.PNG

Remove the DEF/AdBlue filter element assembly from DNOx supply module by turning it counter clockwise. Pull straight down and away from module. NOTE: Use a suitable container to catch any fluid discharged during disassembly.

Lubricate filter element O-ring (1) on housing side. Lubricate housing O-ring (2). Install filter element on housing by turing it clockwise. NOTE: Lubricate O-ring with petroleum jelly. NOTE: Hand tighten filter only.

2100-9

STEP 2

STEP 5

IMG_2023.PNG

IMG-0099.PNG

Lubricate filter element O-ring on control module side.

Turn master electric switch to “on” position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.

NOTE: Lubricate O-ring with petroleum jelly.

STEP 3

IMG_2003.PNG

Insert filter housing assembly into DNOx supply module and turn clockwise to tighten. NOTE: Hand tighten filter only.

STEP 4

WHL015MM.PNG

Reinstall DEF/AdBlue supply line. Push connection together and then pull back to make sure it is secure.

2100-10

4001 Section 4001 REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR

4001-2

TABLE OF CONTENTS STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 5 6 8 8 8

4001-3

STARTER Removal

STEP 4

STEP 1 Park machine on a level surface and lower bucket to ground.

STEP 2

BD06F135

Remove the ground strap from the starter, remove the starter mounting bolts, remove the stater.

BD06F133

Raise the engine compartment with lifting motor. Place the master disconnect switch in the OFF position.

STEP 3

BD06F134

Place identification tags on the positive cables and remove the positive cables from the starter.

4001-4

Installation

STEP 7

STEP 5

1 BD06F134

Install and tighten the wires on the starter solenoid. Remove and discard tags.

STEP 8 BC05G047

1. STUDS 2. NUTS

Apply Loctite 747 primer to studs and holes, apply 2 drops of Loctite 271 to each hole and stud. Immediately install and torque studs to 19 to 29 Nm (14 to 21 pound-feet). Allow adhesive to cure for 20 minutes before installing starter.

STEP 6

2 BD06F135

Position the star ter on the machine, attach the ground cable to the bottom mounting stud (2) and install the nut, attach the ground strap and wire to the outer stud (1) and install the nut, install the lower nut. Torque the three nuts to 40 to 50 Nm (29 to 37 pound-feet).

Place the master disconnect switch in the ON position. Lower the engine compartment with lifting motor.

4001-5

ALTERNATOR Removal

STEP 4

STEP 1 Park machine on a level surface and lower bucket to ground.

STEP 2

BD06F137

BD06F133

Raise the engine compartment with lifting motor. Place the master disconnect switch in the OFF position.

STEP 3

BD06F138

Remove four belt cover mounting bolts, remove cover.

STEP 5

BD06F136

Disconnect wires from the alternator.

BD06F139

Use a wrench to move the belt tensioner to loosen the tension on the belt. Remove the belt.

4001-6

Installation

STEP 6

STEP 7

BD06F140

Remove mounting bolts for alternator, remove alternator.

BD06F140

Place alternator onto engine, install mounting bolts for alternator and tighten.

STEP 8

BD06F139

Use a wrench to move the belt tensioner, install the belt. NOTE: Belt routing instructions are on belt cover.

4001-7

STEP 9

STEP 10

BD06F137

BD06F136

Connect wires to the alternator, place rubber boot over positive post.

STEP 11

BD06F138

Install belt cover, install four belt cover mounting bolts and tighten.

BD06F133

Place the master disconnect switch in the ON position. Lower the engine compartment with lifting motor.

4001-8

BELT INSTALLATION

BC05G045

WITH OUT AIR CONDITIONING

BC05G046

WITH AIR CONDITIONING

ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

4002

Section 4002

4002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................................................................... Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................................................................... POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module A, Power converter F1, Secondary steering F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module B, ACC Power F1, DNOX F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module C, Ignition Power F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................................................................... Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reverse Relay (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 8 47 47 47 48 49 49 49 50 50 50 50 51 51 52 52 52 53 54 54 54 55 55 55 55 56 56 57 58 58 59 60 61 61 62 62 63 63 63 64 64 64 65 66 66 67 67 68 68 68 69 69 69

4002-3 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Warning (AIC) Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4002-4 Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4002-5 Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING / ignition SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................................................................... Ignition Power Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCR SYSTEM/ joystick steering/ misc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOX Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Humidity and ambient temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOX Sensor (NOXS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank heater control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DEF Level and tank temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doser metering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DNOX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear View Camera / Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Lock Switch (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Lock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Sense Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockup Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick PVRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FNR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FNR Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick STR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126 126 126 126 126 127 128 128 128 128 129 129 129 130 130 130 130 131 132 132 132 133 134 135 135 135 135 136 137 137 137 137 137 137 137 137 138 138 138 138 138 139 139 139 139 139 139 139 139 139 139 140 140 140 141

4002-6

4002-7

SPECIFICATIONS Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground System Voltage................................................................................................................................................24 volts Batteries Group Size ..........................................................................................................................................................31 Reserve Capacity ................................................................................................................................ 170 minutes Cold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts................................................700 amperes Load of Capacity (Load) Test .............................................................................................................400 amperes Alternator ..................................................................................................................................... 24 volt, 65 amperes Voltage Regulator ............................................................................................................. Solid State, Not Adjustable Starter................................................................................................................................ 24 volt, Solenoid Actuated Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal)................ 68.2 ohms Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohms Fuel Level Sender............................................................................................................................... 33 to 240 ohms Coolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohms Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open) Closing Set point ............................................................................................................................ 2.8 Bar (40 psi) Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi) Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig) A/C High Pressure Switch Closed With Pressure .................................................................................. Above 27.6 ± 0.7 bar (400.3 ± 10.1 psi) Opens With Pressure ..................................................................................Below 20.7 ± 0.7 bar (300.22 ± 10.1 psi) A/C Low Pressure Switch Closed With Pressure .......................................................................................Below 0.3 ± 0.1 bar (4.35 ± 1.45 psi) Opens With Pressure ......................................................................................... Above 1.4 ± 0.2 bar (20.3 ± 2.9 psi) Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi) Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi) Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi) Brake Lamp Pressure Switch (Normally Open) Closing Set point.....................................................4.13 bar (60 psi) Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi) Fuel Filters Heater Resistance At 20° C (68° F) (Nominal) .......................................................................... 1.9 ohms Water Separator Heater At 20° C (68° F) (Nominal)..................................................................................... 1.9 ohms Parking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohms Pilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohms Pilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohms Ride Control Solenoid DC Resistance At 20° C (68° F) (Nominal)............................................................. 22.7 ohms Pin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohms Secondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohms Fan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal).......................................................... 39.3 ohms Fan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................................. 29.3 ohms Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi) Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohms Grid Heater .................................................................................................................................................. 500 ohms Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7) Analog Throttle ..................................................................................Idle Validation Switch Closes At 0.775V ± 0.1V Throttle Position Potentiometer.................................................................................................. 5V Reference ± 0.2V Low Idle Position .............................................................................................................................. 0.4V ± 0.025V High Idle Position ................................................................................................................................. 4.0V ± 0.1V

4002-8

ELECTRICAL WIRE IDENTIFICATION Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

W 0.8 GXL Twist

JMP1, JSS Load Sense

JMP2, JSS Load Sense

Bk 0.8 GXL Twist

JMP1, JSS Load Sense

JMP2, JSS Load Sense

Alternator D+

Lg 1.0 SXL

AD, Alternator D+

ENG, Engine Cab1

Battery Sensing

R 1.0 SXL

Alt_5 Alternator D+

AB_5 Alternator B+

EDC Relay Control

OR 0.8 GXL

EDC7, Engine Controller

SPL_EDC4, Ultrasonic

Doser Valve B+

R 0.8 GXL

DNOX2, NOX Controller

DEFDM, Doser Metering VLV

Work Lights Switched Fused Pwr R 2.0 GXL

SPL-WL, Ultrasonic

ECC, Elect Center C

Brake Lt Control Power

T 1.0 SXL

BTM_C, Cab bottom bulkhd

PBL, Brake Light Press Switch

Back Lt Power

DU1.0 GXL

D-OR, Diode OR

SPL-BCK-LGT, Spl Back Lgt Pwr

Fan Reverse LSD

W 0.8 TXL

AIC-1, Adv Instr Clust 1

ECB, Electrical Center B

Fan Control PWM

W 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Clust 1

Pin Engage Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

YPE, Pin Engage Jumper

Ride Control Sol Pwr

W 1.0 SXL

PRBF, Rollback Press Sw

YRC, Ride Control Option

Horn Power

Or 1.0 SXL

FRONT, Cab Front Chassis

HN1, Horn Power

460

Fan Speed Sensor Signal

Y 1.0 SXL

Eng, Engine-Cab1

FSS, Fan Speed Sens

016B

Pedal Sensor Grnd

DU 0.8 GXL

BTM_C, Cab Bottom Bulkhd

BPP, Pedal Position

017A

Fan Speed Sensor GND

BK 1.0 SXL

GND_ENG7, Tranny, Cool Temp

FSS, Fan Speed Sens

0D_C

DIAG2 GRND

BK 0.8 GXL

DIA_2, Diagnostic

GND_CAB_SPL, Cab Grnd Splice

0E_A

EXHT Temp Up GND

BK 0.8 GXL

UTS, Upstream Temp Sense

DNOX2, Nox Controller

0_29

RTT/Float GND

BK 0.8 GXL

SFL, Return to Travel SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0 29

RTT/Float Ground

Bk 0.8 GXL

SFL, Return To Travel Sw

SPL-BCK-LT-GD2, Spl Back Lgt Gnd

0 AA

Proximity Switch Grnd

Bk 1.0 SXL

PXH, Height Control RTT

SPL-A2, Ultrasonic

0 AB

Proximity Switch Grnd

Bk 1.0 SXL

SPL-A2, Ultrasonic

GND-FC, Ground A

0 AC

Proximity Switch Grnd

Bk 1.0 SXL

PXF, RTD

SPL-A2, Ultrasonic

0 AD

Ride Control Ground

Bk 1.0 SXL

YRC, Ride Control Option

SPL-A1, Ultrasonic

0 AE

Pin Engage Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

YPE, Pin Engage Jumper

4002-9

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

0 AF

Horn Ground

Bk 1.0 SXL

HN2, Horn Ground

SPL-A1, Ultrasonic

0 AG

Front Chassis Ground

Bk 2.0 SXL

SPL-A1, Ultrasonic

GND-FC, Ground A

0 AH

RH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LRF, Lights RH

0 AJ

LH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LLF, Lights LH

0 AK

Park Brake/Warning Ground

Bk 1.0 SXL

SPL-A4, Ultrasonic

BTM_E, CAB BTTOM

0 AL

Brake Warning Press Sw Gnd

Bk 1.0 SXL

PBW, Brake Warn Press Sw

SPL-A4, Ultrasonic

0 AM

RTD Grnd

Bk 1.0 SXL

PXM, RTD

PXT, RTD

0 AN

Park Brake Solenoid Ground

Bk 1.0 SXL

YPB, Park Brake Solenoid

SPL-A4, Ultrasonic

0 AP

Front To Rear Chassis Ground

Bk 5.0 SXL

GND-S1, Ground A

GND-S2, Ground A

0 AS

GRND, JOYSTICK

Bk 1.0 GXL

JSS_FRM, JSS Frame to CAB

SPL_JSS_17, Ultrasonic

0 AT

GRND, JSS VLV

Bk 1.0 GXL

JSS_Valve, JSS HYD Valve

SPL_JSS_17, Ultrasonic

0 AU

GRND, Pilot Dump

Bk 1.0 GXL

SPL_JSS_17, Ultrasonic

JSS_PIL_DUMP, JSS Pilot Dump

0 AV

GRND

Bk 1.0 GXL

SPL_JSS_17, Ultrasonic

GND_JSS, Ground_A

0 AW

Pin Engage GND

Bk 1.0 SXL

YPE1, Pin Engage Jumper

YPE2, Pin_Engage_OPT

Front Washer Ground

Bk 1.0 SXL

FWW, Front Washer

SPL-ENG-GRD, Gnd Spl 6 Pck

0 B1

Back Light Ground

Bk 0.8 GXL

SPC, Pilot Control Switch

SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck

0 B2

Back Light Ground

Bk 0.8 GXL

SFL, Return To Travel Switch

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B3

Back Light Ground

Bk 0.8 GXL

SHC, Height Control Switch

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B4

Back Light Ground

Bk 0.8 GXL

SRTD, Detent Switch

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B5

Back Light Ground

Bk 0.8 GXL

SPE, Pin Engage Switch

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B6

Cab2 Ground

Bk 1.0 GXL

SPL_BCK_LT_GD, SPL Back Lght GRND

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B7

Back Light Ground

Bk 0.8 GXL

SFC, Fan Control Switch

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B8

Front Wiper Motor Ground

Bk 0.8 GXL

GND_CAB2, Ground_A

FWMG, Wiper Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

GND-CAB2, Ground A

0 B10 Hood Ground

4002-10

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cav

Connector

Cav

0 B11 Back Light Ground

Bk 0.8 GXL

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck

0 B12 Hood Down Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

ECC, Elect Center C

0 B13 Back Light Ground

Bk 1.0 GXL

SPL-BCK-LT-GD, Spl Bk Lt Grnd

SPL_WL1, Ultrasonic

0 B14 Back Light Ground

Bk 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B15 Back Light Ground

Bk 0.8 GXL

SBE, Beacon Switch

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B16 Hood Down Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

ECC, Elect CNTR C

0 B17 Back Light Ground

Bk 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B18 Back Light Ground

Bk 0.8 GXL

SDC, Declutch Switch

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B19 Back Light Ground

Bk 0.8 GXL

SDR, Driving Lights Switch

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B20 Back Light Ground

Bk 0.8 GXL

SRC, Ride Control Switch

SPL-BCK-LT-GD2, Spl Bk Lt Grnd

0 B21 Back Light Ground

Bk 0.8 GXL

SBU, Backup Alarm Disc Sw

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B22 Hood Up Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

ECC, Elect CNTR C

0 B23 Back Light Ground

Bk 0.8 GXL

SRWP, Rear Wiper Switch

SPL-BCK-LT-GD, Spl Bk Lt Grnd

0 B24 Back Light Ground

Bk 0.8 GXL

SHZ, Hazard Switch

SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck

0 B25 Hood Up Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

ECC, Elect CNTR C

0 B26 Buzzer/Switch Pad Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

GND_CAB2, Ground A

0 B27 Buzzer Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

BUZ, AIC Buzzer

0 B28 Switch Pad Ground

Bk 0.8 TXL

SW-PD, Switch Pad

SPL-BUZ, Ultrasonic

0 B29 RTT/Float Ground

Bk 0.8 GXL

SPB, Parking Brake Switch

SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck

0 B31 SDA GND

Bk 0.8 GXL

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

SDA, Diff Lock Switch

0 B32 Back Light GND

Bk 0.8 GXL

SRP, Work Lights SW

SPL_BCK_LT_GD, SPL Back Lght GD

0 BA

Bk 5.0 SXL.

GND-PDST, Ground A

GND-PDST2, Ground A

0 BAC EDC7 Ground

Bk 2.0 SXL

SPL-EDC1, Ultrasonic

GND-ENG2, WIF, EDC

0 BAE EDC7 Sender Ground

Bk 1.0 SXL

RECT, Engine Coolant Temp

GND-ENG7, Tranny, Cool Temp

Pedestal Gnd Strap

4002-11

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

0 BAG Hood Grounds (EURO)

Bk 1.0 SXL

GND-ENG4, Rear Lighting

E-HD, Trans Hood

0 BAG Hood Grounds (NA) N

Bk 1.0 SXL

ENG-H, Engine to Hood

GND-ENG4, Rear Lighting

0 BAR WIF Body Ground

Bk 1.0 SXL

GND-WIF, Gnd WIF Ring Term

GND-ENG6, Dedicated

0 BAT Crank Request FGND

Bk 1.0 SXL

Eng, Engine-CAB1

GND_ENG2, WIF, EDC

0 BAU EVGT_2 GND

Bk 1.0 SXL

Turbo, Eng Dash_Turbo

GND_ENG2, WIF, EDC

0 BB

Bk 1.0 SXL

YFR, Fan Reverse Sol Opt

SPL-FAN, Ultrasonic

0 BBA JOYSTICK GROUND

Bk 0.8 GXL

SPL_JSS_1, Ultrasonic

SJS, Joystick_Control_SW

0 BBB JOYSTICK GROUND

Bk 0.8 GXL

SJS, Joystick_Control_SW

SPL_JSS_1, Ultrasonic

0 BBC JOYSTICK GROUND

Bk 0.8 GXL

GND_CAB_SPL2, SPL Back LGHT GD

SPL_JSS_1, Ultrasonic

0 BBD JOYSTICK GROUND

Bk 0.8 GXL

JSS_CAB, JSS CAB

SPL_JSS_1, Ultrasonic

0 BBE JOYSTICK GROUND

Bk 0.8 GXL

SJS_Joystick_Control_SW

SPL_JSS_1, Ultrasonic

0 BBF DNOX2 Module GND

Bk 2.0 SXL

SPL_DCUG, Ultrasonic

DC2_A, Disconnect-Battery

0 BBR Ground

Bk 1.0 SXL

ENG_B, CAB BTTOM

GND_ENG3, SPLC_PK, WSHR MTR

0 BC

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BD

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BE

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BF

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BG

AIC Power Ground

Bk 0.8 GXL

ENG, Engine Cab1

GND-ENG6, Dedicated

0 BH

AIC Power Ground Red

Bk 0.8 GXL

ENG, Engine Cab1

GND-ENG6, Dedicated

0 BJ

AIC Sensor Ground

Bk 0.8 GXL

ENG, Engine Cab1

GND-ENG6, Dedicated

0 BL

Rear Washer Ground

Bk 1.0 SXL

RWW, Rear Washer

SPL-ENG, Ultrasonic

0 BM

Engine Splice Grounds

Bk 1.0 SXL

SPL_ENG, Ultrasonic

GND-ENG3, SPLC-PK, Washer Motor

0 BP

WIF Sensor Ground

Bk 1.0 SXL

GND-ENG2, WIF, EDC

WIF, Water In Fuel Sensor

0 BQ

Fan Speed PWM Sol Grd

Bk 1.0 SXL

YFN, Fan PWM Solenoid

SPL-FAN, Ultrasonic

0 BR

RH Rear Light Ground (EURO)

Bk 1.0 SXL

LRR-E, RH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LLR, LH Rear Comb Lamp

SPL-J1, Ultrasonic

Bk 1.0 SXL

SPL-FAN, Ultrasonic

SPL-ENG, Ultrasonic

Fan Reverse Solenoid Ground

0 BR N LH Rear Light Ground (NA) 0 BS

Fan Control Ground

4002-12

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire 0 BT

Circuit LH Rear Light Ground (EURO)

0 BT N RH Rear Light Ground (NA)

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cav

Connector

Cav

Bk 1.0 SXL

LLR-E, LH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LRR, RH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BU

Fuel Level Sender Ground

Bk 1.0 SXL

RFLG, Fuel Send Ground

GND-ENG7, Tranny, Cool Temp

0 BV

Grid Heater Control Grnd

Bk 0.8 TXL

GHC, Grid Heater Relay

EDC7, Engine Controller

0 BW

Water Separator Htr Ground

Bk 2.0 SXL

GND-ENG1, Start, FFH, WAT_SEP_HTR

WSH, Water Separator Heater

0 BX

Fuel Filter Heater Ground

Bk 2.0 SXL

FFH, Fuel Filter Heater

GND-ENG1, Start, FFH, WAT_SEP_HTR

0 BY

Air Filter Restriction Sw Grd

Bk 1.0 SXL

SPL_ENG, Ultrasonic

PAF, Air Filter Restriction Sw

0 BZ

Fuel Level Sender GND

Bk 1.0 SXL

RFL_23, Fuel_Level_Send

GND_ENG7, Tranny, Cool Temp

0 CA

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

SPL-SEC Ultrasonic

0 CB

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

SPL-SEC Ultrasonic

0 CC

Sec. Steering Press Sw Ground

Bk 1.0 SXL

PSS, Sec. Steer Press Switch

SPL-SEC Ultrasonic

0 CD

Sec. Steering Splice Ground

Bk 1.0 SXL

SPL_SEC, Ultrasonic

GND-SSMOD, Sec Str Chas Gnd

0 CE

Sec. Steering Chassis Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

GND-SSMOD, Sec. Str Chas Gnd

0 CF

Sec. Steering Sol Ground

Bk 1.0 SXL

YSS, Sec. Strg Sol

SPL-SEC, Ultrasonic

0 CG

Sec STR Flyback GND

Bk 1.0 SXL

245F, SEC_STR_FLYBACK

SSD, SEC_STR_Diode

0 CH

Sec STR Flyback GND

Bk 1.0 SXL

245F, SEC_STR_FLYBACK

SSD, SEC_STR_Diode

0 DA

AIC Chassis Ground

Bk 0.8 TXL

GND-PDST1, Ground A

AIC-2, Advanced Inst Cluster 2

0 DAP Back Light Ground

Bk 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LT-GD, Splice Back Light Ground

0 DAV TECM Diagnostic Ground

Bk 0.8 GXL

108F, Diagnostic connector

GND-CAB3D, Ground A

0 DB

AIC Power Ground Red

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-2, ADV Instr Cluster 2

0 DD

Work Lights Grnd

Bk 2.0 GXL

SPL_WL1, Ultrasonic

GND_CAB1, Ground A

0 DE

Neutral Start Relay Control Grd

Bk 0.8 GXL

GND_CAB_SPL2, SPL Back Light GD

ECB, Elect Center B

0 DF

Crank Request Relay Control Ground

Bk 0.8 GXL

CAB_E, CAB-Engine

ECB, Elect Center B

0 DG

Cab Splice Grounds

Bk 1.0 GXL

GND-CAB-SPL, Cab Grd Spl

GND-CAB3, Ground C

0 DH

Diagnostic Connector Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

DIA, Diagnostic

0 DJ

AC Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

ECD, Elect Center D

B10

0 DK

Seat Compressor Motor Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SC, Seat Comp Motor

4002-13

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

0 DM

Speed Sensor Grounds

Bk 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

0 DN

Output Speed Sensor Ground

Bk 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

0 DP

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DQ

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DR

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DS

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DT

Front Wiper/Washer Sw Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SFWW, Front Wiper/Washer

0 DU

Pilot Pressure Sol Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

YPP, Pilot Press Sol

0 DV

Cigar Lighter Ground

Bk 3.0 SXL

CL, Cigar Lighter

GND-CAB3, Ground C

0 DW

AIC Power Ground

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Cluster 1

0 DX

AIC Sensor Ground

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Cluster 1

0 DY

Roof Splice GNDs

Bk 1.0 GXL

SPL_WL1, Ultrasonic

CAB_RF, CAB to Roof Connection

0 DZ

Work Lights GRND

Bk 2.0 GXL

SPL_WL1, Ultrasonic

CAB_RF, CAB to Roof Connection

0 EA

PWR Relay GND

Bk 0.8 GXL

ECB, Elect CNTR B

SPL_SD3, Ultrasonic

0 EB

Ignition Relay Control Ground

Bk 0.8 GXL

SPL_SD3, Ultrasonic

PRM-C1, PRM Signal

0 EC

ACC Relay Control Ground

Bk 0.8 GXL

SPL_SD3, Ultrasonic

PRM-B1, PRM Signal

0 ED

HVAC Grounds

Bk 3.0 SXL

HVAC2, HVAC2

GND-CAB4, Ground C

0 EE

DIODE Suppression Grounds

Bk 0.8 GXL

GND-CAB-SPL, Cab Grnd Spl

140M, DIODE Module

0 EF

Brake Lights Relay Ctrl Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

ECC, Elec CNTR D

0 EG

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light Ground

0 EH

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light Ground

0 EJ

Power Converter Ground

Bk 1.0 GXL

CNV, 24V to 12V Pwr Convert

GND-CAB4, Ground C

0 EK

AUX Power Outlet 1 Grnd

Bk 1.0 GXL

PO1, Power Outlet

GND-CAB5, Ground C

0 EL

AUX Power Outlet 2 Grnd

Bk 1.0 GXL

PO2, Power Outlet

GND-CAB5, Ground C

0 EM

Radio Ground

Bk 0.8 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB-SPL, Cab Grnd Spl

0 EN

Radio Ground

Bk 0.8 GXL

ROOF, Roof to Cab Conn.

RAD, Radio Power

4002-14

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cav

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SRHSTLK, RH Stalk Switch

Splice Pack GND-CAB-SPL2 Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

GND-CAB6, Start, FFH, Water Sep Htr

0 ER

Power Converter Grnd

Bk 1.0 GXL

CNV, 24V to 12V Pwr Conv

GND-CAB4, Ground C

0 ES

Grid Heater Ground

Bk 19.0 SXL

GH-1, Grid Heater

GND-GH1, STRT, FFH, Water Sep Htr

0 ET

Power Relay GND

Bk 0.8 GXL

ECB, Elect CNTR B

SPL_SDL, Ultrasonic

0 EU

PWR Converter RLY CTRL GND Bk 0.8 GXL

SPL_SD3, Ultrasonic

PRM_A2, PRM Signal

0 EV

IGN Latch GND

Bk 0.8 GXL

ECB, Elect CNTR B

SPL_SD1, Ultrasonic

0 EW

Power Relay GND

Bk 0.8 GXL

ECB, Elect CNTR B

GND_CAB_SPL2, SPL Back LGHT GD

0 EY

Power Relay GND

Bk 0.8 GXL

ECD, Elec CNTR D

SPl_SD1, Ultrasonic

0 EZ

Power Relay Control

W 0.8 GXL

ECD, Elec CNTR D

AIC_1, ADV Instr Cluster 1

Bk 2.0 SXL

GND_CB, Ground, On Cooling Box

GND_GL, Ground, Rear Grill

Wire

Circuit

0 EP

Horn Switch Ground

0 EQ

Connector

Cav

0 GB

Starter Relay Control Ground

Bk 1.0 SXL

SRC-1, Relay

GND-ENG1, STRT, FFH, Water Sep Htr

0 HD

Speed Sensor Grounds

Bk 1.0 SXL

TRANS, Cab Transmission

SPL-H2, Ultrasonic

0 HE

Output Speed Sensor Grnd

Bk 1.0 SXL

TRANS, Cab Transmission

OSS, Out Speed Sensor

0 HF

Engine Speed Sensor Grnd

Bk 0.8 GXL Twist

ESS, Engine Speed Sensor

SPL-H2, Ultrasonic

0 HG

Inter Speed Sensor Grnd

Bk 0.8 GXL Twist

ISS, Inter Speed Sensor

SPL-H2, Ultrasonic

0 HH

Turbine Speed Sensor Grnd

Bk 0.8 GXL Twist

TSS, Turbine Speed Sensor

SPL-H2, Ultrasonic

0 HL

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB2, Redundant Brake Sw

GND_TRANS, Ground_Trans

0 HM

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB1, Redundant Brake Sw

GND_TRANS, Ground_Trans

0 HR

HYD FLTR SW Grnd

Bk 1.0 SXL

PHF9, HYD_FLTR_RES_SW

GND_TRANS, Ground_Trans

0 HW

Hot Ground

Bk 1.0 SXL

HOT, Hydraulic Oil Temp Send

GND_TRANS, Ground_Trans

Start Lockout RLY GND

Bk 0.8 GXL

ECC, Elect CNTR C

B10

GND_CAB_SPL2, SPL Back LGHT GD

0 JA

Hood Grounds (EURO)

Bk 1.0 SXL

HD-E, Hood Trans

SPL-J1, Ultrasonic

Bk 1.0 SXL

HD-N, Hood to Engine

SPL-J1, Ultrasonic

0 JA N Hood Grounds (NA)

4002-15

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

0 JB

Backup Alarm Grnd

Bk 1.0 SXL

BU1, Backup Alarm Grnd

SPL-J1, Ultrasonic

0 JC

License Plate Light Grnd

Bk 1.0 SXL

LPL, Lic Plate Light

SPL-J1, Ultrasonic

Camera GND

BK 0.8 GXL

GND_CAB_SPL2, SPL Back LGHT GD

Mon, Camera/Monitor

0 KA

IGN PWR Control GND

Bk 0.8 GXL

ECD, Elec CNTR D

AA3

GND_CAB_SPL2, SPL Back LGHT GD

Telematics GRND

BK 2.0 GXL

TEL, Telematics

CABE2, CAB to ENG2 Bulkhd

0 LA

DNOX2 Module GND

Bk 2.0 GXL

ENG2, ENG Bulkhd 2

SPL_DCUG, Ultrasonic

0 LB

DNOX2 Module GND

Bk 1.0 GXL

DNOX2, NOX Controller

SPL_DCUG, Ultrasonic

0 LC

DNOX2 Module GND

Bk 1.0 GXL

SPL_DCUG, Ultrasonic

DNOX2, Nox Controller

0 LD

DNOX2 Module GND

Bk 2.0 GXL

ENG2, ENG Bulkhd 2

DC2_A, Disconnect-Battery

0 MA

Rear Wiper Motor Grnd

Bk 1.0 GXL

SPL-ROOF, Spl Rood Grnd

RWMG, Rear Wiper Motor Grnd

0 MB

Dome Light Grnd

Bk 0.8 GXL

LDM3, Dome Light Grnd

SPL-ROOF, Spl Rood Grnd

0 MC

Beacon Light Grnd

Bk 1.0 GXL

LBEGRD, Light Beacon Grnd

SPL-ROOF, Spl Rood Grnd

0 ME

LH Rear Work Light Grnd

Bk 1.0 GXL

LLRW, LH Rear Work Light

SPL_WR, Ultrasonic

0 MF

RH Rear Work Light Grnd

Bk 1.0 GXL

LRRW, RH Rear Work Light

SPL_WR, Ultrasonic

0 MG

RH Front Work Light Grnd

Bk 1.0 GXL

LRFS, Front_WK_LT_OPT

SPL_WRK2, Ultrasonic

0 MH

Rear Work Light Grnd

Bk 1.0 GXL

Roof, Roof to CAB Connection

SPL_WR, Ultrasonic

0 MJ

RH Front Work Light Grnd

Bk 1.0 GXL

LRFW, RH Front Work Light

SPL_WK, Ultrasonic

0 MK

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 ML

RH Front Work Light Grnd

Bk 1.0 GXL

SPL_WRK2, Ultrasonic

LRFR, Front_EWK_LT_OPT

0 MN

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 MP

RH Front Work Light Grnd

Bk 1.0 GXL

SPL_WRK2, Ultrasonic

LRFO, Front_WK_LT_OPT

0 MU

LH Front Work Light Grnd

Bk 1.0 GXL

LLFW, LH Front Work Light

SPL_WK, Ultrasonic

0 MV

RH Front Work Light Grnd

Bk 2.0 SXL

Roof, Roof to CAB Connection

SPL_WK, Ultrasonic

0 NA

Hood Grounds (EU)

Bk 1.0 SXL

HD_9, Hood to ENG

SPL_B1

0 NB

Master Disconnect Grnd

Bk 62.0 SGR

DC2, Discon Black Grnd

STTR-GRN, Grid Heater Fuse

0 NC

Battery Disconnect

Bk 62.0 SGR

BT4, Discon Black Grnd

DC1, Disconnect Battery

0 ND

SSM Ground

Bk 62.0 SGR

242F, Chassis Grnd Sec. Strg Motor

GND-SSCHAS, SSM Ground Cable

4002-16

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector

Wire

Circuit

Cav

Connector

Cav

0 NE

Hood Grounds (EU)

Bk 1.0 SXL

SPL_B1

LLR_9, LH_Rear_Comb_LT

0 NF

Hood Grounds (EU)

Bk 1.0 SXL

SPL_B1

LLR_9, RH_Rear_Comb_LT

0 NG

Hood Grounds (EU)

Bk 1.0 SXL

SPL_B1

SPL_J1, Ultrasonic

0 PA

Left Speaker Grnd

Bk 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

0 PB

Right Speaker Grnd

Bk 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

0 RD

Ride Control Grnd

Bk 1.0 SXL

YRC_J, Ride CNTRL_Jumper

YRC_J2, Ride_Control_OPT

0 SC

GRND, Joystick

Bk 0.8 GXL

JSS_ARM, JSS Armrest to CAB

PVRES, JSS Joystick

0 SD

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

CAB_ARM, CAB to Armrest

0 SE

GRND

Bk 0.8 TXL

SPL_JSS_10, Ultrasonic

CAN_MOD_2, JSS can mod

0 SF

GRND

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

Cab to JSS Frame

0 SG

Common

Bk 0.8 GXL

SPL_JSS_10, Ultrasonic

Arm_Pos, Arm position

0 SH

GRND, CAN MOD

Bk 0.8 GXL

JSS_ARM, JSS Armrest to cab

SPL_JSS_10, Ultrasonic

0 SJ

GRND, CAN MOD

Bk 0.8 GXL

SPL_JSS_9, Ultrasonic

CAB_ARM, Cab to Armrest

0 SK

GRND, CAN MOD

Bk 0.8 GXL

CAB_ARM_FRM, Cab to Arm to Frm

SPL_JSS_9, Ultrasonic

0 SL

Ground

Bk 0.8 GXL

JSS_RLY, Relay K2

87A

SPL_JSS_9, Ultrasonic

0 SM

GRND, Joystick

Bk 0.8 GXL

JSS_CNT, JSS Controller

SPL_JSS_20, Ultrasonic

0 SN

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_20, Ultrasonic

JSS_CNT, JSS Controller

0 SP

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

R1, Resistor

0 SR

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

JSS_CNT, JSS Controller

0 SS

GRND, Joystick

Bk 0.8 GXL

JSS_197F, Main_CAB_FNR

FNR_RLY, Relay K2

87A

0 ST

GRND, Joystick

Bk 0.8 GXL

FNR_RLY, Relay K2

SPL_JSS_9, Ultrasonic

0 SU

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_20, Ultrasonic

SPL_JSS_9, Ultrasonic

DEF Sensor GND

Bk 0.8 GXL

UBJ, DEF Level Temp

Dnox2, NOX Controller

0 TA

DEF Sensor GND

LU 0.8 GXL

UBJM, DEF Level Temp

DTLTS, DEF_Tank_Level_Temp_Sensor

EXHT Temp DWN GND

Bk 0.8 SXL

DNOX2, NOX Controller

DTS, Downstream Temp SENS

12ACC Ignition Switch ACC Power

W 0.8 GXL

S-KEY, Ignition Switch

SPL-ACC, Ultrasonic

12ACC ACC PRM Control Power B

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-B1, PRM Signal

CS0

4002-17

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

12ACC Power Converter PRM Control C Power

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-A2, PRM Signal

12V Pwr To Outlet 1

Or 1.0 GXL

PO1, Power Outlet

ECB, Elect Center B

AA1

12V A 12V Pwr To Outlet 2

Or 1.0 GXL

PO2, Power Outlet

ECB, Elect Center B

AA2

12V B 12V Fused Pwr to Radio

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

ECB, Elect Center B

AA9

12V C 12V Switched Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-12V, Ultrasonic

12V D Plug 1 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

12V E Plug 2 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

12V F Radio 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

12V G 2 Way Radio 12V Switched Pwr

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

A10

12V H 12V Fused Power to Radio

Or 0.8 GXL

ROOF, Roof to Cab Conn.

SPL-RAD, Ultrasonic

12V

12V HA

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

12V HB

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

13A

EVGT Relay

Or 0.8 TXL

Evgt_4, EVGT

EDC7, Engine Controller

13B

EVGT Relay PWR

Or 1.0 GXL

Turbo, ENG Dash_Turbo

EVGT_4, EVGT

13C

Fuel Shutoff Fused Power

Or 1.0 SXL

DC3, Fuel Solenoid Disc

DISC, Disconnect Engine

13C A Fuel Shutoff Fused Power

Or 1.0 SXL

ENG-D, Disc Harness

ENG, Engine Cab1

13C B Fuel Shutoff Fused Power

Or 1.0 SXL

CAB-E, Cab Engine

ECA, Elect Center A

Ignition Switch Pwr

Or 1.0 GXL

S-KEY, Ignition Switch

SPL-PK1, Slice 3-4 Way

13K A Ignition Switch Pwr

Or 1.0 GXL

TDM, Time Delay Module

SPL-PK1, Slice 3-4 Way

13K B Ignition Switch Pwr

Or 1.0 GXL

SPL-PK1, Slice 3-4 Way

PRM-A1, PRM Signal

13K C Ignition Switch Pwr

Or 1.0 GXL

SPL-PK1, Slice 3-4 Way

ECB, Elect Center B

Fuel Shutoff Fused Power

Or 1.0 SXL

DC4, Fuel Sol Disconnect

DISC, Disconnect Engine

13M A Fuel Shutoff Fused Power

Or 0.8 TXL

ENG-D, Disconnect Harness

EDC7, Engine Controller

13K

13M

14 5

Alternator D+

LG 1.0 SXL

ENG, Engine-CAB1

ALT_5, Alternator D+

14 A

Alternator D+

LG 0.8 GXL

SPL_ALT, Ultrasonic

215F, Alternator Resistor

14 AB Alternator D+

LG 0.8 GXL

SPL_ALT, Ultrasonic

CAB_E, CAB-Engine

14 AC Alternator Running

LG 0.8 GXL

SPL_ALT, Ultrasonic

TEL, Telematics

16R C FNR Reverse Signal

LU 0.8 GXL

JSS_197M, FNR-Main_CAB

RVS_DIODE, Diode ASSY

SW-PD, Switch Pad

SPL_SW_PD, Ultrasonic

17P A Switch Pad Power From AIC Pwr Or 0.8 TXL

4002-18

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

17P B SW Pad PWR from AIC PWR

Or 0.8 TXL

SPL_SW_PD, Ultrasonic

AIC_1, ADV Instr Cluster 1

17P C B+ CAN MOD

Or 0.8 GXL

SPL_SW_PD,Ultrasonic

JSS_CAB, JSS CAB

17P D B+ CAN MOD

Or 0.8 GXL

SPL_JSS_18, Ultrasonic

CAB_ARM, Cab to Armrest

17P E B+ CAN MOD

Bk 0.8 TXL

JSS_ARM, JSS Armrest to CAB

CAN_MOD_2, JSS CAN MOD

17P F B+ JSS Controller

Or 0.8 GXL

SPL_JSS_18, Ultrasonic

JSS_CNT, JSS Controller

17P G B+ Joystick

Or 0.8 GXL

SPL_JSS_18, Ultrasonic

CAB_ARM_FRM, Cab to Arm to Frm

LH High Beam Fused Power

Or 2.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18B A LH High Beam Fused Power

Or 2.0 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH High Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

18C A RH High Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

LH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18D A LH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

18E A RH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

LH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18F A LH Position/Tail Fused Power

Or 0.8 GXL

CABE2, CAB to ENG2 Bulkhd

SPL-POS-L, Ultrasonic

LH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG Bulkhd 2

ENG-H, Engine to Hood

18F B LH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG Bulkhd 2

LLR-E, LH Rear Comb Light

LH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

LLR-N LH Rear Combination Light

18F C LH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-L, Ultrasonic

ECB, Electric Center B

AA7

18F E LH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-L, Ultrasonic

18F F LH Position/Tail Fused Power

Or 1.0 SXL

HD-9, Hood to Engine

LLR-9, LH Rear Comb Light

RH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-R, Ultrasonic

ECB, Elect Center B

18G A RH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

RH Position/Tail Fused Power

Or 1.0 SXL

SPL-POS-NA, Ultrasonic

LRR, RH Rear Combination Light

18G D Licence Plate Light Fused Pwr

Or 1.0 SXL

SPL-POS, Ultrasonic

E-HD, Trans Hood

18G E Licence Plate Light Fused Pwr

Or 0.8 GXL

HD-E, Hood Trans

LPL, Licence Plate Light

18B

18C

18D

18E

18F

18F AN

18F BN

18G

18G CN

AA3 3 AA4 2 AA6 2 AA5

AA8

4002-19

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire 18G EN

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

Licence Plate Light Fused Pwr

Or 1.0 SXL

LPL, Licence Plate Light

SPL-POS-NA, Ultrasonic

18G F RH Position/Tail Fused Power

Or 0.8 GXL

CABE2, CAB to ENG2 Bulkhd

SPL-POS-R, Ultrasonic

18G G RH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-R, Ultrasonic

18G H RH Position/Tail Fused Power

Or 1.0 SXL

ENG2, Engine Bulkhd 2

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

ENG2, Engine Bulkhd 2

ENG-H, Engine to Hood

18G J RH Position/Tail Fused Power

Or 1.0 SXL

LRR-E, RH Rear Combination Light

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

SPL-POS-NA, Ultrasonic

18G K RH Position/Tail Fused Power

Or 1.0 SXL

HD-9, Hood to Engine

SPL-P9,

18G L LIC Plate Fused Power

Or 1.0 SXL

SPL-P9,

LPL, LIC_PLATE_LIGHT

18G M RH Position/Tail Fused Power

Or 1.0 SXL

SPL-P9,

LRR-9, RH Rear Combination Light

18J B EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J C EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J D EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J E EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J F

Or 3.0 GXL

PRM_D1, PRM Output

SPL-EDC4, Ultrasonic

18J H Water In Fuel Sensor Fused Pwr Or 1.0 GXL

SPL-EDC2, Ultrasonic

WIF, Water In Fuel Sensor

18K A Diagnostic Fused Power

Or 0.8 GXL

ECC, Elect CNTR C

SPL_PK1, Splice 3-4 way

18K B Diag Fused B+

Or 0.8 GXL

SPL_PK1, Splice 3-4 way

DIA_2, Diagnostic

18K C Telematics FSD Power

Or 0.8 GXL

SPL_PK1, Splice 3-4 way

TEL, Telematics

18K D Diag Fused B+

Or 0.8 GXL

SPL_PK1, Splice 3-4 way

DIA, Diagnostic

Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

ECA, Elect Center A

18N A Blower Motor Fused Power

Or 0.8 GXL

SPL-BLWR, Ultrasonic

HVAC1, HVAC1

18N B Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

HVAC2, HVAC2

18S A B+, JSS Fused

Or 0.8 GXL

ECA, Elect CNTR A

SPL_JSS_3, Ultrasonic

18S B B+, JSS Fused

Or 0.8 GXL

SPL_JSS_3, Ultrasonic

SJS, Joystick_Control_SW

18S C B+, JSS Fused

Or 0.8 GXL

JSS_CAB, JSS CAB

SPL_JSS_3, Ultrasonic

18S D B+, JSS Fused

Or 0.8 GXL

CAB_FRM, CAB to JSS Frame

CAB_ARM_FRM, CAB to ARM to FRM

18G HN

18G JN

18N

EDC7 Fused Power

4002-20

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

From Connector Color, Size, and Material

Connector

Or 1.0 SXL

JSS_PIL_PR, JSS Pilot Pressure

Or 0.8 GXL

ECA, Elect CNTR A

18T A DNOX2 SW B+

Or 1.0 SXL

ENG2, ENG Bulkhd 2

18U A DNOX2 Module B+

Or 3.0 GXL

18U B DNOX2 BATT

18S E B+, JSS Fused

LG = Light Green G = Green P = Purple

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

JSS_FRM, JSS Frame to Cab

A10

CABE2, Cab to ENG2 Bulkhd

DNOX2, NOX Controller

PRMB_L2, B+ Power

CABE2, Cab to ENG2 Bulkhd

Or 3.0 GXL

ENG2, ENG Bulkhd 2

DNOX2, NOX Controller

18U C DNOX2 BATT

Or 3.0 GXL

PRMB_L2, B+ Power

CABE2, Cab to ENG2 Bulkhd

18U D DNOX2 BATT

Or 3.0 GXL

ENG2, ENG Bulkhd 2

DNOX2, NOX Controller

TRANS, Transmisson-CAB

OSS, Out Speed Sensor

18T

19A

DNOX SW B+

Output Speed Sensor Fused Pwr Or 1.0 SXL

19A A Brake Declutch Sw Fused Pwr

Or 1.0 SXL

TRANS, Transmisson-CAB

PBD, Dec. Pressure Switch

19A B FNR Switched Fused Power

Or 0.8 GXL

197M, FNR Main Cab

SPL-FNR, Ultrasonic

19A C FNR Switched Fused Power

Or 0.8 GXL

197F, Main Cab FNR

SPL-TRNS-PWR, Trans Pwr

19A D Trans Enable Switch Fused Pwr

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A E AIC Fused Power

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A F Trans Enable Switch Fused Pwr

Or 0.8 GXL

SPL-TRNS-PWR, Trans Pwr

SPL-D15, Ultrasonic

19A G FNR Sw Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

SFNR, FNR Switch

19A H Trans Shifter Fused Power

Or 0.8 GXL

TS1, Transmission Shifter

SPL-TRNS-PWR, Trans Pwr

19A K TECM Fused Power

Or 0.8 TXL

SPL-TRANS-PWR, Trans Pwr

TECM, Trans

19A L Park Brake Switched Fused Pwr

Or 0.8 GXL

SPB, Parking Brake Switch

SPL-PBS, Ultrasonic

19A M Output Speed Sensor Fused Pwr Or 0.8 TXL

CAB-T, Cab Transmission

SPL-TRNS-PWR, Trans Power

19A N Trans Fused Power

Or 1.0 GXL

SPL-TRANS-PWR, Trans Pwr

ECA, Elect Center A

19A P Backup Alarm Relay Control Fused Power

Or 1.0 GXL

SPL-TRANS-PWR, Trans Pwr

ECD, Elect Center D

AA10

19A Q Trans/Auto Switch Fused Power

Or 0.8 GXL

STA, Trans Auto Switch

SPL-TRANS-PWR, Trans Pwr

19A R Declutch Switch Fused Power

Or 0.8 GXL

SDC, Declutch Switch

SPL-TRANS-PWR, Trans Pwr

19A T Brake Declutch Switch Fused Power

Or 0.8 GXL

CAB-T, Cab-Transmission

SPL-TRANS-PWR, Trans Pwr

19A U Trans Kick Down Switch Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

20M, Trans Kick Down

19A V FNR Switch Fused Power

Or 0.8 GXL

SFNR, FNR Switch

SPL-FNR, Ultrasonic

19A W Diagnostic Conn. Fused Power

Or 0.8 GXL

108F, Diagnostic Connector

SPL-TRANS-PWR, Trans Pwr

4002-21

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire 19B

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

49a

ECA, Elect Center A

19B A FNR SW Fused PWR

W 0.8 GXL

FNR_RLY, Relay K2

JSS_197M, FNR-MAIN_CAB

19B B FNR SW Fused PWR

Or 0.8 GXL

CAB_FNR, MAIN_CAB_FNR

FNR_RLY, Relay K2

19B C FNR SW Fused PWR

Or 0.8 GXL

ARM_FNR, FNR-MAIN_CAB

SPL_AJ, Ultrasonic

19B D FNR SW Fused PWR

Or 0.8 GXL

21M, Trans_KICK-DOWN

SPL_AJ, Ultrasonic

19B E FNR SW Fused PWR

Or 0.8 GXL

SAJ, FNR_SWITCH

SPL_AJ, Ultrasonic

19B F FNR SW Fused PWR

Or 0.8 GXL

SAJ, FNR_SWITCH

SPL_AJ, Ultrasonic

19C A Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECA, Elect Center A

19C B Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

19C C Pilot Ctrl Fused Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

19C D Ride Control SW Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

SRC, Ride Control Switch

19C E Pilot Control SW FSD Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

TEL, Telematics

19C F Pilot Control SW Fused Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

SPC, Pilot_Control_Switch

19D A Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECA, Elect Center A

19D B Parking Brake Relay Fused Pwr

Or 0.8 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

19D C Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

19E A AIC Wake Up Ignition

Or 0.8 TXL

SPL_AP, Ultrasonic

ECA, Elect Center A

Turn Signal Fused Power

19H

Backup Alarm B+

Or 1.0 GXL

ECA, Elect Center A

ECD, Elect Center D

A10

19J

Front Wiper Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

ECA, Elect Center A

19J A Front Wiper Motor Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

FWM, Front Wiper Motor

19J B Front Wip Wash Sw Fused Pwr

Or 0.8 GXL

SFWW, Front Wiper/Washer

SPL-PK3, Splice 3-4 Way

19J C Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

SPL-FW, Ultrasonic

19J D Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

19J E Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

Or 0.8 GXL

SPL-FW, Ultrasonic

K-WCO, Wiper Cutout

Or 1.0 GXL

SPL-RWW, Ultrasonic

ECA, Elect Center A

19K A Rear Wiper Sw Fused Pwr

Or 1.0 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K B Rear Wip Wash Fused Pwr

Or 0.8 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19J F

Front Wiper Relay LS Control Fused Power

19J G Wiper Cutout Relay Fused Pwr 19K

Rear Wiper Fused Pwr

4002-22

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

19K C Rear Wiper Motor Fused Pwr

Or 1.0 GXL

CAB-RF, Cab to Roof Connect

SPL-RWW, Ultrasonic

19K D Rear Wiper Motor Fused Pwr

Or 1.0 SXL

ROOF, Roof to Cab Connect

RWM, rear Wiper Motor

Pwr Converter Fused Power

Or 3.0 GXL

PRM-E1, PRM Output

SPL-CNV, Ultrasonic

19L A Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

19L B Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

Sec. Steering Accessory Fused Pwr

Or 0.8 GXL

CAB-T, Cab Transmission

ECA, Elect Center A

19M A Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19M C Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19L

19M

19N

Seat Compressor Fused Pwr

Or 1.0 GXL

SC, Seat Compressor Motor

ECA, Elect Center A

19P

Pin Engage/Fan Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECA, Elect Center A

19P A Pin Engage Sw Fused Pwr

Or 0.8 GXL

SPE, Pin Engage Sw

SPL-PIN, Spl Back Lgt Pwr

19P C Fan Rev Sw Fused Pwr

Or 0.8 GXL

SFC, Fan Control Switch

SPL-PIN, Spl Back Lgt Pwr

19P D Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19P E Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19R

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

SPL-2 Ultrasonic

19RR

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

ECA, Elect Center A

19R A Sec. Steering Ign Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19R C Sec. Steering Ign Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19R D Alternator Resistor Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

216F, Alternator Resistor

19R E Sec. Steering Ign Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

CAB-T, Cab Transmission

19S1

Sec. Steering Fused Pwr

Or 3.0 GXL

PRM_A1, PRM Output

SPL_19S, Ultrasonic

19S2

Sec. Steering Fused Pw

Or 1.0 GXL

SPL_19S, Ultrasonic

CAB_T, Cab-Transmission

19S1 E Sec. Steering Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19S1 X Sec. Steering Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Module Trans

19S B AIC Delay Fused Power

Or 0.8 GXL

SPL-DKY3, Ultrasonic

ECC, Elect Center C

19S C AIC Delay Fused Power

Or 0.8 TXL

SPL-DKY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19S D AIC Delay Fused Power

Or 0.8 TXL

SPL-DKY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

4002-23

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

19S E AIC BATT B+

Or 1.0 GXL

SPL_AP, Ultrasonic

AIC_1, ADV Instr Cluster 1

19S F AIC BATT B+

Or 1.0 GXL

SPL_AP, Ultrasonic

AIC_2, ADV Instr Cluster 2

19T A Fused_Batt_Pwr

Or 0.8 TXL

TECM, Trans

SPL_D17, Ultrasonic

19T B Fused_Batt_Pwr

Or 0.8 TXL

TECM, Trans

SPL_D17, Ultrasonic

19T C Fused_Batt_Pwr

Or 0.8 TXL

ECC, Elect CNTR C

A10

SPL_D17, Ultrasonic

Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect CNTR C

19U A Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect CNTR C

19U B Beacon Dome Lt Fused Pwr

Or 1.0 GXL

SPL-LT, Ultrasonic

ECC, Elect CNTR C

19U C Dome Lt Fused Pwr

Or 0.8 GXL

ROOF, Roof to Cab Connection

LDM1, Dome Light B+

19U D Dome Lt Fused Pwr

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U E Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect CNTR C

19U F Door Sw Fused Power

Or 0.8 GXL

ROOF, Roof to Cab Connection

DS, Door Switch

19U G Door Sw Fused Power

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U H Beacon Switch Fused Power

Or 1.0 GXL

SBE, Beacon Switch

SPL-LT, Ultrasonic

19U

19W

Cigar Lighter Pwr

Or 3.0 GXL

CL, Cigar Lighter

ECC, Elect CNTR A

19Y

Hood control Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect CNTR C

19Y A Hood Up Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect CNTR C

19Y B Hood Down Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect CNTR C

19Y C Hood Switch Fused Power

Or 1.0 GXL

CABE2, Cab to Eng2 Bulkhd

SPL-HOOD, Ultrasonic

19Y D Hood Switch Fused Power

Or 1.0 GXL

ENG2, Engine Bulkhd 2

HD, Hood Switch

Driving Lights Sw Fused Power

Or 1.0 GXL

SPL_DR, Ultrasonic

ECC, Elect CNTR C

19Z A Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL_DR, Ultrasonic

19Z B Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL_DR, Ultrasonic

19Z C High Beam Flash Fused Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56d

SPL_DR, Ultrasonic

Cab CB Protected Power

R 19.0 SXL

P_C3, B+ Pwr FRM PRMD

CBPW, Cab Power

1CB A Cab CB Protected Power

R 19.0 SXL

P-A3, B+ Power

CAB-PW, Cab Power

19Z

1CB

1DM

Time Delay/Ign Sw Fused Pwr

R 1.0 GXL

ECC, Elect CNTR C

S_Key, Ignition_Switch

1 AA

Brake Lt Sw Pwr

R 1.0 SXL

BTM_C, Cab Bottom Bulkhd

PBL, Brake Light Press Switch

4002-24

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

EVGT Relay PWR

R 1.0 GXL

EVGT_3, EVGT_Fuse

EVGT_4, EVGT

1 BA

Alternator B+

R 13.0 SXL

AB+, Alternator B+

B2 Starter Power

1 BB

Starter Solenoid Pwr

R 8.0 SXL

193 Starter Relay

194 Starter Signal

1 BE

Grid Htr Pwr

R 19.0 SXL

115 Grid Htr Pwr

GH, Grid Htr

1 BF

Alternator B+

R 13.0 SXL

AB_5, Alternator B+

B6, Starter Power

1 BG

B+ PWR PRMC

R 19.0 SXL

B5, Starter PWR Stud

P_C1, B+ PWR FRM PRMD

ECC Bat Power

R 8.0 GXL

P-A1, B+ Power

L1-ECC, ECC Battery Power

1 DR

Brake Light Switch Power

R 1.0 GXL

CAB-B, Cab Front Chassis

SPL-FLSHR-PWR, Ultrasonic

1 DU

Flasher Module Pwr

R 1.0 GXL

FLSHR, Flasher Module

SPL-FLSHR-PWR, Ultrasonic

1 DV

Brake Lights/Flasher Bat Pwr

R 2.0 GXL

SPL-FLSHR-PWR, Ultrasonic

ECC, Elec CNTR C

1 DW

Brake Lt Relay Bat Pwr

R 1.0 GXL

SPL-FLSHR-PWR, Ultrasonic

ECD, Elec CNTR D

Grid heater Fuse Bat Power

R 19.0 SXL

P-C2, B+ Power from PRMD

GHF1, Grid Heater Fuse

1 GA

Filter Htr Pwr

R 3.0 SXL

PRM-D1, PRM Output

SPL-HTR, Ultrasonic

1 GB

Fuel Filter Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

FFH, Fuel Filter Heater

1 GC

Water Sep Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

WSH, Water Separator Heater

1 KA

Hazard Switch Pwr

R 1.0 GXL

SHZ, Hazard Switch

SPL-FLSHR-PWR, Ultrasonic

1 NA

Battery Crossover

R 62.0 SGR

BT3, Starter Battery

BT2, Disconnect Battery

1 NB

Battery Starter

R 62.0 SGR

BT1, Battery Starter

B3, Starter Battery

1 NC

B+ Power PRMC

R 19.0 SXL

B1, Starter Power Stud

P-C1, B+ Power From PRMC

1 ND

SSM Power

R 62.0 SGR

244F Starter Sec. Strg Mtr

B4, Starter Power

1 NE

Battery STRTR

R 62.0 SGR

B7, Starter-Battery

BT1, Battery_Starter

1 NF

SSM PWR

R 62.0 SGR

B8, Starter_Power

244F, Starter-sec_STRG_MTR

EVGT_3 PWR

R 1.0 SXL

P_C6, B+ PWR FRM PRMD

EVGT_3, EVGT_FUSE

Grid Heater Fused Power

R 19.0 SXL

GHF3, Grid heater Fuse

GHF4, Grid Heater

Starter Relay Battery Power

R 8.0 SXL

P-C4, B+, Power From PRMC

195, Starter Relay Power

20G A EDC7 ESO-K Interface

W 0.8 TXL

ENG, Engine Cab1

EDC7, Engine Controller

20G B EDC7 ESO-K Interface

W 0.8 GXL

CAB-E, Cab Engine

DIA, Diagnostic

Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

21C A Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

21C

4002-25

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

21C B Neutral Start Relay Output

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

W 0.8 GXL

SPL-CR, Ultrasonic

ECD, Elect Center D

Starter Relay Signal

W 1.0 SXL

SRC-1, Relay

ENG, Engine Cab1

21D A Starter Relay Signal

W 0.8 GXL

CAB_E, Cab-Engine

ECD, Elect Center D

AA5

Key Switch Crank

W 0.8 GXL

ECB, Elect CNTR B

ECC, Elect Center C

21E A Key Switch Crank

W 0.8 TXL

ENG, Engine Cab1

EDC7, Engine Controller

21E B Key Switch Crank

W 0.8 GXL

ECC, Elect CNTR C

C10

CAB_E, Cab-Engine

EDC7 Digital Ground

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center B

21F A EDC7 Digital Ground

W 0.8 GXL

ENG, Engine Cab

SPL-EDC3, Ultrasonic

21F B EDC7 Digital Ground

W 0.8 TXL

SPL-EDC3, Ultrasonic

EDC7, Engine Controller

21F C EDC7 Digital Ground

W 0.8 TXL

ENG_B, CAB BTTOM

SPL-EDC3, Ultrasonic

21F D EDC7 Digital Ground

W 0.8 TXL

RTHP, Throttle Pedal

BTM_E, CAB BTTOM

EDC7 Crank Control relay

W 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

AA6

21G A EDC7 Crank Control relay

W 0.8 TXL

ENG, Engine Cab1

EDC7, Engine Controller

Crank control relay LSD

W 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

21H A Crank control relay LSD

W 0.8 TXL

ENG, Engine Cab1

EDC7, Engine Controller

TEL, Telematics

21D

21E

21F

21G

21H

21J

Restart Prevent

W 0.8 GXL

ECC, Elect CNTR C

21K

Ign Sw Start Signal

W 0.8 GXL

S-KEY, Ignition Switch

SPL-CRK, Ultrasonic

21K A Ign Sw Start Signal

W 0.8 TXL

SPL-CRK, Ultrasonic

AIC-2, Adv Instrument Cluster 2

21K B Ign Sw Start Signal

W 0.8 GXL

SPL-CRK, Ultrasonic

ECB, Elect Center B

22A

Declutch SW

DU 0.8 TXL

SDC, Declutch_Switch

TECM, Trans

22B

Pedal Sensor +5V

K 0.8 TXL

TECM, Trans

CAB_B, Cab BTM Bulkhd

22C

Pedal POS Signal

Y 0.8 TXL

TECM, Trans

CAB_B, Cab BTM Bulkhd

22D

Pedal Sensor Grnd

LU 0.8 TXL

TECM, Trans

CAB_B, Cab BTM Bulkhd

22E

Pedal Sensor +5V

K 0.8 TXL

BTM_C, Cab Bottom Bulkhd

BPP, Pedal Position

22F

Pedal POS Signal

Y 0.8 GXL

BTM_C, Cab Bottom Bulkhd

BPP, Pedal Position

22G

Pedal Sensor Grnd

LU 0.8 GXL

BTM_C, Cab Bottom Bulkhd

BPP, Pedal Position

23A A DNOX2 Module B+

N 0.8 TXL

ENG2, Eng Bulkhd

NOXS, NOX Sensor

23B A NOX Sensor B+

Or 0.8 GXL

ECD, Elec CNTR D

CABE2, Cab to Eng2 Bulkhd

23B B NOX Sensor B+

N 0.8 GXL

ECD, Elec CNTR D

AA7

CABE2, Cab to Eng2 Bulkhd

23B C NOX Relay GND

Bk 0.8 GXL

ECD, Elec CNTR D

GND_CAB_SPL, Cab Grnd Splice

4002-26

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

23B D NOX Relay B+

Or 0.8 GXL

ECD, Elec CNTR D

AA8

23B E NOX Sensor B+

Or 1.0 GXL

ENG2, Eng Bulkhd 2

23B F NOX Relay B+

Or 1.0 SXL

23D D NOX Sensor GND

Connector

Cav

CABE2, Cab to Eng2 Bulkhd

SPL_EDC2, Ultrasonic

ENG2, Eng Bulkhd 2

SPL_EDC4, Ultrasonic

Bk 0.8 TXL

NOXS, NOX Sensor

GND_ENG2, WIF, EDC

23J B DNOX2 K-Line

W 0.8 GXL

DIA_2, Diagnostic

CAB_Em Cab-Engine

23K A Temp/Humd B+

K 0.8 TXL

HTS, HMDTY and AMB Temp

EDC7, Engine Controller

23K B Temp/Humd Temp

Y 0.8 GXL

HTS, HMDTY and AMB Temp

EDC7, Engine Controller

23K C Temp/Humd Humd

Y 0.8 GXL

HTS, HMDTY and AMB Temp

EDC7, Engine Controller

23K E Temp/Humd GND

LU 0.8 GXL

EDC7, Engine Controller

HTS, HMDTY and AMB Temp

Throttle Signal

W 0.8 TXL

ENG_B, Cab BTTOM

EDC7, Engine Controller

24B A Throttle Signal

W 0.8 TXL

RTHP, Throttle Pedal

BTM+E, Cab BTTOM

Low Idle Sw

W 0.8 TXL

ENG_B, Cab BTTOM

EDC7, Engine Controller

24L A Low Idle Sw

W 0.8 TXL

RTHP, Throttle Pedal

BTM_E, Cab BTTOM

Throttle Grnd

W 0.8 TXL

ENG_B, Cab BTTOM

EDC7, Engine Controller

24R A Throttle Grnd

W 0.8 TXL

RTHP, Throttle Pedal

BTM_E, Cab BTTOM

Throttle Supply

W 0.8 TXL

ENG_B, Cab BTTOM

EDC7, Engine Controller

24S A Throttle Supply

W 0.8 TXL

RTHP, Throttle Pedal

BTM_E, Cab BTTOM

24T B TC Lockup SOL GND

LU 1.0 SXL

TRANS, Cab Transmission

YLS, TC_Lockup_Valve

255E

Pedal Sensor +5V

K 0.8 TXL

BTM_C, Cab Bottom Bulkhd

BPP, Pedal Position

25A

Eng Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

ESS, Engine speed Sensor

25A A Eng Speed Sig

LU 0.8 TXL

TECM, Trans

Cab+T, Cab-Transmission

Int Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

ISS, Int Speed Sensor

25B A Int Speed Sig

LU 0.8 TXL

TECM, Trans

Cab+T, Cab-Transmission

Turbine Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

TSS, Turbine Speed Sensor

25C A Turbine Speed Sig

LU 0.8 TXL

TECM, Trans

Cab+T, Cab-Transmission

Output Speed Sig

LU 1.0 SXL

TRANS, Cab Transmission

OSS, Output Speed Sensor

25D A Output Speed Sig

LU 0.8 TXL

TECM, Trans

Cab+T, Cab-Transmission

24B

24L

24R

24S

25B

25C

25D

25F

Forward Signal

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

25G

Brake Declutch Switch

LU 1.0 SXL

Trans, Transmission-Cab

PBD, Declutch Pressure Switch

4002-27

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

25G A Brake Declutch Switch CTRL

LU 0.8 GXL

CAB-T, Cab Transmission

SPL-DC, Ultrasonic

25G B Brake Declutch Switch CTRL

LU 0.8 GXL

SDC, Declutch Switch

SPL-DC, Ultrasonic

25G C Brake Declutch Switch CTRL

LU 0.8 TXL

SPL-DC, Ultrasonic

TECM, Trans

25H

Trans Auto Signal

LU 0.8 TXL

STA, Trans Auto Switch

TECM, Trans

25J

Trans Sol Valve Y6

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25J A Trans Sol Valve Y6

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K 9 Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K A Trans Sol Valve Y1

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25K

25L

Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25L 9

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25L A Trans Sol Valve Y2

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25M

Trans Sol Valve Y3

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25M A Trans Sol Valve Y3

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y4

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25N A Trans Sol Valve Y4

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y5

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25P A Trans Sol Valve Y5

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Reverse Signal

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

25R A TC Lockup SOL Power

LU 0.8 TXL

TECM, Trans

CAB_T, Cab-Transmission

25R B TC Lockup SOL Power

LU 1.0 SXL

Trans, Transmission-CAB

YLS, TC_Lockup_Valve

Output Sw Power VPS1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Transmission Control

25S A Output Sw Power VPS1

LU 0.8 TXL

CAB-T, Cab Transmission

SPL D12, Ultrasonic

25S B Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

25S C Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

Neutral Signal

LU 0.8 GXL

SPL-NEU, Ultrasonic

ECB, Elect Center B

25T A TC Lockup SOL GND

W 0.8 TXL

SPL_D19, Ultrasonic

CAB_T, Cab-Transmission

25T B Neutral Signal

LU 0.8 GXL

TS1, Transmission Shifter

SPL-NEU, Ultrasonic

25T C Neutral Signal

LU 0.8 TXL

SPL-NEU, Ultrasonic

TECM, Trans

25W

3rd And 4th Gear Signal

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

25Y

Trans Kick Down Signal

LU 0.8 GXL

TS2, Transmission Shifter

SPL D11, Ultrasonic

25N

25P

25R

25S

25T

4002-28

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

25Y A Trans Kick Down Signal

LU 0.8 TXL

SPL D11, Ultrasonic

TECM, Trans

25Y B Trans Kick Down Signal

LU 0.8 GXL

197F, Main Cab FNR

SPL D11, Ultrasonic

25Y C Trans Kick Down Signal

LU 0.8 GXL

20M, Trans Kick Down

197M, FNR Main Cab

25Y D Trans Kick Down Signal

LU 0.8 GXL

KD_Diode, Diode ASSY

JSS_197M, FNR-Main_Cab

25Y E Trans Kick Down Signal

LU 0.8 GXL

CAB_FNR, Main_Cab_Fnr

KD_Diode, Diode ASSY

25Y F Trans Kick Down Signal

LU 0.8 GXL

KD_Diode, Diode ASSY

JSS_197F, Main_Cab_Fnr

25Y G Trans Kick Down Signal

LU 0.8 SXL

21M, Trans_Kick-Down

ARM_FNR, Fnr-Main_Cab

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

26E A Trans Enable Signal

LU 0.8 TXL

STE, Trans Enable Switch

TECM, Trans

26F A FNR Forward Signal

LU 0.8 GXL

197M, FNR Main Cab

SFNR, FNR Switch

26F B FNR Forward Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26F C FNR Forward Signal

LU 0.8 GXL

FWD_DIODE, Diode ASSY

JSS_197M, FNR-Main_Cab

26F D FNR Forward Signal

LU 0.8 GXL

JSS_197F, Main_Cab_Fnr

FWD_DIODE, Diode ASSY

26F E FNR Forward Signal

LU 0.8 GXL

CAB_FNR, Main_Cab_Fnr

FWD_DIODE, Diode ASSY

26F F FNR Forward Signal

LU 0.8 GXL

SAJ, FNR_Switch

ARM_FNR, FNR-Main_Cab

25Z

1st And 4th Gear Signal

26J

FNR Switch Jumper

LU 0.8 GXL

SFNR, FNR Switch

26K

FNR Switch Jumper

LU 0.8 GXL

SAJ, FNR_Switch

26N A FNR Neutral Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26N B FNR Neutral Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26N C FNR Neutral Signal

LU 0.8 GXL

JSS_197M, FNR-Main_Cab

NTRL_DIODE, Diode ASSY

26N D FNR Neutral Signal

LU 0.8 GXL

JSS_197F, Main_Cab_Fnr

NTRL_DIODE, Diode ASSY

26N E FNR Neutral Signal

LU 0.8 GXL

NTRL_DIODE, Diode Assy

CAB_FNR, Main_Cab_Fnr

26N F FNR Neutral Signal

LU 0.8 GXL

SAJ, FNR_Switch

ARM_FNR, FNR-Main_Cab

26R A FNR Reverse Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26R B FNR Reverse Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26R D FNR Reverse Signal

LU 0.8 GXL

JSS_197F, Main_Cab_Fnr

RVS_DIODE, Diode ASSY

26R E FNR Reverse Signal

LU 0.8 GXL

CAB_FNR, Main_Cab_Fnr

RVS_DIODE, Diode ASSY

26R F FNR Reverse Signal

LU 0.8 GXL

SAJ, FNR_Switch

ARM_FNR, Fnr-Main_Cab

28F

Fuel FLTR HTR RLY CTRL

W 0.8 TXL

PRM-D2,PRM Signal

EDC7, Engine Controller

28G

Grid Heater Source Dr.

W 1.0 GXL

GHC, Grid Htr Relay

EDC7, Engine Controller

31A

EVGT Relay B+

Or 0.8 GXL

EVGT_4, EVGT

SPL_EDC4, Ultrasonic

4002-29

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

31B

Filter Heater Control

Or 0.8 GXL

PRM_D2, PRM Signal

SPL_EDC4, Ultrasonic

31F

Air Filter Rest Sw Signal

Y 1.0 SXL

ENG, Engine Cab1

PAF, Air Filter Rest Sw

31F A Air Filter Rest Sw Signal

Y 0.8 TXL

CAB-E, Cab Engine

SW-PD, Switch Pad

31H

Hyd Filter Rest Sw Signal

Y 1.0 SXL

TRANS, Cab Transmission

PHF, Hyd Oil Filter Rest Sw

31H9

HYD FLTR RST SW 9

Y 1.0 SXL

TRANS, Cab Transmission

PHF9, HYD_FLTR_RES_SW

Y 0.8 TXL

SW-PD, Switch Pad

CAB-T, Cab Transmission

31H A Hyd Filter Rest Sw Signal 31L

Pilot Control Switch High

Y 0.8 TXL

SPC, Pilot Control Switch

AIC-2, Advance Instr Cluster 2

32F

Trans Filter Maint Sw

Y 1.0 SXL

TRANS, Cab Transmission

FM, Filter Maint Sw

32F A Trans Filter Maint Sw

Y 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

32J A Trans Enable Indiction

Y 0.8 GXL

SFNR, FNR Switch

197M FNR Main Cab

32J C Trans Enable Indiction

Y 0.8 GXL

STE, Trans Enable Switch

SPL-D16, Ultrasonic

32J D Trans Enable Indiction

Y 0.8 TXL

SPL-D16, Ultrasonic

TECM, Trans

32J E Trans Enable Indiction

Y 0.8 GXL

197F, Main Cab FNR

SPL-D16, Ultrasonic

32J F

Trans Enable Indiction

Y 0.8 GXL

SPL_JSS_21, Ultrasonic

JSS_197M, FNR-Main_Cab

32J G Trans Enable Indiction

Y 0.8 GXL

JSS_197F, Main_Cab_Fnr

SPL_JSS_21, Ultrasonic

32J H Trans Enable Indiction

Y 0.8 GXL

CAB_FNR, Main_Cab_Fnr

SPL_JSS_21, Ultrasonic

32J J

Trans Enable Indiction

Y 0.8 GXL

SAJ, FNR_Switch

ARM_FNR, Fnr-Main_Cab

33P

Brake Warning Press Low

Y 1.0 SXL

BTM_C, Cab Bottom Bulkhd

PBW, Brake Warning Press Sw

33P A Brake Warning Press Low

Y 0.8 TXL

CAB_B, Cab BTM Bulkhd

AIC-2, Advance Instr Cluster 2

Redundant Brake Accumulator Pressure Low

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

33R A Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

TRANS, Cab Transmission

SPL-RD, Ultrasonic

33R B Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB2, Redundant Brake Switch

33R C Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB1, Redundant Brake Switch

Y 0.8 TXL

SPB, Parking Brake Switch

AIC-2, Advance Instr Cluster 2

34A A Diff Lock SW B+

Or 0.8 GXL

SDA, Diff Lock Switch

SPL_PBS, Ultrasonic

34A B Diff Lock SW SIG B+

Or 0.8 GXL

SDA, Diff Lock Switch

SPL_PBS, Ultrasonic

34A C Diff Lock SOL B+

W 0.8 TXL

SPL_D19, Ultrasonic

CAB_T, Cab-Transmission

34A D Diff Lock SOL B+

Or 1.0 SXL

TRANS, Transmission-Cab

YDL, Diff Lock Solenoid

33R

33U

Parking Brake Switch

4002-30

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

34A E Diff Lock SOL B+

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

Or 1.0 SXL

YDL_1, Diff Lock Solenoid

YDL_2, Diff Lock Solenoid

34B

Diff Lock SW SIG

LU 0.8 TXL

SDA, Diff Lock Switch

TECM, Trans

34C

Diff Lock SOL GND

LU 0.8 TXL

TECM, Trans

CAB_T, Cab-Transmission

34C A Diff Lock SOL GND

LU 1.0 SXL

TRANS, Transmission-Cab

YDL, Diff Lock Solenoid

34C D Diff Lock SOL GND

LU 1.0 SXL

YDL_1, Diff Lock Solenoid

YDL_2, Diff Lock Solenoid

Diff Lock SW SIG

LU 0.8 TXL

TECM, Trans

SDM, Diff Lock Switch

35A 9 Backup Alarm RLY OUT

Bk 1.0 SXL

HD-9, Hood to Engine

BU2, Backup_Alarm

35A A Backup Alarm

Y 0.8 GXL

SPL_35A, Ultrasonic

ECD, Elect Control D

AA9

35A B Backup Alarm Disable Switch

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL_35A, Ultrasonic

35A C Backup Alarm Relay Out

Y 0.8 GXL

SPL_35A, Ultrasonic

CABE2, Cab to Eng2 Bulkhd

35A D Backup Alarm Relay Out

Y 0.8 GXL

209M, Backup Alarm Dis Jump

SPL_35A, Ultrasonic

35A E Backup Alarm Relay Out

Y 0.8 SXL

209F, Backup Alarm Dis Jump

SPL-D8-C1, Ultrasonic

35A F Backup Alarm Relay Out

Y 0.8 SXL

CABE2, Cab to Eng2 Bulkhd

SPL-D8-C1, Ultrasonic

35A G Backup Alarm Relay Out

Y 0.8 SXL

ENG2, Eng Bulkhd 2

E-HD, Trans Hood

Backup Alarm Relay Out

Y 1.0 SXL

ENG2, Eng Bulkhd 2

ENG-H, Engine to Hood

35A H Backup Alarm Relay Out

Y 1.0 SXL

HD-E, Hood Trans

BU2, Backup Alarm

Y 1.0 SXL

HD-N, Hood to Engine

BU2, Backup Alarm

35A J Reverse Light

K 1.0 SXL

ENG2, Eng Bulkhd 2

SPL-A1A, Ultrasonic

35A K Reverse Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LRR-E, RH rear Comb Light

35A L Reverse Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LLR-E, LH rear Comb Light

35A M Reverse Signal

K 1.0 SXL

SPL-35A, Ultrasonic

MON, Camera/Monitor

35A N Reverse Light

K 1.0 SXL

SPL-REV

LLR-9, LH Rear Comb Light

35A O Reverse Light

K 1.0 SXL

HD_9, Hood to Eng

SPL_REV

35A P Reverse Light

K 1.0 SXL

LRR-9, RH rear Comb Light

SPL-REV

35A R Backup Alarm Relay Out

Y 1.0 SXL

ENG2, Eng Bulkhd 2

ENG-H, Engine to Hood

34D

35A GN

35A HN

Backup Alarm Relay Out

35B

AIC Buzzer HSD

W 0.8 TXL

BUZ, AIC Buzzer

AIC-1, Advance Instr Cluster 1

35C

Backup Alarm Relay Control

Y 0.8 TXL

TECM, Trans

ECD, Elect Center D

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL-D8-C1, Ultrasonic

35R C Backup Alarm Sw

4002-31

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

35W

Water In Fuel Indicator

W 0.8 TXL

WIF, Water In Fuel Sensor

EDC7, Engine Controller

35X

Sec. Str Low Press Sig

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

35X A Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

PSS, Sec. Steering Press Sw

35X B Sec. Str Low Press Sig

Y 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Mod Option

35X C Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

SS-TR, SS Module Trans

35X D Sec. Str Low Press Sig

Y 1.0 SXL

SSM, Sec. Steering Module

SPL-C3, Ultrasonic

Radiator Cool Temp Signal

P 1.0 SXL

ENG, Engine Cab1

RECT, Engine Coolant Temp

36C A Radiator Cool Temp Signal

P 0.8 TXL

CAB-E, Cab Engine

AIC-1, Advance Instr Cluster 1

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab1

RFL, Fuel Sender

36F A Fuel Level Analog

P 0.8 TXL

CAB-E, Cab Engine

AIC-1, Advance Instr Cluster 1

Torque Conv Output Temp Signal

P 1.0 SXL

TRANS, Cab Transmission

TCOT, TCO Sender

36G A Torque Conv Output Temp Signal

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Hydraulic Oil Temp

P 1.0 SXL

TRANS, Cab Transmission

HOT, Hydraulic Oil Temp Sender

36H A Hydraulic Oil Temp

P 0.8 TXL

CAB-T, Cab Transmission

AIC-1, Advance Instr Cluster 1

Fuel Level Analog

P 1.0 SXL

ENG, Engine-Cab1

RFL_23, Fuel_Level_Send

36R A Trans Temps/Filter Return

P 1.0 SXL

TRANS, Cab Transmission

SPL H1, Ultrasonic

36R B Trans Filter Maint Sw Return

P 1.0 SXL

SPL H1, Ultrasonic

FM, Filter Maint Switch

36R C Valve Body Temp Return

P 0.8 TXL

SPL H1, Ultrasonic

TRC, Trans Control

36R D TCO Temp Return

P 1.0 SXL

SPL H1, Ultrasonic

TCOT, TCO Sender

36R E Trans Temps/Filter Return

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Valve Body Temp Sig

P 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

36T A Valve Body Temp Sig

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

37D A Diagnostic Signal

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

36C

36F

36G

36H

36J

36T

37E

Diagnostic Signal Switched

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

38A

Doser Valve GND

LU 0.8 GXL

DNOX2, NOX Controller

DEFDM, Doser Metering VLV

38B

DEF Level SIG

Y 0.8 GXL

UBJ, DEF Level Temp

DNOX2, Nox Controller

38B A DEF Level SIG

Y 0.8 GXL

UBJM, DEF Level Temp

DTLTS, DEF_Tank_Level_Temp_Sensor

38C

Tank Heat GND

LU 0.8 TXL

DNOX2, NOX Controller

THV, Tank Heater Control Valve

38D

Tank Heat B+

Or 0.8 TXL

DNOX2, NOX Controller

THV, Tank Heater Control Valve

4002-32

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

38E

EXHT Temp DWN B+

Y 0.8 GXL

DNOX2, NOX Controller

DTS, Downstream Temp Sens

38F

EXHT Up Signal

Y 0.8 GXL

UTS, Upstream Temp Sense

DNOX2, NOX Controller

38G

DEF Temp SIG

Y 0.8 GXL

UBJ, DEF Level Temp

DNOX2, NOX Controller

38G A DEF Temp SIG

Y 0.8 GXL

UBJM, Def Level Temp

DTLTS, Def_Tank_Level_Temp_Sensor

38H

DNOX2 K-Line

W 0.8 TXL

ENG, Engine-Cab1

DNOX2, NOX Controller

401B

Pedal POS Signal

Y 0.8 GXL

BTM_C, Cab Bottom Bulkhd

BPP, Pedal Position

41H A High Beam Pwr

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56a

SPL_HB, Ultrasonic

41H B High Beam LH Pwr

Or 0.8 GXL

SPL_HB, Ultrasonic

ECB, Elect Center B

41H C High Beam RH Pwr

Or 0.8 GXL

SPL_HB, Ultrasonic

ECB, Elect Center B

41H D High Beam Pwr

Or 0.8 TXL

SW-PD, Switch Pad

SPL_HB, Ultrasonic

Or 1.0 GXL

SDR, Driving Lights Switch

SRHSTLK, RH Stalk Switch

41L A Low Beam Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56b

SPL-LB, Ultrasonic

41L B Low Beam LH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

41L C Low Beam RH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

K 1.0 GXL

SDR, Driving Lights Switch

SPL_PR, Ultrasonic

41T A Position Lights RH Switched Pwr K 1.0 GXL

SPL_PR, Ultrasonic

ECB, Elect Center B

41T B Position Lights LH Switched Pwr K 1.0 GXL

SPL_PR, Ultrasonic

ECB, Elect Center B

41T C Position Lights Switched Pwr

K 1.0 GXL

D-OR, Diode OR

SPL_PR, Ultrasonic

42C A Front Work Lights Fused Pwr

DU 2.0 GXL

CAB-RF, Cab to Roof Conn.

SPL_42C, Ultrasonic

42C C Front Work Lights Fused Pwr

DU 2.0 GXL

SPL_42C, Ultrasonic

SWL, Work Lights SW

42C D Front Work Lights Fused Pwr

DU 1.0 GXL

SPL_42C, Ultrasonic

D-OR, Diode OR

42C F Front Work Lights Fused Pwr

DU 2.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKF, Ultrasonic

42C G RH Front Work Lights Fused Pwr DU 1.0 GXL

SPL-WRKF, Ultrasonic

LRFW, RH Front Work Light

42C H LH Front Work Lights Fused Pwr DU 1.0 GXL

SPL-WRKF, Ultrasonic

LLFW, LH Front Work Light

42R A RH Front Work Lights Fuse Pwr

DU 1.0 GXL

LRFS, Front_WK_LT_OPT

SPL_WRK1, Ultrasonic

42R B RH Front Work Lights Fuse Pwr

DU 1.0 GXL

SPL_WRK1, Ultrasonic

LRFR, Front_WK_LT_OPT

42R C Rear Work Lights Fused Pwr

DU 2.0 GXL

CAB-RF, Cab to Roof Conn.

SWL, Work Lights SW

42R F Rear Work Lights Fused Pwr

DU 2.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKR, Ultrasonic

42R G RH Rear Work Lt Fused Pwr

DU 1.0 GXL

SPL-WRKR, Ultrasonic

LRRW, RH Rear Work Light

42R H LH Rear Work Lt Fused Pwr

DU 1.0 GXL

SPL-WRKR, Ultrasonic

LLRW, LH Rear Work Light

41J

41T

Driving Light Power

Position Lights Switched Pwr

4002-33

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

42R K RH Front Work Lights Fuse Pwr

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

DU 1.0 GXL

SPL_WRK1, Ultrasonic

LRFO, Front_WK_LT_OPT

42 A

Work Lights Fused Power

R 2.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

42 B

Work Lights Fused Power

R 1.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

43S A Door Open Signal

W 0.8 GXL

CAB-RF, Cab to Roof Conn.

AIC_2, ADV Instr Cluster 2

43S B Door Open Signal

W 0.8 GXL

ROOF, Roof to Cab Conn.

DS, Door Switch

43 A

Dome Light Auto Mode

DU 0.8 TXL

CAB-RF, Cab to Roof Conn.

AIC-1, Adv Instrument Cluster 1

43 B

Dome Light Auto Mode

DU 0.8 GXL

ROOF, Roof to Cab Conn.

LDM2, Dome Light Auto

44A A Brake Light Relay Out

T 0.8 GXL

CABE2, Cab to Eng2 Bulkhd

ECD, Elect CNTR D

AA1

44A D Brake Light Relay Out

T 1.0 SXL

ENG2, Eng Bulkhd2

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

ENG2, Eng Bulkhd2

ENG-H, Engine to Hood

44A E Brake Light Relay Out

T 1.0 SXL

LLR-E, LH Rear Comb Light

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

HD-N, Hood to Engine

SPL-J2-N, Ultrasonic

44A F Brake Light Relay Out

T 1.0 SXL

LRR-E, RH Rear Comb Light

SPL-B8, Ultrasonic

44A DN

44A EN

44A FN

Brake Light Relay Out

T 1.0 SXL

LLR-N, LH Rear Comb Light

SPL-J2-N, Ultrasonic

44A GN

Brake Light Relay Out

T 1.0 SXL

LRR-N, RH Rear Comb Light

SPL-J2-N, Ultrasonic

44A J Brake Light Relay Out

T 1.0 SXL

SPL-L1

HD-9, Hood to Engine

44A K Brake Light Relay Out

T 1.0 SXL

SPL-L1

LRR-9, RH Rear Comb Light

44A L Brake Light Relay Out

T 1.0 SXL

LLR-9, LH Rear Comb Light

SPL-L1

44 A

T 0.8 GXL

CAB-B, Cab BTM Bulkhd

ECD, Elec CNTR D

45A A Left Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

45B A Right Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

Brake Light Control Power

AA2

45H

Hazard Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SHZ, Hazard Switch

45L

Left Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

45L A Left Turn Signal

N 1.0 SXL

ENG2, Eng Bulkhd 2

LLR-E, LH Rear Comb Light

45L AN Left Turn Signal

N 1.0 SXL

ENG2, Eng Bulkhd 2

ENG-H, Engine to Hood

45L B Left Turn Signal

N 0.8 GXL

CABE2, Cab to Eng2 Bulkhd

SPL-PK3, Splice 3-4 Way

45L BN Left Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LLR, LH Rear Comb Light

45L C Left Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

4002-34

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

45L D Left Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

45L E Left Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45L N Left Turn Signal

N 1.0 SXL

HD_9, Hood to Eng

LLR_9, LH_Rear_Comb_LT

45N A Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64F, Flasher Connector

45N B Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64M, Flasher Connector

Right Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

45R 9 Right Turn Signal

N 1.0 SXL

HD-9, Hood to Engine

LRR-9, RH Rear Comb Light

45R A Right Turn Signal

N 1.0 SXL

ENG2, Eng Bulkhd 2

LRR-E, RH Rear Comb Light

Right Turn Signal

N 1.0 SXL

ENG2, Eng Bulkhd 2

ENG-H, Engine to Hood

45R B Right Turn Signal

N 0.8 GXL

CABE2, Cab to Eng2 Bulkhd

SPL-PK3, Splice 3-4 Way

Right Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LRR, RH Rear Comb Light

45R C Right Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45R D Right Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45R E Right Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

46 C

Beacon Switched Power

K 1.0 GXL

CAB-RF, Cab to Roof Conn.

SBE, Beacon Switch

46 D

Beacon Switched Power

K 1.0 GXL

ROOF, Roof to Cab Conn.

LBEPWR, Light Beacon power

49A

Back Light Power

S 0.8 GXL

HVAC1, HVAC1

SPL-BCK-LGT, Spl Back Lgt Pwr

49S

Back Light Power

S 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 A

Back Light Power

S 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 B

Back Light Power

S 0.8 GXL

SBE, Beacon Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 C

Back Light Power

S 0.8 GXL

SRWP, Rear Wiper Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 D

Back Light Power

S 0.8 GXL

SHZ, Hazard SWitch

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 E

Back Light Power

S 0.8 GXL

SPL-BCK-LGT2, Spl Back Lgt Pwr

SPL-BCK-LGT, Spl Back Lgt Pwr

49 F

Back Light Power

S 0.8 GXL

SPE, Pin Engage Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 G

Back Light Power

S 0.8 GXL

SRC, Ride control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 H

Back Light Power

S 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

45R

45R AN

45R BN

4002-35

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

49 J

Back Light Power

S 0.8 GXL

SRTD, Detent Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 K

Back Light Power

S 0.8 GXL

SFL, Return to Travel Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 L

Back Light Power

S 0.8 GXL

SBU, Back Up Alarm Dis Sw

SPL-BCK-LGT, Spl Back Lgt Pwr

49 M

Back Light Power

S 0.8 GXL

SHC, Height Control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 N

Back Light Power

S 0.8 GXL

SPC, Pilot Control Switch

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 P

Back Light Power

S 0.8 GXL

SDR, Driving Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 Q

Back Light Power

S 0.8 GXL

SFC, Fan Control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 R

Back Light Power

S 0.8 GXL

SDC, Declutch Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 S

Back Light Power

S 0.8 GXL

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 T

Back Light Power

S 0.8 GXL

SFWW, Front Wiper/Washer

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 V

Back Light Power

S 0.8 GXL

SPB, Parking Brake Switch

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 W

JSS Backlight

S 0.8 GXL

SJS, Joystick_Control_SW

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 X

Back Light AIC

S 0.8 TXL

SW_PD, Switch Pad

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 Z

Back Light Power

S 0.8 GXL

SPL_BCK_LGT2, Spl_Back Lgt Pwr

SDA, Diff Lock Switch

51B A JSS ACT SW

W 0.8 GXL

SPL_JSS_2, Ultrasonic

SJS, Joystick_Control_SW

51B B JSS ACT SW

W 0.8 GXL

SJS, Joystick_Control_SW

SPL_JSS_2, Ultrasonic

51B C JSS ACT SW

W 0.8 GXL

JSS_CAB, JSS Cab

SPL_JSS_2, Ultrasonic

51B D JSS ACT SW

W 1.0 SXL

CAB_ARM_FRM, Cab to Arm to Frm

SPL_JSS_7, Ultrasonic

51B E B+, JSS

W 0.8 GXL

JSS_RLY, Relay K2

SPL_JSS_7, Ultrasonic

51B G B+, JSS

W 0.8 GXL

SPL_JSS_7, Ultrasonic

JSS_RLY, Relay K2

51B H JSS ACT SW

W 0.8 GXL

SPL_JSS_7, Ultrasonic

CAB_ARM, Cab to Armrest

4002-36

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

51B J JSS ACT SW

Bk 0.8 TXL

JSS_ARM, JSS Armrest to Cab

CAN_MOD_2, JSS Can Mod

51B K JSS Power

W 0.8 GXL

FNR_RLY, Relay K2

SPL_JSS_4, Ultrasonic

51C A JSS ACT BTN

Y 0.8 GXL

JSS_VAB, JSS Cab

SJS, Joystick_Control_SW

51C B JSS ACT BTN

Y 0.8 GXL

CAB_ARM_FRM, Cab to Arm to Frm

JSS_CNT, JSS Controller

51D A GRND, Relay CTRL

Bk 0.8 GXL

JSS_CAB, JSS Cab

AIC_1, ADV Instr Cluster 1

51D B GRND, Relay CTRL

Bk 0.8 GXL

CAB_ARM_FRM, Cab to Arm to Frm

JSS_RLY, Relay K2

51E A Armrest Lower

Or 0.8 GXL

JSS_CNT, JSS Controller

CAB_ARM, Cab to Armrest

51E B Armrest Lower

Or 0.8 GXL

JSS_ARM, JSS Armrest to Cab

ARM_POS, Arm Position

51F A LS Press Sw SIG

G 1.0 GXL

JSS_LS, JSS Load Sense

JSS_FRM, JSS Frame to Cab

51F B LS Press Sw

G 0.8 GXL

CAB_FRM, Cab to JSS Frame

JSS_CNT, JSS Controller

51H B Joystick Signal

Y 0.8 GXL

JSS_CNT, JSS Controller

CAB_ARM, Cab to Armrest

51H C Joystick Signal

Y 0.8 GXL

JSS_ARM, JSS Armrest to Cab

PVRES, JSS Joystick

51J A Valve Alarm

P 0.8 GXL

SPL_JSS_11, Ultrasonic

CAB_FRM, Cab to JSS Frame

51J B Valve Alarm

P 0.8 GXL

JSS_CNT, JSS Controller

SPL_JSS_11, Ultrasonic

51J C JSS Alarm

P 1.0 GXL

JSS_VALVE, JSS HYD Valve

JSS_FRM, JSS Frame to Cab

51J D Valve Alarm

P 0.8 GXL

SPL_JSS_11, Ultrasonic

R1, Resistor

51K B Pilot Press SW

G 0.8 GXL

CAB_FRM, Cab to JSS Frame

JSS_CNT, JSS Controller

51K C Pilot Press SW SIG

G 1.0 GXL

JSS_PIL_PR, JSS Pilot Pressure

JSS_FRM, JSS Frame to Cab

Joystick Signal

Y 1.0 GXL

JSS_VALVE, JSS HYD Valve

JSS_FRM, JSS Frame to Cab

51L A Joystick Signal

Y 0.8 GXL

JSS_CNT, JSS Controller

CAB_FRM, Cab to JSS Frame

51NC

NC Neutral SW

Bk 0.8 TXL

PVRES, JSS Joystick

CAN_MOD_2, JSS Can Mod

51NO NO Neutral SW

Y 0.8 GXL

JSS_ARM, JSS Armrest to Cab

PVRES, JSS Joystick

51NO NO Neutral SW A

P 0.8 GXL

CAB_ARM, Cab to Armrest

JSS_CNT, JSS Controller

51PW JSS Power H

W 1.0 SXL

SPL_JSS_16, Ultrasonic

JSS_FRM, JSS Frame to Cab

51L

CS0

4002-37

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

51PW JSS Power J

W 1.0 SXL

JSS_LS, JSS Load Sense

SPL_JSS_16, Ultrasonic

51PW JSS Power K

W 1.0 SXL

SPL_JSS_16, Ultrasonic

JSS_PIL_DUMP, JSS Pilot Dump

51PW JSS Power M

W 0.8 GXL

SPL_JSS_6, Ultrasonic

CAB_ARM_FRM, Cab to Arm to Frm

51PW JSS Power N

W 0.8 GXL

JSS_CAB, JSS Cab

SJS, Joystick_Control_SW

51PW JSS Power P

W 0.8 GXL

JSS_RLY, Relay K2

SPL_JSS_4, Ultrasonic

51PW JSS Power Q

W 0.8 GXL

JSS_CNT, JSS Controller

SPL_JSS_4, Ultrasonic

51PW JSS Power R

W 0.8 GXL

SPL_JSS_6, Ultrasonic

CAB_ARM, Cab to Armrest

51PW JSS Power S

W 0.8 GXL

SPL_JSS_13, Ultrasonic

JSS_ARM, JSS Armrest to Cab

51PW JSS Power T

W 0.8 GXL

SPL_JSS_6, Ultrasonic

CAB_FRM, Cab to JSS Frame

51PW JSS Power U

Bk 0.8 TXL

SPL_JSS_13, Ultrasonic

CAN_MOD_2, JSS Can Mod

51PW JSS Power V

W 0.8 GXL

SPL_JSS_13, Ultrasonic

PVRES, JSS Joystick

51PW JSS Power W

W 0.8 GXL

SPL_JSS_6, Ultrasonic

SPL_JSS_4, Ultrasonic

51P A SEC STR High Press

W 1.0 SXL

SSM, SEC STR MOD

PSS, Sec Str Press Switch

Bk 0.8 TXL

ARM_POS, Arm Position

CAN_MOD_2, JSS Can Mod

51S A JSS Okay PWR

W 0.8 GXL

JSS_CNT, JSS Controller

SPL_JSS_5, Ultrasonic

51S B JSS Okay PWR

W 0.8 GXL

CAB_ARM, Cab to Armrest

SPL_JSS_5, Ultrasonic

51S C JSS Okay PWR

W 0.8 GXL

SPL_JSS_15, Ultrasonic

JSS_ARM, JSS Armrest to Cab

51S D JSS Okay PWR

Bk 0.8 TXL

CAN_MOD_2, JSS Can Mod

SPL_JSS_15, Ultrasonic

51S E JSS Okay PWR

W 0.8 GXL

PVRES, JSS Joystick

SPL_JSS_15, Ultrasonic

51S F JSS Okay PWR

W 0.8 GXL

CAB_FRM, Cab to JSS Frame

SPL_JSS_5, Ultrasonic

51S J JSS Okay PWR

W 1.0 SXL

JSS_VALVE, JSS HYD Valve

JSS_FRM, JSS Frame to Cab

51 A

W 1.0 SXL

SSM, Sec. Steer Module

SPL-SS, Ultrasonic

51R

Armrest Raise

Sec. Str Motor Control

4002-38

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

51 B

Sec. Str Motor Control

W 1.0 SXL

SPL-SS, Ultrasonic

SSS, SS Mag Switch

51 C

Sec. Str Sol Control

W 1.0 SXL

SPL-SS, Ultrasonic

YSS, Sec. Steering Solenoid

51 D

Sec. Str Flyback

W 1.0 SXL

SSS, SS Mag Switch

SSD, SEC_STR_Diode

52AU

Fan Reverse Auto

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52A A Fan Reverse Relay Out

W 1.0 GXL

CAB-E, Cab Engine

ECB, Elect Center B

52A B Fan Reverse Relay Out

W 1.0 SXL

ENG, Engine Cab1

YFR, Fan Rev Solenoid Option

D8 1

52C

Parking Brake Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument Cluster 1

ECB, Elect Center B

52J

Fan Control Switch Jumper

W 0.8 GXL

SFC, Fan Control Switch

52M

Fan Reverse Manual

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52P

Parking Brk Relay Out

W 1.0 SXL

BTM_C, Cab Bottom Bulkhd

YPB, Park Brake Solenoid

52P A Parking Brk Relay Out

W 0.8 GXL

CAB-B, Cab BTM Bulkhd

SPL-PTM, Ultrasonic

52P B Parking Brk Relay Out

W 0.8 GXL

SPL-PB, Ultrasonic

ECB, Elect Center B

D10

B10

53A

RTD Switch Power

W 0.8 GXL

SRTD, Detent Switch

EM, RTD Height Control RTT

53B

RTD Signal

W 1.0 SXL

FRONT, Cab Front Chassis

PXF, RTD

53B A RTD Signal

W 1.0 SXL

PXM, RTD

PXT, RTD

53B B RTD Signal

W 0.8 GXL

EM, RTD Height Control RTT

CAB-F, Cab Front Chassis

53C A Pilot Control Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument Cluster 1

ECD, Elect Center D

53P A Pilot Control Relay Out

W 0.8 GXL

SPL-D25, Ultrasonic

YPP, Pilot Pressure Solenoid

53P B Pilot Control Relay Out

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D25, Ultrasonic

53P C Pilot Control Relay Out

W 1.0 GXL

SPL-D25, Ultrasonic

ECD, Elect Center D

53P D Pilot Control Relay Out

W 0.8 GXL

SHC, Height Control Switch

SPL-D25, Ultrasonic

53P E Pilot Control Relay Out

W 0.8 GXL

SRTD, Detent Switch

SPL-D25, Ultrasonic

53P F Pilot Control Relay Out

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D25, Ultrasonic

53P G Pilot Control Relay Out

W 1.0 SXL

FRONT, Cab Front Chassis

SPL-A3, Ultrasonic

53P H Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXF, RTD

53P I

Pilot Control Relay Out

W 1.0 SXL

PXM, RTD

PXT, RTD

53P J Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXH, Height Control RTT

54A

Height Control Switch Power

W 0.8 GXL

SHC, Height Control Switch

EM, RTD Height Control RTT

54B

HC RTT Control Signal

W 1.0 SXL

FRONT, Cab Front Chassis

PXH, Height Control RTT

4002-39

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

54B A HC RTT Control Signal

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D1, Ultrasonic

54B B HC RTT Control Signal

W 0.8 GXL

EM, RTD Height Control RTT

SPL-D1, Ultrasonic

54B C HC RTT Control Signal

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D1, Ultrasonic

55A A RTT Float Sw Power

W 0.8 GXL

EM, RTD Height Control RTT

SPL-RTT, Ultrasonic

55A B RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55A C RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55B

RTT Float Switch Control

W 0.8 GXL

SFL, Return to Travel Switch

EM, RTD Height Control RTT

56 A

Fan Control PWM

W 1.0 SXL

ENG, Engine Cab1

YFN, Fan PWM Solenoid

57 A

Pin Engage Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PINE, Ultrasonic

57 B

Pin Engage Sol Pwr

W 0.8 GXL

SPE, Pin Engage Switch

SPL-PINE, Ultrasonic

57 C

Pin Engage Sol Pwr

W 0.8 TXL

SPL-PINE, Ultrasonic

AIC-2, Adv Instrument Cluster 2

57 D

Pin Engage Sol Pwr

W 1.0 SXL

YPE1, PIN Engage Jumper

YPE2, Pin_Engage_OPT

58C

Ride Control Switch Jumper

W 0.8 GXL

SRC, Ride Control Switch

58H A Power VPS2

W 0.8 TXL

TECM, Trans

SPL_D19, Ultrasonic

58H B Power VPSL

W 0.8 TXL

SPL_D19, Ultrasonic

TECM, Trans

58H C Power

W 0.8 GXL

ECD,Elec CNTR D

SPL_D19, Ultrasonic

58L

Ride Control Relay LSD

Bk 0.8 TXL

TECM, Trans

ECD, Elect Center D

58T

Ride Control Relay Sw Pwr

W 0.8 GXL

SRC, Ride Control Switch

ECD, Elect Center D

58 A

Ride Control Sol Pwr

W 1.0 SXL

202M, Rollback Jumper

58 B

Ride Control Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

PRBF, Rollback Pressure Switch

58 C

Ride Control Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D26, Ultrasonic

58 D

Ride Control Sol Pwr

W 0.8 GXL

140M, Diode Module

SPL-D26, Ultrasonic

58 E

Ride Control Sol Pwr

W 0.8 GXL

SPL-D26, Ultrasonic

ECD, Elect Center D

58 F

Ride Control Sol Pwr

W 0.8 GXL

SRC, Ride Control Switch

SPL-D26, Ultrasonic

58 G

Ride Control Sol Pwr

W 1.0 SXL

Front, FRNT_CHAS_CAB

YRC, Ride_Control_OPT

58 H

Ride Control Signal

W 1.0 SXL

YRC_J, Ride CNTR_Jumper

YRC_J2, Ride_Control_OPT

59D

Hood Relay Control Down

W 1.0 GXL

CABE2, Cab to Eng2 Bulkhd

ECC, Elect CNTR C

59D A Hood Relay Control Down

W 1.0 SXL

ENG2, Eng Bulkhd 2

HD, Hood Switch

Hood Relay Control Up

W 1.0 GXL

CABE2, Cab to Eng2 Bulkhd

ECC, Elect CNTR C

59U A Hood Relay Control Up

W 1.0 SXL

ENG2, Eng Bulkhd 2

HD, Hood Switch

W 1.0 GXL

CABE2, Cab to Eng2 Bulkhd

ECC, Elect CNTR C

59U

60D

Hood Down Relay Out

4002-40

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

60D A Hood Down Relay Out

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

W 1.0 SXL

ENG2, Eng Bulkhd 2

HDM, Hood Lift Motor

Hood Up Relay Out

W 1.0 GXL

CABE2, Cab to Eng2 Bulkhd

ECC, Elect CNTR C

60U A Hood Up Relay Out

W 1.0 SXL

ENG2, Eng Bulkhd 2

HDM, Hood Lift Motor

W 1.0 SXL

ENG, Engine Cab1

SPL_ACP, Ultrasonic

61A B Trinary Press Sw Input

W 0.8 GXL

SPL_AC, Ultrasonic

CAB_E, Cab-Engine

61A C AC Switch Input

W 1.0 SXL

SPL_ACP, Ultrasonic

ENG_B, Cab Bttom

61A D AC Switch Input

W 1.0 SXL

SPL_ACP, Ultrasonic

PRH, AC High Press SW

61A E AC Switch Input

W 1.0 SXL

PRL, AC Low Press SW

BTM_E, Cab Bttom

61A F Trinary Press Sw Input

W 0.8 GXL

HVAC1, HVAC1

SPL_AC Ultrasonic

61A G Trinary Press Sw Input

W 0.8 GXL

ECD, Elec CNTR D

SPL_AC Ultrasonic

61B A AC Signal

W 0.8 GXL

HVAC1, HVAC1

AIC_2, ADV Instr Cluster2

AC Relay Out

Or 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61C A AC Relay Out

Or 1.0 SXL

ENG, Engine Cab1

ACT, AC Comp Clutch

AC Relay Control

W 1.0 SXL

ENG, Engine Cab1

SPL_ACS Ultrasonic

61R B AC Relay Control

W 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61R C AC Switch Output

W 1.0 SXL

SPL_ACS, Ultrasonic

ENG_B, Cab Bttom

61R D AC Switch Output

W 1.0 SXL

SPL_ACS, Ultrasonic

PRH, AC High Press SW

61R E AC Switch Output

W 1.0 SXL

PRL, AC Low Press SW

BTM_E, Cab Bttom

60U

61A

61C

61R

AC Press SW input

C10

63C

Front Wiper Park Control

W 0.8 GXL

FWM, Front Wiper Motor

ECD, Elect Center D

63C2

Front Wiper Park Control

W 0.8 GXL

ECD, Elect Center D

63C3

Front Wiper Park Control

W 0.8 GXL

K-WCO, Wiper Cutout

87a

ECD, Elect Center D

63HC

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

SPL-HC, Ultrasonic

63HC Wiper Cutout Relay Control A

W 0.8 GXL

SPL-HC, Ultrasonic

K-WCO, Wiper Cutout

63HC Front Wiper Rly High Speed B

W 0.8 GXL

SPL-HC, Ultrasonic

ECD, Elect Center D

63H A Front Wiper High Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WHS, Ultrasonic

63H B Front Wiper Rly High Speed

W 0.8 GXL

SPL-WHS, Ultrasonic

ECD, Elect Center D

63H C Front Wiper High Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WHS, Ultrasonic

63LC

Front Wiper Low Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

ECD, Elect Center D

63L A Front Wiper Low Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WLS, Ultrasonic

4002-41

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

63L B Front Wiper Low Speed Rly Out

W 0.8 GXL

K-WCO, Wiper Cutout

SPL-WLS, Ultrasonic

63L C Front Wiper Low Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WLS, Ultrasonic

63W

Front Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

SFWW, Front Wiper/Washer

63W A Front Washer Pump

W 1.0 SXL

ENG, Engine Cab1

FWW, Front Washer

64C

Horn Relay Control

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

31b

ECC, Elect CNTR C

64 A

Horn Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECC, Elect CNTR C

65L

Left Speaker

Or 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

65R

Right Speaker

Or 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

66A

RR Camera PWR

OR 0.8 GXL

ECA, Elect CNTR A

MON, Camera/Monitor

67A

Park Brake Signl

OR 0.8 GXL

TEL, Telematics

SPL_PTM, Ultrasonic

67B

Start Lockout

OR 0.8 GXL

ECC, Elect CNTR C

D10

SRP, Work Lights SW

68C

Rear Wiper Park Control

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SRWP, Rear Wiper Switch

68C A Rear Wiper Park Control

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

Rear Wiper Switch Power

Or 1.0 GXL

SRWP, Rear Wiper Switch

SPL-3, Ultrasonic

68L A Rear Wiper Switch Power

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

68L B Rear Wiper Switch Power

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-3, Ultrasonic

68L C Rear Wiper Switch Power

Or 1.0 GXL

140M, Diode Module

SPL-3, Ultrasonic

68W

Rear Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

SRWP, Rear Wiper Switch

68W A Rear Washer Pump

W 1.0 SXL

ENG, Engine Cab

RWW, Rear Washer

CAN1 CAN HI H

Y 0.8 TXL twist

ENG, Engine-Cab1

EDC7, Engine Controller

G 0.8 TXL twist

ENG, Engine-Cab1

EDC7, Engine Controller

JSS_ARM, Jss Armrest to Cab

CAN_MOD_2, JSS Can Mod

CAB_ARM_FRM, Cab to Arm to Frm

CAB_ARM, Cab to Armrest

JSS_CNT, JSS Controller

68L

CAN1 L CAN LO CANS HA CAN HI, CAN MOD2

Y 0.8 TXL twist

CANS HB CAN HI, CAN MOD2

Y 0.8 TXL twist

CANS HD CAN HI, CAN MOD3

Y 0.8 TXL twist

CAB_ARM_FRM, Cab to Arm to Frm

4002-42

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

CANS LA CAN LO, CAN MOD2 CANS LB CAN LO, CAN MOD2 CANS LD CAN LO, CAN MOD3

CAN H CAN High

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

G 0.8 TXL twist

JSS_ARM, JSS Armrest to Cab

CAN_MOD_2, Jss Can Mod

G 0.8 TXL twist

CAB_ARM, Cab to Armrest

CAB_ARM_FRM, Cab to Arm to Frm

JSS_CNT, Jss Controller

Y 0.8 TXL TWIST

ENG, Engine-Cab1

SPL_CAN_DH, Ultrasonic

G 0.8 TXL twist

CAN H2

CAN2 HI, Term

Y 0.8 GXL twist

TERM_CAN_2, Can Bulk Head

SPL_CAN_HV, Ultrasonic

CAN H3

CAN2 HI, NOX

Y 0.8 GXL twist

SPL_CAN_HT, Ultrasonic

EDC7, Engine Controller

CAN HA

CAN High

Y 0.8 TXL TWIST

SPL-CAN-JS_HI, Ultrasonic

SPL_CAN_GH, Ultrasonic

CAN HB

CAN High

Y 0.8 TXL TWIST

SPL-CAN-DIAG, Ultrasonic

DIA, Diagnostic

CAN HC

CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic

SPL-CAN-DIAG, Ultrasonic

CAN HD

CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic

TECM, Trans

CAN HE

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

SPL-CAN-TRANS, Ultrasonic

CAN HF

CAN High

Y 0.8 TXL TWIST

SW-PD, Switch Pad

SPL-CAN, Ultrasonic

CAN HG

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN HH

CAN High

Y 0.8 TXL TWIST

SPL_CAN_TEL, Ultrasonic

TEL, Telematics

CAN HJ

CAN High

Y 0.8 TXL TWIST

SPL_CAN_TEL, Ultrasonic

SPL_CAN_JS_H2, Ultrasonic

CAN HK

CAN HI, EDC

Y 0.8 GXL twist

SPL-CAN-DH, Ultrasonic

EDC7, Engine Controller

CAN HL

CAN High

Y 0.8 TXL TWIST

SPL_CAN_TEL, Ultrasonic

SPL_CAN_DIAG, Ultrasonic

4002-43

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

CAN HM

CAN2 HI, EDC

Y 0.8 GXL TWIST

SPL-CAN-GH, Ultrasonic

CAB_E, Cab-Engine

CAN HN

CAN High

Y 0.8 TXL TWIST

SPL_CAN_JS_HI, Ultrasonic

SPL_CAN_JS_H2, Ultrasonic

CAN HO

CAN2 HI, Diag2

Y 0.8 GXL TWIST

SPL_CAN_GH, Ultrasonic

DIA_2, Diagnostic

CAN HP

CAN HI, Can Mod2

Y 0.8 GXL TWIST

SPL_CAN_JS_HI, Ultrasonic

JSS_CAB, JSS Cab

CAN HQ

CAN HI, DNOX2

Y 0.8 GXL TWIST

SPL_CAN_DH, Ultrasonic

DNOX2, NOX Controller

CAN HR

CAN HI, Can Mod3

Y 0.8 GXL TWIST

SPL_CAN_JS_H2, Ultrasonic

JSS_CAB, JSS Cab

CAN HS

CAN2 HI, NOX

Y 0.8 GXL TWIST

SPL_CAN_HV, Ultrasonc

EDC7, Engine Controller

CAN HU

CAN2 HI, NOX

Y 0.8 TXL TWIST

SPL_CAN_HT, Ultrasonic

NOXS, NOX Sensor

CAN HV

CAN2 HI, TERM

Y 0.8 GXL TWIST

SPL_CAN_HT, Ultrasonic

Term_VAN_2, CAN Bulk Head

CAN HW

CAN2 HI, EVGT

Y 0.8 TXL TWIST

SPL_CAN_HV, Ultrasonic

Turbo, ENG Dash_Turbo

CAN HZ

CAN2 HI

Y 0.8 GXL TWIST

SPL_CAN_HV, Ultrasonic

SPL_CAN_HT, Ultrasonic

CAN L CAN Low

G 0.8 TXL TWIST

ENG, Engine-CAB1

SPL_CAN_DL, Ultrasonic

CAN L2

CAN 2 LO, TERM

G 0.8 GXL TWIST

Term_CAN_2, CAN Bluk Head

SPL_CAN_LV, Ultrasonic

CAN L3

CAN2 LO, NOX

G 0.8 GXL TWIST

SPL_CAN_LT, Ultrasonic

EDC7, Engine Controller

CAN LA

CAN Low

G 0.8 TXL TWIST

SPL-CAN-JS-L1, Ultrasonic

SPL_CAN_GL, Ultrasonic

CAN LB

CAN Low

G 0.8 TXL TWIST

SPL-CAN-DIAG-L, Ultrasonic

DIA, Diagnostic

CAN LC

CAN Low

G 0.8 TXL TWIST

SPL-CAN-TRANS-L, Ultrasonic

SPL-CAN-DIAG-L, Ultrasonic

CAN LD

CAN Low

G 0.8 TXL TWIST

TECM, Trans

SPL-CAN-TRANS-L, Ultrasonic

4002-44

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

CAN LE

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

SPL-CAN-TRANS-L, Ultrasonic

CAN LF

CAN Low

G 0.8 TXL TWIST

SW-PD, Switch Pad

SPL-CAN-L, Ultrasonic

CAN LG

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN LH

CAN Low

G 0.8 TXL TWIST

SPL_CAN_TEL2, Ultrasonic

SPL_CAN_JS_L2, Ultrasonic

CAN LJ

CAN LO, EDC

G 0.8 GXL TWIST

EDC7, Engine Controller

SPL_CAN_DL, Ultrasonic

CAN LK

CAN LO, DNOX2

G 0.8 GXL TWIST

SPL_CAN_DL, Ultrasonic

DNOX2, NOX Controller

CAN LL

CAN2 LO, EDC

G 0.8 GXL TWIST

SPL-CAN-GL, Ultrasonic

CAB_E, Cab-Engine

CAN LM

CAN Low

G 0.8 TXL TWIST

SPL_CAN_TEL2, Ultrasonic

TEL, Telematics

CAN LP

CAN Low, Can Mod3

G 0.8 GXL TWIST

SPL_CAN_JS_L1, Ultrasonic

JSS_CAB, JSS Cab

CAN LQ

CAN Low

G 0.8 TXL TWIST

SPL_CAN_JS_L1, Ultrasonic

SPL_CAN_JS_L2, Ultrasonic

CAN LR

CAN Low, Can Mod2

G 0.8 GXL TWIST

SPL_CAN_JS_L2, Ultrasonic

JSS_CAB, JSS Cab

CAN LS

CAN2 LO, NOX

G 0.8 GXL TWIST

SPL_CAN_LV, Ultrasonic

EDC7, Engine Controller

CAN LU

CAN2 LO, NOX

G 0.8 TXL TWIST

NOXS, NOX Sensor

SPL_CAN+LT, Ultrasonic

CAN LV

CAN2 LO, TERM

G 0.8 GXL TWIST

TERM_CAN_2, Can Bulk Head

SPL_CAN_LT, Ultrasonic

CAN LW

CAN LO, EVGT

G 0.8 TXL TWIST

SPL_CAN_LV, Ultrasonic

Turbo, Eng Dash_Turbo

CAN LX

CAN2 LO, Diag2

G 0.8 GXL TWIST

SPL_CAN_GL, Ultrasonic

DIA_2, Diagnostic

CAN LY

CAN Low

G 0.8 TXL TWIST

SPL_CAN_TEL2, Ultrasonic

SPL_CAN_DIAG_L, Ultrasonic

CAN LZ

CAN 2 LO

G 0.8 GXL TWIST

SPL_CAN_LV, Ultrasonic

SPL_CAN_LT, Ultrasonic

4002-45

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire ECC L1

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cav

Connector

Cav

ECC, Elect CNTR C

L1-1

ECA-L1, B+ Power

cs01

ECA, Elect Center A

ECA-BUSS

ECA, Elect Center A

Emergency Steer AIC Power

ECA-BUSS

ECA, Elect Center A

Emergency Steer AIC Power

ECA-BUSS

ECA, Elect Center A

Emergency Steer Plt EM Dtnts

ECA-BUSS

ECA, Elect Center A

Pltem Dtnts Park Brk Sol

ECA-BUSS

ECA, Elect Center A

Park Brake Solenoid Horn

ECA-BUSS

ECA, Elect Center A

Fan Reverse Turn Signal

ECA-BUSS

ECA, Elect Center A

Turn Signal Engine Shut Down

ECA-BUSS

ECA, Elect Center A

J10

DNOX SW B+

ECA-BUSS

ECA, Elect Center A

J11

Blower Motor Power

ECA-BUSS

ECA, Elect Center A

PRMB_L1, B+ Power

cs01

J12

Blower Motor Front Wiper Washer

ECA-BUSS

ECA, Elect Center A

J13

Front Wiper Rear Wiper Washer

ECA-BUSS

ECA, Elect Center A

J14

Rear Wiper Washer Backup

ECA-BUSS

ECA, Elect Center A

J15

Backup AC

ECA-BUSS

ECA, Elect Center A

J17

Seat Comp EMG Strtr

ECA-BUSS

ECA, Elect Center A

J18

Diagnostic Power

ECA-BUSS

ECA, Elect Center A

J19

ECA-BUSS

ECA, Elect Center A

J10 ECC

BUSS

ECC, Elect Center C

L1-9

ECC, Elect Center C

L1-10

Beacon/Dome Light L1 ECC

BUSS

L1-ECC, ECC Batt Power

Trans ECM Power

ECA-BUSS

Trans ECM Power

J2 ECC

Beacon/Dome Lt Work Lights

ECC-BUSS

ECC, Elect Center C

L1-1

ECC, Elect Center C

L1-2

J3 ECC

Work Lights Driving Lights

ECC-BUSS

ECC, Elect Center C

L1-2

ECC, Elect Center C

L1-3

J4 ECC

Driving Lights Brake Lights

ECC-BUSS

ECC, Elect Center C

L1-3

ECC, Elect Center C

L1-4

J5 ECC

Brake Lights Delay Power

ECC-BUSS

ECC, Elect Center C

L1-4

ECC, Elect Center C

L1-5

J6 ECC

Delay Power Horn

ECC-BUSS

ECC, Elect Center C

L1-5

ECC, Elect Center C

L1-6

4002-46

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

1.0 mm 2.0 mm 5.0 mm DU = Dark Blue W = White Or = Orange

Wire Identification Wire

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cav

ECC-BUSS

ECC, Elect Center C

L1-6

ECC, Elect Center C

L1-7

J9 ECC

ECC-BUSS

ECC, Elect Center C

L1-8

ECC, Elect Center C

L1-9

RAD1 Radio Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD2 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD3 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD4 Left Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD5 Left Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD6 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD7 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD8 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD9 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD10 Right Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD11 Right Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

J7 ECC

Circuit

S = Gray N = Brown R = Red

Horn HOD Control

Connector

Cav

4002-47

UNDERSTANDING THE TROUBLESHOOTING TABLES 1 – Alternator

Check Points

Correct Reading

Check the 10 ampere fuse at location 3 and 4C in the fuse block. Terminal for wire 1A to ground

Good 12 volts

Possible Cause of Bad Reading

Bad fuse. Check wire 1A between the starter terminal (21) and the alternator (1).

NOTE: If the readings are good, see Section 4004 and check the starter.

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

This title is the number and component name on the Electrical Schematic. This column shows the location of the check point. This column shows the indication of the check. This column shows the possible cause of a bad test indication. The numbers in the parentheses show the number of the component on the Electrical Schematic. This statement assumes that all other problems are solved at this point in the test.

LOCATING COMPONENTS ON THE SCHEMATIC POSTERS NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual. Components can be located on the Electr ical Schematic posters (rear pocket) by item number using the key at the bottom of the posters.

4002-48

STARTING AND CHARGING SYSTEMS

9 3

4 11 6 RCPH10WHL094FAH

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

STARTING RELAY RESISTOR 75 OHM ALTERNATOR CRANK CONTROL RELAY BATTERIES CRANK REQUEST RELAY

7. 8. 9. 10. 11. 12.

MASTER DISCONNECT SWITCH STARTER IGNITION SWITCH NEUTRAL START RELAY

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-49

1 – Starting Relay Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access. Check Points Terminal for wire 0-GB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Terminal for wire 1-Z to ground

24 volts

Check circuit to batteries.

NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal for wire 21D to ground

24 volts

Check crank control relay (4), also check circuit 21D.

Terminal for wire 1-BB to ground

24 volts

Bad starting relay.

2 – Resistor Located in the cab access panel for fuses and relays. NOTE: Turn master disconnect switch off, disconnect terminals from resistor. Check Points Between terminals of resistor

Correct Reading 75 ohms

Possible Cause of Bad Reading Bad resistor.

3 – Alternator Located on left side of engine, open engine compartment to gain access. Check Points Between housing of alternator and ground

Correct Reading Continuity

Possible Cause of Bad Reading

Bad ground connection.

NOTE: Put the master disconnect switch in the ON position. Between the B+ terminal of alternator and ground

24 volts

Check circuit to positive post of left battery. Bad master disconnect switch.

Between terminal for wire 1-BA and ground

24 volts

Bad wire 1-BA.

NOTE: Put the ignition switch in the ON position. Between the B+ terminal of alternator and ground

24 volts

Check circuit to positive post of left battery.

Terminal for wire 14 to ground

20 volts

Check circuit 14, 75 ohm resistor, and diode module. Bad fuse ECA-F4. Check power relay module A, and 105 ampere circuit breaker in engine compartment of machine.

NOTE: If the readings are good, repair or replace the alternator.

4002-50

4 – Crank Control Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 21H to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit or bad EDC7 (24).

NOTE: Put the master disconnect switch in the ON position. Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal for wire 21C-B to ground

24 volts

Bad neutral start relay (11), check wire circuit 21C.

Terminal for wire 21G to ground

24 volts

Bad EDC7 (24), check wire circuit 21G.

Terminal for wire 21D-A to ground

24 volts

Bad crank control relay.

5 – Batteries Located on right and left rear sides of the machine. NOTE: See Section 4003 and check the batteries.

6 – Crank Request Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DF to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Have another person hold the ignition switch in the START position. Terminal for wire 21C-A to ground

24 volts

Check circuit 21 to neutral start relay (11).

Terminal for wire 21E to ground

24 volts

Bad crank request relay.

7 –

4002-51

8 – Master Disconnect Switch Located on right side battery box cover, remove battery box cover to gain access. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect switch in ON position. Between terminals of master disconnect switch

Continuity

If there is no continuity, the master disconnect switch (2) is bad.

NOTE: Put the master disconnect switch in the OFF position. Between terminals of master disconnect switch

Open Circuit

If there is continuity, the master disconnect switch is bad.

NOTE: Use the same method to check the master disconnect switch (auxiliary contact).

9 – Starter Motor Located on left side of engine, open engine compartment to gain access. Check Points Between housing of starter and ground

Correct Reading Continuity

Possible Cause of Bad Reading

Bad ground connection.

NOTE: Put the master disconnect switch in the ON position. Starter B+ stud to ground

24 volts

Check circuit to batteries.

NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position. Terminal S to ground

24 volts

Bad starting relay (1). Also check wire 1-BB between starter and starting relay (1).

NOTE: If the readings are good, repair or replace the starter.

4002-52

10 – Ignition Switch Located on steering column. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch in the ON position. Terminal for wire 1DM to ground

24 volts

Check circuit 1DM to ECC-F5 fuse.

NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON. Between Bat and Ign

Continuity

Bad ignition switch.

Between Bat and Accessory

Continuity

Bad ignition switch.

NOTE: Hold the ignition switch in the START position. Between Bat and Starter

Continuity

Bad ignition switch.

Between Bat and Ign

Continuity

Bad ignition switch.

NOTE: Put the switch in the Accessory position. Between Bat and Accessory

Continuity

Bad ignition switch.

11 – Neutral Start Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DE to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL. Terminal for wire 25T to ground

24 volts

Check circuit 25T, check FNR switch (55).

NOTE: Have another person hold the ignition switch in the START position. Terminal for wire 21K-B to ground

24 volts

Check circuit 21K-B and ignition switch (10).

Terminal for wire 21C to ground

24 volts

Bad neutral start relay.

12 –

4002-53

POWER RELAY MODULES AND COLD STARTING SYSTEMS

20 21

13 14 18 15 RCPH10WHL094

13. 14. 15. 16. 17.

POWER RLEAY MODULE A POWER RELAY MODULE B POWER RELAY MODULE C GRID HEATER RELAY GRID HEATER

18. POWER RELAY MODULE D 19. 20. WATER SEPARATOR HEATER 21. FUEL FILTER HEATER

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-54

13 – Power Relay Module A, Power converter F1, Secondary steering F2 Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

Check fuse F1, F2

Continuity

Bad fuse or circuit.

Terminal for wire 0-EU to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position. Terminal for wire 1CB-A to ground

24 volts

Check circuit 1CB.

Terminal for wire 12ACC-C to ground

24 volts

Check circuit 12ACC and check ignition switch (10).

Terminal for wire 19L to ground

24 volts

Bad power relay module A.

14 – Power Relay Module B, ACC Power F1, DNOX F2 Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

Check fuse F1, F2

Continuity

Bad fuse or circuit.

Terminal for wire 0-EC to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position. Terminal for wire 12ACC-B to ground

24 volts

Check circuit 12ACC, check ignition switch (10).

Terminal for wire 1CB-A to ground

24 volts

Check circuit 1CB.

Terminal for wire PRM-B J11 BUSS to ground

24 volts

Bad power relay module B

15 – Power Relay Module C, Ignition Power F1 Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

Check fuse F1

Continuity

Bad fuse or circuit.

Terminal for wire 0-EB to ground

Continuity

Bad ground circuit.

NOTE: Put the ignition switch in the ON position. Terminal for wire 13K-C to ground

24 volts

Check 13K and check ignition switch (10).

Terminal for wires J1 BUSS to ground

24 volts

Bad power relay module.

4002-55

16 – Grid Heater Relay Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access. Check Points Terminal for wire 0-BV to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit or bad EDC7 (24).

NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position. Terminal for wire 1-Y to ground

24 volts

Bad 150 ampere fuse. Check wires 1-Y and 1-E.

NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make sure engine temperature is below -0 ° C (32 ° F). Terminal for wire 28G to ground

24 volts

Bad EDC7 (24), also check circuit 28G.

Terminal for wire 1-BE to ground

24 volts

Bad grid heater relay.

17 – Grid Heater Located in the right side of the engine in intake manifold, open engine compartment to gain access. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect terminal for wire 1-BE from grid heater. Terminal for wire 0-ES to ground

Continuity

Bad ground circuit.

Terminal for wire 1-BE of grid heater to ground

Resistance

If an open or short circuit is obtained, replace the grid heater.

18 – Power Relay Module D, Fuel Filter Heater F1, Engine ECM F2 Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.

Check Points Check fuse F1, F2

Correct Reading

Possible Cause of Bad Reading

Continuity

Bad fuse or circuit.

Continuity

Bad ground circuit or bad EDC7 (24).

NOTE: Make sure engine temperature is below 0 ° C (32 ° F). Terminal for wire 31B to ground

NOTE: Turn the ignition switch to the ON position. Terminal for wire 1-NC to ground

24 volts

Check circuit 1-NC.

Terminal for wire 28F to ground

24 volts

Check EDC7 (24).

Terminal for wire 1-GA to ground

24 volts

Bad power relay module

19 –

4002-56

20 – Water Separator Heater Located in the right side of the engine compartment on water separator housing, open engine compartment to gain access. Check Points Terminal for wire 0-BW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect connector WSH from water separator heater. Between terminals A and B of heater

1.9 ohms

Bad heater.

NOTE: If the readings are good, check circuit 1-GA between water separator heater connector WSH and power relay module D connector PRM-D1.

21 – Fuel Filter Heater Located in the right side of the engine compartment on fuel filter housing, open engine compartment to gain access. Check Points Terminal for wire 0-BX to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect connector FFH from fuel filter heater. Between terminals A and B of heater

1.9 ohms

Bad heater.

NOTE: If the readings are good, check circuit 1-G between fuel filter heater connector FFH and power relay module D connector PRM-D1.

4002-57

ENGINE CONTROLLER

23 RCPH10WHL094FAH

22. WATER IN FUEL SENSOR 23. THROTTLE POTENTIOMETER 24. ENGINE CONTROLLER

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-58

22 – Water In Fuel Sensor Located in the right side of the engine compartment on water separator housing, open engine compartment to gain access. Correct Reading

Check Points

Continuity

Terminal for wire 0-BP to ground

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. 24 volts

Terminal for wire 18J-H to ground

Check power EDC7, also check circuit 18J.

NOTE: Remove sensor from filter and place probes in water. 24 volts

Terminal for wire 35W to ground

Bad water separator sensor.

23 – Throttle Potentiometer Located below cab under throttle pedal. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position. Terminal for wire 24S to 24R Terminal for wire 24R to ground

5 volts

Bad EDC7 (24). Also check wire 24S.

Continuity

Bad EDC7 (24). Also check wire 24R.

NOTE: Throttle pedal in low idle position. Terminal for wire 24B to 24R

0.4 ± 0.025 volts

Bad potentiometer.

NOTE: Throttle pedal in high idle position. Terminal for wire 24B to 24R

4.0 ± 0.1 volts

Bad potentiometer.

NOTE: Put the ignition switch in OFF position and the master disconnect switch in the OFF position. Disconnect connector RTHP. Throttle pedal in low idle position. Between pin 1 and 6 at pedal

Open

Bad potentiometer.

NOTE: Throttle pedal in high idle position.

Between pin 1 and 6 at pedal

1000 ± 400 ohms at 20° C (68° F)

Bad potentiometer.

1200 ± 400 ohms at 20° C (68° F)

Bad potentiometer.

NOTE: Throttle pedal in any position.

Between pin 4 and 5 at pedal

4002-59

24 – Electronic Diesel Control Located on right side of engine, open engine compartment to gain access. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the ignition switch in the OFF position. Put the master disconnect switch in the OFF position. Disconnect connector EDC7. Terminal for wire 0-BE pin 5 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BF pin 6 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BD pin 10 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BC pin 11 to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position. Terminal for wire 18J-C pin 2 to ground

24 volts

Bad fuse ECM-F2, bad wire 18J.

Terminal for wire 18J-B pin 3 to ground

24 volts

Bad fuse ECM-F2, bad wire 18J.

Terminal for wire 18J-D pin 8 to ground

24 volts

Bad fuse ECM-F2, bad wire 18J.

Terminal for wire 18J-E pin 9 to ground

24 volts

Bad fuse ECM-F2, bad wire 18J.

NOTE: Use diagnostic service tool for additional tests on EDC7.

4002-60

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE 28 30

25 26 31 32

27 29

34 RCPH10WHL094FAH

25. 26. 27. 28. 29.

RETURN TO TRAVEL FLOAT SWITCH HEIGHT CONTROL SWITCH ELETROMAGNETIC DETENTS RETURN TO DIG PROXIMITY SWITCH PILOT CONTROL RELAY ECD-K3

30. 31. 32. 33. 34.

HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH RETRUN TO DIG SWITCH PIN ENGAGE SWITCH (OPTION) PILOT PRESSURE SOLENOID PIN ENGAGE SOLENOID (OPTION)

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-61

25 – Return-To-Travel/Float Switch Located on right side console. Check Points

Correct Reading

Possible Cause of Bad Reading

Terminal for wire 0-B2 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-29 to ground

Continuity

Bad ground circuit.

NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-totravel/float switch in FLOAT position. Between switch terminals 1 and 2

Continuity

Bad return-to-travel/float switch.

NOTE: Put the return-to-travel/float switch in the TRAVEL position. Between switch terminals 2 and 3

Continuity

Bad return-to-travel/float switch.

NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put ignition switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 49-K to ground

24 volts

Bad circuit 49-K. Also check driving lamp switch (95). If return-to-travel/float switch illumination LED is not ON with 24 volts at check point, replace return-to-travel/float switch.

Correct Reading

Possible Cause of Bad Reading

26 – Height Control Switch Located on right side console. Check Points Terminals for wire 0-B3 to ground

Continuity

Bad ground circuit.

NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control switch to the ON position. Terminal for wire 53P-D to ground.

24 volts

Bad pilot control relay (29), check fuse ECA-F5.

NOTE: Turn the height control switch to the ON position. Terminal for wire 54A to ground.

24 volts

Bad height control switch.

4002-62

27 – Electromagnetic Detents Located under right side console. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: For joystick controller. Between pins 3 and 4

74 ohms @ 20° C (68° F)

Bad electromagnetic detent

Between pins 2 and 5

74 ohms @ 20° C (68° F)

Bad electromagnetic detent

Between pins 1 and 6

74 ohms @ 20° C (68° F)

Bad electromagnetic detent

Between pins 3 and 4

328 ohms @ 20° C (68° F)

Bad electromagnetic detent

Between pins 2 and 5

328 ohms @ 20° C (68° F)

Bad electromagnetic detent

Between pins 1 and 6

328 ohms @ 20° C (68° F)

Bad electromagnetic detent

NOTE: For single axis controller.

NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFF position and return to travel/float switch (25) in ON position. Wiring harness connector EM, pin 1 to ground

24 volts

Bad return to travel/float switch (25). Also check wires 55A.

NOTE: Place the height control switch in the ON position. Wiring harness connector EM, pin 2 to ground

24 volts

Bad height control switch (26). Also check wires 54A.

NOTE: Place the return to dig switch in the ON position. Wiring harness connector EM, pin 3 to ground

24 volts

Bad return to dig switch (31). Also check wires 53A.

28 – Return-To-Dig Proximity Switch Located on bucket cylinder. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to dig switch in the ON position. Terminal B for wire 0-AM to ground

Continuity

Bad ground circuit.

Terminal A for wire 53B to ground

24 volts

Bad bucket control valve detent electromagnets (27) or return to dig switch. Also check circuit 53B.

Terminal C for wire 53P-I to ground

24 volts

Bad pilot relay (29), also check circuit 53P.

NOTE: If the readings are good, replace the return-to-dig proximity switch.

4002-63

29 – Pilot Control Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch (39) is OFF. Terminal for wire 19C-C to ground

24 volts

Terminal for wire 53C-A to ground

0 volt

Terminal for wire 53P-A to ground

24 volts

Bad fuse ECA-F5, also check circuit 19C. Bad instrument cluster (62). Also check circuit 53C. Bad pilot control relay.

NOTE: Put the pilot control switch in ON position. Terminal for wire 53C-A to ground

24 volts

Bad instrument cluster (62). Also check circuit 53C.

30 – Height Control/Return-To-Travel Proximity Switch Located on left front frame at lift arm pivot. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the connector from the height control/return-to-travel proximity switch. Put the master disconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to travel switch in the ON position. Terminal B for wire 0-AA to ground

Continuity

Terminal A for wire 54B to ground

24 volts

Bad bucket control valve detent electromagnets (27) or return to travel switch. Also check circuit 54B.

Terminal C for wire 53P-J to ground

24 volts

Bad pilot relay (29), also check circuit 53P.

Bad ground circuit.

NOTE: If the readings are good, replace the height control/return-to-travel proximity switch.

31 – Return to Dig Switch Located on right side console. Check Points Terminals for wire 0-B4 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control switch to the ON position. Terminal for wire 53P-E to ground.

24 volts

Bad pilot control relay (29), check fuse ECA-F5.

NOTE: Turn the height control switch to the ON position. Terminal for wire 53A to ground.

24 volts

Bad return to dig switch.

4002-64

32 – Pin Engage Switch (Option) Located on right side console. Check Points Terminal for wire 0-B5 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF position. Terminal for wire 19P-A to ground Terminal for wire 57-B to ground

24 volts 0 volt

Bad fuse ECA-F7 or power relay module C. Also check circuit 19P. Bad pin engage switch.

NOTE: Put the pin engage switch in the ON position. Terminal for wire 57-B to ground

24 volts

Bad pin engage switch.

NOTE: Put the driving lamp switch (95) in position 3.

Terminal for wire 49-F to ground

24 volts

Check the driving lamp switch (95). Also check circuit 49. If LED in pin engage switch is not ON with 24 volts at check point, replace pin engage switch.

Correct Reading

Possible Cause of Bad Reading

33 – Pilot Pressure Solenoid Located on bottom side of pilot controls. Check Points Terminal for wire 0-DU to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control switch (39) is OFF. Terminal A for wire 53P-A to ground

24 volts

Bad pilot control relay (29), also check circuit 53P.

NOTE: If the readings are good, replace the pilot pressure solenoid.

34 – Pin Engage Solenoid (Option) Located on. Check Points Terminal for wire 0-AW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch (32) in the ON position. Terminal for wire 57-D to ground

24 volts

Bad pin engage switch (32), also check circuit 57.

NOTE: If the readings are good, replace the pin engage solenoid.

4002-65

PILOT CONTROL - RIDE CONTROL - FAN CONTROL

43 44

35 37 39

40 41

42 RCPH10WHL094FAH

35. 36. 37. 38. 39.

RIDE CONTROL SWITCH (OPTION) RIDE CONTROL RELAY (OPTION) FAN CONTROL SWITCH (OPTION) FAN REVERSE RELAY (OPTION) PILOT CONTROL SWITCH

40. 41. 42. 43. 44.

RIDE CONTROL SOLENOID (OPTION) ROLLBACK PRESSURE SWITCH (OPTION) ROLLBACK JUMPER FAN PWM SOLENOID FAN REVERSE SOLENOID (OPTION)

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-66

35 – Ride Control Switch Located on right side console. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector SRC from ride control switch. Connector SRC pin 7 to ground

Continuity

Bad ground circuit.

Ride control switch terminal 6 (positive) to terminal 7 (negative)

Continuity

Bad ride control switch.

NOTE: Connect connector SRC to ride control switch. Put master disconnect switch and ignition switch in ON position. Put ride control switch in OFF position. Terminal for wire 19C-D to ground Terminal for wire 58C to ground

24 volts 0 volt

Check fuse ECA-F5 and power relay module C. Also check circuit 19C. Bad ride control switch.

NOTE: Put the ride control switch in the ON position. Terminal for wire 58C to ground

24 volts

Bad ride control switch.

NOTE: Put the driving light switch (95) in position 3.

Terminal for wire 49-G to ground

24 volts

Check driving lamp switch (95). Also check circuit 49. If LED in ride control switch is not ON with 24 volts at check point, replace ride control switch.

36 – Ride Control Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

Terminal 85 for wire 58L to connector TECM pin 57

Continuity

Check wire 58L.

Terminal 86 for wire 58H-C to connector TECM pin 8

Continuity

Check wire 58H-C.

Terminal 87 for wire 58-E to ride control switch (35) pin 6

Continuity

Check wire 58-E

NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position. Terminal for wire 58T to ground

24 volts

Bad ride control switch. Also check wire 58T.

NOTE: If readings are normal, replace ride control relay.

4002-67

37 – Fan Control Switch (Option) Located on right side console. Check Points Terminal for wire 0-B7 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19P-C to ground

24 volts

Check fuse ECA-F7, power relay module C, also check circuit 19P.

NOTE: Put fan control switch in position 1. Terminal for wire 52AU to ground

24 volts

Bad fan control switch.

NOTE: Put fan control switch in momentary position, hold rocker. Terminal for wire 52M to ground

24 volts

Bad fan control switch.

NOTE: Put driving lamp switch in position 3. Terminal for wire 49-Q to ground

24 volts

Check driving lamp switch. If LEDs in fan control switch are not ON with 24 volts at check point, replace fan control switch.

38 – Fan Reverse Relay (Option) Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 19P-D and 19P-E to ground

24 volts

Check fuse ECA-F7 and circuit 19P.

NOTE: Put the fan control switch in the manual reverse position. Terminals for wire 52A-A to ground

24 volts

Bad fan reverse solenoid, bad fan control switch (37), bad advanced instrument cluster (62).

4002-68

39 – Pilot Control Switch Located on steering column pedestal. Check Points Terminal for wire 0B1 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19C-F to ground

24 volts

Bad fuse ECA-F5, also check circuit 19C.

NOTE: Press pilot control switch to turn ON switch LED. Terminal for wire 31L to ground

24 volts

Bad pilot control switch.

NOTE: Put the driving lamp switch (95) in position 3. Terminal for wire 49-N to ground

24 volts

Check driving lamp switch (95) and fuse ECC-F3. Also check circuit 49.

NOTE: If the readings are correct replace the pilot control switch.

40 – Ride Control Solenoid Located on ride control valve inside of front frame. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector YRC from ride control solenoid. Connector YRC pin 2 to ground Between terminals 1 and 2 of ride control solenoid

Continuity 20 to 26 ohms

Bad ground circuit. Bad ride control solenoid.

41 – Rollback Pressure Switch (Option) Located inside of front frame. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Switch opens at 6.2 bar (90 psi). Release all hydraulic pressure from the system, disconnect the wiring harness from the rollback pressure switch. Between terminals A and B on switch

Continuity

Bad rollback pressure switch.

Terminal for wire 58 to ground

37 to 43 ohms

Bad ride control solenoid (40).

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the ride control switch (35) in the ON position. Accelerate the machine to at least 5 km/hr (3 m.p.h.).

Terminal for wire 58-B to ground

24 volts at 5 km/hr (3 m.p.h.)

Bad ride control relay (36) or ride control switch (35). Also check circuit 58.

4002-69

42 – Rollback Jumper (Option) Located inside of front frame. Check Points Between terminals A and B on switch

Correct Reading Continuity

Possible Cause of Bad Reading

Bad rollback jumper.

43 – Fan PWM Solenoid (Option) Located on fan control valve. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid. Between pins A and B of fan PWM solenoid

26 to 32 ohms

Pin B of wiring harness connector YFN to ground

Continuity

Bad fan reversing solenoid.

Bad ground circuit.

NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise transmission temperature to high operating range. Pin A of wiring harness connector YFN to ground

24 volts

Bad instrument cluster. Also check wire 56.

44 – Fan Reversing Solenoid (Option) Located on fan control valve. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector YFR from fan reversing solenoid. Between pins 1and 2 of fan reversing solenoid Pin 2 of wiring harness connector YFR to ground

36 to 42 ohms

Continuity

Bad fan reversing solenoid.

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON position (hold rocker in momentary position). Pin 1 of wiring harness connector YFR to ground

24 volts

Bad fan control switch. Also check wire 52-A.

4002-70

TRANSMISSION

52 55 56 57 60

49 50 51

45 53 54 47 61 58 RCPH10WHL094FAH

45. 46. 47. 48. 49. 50. 51. 52. 53.

OUTPUT SPEED SENSOR TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS FILTER MAINTENANCE SWITCH TORQUE CONVERTER OUTPUT TEMPERATURE SENDER ENGINE SPEED SENSOR INTERMEDIATE SPEED SENSOR TURBINE SPEED SENSOR TRANSMISSION SHIFTER TRANSMISSION ELECTRONIC CONTROL MODULE

54. 55. 56. 57. 58. 59. 60. 61.

TRANSMISSION ENABLE SWITCH FNR SWITCH FOR JOYSTICK CONTROLS TRANSMISSION KICK-DOWN SWITCH FNR SWITCH FOR SINGLE AXIS CONTROLS TRANSMISSION AUTO SWITCH BRAKE DECLUTCH PRESSURE SWITCH DECLUTCH SWITCH DIAGNOSTIC CONNECTOR

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-71

NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for Items 45 through 61.

45 – Output Speed Sensor 46 – Transmission Solenoid Valve and Temperature Sensors 47 – Filter Maintenance Switch 48 – Torque Converter Output Temperature Sender 49 – Engine Speed Sensor 50 – Intermediate Speed Sensor 51 – Turbine Speed Sensor 52 – Transmission Shifter 53 – Transmission Electronic Control Module 54 – Transmission Enable Switch 55 – FNR Switch for Joystick Controls 56 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) 57 – FNR Switch for Single Axis Controls 58 – Transmission Auto Switch 59 – Brake Declutch Pressure Switch 60 – Declutch Switch 61 – Diagnostic Connector

4002-72

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE

66 62 63

67 69

64 RCPH10WHL094FAH

62. 63. 64. 65.

INSTRUMENT CLUSTER CONNECTOR 1 WARNING BUZZER PARKING BRAKE RELAY FUEL LEVEL SENDER

66. 67. 68. 69.

AIR FILTER RESTRICTION SWITCH PARKING BRAKE SOLENOID RADIATOR COOLANT TEMPERATURE SENDER BRAKE PRESSURE WARNING SWITCH

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-73

62 – Instrument Cluster Connector 1 Located on instrument cluster. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad. Connector terminal SW-PD 5 to ground

Open Circuit

Bad air filter restriction switch (66). Also check circuit 31F-A.

Connector terminal SW-PD 4 to ground

Open Circuit

Bad hydraulic filter restriction switch (72). Also check circuit 31H-A.

Connector terminal AIC-1 6 and 12 to ground

Continuity

Bad ground circuit. Check wires 0-DW and 0-DX.

Connector terminal AIC-1 11 to ground

130 to 9500 ohms

Bad engine coolant temperature sender (68). Also check circuit circuit 36C-A and ground circuit at sender.

Connector terminal AIC-1 2 to ground

33 to 240 ohms

Bad fuel level sender (65). Also check circuit 36F-A and ground circuit at sender.

Connector terminal AIC-1 9 to ground

130 to 9500 ohms

Bad hydraulic oil temperature sender (73). Also check circuit 36H-A and ground circuit at sender.

Connector terminal AIC-1 25 to connector terminal SW-PD 9

Continuity

Connector terminal AIC-2 4 to ground

Open Circuit

Bad wire 17P-A or 17P-B. Bad redundant brake switche(s) (75)(76). Also check circuit 33R.

Connector terminal AIC-1 4 and SW-PD 8 to terminals 26 and 27 on the transmission electronic control module (53)

Continuity

Bad circuit CAN-L.

Connector terminal AIC-1 3 and SW-PD 7 to terminal 25 on the transmission electronic control module (53)

Continuity

Bad circuit CAN-H.

NOTE: Put the parking brake switch in the ON position. Connector terminal AIC-1 14 to ground

24 volts

Bad parking brake switch (64). Also check fuse ECA-F6 and circuit 19D-B and 52C.

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise. Connector terminal 10 to ground

24 volts

Check fuse G, blower switch, thermostat switch, and A/C low pressure switch. Also check circuits 61R, 61A, and 61T.

NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position. Connector terminal SW-PD 1 to ground

24 volts

Check high/low beam switch, driving lamp switch, and fuse ECB-F3 or F4. Also check circuit 41H-D.

NOTE: Press pilot control switch to turn ON switch LED. Connector terminal AIC-1 14 to ground

24 volts

Bad parking brake relay or fuse ECA-F6. Also check circuits 52C and 19D-B.

Connector terminal AIC-1 20 to ground

24 volts

Bad pilot control relay or fuse ECA-F5. Also check circuits 53C-A and 19C-C.

4002-74

63 – Warning (AIC) Buzzer Located on steering column under instrument cluster. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on. Terminal for wire 0_B27 to ground

Continuity

Bad ground circuit.

NOTE: Turn the ignition switch to the ON position Terminal for wire 35B to ground

24 volts

Bad instrument cluster

NOTE: If all readings are good, replace buzzer.

64 – Parking Brake Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake switch (74) is OFF. Terminal for wire 19D-B and 19D-C to ground Terminal for wire 52C to ground Terminal for wire 52P-B to ground

24 volts 0 volt 24 volts

Bad fuse ECA-F6, also check circuit 19D. Bad instrument cluster (62). Also check circuit 52C. Bad parking brake relay.

NOTE: Put the parking brake switch in the ON position. Terminal for wire 52C to ground

24 volts

Bad instrument cluster (62). Also check wire 52C.

65 – Fuel Level Sender Located on the fuel tank top right side. Check Points Terminal for wire 0-BU to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 36F to ground

Approximately 5 volts

Check the instrument cluster (62).

NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the wires from the fuel level sender. Between terminals of fuel level sender

33 to 240 ohms

Bad fuel level sender.

4002-75

66 – Air Filter Restriction Switch Located on the air filter left side. Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig). Continuity

Terminal for wire 0-BY to ground

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 31F to ground

Approximately 11.5 volts

Check the instrument cluster (62).

NOTE: If the readings are correct replace the air filter restriction indicator switch.

67 – Parking Brake Solenoid Located on the foot brake valve. Check Points Terminal for wire 0-AN to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF position. Terminal 1 for wire 52P to ground

24 volts

Bad parking brake relay (64). Also check circuit 52P

NOTE: If the readings are good, replace the parking brake solenoid.

68 – Radiator Coolant Temperature Sender Located on the lower radiator hose to engine on left side of engine compartment. Check Points Terminal for wire 0-BAE to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect the connector from the radiator coolant temperature sender. Between terminals of radiator coolant temperature sender

3521 ohms at 20° C (68° F)

Replace radiator coolant temperature sender.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36C to ground

Approximately 5 volts

Check the instrument cluster (62).

4002-76

69 – Brake Warning Pressure Switch Located on the foot brake valve. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi). NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal 2 for wire 0-AL to ground

Continuity

Bad ground circuit.

Terminal 1 for wire 33P to ground

Approximately 11.5 volts

Check circuit 33P.

NOTE: With engine not running pump brakes at least 12 times. Disconnect the wires from the brake warning pressure switch. Between terminals 1 and 2 of the switch

Continuity

Bad brake warning pressure switch.

NOTE: Start and run the engine at idle two minutes. Between terminals 1 and 2 of the switch

Open Circuit

Bad brake warning pressure switch or brake pressure is below 110.3 bar (1600 psi). Refer to Section 7002 to check brake pressure.

4002-77

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE

70 71 74

75 76

72 73 RCPH10WHL094FAH

70. 71. 72. 73.

SWITCH PAD INSTRUMENT CLUSTER CONNECTOR 2 HYDRAULIC FILTER RESTRICTION SWITCH HYDRAULIC OIL TEMPERATURE SENDER

74. PARK BRAKE SWITCH 75. REDUNDANT BRAKE PRESSURE SWITCH 1 76. REDUNDANT BRAKE PRESSURE SWITCH 2 77.

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-78

70 – Switch Pad Located on steering column. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect switch pad connector, put master disconnect switch and ignition switch in ON position. Terminal for wire 17P-A to ground.

24 volts

Bad instrument cluster (62).

NOTE: Disconnect instrument cluster connector 1. Between terminals for wire 17P-A

Continuity

Bad wire 17P-A.

4002-79

71 – Instrument Cluster Connector 2 Located on instrument cluster. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad. Connector terminal AIC-2 5 to ground

Continuity

Bad brake warning pressure switch (69). Also check circuit 33P-A and ground circuit at brake warning pressure switch.

Connector terminal AIC-2 11 to ground

Continuity

Bad secondary steering pressure switch (118). Also check circuit 35X and ground circuit at pressure switch.

Connector terminal SW-PD 5 to ground

Open Circuit

Bad air filter restriction switch (66). Also check circuit 31F-A.

Connector terminal SW-PD 4 to ground

Open Circuit

Bad hydraulic filter restriction switch (72). Also check circuit 31H-A.

Connector terminal AIC-2 15 and 22 to ground. Connector terminal AIC-2 4 to ground

Continuity

Open Circuit

Bad ground circuit. Check wires 0-DB and 0-DA. Bad redundant brake switche(s) (75)(76). Also check circuit 33R.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connector terminal AIC-2 14 and 20 to ground

24 volts

Bad fuse ECD-F8. Also check circuit 19S-C and 19S-D.

Connector terminal AIC-2 21 to ground

24 volts

Bad fuse ECA-F3. Also check circuit 19E-A. Also check power relay module C (15).

NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise. Connector terminal 10 to ground

24 volts

Check fuse G, blower switch, thermostat switch, and A/C low pressure switch. Also check circuits 61R, 61A, and 61T.

NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position. Connector terminal SW-PD 1 to ground

24 volts

Check high/low beam switch, driving lamp switch, and fuse ECB-F3 and F4. Also check circuit 41H-D.

NOTE: Put the turn signal switch in the LEFT TURN position. Connector terminal AIC-2 9 to ground

24 volts on and off every 1-2 seconds

Check fuse ECA-F8, turn signal switch, and flasher module. Also check circuit 45A-A to flasher module, and circuit 45L-D from flasher module to instrument cluster.

NOTE: Put the turn signal switch in the RIGHT TURN position. Connector terminal AIC-2 10 to ground

24 volts on and off every 1-2 seconds

Check fuse ECA-F8, turn signal switch, and flasher module. Also check circuit 45B-A to flasher module, and circuit 45R-E from flasher module to instrument cluster.

NOTE: Press pilot control switch to turn ON switch LED. Connector terminal AIC-2 18 to ground

24 volts

Bad pilot control switch or fuse ECA-F5. Also check wire 31L and circuit 19A.

4002-80 ]

72 – Hydraulic Filter Restriction Switch Located on hydraulic filter block. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi). Check between the housing of the hydraulic filter restriction switch and ground

Continuity

Bad ground connection between the hydraulic filter restriction switch and ground.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 31H to ground.

Approximately 11.5 volts

Check the instrument cluster (62).

NOTE: If the readings are correct replace the hydraulic filter restriction switch.

73 – Hydraulic Oil Temperature Sender Located on hydraulic filter block. Check Points Terminal for wire 0-HW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect the connector from the hydraulic oil temperature sender. Between terminals of hydraulic oil temperature sender

3521 ohms at 20° C (68° F)

Replace hydraulic oil temperature sender.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 36H to ground

Approximately 5 volts

Check the instrument cluster (62).

4002-81

74 – Parking Brake Switch Located on steering column. Check Points Terminal for wire 0-B29 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19A-L to ground

24 volts

Check fuse ECA-F6, also check circuit 19A.

24 volts

Bad parking brake switch.

NOTE: Apply parking brake switch. Terminal for wire 33U to ground

NOTE: Put the driving lamp switch (95) in position 3, 4, or 5. Terminal for wire 49-V to ground

24 volts

Bad driving lamp switch. Also check fuse ECC-F3 and circuits 41 and 19Z.

NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake switch.

75 – Redundant Brake Pressure Switch 1 Located on steel lines at accumulators. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Redundant brake switch close at 62 bar (900 psi). Terminal for wires 0-HM to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wire 33R-C to ground

Approximately 11.5 volts

Bad instrument cluster (62), also check circuit 33R.

NOTE: If the readings are good, replace the redundant brake pressure switch(es).

76 – Redundant Brake Pressure Switch 2 Located on steel lines at accumulators. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Redundant brake switches close at 62 bar (900 psi). Terminal for wireS 0-HL to ground

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal A for wireS 33R-B to ground

Approximately 11.5 volts

Bad instrument cluster (62), also check circuit 33R.

NOTE: If the readings are good, replace the redundant brake pressure switch(es).

4002-82

77 –

4002-83

BACK UP ALARM CONTROLS

78 RCPH10WHL094FAH BS06H241 / BS06H242

78. BACK UP ALARM RELAY

79. BACK UP ALARM DISABLE SWITCH

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-84

78 – Back-up Alarm Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the transmission electronic control module (53) connector TECM. Terminal for wire 35C to terminal 7 of connector TECM

Continuity

Bad wire 35C.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19A-P to ground

24 volts

Bad fuse ECA-F1, also check wires 19A-P, power relay module C, Ignition power (15).

Terminal for wire 19H to ground

24 volts

Bad fuse ECA-F14, also check wires 19H, power relay module B, accessory power (14).

NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE. Terminal for wire 35A-A to ground

24 volts

Bad back-up alarm relay.

79 – Back-up Alarm Disable Switch Located on right side console. Check Points Terminal for wire 0-B21 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF position. Depress brake pedal once. Move the transmission shift lever to REVERSE. Terminal for wire 35A-B to ground

24 volts

Bad back-up alarm relay (78), also check circuit 35A-B.

NOTE: Wires 35A-E and 35A-D are connected together, connectors 209F and 209M, and switch is removed in North American models. The connectors are disconnected and the switch is installed in TUV road approved (Germany) models. Terminal for wire 35R-C to ground

24 volts

Bad back-up alarm disable switch.

4002-85

LIGHTS - 01

87 82 85 81

80 84

RCPH10WHL094FAH

80. 81. 82. 83. 84.

WORK LIGHTS SWITCH DOOR SWITCH ROTATING BEACON (OPTIONAL) DOME LIGHT ROTATING BEACON SWITCH (OPTIONAL)

85. 86. 87. 88. 89.

LEFT HAND FRONT WORK LAMP RIGHT HAND FRONT WORK LAMP LEFT HAND REAR WORK LAMP RIGHT HAND REAR WORK LAMP DIODES

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-86

80 – Work Lamps Switch Located on right side console. Check Points Terminal for wire 0-B14 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit

NOTE: Put master disconnect witch in the ON position. Terminal for wire 42-A and 42-B to ground

24 volts

Bad fuse ECC-F2.

NOTE: Put the work lamps switch in position 2 for front work lamps. Terminal for wire 42C-C to ground

24 volts

Bad work lamps switch.

NOTE: Put the wok lamps switch in position 3 for rear work lamps. Terminal for wire 42R-C to ground

24 volts

Bad work lamps switch.

81 – Door Switch Located above door in cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch in the ON position. Terminal for wire 19U-F to ground

24 volts

Bad fuse ECC-F1.

NOTE: Disconnect connector DS at door switch. Between pins on door switch with door open

Continuity

Bad door switch.

Between pins on door switch with door closed

Open circuit

Bad door switch

82 – Rotating Beacon (Option) Plug is located on left side front of cab. Check Points

Correct Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-MC to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch and beacon switch (84) in ON position. Terminal for wire 46-D to ground

24 volts

Bad circuit between the beacon and the beacon switch (84). Also check the beacon switch (84).

NOTE: If readings are good replace the rotating beacon.

4002-87

83 – Dome Lamp Located in top of cab. Correct Reading

Check Points

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-MB to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position. 24 volts

Terminal for wire 19U-C to ground Terminal for wire 43-B to ground

24 volts 3 to 5 seconds

Check fuse ECC-F1, also check circuit 19U. Check circuit 43, also check advanced instrument cluster (62).

NOTE: If readings are good, replace dome lamp.

84 – Beacon Switch (Option) Located on right side console. Check Points Terminal for wire 0-B15 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3. Terminal for wire 19U-H to ground

24 volts

Check fuse ECC-F1, also check circuit 19U.

NOTE: Put the beacon switch in the ON position. Terminal for wire 46-C to ground

24 volts

Bad beacon switch.

85 – Left Hand Front Work Lamp Located on left front side of cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LLFW to LH front work lamp connector. Terminal for wire 0-MU to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3. Terminal for wire 42C-H to ground

24 volts

Check driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

4002-88

86 – Right Hand Front Work Lamp Located on right front side of cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LRFW to RH front work lamp connector. Terminal for wire 0-MJ to ground

Continuity

Bad ground circuit. (O-MJ, O-MG, O-MP, O-ML)

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3. Terminal for wire 42C-G to ground

24 volts

Check driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

87 – Left Hand Rear Work Lamp Located on left rear side of cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLRW from LH rear work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LLRW to LH rear work lamp connector. Terminal for wire 0-ME to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 4 or 5. Terminal for wire 42R-H to ground

24 volts

Check driving lamp switch (95). Also check circuit 42R from flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.

88 – Right Hand Rear Work Lamp Located on right rear side of cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector. Terminal for wire 0-MF to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3. Terminal for wire 42R-G to ground

24 volts

Check driving lamp switch (95). Also check circuit 42R from flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.

4002-89

89 – Lights Diodes Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector D-OR from diode connector. Multimeter positive on pin A to pin C

Continuity

Bad diode.

Multimeter positive on pin B to pin C

Continuity

Bad diode.

Multimeter positive on pin C to pin A

None

Bad diode.

Multimeter positive on pin C to pin B

None

Bad diode.

4002-90

LIGHTS - 02

93 94

90 92 91 RCPH10WHL094FAH BS06H241 / BS06H242

90. BRAKE LIGHTS SWITCH 91. BRAKE LIGHTS RELAY 92. FLASHER MODULE

93. HAZARD SWITCH 94. TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 95. DRIVING LIGHTS SWITCH

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-91

90 – Brake Lamp Pressure Switch Located on the foot brake valve. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch in ON position. Terminal for wire 1-AA to ground Terminal for wire 44 to ground

24 volts 0 volt

Check fuse ECC-F4, also check wires 1-AA and 1-DR. Bad brake lamp pressure switch.

NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal. Terminal for wire 44 to ground

24 volts

Bad brake lamp pressure switch.

91 – Brake Lamps Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EF to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Terminal for wire 1-DW to ground

24 volts

Check fuse ECC-F4 and wires 1-DW and 1-DV.

Terminal for wire 44A to ground

0 volt

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

0 volt

Bad brake lamps relay.

NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal. Terminal for wire 44A to ground

24 volts

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

24 volts

Bad brake lamps relay.

4002-92

92 – Flasher Module Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite side steady on operation and disconnected for European machines for opposite side off operation. Terminal for wire 0-EG to ground

Continuity

Bad ground circuit.

Terminal for wire 0-EH to ground

Continuity

Bad ground circuit.

Terminal for wire 45N-A to terminal for wire 45N-B (North American machines only)

Continuity

Bad 45N circuit.

NOTE: Put master disconnect switch in ON position. Terminal for wire 1-DU to ground

24 volts

Check fuse ECC-F4. Also check wires 1-DU and 1-DV.

NOTE: Put ignition switch in the ON position. Put the hazard switch (93) ON. Terminal for wire 45H to ground

24 volts

Bad hazard switch (93). Also check wire 45H.

Terminal for wire 45L-D to ground

Intermittent 24 volts

Bad flasher module.

Terminal for wire 45R-E to ground

Intermittent 24 volts

Bad flasher module.

NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position. Terminal for wire 45B-A to ground

24 volts

Terminal for wire 45R-E to ground

Intermittent 24 volts

Bad turn signal switch (94) or fuse ECA-F8. Also check wires 45B-A and 45B. Bad flasher module.

NOTE: Put turn signal switch (94) in LEFT turn position. Terminal for wire 45A-A to ground

24 volts

Terminal for wire 45L-D to ground

Intermittent 24 volts

Bad turn signal switch (94) . Also check wire 45A-A. Bad flasher module.

4002-93

93 – Hazard Switch Located on steering column. Check Points Terminal for wire 0-B24 to ground

Correct Reading

Possible Cause of Bad Reading

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Terminal for wire 1-KA to ground

24 volts

Check fuse ECC-F4. Also check wires 1-KA and 1-DV.

NOTE: Put hazard switch in ON position. Terminal for wire 45H to ground

Bad hazard switch. If hazard switch LED is not ON with 24 volts at check point, replace hazard switch.

24 volts

NOTE: Put driving lamp switch (95) in position 3.

Terminal for wire 49-D to ground

Check driving lamp switch (95). Also check circuit 49 to lamp switch (95). If hazard switch LED is not ON with 24 volts at check point, replace hazard switch.

24 volts

94 – Turn Signal, High-Low Beam, and Horn Switch Located on steering column. Check Points

Correct Reading

Possible Cause of Bad Reading HORN SWITCH

Terminal for wire 0-EP to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 64C to ground

Check fuse ECC-F6 and horn relay (98). Also check wires 64C and circuit 19U.

24 volts

NOTE: If readings are good, replace the switch. TURN SIGNAL NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 19B to ground

24 volts

Check fuse ECA-F8 and power relay module C(15). Also check wire 19B.

NOTE: Move turn signal lever to RIGHT turn position. Terminal for wire 45B-A to ground

24 volts

Bad turn signal switch.

NOTE: Move turn signal lever to LEFT turn position. Terminal for wire 45A-A to ground

24 volts

Bad turn signal switch.

HIGH-LOW BEAM SWITCH Terminal for wire 0-EP to ground

Continuity

Bad ground circuit.

4002-94

95 – Driving Lamp Switch Located on right side console. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch in the ON position. Terminal for wire 19Z-a to ground

24 volts

Check fuse ECC-F3, also check circuit 19Z.

NOTE: Put the driving lamp switch in position 2. Terminal for wire 41T to ground

24 volts

Bad driving lamp switch.

NOTE: Put the driving lamp switch in position 3. Terminal for wire 41J to ground

24 volts

Bad driving lamp switch.

4002-95

LIGHTS - 03 AND HORN

96 99

98 RCPH10WHL094FAH

96. LEFT HAND FRONT COMBINATION LAMPS 97. RIGHT HAND FRONT COMBINATION LAMPS

98. HORN RELAY 99. HORN

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-96

96 – Left Hand Front Combination Lamp Located on the left front of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLF from LH front combination lamp connector. Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb.

Combination lamp connector pin 2 to pin 1

Continuity

Bad low beam lamp bulb.

Combination lamp connector pin 5 to pin 1

Continuity

Bad turn signal lamp bulb.

NOTE: Connect wiring harness connector LLF to LH front combination lamp connector. Terminal for wire 0-AJ to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2. Terminal for wire 18F to ground

24 volts

Check fuse ECB-F7 and driving lamp switch (95). Also check circuit 18F.

NOTE: Put high/low beam lever (94) in HIGH beam position. Terminal for wire 18B to ground

24 volts

Check fuse ECB-F3, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18B and wire 41H-B.

NOTE: Put high/low beam lever (94) in LOW beam position. Terminal for wire 18D to ground

24 volts

Check fuse ECB-F6, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18D and wire 41L-B.

NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position. Terminal for wire 45L to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45L to flasher module.

NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp.

4002-97

97 – Right Hand Front Combination Lamp Located on the right front of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector. Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb.

Combination lamp connector pin 2 to pin 1

Continuity

Bad low beam lamp bulb.

Combination lamp connector pin 5 to pin 1

Continuity

Bad turn signal lamp bulb.

NOTE: Connect wiring harness connector RF to RH front combination lamp connector. Terminal for wire 0-AH to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3. Terminal for wire 18G-A to ground

24 volts

Check fuse ECB-F8 and driving lamp switch (95). Also check circuit 18G and wire 41T-A.

NOTE: Put high/low beam lever (94) in HIGH beam position. Terminal for wire 18C to ground

24 volts

Check fuse ECB-F4, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18C and wire 41H-C.

NOTE: Put high/low beam lever (94) in LOW beam position. Terminal for wire 18E to ground

24 volts

Check fuse ECB-F5, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18E and wire 41L-C.

NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position. Terminal for wire 45R to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45R to flasher module.

NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp.

4002-98

98 – Horn Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

Terminal for wire 19U-A to ground

24 volts

Check fuse ECC-F6, also check wire 19U-A.

Terminal for wire 19U-E to ground

24 volts

Check Fuse ECC-F6, also check wire 19U-E.

Terminal for wire 64C to ground

24 volts

Bad horn relay.

NOTE: Have another person push and hold the horn switch. Terminal for wire 64C to ground

0 volt

Terminal for wire 64-A to ground

24 volts

Bad horn switch. Bad horn relay.

99 – Horn Located on the left front of the machine with combination lamps. Check Points Terminal for wire 0-AF to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch. Terminal for wire 64 to ground.

24 volts

NOTE: If the readings are good replace the horn.

Check the horn relay (98). Also check wires 64 and 64-A.

4002-99

LIGHTS - 04 AND BACK UP ALARM

101 103

100 102

RCPH10WHL094FAH

100.RIGHT HAND REAR COMBINATION LAMPS 101.LEFT HAND REAR COMBINATION LAMPS

102.LICENSE PLATE LAMP 103.BACK UP ALARM

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-100

100 – Right Hand Rear Combination Lamp (North America Only) Located on the right rear of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LRR from RH rear combination lamp connector. Combination lamp connector pin A to pin D

Continuity

Bad stop lamp bulb.

Combination lamp connector pin C to pin D

Continuity

Bad turn lamp bulb.

Combination lamp connector pin B to pin D

Continuity

Bad tail lamp bulb.

NOTE: Connect wiring harness connector LRR-N to RH rear combination lamp connector. Terminal for wire 0-BT-N to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold down the brake pedal. Terminal for wire 44A-GN to ground

24 volts

Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Put turn signal lever in RIGHT turn position. Terminal for wire 45R-BN to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45R to flasher module.

NOTE: Put driving lamp switch (95) in position 2 or 3. Terminal for wire 18G-CN to ground

24 volts

Check fuse ECB-F8 and lamp switch (95). Also check circuit 18G.

NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.

4002-101

100 – Right Hand Rear Combination Lamp (Europe Only) Located on the right rear of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector. Combination lamp connector pin 1 to pin 5

Continuity

Bad stop lamp bulb.

Combination lamp connector pin 2 to pin 5

Continuity

Bad turn lamp bulb.

Combination lamp connector pin 3 to pin 5

Continuity

Bad tail lamp bulb.

Combination lamp connector pin 4 to pin 5

Continuity

Bad reverse lamp bulb.

NOTE: Connect wiring harness connector LRR-E to RH rear combination lamp connector. Terminal for wire 0-BR to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold down the brake pedal. Terminal for wire 44A-F to ground

24 volts

Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Have assistant put transmission in reverse. Terminal for wire 35A-K to ground

24 volts

Check backup alarm relay (78). Also check circuit 35A to backup alarm relay (78).

NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position. Terminal for wire 45R-A to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45R to flasher module.

NOTE: Put driving lamp switch (95) in position 2 or 3. Terminal for wire 18G-A to ground

24 volts

Check fuse ECB-F8 and lamp switch (95). Also check circuit 18G.

NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.

4002-102

101 – Left Hand Rear Combination Lamp (North America Only) Located on the left rear of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLR from LH rear combination lamp connector. Combination lamp connector pin A to pin D

Continuity

Bad stop lamp bulb.

Combination lamp connector pin C to pin D

Continuity

Bad turn lamp bulb.

Combination lamp connector pin B to pin D

Continuity

Bad tail lamp bulb.

NOTE: Connect wiring harness connector LLR-N to LH rear combination lamp connector. Terminal for wire 0-BR-N to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold down the brake pedal. Terminal for wire 44A-FN to ground

24 volts

Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Put turn signal lever in LEFT turn position. Terminal for wire 45L-BN to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45L to flasher module.

NOTE: Put driving lamp switch (95) in position 2 or 3. Terminal for wire 18F-BN to ground

24 volts

Check fuse ECB-F7 and lamp switch (95). Also check circuit 18F.

NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp.

4002-103

101 – Left Hand Rear Combination Lamp (Europe Only) Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector. Combination lamp connector pin 1 to pin 5

Continuity

Bad stop lamp bulb.

Combination lamp connector pin 2 to pin 5

Continuity

Bad turn lamp bulb.

Combination lamp connector pin 3 to pin 5

Continuity

Bad tail lamp bulb.

Combination lamp connector pin 4 to pin 5

Continuity

Bad reverse lamp bulb.

NOTE: Connect wiring harness connector LLR-E to LH rear combination lamp connector. Terminal for wire 0-BT to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold down the brake pedal. Terminal for wire 44A-E to ground

24 volts

Check brake lamps relay (91). Also check circuit 44 to brake lamps relay (91).

NOTE: Have assistant put transmission in reverse. Terminal for wire 35A-L to ground

24 volts

Check backup alarm relay (78). Also check circuit 35A to backup alarm relay (78).

NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position. Terminal for wire 45L-A to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45L to flasher module.

102 – License Plate Lamp (North America Only) Located on the right rear of the machine with combination lamp. Check Points

Correct Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2. Terminal for wire 18G-E to ground

24 volts

Check fuse ECB-F8 and five driving lamp switch (95). Also check circuit 18G.

4002-104

102 – License Plate Lamp (Europe Only) Located on the right rear of the machine with combination lamp. Check Points

Correct Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2. Terminal for wire 18G-E to ground

24 volts

Check fuse ECB-F8 and five driving lamp switch (95). Also check circuit 18G.

103 – Back-up Alarm (North America Only) Located on the left rear of the machine inside engine compartment. Check Points Terminal for wire 0-JB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

24 volts

Bad back-up alarm disable switch (79). If machine is not a TUV model, check connector 209F and 209M is connected.

NOTE: If the readings are good, replace the back-up alarm.

103 – Back-up Alarm (Europe Only) Located on the left rear of the machine inside engine compartment. Check Points Terminal for wire 0-JB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

24 volts

Bad back-up alarm disable switch (79). If machine is not a TUV model, check connector 209F and 209M is connected.

NOTE: If the readings are good, replace the back-up alarm.

4002-105

CAB WINDOW WASHER AND WIPER SYSTEM

110

109

111 112

107 108

113

104 106 105 RCPH10WHL094FAH

104.FRONT WIPER HIGH SPEED RELAY 105.WIPER CUT OUT RELAY 106.FRONT WIPER LOW SPEED RELAY 107.REAR WIPER/WASHER SWITCH 108.FRONT WIPER/WASHER SWITCH

109.FRONT WIPER MOTOR 110.REAR WIPER MOTOR 111.REAR WASHER MOTOR 112.FRONT WASHER MOTOR 113.DIODES

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-106

104 – Front Wiper High Speed Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19J-D and 19J-E to ground

24 volts

Bad fuse ECA-F12, check circuit 19J, also check power relay module B (14).

NOTE: Put the front wiper switch in the HIGH position. Terminals for wire 63HC-B to ground Terminals for wire 63HC-B to ground

Continuity 24 volts

Bad front wiper and washer switch (108). Bad wiper high speed relay.

NOTE: Put the front wiper switch in the LOW position. Terminals for wire 63C2 to ground

24 volts

Bad wiper high speed relay.

105 – Front Wiper Cut Out Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19J-G to ground

24 volts

Check fuse ECA-F12, check circuit 19J, also check power relay module B (14).

Terminal for wire 63L-B to ground

24 volts

Bad wiper cut out relay.

NOTE: Put the front wiper switch in the HIGH position. Terminals for wire 63HC-A to ground Terminals for wire 63L-B to ground

Continuity 0 volts

Bad front wiper and washer switch (108). Bad wiper cut out relay.

4002-107

106 – Front Wiper Low Speed Relay Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19J-F to ground

24 volts

Bad fuse ECA-F12, check circuit 19J, also check power relay module B (14).

NOTE: Put the front wiper switch in the LOW position. Terminals for wire 63C to ground

24 volts

Bad wiper low speed relay.

NOTE: Put the front wiper switch in the HIGH position. Terminals for wire 63LC to ground Terminals for wire 63C3 to ground

Continuity 24 volts

Bad front wiper and washer switch (108). Bad wiper low speed relay, also check high speed wiper relay (104).

107 – Rear Wiper and Washer Switch Located on right side console. Check Points Terminal for wire 0-B23 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 19K-B to ground

24 volts

Bad fuse ECA-F13 or power relay module B (14). Also check circuit 19K.

Terminal for wire 19K-A to ground

24 volts

Bad fuse ECA-F13 or power relay module B (14). Also check circuit 19K.

NOTE: Put the rear wiper and washer switch in the ON position. Terminal for wire 68L to ground

24 volts

Bad rear wiper and washer switch.

NOTE: Press and hold the rear wiper and washer switch in the WASH position. Terminal for wire 68W to ground

24 volts

Bad rear wiper and washer switch.

NOTE: Put the driving lamp switch in position 3.

Terminal for wire 49-C to ground

24 volts

Check rotary lamp switch (95) and circuit 49. If LEDs in rear wiper and washer switch are not ON with 24 volts at check point, replace rear wiper and washer switch.

4002-108

108 – Front Wiper and Washer Switch Located on right side console. Check Points Terminal for wire 0-DT to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and washer switch is in the OFF position. Terminal for wire 19J-B to ground

24 volts

Check fuse ECA-F12, check circuit 19J, also check power relay module B (14).

NOTE: Put the front wiper and washer switch in the LOW position. Terminal for wire 63LC to ground

Continuity

Bad front wiper and washer switch also check grounding circuit.

NOTE: Put the front wiper and washer switch in the HIGH position. Terminal for wire 63HC to ground

Continuity

Bad front wiper and washer switch also check grounding circuit.

NOTE: Put the front wiper and washer switch in the wash position. Terminal for wire 63W to ground

24 volts

Bad front wiper and washer switch.

4002-109

109 – Front Wiper Motor Located in front of steering column. Check Points Terminal for wire 0-B8 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Make sure the front wiper and washer switch (108) is in the OFF position. Between terminals B and D for wires 63C and 63L

Continuity

Bad front wiper motor.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19J-A to ground

24 volts

Check fuse ECA-F12, also check circuit 19J.

NOTE: Put the front wiper and washer switch (108) in the LOW position. Terminal for wire 63L-A to ground Terminal for wire 63C to ground

24 volts 0 volt

Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), low speed relay or cut out relay. Bad front wiper and washer switch (108)

NOTE: Put the front wiper and washer switch (108) in the HIGH position. Terminal for wire 63H-A to ground Terminal for wire 63C to ground

24 volts 0 volt

Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), high speed relay or cut out relay. Bad front wiper and washer switch (108).

NOTE: Put the front wiper and washer switch in the intermittent position. Terminal for wire 63L-A to ground

24 volts pulse

Bad front wiper and washer switch (108).

Terminal for wire 63C to ground

24 volts pulse

Bad front wiper and washer switch (108).

NOTE: If the readings are good, replace the front wiper motor.

4002-110

110 – Rear Wiper Motor Located in top of rear cab head liner. Check Points Terminal for wire 0-MA to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position. Between terminals for wires 68C-A and 68L-A

Continuity

Bad rear wiper and washer switch (107).

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19K-D to ground

24 volts

Check fuse ECA-F13, also check circuit 19K.

NOTE: Put the rear wiper and washer switch (107) in the ON position. Terminal for wire 68C-A to ground

24 volts

Bad rear wiper and washer switch (107).

Terminal for wire 68L-A to ground

0 volt

Bad rear wiper and washer switch (107).

NOTE: If the readings are good, replace the rear wiper motor.

111 – Rear Washer Pump Motor Located in left side engine compartment. Check Points Terminal for wire 0-BL to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer switch (107) in WASH position. Terminal for wire 68W-A to ground

24 volts

Bad rear wiper and washer switch (107) Also check wires 68W-A and 68W.

NOTE: If the readings are good, replace the rear washer pump motor.

112 – Front Washer Pump Motor Located in left side engine compartment. Check Points Terminal for wire 0-B to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check point then push down on front wiper and washer switch (108). Terminal for wire 63W-A to ground

24 volts

Bad front wiper and washer switch (108), also check circuit 63W.

NOTE: If the readings are good, replace the front washer pump motor.

4002-111

113 – Wiper Diodes Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector 140M from diode connector. Multimeter positive on pin A to pin C

None

Bad diode.

Multimeter positive on pin B to pin C

None

Bad diode.

Multimeter positive on pin D to pin C

None

Bad diode.

Multimeter positive on pin E to pin C

None

Bad diode.

Multimeter positive on pin F to pin C

None

Bad diode.

Multimeter positive on pin C to pin A

Continuity

Bad diode.

Multimeter positive on pin C to pin B

Continuity

Bad diode.

Multimeter positive on pin C to pin D

Continuity

Bad diode.

Multimeter positive on pin C to pin E

Continuity

Bad diode.

Multimeter positive on pin C to pin F

Continuity

Bad diode.

4002-112

SECONDARY STEERING

114 116

118

115 117 RCPH10WHL094FAH

114.SECONDARY STEERING DIODES 115.SECONDARY STEERING SOLENOID 116.SECONDARY STEERING MODULE

117.SECONDARY STEERING MOTOR 118.SECONDARY STEERING PRESSURE SWITCH

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-113

114 – Secondary Steering Diodes Located in the cab access panel for fuses and relays, rear of compartment. Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector DM from diode connector. Multimeter positive on pin A to pin C

Continuity

Bad diode.

Multimeter positive on pin B to pin C

Continuity

Bad diode.

Multimeter positive on pin C to pin A

None

Bad diode.

Multimeter positive on pin C to pin B

None

Bad diode.

115 – Secondary Steering Solenoid (Option) Located in the rear frame of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector YSS from secondary steering solenoid. Between pins A and B of secondary steering solenoid

36 to 42 ohms

Between pin 2 of connector YSS and ground

Continuity

Bad secondary steering solenoid.

Bad ground circuit.

NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately to ON position. Between pin 1 of connector YSS and ground

24 volts

Check secondary steering module (116) and secondary steering pressure switch (118).

4002-114

116 – Secondary Steering Module (Option) Located in the rear frame of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the wiring harness connector SSM from the secondary steering module.

Pin 2 of connector SSM to ground

Continuity

Bad relay on secondary steering motor (117) or bad secondary steering solenoid (115). Also Check wires 51-A, 51-B, and 51-C and ground circuit connections (wires 0-ND and 0-CF).

Pin 4 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 8 of connector SSM to ground

Continuity

Bad secondary steering pressure switch (118). Also check wires 35X-D, 35X-C, and 35X-A.

Pin 9 of connector SSM to ground

Open Circuit

Pin 11 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 12 of connector SSM to ground

Continuity

Bad ground circuit.

Bad secondary steering pressure switch (118). Also check wire 51P-A.

NOTE: Put the master disconnect switch and the ignition switch in ON position. Pin 3 of connector SSM to ground

24 volts

Bad wire 19S1-X to power relay module A fuse 2 (13).

Pin 7 of connector SSM to ground

24 volts

Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.

Pin 1 of connector SSM to ground

24 volts

Check fuse ECA-F4, power relay module C(15), ignition switch, and diode module. Also check circuit 19R.

NOTE: Start and run engine at idle speed. Pin 9 of connector SSM to ground

Continuity

Pin 8 of connector SSM to ground

11 volts

Bad secondary steering pressure switch. Check circuit 35X to instrument cluster. If circuit 35X okay, problem is bad instrument cluster.

NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector SSM to secondary steering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engine at idle speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply a ground to pin C of connector PSS. Terminal for wire 51-B to ground

24 volts

Bad secondary steering module.

4002-115

117 – Secondary Steering Motor (Option) Located in the rear frame of the machine. Check Points

Correct Reading

Possible Cause of Bad Reading

Motor ground stud to ground

Continuity

Bad ground circuit.

Secondary steering motor relay ground terminal to ground

Continuity

Bad ground circuit.

Terminal for wire 51-B to ground.

10 to 45 ohms

Bad secondary steering motor relay coil or secondary steering solenoid (115). Also check relay coil and solenoid ground circuit.

NOTE: Put the master disconnect switch in ON position. Terminal for red wire to ground

24 volts

Check circuit to batteries.

NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect wire 51-B from secondary steering motor relay.

Terminal for wire 51-B to ground

24 volts

Check fuses ECA-F4 and F17, secondary steering module (116), and secondary steering pressure switch (118). If 24 volts is obtained the secondary steering motor is bad. If fuse ECA-F4 or F17 was replaced: if fuse F4 blows again, secondary steering module is bad; if fuse F17 blows again, secondary steering module is bad or secondary steering motor relay or secondary steering solenoid is shorted.

118 – Secondary Steering Pressure Switch (Option) Located in the cab access panel for fuses and relays, rear of compartment. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector PSS from secondary steering pressure switch. Pressure switch pin B to pin C

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin A

Open Circuit

Bad secondary steering pressure switch.

Pressure switch pin A to pin C

Open Circuit

Bad secondary steering pressure switch.

NOTE: Start and run engine at idle speed. Pressure switch pin B to pin A

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin C

Open Circuit

Bad secondary steering pressure switch.

4002-116

CAN COMMUNICATION

119 RCPH10WHL094FAH

119.DIAGNOSTIC CONNECTOR

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-117

119 – CAN Communication Diagnostics Connector Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Terminal A for wire 0-DH to ground

Continuity

Terminal B for wire 18K-D to ground

24 volts

Possible Cause of Bad Reading Bad ground circuit. Check fuse ECC-F9, check circuit 18K.

4002-118

RADIO AND POWER CONVERTER

125

122 123 124

121

RCPH10WHL094FAH

120. 121.POWER CONVERTER 24 TO 12 VOLT 122.12 VOLT POWER OUTLETS (OPTION)

123.RADIO 124.RIGHT SPEAKER 125.LEFT SPEAKER

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-119

120 – 121 – Power Converter 24 volts to 12 volts (Option) Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EJ to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 19L-B and 19L-A to ground

24 volts

Bad fuse F1 in power relay module A, also check circuit 19L.

Terminal for wire 12V-C to ground

12 volts

Bad power converter.

122 – Power Outlet (Option) Located in the cab. Check Points

Correct Reading

Terminal for wire 0-EK or 0-EL to ground

Continuity

Terminal for wire 12V or 12V-A to ground

12 volts

Possible Cause of Bad Reading

Bad ground circuit. Bad power converter (121), check fuse ECB-F1 and F2, also check wire 12V-A.

NOTE: If the readings are good replace the power outlet.

123 – 12 Volt Radio Ready (Option) Located in the cab. Check Points

Correct Reading

Terminal in radio connector for wire 0-EN to ground

Continuity

Possible Cause of Bad Reading

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal in radio connector for wire 12V-HA to ground

12 volts

Check fuse ECB-F9, also check circuit 12V. Also check the remote radio power converter (121).

4002-120

124 – Right Speaker (Option) Located in the cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector from right speaker. Put master disconnect switch and ignition switch in ON position. Turn radio (123) on. Put balance control for RH and LH speakers to center position. Pin 1 in wiring harness connector RSPK to ground

Voltage

Pin 2 in wiring harness connector RSPK to ground

Continuity

Bad circuit between the right speaker and the radio or a bad radio (123). Bad circuit between the right speaker and the radio (123).

NOTE: If the readings are good, replace the right speaker.

125 – Left Speaker (Option) Located in the cab. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector from left speaker. Put master disconnect switch and ignition switch in ON position. Turn radio (123) on. Put balance control for RH and LH speakers to center position. Pin 1 in wiring harness connector LSPK to ground

Voltage

Pin 2 in wiring harness connector LSPK to ground

Continuity

Bad circuit between the left speaker and the radio or a bad radio (123). Bad circuit between the left speaker and the radio (123).

NOTE: If the readings are good, replace the left speaker.

4002-121

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR 126 130

129

127

128 RCPH10WHL094FAH BS06H241 / BS06H242

126.AIR SEAT 127.CIGAR LIGHTER 128.AIR CONDITIONING CLUTCH RELAY

129.HIGH/LOW SWITCH 130.AIR CONDITIONING COMPRESSOR CLUTCH

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-122

126 – Seat Compressor and Switch (Option) Located in the cab. Check Points Terminal for wire 0-DK to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19N at seat switch

24 volts

Check fuse ECA-F16 and power relay module B(14). Also check wire 19N.

NOTE: Put the seat compressor switch in the ON position. Terminal for wire from seat switch at compressor

24 volts

Bad seat switch, also check circuit from seat switch to compressor.

NOTE: If the readings are good replace the seat compressor.

127 – Cigar Lighter (Option) Located in the cab. Check Points

Correct Reading

Terminal for wire 19W to ground

24 volts

Terminal for wire 0-DV to ground

Continuity

Possible Cause of Bad Reading Check fuse ECA-F18, also check circuit 19W. Bad ground circuit.

NOTE: If the readings are good replace the cigar lighter.

128 – Compressor Clutch Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-DJ to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed switch (149) to HIGH and thermostat switch to COLD. Terminal for wire 61R-B to ground

24 volts

Check thermostat switch, also check wire 61R-B.

Terminal for wire 61C to ground

24 volts

Bad compressor clutch relay.

NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure switch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position. Terminal for wire 61R-C to ground

24 volts

Check wires 61R-B and 61R.

4002-123

129 – A/C High/Low Pressure Switch Located on the rear frame in front of the rear axle. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put the fan speed switch (149) to HIGH and the thermostat switch to COLD. Terminal B for wire 61A to ground

24 volts

Check the thermostat switch, also check circuit 61A.

NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch. (Low and high switches) Between terminals of trinary pressure switch

Continuity

Bad A/C low pressure switch, also check refrigerant charge level. (Pressure must be above 2.75 bar (40 psi) or below 26 bar (377 psi) for switch to be closed.)

130 – Compressor Clutch Located on the left side of the engine. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put fan speed switch (149) to HIGH and thermostat switch to COLD. Terminals for wire 61C-A to ground

24 volts

Check the compressor clutch relay (128), also check circuit 61C.

4002-124

CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL

135 136 137 140 141

131

132 133 134 138 142

139 RCPH10WHL094FAH

131.ELECTRONIC PANEL 132.EXTERNAL AIR TEMPERATURE SENSOR 133.INTERNAL AIR TEMPERATURE SENSOR 134.SUN SENSOR 135.BLOWER FAN RESISTOR 136.BLOWER MOTORS

137.THERMOCOUPLE SENSOR 138.MIXED AIR SENSOR 139.COMPRESSOR RELAY 140.RECYCLING MOTOR 141.ELETRONIC WATER VALVE 142.24 TO 12 VOLT CONVERTER

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-125

131 – Electronic Panel Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Automatic climate control only.

132 – External Air Temperature Sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Automatic climate control only.

133 – Internal Air Temperature Sensor Check Points

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

NOTE: Automatic climate control only.

134 – Sun Sensor Check Points NOTE: Automatic climate control only.

135 – Blower Motor Resistor Check Points NOTE: Automatic climate control only

136 – Blower Motors Check Points NOTE: Automatic climate control only

137 – Thermocouple Sensor Check Points NOTE: Automatic climate control only.

4002-126

138 – Mixed Air Sensor Check Points

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

NOTE: Automatic climate control only.

139 – Compressor Relay Check Points NOTE: Automatic climate control only

140 – Recycling Motor Check Points NOTE: Automatic climate control only

141 – Electronic Water Valve Check Points NOTE: Automatic climate control only

142 – 24 to 12 Volt Converter Check Points NOTE: Automatic climate control only.

4002-127

STANDARD CLIMATE CONTROL 143 144 145 146 147 148

149 150 151 152 153

RCPH10WHL094FAH

143.ACTUATOR 144.DRIVER 145.ELETRONIC WATER VALVE 146.BLOWER FAN RESISTOR 147.BLOWER MOTOR 148.THERMOSTAT

149.FAN SPEED SWITCH 150.AIR CONDITIONING SWITCH 151.CONTROL PANEL LIGHTS 152.WATER VALVE POTENTIOMETER 153.AIR RECIRCULATING SWITCH

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-128

143 – Actuator Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Remove connectors from DNS Actuator and DNS Driver prior to testing. Pin 6 in wiring harness connector to pin 4 in Driver module (DNS49)

Continuity

Bad wire or connector.

Pin 5in wiring harness connector to pin 5in Driver module (DNS48)

Continuity

Bad wire or connector.

144 – Driver Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Remove connectors from DNS Driver and HVAC2. Between DNSS2 and DNS75

Continuity

Bad wire or connector.

145 – Electronic Water Valve Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: No information at time of print.

146 – Blower Motor Speed Resistors with Thermal Fuse Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect the wiring harness connector DNS RESISTOR from the resistor. Between terminals 1 and 4 of blower motor connector

Approximately x.x ohms

Bad blower motor resistor.

Between terminals 2 and 4 of blower motor connector

Approximately x.x ohms

Bad blower motor resistor.

Between terminals 3 and 4 of blower motor connector

Approximately x.x ohms

Bad blower motor resistor.

4002-129

147 – Blower Motor Check Points

Correct Reading

Terminals for wire DNS66 to ground

Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the fan speed switch (149) to position 4. Terminal for wire DNS65 to ground

24 volts

Check the fan speed switch (149).

NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the fan speed switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower fan resistor (146).

148 – Thermostat Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Remove connector from thernostat.

Between terminals on thermostat

Continuity above 5C (41F) +/-1C, open below 0C (32F)+/-1C.

Bad thermostat.

149 – Blower Switch Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire DNS74 to ground

24 volts

Check fuse ECA-F11.

NOTE: Turn the blower switch to position 1. Terminal for wire DNS61 to ground

24 volts

Bad blower switch.

NOTE: Turn the blower switch to position 2. Terminal for wire DNS62 to ground

24 volts

Bad blower switch.

NOTE: Turn the blower switch to position 3. Terminal for wire DNS63 to ground

24 volts

Bad blower switch.

NOTE: Turn the blower switch to position 4. Terminal for wire DNS73 to ground

24 volts

Bad blower switch.

4002-130

150 – Air Conditioning Switch Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Remove connector from AC switch. Between terminal 1 and 2 on AC switch

Continuity with switch on.

Bad AC switch.

151 – Control Panel Lights Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Remove connector from Control panel lights. Between terminal 1 and 2 on light.

Continuity

Bad light(s).

152 – Water Valve Potentiometer Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Remove connector from Water valve potentiometer. Between terminals measure resistance change.

Resistance change

Bad potentiometer.

153 – Air Recirculating Switch Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Remove connector on Air recirculating switch. Between terminals 1 and 2.

Continuity with switch on.

Bad recirculating switch.

4002-131

HOOD RAISE AND LOWER SYSTEM

157 156

154 155 RCPH10WHL094FAH

154.HOOD UP RELAY 155.HOOD DOWN RELAY

156.HOOD SWITCH 157.HOOD MOTOR

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-132

154 – Hood Up Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-B25 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn the master disconnect switch ON. Terminal for wire 19Y-A

24 volts

Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the raise position. Terminal for wire 59U

24 volts

Bad hood switch (156), check wire 59U.

Terminal for wire 60U

24 volts

Bad hood up relay.

155 – Hood Down Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-B16 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn the master disconnect switch ON. Terminal for wire 19Y-B

24 volts

Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the lower position. Terminal for wire 59D

24 volts

Bad hood switch (156), check wire 59D.

Terminal for wire 60D

24 volts

Bad hood down relay.

156 – Hood Switch Located in the right battery compartment with the master disconnect switch. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector HD, turn the master disconnect ON. Terminal for wire 19Y-D to ground

24 volts

Check fuse ECC-F7, check circuit 19Y.

Hold the hood switch in the raise position, between pin C and B

Continuity

Bad hood switch.

Hold the hood switch in the lower position, between pin A and B

Continuity

Bad hood switch.

4002-133

157 – Hood Motor Located in the left side of the engine compartment. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in the raise position. Terminal for wire 60U-A

24 volts

Bad hood up relay (154), bad hood switch (156), and check fuse ECC-F7.

NOTE: Hold the hood switch (156) in the lower position. Terminal for wire 60D-A

24 volts

Bad hood down relay (155), bad hood switch (156), and check fuse ECC-F7.

NOTE: If all readings are good replace the hood motor.

4002-134

STARTING / IGNITION SYSTEMS

158 159 160 RCPH10WHL094FAH

158.IGNITION POWER LATCH 159.IGNITION POWER CONTROL

160.START LOCKOUT

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-135

158 – Ignition Power Latch Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL. Terminal for wire 13K to ground

24 volts

Check circuit 13K, check Ignition switch (10).

Terminal for wire 0-EA to 0-EU on Program relay module A (13)

Continuity

Bad wire or connector

Terminal for wire 0-ET to ground

Continuity

Bad ignition power latch relay or ignition power control relay (159).

159 – Ignition Power Control Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-KA to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.

Terminal for wire 13K-A to ground

24 volts

Terminal for wire 0-EY to ground

Continuity

Check circuit 13K, check ignition switch (10). Bad ignition power control relay.

160 – Start Lockout Located in the cab access panel for fuses and relays. Check Points

Correct Reading

NOTE: Used with Telematics on future models

Possible Cause of Bad Reading

4002-136

SCR SYSTEM/ JOYSTICK STEERING/ MISC

161 164 167 165

162 166 168 163

169 RCPH10WHL094FAH

161.NOX SENSOR 162.HUMIDITY AND AMBIENT TEMPERATURE SENSOR 163.NOX SENSOR (NOXS) 164.TANK HEATER CONTROL VALVE 165.DEF LEVEL AND TANK TEMPERATURE

166.UPSTREAM TEMPERATURE SENSOR 167.DOWNSTREAM TEMPERATURE SENSOR 168.DOSER METERING VALVE 169.DNOX CONTROLLER

NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system. Use a Multimeter for the following tests.

4002-137

161 – NOX Sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

162 – Humidity and ambient temperature sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

163 – NOX Sensor (NOXS) Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

164 – Tank heater control valve Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

165 – DEF Level and tank temperature Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

166 – Upstream temperature sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

167 – Downstream temperature sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

168 – Doser metering valve Check Points

Correct Reading

NOTE: See SCR controller manual for details

Possible Cause of Bad Reading

4002-138

169 – DNOX Controller Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details

170 – Rear View Camera / Monitor Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: See Camera manual for details

171 – Differential Lock Switch (Manual) Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Remove connector SDM from switch

Between terminals 2 and 3

Normally open, Continuity when switch is closed

Bad Lock Switch.

172 – Differential Lock Switch Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Remove connector from switch

Between terminals 2 and 3

Normally open, Continuity when switch is closed

Bad Lock Switch

173 – Differential Lock Solenoid Check Points Terminal for wire 34C-A to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position. Terminal 1 for wire 34A-D to ground

24 volts

Bad TECM module. Also check circuit 34C.

NOTE: If the readings are good, replace the differenital lock solenoid. NOTE: See transmission section for more details

4002-139

174 – Lockup Solenoid Check Points Terminal for wire 24T-B to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position. Terminal 1 for wire 25R-B to ground

24 volts

Bad TECM TRANS module. Also check circuit 25R.

NOTE: If the readings are good, replace the lockup solenoid. NOTE: See transmission section 6000 for more details

175 – Joystick PVRES NOTE: See service manual section 5009 for Joystick steering details.

176 – Transmission Kick Down Switch NOTE: See service manual section 5009 for Joystick steering details..

177 – ARM POS NOTE: See service manual section 5009 for Joystick steering details..

178 – FNR Switch (option) NOTE: See service manual section 5009 for Joystick steering details.

179 – FNR Relay NOTE: See service manual section 5009 for Joystick steering details.

180 – Pilot Dump Valve NOTE: See service manual section 5009 for Joystick steering details.

181 – JSS Valve NOTE: See service manual section 5009 for Joystick steering details.

182 – Load Sense Pressure Sensor NOTE: See service manual section 5009 for Joystick steering details.

183 – Pilot Pressure Switch NOTE: See service manual section 5009 for Joystick steering details.

4002-140

184 – JSS Relay NOTE: See service manual section 5009 for Joystick steering details.

185 – Joystick STR Switch (option) NOTE: See service manual section 5009 for Joystick steering details.

186 – JSS Controller NOTE: See service manual section 5009 for Joystick steering details.

4002-141

CONNECTORS CONNECTOR 108F - DIAGNOSTIC CONNECTOR

291663A1

CONNECTOR 197F - MAIN CAB FNR

CONNECTOR 140M - DIODE MODULE 225350C1

245488C1

4002-142 CONNECTOR 197M - FNR-MAIN_CAB

CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

225351C1 245481C1

CONNECTOR 209M - BACKUP ALARM DISABLE JUMPER

CONNECTOR 202M - ROLLBACK JUMPER

245480C1

245482C1

4002-143 CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

225316C1

CONNECTOR 215F - ALTERNATOR RESISTOR

CONNECTOR 64F - FLASHER CONNECTOR

245481C1 199436A1

CONNECTOR 216F - ALTERNATOR RESISTOR

CONNECTOR 64M - FLASHER CONNECTOR

199436A1 245480C1

4002-144 CONNECTOR AIC2 - ADV INSTRUMENT CLUSTER 2

CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH

8602417

CONNECTOR AIC1 - ADV INSTRUMENT CLUSTER 87419488

87410948

4002-145

4002-146

CONNECTOR BUZ - AIC BUZZER

222136A1

4002-147

4002-148 CONNECTOR CAB-RF - CAB TO ROOF CONNECTION

CONNECTOR CAB-T - CAB TO TRANMISSION

380839A1

388710A1

4002-149 CONNECTOR CL - CIGAR LIGHTER

3227856R1

CONNECTOR CNV - 24V TO 12V POWER CONVERTER

225351C1

4002-150 CONNECTOR DM - DIODE OR CONNECTOR D-OR - DIODE OR

245485C1

CONNECTOR DISC - DISCONNECT ENGINE

245482C1

4002-151 CONNECTOR DNS-DRIVER

411311A1

4002-152 CONNECTOR DS - DOOR SWITCH

CONNECTOR EM - HEIGHT CONT RTT RTD

245482C1

225351C1

CONNECTOR E-HD - TRANSMISSION HOOD

245485C1

4002-153 CONNECTOR ECA - ELECTRICAL CENTER A

87315248

4002-154

4002-155 CONNECTOR ECB - ELECTRICAL CENTER B

87312843

4002-156

4002-157 CONNECTOR ECC - WORK LIGHTS

87315249

4002-158

4002-159 CONNECTOR ECD - ELECTRICAL CENTER D

87312843

4002-160

4002-161 CONNECTOR EDC7 - ENGINE CONTROLLER

BOSCH-89-POLE

4002-162 CONNECTOR ENG-D - DISCONECT HARNESS

CONNECTOR ESS - ENGINE SPEED SENSOR

245483C1

291718A1

CONNECTOR ENG-H - ENGINE TO HOOD

CONNECTOR FFH - FULE FILTER HEATER

225320C1

182069A1

4002-163 CONNECTOR FLSHR - FLASHER MODULE

225389C1

CONNECTOR FM - FILTER MAINTENANCE SWITCH

CONNECTOR FWM - FRONT WIPER MOTOR

371614A1

245715C1

4002-164 CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

CONNECTOR GHC - GRID HEATER RELAY

3227856R1 245480C1

CONNECTOR FWW - FRONT WASHER

3227856R1

4002-165 CONNECTOR - CAB GROUND SPLICE

87324393

CONNECTOR - SPLICE BACK LIGHT GROUND

87324393

4002-166

4002-167 CONNECTOR HD - HOOD SWITCH

245485C1

CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS

245484C1

4002-168 CONNECTOR HD-N - HOOD TO ENGINE

225319C1

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

194788A1

CONNECTOR HDM - HOOD LIFT MOTOR

225316C1

4002-169 CONNECTOR HVAC2 - HVAC2

87552622

CONNECTOR ISS - INT-SPEED-SENSOR

291718A1

4002-170

4002-171 CONNECTOR LLF - LH FRONT LIGHTS

CONNECTOR LLR-E - LH REAR COMBINATION LAMP

225351C1 225351C1

CONNECTOR LPL - LICENSE PLATE LAMP

245482C1

4002-172 CONNECTOR LRF - RH FRONT LAMP

CONNECTOR LRR-E - RH REAR COMBINATION LAMP

225351C1

CONNECTOR LSPK - LEFT SPEAKER

195552A1

4002-173 CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

291718A1

CONNECTOR OSS - OUTPUT SPEED SENSOR

291719A1

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

245482C1

4002-174 CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH

CONNECTOR PO1 - POWER OUTLET

222136A1 12176446

CONNECTOR PO2 - POWER OUTLET

12176446

4002-175 CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

245483C1

4002-176 CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

CONNECTOR PXF - RTD

245485C1 245485C1

4002-177 CONNECTOR RAD - RADIO POWER

CONNECTOR RAD-J2 - SPEAKER

292495A1

292501A1

CONNECTOR RAD-J1 - RADIO POWER

CONNECTOR RAD-J3 - RADIO JUMPER

411311A1 292497A1

4002-178 CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

194788A1

CONNECTOR ROOF - ROOF TO CAB CONNECTION

388708A1

CONNECTOR RSPK - RIGHT SPEAKER

195552A1

4002-179 CONNECTOR RTHP - THROTTLE PEDAL

CONNECTOR RWMG - REAR WIPER MOTOR GROUND

225351C1 245480C1

CONNECTOR RWW - REAR WASHER

CONNECTOR RWM - REAR WIPER MOTOR

3227856R1

245715C1

4002-180 CONNECTOR S-KEY - IGNITION SWITCH TO PEDESTAL HARNESS

CONNECTOR SC - SEAT COMPRESSOR MOTOR

245482C1

225253C1

CONNECTOR SBE - BEACON SWITCH

CONNECTOR SDC - DECLUTCH SWITCH

382391A1

4002-181 CONNECTOR SDR - DRIVING LIGHTS SWITCH

382391A1

CONNECTOR SFWW - REAR WIPER AND WASHER SWITCH

87345132

CONNECTOR SHC - HEIGHT CONTROL SWITCH

382391A1

4002-182 CONNECTOR SPK - SPEAKER

292494A1

CONNECTOR SPB - PARKING BRAKE SWITCH

382391A1

4002-183 CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT GD

87324393

CONNECTOR SPL-BCK-LGT

87324393

4002-184 CONNECTOR SPL-PED-BL - SPL BACK LIGHT POWER 6 PACK

CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY

87324462 87324391

4002-185 CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

87324462 87324393

CONNECTOR SRC - RIDE CONTROL SWITCH

382391A1

4002-186 CONNECTOR SRC-1 - STARTER RELAY

CONNECTOR SRTD - DETENT SWITCH

225316C1 382391A1

CONNECTOR SRHSTLK - RH STALK SWITCH

87318288

4002-187 CONNECTOR SS-TR - SS-MOD-TRANS

CONNECTOR STA - TRANSMISSION AUTO SWITCH

245489C1

382391A1

CONNECTOR SSM - SECONDARY STEERING MODULE

225389C1

4002-188 CONNECTOR SWL - WORK LIGHTS SWITCH

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

382391A1

291718A1

4002-189 CONNECTOR TECM - TRANSMISSION

411398a1

4002-190 CONNECTOR TRANS - CAB TO TRANSMISSION

CONNECTOR TR-SS - SEC-STR-MOD-OPT

245488C1

380838A1

4002-191 CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TS2 - TRANSMISSION SHIFTER

245487C1

371566A1

CONNECTOR TSS - TURBINE SPEED SENSOR

CONNECTOR TS1 - TRANSMISSION SHIFTER 291718A1

245486C1

4002-192

CONNECTOR WF - WATER IN FUEL SENSOR

CONNECTOR YFN - FNA PWM SOLENOID

8602416

CONNECTOR WSH - WATER SEPARATOR HEATER

182069A1

256340A1

4002-193 CONNECTOR YFR - FAN REVERSING SOLENOID

225316C1

CONNECTOR YPP - PILOT PRESSURE SOLENOID

245482C1

CONNECTOR YPE - PIN ENGAGE

CONNECTOR YRC - RIDE CONTROL OPT

245482C1

291718A1

4002-194

CONNECTOR YSS - SECONDARY STEERING SOLENOID

225316C1

4002-195

NOTES

4002-196

INDEX OF FUNCTIONS

SHT

ECD

SHT

BACKUP ALARM

5 , 14

COLOR ABBREVIATIONS 70 62

SHT

LARGE CONNECTOR LIST SHEET

INDEX / WIRE INFORMATION

SHEET

CONNECTOR LIST

SHEET

CONNECTOR LIST

SHEET

20 5 9

_ 2

158 1 10

Relay in location F5/F6

160

Relay in location F3\F4 6

17 159

COLD START

POWER DISTRIBUTION

IGNITION SWITCH

162 161

Relay in location F7\F8

CAN_L3 G-0.8 CAN_H3 Y-0.8

163

169 164

168

165

167 166

ENGINE CONTROL

92 90 CONNECT FOR NA OPERATION, OPP SIDE STEADY ON. DISCONNECT FOR EUROPEAN OPERATION, OPP SIDE OFF.

Relay in location F1/F2

Relay in location F9\F10

78 91

North American models European and International models 101

100

101

100

Turn Signal

Driving Lights

Light/ Horn

Horn

103 96

102

LIGHTING 1

BACKUP ALARM

87 80

170

LIGHTING 2

172

54 173

171 55

57 59

174

47 45

61 48 58 49

50 51

53 60

TRANSMISSION CONTROLS

74 72 67

65 75 69 73

INSTRUMENT CLUSTER

35 36

98 27

41 42 44

MACHINE CONTROLS

113

155 154 104

108

105 114

106

115 107

117

109 156

111

116 BLUE

BROWN

112 113

UP LIMIT SWITCH

DOWN LIMIT SWITCH

157

NO COM NC

110 118

HOOD LIFT

121

122

129 122 126 128

130

125

124

123

119

Note: Telematics for future models

127

R S

HVAC

R S

AIR SEAT

RADIO POWER/CONVERTER 12

184

177 175

185

176

179

178

181

182 180

183

JOYSTICK STEERING (FOR PL18 & PL23 ONLY)

186

145

144 143 146

147

148

153 149

150

152 151

STANDARD HVAC

721F, 821F, 921F Tier 4 Wheel Loader ELECTRICAL SCHEMATIC LEGEND INDICATES CONSTANT POWER INDICATES POWER WHEN KEY SWITCH IS ON INDICATES POWER WHEN KEY SWITCH IS IN START POSITION POWER RELAY A POWER RELAY B POWER RELAY C POWER RELAY D ILLUMINATION

ELECTRICAL WIRING INFORMATION

COMPONENT NUMBERS COMPONENT STARTING RELAY RESISTOR - 75 OHM ALTERNATOR CRANK CONTROL RELAY BATTERIES CRANK REQUEST RELAY MASTER DISCONNECT SWITCH STARTER IGNITION SWITCH NEUTRAL START RELAY POWER RELAY MODULE A POWER RELAY MODULE B POWER RELAY MODULE C GRID HEATER RELAY GRID HEATER POWER RELAY MODULE D WATER SEPARATOR HEATER FUEL FILTER HEATER WATER IN FUEL SENSOR THROTTLE POTENTIOMETER ENGINE CONTROLLER RETURN TO TRAVEL FLOAT SWITCH HEIGHT CONTROL SWITCH ELECTROMAGNETIC DETENTS RETURN TO DIG PROXIMITY SWITCH PILOT CONTROL RELAY ECD-K3 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW RETURN TO DIG SWITCH PIN ENGAGE SWITCH (OPTION) PILOT PRESSURE SOLENOID PIN ENGAGE SOLENOID (OPTION) RIDE CONTROL SWITCH (OPTION) RIDE CONTROL RELAY (OPTION) FAN CONTROL SWITCH (OPTION) FAN REVERSE RELAY (OPTION) PILOT CONTROL SWITCH RIDE CONTROL SOLENOID (OPTION) ROLLBACK PRESSURE SW (XT WITH RIDE CONTROL ONLY) ROLLBACK JUMPER FAN PWM SOLENOID FAN REVERSE SOLENOID (OPTION) OUTPUT SPEED SENSOR TRANSMISSION SOLENOID VALVE AND TEMP SENDER FILTER MAINTENANCE SWITCH

COMPONENT # SHT 61 8 DIAGNOSTIC CONNECTOR 62 1 INSTRUMENT CLUSTER CONNECTOR 1 63 9 WARNING BUZZER 64 9 PARKING BRAKE RELAY 65 9 FUEL LEVEL SENDER 66 9 AIR FILTER RESTRICTION SWITCH 67 9 PARKING BRAKE SOLENOID 68 9 RADIATOR COOLANT TEMPERATURE SENDER 69 9 BRAKE PRESSURE WARNING SWITCH 70 1 SWITCH PAD 71 1 INSTRUMENT CLUSTER CONNECTOR 2 72 9 HYDRAULIC FILTER RESTRICTION SWITCH 73 9 HYDRAULIC OIL TEMPERATURE SENDER 74 9 PARK BRAKE SWITCH 75 9 REDUNDANT BRAKE PRESSURE SWITCH 1 76 9 REDUNDANT BRAKE PRESSURE SWITCH 2 78 6 BACKUP ALARM RELAY 79 6 BACKUP ALARM DISABLE SWITCH 80 7 WORK LAMPS SWITCH 81 7 DOOR SWITCH 82 7 ROTATING BEACON (OPTIONAL) 83 7 DOME LAMP 84 7 ROTATING BEACON SWITCH (OPTIONAL) 85 7 LEFT HAND FRONT WORK LAMP 86 7 RIGHT HAND FRONT WORK LAMP 87 7 LEFT HAND REAR WORK LAMP 88 7 RIGHT HAND REAR WORK LAMP 89 7 DIODES 90 6 BRAKE LAMP SWITCH 91 6 BRAKE LAMP RELAY 92 6 FLASHER MODULE 93 6 HAZARD SWITCH 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 95 6 DRIVING LAMPS SWITCH 96 6 LEFT HAND FRONT COMBINATION LAMPS 97 6 RIGHT HAND FRONT COMBINATION LAMPS 98 10 HORN RELAY 99 10 HORN RELAY 100 6 RIGHT HAND REAR COMBINATION LAMPS 101 6 LEFT HAND REAR COMBINATION LAMPS 102 6 LICENSE PLATE LAMP 103 6 BACKUP ALARM 104 11 FRONT WIPER HIGH SPEED RELAY 105 11 WIPER CUTOUT RELAY

# 119 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163

SHT 12 12 12 12 12 12 12 12 12 12 12 NA NA NA NA NA NA NA NA NA NA NA NA 14 14 14 14 14 14 14 14 14 14 14 11 11 11 11 4 4 4 5 5 5

8 8 8 8 8

TORQUE CONVERTER OUTPUT TEMPERATURE SENDER ENGINE SPEED SENSOR INTERMEDIATE SPEED SENSOR TURBINE SPEED SENSOR TRANSMISSION SHIFTER

106 107 108 109 110

11 11 11 11 11

FRONT WIPER LOW SPEED RELAY REAR WIPER AND WASHER SWITCH FRONT WIPER AND WASHER SWITCH FRONT WIPER MOTOR REAR WIPER MOTOR

164 165 166 167 168

5 5 5 5 5

TANK HEATER CONTROL VALVE DEF LEVEL AND TANK TEMPERATURE UPSTREAM TEMPERATURE SENSOR DOWNSTREAM TEMPERATURE SENSOR DOSER METERING VALVE

8 8 8 8 8 8 8 8

TRANSMISSION ELECTRONIC CONTROL MODULE TRANSMISSION ENABLE SWITCH FNR SWITCH FOR JOYSTICK CONTROLS TRANSMISSION KICK DOWN SWITCH FNR SWITCH FOR SINGLE AXIS CONTROLS TRANSMISSION AUTO SWITCH BRAKE DECLUTCH PRESSURE SWITCH DECLUTCH SWITCH

111 112 113 114 115 116 117 118

11 11 11 11 11 11 11 11

REAR WASHER MOTOR FRONT WASHER MOTOR DIODES SECONDARY STEERING DIODES SECONDARY STEERING SOLENOID SECONDARY STEERING MODULE SECONDARY STEERING MOTOR SECONDARY STEERING PRESSURE SWITCH

169 170 171 172 173 174 175 176

5 7 8 8 8 8 13 13

DNOX CONTROLLER REAR VIEW CAMERA/MONITOR DIFFERENTIAL LOCK SWITCH (MANUAL) DIFFERENTIAL LOCK SWITCH DIFFERENTIAL LOCK SOLENOID LOCKUP SOLENOID JOYSTICK PVRES TRANSMISSION KICK DOWN SWITCH

# 1 2 3 4 5 6 8 9 10 11 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

SHT 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 8 8 8

48 49 50 51 52 53 54 55 56 57 58 59 60

COMPONENT DIAGNOSTIC CONNECTOR POWER CONVERTER - 24 TO 12 VOLT 12 VOLT POWER OUTLETS (OPTION) RADIO RIGHT SPEAKER LEFT SPEAKER AIR SEAT CIGAR LIGHTER AIR CONDITIONING CLUTCH RELAY AIR CONDITIONING HIGH-LOW PRESSURE SWITCH AIR CONDITIONING COMPRESSOR CLUTCH ELECTRONIC PANEL EXTERNAL AIR TEMPERATURE SENSOR INTERNAL AIR TEMPERATURE SENSOR SUN SENSOR BLOWER FAN RESISTOR BLOWER MOTORS THERMOCOUPLE SENSOR MIXED AIR SENSOR COMPRESSOR RELAY RECYCLING MOTOR ELECTRONIC WATER VALVE 24 TO 12 VOLT CONVERTER ACTUATOR DRIVER ELECTRONIC WATER VALVE BLOWER FAN RESISTOR BLOWER MOTOR THERMOSTAT FAN SPEED SWITCH AIR CONDITIONING SWITCH CONTROL PANEL LAMPS WATER VALVE POTENTIOMETER AIR RECIRCULATING SWITCH HOOD UP RELAY HOOD DOWN RELAY HOOD SWITCH HOOD MOTOR IGNITION POWER LATCH IGNITION POWER CONTROL START LOCKOUT NOX SENSOR HUMIDITY AND AMBIENT TEMPERATURE SENSOR NOX SENSOR (NOXS)

COMPONENT NUMBERING INFORMATION

# 177 178 179 180 181 182 183 184 185 186

SHT 13 13 13 13 13 13 13 13 13 13

COMPONENT ARM POS FNR SWITCH (OPTION) FNR RELAY PILOT DUMP VALVE JSS VALVE LOAD SENSE PRESSURE SENSOR PILOT PRESSURE SWITCH JSS RELAY JOYSTICK STR SWITCH (OPTION) JSS CONTROLLER

BATTERIES

4003

Section 4003

4003-2

TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 5 5 6 7 7 8 8

4003-3

SAFETY RULES WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83A

WARNING: Never cause sparks to occur or smoke near batteries that are charging or have been recently charged. 13-8A

WARNING: Disconnect the ground cable first when the battery cables are disconnected from the battery. Connect the ground cable last when the battery cables are connected to the battery. 47-55A

WARNING: Some batteries have a ventilation tube. If there is battery acid in the ventilation tube, this battery acid can be released when the battery is turned upside down. If you turn the battery upside down, make sure that the end of the ventilation tube is away from you and away from any other people in the area. Battery acid can cause severe burns.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in enclosed area. Always shield eyes when working near batteries. Keep out of reach of children.

48-57B

SPECIAL TOOLS

B795328

The CAS10147 tester is used to do the Capacity (Load) Test. This tool is first used on Page 6.

D-47-53A

4003-4

MAINTENANCE Electrolyte Level

Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the level of the electrolyte every 1000 hours of operation or six months, whichever occurs first. For all other batteries, check the level of the electrolyte every 250 hours of operation.

If damage causes an electrolyte leak, replace the battery.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed for access to the battery caps, it is possible that the words Maintenance Free have been removed from the decal. Check the level of the electrolyte more often during hot weather. The use of a large amount of water by the batter y can be caused by high batter y temperature or a voltage regulator setting that is too high. Keep the electrolyte level above the top of the plates in the battery at all times to prevent damage to the battery. NOTE: On maintenance free batteries it is necessary to remove the center part of the decal for access to the battery caps. Do not discard the center part of the decal. Install the center part of the decal after the battery caps have been installed. If the level of the electrolyte is low, add distilled water or other clean water until the electrolyte is just below the cell opening. Do not add more water than is n e e d e d . To o m u c h w a t e r c a n c a u s e b a d performance, a short service life, and corrosion around the battery. NOTE: Add water only. DO NOT add electrolyte.

Inspect the battery at regular intervals for dir t, corrosion, and damage. Electrolyte and dirt on the top of the battery can cause the battery to discharge by making a passage for the current to flow. If the battery must be cleaned, remove the battery from the battery carrier and clean the battery, cable terminals, and the battery carrier. When available, use Case Battery Saver and Cleaner according to the instructions on the container. Case Battery Saver and Cleaner also helps prevent corrosion. If Case Battery Saver and Cleaner is not available, use baking soda and water as a cleaner. DO NOT permit any type of cleaner to enter the cells of the battery. Install the battery in the machine and make sure the fasteners are tight. Apply Case Battery Saver and Cleaner or Urethane Seal Coat to the cable terminals to prevent corrosion. See the Parts Counter Catalog. DO NOT apply grease.

4003-5

BATTERY TEST NOTE: To correctly test a battery, do each part of the battery test until you know the condition of the battery.

Visual Checks 1. Make sure the cable connections are clean and tight. Clean foreign material from the top of the battery. 2. Inspect the battery case, battery posts, and cables for damage. 3. Check the electrolyte level. See Page 4. 4. If you added water to the battery, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte.

Specific Gravity Check A hydrometer is used to check the specific gravity (weight) of the electrolyte. The specific gravity is an indication of the level of charge for each cell. Hydrometers are made to show the correct specific gravity when the temperature of the electrolyte is 26.7°C (80°F). When you check the specific gravity, you must know the temperature of the electrolyte. If your hydrometer does not have a thermometer, get a thermometer to check the temperature of the electrolyte. The thermometer must indicate a high temperature of at least 52°C (120°F). 1. Remove enough electrolyte from a cell so that the float is free in the tube. NOTE: If the specific gravity cannot be checked without first adding water to the cell, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte. Then check the specific gravity. 2. Read the float. 3. Read the thermometer. If the reading is above 26.7°C (80°F) add specific gravity points to the reading for specific gravity. If the reading is below 26.5°C (80°F) subtract specific gravity points from the reading for specific gravity. See the following illustration and add or subtract specific gravity points as needed.

B790863

1. TEMPERATURE IN F

2. TEMPERATURE IN C

SPECIFIC GRAVITY CHART

4. Make a record of the corrected specific gravity reading for each cell. 5. If the difference between the high reading and the low reading is 0.050 or more, charge the battery and check the specific gravity again. If after charging, the difference is still 0.050 or more, install a new battery. 6. The corrected specific gravity reading shows the level of charge for the cell. The level of charge must be at least 75% in each of the cells. ln maintenance free batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.240 or higher. In all other batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.230 or higher. 7. If the difference between the high reading and the low reading is less than 0.050, and the level of charge is at least 75% in all of the cells, do the Capacity (Load) Test. 8. If the difference between the high reading and the low reading is less than 0.050, but the level of charge is less than 75% in any of the cells, charge the battery and check the specific gravity again. If after charging: A. The level of charge is less than 75% in any of the cells, discard the battery. B. The level of charge is at least 75% in all of the cells, do the Capacity (Load) Test.

4003-6

Capacity (Load) Test This test can be done using a variable load tester s u c h a s t h e S u n E l e c t r i c VAT- 3 3 . O t h e r t e s t equipment can be used. Connect the test equipment according to the instructions of the manufacturer of the equipment. 1. The level of charge of the battery must be at least 75%. Do the Specific Gravity Check in this section. 2. Prepare the tester (Sun Electric VAT-33 shown) for the test. A. Select the voltmeter range that will measure 1 to 18 volts. B. Make sure the load control knob is in the OFF position. C. Select the ammeter range that will measure 0 to 1000 amperes. D. Move the volt lead switch to the NT. position. 3. Connect the tester to the battery as shown.

NOTE: Never apply a load for longer than 15 seconds. After each 15 seconds, turn the load control knob to OFF for at least one minute. 4. Apply a 15 ampere load to the battery for 15 seconds. Wait at least three minutes before applying the load again. 5. Check and make a record of the temperature of the electrolyte. 6. Find the correct load for this test in Specifications in Section 4001. NOTE: The correct load is half of the cold cranking amperes at -17°C (0°F). 7. Turn the load control knob until the ammeter indicates the specified load. Keep the load for 15 seconds and read the voltmeter. Turn the load control knob to OFF. 8. Compare the test reading and the temperature of the electrolyte to the chart below. Temperature of . . . . . . . . . . . . . . . Minimum Voltage electrolyte 21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6 16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 -1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 -12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 A. If the test result is equal to or more than the vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d condition. B. If the test result is less than the voltage shown, discard the battery.

B790499

1. LOAD CONTROL KNOB

2. AMMETER CLAMP (TIP OF ARROW AWAY FROM BATTERY)

4003-7

CHARGING A BATTERY The charging rate must be decreased if: WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83

1. Too much gas causes the electrolyte to flow from the cells.

Before you charge the battery, check the level of the electrolyte.

2. The temperature of the electrolyte rises above 52°C (125°F).

It is difficult to give an exact charging rate because of the following variable conditions: (1) temperature of the electrolyte, (2) level of charge, and (3) condition of the battery. Use the charging guide for the correct charging rate and time.

NOTE: For the best charge, use the slow charging rates. The battery is fully charged when, over a three hour period at a low charging rate, no cell is giving too much gas, and the specific gravity does not change.

See Specifications in Section 4001 for the reserve capacity of the battery in this machine.

Charging Guide For Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery Battery Capacity - See Reserve Capacity under Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes 1.5 Hours at 50 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

5 Hours at 20 Amperes 2 Hours at 50 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

7.5 Hours at 20 Amperes 3 Hours at 50 Amperes

80 Minutes or Less

*initial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been removed from the decal. Continued on next page

4003-8

Charging Guide For Batteries Other Than Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - See Reserve Capacity under Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes 1.5 Hours at 50 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

5 Hours at 20 Amperes 2 Hours at 50 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

7.5 Hours at 20 Amperes 3 Hours at 50 Amperes

Above 250 Minutes

24 Hours at 10 Amperes

6 Hours at 40 Amperes 4 Hours at 60 Amperes

80 Minutes or Less

*initial rate for standard taper charger.

PREPARING A DRY CHARGED BATTERY FOR USE 1. Remove the caps from the battery. 2. Fill each cell to the top of the separators with electrolyte. This will per mit the volume of electrolyte to increase when heated by charging the battery. 3. Install the caps on the battery. 4. Connect a battery charger to the battery.

5. Charge the battery at 30 amperes until the spe cific gravity is 1 .25 0 or m ore a nd the temperature of the electrolyte is at least 15.5°C (60°F). 6. If necessary, fill each cell with electrolyte until the electrolyte is just below split ring at the bottom of the cell opening.

JUMP POST OPTION

4003a

Section 4003a

4003-2

TABLE OF CONTENTS Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4003-3

JUMP POST OPTION STEP 1

7. Remove the booster battery negative (-) cable from the jump post and then from the machine being used for starting. Remove the positive (+) cable from the jump post terminal and then from the booster battery. 8. Install the terminal covers.

RCPH10WHL214AAH.PNG

The Jump Post option can be used to provide power to star t the machine if its batteries become discharged. The option can be used to provide power to the machine for the purpose of raising the hood if its batteries have become discharged. The option can be used to star t other disabled equipment without accessing the main batter y terminals. NOTE: Note: Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts). The jump post is located on the left hand side of the machine inside the main electrical disconnect compartment. 1. Turn off the ignition and all accessories on the machine(s). Use the jump post to connect the auxiliary battery. 2. Remove the terminal covers and connect one end of the positive (+) cable to the positive (+) terminal on the booster battery. 3. Connect the other end of the positive (+) cable to the positive (+) terminal of the jump post (red). 4. Connect the negative (-) cable to the negative (-) terminal on the booster battery. 5. Connect the other end of the negative (-) cable to the negative (-) terminal of the jump post (black). Do not connect it to sheet metal or any rotating part, as damage can result. Do not connect to the negative (-) terminal on the battery. 6. Start the engine.

4003-4

Section 4005

4005

INSTRUMENT CLUSTER

4005-2

TABLE OF CONTENTS INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 6 9 11 11 12 12 12 12 14 18 18 18 19 23 43 51 54

4005-3

INSTRUMENT CLUSTER

15 14

12 BD06H039

1. 2. 3. 4. 5. 6. 7. 8.

LOW BRAKE PRESSURE INDICATOR HIGH BEAM INDICATOR TRANSMISSION OIL TEMPERATURE GAUGE CAUTION MASTER INDICATOR MULTI FUNCTION LCD DISPLAY STOP MASTER INDICATOR HYDRAULIC OIL TEMPERATURE GAUGE WAIT TO START ENGINE PREHEAT

9. 10. 11. 12. 13. 14. 15.

LACK OF AUX STEER PRESSURE (OPTIONAL) PARKING BRAKE INDICATOR RIGHT TURN INDICATOR FUEL LEVEL GAUGE FUEL LEVEL AT MINIMUM ENGINE COOLANT TEMPERATURE GAUGE LEFT TURN INDICATOR

The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a possible malfunction and when immediate action is needed due to a possible critical malfunction. When the machine is started, the instrument cluster will perform the following self-test:

4005-4

Self-Test 1. Turn the ignition (key) switch to the ON position. 2. The instrument cluster will automatically check each monitored system. 3. All LED’s (Light Emitting Diodes) will illuminate for 2 - 3 seconds. 4. Four gauges will energize for 2 - 3 seconds. 5. The warning alarm will sound for 2 - 3 seconds.

Power Circuit Test A. Check fuse ECA-F3. If the fuse is bad, replace the fuse and repeat Self-Test. If the fuse is good, go to next step. B. Check wire 19EA for continuity. Repair/replace the wire as required. If continuity is found go to next step. C. Check power relay module A for proper operation, see Section 4002. If the power relay module checks good, go to next step.

6. If there is an open circuit between a sensor and the instrument cluster, the LED will flash and the warning alarm will sound for 5 seconds.

D. Check the ignition switch for proper operation, see Section 4002. If the ignition switch checks good, go to next step.

7. If there were no faults detected during the check, all monitored systems will return to normal operation.

E. Check fuse ECC-F5. If the fuse is bad, replace the fuse.

8. If only some of the LEDs illuminate, replace the instrument cluster. 9. If the LEDs illuminate, but the warning alarm does not sound, see section 4002 and test the alarm circuit. 10. If the warning alarm sounds but the LEDs do not illuminate, if no power is present at buzzer, replace the instrument cluster, if power is present at the buzzer, replace the buzzer. 11. If the warning alarm does not sound and the LEDs do not illuminate on the instrument cluster, do the following steps to test the power circuit:

4005-5

LCD Multi-function Display

2. This example, shows that the Transmission Control Lever is in Forward. The display will show Forward, Neutral, or Reverse, depending on where the Directional Control Lever is positioned. NOTE: Forward and Reverse will blink if the transmission clutches are disconnected. 3. This example shows the maximum gear allowed when in Automatic mode. If display is blank the Manual mode has been selected. 4. This example shows the current transmission mode that has been selected. A. If the Transmission is operating normally it will display either BD06J132

The LCD Multi-Function Display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps and the LCD Multi-Display will display, CASE, with the machine model and current hour reading.

●

A - Automatic

●

M - Manual operation.

B. If the Transmission is not operating normally the display will show ●

C - Substitute Clutch.

●

L - Limp Home.

●

S - Transmission Shutdown.

●

U - TCU Shutdown.

5. This example (not displayed) will show the transmission clutches disengaged, if the Park Brake is OFF. 6. This example shows the Power Boost Status. ●

MAX - Maximum Power.

●

STD - Normal/Standard mode of Operation.

●

AUTO - Switches automatically Maximum and Standard Power.

●

ECO - Limited Power for fuel efficiency.

between

7. This example will show the Time in either 12 hour or 24 hour. BD06F185

LCD MULTI-FUNCTION DISPLAY

The LCD Multi-function display (liquid crystal display is located at the center of the modular dashboard. On start up, the console indicator lamps will momentarily flash. The LCD Multi-display will flash the machine model. The initial standard driving screen will then appear. Once operator preferences are set, the screen will reflect those selections. 1. In the example, above, the machine hours are d i s p laye d . M a c h i n e h o u r s w i l l a l way s b e displayed briefly, on start up. After, the machine is started, the display will show engine rpm’s. After, beginning travel, the machine will display travel speed, if default settings were not changed by the operator.

4005-6

Navigating Through The LCD Multi-function Display Screens

Using The Arrow Keys At any time, during operation or with the key switch on, the operator may scroll through three information screens and two trip screens by using the arrow keys. These five screens are in a circular loop and may be reached by pressing the up or down key. The following sequence is using the down key only.

NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

D BD06F186

Located on the steering column, just to the left of the Park Switch, is the key pad. Use this key pad to move fr o m on e s c r e e n to a n o th e r, c h o o s e va r i o u s selections, monitor the machine functions, and retrieve information. All functions can be accessed in the same basic manner. A. Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to start over and begin again, plus use to check active, acknowledge errors.

BD06F188

From the driving screen push the down arrow, as shown.

B. Enter key: Use this key to confirm, yes, this is the desired function. C. Up arrow key: Use this key to scroll up to selections. D. Down arrow key: Use this key to scroll down to selections. NOTE: Arrows on the screen will indicate if selections are up or down from the current selection. NOTE: Display units can be changed by the operator. BD06F183

Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, fuel level, and the DEF fluid level.

4005-7

BD06F169

BD06F027

Info 2 will be displayed next. The Info 2 screen will display coolant temperature, engine oil temperature in either Fahrenheit or Celsius, DEF fluid level, as well as oil pressure PSI.

Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in h o u r s , t h e t o t a l f u e l , a n d t h e a ve r a g e f u e l consumption per hour.

BD06F170

BD06F184

Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and DEF fluid level.

By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.

4005-8

Reset The Trip Information

BD06F170

Highlight the trip screen you wish to set.

BD06F187

Press the confirm button to reset the trip selection to zero. The trip screen will indicate a reset message. At this screen, press confirm to clear the numbers and reset the trip information. The current date and time will display automatically. The hours, fuel consumption, and fuel used per hour will reset and revert to zero.

4005-9

Entering The Service Screens After the machine has been started or the key switch has been turned to on the operator or service technican may use this service menu to adjust machine configurations to working conditions, test components, view faults that may have occurred, or select preferences. NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.

BD06H038 / BD06F188

Press and hold the confirmation button for two seconds to arrive at the main menu screen. Use down arrow to scroll through the menu’s. Items and selections in this menu are: 1. Settings 2. Display 3. Diagnostics 4. Service

4005-10

RCPH10WHL060HAH

4005-11

Service screens After the machine has been started or the key switch has been turned to ON, the operator or service technician may use the main menu to adjust machine con figura tio ns to wor king c ond itio ns, to te st components, view faults that may have occurred, or to select preferences. Languages can be set at the beginning of the menu configuration to allow the operator to work in the language of choice.

RCPH10WHL367BAH

Engine selections RCPH10WHL366AAH

Settings Selections at the setting menu include: Engine Transmission

Auto idle (Off, Low, Accelerated) Power Mode (Max, Standard, Auto, Eco) Engine options (fan auto, Work idle) Auto Shutdown (optional) is used for interval settings

Joystick steering (option will display only if machine is joystick steering equipped).

RCPH10WHL369BAH

Transmission selections Max gear Min gear POWERINCH (Optional 5-speed)

4005-12

Display

Diagnostics

RCPH10WHL447AAH

Highlight the desired selection and press confirm.

●

Languages (English, German, French, Italian, spanish, Portuguese)

NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to return to the main screen. turning the machine off will also lock the settings into memory.

●

Units (metric, English, Imperial)

Selecting Power Modes

●

Clock (Hour, minute, month, day, year)

●

Backlight (Day display, day LED, night display, night LED).

The power mode allows the operator to choose the most effective machine power for the current job conditions. Most commonly auto is chosen, as the power will automatically increase or decrease between maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency.

RCPH10WHL358BAH

Highlight the display selection and press confirm Items and selections in this menu are:

Press and hold the confirmation button for two seconds to arrive at the service screen.

RCPH10WHL376BAH

Service Highlight the desired selection and press confirm. The tests in the configuration menu should be performed only by a qualified operator or technician. Some test require the engine to be running at high RPM’S. Items and selections in this menu are: ●

Calibration (Park brake and pedal calibration)

●

Select tires (tire size)

RCPH10WHL372BAH

At the screen shown above, highlight the power mode and press the confirmation button to move to the Power Mode Selection Menu.

4005-13 Auto idle shutoff (optional)

BD06F178

At the Power Mode Menu press the confirmation bu t t o n a g a i n t o a c t i va t e t h e s e l e c t i o n s. T h e highlighted section will flash to indicate a new selection can be made. Press the up or down button to select the Power Mode, and then press the confirmation button again. This changes the mode and locks it into memory. The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected. NOTE: Selecting options and navigating through the screen menus are the same for all functions. The display will tell the operator if errors have occurred. S h o u l d a n e r r o r m e s s a g e d i s p l ay, p r e s s t h e confirmation button to acknowledge and begin again.

RCPH10WHL375BAH

An optional feature that allows the operator to turn the economy auto engine shutdown on or off along with setting the shutdown intervals (5-60 minutes) in five minute increments. The engine and key switch electric power shut down when the machine is stopped, the transmission is in neutral, and the engine is at idle. the screen will display engine shutdown in a count down of seconds. This allows the operator to cancel this operation. The feature is d e s i g n e d s ave f u e l a n d m a c h i n e we a r w h e n machines are at an idling condition for a set period of time. In the engine protection mode, a higher level of system protection is offered. If a warning occurs while the machine is moving, the engine speed will reduce to low idle (900 RPM’s) to allow continued movement. When the machine stops, the engine will shut down. the protection system activates if a critical problem occurs. At the screen shown, highlight the selection, and press the confirm key.

4005-14

Preferences

Clock

RCPH10WHL358BAH

Language Screen, Measurement Units, and Clock The LCD screen can be set with language, units, and clock preferences. Use the arrow keys to scroll to the preferences menu. Press confirm. Choose the preferences desired, language in (English, Italian, Spanish, Portuguese, German, French, measurement units in English, Metric, or Imperial and clock units in either 12 or 24 hour). Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, use the confirm key to lock in the preference for the display. The escape key will allow you to leave this application.

RCPH10WHL363BAH

To set hour and date, from the select screen choose the clock designation and press the confirm key. Use the arrow keys to show field for time and date by pressing the arrow key. When the correct time and date have been entered by using the up and down arrow keys (up increases numbers, down decreases the numbers), press the confirm key to lock in correct time. Press the escape key to return to the main driving screen and lock selections into memory. Display backlight menu

RCPH10WHL364BAH

The background and brightness of the screen can be changed with the backlight menu. Use the arrow keys to make the selection to suit working conditions. The screen will change to night function illumination when the head lamps are turned on. RCPH10WHL361BAH

4005-15 Fan auto (if equipped)

RPM’S/Speedometer

RCPH10WHL373BAH

RCPH10WHL359BAH

Speed or RPM’s can be shown on the machine as desired. Highlight the desired choice, press the confirm key, then the escape key to lock selection into memory. If engine speed or RPM’s settings are not selected, the screen will display the hourmeter.

In automatic mode, the fan speed switches between high, low, or reverse as conditions require. This will depend upon system temperatures. Scroll through selections and selection the desired fan mode. Auto idle (if equipped)

Engine settings menu

RCPH10WHL371BAH

RCPH10WHL366BAH

Use the arrow keys to choose the settings menu. Press the enter key, and the settings sub-menu will appear. choose options for the fan, idle, power mode, etc.

The auto idle feature has three settings that control the engine low idle speed. this feature only applies when the wheel loader is stationary, in neutral, and not under load. The OFF setting will keep the low idle speed constant at the factory setting independent of engine or ambient temperature. The LOW setting will allow the low idle speed to decrease below the factory setting. By reducing the low idle speed, fuel consumption will be reduced. The ACCELERATED setting will allow the low idle speed to increase above the factory setting. Increasing the low idle speed helps at warm-up and can improve A/C performance. NOTE: If the machine is shifted out of neutral, put under any load, or if the temperature limits are not met, the idle will default to the standard factory set idle speed.

4005-16

Calibrating the gear box

Work Idle

After warming the oil temperature: 1. Park the machine on a firm level surface. 2. Place the NEUTRAL.

Transmission

Control

Lever

3. Set the Park Brake. 4. With the engine running, at idle, enter the Service Screen and scroll to Calibration.

RCPH10WHL373BAH

The work idle feature allows the low engine idle speed to be adjusted to a value different from the factory set default low idle. This feature only applies when the transmission is in gear and when the engine speed has gone above the work idle set speed. Setting the work low idle to a low engine speed allows for increased machine control during delicate work and improves fuel consumption. Setting the work low idle to a higher engine speed increases the responsiveness of the machine for maximum performance. To change the work idle setting, highlight the Eng Options selection and press confirm. Select the Work idle selection and press confirm. Increase or decrease the work idle speed using the arrow keys, then press confirm. Return to the main driving screen by pressing the escape key.

RCPH10WHL37BAH

Scroll to Calibration, high light and press the confirm key. always follow the prompts on the screen. Should an error occur, use the escape key to start over again. .

NOTE: If the transmission is shifted into neutral, the work idle feature will be deactivated.

BD06F195

This screen will prompt the operator or technican to confirm or escape. If, conditions are not correct, an error message will appear. Follow the prompts. There are six, if conditions not met errors: ●

Not in neutral

●

Park Brake OFF

●

Machine moving

●

Oil temp too low

4005-17 ●

Oil temp too high

●

Engine RPM low

●

Engine RPM high

If conditions are correct the operator or technican will see six calibration screens pass. They will display in this order: ●

Adjust K1

●

Adjust K2

●

Adjust K3

●

Adjust K4

●

Adjust KV

●

Adjust KR

●

Adjust KW (5-speed only)

Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start. If the process is not completed the operator or technican will be prompted to escape.

4005-18

RETRIEVING FAULT CODES General Fault Code Identification 1. Press and hold the escape key and up arrow key for more than 2 seconds to access the fault codes.

Fault Code Grouping 1. 1000 to 1999 vehicle errors. 2. 2000 to 2999 not used. 3. 3000 to 3999 engine errors. 4. 4000 to 4999 transmission errors.

5. 5000 to 5999 eltro-hydraulic system errors.

6. 6000 to 6999 reserved. 7. 7000 to 7999 reserved. 8. 8000 to 8999 optional equipment IE: GPS. 9. 9000 to 9999 internal AIC errors.

10. 19000 to 19999 Selective Catalytic Reduction (SCR) errors. BD06F186

A. Escape key B. enter key C. up key D. down key 2. Yellow Faults, buzzer will beep once every 2 seconds: A. Operator can acknowledge it by pressing the enter key. B. The message will disappear. C. Buzzer will not beep anymore. D. Yellow lamp will stay ON. E. Fault will remain in Yellow list until it is closed. 3. Red Faults, buzzer will be continuous, alternating sounds: A. Operator can acknowledge it by pressing the enter key. B. Buzzer will change to a less stressing sound, but will remain. C. Message will remain on display with indication of URGENT STOP.

4005-19

VEHICLE FAULT CODES DEFINITION

POSSIBLE STEPS FOR REPAIR

1310

Hydraulic filter blocked

Change filter

1311

Engine air filter blocked

Change filter

1312

Hydraulic oil temperature above normal

1313

Hydraulic oil temperature to high

1314

Transmission oil temperature above normal

1315

Transmission oil temperature to high

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check fan operation Check cooling core for clogs

Brake pressure too low

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check brake system pressure Check brake system for leaks

1317

Steering pressure too low

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check steering system for operation Check steering system for leaks

1318

Engine coolant temperature above normal

1319

Engine coolant temperature high - critical

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check fan operation Check radiator core for clogs

1320

Engine oil pressure too low

1321

Engine oil pressure below normal

1. Stop machine operations 2. Check engine oil level 3. Check pressure sender unit

1322

Engine oil pressure above normal

1. Check engine oil for proper type 2. Check pressure sender unit

1323

Battery voltage low

1324

Battery voltage high

1325

Oil temperature too high

1326

Coolant level low

Fill radiator level

1327

Moved during accelerated idle

No information available at time of print.

1328

Moving when shifting to low idle

No information available at time of print

1329

WIF sensor not present

No information available at time of print

1331

Electrical charging system voltage low critical level

1332

Water detected in fuel

Drain fuel filter

1333

Engine overspeed

Check engine speeds

1334

Intake manifold temperature high - critical

Check for defective or clogged after cooler

1316

Check charging system 1. Stop machine operations 2. Run engine at 1500 rpm 3. Check sending unit

1. Stop machine operations 2. Check charging system

4005-20 DEFINITION

POSSIBLE STEPS FOR REPAIR 1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check brake system pressure Check brake system for leaks

1335

Brake pressure too low

1336

Transmission oil filter blocked

Replace filter

1341

Sec. steering pressure too low

No information available at time of print.

1342

Steering pressure sensor open circuit

Check wiring, sensor installation and proper functioning of steering pressure sensor

1343

Sec. steering pressure sensor open circuit

Check wiring, sensor installation and proper functioning of sec steering pressure sensor

1812

Open circuit, Short to battery or short to ground at JSS armrest switch.

Check wiring, switch installation and proper functioning of armrest switch.

1816

Open circuit / JSS activation switch mechanical defect

Check wiring, switch installation and proper functioning of JSS activation switch.

1820

Check JSS relay, JSS valve, JSS joystick power supply connections

Check wiring, installation, and proper functioning of JSS components. See electrical schematics and section 5009 for details.

1821

Short to ground on JSS relay 85/AIC 1.21 or short to power on relay 86/87a. Or activation switch failure

Check wiring, installation, and proper functioning of JSS components. See electrical schematics and section 5009 for details.

1823

JSS relay, ground connect., bad elec. connect. Permanent ground at JSS relay (87) open circuit or short to power

Check wiring, installation, and proper functioning of JSS components. See electrical schematics and section 5009 for details.

1824

Short to battery at activation button. Activation switch failure

Check wiring, installation, and proper functioning of JSS components. See electrical schematics and section 5009 for details.

1830

Open circuit between activation switch Pin 3 and C5.E Pin 1

Check wiring, installation, and proper functioning of JSS components. See electrical schematics and section 5009 for details.

1831

JSC controller, wrong operation. JSC controller internal fault

Check wiring, installation, and proper functioning of JSS controller. See electrical schematics and section 5009 for details.

1832

JSC controller, JSC signal in, out of limits. Input signal from JSS joystick to JSC controller out of limits.

Check wiring, installation, and proper functioning of JSS components. See electrical schematics and section 5009 for details. (Joystick Neutral: USignal>40%UBat+<60%Ubat;Joystick actuated: USignal>20%UBat+<80%UBat)

1833

Output signal from JSC controller to valve out of limits.

1834

JSS controller, JSC output, SC to BAT Power is applied to one of the JSC controller outputs.

Check connector of JSS valve and JSC controller. Check electrical connection for short to power. Or JSC internal relay is defective.

4005-21 DEFINITION

POSSIBLE STEPS FOR REPAIR

1835

JSS-valve/Pin4 JSC/Pin5 short to power, short to ground or open circuit

Check wiring, installation, and proper functioning of JSS valve. See electrical schematics and section 5009 for details.

1836

JSS controller, board temperature, out of limits temperature on the JSC board is <-40C or >+85C;

Check ambient temperature or short circuit at JSC power outputs

1837

JSS controller, switched power, out of limits switched power supply at JSC Pin3 is out of limit;

Check elect connection for electrical transients, burst or drifts.

1838

Neutral switch out of range

Check wiring, installation, and proper functioning of neutral switch. See electrical schematics and section 5009 for details.

1839

Joystick steering is not calibrated

See electrical schematics and section 5009 for details.

1841

JSS valve internal error, spool position not accurate or signal voltage out of range

1842

JSS valve Pin2 (alarm signal) open circuit

Check wiring, installation, and proper functioning of JSS valve. See electrical schematics and section 5009 for details.

1843

Pilot pressure switch open when HSS is deactivated. High pilot pressure on JSS valve even when JSS is not active.

Pilot dump valve stuck close or short to power on valve power supply. Or open circuit on JSS pilot pressure switch lines or JSC/Pin8.

1844

Pilot pressure switch short to ground

Check wiring, installation, and proper functioning of pilot pressure switch. See electrical schematics and section 5009 for details.

1845

Pilot pressure switch stays closed (Input JSC8+1) although JSS is activated. With low pilot pressure on JSS valve no steering with JSS possible.

Error is displayed when JSS active and Pilot pressure stays low. Pilot dump valve stuck open or open circuit or short to ground on JSS valve power supply (valve connector Pin4). Or short to power on JSS pilot pressure switch lines or input JSC/Pin8.

1846

Standard steering orbit or tank pressure transducer switch short to power or short to ground

Check wiring, installation, and proper functioning of switch. See electrical schematics and section 5000 for details.

1847

JSC Model type not available, no model type information available in JSC, probably missing information from AIC

No information available at time of print.

1850

JSS joystick Pins2, 4, or 6 short to ground, short to battery or open circuit, or JSS joystick internal failure.

Check wiring, installation, and proper functioning of JSS joystick. See electrical schematics and section 5009 for details.

1852

JSS joystick Pins5 open circuit, or JSS joystick internal failure

Check wiring, installation, and proper functioning of JSS joystick. See electrical schematics and section 5009 for details.

Check wiring, installation, and proper functioning of JSS valve. See electrical schematics and section 5009 for details.

4005-22 DEFINITION

POSSIBLE STEPS FOR REPAIR

1860

CAN timeout of C5.E detected by JSC

No information available at time of print.

1861

CAN timeout of AIC detected by JSC controller

No information available at time of print.

1863

Internal malfunction transmission controller. TCU message JSS F-N-R disabled or JSS F-N-R not activated.

No information available at time of print.

1864

Test

No information available at time of print.

NOTE: The following fault codes are for optional climate controlled heating and air conditioning system. CODE 1909

DEFINITION Open circuit evaporator temperature sensor

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR AC relay compressor is disabled.

1910

Short circuit evaporator temperature sensor

1. Check sensor for short circuit to ground or open circuit. 2. Check harness between control module and relay.

1919

Water valve motor output failure, does not work correctly

1. Verify if the system controls are functioning properly when requesting heat or AC. 2. The motor is working in a degraded mode, replace valve.

Recirculation actuator DC motor output failure, does not work correctly

1. Turn system on with fan speed on low, verify position of flap. 2. Place the fan speed on high, check position of flap. 3. Check harness between controller and flap motor.

AC relay output failure, does not work.

1. Check for proper connection of relay. 2. Replace relay with known good relay and retest system. 3. Verify system activation when AC button is pressed. 4. Check charge level of AC system.

1920

1921

4005-23

ENGINE FAULT CODES CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3001

Foot throttle sensor signal not plausible

Idle switch defect or wiring of idle switch broken or accelerator pedal defect. Check wiring, replace idle switch or replace accelerator pedal.

3002

Foot throttle sensor signal above range max.

Short circuit in wiring or in accelerator pedal. Check wiring or replace accelerator pedal.

3003

Foot throttle sensor signal below range min.

Short circuit in wiring or in accelerator pedal. Check wiring or replace accelerator pedal.

3004

Foot throttle sensor - no signal

Check wiring or replace accelerator pedal

3006

Coolant temperature sensor signal not plausible

See OTS (Oil Temperature Sensor) plausibility check (Fault 3033)

3007

Coolant temperature sensor signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

3008

Coolant temperature sensor signal below range min.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3009

Coolant temperature sensor null (via CAN)

No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.

Air intake temperature sensor - signal above range max.

The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the temperature sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a default value of 29.96 °C (86 °F). Cause: The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit.

3010

4005-24 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3011

Air intake temperature sensor - signal above range min.

3012

Air intake temperature sensor - (via CAN) No signal.

See engine manual for details.

3015

Fuel temperature signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

3016

Fuel temperature signal below range min.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3019

Boost pressure sensor signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

3021

Boost pressure sensor null (via CAN)

No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.

3022

Boost pressure sensor signal not plausible

Difference of ambient and boost pressure is out of range. Check wiring or replace sensor.

3023

Atmospheric pressure sensor signal not plausible

3024

Atmospheric pressure sensor signal above range max.

3025

Atmospheric pressure sensor signal below range min.

Ambient pressure sensor inside ECU is defect. Replace ECU (not necessary if never running in high altitude and if turbocharger is without VGT)

3028

Oil pressure sensor pressure too low

Inaccurate oil pressure sensor or defect (e.g. too low oil level, leakage...) in the oil system. Check oil pressure sensor for accuracy and check oil system.

3029

Oil pressure sensor short-circuit to battery

Sensor defective or short circuit to external source. Check wiring or replace sensor.

3030

Oil pressure sensor short-circuit to ground

Sensor defective or short circuit to ground. Check wiring or replace sensor.

4005-25 CODE

3031

DEFINITION

Oil pressure sensor ADC conversion error

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The Engine Control Unit (ECU) generated a fault associated with the Oil temp / press sensor. The Oil temp / press sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the pressure sensing function of the device. This error could result from a signal out of range or a plausibility check (oil pressure too high). The plausibility check is only started if there are no sensor power supply ( 5 volts dc) or Analog to Digital Converter (ADC) signal errors detected. Cause: The Oil temp / press sensor signal to the ECU is either erratic or intermittent. Possible failure modes: 1. Faulty Oil temp / press sensor. 2. Faulty electrical wiring or intermittent connection between Oil temp / press sensor and ECU. 3. Faulty ECU, supply voltages or grounds.

3032

Oil pressure sensor pressure too high

Oil pressure sensor pressure too high.

3033

Oil temperature sensor signal not plausible

Inaccurate oil or coolant temperature sensors or insufficient oil or coolant recirculation (low coolant level etc.). Check oil and coolant temperature sensor for accuracy and check oil and coolant system for proper functioning.

3034

Oil temperature sensor signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

3035

Oil temperature sensor signal below range min.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3036

Oil temperature sensor signal CAN transmission disturbed

No CAN plausibility check performed, restart system, if problem reoccurs. Check wiring or replace sensor.

3037

Boost pressure sensor signal low

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3039

Cruise control actuating device - Evaluation error.

See engine manual for details.

High pressure Pump relay - Short circuit to battery

1. Faulty reading from component. 2. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector. 3. Wiring or circuits open. 4. Wiring or circuits shorted. 5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by installing and removing.

3047

4005-26 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3048

High pressure Pump relay - Short circuit to ground.

1. Faulty reading from component. 2. Wiring or circuits shorted.

3051

Battery voltage to ECM too high

Alternator voltage governor defect. Replace alternator governor device or alternator.

Battery voltage to ECM too low

Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect. Occurrence possible during cold start. Replace battery or alternator. Check ECU and wiring.

ECM afterrun was interrupted.

3060

Cylinder 1 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3061

Cylinder 1 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3062

Cylinder 1 signal low

Check the wiring and the injection signals, replace ECU

3063

Cylinder 1 short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3064

Cylinder 5 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3065

Cylinder 5 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3066

Cylinder 5 signal low

Check the wiring and the injection signals, replace ECU.

3067

Cylinder 5 injector cable short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

Cylinder 3 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3052

3059

3068

4005-27 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3069

Cylinder 3 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3070

Cylinder 3 signal low

Check the wiring and the injection signals, replace ECU.

3071

Cylinder 3 short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3072

Cylinder 6 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3073

Cylinder 6 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3074

Cylinder 6 signal low

Check the wiring and the injection signals, replace ECU.

3075

Cylinder 6 injector cable short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3076

Cylinder 2 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3077

Cylinder 2 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3078

Cylinder 2 signal low

Check the wiring and the injection signals, replace ECU.

3079

Cylinder 2 injector cable short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3080

Cylinder 4 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3081

Cylinder 4 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3082

Cylinder 4 signal low

Check the wiring and the injection signals, replace ECU.

3083

Cylinder 4 injector cable short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

Crankshaft sensor lost synchronization

Signal interrupted due to wiring problem, defective or incorrectly installed crankshaft speed sensor. Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals)

3088

4005-28 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Crankshaft sensor defective

Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals).

3090

Camshaft sensor lost phase

Signal interrupted due to wiring problem, defective or incorrectly installed camshaft phase sensor. Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals)

3091

Camshaft sensor phase synchronization failure

Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals).

3092

Offset between camshaft and crankshaft - Not plausible.

See engine manual for details.

3093

Offset between camshaft and crankshaft outside boundaries

Signal interrupted due to wiring problem, defective or incorrectly installed camshaft or crankshaft sensor. Check wiring, sensor installations and proper functioning of camshaft and crankshaft sensors (evaluate raw signals)

3095

Operating with camshaft sensor only

Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluated raw signals).

3096

ECM Busoff on vehicle CAN

See engine manual for details.

3097

ECM Busoff on Engine private CAN

See engine manual for details.

3098

Timeout of CAN Message TSC1-TE (when active).

See engine manual for details.

3099

Timeout of CAN Message TSC1-TE (when inactive).

See engine manual for details.

3100

Timeout of CAN Message TSC1 -AE (when active).

See engine manual for details.

3101

Timeout of CAN Message TSC1-AE (when inactive).

See engine manual for details.

3102

Rail pressure sensor CP3 signal below range min.

Short circuit of wiring to ground or defective pressure sensor. Check wiring and proper functioning of rail pressure sensor

Rail pressure relief valve open

Defective rail pressure sensor, defect in other injection relevant component. Check rail pressure sensor for plausible values, ensure proper functioning of the injection components

3089

3104

4005-29 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3105

Rail pressure relief valve pressure shock requested

PRV does not open once the pressure limit is reached: Mechanical defect or wrong application parameter. Check application value of maximum rail pressure, check functioning of the PRV

3106

Rail pressure relief valve did not open after pressure shock

PRV does not open even after pressure shock: Stuck PRV or wrong application parameter. Check application value of maximum rail pressure, check functioning of the PRV

3107

Metering unit output short-circuit to battery on low side

Short circuit of wiring to external source or inside relay. Check wiring or replace relay

3108

Metering unit - short circuit to Ground.

The engine control unit (ECU) has determined that a short to low source circuit condition exists in the fuel high pressure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it is switched off for some reason. Failure detection of is only possible if the low side power stage is switched off. With the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware report of ’short circuit to ground’ (on the low side of the metering unit) longer than 0.28 seconds and the power stage has most likely switched off.

3110

Rail pressure sensor offset monitoring signal above range max.

3111

Rail pressure sensor offset monitoring signal below range min.

Rail pressure sensor inaccurate. Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor

3112

Rail pressure sensor CP3 signal above range max.

Short circuit of wiring to external source or defective pressure sensor, rail pressure overshoot. Check wiring and proper functioning of rail pressure sensor

3113

Main Relay 1 (High Pressure Pump) short to battery.

Short circuit of main relay to external source or defective main relay. Check the wiring connecting the battery to the EDC or replace main relay

4005-30 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR Short circuit to ground of main relay or defective main relay. Check the wiring connecting the battery to the EDC or replace main relay

3114

Main Relay 1 (High Pressure Pump) short to GND.

3118

ECM 12V sensor supply voltage high

3119

ECM 12V sensor supply voltage low

3131

Grid heater always switched on

Short circuit to ground of grid heater. Check grid heater switch and replace it

3133

Cold start lamp - No load

See engine manual for details.

3134

Cold start lamp - Short circuit to battery

See engine manual for details.

3135

Cold start lamp - Short circuit to ground.

See engine manual for details.

3136

Cold start lamp - Excessive temperature.

See engine manual for details.

3137

Metering unit open load

Broken or disconnected wiring or defective relay. Check of wiring or replace relay

Metering unit signal not plausible

Defective wiring, ECU, power stage or metering unit. Check wiring, ECU, power stage and metering unit

Set point of fuel volume flow through metering unit is lower than calculated limit

High pressure system: Rail pressure sensor inaccurate, high pressure pump defective. Low pressure system: Metering unit reflux too low. Check for defects according to failure list.

High pressure test - Test active

The engine control unit (ECU) has acknowledged that the ’High Pressure Test’ is running. The ’High Pressure Test’ is a test procedure used to evaluate the performance of the fuel high pressure unit (pump, rail pressure control valve, etc.) and is executed via a diagnostic tester request. If this test is running the rail pressure monitoring has to be deactivated, which is done by setting this fault path. Therefore, this failure path is used more for information purposes and inhibit handling than as an actual error status.

3138

3141

3142

Ambient pressure sensor inside ECU is defective. Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)

4005-31 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3145

Terminal 15 - No signal

NOTICE: Fault Code 3145 is stored historical information. For multiple occurrences of this fault proceed with the following tests. NOTE: See engine repair manual for electrical schematic information. When available use special tool 380040185 harness diagnostic/repair kit. Cause: 1. Faulty reading from component. 2. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector. 3. Wiring or circuits open. 4. Wiring or circuits shorted. 5. Connector pins corroded or dirty.

3147

Oil temperature sensor signal above normal range

Check oil temperature sensor for accuracy and check oil system.

3148

Coolant temperature sensor dynamic test Failure (Minimum temperature raise not reached).

See engine manual for details.

3154

Grid heater relay short-circuit to battery

Short circuit of wiring to external source or inside relay. Check wiring or replace relay

3155

Grid heater relay short-circuit to ground

Short circuit of wiring to ground or inside relay. Check wiring or replace relay

3156

Grid heater relay no load

Broken or disconnected wiring or defective relay. Check wiring or replace relay

3157

Engine dataset information was not available from EDC in required time

See engine manual for details.

3158

Engine dataset does not match dataset registered for this machine

See engine manual for details.

3160

Fan actuator - Short circuit to battery

See engine manual for details.

3161

Fan actuator signal low

See engine manual for details.

3162

Fan actuator - Open load

See engine manual for details.

3163

Fan actuator - Temperature too high

See engine manual for details.

3166

Fuel filter heater relay - Short circuit to battery

See engine manual for details.

3167

Fuel filter heater relay - Short circuit to ground.

See engine manual for details.

3168

Fuel filter heater relay - Open load.

See engine manual for details.

3169

Fuel filter heater relay - Signal not plausible.

See engine manual for details.

4005-32 DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Fuel delivery exceeded threshold for pressure in overrun mode

High pressure system: Leakage in the high pressure section, injection nozzle stuck in open position, worn or defective high pressure pump, worn injector, leaking pressure relieve valve. Low pressure system: 'Zero delivery' is not active in metering unit (excessive leakage in metering unit). Check for defects according to failure list.

3177

Engine overspeed detected.

The Engine Control Unit (ECU) has detected an engine over-speed condition. An engine over-speed can occur both during certain engine operating conditions without any defect in a component, for example downhill driving, or as a result of, for example another ECU error. This error is for information purposes and is initiated by engine speed in excess of 2800 RPM for over 5 seconds and is reset once the engine speed is below the threshold for over 2 seconds. Though this error by itself does not require any action, the over-speed state can cause an injection shutoff request within the ECU. If this error reoccurs frequently, check driving conditions of the vehicle, engine speed acquisition and injection system for quantity set-point and actual value during fault recognition, check also for other ECU errors.

3178

Time-out of CAN message BC2EDC1

3179

Time-out of CAN message BC2EDC2

CODE

3176

Defective CAN controller of Body Computer, undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring. Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.

3180

Time-out of CAN message VCM2EDC

Defective CAN controller of Vehicle Control Module, undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring. Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.

3181

Rail pressure positive deviation too high concerning setpoint.

See engine manual for details.

3182

Timeout of CAN Message RXCCVS

See engine manual for details.

3183

Timeout of CAN Message TSC1-VR (when active)

See engine manual for details.

3184

Timeout of CAN Message TXC1-VR (when inactive)

See engine manual for details.

3185

Timeout of CAN message TF

See engine manual for details.

4005-33 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3188

Cylinder 1 open load

3192

Cylinder 2 open load

3196

Cylinder 3 open load

3200

Cylinder 4 open load

3204

Cylinder 5 open load

3208

Cylinder 6 open load

3210

Bank 1 general short-circuit on injection cable

Short circuit of high-side to battery or ground. Check the wiring or replace injector.

3211

Bank 1 injection cable short-circuit low side to ground

Short circuit of low-side to ground in injector cable. Check the wiring or replace injector.

3212

Bank 1 no signal

See engine manual for details.

3213

Bank 1 unclassified error

Depending on the pattern, various reasons can cause the defect, internal ECU problem. Check the wiring and the injection signals, replace ECU

3218

Bank 2 general short-circuit on injection cable

Short circuit of high-side to battery or ground. Check the wiring or replace injector.

3219

Bank 2 injection cable short-circuit low side to ground

Short circuit of low-side to ground in injector cable. Check the wiring or replace injector.

3220

Bank 2 no signal

See engine manual for details.

Bank 2 unclassified error

Depending on the pattern, various reasons can cause the defect, internal ECU problem. Check the wiring and the injection signals, replace ECU

3227

Injection processor error - stop engine

Clock error or interruption of the power supply voltage. Check the power supply or replace ECU if problem reoccurs.

3228

Injection processor error - stop engine

Defective ECU, reset ECU. If no recovery, replace ECU.

Injection processor error - stop engine

Internal failure of ECU or 'TESTMODE' takes too long. Check 'TESTMODE' parameters or replace ECU if problem reoccurs

Injection processor error - stop engine

Defective SPI-bus participant, timing problem due to software bug. Replace ECU if problem reoccurs (Send in ECU for investigation)

3221

3229

3230

Broken wire or disconnection of wiring or inside injector. Check the wiring or replace injector.

4005-34 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3231

Injection processor error - stop engine

3232

Injection processor error - stop engine

3233

Injection processor error - stop engine

3234

Injection processor error - stop engine

3238

Communication error of CJ940 processor

Electric disturbances, internal defect of the ECU leading to a SPI bus communication error. Replace ECU if failure remains present

ECM EEPROM - Read operation failure

The engine control unit (ECU) has detected an error during the last EEPROM read operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

ECM EEPROM - Write operation failure

The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

3239

3240

Defective ECU. Replace ECU if problem reoccurs

4005-35 CODE

DEFINITION

3241

ECM EEPROM - Default value used

3242

Recovery which is locked

3243

Recovery which is suppressed

3244

Recovery which is visible

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The engine control unit (ECU) has detected that substitute values for the EEPROM values are used. This happens if a checksum error (CRC) is registered during reading. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU. Electronic disturbances, various hardware defects (ECU internal) or configuration problems. Analyze what error triggered the recovery (Read out label HWEMon_numRecovery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.

3245

Communication supervision watchdog control flag

Defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC. Disturbed SPI-Bus. If error exists only temporary (i.e. injection reoccurs) error can be ignored and error deleted in the fault memory. In case of a permanent error the injection remains blocked and the ECU has to be replaced

3246

Redundant shutoff paths during initial

Watch dog switch off path defect. If failure remains after ECU initialization: replace ECU

3247

Redundant shutoff paths during initial

3248

Redundant shutoff paths during initial

Electronic disturbances, internal ECU problem. If failure remains after ECU initialization: replace ECU

4005-36 DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3249

TPU monitoring - Time deviation between TPU and system not plausible

The engine control unit (ECU) has detected that the TPU (time processing unit) and CPU (central processing unit) have operated outside the established parameters more than 4 times since last ECU recovery (initialization). As the time base of the CPU is checked according to a query / response communication with the monitoring module (watchdog) it should be correct if no error has been detected and therefore can be used to check the time base of the TPU. For this purpose the time basis of the TPU and CPU are compared every 10 ms. After 100 ms the maximum and the minimum value together with the absolute value of the sum of the time differences are evaluated. If the maximum time difference between the TPU and CPU time base exceeds the threshold of 81 ms or the minimum time difference is below the limit of 81 ms or the absolute value of the sum of the time differences is above 81 ms an error counter is incremented. If this counter exceeds the value of 4, this fault is set and initiates an ECU recovery (reset). If this failure persists, the ECU will need to be replaced.

3250

ECU software variant Dataset failure - Dataset not valid.

NOTE: See engine repair manual for electrical schematic information. Cause: 1. Internal ECU error

Dataset - Requested variant could not be set.

NOTE: See engine repair manual for electrical schematic information. Cause: 1. Internal ECU error

Controller watchdog - SPI communication failure.

The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between them fails this monitoring is impaired and an error counter is incremented. If the error counter exceeds 2 over two 20 ms (two tests) checks, this fault is activated. Communication status is checked autonomously by the SPI driver component every 20 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.

CODE

3251

3252

4005-37 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3253

Error status ADC monitoring

3254

Error status ADC monitoring

3255

Error status ADC monitoring

3256

Error status ADC monitoring

3258

Short-circuit to battery at high side power stage

Short circuit of wiring to external source or inside relay. Check wiring or replace relay

3259

Short-circuit to ground at high side power stage

Short circuit of wiring to ground or inside relay. Check of wiring or replace relay

3260

Open load at low side power stage

Broken or disconnected wiring or defective relay. Check wiring or replace relay

3261

Short-circuit to battery or excessive temperature at low side power stage

Short circuit of wiring to external source or inside relay. Check wiring or replace relay

3262

Short-circuit to ground at low side power stage

Short circuit of wiring to ground or inside relay. Check wiring or replace relay

3265

Energizing time exceeds limit of over run monitoring

Electronic disturbances, requested torque increase via tester, wrong application of injection relevant parameters, defective ECU. Check injection relevant application, if failure persists replace ECU

3266

Plausibility error in engine speed check

Electronic disturbances, internal ECU problem. If failure persists after reinstallation replace ECU

3267

Main relay 3 - Short circuit to battery

See engine manual for details.

3268

Main relay 3 - Short circuit to ground

See engine manual for details.

Supply voltage CJ940 upper limit

Excessive voltage supply of a CJ940 component: High battery voltage, defective wiring, internal defect of the EDC. Check the battery for correct voltage supply, check wiring. If defect remains replace EDC (internal defect)

Supply voltage CJ940 lower limit

Insufficient voltage supply of a CJ940 component: Low battery voltage, defective wiring, internal defect of the EDC. Check the battery for sufficient voltage supply, check wiring. If defect remains replace EDC (internal defect)

Sensor supply voltage 1 high

Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC

3278

3279

3280

Buffer overrun No additional information available at time of print

4005-38 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Sensor supply voltage 1 low

Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC

Sensor supply voltage 2 high

Sensor supply voltage 2 low

Sensor supply voltage 3 high

3286

Sensor supply voltage 3 low

3290

Turbo compound monitoring signal not plausible

See engine manual for details.

3297

Rail pressure governor deviation exceeded max limit with fuel delivery quantity on limit.

See engine manual for details.

3301

Rail pressure governor deviation exceeded min limit with fuel delivery quantity on limit.

See engine manual for details.

3305

Rail pressure governor deviation below min limit for speed

See engine manual for details.

3309

Rail pressure governor deviation exceeded max limit

See engine manual for details.

3313

Rail pressure drop rate is higher than expected.

See engine manual for details.

3315

Minimum number of injections not reached stop engine.

See engine manual for details.

3281

3283

3284

3285

4005-39 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The engine control unit (ECU) has determined that the minimum number of injections was not reached. The injector shutoff function (within the ECU) can switch off a single injector valve or an entire injection bank if a defect has been detected in a component (monitoring is performed in other fault paths). The shutoff procedure is performed either for an individual cylinder or for an entire bank. However, if too many cylinders are shut down by the shutoff function it is no longer possible to run the engine securely and it has to be shut down entirely. In this case the fault path at hand is set. It is possible for the engine to continue running on two cylinders. The test frequency is once per injection. If this error occurs, see individual injector and injection-bank errors which have triggered the shutoff or error in the component.

3316

Minimum number of injections not reached stop engine.

3317

Minimum number of injections not reached stop engine.

See engine manual for details.

3318

Minimum number of injections not reached stop engine.

See engine manual for details.

3319

DM1DCU SPN2 message - Error in DCU active.

See engine manual for details.

3320

DM1DCU SPN3 message - Error in DCU active.

See engine manual for details.

3321

DM1DCU SPN4 message - Error in DCU active.

See engine manual for details.

3322

DM1DCU SPN5 message - Error in DCU active.

See engine manual for details.

3334

Timeout of CAN message TSC1-PE Torque (when active).

4005-40 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3335

Timeout of CAN message TSC1-PE Torque (when inactive).

See engine manual for details.

3338

Timeout of CAN message TSC1-VE Torque (when inactive).

See engine manual for details.

3339

Timeout of CAN message TSC1-VE Torque (when active).

CAN Data Link communications from the ECU have been lost. Cause: CAN Data Link communications from the ECU have been lost. This fault code will be displayed with other CAN Data Link fault messages. The engine may go into Limp Home Mode and engine speed will be set to 1500 RPM. Possible failure modes: 1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector. 2. Wiring or circuits open. 3. Wiring or circuits shorted. 4. Faulty Instrument Cluster 5. Faulty ECU NOTICE: Replace Starter Relay and test system before proceeding. NOTE: See engine repair manual for electrical schematic information. Cause: 1. Faulty reading from component. 2. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector. 3. Wiring or circuits open. 4. Wiring or circuits shorted. 5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by installing and removing.

3350

Terminal 50 - Always On

3354

Main Relay 4 (Engine brake exhaust valve) Short circuit to ground.

See engine manual for details.

3355

Main Relay 4 (Engine brake exhaust valve) Short circuit to battery or open load.

See engine manual for details.

3358

CAN Transmit timeout

See engine manual for details.

3363

Atmospheric pressure sensor - signal not plausible.

NOTE: See engine repair manual for electrical schematic information. Cause: 1. ECU internal error

3367

Coolant temperature test failure.

See engine manual for details.

4005-41 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3368

Info: Torque limitation due to OBD performance limiter by legislation.

See engine manual for details.

3369

Torque reduction due to smoke limitation.

See engine manual for details.

3370

Info: Torque limitation due to engine protection (against excessive torque, Engine overspeed and overheat)

See engine manual for details.

3371

Info: Torque limitation due to fuel quantity limitation because of injection system errors.

See engine manual for details.

3512

DCU State monitoring - DCU not ready in time

See engine manual for details.

3513

SCR catalyst not present - Relation of temperature behavior between both catalyst temperatures not plausible

See engine/SCR manual for details.

3517

Ambient air temperature sensor failure (of humidity sensor) - Signal too high

See engine/SCR manual for details.

3518

Ambient air temperature sensor failure (of humidity sensor) - Signal too low

See engine/SCR manual for details.

3521

NOX estimation failure - Estimated NOX signal not reliable.

See engine/SCR manual for details.

3528

NOX sensor plausibility failure - signal not plausible

See engine/SCR manual for details.

3529

NOX sensor failure - Open load

See engine/SCR manual for details.

3530

NOX sensor failure - Short circuit

See engine/SCR manual for details.

3532

NOX sensor failure - Sensor not ready in time

See engine/SCR manual for details.

3533

CAN message timeout NOX (from NOX sensor) - CAN timeout

See engine/SCR manual for details.

3537

Message DM1DCU timeout

See engine/SCR manual for details.

3541

Message SCR1 timeout

See engine/SCR manual for details.

3545

Info: SCR Dosing valve overheat protection Torque limitation level2 for SCR protection active

See engine/SCR manual for details.

3546

Info: SCR Dosing valve overheat protection Torque limitation level1 for SCR protection active

See engine/SCR manual for details.

3549

Humidity sensor signal ratio failure - Signal ratio above limit

See engine/SCR manual for details.

3550

Humidity sensor signal ratio failure - Signal ratio below limit

See engine/SCR manual for details.

3555

CAN message timeout SCR2 (from DCU) CAN timeout

See engine/SCR manual for details.

3557

Info: Humidity sensor possibly saturated with water droplets - Signal ratio above limit

See engine/SCR manual for details.

4005-42 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3558

Info: Humidity sensor possibly saturated with water droplets - Signal ratio below limit

See engine/SCR manual for details.

3561

NOX value not plausible (After treatment plausibility)

See engine/SCR manual for details.

3577

DM1DCU SPN1 message- Error in DCU active

See engine/SCR manual for details.

3581

Performance limit active due to either stage Performance limitation active

See engine/SCR manual for details.

3585

Engine shut off (after idling phase)

See engine/SCR manual for details.

3586

Plausibility check of catalyst system Temperature after catalyst not plausible

See engine/SCR manual for details.

3587

Plausibility check of catalyst system Temperature before catalyst not plausible

See engine/SCR manual for details.

3588

Plausibility check of catalyst system - Ambient temperature of humidity sensor or both catalyst temperatures not plausible

See engine/SCR manual for details.

3589

Plausibility check of catalyst system Temperature deviation between up and downstream catalyst temperature too high during operation

See engine/SCR manual for details.

3591

SCR Catalyst thermal ageing limit exceeded Main catalyst efficiency below threshold

See engine/SCR manual for details.

3593

Poor reagent quality

See engine/SCR manual for details.

3594

Indicates torque limitation due to SCR

See engine/SCR manual for details.

3599

Error path of oxidation catalyst not present: Warm up catalyst efficiency below threshold

See engine/SCR manual for details.

3602

Defect ratio between threshold limits - Catalyst temperature sensor circuit

See engine/SCR manual for details.

3611

Catalyst efficiency lower than first NOX prediction threshold level

See engine/SCR manual for details.

3612

Catalyst efficiency lower than second NOX prediction threshold level

See engine/SCR manual for details.

3613

Too high efficiency of catalyst system

See engine/SCR manual for details.

3614

SRA2EDC high effort fault

See engine/SCR manual for details.

3615

SRA2EDC initialization fault

See engine/SCR manual for details.

3616

Torque limitation due to turbo charger protection

See engine/SCR manual for details.

4005-43

TRANSMISSION FAULT CODES CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Logical error at Gear Range Signal

1. Check the cables from the TCU to the FNR switch. 2. Check the connectors from the TCU to the FNR switch. 3. Check the FNR switch.

4114

Logical error at direction select signal

1. Check the cables from the TCU to the FNR switch. 2. Check the connectors from the TCU to the FNR switch. 3. Check the FNR switch signal combinations.

4116

Logic error at park brake status

1. Check the cables from the TCU to the instrument cluster connector 2 pin 6. 2. Check park brake switch.

4117

Logic error at direction select signal 2

1. Check the cables from the TCU to the FNR switch. 2. Check the connectors from the TCU to the FNR switch. 3. Check the FNR switch signal combinations.

4119

Short circuit to ground at ride control

4120

Short circuit to battery voltage at ride control

4121

Open circuit at ride control

4113

4122

4123

4124

4125

4126

4127

1. Check the cables from the TCU to the ride control relay. 2. Check the connectors from the TCU to the ride control relay. 3. Check the ride control relay.

Short circuit to ground at brake light 1

1. Check the cable from TCU to brake light 2. Check the connectors from brake light device to TCU 3. Check the resistance of brake light

Short circuit to battery voltage at brake light 1

1. Check the cable from TCU to brake light 2. Check the connectors from brake light device to TCU 3. Check the resistance of brake light

Open circuit at brake light 1

1. Check the cable from TCU to brake light 2. Check the connectors from brake light device to TCU 3. Check the resistance of brake light

Short circuit to ground at brake light 2

1. Check the cable from TCU to brake light 2. Check the connectors from brake light device to TCU 3. Check the resistance of brake light

Short circuit to battery voltage at brake light 2

1. Check the cable from TCU to brake light 2. Check the connectors from brake light device to TCU 3. Check the resistance of brake light

Open circuit at brake light 2

1. Check the cable from TCU to brake light 2. Check the connectors from brake light device to TCU 3. Check the resistance of brake light

4005-44 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

4133

Short circuit to battery voltage or open circuit at transmission sump temperature sensor input

4134

Short circuit to ground at transmission sump temperature sensor input

4135

Short circuit to battery voltage or open circuit at retarder/torque converter temperature sensor input

4136

Short circuit to ground at retarder/torque converter output temperature sensor input

4137

Short circuit to battery voltage or open circuit at parking brake sensor input

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the parking brake sensor.

4138

Inchsensor - Signal mismatch

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the sensor.

4145

Short circuit to battery voltage or open circuit at engine speed input

4146

Short circuit to ground at engine speed input

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the temperature sensor.

1. Check the parking brake fuse. 2. Check the parking brake relay. 3. Check the parking brake solenoid. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.

4147

Logical error at engine speed input

4148

Short circuit to battery voltage or open circuit at turbine speed input

4149

Short circuit to ground at turbine speed input

4150

Logical error at turbine speed input

NOTE: This fault code is reset after power up of the TCU. It is also reset if the signal is above zero speed threshold. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. NOTE: This fault code is reset after power up of the TCU.

4151

Short circuit to battery voltage or open circuit at intermediate speed input

4152

Short circuit to ground at intermediate speed input

4153

Logical error at intermediate speed input

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. NOTE: This fault code is reset after power up of the TCU.

4005-45 CODE

DEFINITION

4154

Short circuit to battery voltage or open circuit at output speed input

4155

Short circuit to ground at output speed input

4156

Logical error at output speed input

POSSIBLE STEPS FOR REPAIR 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. NOTE: This fault code is reset after power up of the TCU.

4158

Output speed zero, doesn’t fit to other speed signals.

1. Check the sensor signal of the output speed sensor. 2. Check the connector connected to the output speed. 3. Check the cable from the TCU to the sensor. NOTE: This fault code is reset after power up of the TCU.

4180

Vehicle controller time-out (CAN)

1. Check the cluster controller. 2. Check wire of CAN-Bus 3. Check the cable to the cluster controller

4181

JSS timeout

1. Check Joystick steering controller. 2. Check wire of CAN-Bus. 3. Check cable to Joystick steering controller.

4182

Engine CONF timeout

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

4183

EEC1 timeout

1. Check EEC controller 2. Check wire of CAN-Bus 3. Check cable to EEC controller

4184

EEC3 timeout

1. Check EEC controller 2. Check wire of CAN-Bus 3. Check cable to EEC controller

4185

Invalid test mode signal (CAN)

1. Check the cluster controller. 2. Check wire of CAN-Bus 3. Check the cable to the cluster controller

4193

AEB Request signal

1. Check I/O controller 2. Check wire of CAN-Bus 3. Check cable to I/O controller

4197

Engine torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

4201

Reference engine torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

4202

Actual engine torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

4203

NOM friction torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

4005-46 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

EEC2 timeout

1. Check EEC timeout 2. Check wire of CAN-Bus 3. Check cable to EEC controller

Short circuit to battery voltage at clutch K1

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to ground at clutch K1

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Open circuit at clutch K1

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to battery voltage at clutch K2

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to ground at clutch K2

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Open circuit at clutch K2

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to battery voltage at clutch K3

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to ground at clutch K3

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

4217

Open circuit at clutch K3

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from TCU to the gearbox Check the regulator resistance Check internal wire harness of the gearbox

4218

Short circuit to battery voltage at converter clutch.

1. Check the cable from TCU to the valve 2. Check the regulator resistance

4219

Short circuit to ground at converter clutch

1. Check the cable from TCU to the valve 2. Check the regulator resistance

4220

Open circuit at converter clutch

1. Check the cable from TCU to the valve 2. Check the regulator resistance

Short circuit to battery voltage at clutch K4

1. 2. 3. 4.

4206

4209

4210

4211

4212

4213

4214

4215

4216

4225

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

4005-47 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Short circuit to ground at clutch K4

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

Open circuit at clutch K4

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to battery voltage at clutch KV

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to ground at clutch KV

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

Open circuit at clutch KV

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to battery voltage at clutch KR

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

Short circuit to ground at clutch KR

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

4233

Open circuit at clutch KR

1. 2. 3. 4.

Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox

4234

Short circuit to ground at DLM transversal output

1. Check the cable from TCU to the valve 2. Check the connectors 3. Check the resistance of valve

4235

Short circuit to battery voltage at DLM transversal output

1. Check the cable from TCU to the valve 2. Check the connectors 3. Check the resistance of valve

4236

Open circuit at DLM transversal output

1. Check the cable from TCU to the valve 2. Check the connectors 3. Check the resistance of valve

4241

Short circuit to ground at relay reverse warning alarm

4242

Short circuit to battery voltage at relay reverse warning alarm

4243

Open circuit at relay reverse warning alarm

4226

4227

4228

4229

4230

4231

4232

1. Check the cable from the TCU to the backup. alarm relay. 2. Check the connectors from the backup alarm relay to TCU. 3. Check the resistance of backup alarm relay circuit.

4005-48 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Slippage at clutch K1

1. 2. 3. 4. 5.

Check pressure at clutch K1. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch K2

1. 2. 3. 4. 5.

Check pressure at clutch K2. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch K3

1. 2. 3. 4. 5.

Check pressure at clutch K3. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch K4

1. 2. 3. 4. 5.

Check pressure at clutch K4. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch KV

1. 2. 3. 4. 5.

Check pressure at clutch KV. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch KR

1. 2. 3. 4. 5.

Check pressure at clutch KR. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

4279

Overtemp SUMP

1. A critical stop function warning has occurred. 2. Red stop indicator comes on and continuous buzzer sounds. 3. Stop machine and perform required service on the critical area. 4. Cool down machine. 5. Check oil level. 6. Check temperature sensor.

4281

Overspeed Engine

4273

4274

4275

4276

4277

4278

4282

Differential Pressure Oil Filter

Check engine speed sensor 1. Check oil filter. 2. Check wiring from TCU to filter maintenance switch. 3. Check filter maintenance switch (measure resistance).

4005-49 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR 1. 2. 3. 4. 5. 6. 7.

Check pressure at converter lockup clutch Check main pressure in the system Check sensor gap at engine speed sensor Check sensor gap at turbine speed sensor Check signal at engine speed sensor Check signal at turbine speed sensor Replace clutch

4283

Slippage at converter lockup clutch

4284

Overspeed output

No information available at time of print.

4288

Engine torque or engine power overload

No information available at time of print.

4289

Transmission output torque overload

No information available at time of print.

4290

Transmission input torque overload

No information available at time of print.

Overtemp converter output

Short circuit to ground at joystick status indicator.

1. Check the cables from the TCU to the joystick. 2. Check the connectors from the TCU to the joystick. 3. Check the resistance of the joystick.

Short circuit to battery voltage at joystick status indicator

1. Check the cables from the TCU to the joystick. 2. Check the connectors from the TCU to the joystick. 3. Check the resistance of the joystick.

Over current at joystick status indicator

1. Check the cables from the TCU to the joystick. 2. Check the connectors from the TCU to the joystick. 3. Check the resistance of the joystick.

Engine retarter config timeout

1. Check EEC controller 2. Check wire of CAN-Bus 3. Check cable to EEC controller

4299

ERC1 timeout

1. Check EEC controller 2. Check wire of CAN-Bus 3. Check cable to EEC controller

4305

Short circuit to battery voltage at power supply for sensors.

1. Check the cables from the sensors TCU. 2. Check the connectors from the sensors to the TCU.

4306

Short circuit to ground at power supply for sensors.

4307

Low voltage at battery

4308

High voltage at battery

4309

Error at VPS 1 for solenoid power supply

4310

Error at VPS 2 for solenoid power supply

4291

4292

4293

4294

4298

1. Check batteries. 2. Check B+ wires from batteries to TCU. 3. Check voltage at TCU connector pin 45. 1. 2. 3. 4.

Check fuse A2. Check cable from control valve to TCU. Check connectors from control valve to TCU. Replace TCU.

4005-50 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Short circuit to battery voltage at display output.

1. Check the cable from TCU to the display 2. Check the connectors at the display 3. Change display

Short circuit to ground at display output

1. Check the cable from TCU to the display 2. Check the connectors at the display 3. Change display

4325

Vehicle ID #1 time out

1. Check display controller 2. Check wire of CAN-Bus 3. Check cable to display controller

4326

Illegal ID request via CAN.

No information available at time of print.

4337

General EEPROM fault

Replace the TCU.

4338

Configuration lost

Reprogram the correct configuration for the vehicle.

4339

Application error

Replace the TCU.

4341

Clutch failure during AEB

4342

Clutch adjustment data lost or inchpedal calibration data lost

4323

4324

Do the transmission clutch calibration procedure.

4005-51

INSTRUMENT CLUSTER FAULT CODES CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

9100

CreateMbx 20ms DM1 BAM

No information available at time of print.

9101

AddMsg DM1 BAM

No information available at time of print.

9102

AddMsg DM1 PCK

No information available at time of print.

9103

Timeout Packet

No information available at time of print.

9104

Missed a Packet

No information available at time of print.

9105

CreateMbx 20ms DM1 Packets

No information available at time of print.

9106

InitCAN, check diagmsg

No information available at time of print.

9107

InitCAN, check diagmsg

No information available at time of print.

9108

InitCAN, check diagmsg

No information available at time of print.

9109

InitCAN, check diagmsg

No information available at time of print.

9110

Error Index out of range in set error

No information available at time of print.

9111

Null error, not permitted

No information available at time of print.

9121

Logical error when retrieving flash data

No information available at time of print.

9122

Logical error when retrieving flash data

No information available at time of print.

9123

Logical error when retrieving flash data

No information available at time of print.

9124

Logical error when retrieving flash data

No information available at time of print.

9125

Never started receiving message

No information available at time of print.

9126

Never started receiving message

No information available at time of print.

9127

Never started receiving message

No information available at time of print.

9128

CAN timed out during operation

9129

CAN timed out during operation

9130

CAN timed out during operation

9131

CAN timed out during operation

No information available at time of print.

9132

CAN timed out during operation

No information available at time of print.

9133

Never started receiving message

No information available at time of print.

9134

CAN timed out during operation C5.E detected by AIC

No information available at time of print.

9135

CAN timed out during operation JSC detected by AIC

No information available at time of print.

9136

CAN time out speed limit module C5F

No information available at time of print.

9138

HW Part number unknown in SW

No information available at time of print.

1. CAN communication interrupted during normal operation. 2. Faulty reading from component. 3. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector. 4. Wiring or circuits open. 5. Wiring or circuits shorted.

4005-52 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

9140

LogicalError in list0

No information available at time of print.

9141

LogicalError in list1

No information available at time of print.

9142

Logical Error in list2

No information available at time of print.

9143

Logical Error in list3

No information available at time of print.

9144

Logical Error in list4

No information available at time of print.

9145

Logical Error in list5

No information available at time of print.

9146

Logical Error in list6

No information available at time of print.

9147

Logical Error in list7

No information available at time of print.

9151

Logical Error when retrieving flash data

No information available at time of print.

9152

Logical Error when retrieving flash data

No information available at time of print.

9153

Logical Error when retrieving flash data

No information available at time of print.

9154

Logical Error when retrieving flash data

No information available at time of print.

9155

Logical Error when retrieving flash data

No information available at time of print.

9156

Logical Error when retrieving flash data

No information available at time of print.

9157

Logical Error when retrieving flash data

No information available at time of print.

HourMeter Failure - Both copies are wrong

HourMeter Failure - One of two copies are wrong

9162

HourMeter Failure - Pre-crank and after-crank check are wrong

9173

SCR controller CAN timeout

No information available at time of print.

9174

SCR controller CAN did not start

No information available at time of print.

9175

CreateMbx 20ms DM1 BAM (SCR controller)

No information available at time of print.

9160

9161

4005-53 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

9176

AddMsg DM1 BAM (SCR controller)

No information available at time of print.

9177

AddMsg DM1 PCK (SCR controller)

No information available at time of print.

9178

TimeOut Packet (SCR controller)

No information available at time of print.

9179

CreateMbx 20ms DM1 Packets (SCR controller)

No information available at time of print.

9180

VCM controller CAN timeout

No information available at time of print.

9181

VCM controller CAN did not start

No information available at time of print.

9182

Wheel Loader Configuration Plausibility Failure - Wrong engine type

No information available at time of print.

4005-54

SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

19001

Battery voltage evaluation - Above upper limit

1. Faulty electrical wiring or connections 2. Faulty DCU

19002

Battery voltage evaluation - Below lower limit

1. Faulty electrical wiring or connections 2. Faulty DCU

19003

Battery voltage sensing (electrical) - Above upper limit.

The selective catalytic reduction (SCR) controller has detected a high voltage condition in the voltage supply circuit. The fault becomes active when the supply voltage is greater than 36.738 V for at least 0.3 s. The code will heal if the supply voltage returns to less than 36.738 V for 0.8 s. Cause: The supply voltage to the SCR controller is greater than 36.738 V. Possible failure modes: 1. Faulty electrical wiring or connections 2. Faulty Power converter 3. Faulty SCR controller

19004

Battery voltage sensing (electrical) - Below lower limit

The selective catalytic reduction (SCR) controller has detected a low voltage condition in the voltage supply circuit. The fault becomes active when the supply voltage is less than 13.143 V for at least 0.3 s. The code will heal if the supply voltage returns to greater than 13.143 V for 0.8 s. Cause: The supply voltage to the SCR controller is less than 13.143 V (13.143 V). Possible failure modes: 1. Faulty electrical wiring or connections 2. Faulty Power converter 3. Faulty SCR controller

19010

Catalyst temperature sensor circuit high - After catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19011

Catalyst temperature sensor circuit low - After catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19019

Catalyst temperature sensor circuit high Before catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19020

Catalyst temperature sensor circuit low Before catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module/supply module

19021

Temperature sensor before catalyst (electrical) - signal above high error threshold

No information available at time of print.

19022

Temperature sensor before catalyst (electrical) - signal below low error threshold

No information available at time of print.

4005-55 CODE

19037

19038

19046

19047

19048

19055

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Reagent - pressure sensor - Short circuit high (high supply voltage)

The denox module/supply module has detected a high supply voltage for urea pressure sensors, located inside the denox module/supply module. Attempt to clear the code. If this code reoccurs, there is a problem with the supply voltage internal to denox module/supply module. Replace the denox module/supply module.

Reagent - pressure sensor - Short circuit low (low supply voltage)

Reagent - pressure sensor - Open circuit

The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module. This error occurs when the sensor signal level has reached its internal limit. This error is corrected if sensor returns to its normal output. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Reagent - pressure sensor - Short circuit high (signal high)

The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module. The sensor signal level is above 5.0 V for over 700 ms. This fault will reset if the raw signal level goes below 5.0 V for over 1000 ms. Attempt to clear the code. If this code reoccurs, the sensor is defective and the denox module should be replaced.

Reagent - pressure sensor - Short circuit low (signal low)

The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module. This error occurs when the sensor signal level is below 0.152 V for over 700 ms. This error is corrected if sensor returns to normal output for greater than 1.0 s. Ensure all connectors are secured properly on the denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module.

Reagent - temperature sensor of pump module - Short circuit high

The denox module/supply module has detected a failure of the urea temperature sensor, located inside the denox module. The sensor signal level is above 5.0 V for over 700 ms. This fault will reset if the raw signal level goes below 5.0 V for over 1000 ms. If the sensor is defective the denox module should be replaced.

4005-56 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19056

Reagent - temperature sensor of pump module - Short circuit low

The denox module/supply module has detected a failure of the urea temperature sensor, located inside the denox module. This error occurs when the sensor signal level is below 0.283 V for over 700 ms. This error is corrected if sensor returns to normal output for greater than 1.0 s. Ensure all connectors are secured properly on the denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module.

19057

UREA Temperature sensor in box (electrical) signal above high error threshold Out of range

No information available at time of print.

19058

UREA Temperature sensor in box (electrical) signal below low error threshold Out of range

No information available at time of print.

Voltage supply internal heaters 1 (UB1) electrical - Internal heating Open circuit

The denox module/supply module has sensed a fault with the voltage supply for the internal heaters, located in the supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the supply module.

Pump module - Internal heating - Short circuit high

Voltage supply 2 - tube heaters (UB2) electrical - Short circuit high

The denox module/supply module has sensed a fault with the voltage supply for the internal heaters, located in the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Voltage supply 2 - tube heaters (UB2) electrical - Short circuit low

19064

19065

19073

19074

4005-57 CODE

19075

19082

19083

DEFINITION

Reagent - suction tube heating - open circuit

Vent valve (Reductant purge control valve) Short circuit high

Voltage supply 3 - Coolant control valve and reverting.valve (UB3) electrical - Short circuit low

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The denox module/supply module has sensed a fault with the voltage supply for the internal heaters, located in the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module. The denox module/supply module has sensed a fault with the voltage supply for the coolant control valve and the reverting valve, located in the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module. The denox module/supply module has sensed a fault with the voltage supply for the coolant control valve and the reverting valve, located in the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module. If this error has occurred, there is a failure in denox module/supply module. Ensure all connectors are ensured properly on the denox module/supply module and all lines are in operable condition. If fault does not reset or reoccurs, replace denox module/supply module.

19084

Vent valve (Reductant purge control valve) Short circuit low

19091

12 Volt supply for dosing module - Above upper limit

1. Problem with battery or charging system 2. Denox module/supply module internal failure.

19092

12 Volt supply for dosing module - Below lower limit

1. Problem with battery or charging system 2. Denox module/supply module internal failure.

19093

Dosing valve/Pump motor - Above upper limit

No information available at time of print.

19094

Dosing valve/Pump motor - Below lower limit.

No information available at time of print.

UREA level sensor (electrical) - supply voltage error.

The dosing control unit (DCU) has detected a failure of the Internal level sensor, located inside the DCU. This error occurs when there is a short circuit or broken supply wire inside the denox module/supply module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If the fault does not reset or reoccurs, replace the DCU.

19100

4005-58 CODE

19101

DEFINITION

Reagent - tank level sensor - Short circuit high

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The dosing control unit has sensed the level of AdBlue™/Def drops below a predetermined level. If the signal is higher than 4.7 V for 0.5 s. Cause: There is an short circuit in the AdBlue™/Def level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19102

Reagent - tank level sensor - Short circuit low

The Dosing Control Unit (DCU) has sensed the level of AdBlue™/Def has dropped below a predetermined level. If the signal is lower than 0.2 V for 0.5 s this error will occur. Cause: There is an short to ground in the AdBlue™/Def level sensor circuit. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19109

Reagent - tank temperature sensor (temperature of the reagent - solution in the tank) - Short circuit high

1. Faulty wiring 2. DEF/AdBlue® tank temperature sensor is faulty.

19110

Reagent - tank temperature sensor (temperature of the reagent - solution in the tank) - Short circuit low

1. Faulty wiring 2. DEF/AdBlue® tank temperature sensor is faulty.

19145

Reductant injector circuit high - Dosing valve

1. Dosing valve harness short to power 2. Denox module/supply module is faulty

19146

Reductant injector circuit low - Dosing valve

No information available at time of print.

19147

Reductant injector circuit/open - Dosing valve

1. Dosing valve harness open circuit 2. Dosing valve solenoid open circuit 3. Denox module/supply module is faulty

19148

Reagent - dosing nozzle - Pressure too high Dosing valve

1. Dosing valve faulty. 2. Denox module/supply module is faulty

19149

Dosing valve (electrical) - short circuit to ground.

The dosing injection valve, which is fed with AdBlue™/DEF, is an injector located on the exhaust pipe. Cause: There is a open circuit in the dosing injection valve circuit. Possible failure modes: 1. Faulty dosing injection valve. 2. Faulty electrical wiring or connections X904, X914. 3. Faulty selective catalytic reduction (SCR) controller.

4005-59 CODE

19150

DEFINITION

Dosing valve (electrical) - dosing valve permanent.”ON” - Pressure too high

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The dosing control unit (DCU) has detected an error with the dosing module. Cause: There is a short circuit in the dosing module circuit. Possible failure modes: 1. Faulty dosing valve. 2. Faulty electrical wiring or connections. 3. Faulty DCU.

19154

19155

19156

Reagent - pump - not delivering

The supply module/denox module has detected a urea pump speed sensor fault. This error occurs when the supply module/denox module has sensed all three hall sensors outputs are high for greater than 7 s. This error is corrected if all three sensors return to normal output for greater than 1 s. Ensure all connectors are secured properly on the supply module/denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the supply module/denox module.

Reagent - pump motor blocked

The denox module/supply module has detected this failure because the averaged pump flow is less than a predetermined flow rate, and pump control duty cycle is greater than expected as determined by the denox module/supply module. The pump is blocked internally because of contamination, frozen DEF/AdBlue®, damaged pump motor, or damaged pump flow measurement. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Reagent - pump - over speed

The denox module/supply module has detected this failure because the averaged pump flow is greater than a predetermined value for over 7.0 s. Check hose from DEF/AdBlue® tank to pump module. If hose is detached, reconnect hose and secure to pump. If hose is defective, replace the hose. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. Replace denox module/supply module if fault reoccurs

4005-60 CODE

19157

19163

19164

19172

19181

19182

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Reagent - pump - not delivering

The supply module/denox module has detected a urea pump speed sensor fault. This error occurs when the supply module/denox module has sensed all three hall sensor outputs are low for greater than 7 s. This error is corrected if all three sensors return to normal output for greater than 1 s. If the fault does not reset or reoccurs, replace the supply module/denox module.

Vent valve (Cooling control valve) - Short circuit high

The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, the power stage is switched OFF and ON again and the check is repeated for ten times. Failure is reported if test fails each time. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault does not reset or reoccurs, replace the DCU.

Vent valve (Cooling purge control valve) Open circuit

The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, there is a short internal to the pump module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault does not reset or reoccurs, replace the DCU.

Vent valve (Cooling purge control valve) Short circuit low

The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, there is a internal failure to the pump module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault does not reset or reoccurs, replace the DCU.

Vent valve (Reverting purge control valve) Short circuit high

The denox module/supply module has detected a failure of the reverting valve, located inside the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Vent valve (Reverting purge control valve) Short circuit low

The dosing control unit (DCU) has detected a failure of the reverting valve, located inside the supply module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If the fault does not reset or reoccurs, replace the supply module.

4005-61 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19183

Vent valve (Reverting purge control valve) Open circuit

19184

Reverting valve electrically - Short circuit to ground

No information available at time of print.

Tank heating valve - Short circuit high

A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlue® from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. Cause: A open circuit has been detected in the tank heater control valve circuit. Possible failure modes: 1. Faulty DEF tank heater control valve. 2. Faulty electrical wiring or connection. 3. Faulty denox module/supply module.

Tank heating valve - Short circuit low

A valve remote from the storage tank is used to control coolant to prevent AdBlue™/DEF from freezing in cold temperatures. The valve will respond to a signal from the DCU based on temperature signals from the temperature sensor.

Tank heating valve - Open circuit

A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlue® from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. Cause: A open circuit has been detected in the DEF tank heater control valve circuit. Possible failure modes: 1. Faulty DEF tank heating control valve. 2. Faulty electrical wiring or connection. 3. Faulty denox module/supply module.

19262

19263

19264

4005-62 CODE

19265

19289

19290

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Tank heating valve - short circuit to ground.

A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlue® from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. Cause: A short circuit has been detected in the DEF tank heater control valve circuit. Possible failure modes: 1. Faulty DEF tank heating control valve. 2. Faulty electrical wiring or connection. 3. Faulty denox module/supply module.

Temperature after catalyst too low

Catalyst temperature sensor circuit range/performance

NOTE: After the repair has been completed, the code will still be present and active until it has been determined that the selective catalytic reduction (SCR) system is operating properly. The engine must be brought to normal operating temperature and run under load until the fault clears. If the code is still present and active after running the engine for 30 minutes, further diagnostics is necessary. Context: The selective catalytic reduction (SCR) controller has sensed the Downstream catalyst temperature sensor is giving an implausible reading. This occurs when the SCR controller senses the Downstream catalyst temperature sensor reading is less than 110 °C (230 °F) for longer than 450 s (450 s) with engine speed of greater than 800 RPM (800 RPM) and an engine load of at least 15 % (15 %). Cause: The SCR controller has sensed a low Downstream catalyst temperature sensor reading. Possible failure modes: 1. Downstream catalyst temperature sensor not installed properly.

4005-63 CODE

19298

DEFINITION

Reagent - pump - Not delivering; UREA pressure too low at system start

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The denox module/supply module has detected the DEF/AdBlue® pressure has not reached 500 kPa within 2.5 min. Manually check DEF/AdBlue® level is filled to operating level. Check feeding tubes, connectors and O-rings in connectors for any air leaks. If error is still present, use the electronic service tool (EST) to run urea dosing system test (UDST) to troubleshoot the system further. NOTE: After the repair has been completed, the code will still be present and active until it has been determined that the selective catalytic reduction (SCR) system is operating properly. The engine must be brought to normal operating temperature and run under load until the fault clears. If the code is still present and active after running the engine for 30 minutes, further diagnostics is necessary.

19307

19316

Reagent - pressure - Above threshold; UREA pressure not plausible (urea pressure too high)

Reagent - temperature sensor of pump module - Out of range

The denox module/supply module has detected the DEF/AdBlue® pressure exceeds 6.5 bar for 30 s. Reasons for failure could be internal control valve blocked or pump speed to high. These are indications of internal failure of supply module. Use the electronic service tool (EST) to run the urea dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500 kPa, and the pump speed should not exceed 6000 RPM. Replace denox module/supply module if values are out of range. The denox module/supply module has detected the DEF/AdBlue® temperature in module box is less than 75 °C (167°F) or greater than 9 °C (48 °F), and system is not in defreezing mode. This error occurs if, in the previous driving cycle, box temperature was less than 85 °C (185 °F) and in shutdown mode. If during the actual driving cycle the box temperature remains less than 70 °C (158 °F) for more than 10.0 s, the system goes into emergency shutdown and will not start until EEPROM is cleared. Use the electronic service tool (EST) to clear code. Verify tank heater codes are not present, and there is no temperature plausibility errors. If other errors are present, correct as well.

4005-64 CODE

19325

19334

19335

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Reagent - tank temperature sensor (temperature of the reagent - solution in the tank) - Out of range

The DEF/AdBlue® temperature in tank is greater than 75.0 °C (167.0 °F) for 300 s and system is not in defreezing mode. This code will heal when the temperature returns below 75.0 °C (167.0 °F) for 1.0s. Cause: The DEF/AdBlue® tank temperature is out of range. Possible failure modes: 1. Tank heating valve stuck open. 2. Check for other DEF tank heater control valve related error codes.

Defreezing mode and detection errors (inlet line defreezing failed)

The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system start up. If DEF/AdBlue® pressure does not reach 390 kPa within 2.5 min the inlet line is frozen. This failure is stored after 30 repetitions with 2.5 min heating phases between the checks. Cause: The denox module/supply module has detected this error because of no DEF/AdBlue® pressure. Possible failure modes: 1. AdBlue™/DEF tank empty. 2. Inlet line broken. 3. Pump does not feed. 4. DEF/AdBlue® box heater does not work correctly.

Defreezing mode and detection errors (pressure line defreezing failed)

The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system start up, and inlet line is detected open. If DEF/AdBlue® pressure does not drop to 350 kPa within 40 s with the dosing valve open to 99.0 %, the pressure line is frozen. This failure is stored after 28 repetitions with 2.5 min heating phases between the checks. Cause: The denox module/supply module has detected this error because of no DEF/AdBlue® injection. Possible failure modes: 1. Dosing valve does not open 2. Pressure line blocked 3. Injection nozzle blocked 4. Faulty box heater

4005-65 DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Defreezing mode and detection errors (pressure build-up in detection mode failed); Pump module - Internal heating - Open circuit

The dosing control unit (DCU) has detected this failure when ambient temperature is below 17.0 °F at system start up. The pressure line and inlet line is detected open. If DEF/AdBlue® pressure does not reach 390 kPa within 40 s with full pump speed, the system is not unfrozen. This failure is stored after 26 repetitions with 2.5 min heating phases between the checks. Check if the internal heater is working correctly.

Defreezing mode and detection errors (Back-flow line defreezing failed)

The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system start up. The inlet and pressure line is detected open and pressure build up was OK. If DEF/AdBlue® pressure does not drop to 140 kPa within 50 s with the vent valve open to 100 %, the back flow line is frozen. This failure is stored after 24 repetitions with 2.5 min heating phases between the checks. Cause: The denox module/supply module has detected this error because of no DEF/AdBlue® back flow line is frozen. Possible failure modes: 1. DEF/AdBlue® tank ventilation clogged 2. Back flow line clogged 3. Ventilation valve does not open 4. Back flow line frozen

Coolant control valve mechanically Mechanical defective blocked open

The dosing control unit (DCU) has detected a short circuit. If at normal operating speed the AdBlue™/DEF pressure is greater than 450 kPa, and the cooling valve is closed from 100 - 0 %, the AdBlue™/DEF pressure must rise at least 15 kPa within 2 s. Ensure all connections and connectors are secured to the DCU properly. If error is still present, there is an internal failure of the box. Replace the DCU.

19344

Coolant control valve mechanically Mechanical defective blocked closed

The dosing control unit (DCU) has detected a open circuit. If at normal operating speed the AdBlue™/DEF pressure is greater than 450 kPa, and the cooling valve is open from 0 - 100 %, the AdBlue™/DEF pressure must drop at least 15 kPa within 2 s. Ensure all connections and connectors are secured to the DCU properly. If error is still present, there is an internal failure of the box. Replace the DCU.

19352

Vent valve (Reductant purge control valve) Open circuit; reverting control valve

Possible failure modes: 1. Valve is mechanically stuck 2. System was empty, needs primed

CODE

19336

19337

19343

4005-66 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

19361

Battery voltage evaluation - Below lower limit

Possible failure modes: 1. Problem with battery or charging system. 2. Denox module/supply module internal failure.

19362

Battery voltage evaluation - Above upper limit

Possible failure modes: 1. Problem with battery or charging system. 2. Denox module/supply module internal failure.

Pump motor error during commissioning (pump not delivering); UREA pressure too low

During operation, the ventilation valve is fully opened, the pump is then set to 100 % operation until DEF/AdBlue® pressure has reached 500 kPa. The ventilation valve is then closed. If DEF/AdBlue® pressure does not reach 500kPa within 2.5 min, this error occurs. Cause: The denox module/supply module has detected the pump motor is not delivering. Possible failure modes: 1. No DEF/AdBlue® in tank 2. System was empty, needs primed 3. Faulty pump 4. Faulty feeding line

Temperatures not plausible during commissioning

The denox module/supply module has detected the temperatures are not correct within 30 min of operation. The module box temperature is less than -9 °C (16 °F) or greater than 75 °C (167 °F), or the DEF/AdBlue® tank is less than -17 °C (2 °F) or greater than 75 °C (167 °F). Bring temperature to a normal level, between 0 - 30 °C (32 - 86 °F). Possible failure modes: 1. Extreme cold ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

19415

Empty UREA tank - fluid level in tank too low

The denox module/supply module has detected the DEF/AdBlue® level is constantly less than 0.1 % for more than 25 s. Possible failure modes: 1. Tank is empty 2. Faulty level sensor

19496

Pressure - Above threshold

No information available at time of print.

19505

Plausibility of pump module temp. sensor; dynamic

No information available at time of print.

19514

Plausibility of UREA tank temp. sensor; dynamic

No information available at time of print.

19370

19379

4005-67 CODE

19532

19541

19550

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Back flow line blocked; dosing valve - Short circuit low

The denox module/supply module has generated this fault because it has sensed the back flow line is clogged. This fault occurs when the denox module/supply module performs the a test and determines: DEF/AdBlue® pressure is greater than 345 kPa (50 psi), pump speed greater than 300 RPM (300 RPM), downstream temperature is greater than 60 °C (140 °F), and dosing is greater than 6 % (6 %) for 20 s (20 s). If these parameters are met, the cooling valve is closed, the DEF/AdBlue® pump is stopped and the dosing valve is fully opened and the pressure is rechecked by the denox module/supply module. If the pressure is less than 30 kPa (4.35 psi), the back flow line is clogged. Ensure the lines are open and free flowing. If the lines are free of blockage, replace the denox module/supply module.

Vent valve test - Plausibility test (start-up) ; cooling control valve

The denox module/supply module has detected at start up, after opening the coolant control valve for 40 s, DEF/AdBlue® pressure is less than 150 kPa. First check that pressure and back flow line are not frozen or clogged. If all lines are open and in proper operation, the denox module/supply module has failed. Replace the denox module/supply module

Dosing nozzle - Pressure too high

4005-68 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Low UREA level 1 (warning) - Too low

The denox module/supply module has detected low DEF/AdBlue® level. This error occurs when the DEF/AdBlue® fluid level is too low or level sensor has faults present. Ensure the heated level sensor is connected properly. Check DEF/AdBlue® tank level is full. If fluid level is low, fill tank to proper capacity. Check for any other errors that may be present. Correct those errors first, then recheck original error has been corrected. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

19568

Low UREA level 2 (warning) - Too low

19577

CAN receive frame E2SCR: (UREA quantity not in range.

Possible failure modes: 1. Controller communication error

19578

CAN receive frame E2SCR (Dosing status not in range).

Possible failure modes: 1. Controller communication error

19579

CAN receive frame E2SCR - timeout

Possible failure modes: 1. Controller communication error

19580

CAN receive frame E2SCR - too many messages

Possible failure modes: 1. Controller communication error

19581

CAN receive frame E2SCR - Serial Communication link

Possible failure modes: 1. Controller communication error

19595

CAN receive frame EEC1 (Engine torque not in range).

Possible failure modes: 1. Controller communication error

19596

CAN receive frame EEC1 (Engine speed not in range).

Possible failure modes: 1. Controller communication error

19597

CAN receive frame EEC1 - timeout

Possible failure modes: 1. Controller communication error

19598

CAN receive frame EEC1 - too many messages

Possible failure modes: 1. Controller communication error

19559

4005-69 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19599

CAN receive frame EEC1 (Torque driver demand not in range).

Possible failure modes: 1. Controller communication error

19604

CAN receive frame ET1 (Oil temperature not in range).

Possible failure modes: 1. Controller communication error

19605

CAN receive frame ET1 - timeout

Possible failure modes: 1. Controller communication error

19606

CAN receive frame ET1 - too many messages

Possible failure modes: 1. Controller communication error

19607

CAN receive frame ET1 (Water temperature not in range).

Possible failure modes: 1. Controller communication error

UREA Tank level sensor - open circuit

Cause: There was an open circuit detected in the DEF/AdBlue® level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

UREA Tank level sensor - Short circuit high

Cause: There was a short to power detected in the DEF/AdBlue® level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19651

UREA Tank level senor - Short circuit low

Cause: There was a short to ground detected in the DEF/AdBlue® level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19652

UREA Tank level error (CAN message or electrical with real sensor) - (timeout))

No information available at time of print.

19653

UREA Tank level error (too many CAN messages)

No information available at time of print.

19654

UREA Tank level error - Open circuit

No information available at time of print.

19649

19650

4005-70 CODE

19676

19677

19678

19679

19721

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Ambient temperature CAN receive signal: (Ambient air temperature not in range)

The denox module/supply module has detected this failure because the ambient air temperature is out of range. Ambient air is measured through the denox module/supply module. If the tractor has been exposed to extreme ambient temperatures, either high or low, take steps to get tractor back into normal operating temperature range. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Ambient air temperature sensor range/performance - CAN timeout

The denox module/supply module has detected this failure because the ambient air temperature has timed out. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Ambient air temperature sensor range/performance - too many CAN messages

The denox module/supply module has detected this failure because the ambient air temperature has faulty can bus signal. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Ambient temperature CAN receive signal: (Barometric pressure not in range)

The denox module/supply module has detected this failure because the ambient air temperature has faulty sensor range. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

EEPROM/Checksum failures - EEPROM write error (P062F)

The denox module/supply module has suffered a detection error. This error indicates a defect in the dataset that is presently loaded in the denox module/supply module. If this error is present and active, reload the software dataset. If this error then reoccurs, replace the denox module/supply module.

4005-71 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

EEPROM/Checksum failures -No corresponding variant number error (P062F)

The denox module/supply module has an internal cycle counter to check if the afterrun is correctly finished. This cycle counter data is then stored in the EEPROM memory. This error indicates the denox module/supply module has attempted to store this data in a protected area of memory. If this error is present and active, first verify the denox module/supply module and other components have not been tampered with and reload the software. If this error reoccurs replace the denox module/supply module.

EEPROM/Checksum failures -EEPROM communication error (P062F)

The denox module/supply module memory in EEPROM is not correct or a SPI communication error has occurred. This error indicates an internal denox module/supply module error. If this error is present and active, ensure all electrical connectors are secure and reload the denox module/supply module software. If this error reoccurs, replace the denox module/supply module.

EEPROM/Checksum failures -EEPROM detection error or codierwort error (P062F)

The denox module/supply module has an internal error in software. If the code is present and active, reload the software. If this error reoccurs, replace the denox module/supply module.

19725

EEPROM/Checksum failures -Wrong EEPROM size (P062F)

The denox module/supply module has the incorrect EEPROM installed. This error would only occur during initial startup when the denox module/supply module has previously been replaced. Replace the denox module/supply module.

19730

Ignition switch - plausibility error

Possible failure modes: 1. Faulty connector 2. Faulty ignition switch

ECM/PCM Power relay control circuit/open main relay shut off too late

Context: The denox module/supply module has detected the main relay is not switched off within 2 s. Cause: The main relay is shutting off too late. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

ECM/PCM Power relay control circuit/open main relay short circuit

Cause: Switched power relay control circuit open. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

19722

19723

19724

19739

19740

4005-72 CODE

19741

19742

19748

19749

19757

19766

19775

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

ECM/PCM Power relay control circuit/open main relay open circuit

Cause: Switched power relay control circuit high. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

ECM/PCM Power relay control circuit/open main relay shut off too early

Cause: Switched power relay control circuit open. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

UREA Temperature sensor of pump module Out of range

Cause: High urea temperature in pump module. Possible failure modes: 1. Tank heating valve stuck open. 2. Check for other tank heating valve/coolant flow solenoid related error codes.

Dynamic UREA leakage test - Leakage detected

Cause: High urea temperature in pump module. Possible failure modes: 1. Tank heating valve stuck open. 2. Check for other tank heating valve/coolant flow solenoid related error codes.

Reagent - pump - Not delivering

The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue® injection control being active. Diagnose those fault codes to clear this fault. If this fault is active without any other codes active, reload the software in the DCU or replace the DCU.

Compressed air regulation valve

Plausibility of catalyst temperature sensors Plausibility error

The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue® injection temperature being active. Diagnose those fault codes to clear this fault. If this fault is active without any other codes active, reload the software in the DCU or replace the DCU.

4005-73 CODE

19784

19793

19802

19803

19804

19805

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

NOX Trap efficiency below threshold

Fluid level in UREA tank - Too low

The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue® system urea low tank level. Confirm the urea tank is full. Diagnose those fault codes to clear this fault. If this fault is active without any other codes active, reload the software in the DCU or replace the DCU.

UREA Tank temperature Temp over CAN timeout

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Can communication error. 2. DEF/AdBlue® tank temperature sensor is faulty.

UREA Tank temperature - Temp over CAN: SAE J1939 Too many messages

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Extreme cold ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

UREA Tank temperature Temp over CAN: SAE J1939 erroneous signal - Open circuit

UREA Tank temperature - SRC High: Short circuit high

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Extreme hot ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

4005-74 CODE

19806

19807

19808

19813

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

UREA Tank temperature - SRC Low: Short circuit low.

UREA Tank temperature - SRC High: UREA temperature too high - Out of range

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Extreme hot ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

UREA Tank temperature - SRC Low: UREA temperature too low - Out of range

Reagent - pump - Not delivering

Context: During operation, the ventilation valve is fully opened, the pump is then set to 100 % operation until DEF/AdBlue® pressure has reached 500 kPa. The ventilation valve is then closed. If DEF/AdBlue® pressure does not reach 500kPa within 2.5 min, this error occurs. Cause: The denox module/supply module has detected the pump motor is not delivering. Possible failure modes: 1. No DEF/AdBlue® in tank 2. System was empty, needs primed 3. Faulty pump 4. Faulty feeding line

4005-75 CODE

19817

19818

19822

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Dosing valve - Blocked (only stuck closed)

The denox module/supply module has detected the DEF/AdBlue® pressure exceeds 6.5 bar for 30 s. Reasons for failure could be internal control valve blocked, blocked dosing valve nozzle or too high a pump speed. These are indications of internal failure of supply module. Use the electronic service tool (EST) to run the Urea dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500kPa, and the pump speed should not exceed 6000 RPM. Replace denox module/supply module if values are out of range.

Dynamic UREA leakage test - Leakage detected

The denox module/supply module has detected leakage. Visual inspect all urea lines and connections for leakage. These are indications of internal leakage of supply module. Use the electronic service tool (EST) to run the urea dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500 kPa , and lower values can indicate leakage, and the pump speed should not exceed 6000 RPM. Replace denox module/supply module if values are out of range.

Dynamic UREA leakage test - Leakage detected

4005-76

5 - UNDERCARRIAGE 6 - DRIVE TRAIN

721F Tier 4 Wheel Loader

SERVICE MANUAL

Part number 84487559 1st edition English April 2011

5001 Section 5001 REMOVAL AND INSTALLATION OF STEERING COMPONENTS

5001-2

TABLE OF CONTENTS STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 8 8 8 10 10 10 12 12 12 14 14 14 16 16 16

5001-3

STEERING CONTROL VALVE Removal

STEP 7

STEP 1 Remove the cab skirts from the cab or canopy.

STEP 2 Remove all dirt and grease from steering control valve.

STEP 3 Remove hydraulic reservoir fill cap, attach a vacuum pump to the reservoir, start the pump. BD06G245

STEP 4 Tag hoses connected to steering control valve.

Remove the mounting nut and washers from the steering shaft.

STEP 5

STEP 8

BD06G262

Disconnect hoses from steering control valve, cap or plug the fittings and hoses, turn off the vacuum pump.

BD06G246

Remove the steering wheel from the shaft.

STEP 9

STEP 6

BD06G247 BD06G244

Remove the center cap from the steering wheel.

Remove the six mounting screws from the instrument cover.

5001-4

STEP 10

STEP 13

BD06G248

BD06G258

Remove the five mounting screws for the left and right hand trim.

Remove the two mounting screws from the lower trim.

STEP 11

STEP 14

BD06G249

BD06G259

Disconnect the ignition switch, remove the right and left hand trim pieces from the column.

Pull floor mat away from the column and remove the lower trim from the column.

STEP 12

STEP 15

BD06G257

Remove the screw from the brace.

BD06G260

Remove the two lower mounting screws from the front vent.

5001-5

Installation

STEP 16

STEP 18

BD06G261

Remove the three vents from the front trim, remove the three mounting bolts inside of the vent holes, remove the vent.

STEP 17

BD06G264

Put the rubber bushing on the spacer with the tapered end towards the steering valve.

STEP 19 Have an assistant push the valve into place while turning the steering shaft, this will engage the splines.

STEP 20

BD06G263

Remove the four mounting bolts for the steering control valve. IMPORTANT: Have an assistant support and remove the valve while removing the mounting bolts. BD06G263

Install and tighten the four mounting bolts for the steering control valve.

5001-6

STEP 21

STEP 24

BD06G261

Install the front trim, install and tighten the three mounting bolts inside of the vent holes, install three vents into the front trim.

BD06G257

Install the screw into the brace.

STEP 25

STEP 22

BD06G249

BD06G260

Install the two lower mounting screws that mount the front vent to the cab.

Connect the ignition switch, install the right and left hand trim pieces onto the column.

STEP 26

STEP 23

BD06G248

BD06G258

Install the lower trim onto the column, instal and tighten the two mounting screws mounting the lower trim, place the floor mat into position.

Install and tighten the five mounting screws for the left and right hand trim.

5001-7

STEP 27

STEP 30

BD06G247

BD06G262

Install and tighten the six mounting screws for the instrument cover.

Start the vacuum pump, remove the caps and plugs the fittings and hoses. Connect hoses to steering control valve according to the tags installed during removal, remove and discard the tags.

STEP 28

STEP 31 Remove the vacuum pump from the reservoir, install and tighten the reservoir fill cap.

STEP 32 Start and run the machine at low idle, turn the wheel to full left and then to full right, stop the machine and check for leaks.

STEP 33 BD06G245

Install the skirts onto the cab or canopy.

Install the steering wheel, install and tighten the mounting nut and washers.

STEP 34

STEP 29

Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

BD06G244

Install the center cap on the steering wheel.

5001-8

AUXILIARY STEERING PRIORITY VALVE Removal

Installation

1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine,

1. Connect and hand tighten fitting (5) to the elbow in the steering priority valve.

2. Put master disconnect switch in OFF position.

3. Tighten pressure tube fitting (5).

3. Remove all dirt and grease from auxiliary steering priority valve and adjacent area. See illustration on page 9.

4. Tighten the nuts (6).

4. Remove hydraulic reservoir fill cap.

2. Install cap screws, washers and nuts (6).

5. Connect and tighten pressure hose (7). 6. Connect and tighten steering pressure hose (9).

5. Connect a vacuum pump to hydraulic reservoir.

7. Connect and tighten steering load sensing hose (1).

6. Start vacuum pump.

8. Connect and tighten load sensing hose (2).

7. Tag and disconnect suction hose from the suction port (4) from auxiliary steering pump and motor. Install a cap on the fitting and a plug in the hose.

9. Connect electrical connector to the pressure switch (3).

8. Tag and disconnect tank return tube (10) from the priority valve. Install a cap on the elbow and a plug in the tube. 9. Stop the vacuum pump. 10. Tag and disconnect the wiring from the steering solenoid (8). 11. Tag and disconnect the wiring from the pressure switch (3).

10. Connect electrical connector to the steering solenoid (8). 11. Start vacuum pump. 12. Connect and tighten tank return tube (10). 13. Connect and tighten hose to auxiliary steering pump port (4). 14. Stop vacuum pump. Disconnect vacuum pump from hydraulic reservoir. 15. Install fill cap on hydraulic reservoir.

12. Tag and disconnect load sensing hose (2) from auxiliary steering priority valve. Install a cap on the elbow and a plug in the hose.

16. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks.

13. Tag and disconnect load sensing hose (1) from the priority valve. Install a cap on the elbow and a plug in the hose.

17. Check to make sure priority valve operates correctly. See Section 5002.

14. Tag and disconnect steering pressure hose (9) from priority valve. Install a cap on the fitting and a plug in the hose. 15. Tag and disconnect pressure hose (7) from priority valve. Install a cap on the fitting and a plug in the hose. 16. Loosen fitting (5) connected to elbow installed in steering priority valve. 17. Support auxiliary steering priority valve. Remove four nuts (6), cap screws, and washers. 18. Remove auxiliary steering priority valve.

18. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

5001-9

1 2 3 6

10 4

9 8

BC05M084

1. 2. 3. 4. 5.

STEERING LOAD SENSING HOSE TO PRIORITY VALVE STEERING LOAD SENSING HOSE TO STEERING VALVE PRESSURE SWITCH SUCTION PORT PUMP OUT PRESSURE TUBE FITTING

6. 7. 8. 9. 10.

CAP SCREWS AND NUTS PRESSURE HOSE STEERING SOLENOID STEERING PRESSURE HOSE TANK RETURN TUBE

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

5001-10

STEERING PRIORITY VALVE Removal 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine, 2. Put master disconnect switch in OFF position. 3. Remove all dirt and grease from steering priority valve (7) and adjacent area. See illustration on page 11. 4. Remove hydraulic reservoir fill cap. 5. Connect a vacuum pump to hydraulic reservoir.

Installation 1. Install bolts with washers (8) through priority valve. Install new O-ring on top of priority valve (not shown). Install priority valve (7) onto low pressure pump, tighten bolts to37 to 48 Nm (27 to 35.5 pound feet). 2. Install new O-rings (6) onto high pressure pump discharge tube (5). 3. Place tube into position and intsall four split flanges (3) and eight bolts (4) with washers, tighten bolts.

6. Start vacuum pump.

4. Connect all hoses as tagged to the steering priority valve (7).

7. Tag and disconnect all hoses connected to the steering priority valve (7).

5. Stop vacuum pump.

8. Loosen and remove eight bolts (4) and four spit flanges (3). 9. Remove the high pressure pump discharge tube (5), discard O-rings (6). 10. Support the steering priority valve (7), remove mounting bolts (8). 11. Remove steering priority valve (7).

6. Disconnect reservoir.

vacuum

pump

from

hydraulic

7. Install fill cap on hydraulic reservoir. 8. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks. 9. Check to make sure steering priority valve operates correctly. See Section 5002. 10. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

5001-11

3 6

BC05M087

1. 2. 3. 4.

LOW PRESSURE PUMP (LOADER PUMP) HIGH PRESSURE PUMP (STEERING PUMP) SPLIT FLANGE BOLT

5. 6. 7. 8.

STEERING PUMP OUTPUT LINE O-RINGS STEERING PRIORITY VALVE BOLT

STEERING PRIORITY VALVE ILLUSTRATION

5001-12

AUXILIARY STEERING PUMP AND MOTOR Removal 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine,

7. Connect ground cable (1) to ground stud of auxiliary steering pump and motor (7) following tag installed during removal.

2. Put master disconnect switch in OFF position.

8. Connect positive cable (2) to B+ stud of auxiliary steering pump and motor (7) following tag installed during removal.

3. Tag and disconnect two wiring harness (8) from auxiliary steering pump and motor (7) solenoid. See illustration on page 13.

9. Connect wiring harness wires (8) to auxiliary steering pump and motor (7) following tags installed during removal.

4. Tag and disconnect positive cable (2) from B+ stud of auxiliary steering pump and motor (7). 5. Tag and disconnect ground cable (1) from ground stud of auxiliary steering pump and motor (7). 6. Remove hydraulic reservoir fill cap. 7. Connect a vacuum pump to hydraulic reservoir. 8. Start vacuum pump. 9. Disconnect suction hose (4) from auxiliary steering pump and motor (7). Install a plug in suction hose and cap on fitting. 10. Stop vacuum pump. 11. Loosen fittings on pressure tube (5). 12. Support auxiliary steering pump and motor (7). Remove nuts (3), cap screws, and washers securing auxiliary steering pump and motor (7). 13. Remove pressure tube (5) and auxiliary steering pump and motor (7).

Installation 1. Position auxiliary steering pump and motor (7) on its mounting plate while connecting and hand tightening pressure tube (5) to auxiliary steering priority valve (6). See illustration on page 13. 2. While supporting auxiliary steering pump and motor (7) have an assistant install cap screws, washers, and nuts (3) to secure auxiliary steering pump and motor (7), tighten the nuts. 3. Tighten pressure tube (5) fittings securely. 4. Start vacuum pump. 5. Remove plug from suction hose (4) and cap from elbow. Connect suction hose to elbow installed in auxiliary steering pump and motor (7). 6. Stop and disconnect vacuum pump. Install fill cap in hydraulic reservoir.

10. Put master disconnect switch in ON position. 11. Start and run engine at low idle and raise bucket 500 mm (20 inches) above ground. Check that auxiliary steering light on information center is OFF. IMPORTANT: In following Step, do not run auxiliary steering pump and motor continuously for more than 20 seconds at a time without a two minute cool down. 12. With engine at low idle and machine steering straight ahead, turn key switch to OFF position to stop engine and then immediately back to ON position (not START position). Auxiliary steering pump and motor should star t operating immediately. Check that auxiliary steering light on infor mation center is ON and auxiliar y steering pump and motor is operating. 13. Turn steering wheel all the way to left and right to make sure that auxiliary steering pump and motor operates correctly. 14. Restart engine. Check that auxiliary steering light on information center stays ON and auxiliary steering pump and motor is operating. After about three seconds motor should stop operating and auxiliary steering light should go out. 15. Let engine run and allow batteries to recharge for a minimum of 10 minutes.

5001-13

2 1

3 8 7

4 5

BC05M085

1. GROUND CABLE 2. POSITIVE CABLE 3. NUT (4)

4. SUCTION HOSE 7. AUXILIARY STEERING PUMP AND MOTOR 5. PRESSURE TUBE 8. WIRING HARNESS 6. AUXILIARY STEERING PRIORITY VALVE AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

5001-14

STEERING CYLINDER Removal 1. Loosen the fill cap for the hydraulic reservoir to release pressure in the reservoir, then tighten the fill cap. 2. Disconnect grease hoses (1 and 16) from steering cylinders (11). See illustration on page 15. 3. Disconnect hydraulic hoses (2, 3, 9, and 10) from steering cylinders (11). 4. Install a plug in each hose (2, 3, 9, and 10) to prevent entry of foreign matter. 5. Remove locknut (15). 6. Remove cap screw (13). 7. Remove pin (12). 8. Remove washers (14). 9. Remove cap screw (8), washer (7), and spacer (6) securing pivot pin (5) at rear of steering cylinders (11). 10. Use a suitable driver and drive pivot pin (5) out of steering cylinder (11). 11. Remove washer(s) (4) from between steering cylinders (11) and rear frame of machine. 12. Remove steering cylinders (11).

Installation 1. Put steering cylinders (11) in position in machine. Make sure that washers (4) are installed between steering cylinder (11) and rear frame. See illustration on page 15. NOTE: Install a washer (4) on top and bottom of steering cylinders (11) if possible. If only one washer (4) can be installed, place washer (4) at bottom of steering cylinders (11). 2. Make sure washers (14) are installed between steer ing cylinders (11) and front frame of machine. 3. Install the pivot pin (5) to secure rear of steering cylinders (11) to machine frame. Install spacer (6), washer (7), and cap screw (8) to secure pivot pin (5). 4. Tighten cap screw (8). 5. Install pin (12) in front of steering cylinders (11). Make sure that washers (14) are installed in correct position. 6. Install cap screw (13) and new locknut (15) in steering cylinders (11) rod end and pin (12). Tighten locknut (15). NOTE: Cap screw (13) should turn freely in hole after tightening. 7. Connect hose assemblies (2, 3, 9, and 10) to steering cylinders (11). 8. Connect grease hoses (1 and 16) to steering cylinders (11). 9. Tighten hydraulic reservoir fill cap. 10. Start engine. 11. Turn steering wheel all the way to right and then to the left several times. 12. Stop the engine. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

5001-15

8 7 6 5 4 3

2 12

13 14 15

16 BS03B141

1. 2. 3. 4.

GREASE HOSE HOSE ASSEMBLY HOSE ASSEMBLY WASHER

5. 6. 7. 8.

PIVOT PIN SPACER WASHER CAP SCREW

9. 10. 11. 12.

HOSE ASSEMBLY HOSE ASSEMBLY STEERING CYLINDER PIN

STEERING CYLINDER ILLUSTRATION

13. 14. 15. 16.

CAP SCREW WASHER LOCKNUT GREASE HOSE

5001-16

STEERING BACK PRESSURE VALVE Removal 1. Remove the fill cap for the hydraulic reservoir to release pressure in the reser voir, attach a vacuum pump to the reservoir, start the pump. 2. Disconnect hoses 2 and 6 from the pressure valve. 3. Remove the nuts, bolts and spacers from the pressure vale, remove the valve from the machine.

Installation 1. Install the valve, bolts, spacers and nuts onto the machine, tighten the bolts. 2. Install new O-rings onto the fittings of the hoses, install and tighten the hoses. 3. Stop the vacuum pump, install and tighten the reservoir filler cap. 4. Start and run the machine at low idle, turn the steering wheel from full left lock to full right lock holding the steering over relief. 5. Stop the machine and check for leaks. 6. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

5001-17

BS06G529

1. 2. 3. 4.

STEERING CONTROL VALVE RETURN HOSE PRESSURE HOSE CONNECTOR M27 ORB

5. RELIEF VALVE 6. RETURN HOSE TO FILTERS 7. RETURN MANIFOLD

STEERING BACK PRESSURE VALVE ILLUSTRATION

5001-18

NOTES

STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

5002

Section 5002

5002-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 5 5 5 6 6 7 8 9 10

5002-3

SPECIAL TOOLS

B785789

OEM-1239 (CAS-10280) FLOWMETER

B009638

CAS-1804 PRESSURE TEST FITTING KIT

B797157

CAS-1808 FLOWMETER FITTING KIT

TROUBLESHOOTING THE STEERING SYSTEM NOTE: The steering hydraulic schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual.

4. Do the main hydraulic pump test. See Section 8002. If the main pump is bad, repair or replace the main hydraulic pump.

1. Make sure the oil level in the hydraulic reservoir is correct. Visually inspect the steering system for leakage and damage.

5. Test the steering cylinders for leakage, refer to instructions on page 8. If a steering cylinder is leaking, repair or replace the steering cylinder.

2. The loader/steering pump differential pressure must be properly adjusted. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump differential Pressure.

6. If the steering system is noisy test the back pressure relief valve, refer to instructions on page 9.

3. Do the steering limit valve pressure test. Refer to page 6. If the pressure is above or below specifications, adjust the steering limit valve.

5002-4

AUXILIARY STEERING SYSTEM PUMP TEST Equipment Required

6. Connect the ammeter clamp (1) to the cable as in illustration.

1. CAS- 10280 Flowmeter 2. CAS-1808 Flowmeter fitting kit

Test Procedure 1. Install articulation lock.

BB830300

1. AMMETER CLAMP

7. Make sure that the parking brake is applied and the bucket is on the floor.

1 BD03A040

1. ARTICULATION LOCK

NOTE: When performing this pressure check, always be sure the articulation lock is in place, especially when working in the articulation joint areas. 2. Loosen and remove the outlet hose to the Auxiliary Steering Pump from the Auxiliar y Steering Priority Valve. 3. Install a plug into the Auxiliary Steering Priority Valve. 4. Connect the inlet of the flowmeter to the outlet line of the Auxiliary Steering Pump. 5. Install the outlet hose of the flowmeter in the hydraulic reservoir and hold in place with wire.

8. Make sure that temperature.

the

oil

operating

9. Make sure that the load valve for the flowmeter is open (zero pressure). 10. Start and run the engine. 11. Stop the engine and turn the key back to the On position. 12. Turn the steering wheel, this will activate the auxiliary steering pump. 13. Turn the load valve on the flowmeter towards CLOSED until the pressure is 104 bar (1500 psi). 14. Read the flowmeter and ammeter gauges and record the readings. 15. The flowmeter reading must not be less than 24.6 L/min, (6.5 U.S. gpm). The ammeter reading must be 315 amps. 16. Turn the key switch to the OFF position. If the flow was less than the specification, or if the amperage was more than 315 amperes, remove the auxiliary steering motor and pump. Test the auxiliary steering motor. If the motor is good, make repairs to the pump.

5002-5

AUXILIARY STEERING SYSTEM MOTOR TEST Test Equipment

5. Push the button on the remote starter switch (1) and look at the voltmeter in the tester.

1. A 24 volt battery that is fully charged. NOTE: A 24 volt battery system (two 12 volt batteries in a series) is used for this test. A 12 volt battery system will cause damage to the auxiliary steering motor.

6. Turn the load control (8) until the voltmeter (7) indicates 24 volts. Look at the ammeter (6) in the tester. Make a record of the ammeter indication.

2. A remote starter switch.

3. A tachometer to check the armature speed. 4. A Sun Electric VAT-33 Starting and Charging System Tester.

Test Procedure 1. Remove the connector that is between the ter minals on the magnetic switch and the auxiliary steering motor. 2. Remove the auxiliary steering motor from the auxiliary steering pump. 3. Remove the drive coupling from the auxiliary steering motor (3). 4. Connect the auxiliary steering motor (3), remote starter switch (1) and tester (2) to the 24 volt battery system (5) as illustrated.

B795328

6. AMMETER 7. VOLTMETER 8. LOAD CONTROL

7. Hold the tachometer against the armature shaft. Look at the tachometer. Make a record of the indication. 8. Release the button on the remote starter switch (1).

Understanding The Results Of The Test 1. If the ammeter indication in step 6 was 30 amperes or less and the tachometer indication in step 7 was 6950 r/min (r pm) or more, the auxiliary steering motor is good.

5 B790852

1. 2. 3. 4. 5.

REMOTE STARTER SWITCH TESTER AUXILIARY STEERING MOTOR AMMETER CLAMP 24 VOLT BATTERY SYSTEM

2. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was higher than 30 amperes, replace the motor.

5002-6

STEERING PRIORITY VALVE NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.

Pressure Setting Test

4. Make sure that the temperature of the hydraulic oil is at least 54° C (129° F).

1. Install articulation lock (1).

5. To measure the temperature of the oil using the instrument panel: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored. 6. Apply the parking brake. 7. Start and run the engine at full throttle. 8. Lower the lift arms and hold the control lever in the FLOAT position. 9. Hold the bucket control lever in the rollback position.

1 BD03A040

1. ARTICULATION LOCK

IMPORTANT: When performing the following pressure check and adjustment, the articulation lock must be installed. Use caution when working in or near the articulation area. 2. Remove the dust cap from the test port (1).

10. Continue holding until the specified temperature of the oil is reached. 11. Stop the engine. 12. Start the engine and operate the machine at full throttle. 13. With the articulation lock still in place, turn and hold the steering wheel for a hard right turn. 14. Continue holding the steering wheel, and read the pressure gauge. 15. The pressure gauge must indicate 239 to 243 bar (3465 to 3525 psi). If the pressure is not correct, adjust the steering relief valve.

2 1 BD06F148

1. G1 TEST PORT 2. G2 TEST PORT

3. Connect a 345 bar (5000 psi) pressure gauge to the test port (2). NOTE: Make sure when you connect the pressure gauge that you do so in a manner that you can read the pressure gauge while sitting in the operators seat.

5002-7

Pressure Setting Adjustment 1. Turn the adjusting screw clockwise to increase the pressure setting. Turn the adjusting screw counterclockwise to decrease the pressure setting.

2. Repeat pressure test procedure. 3. If necessary, adjust the limit valve again until within the specified range.

4. Stop the engine before removing the pressure gauge. BD06F147

1. STEERING PRIORITY VALVE 2. LIMIT VALVE

5002-8

STEERING CYLINDER LEAK TEST NOTE: Make sure all persons are clear of the area of the center pivot. Make sure the center pivot is free of any obstructions. 1. Park the machine on a level surface. 2. Turn the machine all the way to the right. 3. Stop the engine and apply the parking brake. 4. Find the tube that is connected to the rod end of the left-hand steering cylinder. Disconnect the tube from the left-hand cylinder. 5. Install a plug in the tube. 6. Start and run the engine at full throttle. 7. Turn the steering wheel to the right. Hold the steering wheel for a full right turn. Have another person check for leakage from the opening of the rod end of the left-hand steering cylinder. 8. If there is constant leakage from the rod end, the piston packing in the left-hand steering cylinder is damaged. Repairs must be made. See Section 5005.

9. Connect the tube to the rod end of the left-hand steering cylinder. 10. Turn the machine all the way to the left. 11. Stop the engine. 12. Find the tube that is connected to the rod end of the right-hand steering cylinder. Disconnect the tube from the right-hand steering cylinder. 13. Install a plug in the tube. 14. Start and run the engine at full throttle. 15. Turn the steering wheel to the left. Hold the steering wheel for a full left turn. Have another person check for leakage at the opening of the rod end of the right-hand steering cylinder. 16. If there is constant leakage from the rod end, the piston packing in the right-hand steering cylinder is damaged. Repairs must be made. See Section 5005. 17. Connect the tube to the rod end of the right-hand steering cylinder.

5002-9

STEERING BACK PRESSURE VALVE 1

BS06G529

1. 2. 3. 4.

STEERING CONTROL VALVE RETURN HOSE PRESSURE HOSE CONNECTOR M27 ORB

5. RELIEF VALVE 6. RETURN HOSE TO FILTERS 7. RETURN MANIFOLD

5002-10

Pressure Test 1. Disconnect the return hose (2) from the connector (4). 2. Install a “T” fitting and connect a pressure gauge capable of reading 35 bar (500 psi). 3. Start and run the machine at high idle.

4. Turn the steering wheel and observe the pressure. 5. The pressure should be 8 to 10 bar (115 to 145 psi). 6. If pressure is not as specified, replace the relief valve. NOTE: The relief valve is not adjustable.

Section 5005

5005

STEERING CYLINDERS

5005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 5

5005-3

SPECIFICATIONS Torque for piston cap screw........................................................................ 810 to 925 Nm (597.5 to 682 pound feet) Torque for gland............................................................................................. 339 to 475 Nm (250 to 350 pound feet)

STEERING CYLINDER Disassembly 1. Fasten tube (18) in a vise. Be careful not to damage the tube. See illustration on page 4. 2. Remove gland (1) from tube (18). 3. Pull piston rod (14) and piston (9) straight out of tube (18). 4. Fasten piston rod (14) yoke in vise and put a support below piston rod near piston (9). Put a shop cloth between support and piston rod to prevent damage to piston rod. 5. Loosen and remove bolt and washer (8) that hold piston (9). 6. Remove piston (9) from piston rod (14). 7. Remove and discard seal (13), loader ring (12), wear ring (11), and cast iron ring (10) from piston (9). 8. Remove gland (1) from piston rod (14). 9. Remove and discard O-ring (7), backup ring (6), rod wiper (2), rod seal (3), buffer seal (4), and bearing (5) from gland (1).

Inspection 1. Clean all parts in cleaning solvent. 2. Check to be sure that piston rod (14) is straight. If piston rod is bent, install a new piston rod. 3. Inspect inside of tube (18) for deep grooves and other damage. If there is any damage to tube, a new tube must be used. 4. Remove small scratches on piston rod (14) or inside tube (18) with emery cloth of medium grit. Use emery cloth with a rotary motion. 5. Inspect bushing (17). If bushing requires replacement, remove grease fitting (15) and retaining rings (16) then press bushing from tube end.

5005-4

17 16

18 8 9

19 13 12 11 10

BC05M089

1. 2. 3. 4. 5.

GLAND ROD WIPER ROD SEAL BUFFER SEAL BEARING

6. 7. 8. 9. 10.

BACKUP RING O-RING BOLT AND WASHER PISTON RING CAST IRON

11. 12. 13. 14.

WEAR RING RING LOADER SEAL PISTON ROD

STEERING CYLINDER ILLUSTRATION

15. 16. 17. 18.

GREASE FITTING RETAINING RING BUSHING TUBE

5005-5

Assembly 1. Install bearing (5) in gland (1). 2. Install buffer seal (4) in gland (1) so that lips of seal are toward small end of gland. 3. Install rod seal (3) in gland (1). Rod seal must be installed so that lips of seal are toward small end of gland. Seal can be difficult to install. Use tools that will not damage seal. See illustration on page 4. 4. Install rod wiper (2) in gland (1) with wiper lips toward large end of gland. 5. 6. Install O-ring (7) on gland (1). 7. Install backup ring (6) on gland (1). The backup ring must be toward large end of gland. If backup ring is not flat on both sides, the side that is not flat must be toward O-ring (7). 8. Fasten piston rod (14) yoke in vise.

17. Install bolt and hardened washer (8) in piston (9). 18. Install piston (9) on piston rod (14) and start bolt (8) into piston rod. 19. Tighten bolt (8) to a torque of 810 to 925 Nm (597.5 to 682 pound feet). 20. Fasten tube (18) in vise. Be careful not to damage tube. 21. Apply petroleum jelly to O-rings (7) and backup ring (6) on gland (1) and to sealing surface in tube (18). 22. Lubricate piston (9) and inside of tube (18) with clean hydraulic oil. 23. Push the piston (9) straight into tube (18). Be careful not to damage cast iron ring (10), wear ring (11), and seal (13) on piston (9). 24. When piston (9) is in smooth part of tube (18), start gland (1) into tube (18). 25. If the original parts are being assembled:

9. Lubricate piston rod (15) and bore in gland (1) with clean hydraulic oil.

A. Tighten gland to a torque of 339 to 475 Nm (250 to 350 pound-feet).

NOTE: If a new gland (1) is being installed, write part number of cylinder on gland.

B. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds).

10. Push gland (1) onto piston rod (14) large end first. If necessary, use a soft hammer to drive the gland onto piston rod.

C. If, after tightening gland, the self-tapping screw (19) holes are not aligned, a new hole for self-tapping screw must be drilled. See Step 26.

11. Put a support below and near the end of piston rod (14). Put a cloth between support and piston rod to prevent damaging piston rod.

26. If a new gland (1) or a new tube (18) are being assembled:

12. Install new cast iron ring (10) on piston (9). 13. Install new wear ring (11) on piston (9). 14. Install a new loader ring (12) on piston (9). 15. Install a new seal (13) over loader ring (12). 16. Clean the threads on the end of piston rod (14) and threads of bolt (8) using Loctite cleaning solvent. Allow to dry. Apply Loctite 243 to piston rod threads 6.4 mm (1/4 inch) from open end of piston rod so that there is 12.7 mm (1/2 inch) of Loctite 243 on piston rod threads. DO NOT apply Loctite to first 6.4 mm (1/4/inch) of piston rod threads.

A. Tighten gland (1) to a torque of 339 to 475 Nm (250 to 350 pound-feet). B. Use a No. 27 drill bit and drill a hole half in gland (1) and half in tube (18). Drill to a depth of 11 mm (7/16 inch). Do not drill within 13 mm (1/2 inch) of a hole for gland wrench. C. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds). 27. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.

5005-6

NOTES

Section 5006

5006

CENTER PIVOT

5006-2

TABLE OF CONTENTS SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 6 9

5006-3

SPECIFICATIONS SPECIAL TORQUES M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet) M12 bolts for bearing retainers and lower pivot pin...........................................................124 Nm (91 pound-feet) M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet) Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet) LUBRICANT Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease

SPECIAL TOOLS CAS10219 ....................................................................................................................... Hand pump (hydraulic ram) CAS10512 ....................................................................................................................................... 10 ton ram (long) CAS10592 ........................................................................................................... Puller set, includes 24827 leg ends CAS10600 ................................................................................ Bearing cup and seal puller, includes 24850 adapter CAS10193 .............................................................................................................................. Vacuum pump (12 volt) CAS2029 ................................................................................... *Top bearing driver, bottom bearing driver and plate * (Requires screw, two nuts, and two washers from CAS10592)

BC06A174

CAS2029 DRIVER SET

5006-4

CENTER PIVOT Disassembly

19. Disconnect the supply hose.

1. Remove all dirt and grease from the area of the center pivot. Park the machine on a level surface.

20. Install a cap on the hose and a plug in the fitting.

2. Lower the bucket until the bucket is flat on the floor. 3. Stop the engine and apply the parking brake.

22. Loosen and remove the self-locking nut and bolt that hold the pivot pin for the steering cylinder rod eye.

4. Remove the covers from both sides of the machine.

23. Remove the pivot pin from the rear frame and the steering cylinder rod eye.

5. Disconnect the front wiring harness from the cab floor.

24. Remove the washer from the rear frame. Move the steering cylinder out of the way.

6. Remove any tie straps that fasten the front wiring harness to the chassis near the center pivot.

25. Repeat steps 22, 23 and 24 for the other steering cylinder.

7. Loosen and remove the nut and washer that fasten the chassis ground wire and cab ground wire to the studs.

26. Loosen and remove the Ferry head screws and retainers that fasten the drive shaft to the front yoke. Move the drive shaft out of the way.

8. Loosen and remove the bolt, lock washer, and nut that fasten the clamp on the front wiring harness to the bracket on the rear frame. Move the front wiring harness out of the way.

27. Place two stands below and in contact with the front frame.

9. Loosen and remove the fill cap for the hydraulic reservoir. 10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 11. Disconnect the brake hose from the backside of front brake line bracket.

21. Stop the vacuum pump.

28. Install blocks between the rear axle and the rear frame on both sides of the machine to prevent the rear frame from tipping. 29. Put a jack in contact with both sides of the rear frame near the center pivot area. Use another jack at the rear of the machine to prevent the rear frame from tipping.

12. Install a plug in the tube and a cap on the fitting.

30. Loosen and remove the bolt (1), washer (2), and spacer (3) that fasten the upper pivot pin (4) to the rear chassis (5).

13. Disconnect the hoses for the steering cylinder.

31. Use a prybar to remove the upper pivot pin (4).

14. Install caps on the fittings and plugs in the hoses.

32. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10).

15. Loosen and remove the bolts, lock washers, and self-locking nuts that fasten the mounting bracket for the hoses to the bracket on the front frame. 16. Loosen and remove the bolts, flat washers, and self-locking nuts that fasten the bracket for the hoses to the rear frame.

33. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the bottom of the rear chassis (5).

17. Disconnect the return hose.

34. Use the ram and hand pump to remove the lower pivot pin (10).

18. Install the cap on the hose and a plug in the fitting.

35. Install the puller on the bottom spacer (14), see Special Tools in this section.

5006-5

2 3

7 5 8

10 6

9 5

11 6

8 13 6 2

1 5

8 15

BS03B152

1. 2. 3. 4.

BOLT WASHER SPACER UPPER PIVOT PIN

5. 6. 7. 8.

REAR CHASSIS SEAL BEARING RETAINER SHIM

9. 10. 11. 12.

UPPER PIVOT BEARING LOWER PIVOT PIN LOWER BEARING SPACER LOWER PIVOT BEARING

CENTER PIVOT ASSEMBLY

13. 14. 15. 16.

BEARING RETAINER BOTTOM SPACER LOWER PIN PLATE FRONT CHASSIS

5006-6 36. Remove the bottom spacer (14). 37. Release the parking brake. 38. Use prybars to turn the left rear wheel backwards and the right rear wheel forward to move the front of the rear frame to the left for access to the bearings. Install blocks under the wheels to prevent the rear frame from moving.

Assembly 1. Pack the bearing cones with grease. Be careful not to mix the bearing cones. 2. Lubricate the bore in the top pivot with grease. 3. Install a bearing cup (20) in the top pivot (22). 4. Install the bearing driver (17) and plate (21).

39. Apply the parking brake.

17 18

40. Hold the bearing retainer (13) in place and loosen and remove the bolts (1) and washers (2) that fasten the bearing retainer (13) and shims (8) to the bottom of the rear pivot.

41. Remove the bearing retainer (13) and shims (8). 42. Remove the lower bearing spacer (11) from the top of the lower pivot.

43. Loosen and remove the bolts (1) and washers (2) that fasten the bearing retainer (7) and shims (8) to the top of the top pivot. 44. Remove the bearing retainer (7) and shims (8). 45. Use the puller to remove the seal (6) from the top of the bottom pivot. 46. Use the puller to remove the seal (6) from the bottom of the top pivot. 47. Use an acceptable driver, the hydraulic ram, and the hand pump to remove the upper pivot bearing (9) from the top pivot. See Special Tools in this section. NOTE: The spacers are matched to the bearing sets. Do not mix the spacers. Do not use the old spacers if new bearing sets are being installed. 48. Use an acceptable driver, the hydraulic ram, and the hand pump to remove the lower pivot bearing (12) from the bottom pivot. See Special Tools in this section. NOTE: The spacers are matched to the bearing sets. Do not mix the spacers. Do not use the old spacers if new bearing sets are being installed.

22 BC06A118

17. BEARING DRIVER 18. NUT 19. SREW

20. BEARING CUP 21. PLATE 22. TOP PIVOT

5. Tighten a nut (18) on the screw (19) until the bearing cup (20) is seated in the bore of the top pivot (22). Remove the bearing driver (17) and plate (21) from the top pivot (22). 6. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the top pivot (22). 7. Install the bearing driver (17) and plate (21). 8. Tighten a nut (18) on the screw (19) until the bearing cup (26) is seated against the spacer (24). Remove the bearing driver (17) and plate (21) from the top pivot (22).

17 23

19 26

49. Use an acceptable driver to press the seal (6) out of each bearing retainer (7 and 13).

22 BC06A119

23. BEARING CONE 24. SPCAER

25. BEARING CONE 26. BEARING CUP

5006-7 9. Put the bearing retainer (7) in place on the upper pivot bearing assembly (9). 10. Install the bearing driver (17) and plate (21). 11. Tighten a nut (18) on the screw (19) until the bearing retainer (7) is tight against the upper pivot bearing assembly (9).

18. Use an acceptable driver to install the seal (6) in the bottom of the top pivot. 19. The bottom of the seal (6) must be even with the bottom of the top pivot.

BC06A125.

20. Apply grease to the upper pivot pin (4). BC06A120

12. Measure the gap (27) between the bearing retainer (7) and the top pivot (22). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 13. Remove the bearing driver (17), plate (21), and bearing retainer (7) from the top pivot. 14. Install the shims (8) and the bearing retainer (7). 15. Install the washers (2) and bolts (1). Tighten the bolts (1) to 124 Nm (91 pound-feet).

21. Install the upper pivot pin (4) in the top pivot. 22. Lubricate the top pivot until grease is forced out of the seal (6). 23. Rotate the upper pivot pin (4) to check the bearing assembly. The upper pivot pin (4) must rotate smoothly, but not easily. Leave the upper pivot pin (4) in place to keep dirt out of the upper pivot bearing (9). 24. Lubricate the bore for the bottom pivot with grease. Install a bearing cup in the bottom pivot. 25. Install the bearing driver (17) and plate (21).

16. Install the seal (6) in the bearing retainer (7). The top of the seal (6) must be even with the top of the bearing retainer (7).

19 18 28 29

17 BC06A123

BC06A121

17. Fill the other seal (6) for the top pivot with grease.

26. Tighten a nut (18) on the screw (19) until the bearing cup (28) is seated in the bore in the bottom pivot (29). 27. Remove the bearing driver (17) and plate (21) from the bottom pivot (29). 28. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the bottom pivot (29). 29. Install the bearing driver (17) and plate (21).

5006-8

40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13).

24 29

26 17 BC06A124

30. Tighten a nut (18) on the screw (19) until the bottom bearing cup (26) is seated against the spacer (24). 31. Remove the bearing driver (17) and plate (21) from the bottom pivot (29).

BC06A126

41. Install the other seal (6) in the bottom pivot. The top of the seal (6) must be even with the top of the bottom pivot.

32. Put the bearing retainer (13) in place on the lower pivot bearing (12). 33. Install the bearing driver and plate.

19 29 30

BC06A121

42. Install the lower bearing spacer (11) and the bottom spacer (14).

13 BC06A125

34. Tighten a nut (18) on the screw (19) until the bearing retainer (13) is tight against the lower pivot bearing assembly (12). 35. Measure the gap (30) between the bearing retainer (13) and the bottom pivot (29). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 36. Remove the bearing driver (17), plate (21) and bearing retainer (13) from the bottom pivot. 37. Install the shims (8), the bearing retainer (13), washers (2) and bolts (1). 38. Tighten the bolts (1) to 124 Nm (91 pound-feet). 39. Fill the seal (6) for the bearing retainer (13) with grease.

43. Apply grease to the lower pivot pin (10). 44. Install the lower pivot pin (10) in the bottom pivot. 45. Hold the bottom spacer (14) in place and lubricate the bottom pivot until grease is forced out of the seal (6). 46. Rotate the lower pivot pin (10) to check the bearing assembly. The lower pivot pin (10) must rotate smoothly, but not easily. 47. Remove the lower pivot pin (10) and the upper pivot pin (4). 48. Remove the bottom spacer (14).

5006-9

CONNECTING THE FRONT FRAME TO THE REAR FRAME 1. Release the parking brake. 2. Move the rear frame into alignment with the front frame. 3. Move the steering cylinders as required to move the rear frame into alignment with the front frame.

26. Align the hole in the pivot pin with the holes in the steering cylinder rod eye, and install the pivot pin. 27. Install the bolt and self-locking nut that hold the pivot pin. 28. Repeat steps 25, 26 and 27 for the other steering cylinder.

4. Apply the parking brake.

29. Start the vacuum pump.

5. Apply grease to the upper pivot pin (4).

30. Connect the return hose.

6. Install the upper pivot pin (4), spacer (3), washer (2) and bolt (1). Be careful not to damage the seal (6).

31. Connect the supply hose.

7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184 pound-feet). 8. Apply grease to the lower pivot pin (10). 9. Install the lower pivot pin (10) in the frames. Be careful not to damage the seal (6). 10. Use the ram and hand pump to install the bottom spacer (14). See Special Tools in this section.

32. Put the bracket for the hoses in position on the rear frame. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the rear frame. 33. Put the bracket for the hoses in position on the front frame. 34. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the front frame. 35. Connect the hoses for the steering cylinders.

11. Install the lower pin plate (15), three inner bolts (1), and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10).

36. Connect the brake hose for the front brakes at the front bracket.

12. Tighten the bolts (1) to 69 Nm (51 pound-feet).

38. Connect the front wiring harness to the rear wiring harness.

13. Measure the gap between the lower pin plate (15) and the bottom pivot. Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims equal to that value. 14. Loosen the bolts (1) that fasten the lower pin plate (15) to the lower pivot pin (10). 15. Start the six outer bolts (1) into the lower pin plate (15) and the bottom pivot.

37. Stop the vacuum pump.

39. Put the clamp on the wiring harness in position on the bracket. Install the bolt, lock washer, and nut that fasten the clamp on the wiring harness to the bracket. 40. Put the ground wire in position on the stud. Install the washer and nut that fasten the ground wire to the stud.

16. Install the shims (8).

41. Install a tie strap to fasten the wiring harness to the tube.

17. Tighten the six outer bolts (1) to 128 to 136 Nm (94 to 100 pound-feet).

42. Disconnect the vacuum pump from the hydraulic reservoir.

18. Tighten the three inner bolts (1) to 124 Nm (91 pound-feet).

43. Check the fluid level in the hydraulic reservoir. Add oil as required.

19. Remove the jacks from the rear frame.

44. Install the fill cap in the hydraulic reservoir.

20. Remove the blocks from the rear axle.

45. Bleed air from the front axle bleed screws. Refer to Section 7002 for complete brake bleeding instructions.

21. Remove the stands from the front frame. 22. Put the drive shaft in position on the front yoke. 23. Install new Ferry head screws that fasten the drive shaft to the front yoke. 24. Tighten the Ferry head screws to 61 to 81 Nm (45 to 60 pound-feet). 25. Put the steering cylinder rod eye in position in the frame. Install the washer between the steering cylinder rod eye and the rear frame.

46. Lubricate the pivot pins for the steering cylinder rod eyes. 47. Install the covers on both sides of the machine.

5006-10

NOTES

Section 5008

5008

AUXILIARY STEERING MOTOR AND PUMP

5008-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 4 4

5008-3

SPECIFICATIONS Auxiliary steering motor Maximum amperes...............................................................................................................................30 amperes Minimum armature speed ............................................................................................................ 6950 r/min (rpm) Motor ...........................................................................................................................................................24 volts Auxiliary steering pump Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes (6.5 U.S. gpm at 1500 psi at 315 amperes)

5008-4

AUXILIARY STEERING MOTOR AND PUMP Disassembly

Assembly

NOTE: Refer to Section 5001 for removal and installation of the auxiliary steering motor and pump.

1. Lubricate all parts with clean hydraulic oil before assembly.

NOTE: The pump is the only component that is disassembled. The switch (8) and motor (1) are replaced as units and are not serviced. Refer to the illustration on page 5.

2. Lubricate and install a new seal (4) and retaining ring (3) on the plate (17). Refer to the illustration on page 5.

1. Make an alignment mark on the pump assembly and motor (1). 2. Loosen and remove the two screws (15) and lock washers (14) that hold the pump assembly to the motor (1). 3. Remove and discard the mounting gasket (13), retaining ring (3) and seal (4) from the pump assembly. 4. Loosen and remove the four bolts (2) that hold the pump assembly together. 5. Remove the end plate (21) from the body (18). 6. Remove and discard the seal (6) and backup ring (5) from the end plate (21). 7. Remove the wear plate (23), drive gear (20) and driven gear (19) from the body (18). 8. Remove the body (18) from the plate (17). 9. Remove and discard the O-rings (7) from the body (18). 10. Remove the pins (22) and wear plate (23) from the body (18). 11. Remove and discard the seal (6) and backup ring (5) from the plate (17). NOTE: The only serviceable items on the pump assembly are the seals (6), backup rings (5), O-rings (7), seal (4), retaining ring (3) and gasket (13). If any of the other items are damaged, replace the pump assembly.

Inspection 1. Inspect the wear plates (23) for grooves, scoring and pitting. If damage is found replace the pump assembly. Refer to the illustration on page 5. 2. Inspect the drive gear (20) and driven gear (19). If the shafts are worn or damaged, replace the pump assembly. 3. Clean all parts in cleaning solvent and air dry. 4. Inspect the plate (17), end plate (21) and body (18). Replace the pump assembly as necessary.

3. Lubricate and install a new backup ring (5) and a new seal (6) on the plate (17). 4. Lubricate and install new O-rings (7) on the body (18). 5. Lubricate and install the pins (22), drive gear (20), driven gear (19) and wear plates (23) on the body (18). 6. Lubricate and install a new backup ring (5) and a new seal (6) on the end plate (21). 7. Align the marks, made during disassembly, on the end plate (21), body (18) and plate (17) and install the four bolts (2). Tighten the four bolts (2). 8. Install a new gasket (13) on the pump assembly. 9. Align the marks, made during disassembly, on the pump assembly and the motor (1). 10. Install the lock washer (14) and screw (15). Torque the screw (15) to 35 to 39 Nm (312 to 348 pound-inches).

5008-5

11 16

1 13 3

14 15

5 6 23

19 7 22 18 22 7 20 23 6 5 21 2 BS01C121

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

MOTOR BOLT RETAINING RING SEAL BACKUP RING SEAL

7. 8. 9. 10. 11. 12.

O-RING SWITCH CABLE SCREW LOCK WASHER WASHER

13. 14. 15. 16. 17. 18.

GASKET LOCK WASHER SCREW WIRE PLATE BODY

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

19. 20. 21. 22. 23.

DRIVEN GEAR DRIVE GEAR END PLATE PINS WEAR PLATE

5008-6

NOTES

Section 5009

5009

JOYSTICK STEERING SYSTEM (JSS)

5009-2

TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JOYSTICK STEERING SYSTEM (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-N-R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures for Turning the JSS On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kick-down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustration of the valve PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustration of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exploded view of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS HYDRAULIC PRESSURE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING SPEED CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 5 5 8 9 10 11 11 14 19 19 23 33 33 39 45 45 46 46 47

5009-3

SAFETY RULES WARNING This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of machine damage, serious injury, or death. M171C

WARNING Be cautious when turning with joystick steering. Abrupt movements of the joystick to the left or right could cause the machine to turn more sharply than acceptable. Take necessary precautions. Do not use the joystick for primary steering. It is intended for short repetitive operations. Failure to comply could result in machine damage, death or serious injury. M1336 .

WARNING If hydraulic pilots are disengaged, the joystick steering still remains active. Always disengage joystick steering when not in use. Failure to comply could result in machine damage, death or serious injury. M1348

WARNING Do not use joystick steering when loading or unloading the machine from a truck or trailer. Always use the primary steering wheel when loading or unloading the machine from transport. Failure to comply could result in machine damage, death or serious injury. M1345

WARNING Use caution when moving about in the operator’s compartment when joystick steering is active. An inadvertent movement against the joystick steering control could cause the machine to turn or move abruptly. Failure to comply could result in machine damage, death or serious injury. M1347

WARNING Do not use joystick steering when traveling on a public road or highway. The left arm rest must be raised and in a locked position. Use the primary steering wheel if travel on a public road or highway is required. Failure to comply could result in machine damage, death or serious injury. M1346

WARNING Do not use joystick steering if operating at speeds over 20 km/h (12.4 mph). Always use the primary steering wheel at higher speeds for optimum control of the machine. Failure to comply could result in machine damage, death or serious injury. M1349

5009-4

JOYSTICK STEERING SYSTEM (JSS) Description of the JSS

Preliminary check

The JSS is mounted in parallel with the standard steering system. The standard steering system always has priority. If during joystick operation, the primary steering wheel is moved, steering will revert to primary steering. Joystick steering is designed for short, repetitive machine operations.

Preset condtion must be met by:

●

left armrest completely lowered

●

gear lever in neutral

●

equipment locking switch disenabled

●

pilot pressure switch on

●

joystick steering switch in neutral

●

machine is stationary.

System efficiency check ●

with the JSS off, the pilot pressure must be less than or equal to 8 bar (115 psi).

●

the software monitors the armrest position switch. When the JSS is turned on and during operation, the switch position is checked. If the position of the armrest is raised or the switch is shorted, the system will deactivate.

After all conditions have been met, the JSS will be powered by closing PIN 1:21 of the output AIC that switches over the relay K2 enabling the electric supply of the JSS with consequent activation of the system under safety conditions. The system will stay active if the following conditions are maintained:

●

the left armrest stays lowered

●

the main gear lever stays in neutral

●

the steering wheel stays inactive

●

the control switch stays ON

●

no system errors occur

Joystick steering is turned off as soon as:

521E-4R001

1. 2. 3. 4. 5.

JOYSTICK STEERING CONTROL ARMREST MONITOR FORWARD - NEUTRAL- REVERSE SWITCH KICK-DOWN BUTTON

Activation logic of the software and joystick steering To activate the joystick steer ing system, it is necessary that the machine meet specific conditions prior to activation. The software will run a preliminary test to verify the machine is in the preset conditions and check the condition of the JSS system.

●

the left armrest is raised.

●

the gearbox / main lever control is moved from neutral to forward or reverse drive.

●

the steering wheel is operated.

●

the proportional valve suffers trouble.

●

system errors occur.

●

the JSS switch is disconnected.

●

ignition turned off.

5009-5 ALARM

●

An audible alarm and a message on the instrument cluster display will indicate the JSS is not functioning.

A. the JSS F-N-R switch must be in neutral

To reactivate the JSS, turn the switch OFF and back to the ON position. Errors for the JSS system are only displayed when the JSS switch is in the ON position. They can be reset by cycling the JSS switch to OFF and then back to the ON position.

F-N-R Switch The joystick steering system requires the integration o f t h i r d F - N - R sw i t c h . T h e s o f t w a r e o f t h e transmission control unit (TCU) is able to turn the F-N-R switch on the armrest ON/OFF when the JSS is activated.

In order to activate the JSS F-N-R switch, it is necessary to check the position of the switch B. if the JSS F-N-R switch is not in neutral, move the JSS F-N-R switch to the neutral position and the system will be activated without pressing the JSS activation switch again

●

The JSS F-N-R switch is deactivated when the JSS is turned OFF

Turning the JSS ON ●

Press the JSS switch to the ON position A. the armrest on left-hand side must be lowered B. loader locking switch disabled C. JSS pilot pressure must be low D. JSS joystick in neutral

Locations of F-N-R switches

E. no error in the JSS system

1. Main F-N-R located on steering column

F. steering column F-N-R lever in neutral

2. AUX F-N-R on the equipment control joystick (or on right-hand console)

G. vehicle stationary

3. AUX JSS F-N-R on the armrest on the left-hand side

The JSS is turned OFF by one of the following: A. Using the steering wheel

Procedures for Turning the JSS On and Off

B. F-N-R lever on the steering column is moved out of the neutral position

Of the three F-N-R controls, the one on the steering column has priority over the two auxiliary F-N-R switches. The auxiliary F-N-R switches have a specific signal when activated. If activated, the JSS F-N-R switch on the left-hand armrest has priority over the F-N-R switch on the equipment control joystick (or on right-hand console).

D. JSS switch is turned OFF

Steering Column F-N-R Lever ●

The steering column F-N-R lever is always active

●

The steering column F-N-R lever has priority over all the auxiliary F-N-R switches

●

One of the auxiliary F-N-R switches can be activated only if the steering column F-N-R lever is in neutral

Activation Procedure For Auxiliary JSS F-N-R The JSS F-N-R switch is in the left-hand side armrest: ●

The JSS F-N-R switch will be enabled with the activation of the JSS

●

When the JSS is activated, a message is sent via CAN to the transmission control unit (TCU)

●

This will activate the JSS F-N-R switch

C. armrest on left-hand side is raised E. an error occurs in the JSS system F. ignition switch is turned OFF

Kick-down Button The joystick steering system in the left arm rest features a kick down button that can be activated when the JSS system is activated.

5009-6

Summary table of the ON/OFF statuses State of activation of the JSS, JSS F-N-R and auxiliary F-N-R:

Starting status

Activation signal

JSS OFF

JSS ON

JSS / AUX F-N-R disabled

(JSS) AUX F-N-R enabled

JSS / AUX F-N-R disabled

JSS (AUX) F-N-R enabled

JSS activation signal

Auxiliary F-N-R enabling signal

F-N-R enable signal or JSS enable signal

JSS safety conditions to be met

Equipment locking switch disabled; Armrest on left-hand side lowered; Vehicle stationary; Main F-N-R gear lever = neutral; JSS pilot pressure less than 8 bar; JSS Joystick = neutral; No errors on JSS system.

Equipment locking switch disenabled; Armrest on left-hand side lowered; Vehicle stationary; Main F-N-R gear lever = neutral; JSS pilot pressure less than 8 bar; JSS Joystick = neutral; No errors on JSS system.

Resulting JSS status

JSS ON

JSS OFF

JSS ON

F-N-R conditions

JSS ON JSS F-N-R = neutral.

Vehicle stationary; Main F-N-R gear lever = neutral; AUX F-N-R = neutral.

Vehicle stationary Main F-N-R gear lever = neutral; AUX F-N-R = neutral.

Resulting F-N-R status

JSS F-N-R Enabled Stays enabled.

AUX F-N-R Enabled within 8 seconds release parking brake and engage F or R to maintain enabling.

JSS F-N-R Enabled

F-N-R conditions not met

If JSS F-N-R not in neutral.

If AUX F-N-R not in neutral.

F-N-R alternative status

JSS / AUX F-N-R disabled.

5009-7

ERROR CODES Errors for the JSS will only be displayed if the switch is in the ON position. The errors can be reset by turning the JSS system OFF and On. The following two errors will not reset: ● 1821r Power Supply Failure ● 1830y Activation Switch failure. The errors will always be shown on the display once they are present. To reset these errors the engine must be turned off.

ERROR CODES TABLE

Error Item 1 2 3 4

Error 1812 1816 1820 1821

JSS JSS JSS JSS

5 6 7 8 9 10

1823 1824 1830 1831 1832 1833

JSS JSS JSS JSS JSS JSS

1834

JSS JSS controller, JSC output, short to BAT power

12 13 14 15 16 17

1835 1836 1837 1838 1839 1841

JSS JSS JSS JSS JSS JSS

1842

JSS Valve Alarm Open Circuit

1843

JSS Pilot Pressure is High

1844

JSS Pilot Pressure Switch Short to Ground

1845

JSS Pilot Pressure is Low

22 23 24 25 26 27 28 29 30

1846 1847 1850 1852 1860 1861 1863 9134 9135

JSS JSS JSS JSS JSS JSS JSS JSS JSS

Message Failure Armrest Switch- short to battery or ground Activation Button Failure – mechanical defect Power Supply Failure – check JSS relay, valve, or joystick Short to ground or power on relay, or activation switch failure Relay Ground Failure Activation Switch Short to Battery Activation Switch failure Error JSC – wrong operation, controller internal fault Signal Input Error JSC – controller out of limits Signal Output Error JSC – controller out of limits Valve Failure Power Supply JSS controller, board temperature out of limts JSS controller, switched power out of limits Neutral switch out of range Joystick steering is not calibrated Valve Alarm

Failure on LS Pressure Switch JSC model type not available Joystick Failure - Neutral Switch / Power Supply Error in Ground Connection CAN timeout of C5.E detected by JSC CAN timeout of AIC detected by JSC controller Internal malfunction transmission controller CAN communication failed CAN communication failed

2 210 bar

1 211.6 bar

3 210 bar

5009-8

W190-4R091

ILLUSTRATION OF THE VALVE PVFC

Connections Port 1 - to the steering priority valve Port 2 - to the auxiliary steering valve Port 3 - to the LS port of the valve PVG32

5009-9

PP A

W190-4R092

ILLUSTRATION OF THE VALVE PVG32

Connections Ports A / B LS port Port P

to the steering cylinder on the stem side and bottom side 350 bar, 65 l/min to port 3 of the valve PVFC to the steering priority valve 350 bar, 65 l/min

Port PP Port T Port T2 Port TO LX

pilot pressure switch 8 bar outlet 25/40 bar not used not used

5009-10

W190-4R099

EXPLODED VIEW OF THE VALVE PVG32

1. Valve PVPV

7. Screws

2. Valve PVM

8. Seal

3. Valve PVB

9. Seal

4. Shuttle PVBS

10. Seal

5. Valve PVES

11. Seal

6. Shuttle PVSI

5009-11

ELECTRICAL SYSTEM Removal

STEP 4

STEP 1 1

Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine. Put the master disconnect switch in the OFF position.

STEP 2

Remove all dirt and grease from the steering system valves and adjacent area. IMPORTANT: disassembly.

Tag

all

connections

prior

9 10

STEP 3 1

W190-4R072

Remove nut (11) from the stud (9) to release the chassis grounding cable (1).

2 STEP 5 4

2 8 5 6 W190-4R071

Disconnect the chassis harness (1) from the valve PVG32 (2). Disconnect connector (3) from the pilot pressure switch, connector (4) from the proportional valve, connector (5) from the solenoid valve. From the PVFC valve (6) disconnect connector (7) and remove strap (8).

W190-4R073

Open the access panel on the right-hand side of the cab to access the fuse and relay compartment. Disconnect the connector from the chassis harness (1) from the joystick cable (2). Remove the chassis frame cable (1).

5009-12

STEP 6

STEP 8 5

6 4

7 3

2 W190-4R074

Disconnect the joystick harness (2) from the cab wiring harness (3).

W190-4R076

Disconnect the joystick cable (2) from the steering control module (5) by detaching the sixteen-position connector (6). Disconnect connector (7) from the transmission switch and the cab harness connector (8).

STEP 7

STEP 9

10 2 W190-4R075

Disconnect the connector (1) from the joystick harness (2). Disconnect the armrest harness (3) from the six-position connector (4).

5 12 11 W190-4R077

Remove the steering control module (5) from the supporting plate (9) by removing the three nuts (10), capscrews (11) and washers (12).

5009-13

STEP 10 6

1 5

W190-4R078

Detach the joystick harness (1) from the mounting brackets on the fuse and relay panel (2). Remove the two connectors (3) by removing the two nuts (4), washers (5) and capscrews (6). Remove the joystick harness (1).

STEP 11

W190-4R080

To remove the armrest harness (9), see page 33.

5009-14

Installation

STEP 14

STEP 12 1 3 2 4

12 14 13 16 15

W190-4R083

5 6 W190-4R071

Connect the chassis harness (1) to PVG32 valve (2), connect connector (3) to the pilot pressure switch connector (4). Connect connector (5) to the solenoid valve. Connect connector (7) to the pressure switch on valve PVFC (6) and secure the harness with strap (8) on the valve.

Open the access panel on the right-hand side of the cab to access the fuse and relay compartment. Install the steering control module (12) on the supporting plate (13) by installing the three nuts (14), capscrews (15) and washers (16). Tighten the capscrews.

STEP 15 4

STEP 13

9 7

10 W190-4R088

Connect the chassis harness (1) to the grounding stud (9), install and tighten the nut (11). W190-4R084

Connect the joystick harness (1) to the steering control module (4) with connector (5). Connect connector (6) to the cab harness connector (7).

5009-15

STEP 16

STEP 18 12

9 10

8 1

W190-4R085

Mount the joystick cable (1) to the fuse and relay panel (9) by installing the two nuts (10), washers (11) and capscrews (12). Tighten the capscrews.

STEP 17 W190-4R073

Connect connector (1) to the joystick harness (2).

STEP 19

13 1 W190-4R086

Connect the joystick harness (1) to the cab harness (13) with connector (14).

3 W190-4R082

To install the armrest cable (3), see page 39.

5009-16

STEP 20

2 W190-4R087

Connect interface connector (4) of the joystick harness (2), connect the armrest harness (3) to connector (5).

5009-17

D C

20 19

12 11 10

27 28 15 F

E Detail C view from D

1 21 2

22 A

3 7

Detail E view from F

23 26

6 5 24 25 4

30 17 View from A

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

Plate Steering control device Cab/joystick cable Chassis cable Washer Screw Nut Joystick Steering System switch Nylon strap Screw Washer Nut 10A fuse in position ECA-F2 Cab Stud pin on rear chassis frame Cable terminal with eyelet Metal cable clamp Armrest cable Control joystick

20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

CAN Module Relays Diode 8 bar pressure switch 60 bar pressure switch Steering valve PVFC Steering valve PVG32 Armrest position switch F-N-R switch Kick-Down switch Solenoid valve

721E-4R001

ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM

5009-18

21 21

22 88 29

22 22 21 21

13 13

26 24 24 25

23 23

22 84419913sht sht13 13 84419913

WIRING DIAGRAM DIAGRAM OF OF THE THE JOYSTICK JOYSTICK STEERING STEERING SYSTEM SYSTEM WIRING

5009-19

STEERING VALVES PVG32 AND PVFC Removal

STEP 3

STEP 1 Clean all dirt and grease from the steering valves and adjacent areas.

STEP 2

3 1 2

W190-4R003

Tag and disconnect the hose (4) and (5) from valve PVFC (2). Plug hoses and cap fittings.

STEP 4

W190-4R002

Loosen and remove the LS (3) tube from valve PVG32 (1) and valve PVFC (2).

W190-4R004

Tag and disconnect the hose from the steering priority valve to valve PVG32.

5009-20

STEP 5

STEP 8

2 W190-4R005

Tag and disconnect the outlet hose.

STEP 6

3 W190-4R008

Remove the steering valve PVG32 (2) from the support bracket (1) by removing the four capscrews (3) and washers (4). W190-4R006

Tag and disconnect the supply hose to the steering cylinder line.

STEP 9

STEP 7

3 2 5 4 W190-4R009

W190-4R007

Tag and disconnect the supply hose to the steering cylinder line.

Remove the mounting bracket (1) from the rear chassis removing three nuts (2), washers (3), capscrews (4) and washers (5).

5009-21

STEP 10

STEP 13 1 14

14 2 W190-4R010

Remove the mounting bracket (1).

W190-4R013

Unscrew the fittings (14) from the steering valve PVFC (2).

STEP 11 1

STEP 14

6 2 W190-4R011

Remove the steering valve PVFC (6) from the mounting bracket (1) by removing the two nuts (7), washers (8), capscrews (9) and washers (10).

STEP 12

W190-4R014

Remove the pilot pressure switch (1) with seal (2) from the steering valve PVG32.

STEP 15 12

13 3 11 2

W190-4R015

Remove the reduction fitting (3). W190-4R012

Unscrew the pressure switch (12) with seal (13) from the “T” fitting (11).

5009-22

STEP 16

STEP 19 7

4 W190-4R016

Unscrew the union (4) from the “LS” port of the steering valve PVG32. W190-4R019

STEP 17

Remove joint (7) from port “T”.

W190-4R017

Remove the two fittings (5) from ports “A” and “B”.

STEP 18 6

W190-4R018

Remove the fitting (6) from the port “P”.

5009-23

Installation

STEP 22

NOTE: Before assembling the steering valves, clean the parts using solvent and dry them.

1. Inspect each part for defects. 2. Replace all damaged or deformed parts with new ones.

STEP 20 1 W190-4R022

Install the two fittings (3) into ports “A” and “B”. Tighten the fittings to 100 N m (75 pound feet).

STEP 23

W190-4R020

Install the joint (1) into port “T” of the steering valve PVG32. Tighten the joint to 310 N m (230 pound feet).

STEP 21

W190-4R023

Install the firing (1) into port “LS”. Tighten the fitting to 45 N m (33 pound feet).

STEP 24

W190-4R021

Install fitting (2) into port “P”. Tighten the fitting to 170 N m (125 pound feet).

W190-4R024

Install the reducer (2) for the pilot pressure switch on the port “Pp”. Tighten the reducer to 45 N m (33 pound feet).

5009-24

STEP 25

STEP 27 3

2 4 9 W190-4R025

Install the pilot pressure switch (3) with seal (4) into the reducer (2). W190-4R027

STEP 26

Install the pressure switch (10) with seal (11) into the “T” fitting (9).

STEP 28 6

4 3

8 5 5

W190-4R026

Install fitting (6) into port “1” of the steering valve PVFC (5), “T” fitting (7) into port “2” and fitting (8) into the port “3”. Tighten all the fittings to 45 N m (33 pound feet).

W190-4R028

Mount the steering valve PVFC (2) onto the mounting bracket (1) using two capscrews (3), washers (4), nuts (5) and washers (6).

STEP 29 1

W190-4R010

Position the mounting bracket (1) for the steering valves into the LH side rear chassis.

5009-25

STEP 30

STEP 32 9

11 10 7

W190-4R029

W190-4R007

Install three capscrews (7), washers (8), nuts (10) and washers (11). Tighten the nuts to 110 N m (80 pound feet).

Connect the stem side steering cylinder supply hose onto the fitting. Tighten the hose to 60 N m (44 pound feet).

STEP 31

STEP 33

12 W190-4R006

Connect the bottom side steering cylinder hose. Tighten to a torque of 60 N m (44 pound feet).

STEP 34

14 13 W190-4R030

Install the steering valve PVG32 (12) onto the mounting bracket (1) using the four capscrews (13) and washers (14). Tighten the screws to a torque of 30 N m (22 pound feet). W190-4R005

Connect and tighten the outlet hose to 125 N m (92 pound feet).

5009-26

STEP 35

STEP 37

W190-4R004

Connect the suction hose of the steering priority valve. Tighten the pipe to a torque of 60 N m (44 pound feet).

5 4

STEP 36 1

W190-4R032

Connect the line for the “LS” (5) on the valve PVG32 (4) and on the valve PVFC (1). Tighten the line 14 N m (10 pound feet).

1 W190-4R031

Connect the hose (2) and hose (3) to valve PVFC (1). Tighten to 14 N m (10 pound feet).

5009-27

26 27 33

View from “B” E

See table 2 7 18

C 6

27 22 24

8 2

5 23 22 17 1 15 20 19

19 21 Detail “A”

6 3

F See table 2

4 View from “C”

W190-4R033

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 1

5009-28

28 29

11 10 10

13 Detail J 35

J 11 13 36 16

D H

Detail D view from H

Detail E Detail F view from G

9. 10. 11. 13. 14. 16. 28. 29. 30. 35. 36.

Joint Steering cylinder line pipes Joint Outlet pipe of valve PVG32 Joint Priority valve suction pipe Steering cylinder line pipe (bottom side) Steering cylinder line pipe (stem side) LS priority steering valve pipe Hydraulic pump Steering priority valve

W190-4R034

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 2

5009-29

26 27

34 * E

33 18

View from B

* D

31 25

22 24

8 6

5 23 17 27 22

20 19 21 19

F *

View from C

4 3

1. 2. 3. 4. 5. 6. 7. 8. 10. 12. 13. 15. 16. 17. 18. 19. 20. 21.

Steering valve support Steering valve PVG32 Washer Screw Steering valve PVFC Joint Steering LS pipe Joint Steering cylinder line pipes Joint Outlet pipe of valve PVG32 Joint Priority valve suction pipe Joint Flexible pipe LS of power steering line Washer Nut Screw

22. 23. 24. 25. 26. 27. 30. 31. 33. 34.

Washer Nut Screw 60 bar pressure switch 8 bar pressure switch Seal LS priority steering valve pipe Joint Reduction Power steering valve

* See table 2 W190-4R119

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERINGSYSTEM - Table 1

5009-30

34 Detail J 9

28 29

32 13 10

Detail D

36 11

Detail E

32 16

30 Detail F view from G

9. 10. 11. 13. 14. 16. 18. 28. 29. 30. 32. 34. 36.

Joint Steering cylinder line pipes Joint Outlet pipe of valve PVG32 Joint Priority valve suction pipe Flexible pipe LS of power steering line Steering cylinder line pipe (bottom side) Steering cylinder line pipe (stem side) LS priority steering valve pipe Flexible hose feed of power steering valve Power steering valve Steering priority valve

W190-4R120

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERINGSYSTEM - Table 2

5009-31

YPP

UNLOCK

LOCK

16B

16A

20D 12

20A

280 bar

16C

20C

F YRC

13A

20B

16D

13F

13E

13B

OPTION

240±20 L/min

ø2.0

A3 528789

ø0.8

936718

22E

22D

290 bar

R901007569

R901047887

290 bar

936725

859551

R900756264

290 bar

22J

ø2.0

868050

ø0.8 22K

A2 ø2.0

ø0.8

899039

22K

234 bar

234

TANK

bar

Note 2

45B

45D

0.025

23cc

24C

34A

33A

34B

33B

34C

SLS

0.7

240 bar 30B

0.6 mm

0.31

30A

33C

33D

30C P

28A

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 721F

28C

28B

11 cc

1.6 mm

34D

Note 1

24B

24A

.71

35C

35B 34

35A

136.2 BAR

45B

45A

240±10 L/min

b1 45C

22H

TP9: PILOT PRESSURE SUPPLY

22D

22E

TP1: UNLOADING PUMP PRESSURE

23cc

936718

TP2: IMPLEMENT LOAD SENSE

TP5: STEERING PUMP PRESSURE

936718

TP3: STEERING LOAD SENSE

22D

290 bar

737012

22B

)(

224±3 bar

22G

329140

MT1

TP7: REAR BRAKE ACCUMULATOR

8-10.8 bar

TP6: FRONT BRAKE ACCUMULATOR

30 bar

22C

847160

22C

10 TP10: FRONT BRAKE TO AXLE

22F

Pst 528789

528789

R901007569

1.2

TP11: REAR BRAKE TO AXLE

22C

765876

868050

BOOM

B2 230+20 L/min

ø2.0

A2 20+10 L/min

868050

ø0.8

B1 240±10 L/min

22A

22K

Pst

0.6 R2

22K

BUCKET

N 13C

T1'

16E

13D

5009-32

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 721F

5009-33

JOYSTICK STEERING SYSTEM ARMREST Removal

STEP 3

STEP 1 3 2

6 4 W190-4R037

W190-4R036

Unscrew and remove the knob (1) and the washer (2) for armrest adjustment.

Remove the four locking screws (6) from the armrest (3) and support (4). Remove the armrest (3).

STEP 4

STEP 2

9 5

W190-4R101 W190-4R035

Remove the cover (3), support (4) from the armrest adjustment (5).

Disconnect connector (7) from the “Kick-Down” button (8) from the armrest cable connector (9).

5009-34

STEP 5

STEP 7

3 8

9 2 11

W190-4R102

From the inside and bottom of the armrest cover (1) unscrew the threaded washer (2) and remove the “Kick-Down” button (3).

STEP 6

W190-4R038

Remove the two nuts (8), washers (9), screws (10) and washers (11) from the PVRES joystick (7). Disconnect the connector (12) from the valve (7).

STEP 8

7 1

2 6 W190-4R040

Disconnect the connector (2) from the CAN module (1). Release the armrest cable (3) from the mounting bracket by removing the nut (4) and the washer (5), capscrew (6) and the washer (7).

W190-4R103

Disconnect the connector (4) from the “F-N-R” switch (5) from the armrest cable (6). Remove the switch (5) from the armrest (1).

5009-35

STEP 9

STEP 11

12 1 10 2 W190-4R039

Detach the CAN module (1) from the support (8).

STEP 10 13 11 9

W190-4R041

Unscrew and remove the knob (10) for height adjustment of the armrest and spacer (11). Raise and remove the armrest (12) from the support (13). W190-4R042

STEP 12

Disconnect the connector (9) from the armrest positioning switch. Remove the armrest cable.

4 2

6 W190-4R043

Remove the armrest height / angle adjustment (2) from the support assembly (1) by removing the nut (3), washers (4), capscrew (5) and two nylon bushings (6).

5009-36

STEP 13

STEP 14 10

11 3

4 9 2

7 5

W190-4R104

Remove the locking bracket (7) with pin (8) from the armrest height/angle adjustment (2). Unscrew the two nuts (9), capscrews (10) and the washers (11). Remove the pin (8) from inside the seat of the bracket (7).

W190-4R044

Unscrew the knob (2) from the suppor t (1) and extract the armrest height/angle adjustment pin (3). Remove the plate (4) from the suppor t (1) by removing the four capscrews (5) with washers. Remove the armrest position switch (6) from the inside of the support (1) by removing the two screws (7) and washers.

STEP 15

W190-4R045

Disconnect the wiring harness from the operator’s seat (if equipped with air seat). Remove the four capscrews (8), washers (9) from the base of the seat. Remove the seat.

5009-37

STEP 16

STEP 19 13 12 10 11

1 W190-4R046

Remove the suppor t fastening the seat belt by removing nut (10), washer (11), capscrew (12) and washer (13).

W190-4R049

Raise while slowly rotating the seat cushion support plate (1).

STEP 20

STEP 17

4 1 14 3

W190-4R050 W190-4R047

Remove the four screws (14) and washers from the seat cushion.

Unhook the rod (4) from the support (3) and remove the seat cushion plate (1).

STEP 21

STEP 18

5 7

6 W190-4R051 W190-4R048

Pressing down on the seat cushion support plate (1), slightly tilt the aluminium tongue (2) to release the support (1) and allow raising/rotating the front. Use caution when releasing aluminium tongue (2) to avoid breaking it.

Turn the knob of the support (3) clockwise and move plate (5) forward until the four sliding blocks (6) are in slots (7). Remove the plate (5).

5009-38

STEP 22

STEP 23

1 2

W190-4R052

Remove the plate (1) of the seat by removing the four retaining bolts (2) and washers (3). Slide the plate (1) forwards to gain access to the two front nuts (4) and washers (5) inside the two guides (6) under the plate (1) of the seat. Repeat the procedure for the two rear screws (7) by sliding the plate (1) back.

W190-4R053

Remove the armrest support plate (8).

5009-39

Installation

STEP 26

STEP 24 8

1 3 4 8 W190-4R054

Position the armrest support plate (8) on the seat runners (6).

STEP 25

W190-4R056

W190-4R055

Position the seat plate (1) on the seat support plate (2).

Push the seat plate (1) forward. From the top, insert the two front capscrews (3) and washers (4). From the seat runners (7) install nuts (5) and washers (6). Tighten the nuts to a torque of 32 Nm. Repeat the procedure for the two rear capscrews.

5009-40

STEP 27

STEP 30

4 3 1

W190-4R057

W190-4R059

Install the seat plate (9). Turn the locking support (10) clockwise and at the same time push the plate (9) toward the rear of the seat to locking it.

Install the seat cushion (3) onto plate (1) and secure it with four screws (4) and washers.

STEP 31 STEP 28 13

6 7

12 W190-4R060 W190-4R058

Insert the two lugs for the seat cushion plate (11) inside the two openings on the seat plate (9). Hook the rod (13) to the catch (12). Slowly lower the seat cushion support plate (11).

Install the seat belt, install capscrew (5) and washer (6), nut (7) and washer (8). Tighten the nut to a torque of between 47 and 68 Nm. Check that the seat belt mounting hardware is tight and the seat belt is not cut or frayed.

STEP 32

STEP 29

1 9 10 2 W190-4R048

Lock the seat cushion support plate (1) by bending the aluminium tongue (2) into position. Use caution when bending the aluminium tongue (2) to avoid breaking it.

W190-4R061

Put the seat in the cab. Connect the wiring harness to the operator’s seat (if equipped with air seat). Install the seat on the base and secure it with the four capscrews (9) and washers (10). Tighten the screws to a torque of between 73 and 87 Nm.

5009-41

STEP 33

STEP 34 11

5 9

6 13 10

3 7

2 W190-4R062

Install the armrest position switch (2) on the support (1) using the two screws (3) and washers. Insert the adjuster pin (4) inside the support (1) and screw the knob (5) on it. Install the plate (6) on support (1), secure it using four capscrews (7) and washers.

W190-4R105

Insert the armrest locking pin (8) in the bracket (9). install it on the armrest height/angle adjustment (10) using the two capscrews (11), washers (12) and nuts (13). Tighten the nuts to 7 Nm.

STEP 35

8 W190-4R106

Insert, rotate and secure the armrest locking pin (8) as shown.

5009-42

STEP 36

STEP 38 1

5 2

W190-4R065

Connect the positioning switch connector (11). W190-4R063

Install the armrest height/angle adjustment (2) on the support assembly (1), insert the two nylon bushings (3), capscrew (4), washers (5) and nut (6).

STEP 39

STEP 37 1 7

W190-4R066

Install the CAN module (1) in the seat (2) on the armrest.

STEP 40 8

6 1

8 10 4 W190-4R064

Insert the armrest (7) inside the support (8), Install the knob (9) for armrest height adjustment with spacer (10).

3 W190-4R067

Connect the connector (3) to the CAN module (1). Secure the cable (4) to the mounitng bracket using capscrew (5), washer (6), nut (7) and washer (8).

5009-43

STEP 41

STEP 43 2

12 1

11 13

3 W190-4R068

Connect connector (10) to the PVRES Joystick (9). Mount the Joystick to support (11), install the two capscrews (12), four washers (13) and two nuts (14). Position the valve (9) so the letter “A” stamped on it is on the left-hand side of the armrest. W190-4R108

STEP 42

Connect connector (1) of the “Kick-Down” button (2) to the cable (3).

16 STEP 44 15

17 W190-4R107

Insert the “Kick-Down” button (16) on the armrest (15) and secure it with the nut (17).

W190-4R109

Insert the “F-N-R” switch (5) in the armrest (4), connect connector (6) to the cable (7).

5009-44

STEP 45

STEP 46

2 4

9 8

3 W190-4R069

Put the armrest (4) on the support (8), secure it with the four capscrews (9).

W190-4R070

Position armrest (1) with support (2) onto the armrest adjustment (3) and inatll knob (4) with washer (5).

5009-45

JSS HYDRAULIC PRESSURE ADJUSTMENTS NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.

Pressure Setting Test

4. Make sure that the temperature of the hydraulic oil is at least 54° C (129° F).

1. Install articulation lock (1).

5. To measure the temperature of the oil using the instrument panel: A. Press the up or down arrow key.

DANGER

B. Stop at the info screen with the temperatures that need to be monitored. WARNING

6. Apply the parking brake. 7. Start and run the engine at full throttle. 8. Lower the lift arms and hold the control lever in the FLOAT position. 9. Hold the bucket control lever in the rollback position.

BD03A040

1. ARTICULATION LOCK

10. Continue holding until the specified temperature of the oil is reached. 11. Operate the machine at full throttle. 12. With the articulation lock still in place, turn and hold the steering wheel for a hard right turn. 13. Continue holding the steering wheel, and read the pressure gauge. 14. The pressure gauge must indicate 239 to 243 bar (3465 to 3525 psi). If the pressure is not correct, adjust the steering relief valve. NOTE: See section 8002 for pump 1 high pressure pump differential pressure testing. 15. With the engine at low idle, with all the controls in neutral, JSS NOT active, a differential reading of 28 to 30 bar (405 to 435 psi) should be obtained.

2 1 BD06F148

1. G1 TEST PORT 2. G2 TEST PORT

16. With the engine at low idle, with all the controls in neutral, JSS ON and joystick in neutral, a differential reading of 28 to 30 bar (405 to 435 psi) should be obtained. 17. With the engine at low idle, with all the controls in neutral, JSS ON and joystick in full left or right turn, a differential reading of 28 to 30 bar (405 to 435 psi) should be obtained. NOTE: If the setting is not correct, verify that the hydraulic connection from the hydraulic steering valve PVFC that manages the LS signals connected or is not kinked.

5009-46

Pressure Setting Adjustment

Steering Times

1. Turn the adjusting screw clockwise to increase the pressure setting. Turn the adjusting screw counterclockwise to decrease the pressure setting. 2. Repeat pressure test procedure. 3. If necessary, adjust the limit valve again until within the specified range. 4. Stop the engine before removing the pressure gauge.

IMPORTANT: When performing the following procedure check that the articulation of the unit is NOT locked. The speed of steering is not constant but depends on the speed reached by the vehicle. On reaching 20 km/h the steering sensitivity is reduced by 80% compared to the normal speed of steering. The JSS can be set on three different levels of steering speed. The three speed levels are: 1. from 4.5 to 5.5 sec.* 2. from 3.2 to 4.5 sec.* 3. from 2.8 to 3.2 sec.* *(time to take the unit from full right to full left turn). The purpose of these settings is to make steering the unit similar to the standard steering system.

1. With the engine at low idle, with all the controls in neutral and JSS ON, steer the unit completely to the left.

2. Set a speed level (e.g. 1, 2 or 3).

BD06F147

1. STEERING PRIORITY VALVE 2. LIMIT VALVE

3. Move the joystick to the right, time the steering rate from full left to full right. Compare the time with the time specified in the table of speed levels. 4. Move the joystick to the left, time the steering rate from full right to full left. Compare the time with the time specified in the table of speed levels. 5. If the times are not in the range shown in the table, calibrate the system, see page 47. 6. Repeat tests 1 through 4 with the engine at high idle.

5009-47

STEERING SPEED CALIBRATION PROCEDURE STEP 1

STEP 4

Before running the unit calibration the following procedures must be completed: - Start the engine; - Set the unit in a straight position; - Activate the Joystick Steering System; - Slightly lift the bucket off the ground; - Release the parking brake.

STEP 2 1 521E-4R005

Press the enter button (2) within two seconds to confirm the calibration procedure. If you do not press any buttons after two seconds, the screen will show “Calibration”, “Timeout”, “Cancelled”. Repeat Step 2 reenter the calibration procedure.

STEP 5 2 521E-4R003

At the same time press the Joystick Steering activation switch (1) and the enter button (2).

STEP 3

521E-4R006

If the enter button is pressed longer than two seconds, the main menu screen appears.

521E-4R004

Keep pressed until the screen shows “Calibration?”.

5009-48

STEP 6

STEP 9

521E-4R007

The display will show a screen with the wording “Steer. Straight?” Press the enter button to confirm.

STEP 7

521E-4R010

Afterwards, the display will automatically read “Joyst Full Right” “Release when WL starts moving”. Move the Joystick lever completely to the right. As soon as machine movement is noticed release the lever.

STEP 10

521E-4R008

The display will read “Joyst Full Left” “Release when WL starts moving”. Move the Joystick lever completely to the left. As soon as mahcine movement is noticed release the lever.

STEP 8

521E-4R009

After this operation, the display will read “O. K.”. The display will automatically read “Joyst Full Right” “Release when WL starts moving”. Move the Joystick lever completely to the right. As soon as machine movement is noticed release the lever.

STEP 11

521E-4R009

After this operation, the display will read “O. K.” The display will automatically read “Joyst Full Left” “Release when WL starts moving”. Move the Joystick lever completely to the left. As soon as mahcine movement is noticed release the lever.

521E-4R011

The display will read “Calibration Successful” indicating calibration is complete.

6001 Section 6001 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS

6001-2

TABLE OF CONTENTS TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 7 8 12 12 15 16 19 19 21 22

6001-3

TRANSMISSION Removal

STEP 7

STEP 1 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

STEP 2 Place the master disconnect switch in the OFF position.

STEP 3 Refer to Section 9007 and remove ROPS cab or ROPS canopy.

STEP 4 Refer to Section 8001 and remove the hydraulic pump.

BD01D315

Disconnect transmission wiring harness connector from control valve connector. Remove socket head bolt securing wiring harness clamp. Move wiring harness away from transmission.

STEP 8

STEP 5 Put a 25.5 liter (27 quar ts) container under transmission drain plug. Remove drain plug and drain transmission oil. Install drain plug after oil has drained.

STEP 6

BD01D317

Just above where clamp was installed, tag and disconnect transmission wiring harness connector from temperature sensor. Move wiring harness away from transmission.

STEP 9 BD01D306

Identify, tag, and disconnect brake pump pressure hose and brake to hydraulic reservoir hose. Position hoses away from transmission. Remove and discard O-ring face seals from fittings. Plug hoses and cap fittings to prevent entr y of foreign matter into hydraulic system.

BD01D310

Remove two socket head bolts securing transmission wiring harness clamps.

6001-4

STEP 10

STEP 13

BD01D312

BD03A165

Identify, tag, and disconnect transmission wiring harness connectors from engine speed sensor, intermediate speed sensor, and turbine speed sensor. Move transmission wiring harness away from transmission.

Identify, tag, and disconnect parking brake hose from parking brake. Plug hose and cap fitting to prevent entry of foreign matter into hydraulic system. Move hose away from transmission. Remove four bolts and two straps securing center drive shaft to transmission output flange. Disconnect center drive shaft from transmission.

STEP 11

STEP 14

BD01D316

Remove socket head bolt securing wiring harness clamp. Move wiring harness away from transmission.

BD03A161

Remove four bolts and two straps securing rear drive shaft to transmission output flange. Disconnect rear drive shaft from transmission.

STEP 12

BD01D314

Identify, tag, and disconnect transmission wiring harness connectors from filter maintenance switch and output speed sensor. Move transmission wiring harness away from transmission.

6001-5

STEP 15

STEP 18

BD03A160

BD01D342

Remove two bolts. Remove fill tube, with cap and oil gauge assembled, two seals, and metal strainer. Discard seals.

In area between the transmission and the engine, remove four bolts and two straps. Use pry bar to disconnect engine drive shaft from transmission. Using 3/4 inch drive socket, extensions, and impact wrench, remove four bolts and washers securing transmission to top mounting bracket.

STEP 16

STEP 19

IMG_2114.PNG

Identify, tag, and disconnect cooler hoses from fittings installed in thermo bypass valve located on the left hand side of transmission. Install plugs in hoses. Remove and discard O-ring face seals from fittings.

STEP 17

BD01D343

Connect lifting equipment to transmission lifting eyes. Take up all slack in lifting equipment.

BD03A163

Remove bolts and washers securing RH and LH mounting brackets to rear chassis.

6001-6

STEP 20

STEP 22

BD01D361 BD03A164

Raise transmission just enough to enable removal of RH and LH mounting brackets. Remove two bolts and washers securing RH and LH mounting brackets to transmission. Remove RH and LH mounting brackets.

STEP 21

BD01D345

Slowly and carefully raise transmission from loader while checking that all hoses, electrical connectors, and wires have been disconnected and nothing interferes with transmission removal. Remove transmission from loader.

If top mounting bracket requires removal, remove bolt and washer then remove bracket.

6001-7

Transmission Mounting 4

2 1

C B 1 3

2 2

5 7

1 5

2 A

BS03B153

1. 2. 3. 4. 5.

ISOLATOR BOLT WASHER BOLT BOLT BOLT

6. 7. A. B. C.

MOUNTING BRACKET TOP MOUNTING BRACKET REAR CHASSIS TRUNNION BRACKET (6 OR 7) SMALLER PIECE ON TOP

6001-8

Installation

STEP 26

STEP 23 Check isolators for deterioration, tears, deformation, or other damage. Replace as necessary: refer to mounting illustration.

STEP 24

BD03A164

Install RH and LH mounting brackets on transmission using two washers and bolts. Do not tighten bolts.

STEP 27

BD01D361

If top mounting bracket was removed, put bracket on rear chassis trunnion and secure using washer and bolt. Do not tighten bolt. NOTE: Mounting hole use is based upon 4-speed or 5-speed installation. The 5-speed transmission installation uses rear mounting hole.

STEP 25 BD03A163

Loosely install washers and bolts to secure RH and LH mounting brackets to rear chassis. Tighten bolts securing RH and LH mounting brackets to transmission to a torque of 481 to 590 Nm (355 to 435 pound feet).

BD01D345

Move transmission into position above loader. Slowly lower transmission into loader.

6001-9

STEP 28

STEP 30

NOTE: In this step, new straps and bolts securing the drive shaft must be installed whenever these parts are removed. Bolts have a nylon patch to maintain torque which requires new bolts.

BD01D343

Disconnect lifting equipment from transmission lifting eyes. BD01D342

Using 3/4 inch drive socket, extensions, and impact wrench, install four washers and bolts to secure top mounting bracket to transmission. Then tighten bolts to a torque of 251 to 319 Nm (185 to 235 pound feet). If bracket had been removed, tighten bolt to a torque of 890 to 1000 Nm (655 to 735 pound feet). Connect engine drive shaft to transmission. Install two new straps and four new bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

STEP 31 Remove plugs in thermo bypass valve ports.

STEP 32

STEP 29

IMG_2114.PNG

Install new O-ring face seals in fittings on thermo bypass valve. Connect cooler hoses to fittings following tags installed during removal. Remove and discard tags.

BD03A163

Tighten bolts securing RH and LH mounting brackets to a torque of 890 to 1000 Nm (655 to 735 pound feet).

6001-10

STEP 33

STEP 36

BD03A160

BD01D314

Position fill tube, two new seals, and metal strainer on transmission; metal strainer is installed between seals. Secure using two bolts. Tighten bolts to a torque of 17 to 33 Nm (12 to 24 pound feet).

Connect transmission wiring harness connectors to output speed sensor and filter maintenance switch following tags installed during removal. Remove and discard tags.

STEP 34

STEP 37

BD03A161

BD01D316

Connect rear drive shaft to transmission then install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

Install socket head bolt to secure wiring harness clamp.

STEP 38 STEP 35

BD01D312 BD03A165

Connect center drive shaft to transmission and install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet). Connect parking brake hose to parking brake following tag installed during removal. Remove and discard tag.

Connect transmission wiring harness connectors to turbine speed sensor, intermediate speed sensor, and engine speed sensor following tags installed during removal. Remove and discard tags.

6001-11

STEP 39

STEP 42

BD01D310

BD01D306

Install two socket head bolts to secure transmission wiring harness clamps.

At brake valve, install new O-ring face seals in fittings. Connect brake to hydraulic reservoir hose and brake pump pressure hose following tags installed during removal. Remove and discard tags.

STEP 40

STEP 43

BD01D317

Connect transmission wiring harness connector to temperature sensor following tag installed during removal. Remove and discard tag.

Check that transmission drain plug is tight.

STEP 41

STEP 44

BD03A177

Fill transmission with Standard Multi-G Hydraulic oil until oil level is up to the arrow in sight glass.

STEP 45 Refer to Section 8001 and install the hydraulic pump.

STEP 46 Refer to Section 9007 and install ROPS cab or ROPS canopy.

STEP 47 BD01D315

Install socket head bolt to secure wiring harness clamp. Connect transmission wir ing har ness connector to control valve connector.

Start and run engine at idle speed with transmission in neutral. If transmission oil level is at or below bottom of crosshatch region, put articulation lock in LO CKED po sition a nd ad d Stan da rd M ulti- G Hydraulic oil until oil level is up to crosshatch region. Shut down engine and put ar ticulation lock in OPERATING position.

6001-12

FRONT AXLE Removal

STEP 4

STEP 1

BD03A167

BD03A040

Park machine on level surface. Have assistant put articulation lock in LOCKED position.

Remove four bolts and two straps securing front drive shaft to front axle.

STEP 5

IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

STEP 2

BD03A166

BD03A092

Raise bucket and have assistant install safety link. Lowe r loa der ar ms slowly until sa fety link is supporting loader arms.

STEP 3 Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

Remove clamp securing lubrication hose to machine and nut securing opposite end of hose. Remove four bolts and two straps securing center drive shaft to front drive shaft. Use a pry bar to separate drive shafts. While supporting center bearing and front drive shaft, remove four nuts and bolts and eight washers. Lower center bearing and front drive shaft from mounting plate and remove from machine.

6001-13

STEP 6

STEP 8

BD03A168

For machines without brake damping accumulators, disconnect brake hose from elbow. Remove and discard O-ring face seal from elbow. NOTE: 721F machines with heavy duty axles are equipped with brake damping accumulators.

IMG_1998 RESIZED.JPG

If equipped, disconnect differential lock hose. NOTE: Locking front differential is available on 721F machines equipped with heavy duty axles.

STEP 9

STEP 7

BD01F298

100_0174 RESIZED.JPG

For machines with brake damping accumulators, disconnect brake line from elbow at axle connection. Remove and discard O-ring face seal from elbow. To remove accumulator, also disconnect brake line and hose from accumulator. Unbolt accumulator from machine frame. NOTE: 721F machines with heavy duty axles are equipped with brake damping accumulators. BD01D392

Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine.

STEP 10 Repeat Step 9 to raise other front axle tire from ground.

6001-14

STEP 11

STEP 13

IMG_2121.PNG

Use an acceptable jack to hold front axle.

BD01F296

Remove eight nuts bolts, and washers securing front axle to machine.

STEP 12 STEP 14 Carefully lower front axle and remove from under machine.

BD01F295.TIF

Remove wheel nuts/bolts and washers from front wheels. Remove both wheels from front axle. NOTE: 721F heavy duty axles have wheel studs on the axles and use wheel nuts.

6001-15

Front Axle Mounting

1 2

FRONT AXLE MOUNTING.PNG

1. BOLT 2. WASHER 3. WASHER

4. NUT 5. FRONT AXLE

6001-16

Installation STEP 15 Carefully move front axle under machine and raise against mounting pads on machine.

STEP 16

B0987A88.TIF

721F Torque Pattern BD01F296

Apply one drop of engine oil to threads prior to assembly. Install eight washers, bolts, washers, and nuts to secure front axle to machine. Tighten bolts to a torque of 765 to 865 Nm (565 to 630 pound feet).

NOTE: 721F units use a 12 hole mounting pattern.

STEP 18

STEP 17

IMG_2121.PNG

Remove jack from front axle.

BD01F295.TIF

Install both wheels on front axle and secure. Tighten wheel nuts/bolts to a preliminary torque of 278 Nm (205 lb ft.) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence. NOTE: 721F heavy duty axles have wheel studs on the axles and use wheel nuts.

6001-17

STEP 19

STEP 22

100_0174 RESIZED.JPG BD01D298

For machines with brake damping accumulators, install a new O-ring face seal and connect brake line to elbow at axle connection. If accumulator has been removed, bolt accumulator to machine frame and connect brake line and hose to accumulator.

STEP 23

BD01D392

Using an acceptable hydraulic jack, raise axle and remove jack stand from under machine.

STEP 20 Repeat Step 19 to remove other jack stand from under machine.

IMG_1998 RESIZED.JPG

If equipped, connect differential lock hose.

STEP 21

NOTE: Locking front differential is available on 721F machines equipped with heavy duty axles.

BD03A168

Install a new O-ring face seal in elbow. Connect brake hose to elbow. NOTE: 721F machines with heavy duty axles are equipped with brake damping accumulators.

6001-18

STEP 24

STEP 26 If necessary, fill axle with Standard Multi-G Hydraulic oil.

STEP 27 Refer to Section 7002 and bleed brakes.

STEP 28 Star t engine and raise bucket. Have assistant remove safety link. Lower bucket to ground and stop engine. BD03A166

Position and support center bearing and front drive shaft and install eight washers and four bolts and nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to 94 pound feet). Install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet). Secure lubrication hose to machine using clamp; secure opposite end of hose using nut.

STEP 25

BD03A167

Secure drive shaft to front axle using two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

STEP 29 Put articulation lock in OPERATING position.

6001-19

REAR AXLE Removal

STEP 5

STEP 1 Park machine on a level surface; be sure to allow adequate space at side of machine for removal of rear axle. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and for th at least 30 times to release any pressure from hydraulic circuit.

STEP 2 BD03A169

Disconnect brake hose from elbow. Remove and discard O-ring face seal from elbow.

STEP 6

BD03A040

Put articulation lock in LOCKED position.

STEP 3 Install wood blocks between rear axle and chassis to prevent rear axle from pivoting.

BD01F299

Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine. Repeat this step for other tire.

STEP 4

STEP 7

BD03A162

Remove four bolts and two straps. Use a pry bar to disconnect rear drive shaft from rear axle. IMG_2124.PNG

Use an acceptable jack to hold rear axle.

6001-20

STEP 8

STEP 9

BD01F295.TIF

IMG_2133.PNG

Remove wheel nuts/bolts and washers from rear wheels. Remove both wheels from rear axle.

At front of trunnion, remove three Allen head bolts and washers. Remove front cap: if necessary use two M12 by 32 mm (1.25 inches) bolts in puller holes (A); tighten bolts evenly to pull cap from axle and trunnion. Remove and discard O-ring from cap. Repeat this step at rear of trunnion except remove and retain shim(s) after removal of rear cap. Remove pivot shaft using acce ptable sle eve or rod if necessary.

NOTE: 721F heavy duty axles have wheel studs on the axles and use wheel nuts.

6001-21

Rear Axle Mounting

5 4 2

5 1 2 6

8 9

REAR AXLE MOUNTING.PNG

1. O-RING 2. SEAL 3. FRONT CAP

4. WASHERS 5. BOLTS 6. FRONT CAP

7. SHIM(S) 8. PIVOT PIN 9. REAR AXLE

6001-22

Installation

STEP 13

NOTE: If shim(s) (7) have been lost or pivot pin (8) has been replaced, do Step 12 to determine required shim(s) otherwise go to Step 13.

STEP 12 5

8 6

PIVOT BUSHING 2.PNG

B INSTALL PIVOT PIN.PNG

Install pivot pin (8) and caps (3 and 6) in trunnion (B) without rear axle or shim(s). Install washers (4) and bolts (5). Tighten bolts securely. Push assembled pivot pin and caps to rear of machine as far as possible. Measure and record gap (A) between rear cap (6) and trunnion. Select shims from the following: NOTE: Shims are available in following sizes: 0.50 mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm (0.059 inch). MEASURED GAP (mm)

SHIM(S) REQUIRED (mm)

0.07 to 0.55

None

0.56 to 1.09

0.50

1.10 to 1.59

1.0

1.60 to 2.09

1.50

2.10 to 2.59

0.50 plus 1.50

2.60 to 3.02

1.0 plus 1.50

PIVOT BUSHING.PNG

Clean front (A) and rear (B) pivot area of rear axle where seals will be installed.

STEP 14 A 2 3 6

2 PIVOT PIN SEAL.PNG

Lubricate two new seals (2) and new O-rings (1) using Molydisulfide Grease. Install seals, smooth side out, into front and rear of axle housing (A) until flush with housing. Install an O-ring in each cap (3 and 6).

STEP 15 Carefully move rear axle under machine. Raise axle into position in trunnion and align pivot holes in trunnion with pivot holes in axle.

6001-23

STEP 16 7 5

B INSTALL PIVOT PIN 2.PNG

Lubricate pivot pin (8) using Molydisulfide Grease. At rear of trunnion (B), install pivot pin into trunnion and axle (A). Install shim pack (7), rear cap (6) with O-ring installed, and two washers and bolts (4 and 5). At front of trunnion install front cap (4) with O-ring installed, and two washers and bolts (4 and 5). Tighten bolts (5) to a torque of 651 to 678 Nm (480 to 500 pound feet).

B0987A88.TIF

721F Torque Pattern NOTE: 721F units use a 12 hole mounting pattern.

STEP 18

STEP 17

IMG_2124.PNG

BD01F295.TIF

Install both wheels on rear axle and secure. Tighten wheel nuts/bolts to a preliminary torque of 278 Nm (205 lb ft.) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence.

Remove hydraulic jack supporting rear axle.

STEP 19

NOTE: 721F heavy duty axles have wheel studs on the axles and use wheel nuts.

BD01F299.TIF

Using a suitable hydraulic jack, raise one tire from the ground and remove jack stand supporting loader. Reapeat this step for other tire.

6001-24

STEP 20

STEP 22 If necessary, fill axle with Standard Multi-G Hydraulic oil.

STEP 23 Refer to Section 7002 and bleed brakes.

STEP 24 Place articulation lock in OPERATING position.

BD03A169

Install a new O-ring face seal in elbow. Connect brake hose to elbow.

STEP 21

BD03A162

Connect rear drive shaft to rear axle. Install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

6002

Section 6002

6002-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration (4-Speed Transmission Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Transmission Declutch (4-Speed Transmissions Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . .

3 3 9 9 9 9 9 10 10 10 10 10 11 11 11 11 11 12 12 12 12 12 12 13 14 16 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 19 20 20 20

6002-3

SPECIAL TOOLS CAS-1953A Transmission supplemental fitting kit. Includes: CAS-2324 special 90 degree adapter and CAS-2325 plug and cap set. CAS-1804 Master pressure test kit

CAS-1808 Flowmeter kit CAS-2702 Flowmeter adapter CAS-2278 Flow test kit

SPECIFICATIONS Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi) Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi) Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi) Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi) Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi) Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm) Transmission oil operating temperature..........................................................................80 to 120 °C (176 to 248 °F) Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K4 ........................................................................................................................16 to 18 bar (232 to 261 psi)

6002-4

1 3

9 6 8

11 14 7

13 10

BS01A190

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

TRANSMISSION ELECTRONIC CONTROL MODULE DOWNSHIFT BUTTON DECLUTCH ROCKER SWITCH MANUAL/AUTOMATIC ROCKER SWITCH SHIFTER SUPPLY SYSTEM CONNECTIONS B+ AND RETURN

7. TRANSMISSION

8. 9. 10. 11. 12. 13.

INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR HALL SENSOR - OUTPUT SPEED SENSOR TRANSMISSION CONTROL VALVE CABLE DECLUTCH LIMIT SWITCH (APPLIES TO 4-SPEED TRANSMISSION ONLY) 14. PLUG

COMPONENT LOCATIONS SYSTEMS

6002-5

12 11 1

2 10 3

9 4

14 8 13

BS03A262

1. 2. 3. 4. 5. 6. 7. 8.

CLUTCH SHAFT KR POWER TAKE OFF CLUTCH SHAFT KV CLUTCH SHAFT K2 CLUTCH SHAFT K3 OUTPUT FLANGE REAR OUTPUT FLANGE CONVERTER SIDE OUTPUT SHAFT

9. 10. 11. 12. 13. 14. 15.

TRANSMISSION PUMP INPUT FLANGE CONVERTER INDUCTIVE TRANSMITTER FOR ENGINE SPEED CLUTCH SHAFT K4 CONVERTER RELIEF VALVE CLUTCH SHAFT K1

COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6

BS01A191

1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK 2. TRANSMISSION SUSPENSION BORES

3. OUTPUT FLANGE CONVERTER SIDE 4. OIL DRAIN PLUG

COMPONENT LOCATIONS FRONT VIEW

6002-7

5 9 10 8

BS01A192

1. 2. 3. 4. 5.

CONVERTER BELL HOUSING BREATHER TRANSMISSION CASE COVER FILTER HEAD FILTER

6. 7. 8. 9. 10.

OUTPUT FLANGE REAR OIL DRAIN PLUG OUTPUT FLANGE CONVERTER SIDE TRANSMISSION CASE PARKING BRAKE

COMPONENT LOCATIONS SIDE VIEW

6002-8

BS01B048

1. 2. 3. 4.

LIFTING LUGS POWER TAKE OFF TRANSMISSION CONTROL VALVE TRANSMISSION SUSPENSION BORES

5. OUTPUT FLANGE REAR 6. FILTER 7. FILTER HEAD

COMPONENT LOCATIONS REAR VIEW

6002-9

TRANSMISSION OPERATION General

Transmission ECM Tasks

The transmission is equipped with a Transmission ECM (Electronic Control Module). This module controls modulation and shifting that were normally a s s o c i a t e d w i t h hy d r a u l i c a l l y m o d u l a t e d transmissions, providing smoother shifts and enhanced clutch life.

The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM:

The Transmission ECM relies on signals from several sensors that are incorporated into the design. These sensors measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. In a d d i t i o n , th e t ra n s m i s s i o n i n c o r p o ra t e s a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise, and all external hoses have been eliminated (all oil passages are internal).

B. Protects the engine and transmission turbine from overspeed conditions dur ing downloading. C. Receives speed information from the engine speed sensor, the turbine speed sensor, the intermediate shaft speed sensor and the transmission output shaft speed sensor. T h e s e s p e e d s e n s o r s a r e c h e ck e d t o deter mine if nor mal sensor operation is present. The data is also used to control modulation during shifting and to determine the appropriate shift patterns. D. Detects system failures and determines the appropriate alternative actions.

Transmission ECM Modulation and shifting are controlled by the Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e (Transmission ECM). This module replaces the oil and springs that are found in hydraulically modulated transmissions. T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d enhanced clutch life, whether the transmission is set to the automatic or manual shift mode. The Transmission ECM also informs the Information Center, by the use of diagnostic codes, of any transmission error and the hours of operation that the error occurred.

Electrical Shift Solenoids Electrical Shift Solenoids control the modulation of the clutches, eliminating the need for a modulation valve, and providing a smooth shift while maintaining constant control over clutch engagement as follows: A. A temperature sensor relays the temperature to the Transmission ECM.

A. Determines which clutches to engage in the transmission.

oil

B. The Transmission ECM times the rate the solenoid energizes and de-energizes. C. As the transmission changes gears, there is reduced hesitation from one gear to the next.

E. Provides various diagnostic messages to the Information Center. F. Provides other information to the information center, which in turn displays engine speed, wheel speed, gear shift selection, and actual gear selection. G. Provides a method to transmission clutch control.

calibrate

the

H. Establishes clutch modulation pressure during transmission shifts.

6002-10

Transmission Sensor Data Collection The Transmission ECM collects and uses information from four sensors to accurately shift the transmission and determine if any clutches are slipping. These sensors are: Engine (Speed) Sensor - monitors engine speed to determine the load on the engine for shift points and sends the engine rpm to the Transmission ECM, which sends the information to the tachometer in the Information Center. Turbine (Speed) Sensor - assists the engine speed sensor in deter mining the load going into the transmission and helps determine shift points. Intermediate (Shaft Speed) Sensor - determines differential gear speed in the transmission to check for clutch slippage. Output (Speed) Sensor - monitors transmission output shaft speed to help determine the load on the transmission and to assist in determining shift points. Sends output shaft speed to Transmission ECM which sends the information to the speedometer in the Information Center. T h e t ra n s m i s s i o n E C M a l s o r ev i ew s vo l t a g e infor mation from the shifter and transmission solenoids to determine if there are any short circuits or open circuits in the system.

Automatic Problem Modes If the Transmission ECM detects an error condition in the transmission system, it will generate a service code in the Information Center and will enter one of three modes: A. Clutch Modulation Substitute Mode B. Limp-Home Mode C. Transmission/Transmission ECM Shutdown Mode

Clutch Modulation Substitute Mode In this mode, the transmission clutch modulation is time dependant rather than load dependant. The transmission will go into the Clutch Modulation Substitute Mode if any of the four speed sensors fail. If the output speed sensor is working and the transmission is in gear, the shift points in Automatic mode will be speed dependant but the modulation will be a predetermined amount of time. If the output speed sensor is not working and the transmission is in gear, the shift points will be load d e p e n d a n t bu t t h e m o d u l a t i o n w i l l s t i l l b e a predetermined amount of time. If the transmission is shifted from neutral into a direction in the Clutch Modulation Substitute Mode in automatic, the transmission will shift into 4th gear and shift down until it gets the correct output speed from the turbine.

Limp-Home Mode In this mode, the transmission will go into second gear, forward or reverse, no matter what gear is selected. If second gear is not obtainable, the Transmission ECM selects a series of prioritized g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e transmission will go into the Limp Home Mode if there is a fault on one clutch, a fault on one clutch valve, or a fault on more than one speed sensor.

Transmission/Transmission ECM Shutdown Mode In this mode, the Transmission ECM has detected a s e ve r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e transmission. The transmission will go into Shutdown Mode if there is a fault on more than one clutch, a fault on the solenoid power supply, or invalid voltage. In this mode, the Transmission ECM will shut off all solenoid valves and the power supply and the transmission shifts into and stays in neutral. If the Transmission ECM generates a code, the wren ch over th e se r vice m anual ico n will be displayed on the Information Center.

6002-11

Transmission Clutch Calibration (4-Speed Transmission Only) The Transmission ECM has the capability to find the optimal adjustment of the clutch filling parameters for each individual transmission, providing the ability to individually adjust the optimum fill time for the individual transmission in the machine. Clutch Filling Parameter Calibration is performed on each machine at the plant and should be repeated at the first 250 hours of use and every 1000 hours thereafter. Before doing the following transmission clutch calibration procedures make sure of the following: 1. The machine is running and the transmission oil is warm. 2. Engine low idle speed is correct. 3. The transmission is in neutral.

Gear Selections The 4 speed transmission provides 4 forward and 3 reverse gear selections. The 5 speed transmission provides 5 forward and 3 reverse gear selections. The transmission ratios were designed to give optimized speed and torque for each gear selection. The torque conver ter is a single stage torque converter (one locking unit in the torque converter). The 5-speed transmissions locku-up.

Automatic/Manual Modes The automatic/manual switch is located on the right control panel. The transmission is in automatic mode when the top of the automatic/manual switch is depressed. The Transmission Display Center indicates when the machine is in the automatic mode.

4. The park brake is applied.

Upshifting in Automatic Mode

5. If steps 1 through 4 have been accomplished, calibrate the transmission clutches as follows:

Upshifting is determined by machine speed and the torque on the transmission.

A. Press and hold the enter key for 2 to 3 seconds and the monitor will change to SELECT.

The transmission will shift from first or second gear up to the highest gear selected as the accelerator is depressed, machine speed increases, and required torque is reduced.

B. Use the down arrow and high light “CONFIG”, press the enter key. C. Press the down arrow and high light “CALIB G/B”, press the enter key. D. Monitor will state “CALIB G/B” “CONFIRM PLEASE”, press the enter key. E. If the conditions are not correct for clutch calibration the monitor will display the problem that needs to be corrected. F. Clutch calibration status will be displayed on the monitor, “ADJUST K1, K2, K3, K4, KV, KR”. G. After completing the Clutch Calibration procedure, turn the machine OFF for 15 seconds. This sets the calibration in the controller.

If the machine speed is increasing, but the operator is not depressing the accelerator (such as when going down a hill), the transmission will not upshift. As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.

Downshifting in Automatic Mode Downshifting is determined directly by machine speed and transmission torque. The transmission will downshift to first or second gear as machine speed decreases and transmission torque increases. For example, if the unit begins to climb a hill in forth gear and the machine speed decreases, as the torque requirement increases, the transmission will downshift into third, then second, and down to first gear, if necessary.

6002-12

Upshifting in Manual Mode In the manual mode, the transmission starts out in the selected gear and stays in that gear until the operator selects another gear or direction. The transmission can be upshifted without reducing engine speed or machine speed. If the gear selected is two or more gears higher than the present gear, the transmission will shift up through the gears at 2.5 second intervals until the selected gear has been reached.

Downshifting in Manual Mode The transmission can be downshifted in the manual mode without reducing engine speed or machine speed.

B. The shifter is moved into neutral and then into forward or reverse. C. The autoshift switch is recycled.

Manual Mode In the manual mode, the downshift button toggles between 1st and 2nd gear. The manual mode is useful in short haul operations. In this mode, the downshift button functions in two ways in 1st and 2nd gear. When the operator is in 2nd gear and pushes the downshift button, the transmission instantly shifts into 1st gear. When the operator pushes the downshift button again, the transmission upshifts into 2nd gear.

If 1st gear is selected from 3rd or 4th gear, the transmission will downshift into 2nd gear for 1.2 seconds and then will shift into 1st gear.

If the machine is in 2nd gear and the downshift button is pushed, the transmission instantly shifts into 1st gear. When the operator shuttles the shifter, the transmission upshifts back into 2nd gear.

Downshift Button

Cold Start Protection System

The downshift button is located on front of the joystick control lever in machines with a single lever configuration, and on top of the control tower in machines with two or three lever configurations.

The transmission has a cold start protection system. When the transmission sump temperature is minus 10° C (14° F), the Transmission ECM will keep the transmission in neutral.

With the number of different ways the downshift button functions, the operator can tailor the use of the machine to the application at hand.

When the transmission sump temperature warms up to minus 10° C (14°F) (within approximately one minute), the machine will operate in all gears.

Automatic Mode In the Automatic Mode, the downshift button only shifts down. The downshift button allows the operator to downshift through the entire range of gears. This is useful in long haul applications or roading. Each time the button is pushed the transmission will instantly downshift one gear from 4th to 3rd, then from 3rd to 2nd, and then from 2nd to 1st. The transmission will automatically downshift and then upshift, as needed, to the last gear that was selected with the downshift button. Example: If the downshift button was used to shift from 4th to 3rd gear, the transmission will automatically shift from 3rd down and then back up to 3rd again. It will not shift into 4th until the transmission has been returned to the full range automatic mode. The transmission will retur n to the full range automatic mode when: A. Another gear is selected.

6002-13

Brake Pedal Transmission Declutch (4-Speed Transmissions Only) A transmission declutch feature concentrates more engine power on the loader when digging in heavy or tough conditions, providing smoother stops and starts. Total disconnection of the transmission from the engine is prevented. This feature will function in 1st, 2nd, or 3rd gear only. It will not function in 4th gear. When the transmission declutch switch is in the on p o s i t i o n a n d t h e b ra ke p e d a l i s p u s h e d , t h e Transmission ECM reduces the pressure to the transmission forward or reverse clutch. T h e Tr a n s m i s s i o n E C M w i l l n o t c o m p l e t e l y disconnect the clutch from the engine, but gradually reduces the forward or reverse clutch pressure down to a lower level. When the brake pedal is released, the Transmission ECM gradually increases the forward or reverse clutch back up to system clutch pressure. If the direction is changed while the transmission is declutched, the selected forward or reverse clutch will be filled and maintain a low pressure until the brake pedal is released. Then the selected forward or reverse clutch pressure will gradually increase up to system clutch pressure.

6002-14

TRANSMISSION PRESSURE TEST POINTS DIAGRAM No.

IDENTIFICATION/LOCATION

CONNECTION

DESIGNATION ON VALVE BLOCK H

Measuring Points for Pressure Oil and Temperature 51

Before the Converter - Opening Pressure 8 bar (116 psi)

M10x1

Behind the Converter - Opening Pressure 2.5 bar (36 psi)

M14x1.5

Clutch Forward 16+2 bar (232 + 29 psi)

KV M10x1

Clutch Reverse 16+2 bar (232 + 29 psi)

KR M10x1

Clutch 16+2 bar (232 + 29 psi)

K1 M10x1

Clutch 16+2 bar (232 + 29 psi)

K2 M10x1

Clutch 16+2 bar (232 + 29 psi)

K3 M10x1

Clutch 16+2 bar (232 + 29 psi)

K4 M10x1

Behind the Converter Temperature 100° C, Short Time 120° C

M14x1/5

System Pressure 16+2 bar (232 + 29 psi)

M10x1

Measuring Points for Delivery Rates 15

Connection to the Heat Exchanger

1 5/16” - 12 UNF-2B

Connection from the Heat Exchanger

1 5/16” - 12 UNF-2B

Inductive Transmitter and Speed Sensor 21

Inductive Transmitter for Turbine Speed

M18x1.5

Output Speed Sensor

Inductive Transmitter for Central Gear Train Speed

M18x1.5

Inductive Transmitter for Engine Speed

M18x1.5

Connections 49

Plug Connection on the Hydraulic Control Unit

System Pressure

M16x1.5

Pilot Pressure

M16x1.5

NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

6002-15

4-SPEED TRANS. CLUTCH KV KR K1 K2 K3 K4

ͻ PRESSURE REGULATOR UNDER VOLTAGE FORWARD REVERSE NEUTRAL PRESSURE REGULATOR 1 2 3 4 1 2 3 Y5 ͻ ͻ ͻ Y2 ͻ ͻ ͻ Y3 ͻ ͻ Y6 ͻ ͻ Y4 ͻ ͻ ͻ Y1 ͻ

5-SPEED TRANS. CLUTCH KV KR K1 K2 K3 K4

ͻ PRESSURE REGULATOR UNDER VOLTAGE FORWARD REVERSE NEUTRAL PRESSURE REGULATOR 1 2 3 4 5 1 2 3 Y5 ͻ ͻ ͻ Y2 ͻ ͻ ͻ Y3 ͻ ͻ Y6 ͻ ͻ ͻ Y4 ͻ ͻ ͻ Y1 ͻ ͻ

MEASURING POINTS AND CONNECTIONS

BC01B047

6002-16

CHART FOR RECORDING PRESSURE READINGS Use this chart to record the pressure readings. P.I.N. Number:

Date: TEST POINTS

Shift Speed

P 65

V 53

R 55

1 56

2 57

3 58

4 60

5 51

1st F 2nd F 3rd F 4th F 1st R 2nd R 3rd R Neut P= MAIN PRESSURE

1= FIRST GEAR CLUTCH

4= FOURTH GEAR CLUTCH

V= FORWARD CLUTCH

2= SECOND GEAR CLUTCH

5= CONVERTER IN

R= REVERSE CLUTCH

3= THIRD GEAR CLUTCH

6= CONVERTER OUT

LP= LUBE PRESSURE

6 52

6002-17

PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low Possible causes include: 1. Oil level not correct. 2. Oil type and grade not correct. 3. Oil operating temperature high. 4. Screen for suction tube plugged. 5. Suction tube or gaskets leak. 6. Main pressure valve, springs, or valve bore. 7. Reduction valve, springs, or valve bore.

Not Enough Power Possible causes include: 1. Check Electrical Troubleshooting in this Section to verify actual gear selected. 2. Engine RPM below Stall Test specified RPM. (Refer to Section 2002 for specifications.) A. Check engine and fuel system for problem. B. Check that torque converter installation is correct. 3. Engine RPM above Stall Test specified RPM. (Refer to Section 2002 for specifications.)

8. Charge pump seals or gaskets leak.

A. Check converter pressures and flow.

9. Charge pump worn.

B. Check that torque converter installation is correct.

10. Oil supply flange not sealing correctly.

Some Pressures Low Possible causes include: 1. Circuit isolation does not correct low pressure. A. Control valve or gasket. B. Channel plate or gasket. 2. Circuit isolation corrects low pressure. A. Clutch shaft or seals. B. Clutch drum or piston.

Machine Stops or Hesitates While Shifting - Intermittent Possible causes include: 1. Check orifice and O-ring. (See Section 6007 for replacing.) 2. Check for foreign material plugging orifices or sticking valves. 3. Check for reduced pressure at test pressure points. 4. See Electrical Troubleshooting in this Section for electrical system problem.

6002-18

CONVERTER OUT PRESSURE CHECK Test Equipment Required

3. Install the pressure gauge.

0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and CAS-2324 Special Adapter.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F).

Test Procedure 1. Block the machine tires.

5. While in the cab, put the transmission in NEUTRAL. Run the engine at full throttle. Record the reading in the chart on page 16. Pressure must be a minimum of 3.5 to 6.5 bar (51 to 96 psi).

2. Apply the parking brakes.

LUBRICATION PRESSURE CHECK Test Equipment Required

3. Install the pressure gauge in the cooler return line at the transmission.

0 to 7 bar (100 psi) gauge.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F).

Test Procedure

5. While in the cab, run the engine at full throttle. Put the transmission in each gear and record the reading in the chart on page 16. Pressure must be 0.2 to 1.2 bar (3 to 18 psi).

1. Block the machine tires. 2. Apply the parking brakes.

FLOWMETER TEST Test Equipment Required CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter Adapter.

Flowmeter Test Procedure 1. Block the machine tires.

3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F). 4. Remove the filter and install the CAS-2702 adapter. 5. Install the flowmeter between the adapter and the filter. 6. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The correct flow is 80 L/min (21 U.S. gpm) at 2000 rpm.

2. Apply the parking brakes.

CONSUMPTION TEST PROCEDURE 1. Block the machine tires. 2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F). 4. Install the flowmeter to converter outlet line (line to cooler) in series. 5. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The flow must be 9.1 L/min (2 U.S. gpm).

6. Repeat the procedure with the transmission in FORWARD in third gear. The flow must be 9.1 L/min (2 U.S. gpm). 7. Repeat the procedure with the transmission in REVERSE in third gear. The flow must be 9.1 L/min (2 U.S. gpm).

6002-19

TRANSMISSION OVERHEATING 1. Operate machine in normal operating conditions and observe: A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the ambient temperatures. B. Use a stop watch to establish the exact length of time required to reach the overheating condition. C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission? 2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle (1250 to 1450 RPM). A. Oil temperature returns to Normal - establish length of time. 1. Check oil level, type and grade is correct (See Section 1002). 2. Check operator’s gear selection is correct for conditions. 3. Make sure brakes are fully released. 4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002). B. Oil temperature remains overheated. 1. Check for dirty radiator - airflow restricted. 2. Check for engine overheating problem. 3. Check for faulty oil temperature gauge and sender or switch (See Section 4002). 3. Perform all the pressure and flow tests. 4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are not within specifications. 5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

6002-20

ERROR CODES In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with a recorded error number. See section 4005 for error code retrieval procedures and definitions.

TRANSMISSION SHIFTER LOGIC INFORMATION Function

Shifter

Shifter Wire Color

Shifter Tower Connector

Shifter Shroud Connector

Harness Wire #

Harness ped/cab #

Trans. ECM #

power

B+

black/red

19A_H

forward

yellow

25F

reverse

pink

25R

neutral

gray

25T_B

gear2(3-4)

green

25W

gear1(1-2)

blue

25Z

downshift

purple

25Y

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is engaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES Transmission ECM Function

Transmission ECM Pin #

Transmission Valve

Clutch #

Transmission Valve Pin #

Wire #

Trans/Cab Pin #

A1P1

25K

A1P2

25L

A1P3

25M

A1P4

25N

A1P5

25P

A1P6

25J

VPSI

12,13

all Y

all K

25S

TEMP

none

36T

TEMP

none

36R

6002-21

NOTES

6002-22

4 & 5 SPEED TRANSMISSION

6003

Section 6003

6003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.0 Electro-hydraulic control and oil filter (replaceable filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.0 Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . 9 3.0 Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring point “63” after the converter as described in the specifications, pressure checks and troubleshooting section of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.0 Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.0 Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches . . . . . . . . . . . . . . . . . . . . 15 7.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 8.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches . . . . . . . . . . . 66 10.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 11.0 Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring point “63” after the converter as described in the specifications, pressure checks and troubleshooting section of the manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 12.0 Reassembly - Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . 81 14.0 Reassembly Electro-hydraulic control with proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6003-3

SPECIAL TOOLS

CAS2885 TRANSMISSION VALVE ADJUSTMENT TOOL SET 380001560 TRANSMISSION INPUT/OUTPUT SHAFT SEAL INSTALLATION TOOL

CAS2869 TRANSMISSION OUTPUT SHAFT SEAL INSTALLATION TOOL (521 AND 621 MODELS ONLY)

380001559 TRANSMISSION TORQUE CONVERTER SEAL INSTALLATION TOOL CAS40075 TRANSMISSION TOOL KIT

CAS2802 ALIGNMENT DOWEL SET

380001556 CLUTCH PACK H0LDER AND SPRING COMPRESSOR TOOLS CAS2801 TRANSMISSION MOUNTING BRACKETS

CAS2796 NESTING PLATE

CAS2798 GEAR PULLER COLLET SET

BS02C093 THRU 096

380001557 CLUTCH ASSEMBLY HOLDING KNOB SET

CAS2797 LIFTING EYEBOLT SET

CAS40079 TRANSMISSION OVERHAUL KIT

CAS2868 CLUTCH SPRING COMPRESSOR (521 AND 621 MODELS ONLY)

BS02C097 THRU 104

6003-4

SPECIAL TORQUES Oil pipes Studs ............................................................................................................................... 9 Nm (80 pound inches) Socket head bolt................................................................................................................. 23 Nm (17 pound feet) Screw plug.......................................................................................................................... 51 Nm (38 pound feet) Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches) Plugs........................................................................................................................................ 25 Nm (18 pound feet) Output shaft Output shaft bolts (apply Loctite 243 to threads) ............................................................... 23 Nm (17 pound feet) Housing cover bolts (apply Loctite 574 to threads) ............................................................ 46 Nm (34 pound feet) Output flange bolts ............................................................................................................. 34 Nm (25 pound feet) Oil feed housing and transmission pump Transmission pump bolts.................................................................................................... 46 Nm (34 pound feet) Oil feed housing bolts......................................................................................................... 25 Nm (18 pound feet) Engine connection and converter Input shaft bolts................................................................................................................ 115 Nm (85 pound feet) Converter housing bolts ..................................................................................................... 68 Nm (50 pound feet) Cover................................................................................................................................... 23 Nm (17 pound feet) Converter cover.................................................................................................................. 46 Nm (34 pound feet) Input flange ......................................................................................................................... 34 Nm (25 pound feet) Duct plate bolts.................................................................................................................................... 25 Nm (18 pound feet) bolt plug.............................................................................................................................. 30 Nm (22 pound feet) Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches) Filter Filter head bolts.................................................................................................................. 25 Nm (18 pound feet) Oil distribution cover bolts .................................................................................................. 25 Nm (18 pound feet) Speed sensor and inductive transmitter Speed sensor bolt .............................................................................................................. 23 Nm (17 pound feet) Inductive transmitter ........................................................................................................... 30 Nm (22 pound feet) Cover plate ......................................................................................................................... 23 Nm (17 pound feet) bolt plug.......................................................................................................................... 140 Nm (103 pound feet)

SPECIFICATIONS Clutch KV and KR plate clearance ..................................................................... 2.65 to 2.95 mm (0.104 to 0.116 in) Clutch K1plate clearance.................................................................................... 2.35 to 2.65 mm (0.092 to 0.104 in) Clutch K2 and K3 plate clearance ...................................................................... 1.75 to 2.05 mm (0.069 to 0.081 in) Clutch K4 plate clearance................................................................................... 1.35 to 1.65 mm (0.053 to 0.065 in)

6003-5

DISASSEMBLY 1.0 Electro-hydraulic control and oil filter (replaceable filter)

STEP 2 1.1 Removal of filter

STEP 1

BILD-02

Remove and properly discard filter (1).

STEP 3

2 1

BILD-01

Fasten transmission on assembly stand CAS2801 or similar tool. Drain oil prior to starting disassembly. WARNING: Dispose requirements.

oil

according

legal

BILD-03

Remove Torx bolts (2) and separate filter head (1) from transmission. Remove and discard O-rings.

6003-6

STEP 4

STEP 6

1.2 Removal of electronic gear-shift control

2 1

1 4

BILD-06 BILD-04

Remove gear-shift control (1). Remove Torx bolts (2) and separate gear-shift control housing from intermediate plate. NOTE: For version with torque converter lock-up clutch Solenoid valve, go to Steps 20 thru 22.

Remove differential pressure switch (1) from fine filter duct plate (4). 1. Switch with O-ring 2. Piston 3. Compression spring.

STEP 7

STEP 5 2 S

BILD-07

BILD-05

Remove gear-shift control assembly (1) and sealing plate (2). Adjusting bolts M6 (S).

Remove hex nuts and Torx bolts. Separate the duct plate (1) and seal (2) from rear housing.

6003-7

STEP 8

STEP 11 1

2 1

BILD-11

Separate duct plate (1) and sealing plate (2) from valve block (3). BILD-08

Remove converter safety valve (1) out of the housing hole.

STEP 12 1

STEP 9

BILD-12

Remove retaining clamp (1). BILD-09

Mark installation position of wiring harness (1) towards the valve block (2).

STEP 10

STEP 13 1 2

3 BILD-13

Remove Torx bolts (1) and cover (2). Repeat the procedure on the opposite end cover (3). BILD-10

Remove Torx bolts (1).

6003-8

STEP 14

STEP 17 S

2 1

3 BILD-14

BILD-17

Remove wiring harness (1). Remove cylindrical bolts (3), securing plates and pressure controllers (2).

Loosen the adjusting bolts (S) equally releasing the valve’s spring pressure. Remove the housing.

STEP 15

STEP 18 1 3

2 BILD-18

BILD-15

Remove cylindrical bolts, securing plates and pressure controllers (1) on opposite side.

Remove individual parts including pressure reducing valve (1), vibration dampers (2), follow-on slide (3).

STEP 16

STEP 19 1

S 1

3 BILD-16

Remove two Torx bolts (1) and temporarily attach housing using 380001577 adjusting bolts (S). (Housing is spring-loaded.) Remove remaining Torx bolts.

2 BILD-19

Remove individual parts of opposite side including main pressure valve (1), vibration dampers (2), follow-on slide (3).

6003-9

STEP 20

STEP 22

1.3 Version with torque converter lock-up clutch solenoid valve

5 4

4 3

BILD-20

BILD-32

Loosen nuts (1 and 2) and remove system pressure pipe (3) from lock-up clutch valve to lock-up clutch. Remove screw-in sleeve (4).

Mark installation position of connecting housing (4) towards valve block (5). Remove cylinder bolts (1) and lock-up clutch valve. Remove bolt neck (2) and discard O-rings. Remove Torx bolts (3), and the connecting housing. NOTE: For further disassembly, go back to Steps 15 thru 19.

STEP 21

2.0 Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug STEP 1 3

1 2

6 BILD-31

Remove hollow bolt (1) and O-ring. Loosen bolt nut (2). Remove system pressure to lock-up clutch valve pipe and O-rings. NOTE: For further disassembly, go back to steps 4 to 8.

2 1 BILD-01

Attach transmission to assembly stand CAS2801. Remove oil drain plug (1), oil filler tube with oil dipstick (2), breather (3), inductive sensor - n central gear chain (4), inductive sensor - n turbine (5), inductive sensor - n engine (6).

6003-10

STEP 2

1 2

BILD-02

BILD-04

Remove cylindrical bolt (1) and remove Hall effect speed sensor - n output and O-ring (2).

Separate cover from converter bell housing using a suitable lifting device.

3.0 Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring point “63” after the converter as described in the specifications, pressure checks and troubleshooting section of the manual)

STEP 3

STEP 1 3.1 Engine connection (remote mount)

1 2

BILD-05

Remove output flange.

STEP 4

BILD-03

Remove hex bolts (1) and washer. Loosen the cover/converter bell housing bolts (2). NOTE: Mark radial installation position cover/converter bell housing with center punch.

BILD-06

Press input shaft and converter out of cover (ball bearing).

6003-11

STEP 5

STEP 8 3.2 Oil pressure pump

2 2

BILD-07

Remove retaining ring (1) and ball bearing (2).

BILD-10

Loosen bolted connection (1) between converter bell housing and oil feed housing. Remove converter bell housing (2).

STEP 6 1

STEP 9

BILD-08

Remove hex bolts (1) and flex plate (2) from converter. BILD-11

STEP 7

Remove the Torx bolts (1) from the oil feed housing and front transmission housing. Remove cylindrical bolts (2) from the oil pressure pump and front transmission housing.

2 1

NOTE: Separate oil feed housing together with oil pressure pump from front transmission housing.

BILD-09

Remove hex bolts (1) and flex plate (2) from input shaft (3).

6003-12

STEP 10

STEP 12 2

2 3

4 BILD-12

BILD-14

Separate oil pressure pump (1) from oil feed housing (2).

Check oil gear pump for wear. In case of wear marks on the pump housing, cover, inner rotor, or outer rotor; replace the oil pressure pump.

STEP 11

1. Cover 2. Inner rotor 3. Outer rotor

4. Pump housing

2 STEP 13

1 BILD-13

Remove O-ring (1) and cylindrical bolts (2).

2 BILD-15

Remove shaft seal (1) from the pump housing (2).

6003-13

STEP 14

STEP 16

3.3 Converter back-pressure valve

2 1

1 BILD-18 BILD-16

With a screwdriver, release the converter safety valve (1) pressure and remove the locking plate (2).

Remove temperature sensor (1).

STEP 17

STEP 15 1

2 1

BILD-19

BILD-17

Remove individual parts of converter safety valve which are released. 1. Pressure plate 2. Compression spring 3. Piston

Remove stator shaft (1). If applicable, remove the pressure relief valve (2) out of the housing hole. NOTE: The pressure relief valve is not mounted on all versions. Versions concerned, see the corresponding spare parts list.

6003-14

4.0 Emergency steering pump

STEP 2

STEP 1

4.1 Version without emergency steering pump

2 2 1

BILD-02

Pull off output flange (1) and remove shaft seal (2).

BILD-01

STEP 3 5.2 Output flange on output side with parking brake FSG-88

Remove hex bolts (1), cover (2) and seals.

5.0 Outputs and closure parts pump shaft (PTO-shaft) 2

STEP 1

5.1 Output flange on converter side (Standard version)

BILD-11

Connect a hand-operated pump at port (see arrow) and apply approximately 80 bar (1160 PSI) pressure to the hydraulically actuated parking brake (1) until the brake disc (2) can be rotated by hand. BILD-01

STEP 4

Remove hex bolts (1), washer and O-ring.

BILD-12

Remove hex nut with open end wrench.

6003-15

STEP 5

6.0 Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches

STEP 1 1

BILD-13

Remove hex bolts (2) and parking brake (1).

STEP 6

BILD-01

Force out both cylindrical pins (1). Loosen bolted connection (2) between front and rear transmission housings. Separate housing sections using a suitable lifting device.

STEP 2 1

BILD-14

Remove hex bolts (1) of bolted brake disc/output flange connection and remove brake disc (2).

STEP 7 2

BILD-02

Loosen bolted connection (1) of oil screen sheets.

BILD-15

Remove hex bolts (1), washer and O-ring. Remove output flange (2) and shaft seal. Remove cylinder bolt with washer (3).

6003-16

STEP 3

STEP 6 1 2

BILD-03

BILD-06

Remove output shaft (1) and lower oil screen sheet (2) from housing.

Secure all clutches K1, K2, K3 and K4 by using 380001557 handle (1). WARNING: Clutches KV, KR and input shaft (2) are only secured by the gear chain. Care must be taken to ensure these non-secured components do not detach.

STEP 4 2

NOTE: Due to the installation conditions, the removal of single clutches without using the special tool is not possible.

STEP 7

BILD-04

Remove all rectangular rings (1) from the clutches and all O-rings (2) from the oil tubes.

STEP 5

1 1

3 2

4 BILD-07

Separate rear housing section including clutches from front housing section using a suitable lifting device and attach it to the assembly truck. 1. Clutch KV 2. Input shaft 3. Clutch KR

4. Pump shaft BILD-05

Use a suitable lifting device to lower rear housing section (1) into contact position with front housing section (2).

WARNING: Clutches KV, KR and input shaft are only secured by the gear chain. Care must be taken to ensure these non-secured components do not detach.

6003-17

STEP 8

STEP 10 1 1

BILD-08

BILD-10

Remove cylindrical bolts of oil tubes (1) from the front housing.

Remove bearing outer rings (arrows) from the front housing. NOTE: If contrary to recommendation, the tapered roller bearings of clutches, input and output are not replaced, the technician must ensure the previous pairing (bearing outer ring/bearing inner ring). Bearing outer ring and bearing inner ring must be marked.

STEP 9

2 STEP 11

1 BILD-09

NOTE: The suction tube (1) and the lubrication lines (2) are rolled in and difficult to remove. In case of damage, use special tools 380001285 (EU) or 380001286 (EU) for fitting or replacing these components. North American Dealers contact special tools.

2 1 BILD-11

Disengage retaining ring (1) and remove pump shafts (2).

6003-18

STEP 12

STEP 14

BILD-12

BILD-14

Press ball bearing (1) off the pump shaft. Snap out rectangular ring (2).

Remove bearing outer rings (arrows) from the rear housing. NOTE: If contrary to recommendation, the tapered roller bearings of clutches, input and output are not replaced, the technician must ensure the previous pairing (bearing outer ring/bearing inner ring). Bearing outer ring and bearing inner ring must be marked.

STEP 13 7 6 2

5 4

STEP 15

BILD-13

Lift the clutches out of the housing in numerical order as described in the legend. 1. K1 clutch 2. K2 clutch 3. K3 clutch (Version with emergency steering pump) 4. K4 clutch 5. KR clutch 6. KV clutch 7. Input shaft

BILD-15

NOTE: The lubrication lines (1 and 2) are rolled in and difficult to remove. In case of damage, use special tool 380001285 (EU) for fitting or replacing these components. North American Dealers contact special tools.

6003-19

7.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft.

STEP 3

STEP 1 2

3 1 BILD-03

Pull tapered roller bearing off the shaft using special tool CAS2798.

7 BILD-01

STEP 4

1. K1 clutch 2. K2 clutch

3. K3 clutch 4. K4 clutch 5. KR clutch 6. KV clutch 7. Input shaft.

STEP 2 7.1 KV clutch BILD-04

Snap out retaining ring (1).

STEP 5

BILD-02

Remove stud bolt (1) and snap out piston ring (2).

BILD-05

Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 11-16.

6003-20

STEP 6

STEP 9 1

BILD- 06

BILD-09

Secure idler gear (1) using a cut-off device and pull it off the clutch shaft.

Turn shaft (2) 180 degrees and snap out piston ring (1).

STEP 7

STEP 10 1 3

BILD-07

BILD-10

Snap retaining ring (1) out of the idler gear (2) and remove ball bearing (3).

Pull tapered roller bearing off shaft with special tool CAS2798.

STEP 8

STEP 11 1 1

BILD-08

Remove needle cage (1) from the shaft (2).

BILD-11

Unsnap snap ring (1).

6003-21

STEP 12

STEP 15 1 1

3 BILD-12

BILD-15

Remove end shim (1) and disc set (2) from the disc carrier (3).

Using compressed air, remove the piston (1) from the disc carrier.

STEP 13

STEP 16

1 2

BILD-13

Preload compression spring with special tool 380001556 and unsnap L-ring (1).

BILD-16

Remove both O-rings (1 and 2).

STEP 1 STEP 14

7.2 KR clutch

2 3

BILD-14

Remove support shim (1), compression spring (2) and washer (3).

BILD-01

Remove stud bolt (1) and snap out piston ring (2).

6003-22

STEP 2

STEP 5

BILD-02

BILD- 05

Pull tapered roller bearing off the shaft with special tool CAS2798.

Secure idler gear (1) using a cut-off device and pull it off the clutch shaft.

STEP 3

STEP 6 1

1 3

BILD-03

Snap out retaining ring (1).

BILD-06

Snap retaining ring (1) out of the idler gear (2) and remove ball bearing (3).

STEP 4 STEP 7 1

2 1

BILD-04

Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 10-15.

BILD-07

Remove needle cage (1) from the shaft (2).

6003-23

STEP 8

STEP 11 1

2 2 3 BILD-08

BILD-11

Turn shaft (2) 180 degrees and snap out piston ring (1).

Remove end shim (1) and disc set (2) from the disc carrier (3).

STEP 9

STEP 12

BILD-09

BILD-12

Pull tapered roller bearing off shaft using special tool CAS2798.

Preload compression spring with special tool 380001556 and unsnap L-ring (1).

STEP 10

STEP 13 1

2 3

BILD-10

Unsnap snap ring (1).

BILD-13

Remove support shim (1), compression spring (2) and washer (3).

6003-24

STEP 14

STEP 2

BILD-14

BILD-02

Using compressed air, remove the piston (1) from the disc carrier.

Pull tapered roller bearing off the shaft with special tool CAS2798.

STEP 15

STEP 3 1 1

BILD-15

BILD-03

Remove both O-rings (1 and 2).

Snap out retaining ring (1).

STEP 1

STEP 4

7.3 K1 clutch

1 2

BILD-04 BILD-01

Remove stud bolt (1) and snap out piston ring (2).

Remove axial bearing assembly (1).

6003-25

STEP 5

STEP 8 1 3 2

BILD-05

BILD-08

Take off idler gear (1), remove needle cage (2) and axial bearing assembly (3).

Pull tapered roller bearing off the shaft with special tool CAS2798.

STEP 6

STEP 9 1

BILD-06

Pull clutch (1) off the shaft.

BILD-09

Unsnap snap ring (1).

NOTE: For disassembly of clutch see Steps 9-14.

STEP 10

STEP 7 1

1 2

2 3 BILD-10 BILD-07

Turn shaft (2) 180 degrees and snap out piston ring (1).

Remove end shim (1) and disc set (2) from the disc carrier (3).

6003-26

STEP 11

STEP 14

1 2

BILD-11

Preload cup springs using special tool 380001556 and unsnap L-ring (1).

BILD-14

Remove both O-rings (1 and 2).

STEP 1 STEP 12

7.4 K2 clutch

BILD-12 BILD-01

Remove cup spring package (1).

Remove stud bolt (1) and snap out piston ring (2).

STEP 13

STEP 2

BILD-13

Using compressed air, remove the piston (1) from the disc carrier.

BILD-02

Pull tapered roller bearing off the shaft using special tool CAS2798.

6003-27

STEP 3

STEP 6 1

1 BILD-03

Snap out retaining ring (1).

BILD-06

Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 9-14.

STEP 4

STEP 7

BILD-04

Remove axial bearing assembly (1).

BILD-07

Turn shaft (2) 180 degrees and snap out piston ring (1).

STEP 5

STEP 8

1 3 2

BILD-05

Remove idler gear (1), needle cage (2) and axial bearing assembly (3).

BILD-08

Pull tapered roller bearing off the shaft using special tool CAS2798.

6003-28

STEP 9

STEP 12 1

BILD-09

BILD-12

Unsnap snap ring (1).

Remove cup spring package (1).

STEP 10

STEP 13 1 1

3 BILD-10

BILD-13

Remove end shim (1) and disc set (2) from the disc carrier (3).

Using compressed air, remove the piston (1) from the disc carrier.

STEP 11

STEP 14

1 2

BILD-11

Preload cup springs using special tool 380001556 and unsnap L-ring (1).

BILD-14

Remove both O-rings (1 and 2).

6003-29

STEP 1

STEP 4

7.5 K3 clutch

1 1 3 2

BILD-04 BILD-01

Snap out piston ring (1).

Take off idler gear (1), remove needle cage (2) and axial bearing assembly (3).

STEP 5

STEP 2

BILD-05 BILD-02

Pull tapered roller bearing off the shaft using special tool CAS2798.

STEP 3

Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 8-13.

STEP 6 1 1

BILD-03

Remove axial bearing assembly (1).

BILD-06

Remove stud bolt (1) and snap out piston ring (2).

6003-30

STEP 7

STEP 10

BILD-07

BILD-10

Pull tapered roller bearing off the shaft using special tool CAS2798.

Preload cup springs using special tool 380001556 and unsnap L-ring (1).

STEP 8

STEP 11

BILD-08

BILD-11

Unsnap snap ring (1).

Remove cup spring package (1).

STEP 9

STEP 12 1 1

BILD-09

BILD-12

Remove end shim (1) and disc set (2) from the disc carrier (3).

Using compressed air, remove the piston (1) from the disc carrier.

6003-31

STEP 13

STEP 3

1 1 2

BILD-13

BILD-03

Remove both O-rings (1 and 2).

Snap out retaining ring (1).

STEP 1

STEP 4

7.6 K4 clutch

BILD-04 BILD-01

Pull clutch (1) off the shaft.

Remove stud bolt (1) and snap out piston ring (2).

NOTE: For disassembly of clutch see Steps 9-14.

STEP 2

STEP 5 1

BILD-02

BILD-05

Pull tapered roller bearing off the shaft using special tool CAS2798.

Remove axial bearing assembly (1) and idler gear (2).

6003-32

STEP 6

STEP 9 1 2

3 BILD-06

Remove needle cage (1) and axial bearing assembly (2). NOTE: The gear (3) cannot be removed, it is a shrink fit.

BILD-09

Unsnap snap ring (1).

STEP 10 1

STEP 7 1

3 2

BILD-10

Remove end shim (1) and disc set (2) out of the disc carrier (3). BILD-07

Turn shaft (2) by 180 degrees and snap out piston ring (1).

STEP 11

STEP 8

BILD-11

Preload cup springs using special tool 380001556 and unsnap L-ring (1). BILD-08

Pull tapered roller bearing off the shaft using special tool CAS2798.

6003-33

STEP 12

STEP 1 7.7 Input shaft

2 1

BILD-12

Remove cup spring package (1).

BILD-01

Snap out piston ring (1). Turbine wheel shaft and drive gear (2) are secured by a snap ring.

STEP 13

NOTE: When separated, the snap ring will be destroyed.

STEP 2

BILD-13

Using compressed air, remove the piston (1) from the disc carrier.

STEP 14 BILD-02

Pull tapered roller bearing off drive gear using special tool CAS2798.

1 2

BILD-14

Remove both O-rings (1 and 2).

6003-34

STEP 3

BILD-03

Pull tapered roller bearing off drive gear using special tool CAS2798. NOTE: It is not possible to separate the input shaft and gear (1). It is a shrink fit.

STEP 1 7.8 Output shaft

1 BILD-01

Pull tapered roller bearing off of output shaft using special tool CAS2798 and remove oil sheet (1).

STEP 2

BILD-02

Turn output shaft 180 degrees and pull off tapered roller bearing using special tool CAS2798.

6003-35

REASSEMBLY 8.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft

STEP 3 1

STEP 1 8.1KV Clutch

BILD-03

Mount bearing cage (1) onto the shaft and oil it.

STEP 4 BILD-01

Heat bearing to approximately +120° C (+248° F).

STEP 2 1

2 2 1

BILD-04

Install ball bearing (2) into the idler gear (1) until contact occurs and secure it using retaining ring (3).

STEP 5 BILD-02

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2). WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-05

Press pre-assembled idler gear (1) onto the shaft until contact occurs.

6003-36

STEP 6

STEP 9 4 3 1

2 1 S

BILD-06

BILD-09

Place both O-rings (1 and 2) into the piston grooves and oil them.

Mount inner installer (S) onto the disc carrier. Install disc (1), compression spring (2), support shim (3) and L-ring (4).

NOTE: Check function of the drain valve (see arrow). The ball must not jam.

NOTE: For installation position of support shim and L-ring see Step 11. (S) Inner installer, see Step 10.

STEP 7 STEP 10

1 S1 S2

BILD-07

Place piston (1) into the disc carrier.

BILD-10

Preload compression spring using special tool 380001556 (S1) and pressure piece (S2), until L-Ring has engaged into the annular grove.

NOTE: Observe installation position.

STEP 8

NOTE: Always use a new L-ring.

BILD-08

Use special tool 380001556 (S) to place piston into the disc carrier.

6003-37

STEP 11

STEP 12 1

5 6

2 3

7 4 4

BILD-11

Disc carrier with piston retraction:

BILD-12

Install outer and inner discs into the disc carrier (4).

1. Washer

1. Friction disc - coated on one side (1 pcs)

2. Compression spring

2. Outer discs (10 pcs)

3. Support shim

3. Inner discs (10 pcs)

4. L-Ring 5. Disc carrier 6. Drain valve (piston) 7. Piston with O-Rings

NOTE: Make sure that the uncoated (blank) side of the friction disc (1) is showing towards the piston. Number of friction surfaces is 18. NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version. NOTE: The actual installed clutch and disc arrangement must be taken from the corresponding spare parts list. The spare parts list is binding.

STEP 13

1 2

BILD-15

Mount end plate (1) and secure disc package using snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)/recommended value.

6003-38

STEP 14

STEP 16

BILD-16

Press on end plate with F (approximately 100 N = 10 kg) and set dial indicator to “zero”.

BILD-18

Heat clutch to approximately +120° C (+248° F).

STEP 17 STEP 15 L

BILD-19 BILD-17

Then press end plate against the snap ring (upwards) and read disc clearance. Disc clearance should be: 2.65 to 2.95 mm (0.104 to 0.116 in.). NOTE: In cases of deviation, the disc clearance must be corrected with the appropriate snap ring. Optional thicknesses range from 2.1 to 4.2 mm (0.08 to 0.17 in.).

Install clutch until contact is made. Mount inner discs onto the inner disc carrier using shor t left/right rotations. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 18 2

BILD-20

Secure clutch (1) using retaining ring (2).

6003-39

STEP 19

STEP 22

BILD-21

BILD-24

Heat bearing inner ring to approximately +120° C (+248° F).

Check clutch operation using compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

STEP 20 STEP 23 1

BILD-22

Mount bearing (1) until contact is made. Adjust bearing after it cools. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 21 2 1

BILD-23

Mount stud bolt (1), torque to 17 Nm (150 pound inches). Fit rectangular ring (2).

BILD-25

Install sealing cap on orifice (1). NOTE: Wet contact surface with Loctite (Type No. 262). NOTE: The sealing cap is not mounted on all versions. For versions concerned, see corresponding spare parts list.

6003-40

STEP 1

STEP 4

8.2 KR Clutch

3 2

BILD-04 BILD-01

Heat bearing to approximately +120° C (+248° F).

STEP 5

STEP 2

Install ball bearing (2) into the idler gear (1) until contact occurs and secure it using retaining ring (3).

2 1

BILD-05 BILD-02

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2). WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

Press in pre-assembled idler gear (1) onto the shaft until contact occurs.

STEP 6

STEP 3

1 1

3 2

BILD-06

Place both O-rings (1 and 2) into the piston grooves and oil them. BILD-03

Mount needle bearing (1) onto the shaft and oil it.

NOTE: Check function of the drain valve (3). The ball must not jam.

6003-41

STEP 7

STEP 10

S1 S2

BILD-07

Place piston (1) into the disc carrier.

BILD-10

Preload compression spring using special tool assembly 380001556 (S1) and pressure piece (S2), until L-Ring has engaged the annular grove.

NOTE: Observe installation position.

STEP 8

NOTE: Always use a new L-ring.

STEP 11 1

5 6 7 4 BILD-08

Use special tool 380001556 (S) to place piston into the disc carrier.

BILD-11

Disc carrier with piston retraction:

STEP 9

1. Washer

2. Compression spring

3. Support shim 4. L-Ring

5. Disc carrier

6. Drain valve (piston) 7. Piston with O-Rings.

BILD-09

Mount inner installer (S) onto the disc carrier. Install disc (1), compression spring (2), support shim (3) and L-ring (4). NOTE: Installation position support shim and L-ring see Step 11. (S) Inner installer, see Step 10.

6003-42

STEP 12

STEP 14

F 2 3

1 BILD-12

Install outer and inner discs into the disc carrier (4). 1. Friction disc - coated on one side (1 pcs)

BILD-16

Press on end plate (F) approximately 100 N = 10 kg and set dial indicator to “zero”.

STEP 15

2. Outer discs (10 pcs) 3. Inner discs (10 pcs) NOTE: Make sure that the uncoated (blank) side of the friction disc (1) is showing towards the piston. Number of friction surfaces is 18.

NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version. NOTE: The actual installed clutch and disc arrangement must be taken from the corresponding spare parts list. The spare parts list is binding.

STEP 13

BILD-17

Press end plate against the snap ring (upwards) and read disc clearance. Disc clearance should be 2.65 to 2.95 mm (0.104 to 0.116 in.).

1 2

NOTE: In cases of deviation, the disc clearance must be corrected with an appropriate snap ring. Optional thicknesses range from 2.1 to 4.2 mm (0.08 to 0.17 in.).

BILD-15

Mount end plate (1) and secure disc package using snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)/recommended value.

6003-43

STEP 16

STEP 19

BILD-18

BILD-21

Heat clutch to approximately +120° C (+248° F).

Heat bearing to approximately +120° C (+248° F).

STEP 17

STEP 20 L

BILD-19

BILD-22

Install clutch until contact is made. Mount inner discs onto the inner disc carrier using shor t left/right rotations.

Mount bearing (1) until contact is made. Adjust bearing after it cools.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 21 STEP 18 2 2

BILD-23 BILD-20

Secure clutch (1) using retaining ring (2).

Mount stud bolt (1) and torque to 17 Nm (150 pound inches). Fit rectangular ring (2).

6003-44

STEP 22

STEP 1 8.3 Clutch K1

BILD-24

Check clutch operation by using compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

BILD-01

Heat bearing to approximately +120° C (+248° F).

STEP 2

STEP 23

BILD-25

Install sealing cap on orifice (1). NOTE: Wet contact surface with Loctite (Type No. 262). NOTE: The sealing cap is not mounted on all versions. Versions concerned, see corresponding spare parts list.

BILD-02

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2). WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

6003-45

STEP 3

STEP 6 2 1 1

3 2

BILD-03

BILD_06

Place both O-rings (1 and 2) into the piston grooves and oil them.

Mount inner installer (S) onto the disc carrier. Install cup spring package (1) and L-ring (2).

NOTE: Check function of the drain valve (3). There must be no jamming of the ball.

NOTE: For installation position of cup spring package and L-ring see Step 8. (S) Inner installer, see Step 7.

STEP 4 STEP 7

1 S2

BILD-04

Place piston (1) into the disc carrier.

BILD-07

Preload cup spring package using special tool 380001556 (S1) and pressure piece (S2), until L-Ring has engaged the annular grove.

NOTE: Observe installation position.

STEP 5

NOTE: Always use a new L-ring.

BILD-05

Use special tool 380001556 (S) to place piston into the disc carrier.

6003-46

STEP 8

STEP 10 1

2 1

BILD-08

Disc carrier with piston retraction:

BILD-11

Mount end plate (1) and secure disc package using snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)/recommended value.

1. Cup spring package 2. L-Ring

STEP 11

3. Disc carrier 4. Piston with O-rings

STEP 9

BILD-12

1 BILD-09

Install outer and inner discs into the disc carrier (4). 1. Friction disc - coated on one side (1 pcs) 2. Outer discs (9 pcs) 3. Inner discs (9 pcs) NOTE: Make sure that the uncoated (blank) side of the friction disc (1) is showing towards the piston. Number of friction surfaces is 16. NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version. NOTE: The actual installed clutch and disc arrangement must be taken from the corresponding spare parts list. The spare parts list is binding.

Press on end plate (F) approximately 100 N = 10 kg and set dial indicator to “zero”.

6003-47

STEP 12

STEP 14 F 1

BILD-13

Press end plate against the snap ring (upwards) and read disc clearance. Disc clearance should be 2.35 to 2.65 mm (0.092 to 0.104 in.). NOTE: In cases of deviation, the disc clearance must be corrected with an appropriate snap ring. Optional thicknesses range from 2.1 to 4.2 mm (0.08 to 0.17 in.).

BILD-15

Install clutch (1) until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 15 3

STEP 13

BILD-16

Mount running disc (1), axial cage (2) and axial washer (3) and oil it. BILD-14

Heat clutch to approximately +120° C (+248° F).

NOTE: Install chamfer (see arrow) of running disc (1) showing towards the axial cage.

STEP 16 1

BILD-17

Mount needle bearing (1) and oil it.

6003-48

STEP 17

STEP 20 L

R 1

BILD-18

Install (1) idler. Mount inner discs onto the inner disc carrier (idler) by using short left/right rotations.

BILD-21

Heat bearing to approximately +120° C (+248° F).

STEP 21 STEP 18 1

2 1

BILD-22 BILD-19

Mount axial washer (1), axial cage (2) and running disc (3) and oil it.

Mount bearing (1) until contact is made. Adjust bearing after it cools.

NOTE: Install chamfer (see arrow) of running disc (3) showing towards the axial cage.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 19

STEP 22 1

BILD-20

BILD-23

Secure idler gear (1) and single par ts by using retaining ring (2).

Mount stud bolt (1) and torque to 17 Nm (150 pound inches). Fit rectangular ring (2).

6003-49

STEP 23

STEP 2 1

BILD-24

BILD-02

Check clutch operation by using compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2).

STEP 1

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

8.4 Clutch K2

STEP 3

1 3 2

BILD-01

Heat bearing to approximately +120° C (+248° F).

BILD-03

Place both O-rings (1 and 2) into the piston grooves and oil them. NOTE: Check function of the drain valve (3). There must be no jamming of the ball.

6003-50

STEP 4

STEP 7

1 S1

BILD-04

Place piston (1) into the disc carrier.

BILD-07

Preload cup spring package using special tool 380001556 (S1) and pressure piece (S2), until L-Ring has engaged into the annular grove.

NOTE: Observe installation position.

STEP 5

NOTE: Always use a new L-ring.

STEP 8 1

BILD-05

Use special tool 380001556 (S) to place piston into the disc carrier.

BILD-08

Disc carrier with piston retraction:

STEP 6

1. Cup spring package

2. L-Ring 3. Disc carrier 4. Piston with O-rings

BILD_06

Mount inner installer (S) onto the disc carrier. Install cup spring package (1) and L-ring (2). NOTE: For installation position cup spring package and L-ring see Step 8. (S) Inner installer, see Step 7.

6003-51

STEP 9

STEP 11

F 2

BILD-09

Install outer and inner discs into the disc carrier (4). 1. Friction disc - coated on one side (1 pcs)

BILD-12

Press on end plate with (F) approximately 100 N = 10 kg and set dial indicator to “zero”.

STEP 12

2. Outer discs (7 pcs) 3. Inner discs (7 pcs) NOTE: Make sure that the uncoated (blank) side of the friction disc (1) is showing towards the piston. Number of friction surfaces is 12.

STEP 10

BILD-13

Press end plate against the snap ring (upwards) and read disc clearance. Disc clearance should be 1.75 to 2.05 mm (0.069 to 0.081in.) see Step 9.

NOTE: In cases of deviation, the disc clearance must be corrected with an appropriate snap ring. Optional thicknesses range from 2.1 to 4.2 mm (0.08 to 0.17 in.).

BILD-11

Mount end plate (1) and secure disc package using snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)/recommended value.

6003-52

STEP 13

STEP 16 1

BILD-14

BILD-17

Heat clutch to approximately +120° C (+248° F).

Mount needle bearing (1) and oil it.

STEP 14

STEP 17 L

1 1

BILD-15

Mount clutch (1) until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-18

Install (1) idler. Mount inner discs onto the inner discs carrier (idler) by using short left/right rotations.

STEP 18 3

STEP 15

2 1

BILD-19

BILD-16

Mount running disc (1), axial cage (2) and axial washer (3) and oil it. NOTE: Install chamfer (see arrow) of running disc (1) showing towards the axial cage.

Mount axial washer (1), axial cage (2) and running disc (3) and oil it. NOTE: Install chamfer (see arrow) of running disc (3) showing towards the axial cage.

6003-53

STEP 19

STEP 22 2

BILD-20

BILD-23

Secure idler gear (1) and single parts using retaining ring (2).

Mount stud bolt (1) and torque to 17 Nm (150 pound inches). Fit rectangular ring (2).

STEP 20

STEP 23

BILD-21

Heat bearing to approximately +120° C (+248° F).

STEP 21

BILD-24

Check clutch operation by using compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

STEP 1 1

8.5 Clutch K3

BILD-22

Mount bearing (1) until contact is made. Adjust bearing after it cools. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-01

Heat bearing to approximately +120° C (+248° F).

6003-54

STEP 2

STEP 4 3

2 1

BILD-02

BILD-04

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2). Mount stud bolt and torque to 17 Nm (150 pound inches).

Place piston (1) into the disc carrier.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 5

NOTE: Observe installation position.

STEP 3 S 1 3 2

BILD-05

Use special tool 380001556 (S) to place piston into the disc carrier. BILD-03

STEP 6

Place both O-rings (1 and 2) into the piston grooves and oil them.

NOTE: Check function of the drain valve (3). There must be no jamming of the ball.

BILD_06

Mount inner installer (S) onto the disc carrier. Install cup spring package (1) and L-ring (2). NOTE: For installation position of cup spring package and L-ring see Step 8. For inner installer (S), see Step 7.

6003-55

STEP 7

STEP 9

2 3

4 BILD-07

Preload cup spring package using special tool 380001556 (S1) and pressure piece (S2), until L-Ring has engaged into the annular grove.

BILD-10

Install outer and inner discs into the disc carrier (4). 1. Friction disc - coated on one side (1 pcs) 2. Outer discs (7 pcs)

NOTE: Always use a new L-ring.

3. Inner discs (7 pcs)

STEP 8 1

NOTE: Make sure that the uncoated (blank) side of the friction disc (1) is showing towards the piston. Number of friction surfaces is 12.

NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version.

NOTE: The actual installed clutch and disc arrangement must be taken from the corresponding spare parts list. The spare parts list is binding.

STEP 10 BILD-08

Disc carrier with piston retraction: 1. Cup spring package

1 2

2. L-Ring 3. Disc carrier 4. Piston with O-rings.

BILD-11

Mount end plate (1) and secure disc package using snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)/recommended value.

6003-56

STEP 11

STEP 13

BILD-12

BILD-14

Press on end plate with (F) approximately 100 N = 10 kg and set dial indicator to “zero”.

Heat clutch inner diameter to approximately +120° C (+248° F).

STEP 12

STEP 14 F

BILD-13

Press end plate against the snap ring (upwards) and read disc clearance. Disc clearance should be 1.75 to 2.05 mm (0.069 to 0.081 in.). NOTE: In cases of deviation, the disc clearance must be corrected with an appropriate snap ring. Optional thicknesses range from 2.1 to 4.2 mm (0.08 to 0.17 in.).

BILD-15

Mount clutch (1) until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

6003-57

STEP 15

STEP 18 3

3 2

BILD-16

BILD-19

Mount running disc (1), axial cage (2) and axial washer (3) and oil it.

Mount axial washer (1), axial cage (2) and running disc (3) and oil it.

NOTE: Install chamfer (see arrow) of running disc (1) showing towards the axial cage.

NOTE: Install chamfer (see arrow) of running disc (3) showing towards the axial cage.

STEP 16

STEP 19 1

BILD-17

Mount needle bearing (1) and oil it.

BILD-20

Make sure that the running disc is flush with the shaft collar (see arrow) to ensure that all inner discs are mounted on the idler gear teeth.

STEP 17

STEP 20 1 L

BILD-18

Install (1) idler. Mount inner discs onto the inner disc carrier (idler) using short left/right rotations.

BILD-21

Heat bearing to approximately +120° C (+248° F).

6003-58

STEP 21

STEP 1 8.6 K4 Clutch

BILD-22

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2). WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-01

Heat bearing to approximately +120° C (+248° F).

STEP 2 2

STEP 22

BILD-02

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit angular ring (2). BILD-23

Check clutch operation by using compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

6003-59

STEP 3

STEP 5 2

BILD-03

BILD-05

Cool shaft (1) to approximately -80° C (-112° F), heat gear (2) to approximately +120° C (+248° F) and mount until contact is made.

Mount lower axial washer (1), axial needle cage (2) and upper axial washer (1) and oil it.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

NOTE: Upper and lower axial washer are identical.

STEP 6 1

STEP 4

1 BILD-06

Mount needle bearing (1) and oil it. BILD-04

STEP 7

Secure gear using retaining ring (1).

BILD-07

Mount idler gear (1).

6003-60

STEP 8

STEP 10 3 2 1

BILD-08

Mount axial washer (1), axial needle bearing (2) and running disc and oil it. NOTE: Mount running disc (3) with the chamfer (see arrow) pointing to the needle cage.

BILD-10

Place piston (1) into the disc carrier. NOTE: Observe installation position.

STEP 11

STEP 9 S 1 3 2 BILD-11

BILD-09

Place both O-rings (1 and 2) into the piston grooves and oil them.

Use special tool 380001556 (S) to place piston into the disc carrier.

STEP 12

NOTE: Check function of the drain valve (3). There must be no jamming of the ball.

BILD-12

Mount inner installer (S) onto the disc carrier. Install cup spring package (1) and L-ring (2). NOTE: For installation position of cup spring package and L-ring see Step 14. For inner installer, see Step 13.

6003-61

STEP 13

STEP 15

S2 S1

4 BILD-13

Preload cup spring package using special tool 380001556 (S1) and pressure piece (S2), until L-Ring has engaged into the annular groove.

BILD-15

Install outer and inner discs into the disc carrier (4). 1. Friction disc - coated on one side - (1pcs) 2. Inner discs (5 pcs)

NOTE: Always use a new L-ring.

3. Outer discs (5 pcs)

STEP 14 1

NOTE: Make sure that the uncoated (blank) side of the friction disc (1) is showing towards the piston. Number of friction surfaces is 10.

NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version.

NOTE: The actual installed clutch and disc arrangement must be taken from the corresponding spare parts list. The spare parts list is binding.

STEP 16 BILD-14

Disc carrier with piston retraction: 1. Cup spring package

2. L-ring 3. Disc carrier 4. Piston with O-rings

BILD-16

Mount end plate (1) and secure disc package using a snap ring (2) e.g. thickness = 2.65 mm (0.104 in.)/recommended value.

6003-62

STEP 17

STEP 19

BILD-17

BILD-19

Press on end plate with (F) approximately 100 N = 10 kg and set dial indicator to “zero”.

Heat clutch inner diameter to approximately +120° C (+248° F).

STEP 18

STEP 20 F

BILD-18

BILD 20

Press end plate against the snap ring (upwards) and read disc clearance. Disc clearance should be 1.35 to 1.65 mm (0.053 to 0.65 in.) see Step 15.

Mount clutch (1) until contact is made. Mount inner discs onto the inner disc carrier using short left/right rotations.

NOTE: In cases of deviation, the disc clearance must be corrected with an appropriate snap ring. Optional thickness range from 2.1 to 4.2 mm (0.08 to 0.17 in.).

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 21

BILD-21

Secure clutch using retaining ring (1).

6003-63

STEP 22

STEP 24

BILD-22

BILD-24

Heat bearing inner ring to approximately +120° C (+248° F).

Check clutch operation by using compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

STEP 23 STEP 1 2

8.7 Input shaft

3 1

1 BILD-23

Mount bearing (1) until contact is made. Adjust bearing after it cools. Fit rectangular ring (2). Mount stud bolt (3). Torque to 17 Nm (150 pound inches). WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-01

Cool input shaft (1) to approximately -80° C (-112° F) and heat drive gear (2) to approximately +120° C (+248° F). Mount until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.

6003-64

STEP 2

STEP 5

BILD-02

BILD-05

Secure drive gear using retaining ring (1).

Heat bearing to approximately +120° C (+248° F).

STEP 3

STEP 6

BILD-03

Heat bearing to approximately +120° C (+248° F).

STEP 4

BILD-06

Mount bearing (1) until contact is made. Adjust bearing after it cools. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 7

2 BILD-04

Mount bearing (1) until contact is made. Adjust bearing after it cools. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-07

Install snap ring (1) into the annular groove of the turbine shaft (2).

6003-65

STEP 8

STEP 1 8.8 Output Shaft

1 2

BILD-08

Mount turbine shaft (1) until the snap ring engages into the input shaft groove. Snap in and interlock rectangular ring (2).

BILD-01

Heat bearing to approximately +120° C (+248° F).

STEP 2

NOTE: Turbine shaft is axially secured.

STEP 9 1

3 1

2 BILD-02

BILD-09

Version with lock-up clutch: Mount turbine shaft (1) until the snap ring engages into the input shaft groove. Snap in and interlock rectangular ring (2 and 3). NOTE: Turbine shaft is axially secured.

Mount bearing (1) until contact is made. Adjust bearing after it cools. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 3 1

BILD-03

Mount screen sheet (1).

6003-66

STEP 4

9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches STEP 1

BILD-04

Heat bearing to approximately +120° C (+248° F).

2 STEP 5 BILD-01

NOTE: If the suction tube (1) in the front housing is to be replaced, a special rolling tool 380001285 (EU) must be used for assembly. North American Dealers contact special tools. Secure the tube with cylindrical bolt (2). Torque to 23 Nm (17 pound feet).

NOTE: Oil cylindrical bolt. It is always necessary to use new cylindrical bolts.

STEP 2 BILD-05

Mount bearing (1) until contact is made. Adjust bearing after it cools. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

BILD-02

NOTE: The lubricating oil tube (1) is supplied as a complete package with the front housing only. Single parts delivery are available only upon request. NOTE: Assembly is only possible with special tool 380001286 (EU), North American Dealers contact special tools.

6003-67

STEP 3 3

STEP 5 3 1

4 BILD-03

BILD-05

Mount O-rings into the oil tube annular grooves (1 and 2) and oil them. Then insert tubes into the front housing. Oil cylindrical bolts (3 and 4) and secure them. Torque to 23 Nm (17 pound feet).

NOTE: The lubricating oil tubes (1 and 2) are supplied as a complete package with the rear housing. Single parts delivery available only upon request.

NOTE: Always use new cylindrical bolts.

NOTE: Assembly is only possible with special tool380001287 (EU), North American Dealers contact special tools.

STEP 4

STEP 6 4 1

3 6 1

7 2

8 5 2

BILD-04

Mount O-rings into the oil tube annular grooves (1 and 2) and oil them. Then insert tubes into the front housing.

BILD-06

Insert all bearing outer rings into the bearing holes of both housing sections. Front housing. 1. Input 2. Output 3. Forward clutch 4. Reverse clutch 5. K1 = 1st gear clutch 6. K2 = 2nd gear clutch 7. K3 = 3rd gear clutch 8. K4 = 4th gear clutch. NOTE: For installation position, see Step 6 and 7.

6003-68

STEP 7

STEP 9 1

1 8

6 7

BILD-07

Rear housing legend see Figure 6. Place bearing outer rings into the bearing holes using assembly grease.

BILD-09

Slightly lift drive gear (1) and position K4 clutch (2).

STEP 10

NOTE: If contrary to manufacturer recommendation, the tapered roller bearings of clutches, input and output are not replaced, you must ensure the previous pairing (bearing inner ring/bearing outer ring) - see disassembly instructions.

STEP 8 2 1 BILD-10

Mount K3 clutch (1).

STEP 11

BILD-08

Place KR clutch (1), AN input shaft (2) and KV clutch (3) into the housing rear section at the same time. WARNING: Risk of injury. NOTE: Due to installation conditions, the installation of single clutches without using the special tool is not possible. NOTE: Housing rear section will be removed again later.

BILD-11

Position K2 clutch (1).

6003-69

STEP 12

STEP 15

5 2

2 6

1 3 4 S

BILD-12

Slightly lift K4 clutch (1) and position K1 clutch (2).

STEP 13

BILD-15

Secure clutches K1 (1), K2 (2), K3 (3) and K4 (4) by using a special handle tool 380001557 (S). Check all rectangular rings, grease and align them centrically. NOTE: This step shows the installation position of the individual clutches in the rear housing. WARNING: Clutches KV (5), KR (6) and input shaft AN (7) are only secured by the gear chain. Care must be taken to ensure these non-secured components do not detach.

STEP 16 3

1 BILD-13

Press ball bearing (1) onto the pump shaft (2) until contact is made. Mount rectangular ring (3). Grease and centrically align rectangular ring.

STEP 14

1 2

4 BILD-16

Pivot rear housing 180 degrees by using a suitable lifting device. 1. Clutch KV 2. Input shaft 3. Clutch KR

4. Pump shaft.

2 BILD-14

Mount pump shaft (1) until contact is made. Attach pump shaft using retaining ring (2).

WARNING: Clutches KV, KR and input shaft (2) are only secured by the gear chain. Care must be taken to ensure these non-secured components do not detach.

6003-70

STEP 17

STEP 20 4

BILD-17

BILD-20

Use the suitable lifting device to bring the rear housing into contact position with the front housing by cautiously assembling the clutches. Then remove handles.

Oil cylindrical bolts (1) and use them to attach screen sheet (1). Torque to 23 Nm (17 pound feet). Mount O-rings (2) into the annular grooves of the oil tubes and oil them. Mount all rectangular rings (4), grease and align them centrally. Wet mounting face (3) with sealing agent Loctite (type No. 574).

STEP 18

NOTE: Always use new cylindrical bolts.

STEP 21

BILD-18

Remove the rear housing again.

STEP 19

BILD-21

Carefully bring the front housing into contact position with the rear housing by using a suitable lifting device.

NOTE: Be sure that both oil tubes are aligned with the holes in the rear housing.

BILD-19

Position screen sheet (1). Install pre-assembled output shaft (2).

6003-71

STEP 22

STEP 24 1

BILD-22

BILD-24

Fit both cylindrical pins (1) centrically to the mounting face

Join front and rear housing sections using cylindrical bolts (1). Torque to 46 Nm (34 pound feet). Mount securing plate (2). Mount stud bolts (3) and torque to 15 Nm (133 pound inches).

STEP 23

NOTE: Wet bolt-in thread with Loctite (type No. 243).

S STEP 25 1

BILD-23

Check clearance of the gear drive train. Position driving element (S) and rotate KV clutch shaft. Driving element can be fabricated by dealer. NOTE: If interference of the movable parts (e.g. on the screen sheet or on the oil tubes) is found, it must be corrected. Do this step on all clutch shafts.

BILD-25

The bolt plugs (1) must be mounted with a hydraulic pneumatic pressing tool. NOTE: In case of damage the pre-mounted rear transmission housing must be fully replaced.

6003-72

10.0 Outputs and closure parts pump shaft (PTO-shaft)

STEP 3

STEP 1

10.1 Output flange output side with brake FSG-88

BILD-16

BILD-14

Use driver tool 380001560 (S) to mount shaft seal with the sealing lip showing to the oil sump. Fill space between sealing lip and dust lip with grease. Wet outer diameter (rubber-coated) with mineral spirit. NOTE: Use of specified driver (S) ensures the exact installation position.

Insert O-ring into the space between output flange and shaft. Attach output flange (1) using washer (2) and hex bolts. Oil hex bolts before the assembly. Torque to 46 Nm (34 pound feet). Mount cylindrical bolt with washer (3) for stop of the parking brake set screw. Tightening torque 48 Nm (35 pound feet). NOTE: Always use new hex bolts.

STEP 4

NOTE: For installation position of shaft seal see Step 4.

2 1

STEP 2

2 1

BILD-17

BILD-15

Press screen sheet (1) onto the output flange (2). Mount output flange (2) until contact is made.

Secure brake disc (1) at output flange (2) using hex bolts and washers. Torque to 68 Nm (50 pound feet). Connect a hand-operated pump at port (see arrow) and apply approximately 80 bar (1160 PSI) pressure to the parking brake (3) and bring it in contact position.

6003-73

STEP 5

STEP 7 2 1

BILD-18

BLD-20

Attach parking brake (1) on transmission housing using the hex bolt - guide pin (2). Torque to 46 Nm (34 pound feet).

Insert setting gauge on both sides between base disc and brake disc and hold in its position. Clearance: 0.5 - 1.5 mm (0.020 - 0.059 in.). Nominal clearance: 1.0 mm (0.039 in.).

STEP 6

NOTE: For all installation, fitting and maintenance instructions, functional characteristics and setting specifications of the parking brake, see manufacturer’s documentation.

STEP 8 10.2 Output flange on converter side (Standard versions)

BILD-19

Secure hex nut on brake caliper using the open end wrench insert. Torque to 230 Nm (170 pound feet).

BILD-26

Use driver tool 380001560 (S) to mount shaft seal, with the sealing lip showing to the oil sump. NOTE: Use of the specified driver (S) ensures the exact installation position. NOTE: Fill space between sealing lip and dust lip with grease. NOTE: For installation position shaft seal see Step 34.

6003-74

STEP 9

STEP 11 2 1

5 BILD-27

1. Shaft seal

BILD-29

3. Roller bearing

Insert O-ring into the space between output flange and shaft. Secure output flange (1) using washer (2) and hex bolts (3). Oil hex bolts before the assembly. Torque to 46 Nm (34 pound feet).

4. Output shaft

NOTE: Always use new hex bolts.

2. Gearbox housing - rear section

5. Screen sheet

STEP 10 2 1

BILD-28

Press screen sheet (1) onto the input flange (2). Mount output flange (2) until contact is made.

6003-75

11.0 Reassembly: Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring point “63” after the converter as described in the specifications, pressure checks and troubleshooting section of the manual)

STEP 3

STEP 1 11.1 Converter back-pressure valve

BILD-03

Mount temperature sensor (1) with O-ring. Torque to 25 Nm (18 pound feet).

NOTE: For version without a temperature sensor, fit a plug (1) with O-ring and torque to 25 Nm (18 pound feet).

STEP 4 11.2 Oil pressure pump

4 BILD-01

The Step shows the single parts of the converter back-pressure valve. 1. Oil feed housing

2. Piston

3. Compression spring 4. Pressure plate

5. Locking plate. NOTE: Install pressure plate (4), with the pin (6 mm diameter) facing towards the locking plate (1).

BILD-04

Insert pressure relief valve (1) into the housing hole until contact is made. Mount two M8 adjusting bolts (S) and position gasket (2) and oil feed housing (3). Use assembly grease.

STEP 2

NOTE: The pressure relief valve is not mounted on all versions. Versions concerned, see the corresponding spare parts list.

2 1

BILD-02

Assemble single par ts, preload them with screwdriver (1) and secure them with the locking plate (2).

6003-76

STEP 5

STEP 8 1 1

2 BILD-05

BILD-08

Install two adjusting bolts (S) and mount stator shaft (1).

Position control disc and secure it radially using two cylindrical bolts (1). Place O-ring (2) into the annular groove and oil it.

NOTE: Pay attention to radial installation position.

NOTE: Do not tighten the cylindrical bolts - only turn them in until contact is made and then turn them back by approximately 1/2 a turn. Pay attention to the installation position of the control disc in figure.

STEP 6

STEP 9

BILD-06

Install outer rotor with the chamfer (see arrow) facing downwards. NOTE: If there are wear marks in the pump housing or on the control disc, replace the pump assembly.

STEP 7

2 BILD-09

With the sealing lip positioned facing downward, carefully insert the shaft seal (1) into the pump housing with suitable driver (2) until contact is made. NOTE: Wet outer diameter of shaft seal with mineral spirits.

BILD-07

Install inner rotor with the teeth (see arrow) facing upwards.

6003-77

STEP 10

STEP 13 1

4 3 S

BILD-10

BILD-13

Oil sliding bearing (see arrow) before assembly. Mount inner installer (S) onto the stator shaft. Mount pre-assembled transmission pump (1).

Secure oil feed housing (1) equally using Torx bolts (2). Torque to 23 Nm (17 pound feet). Secure plate (3) using cylindrical bolts (4). Torque to 34 Nm (25 pound feet).

NOTE: Pay attention to radial installation position.

STEP 14

STEP 11

BILD-14 BILD-11

Mount pre-assembled pump with driver (S) until contact is made.

STEP 12

BILD-12

Grease O-rings and fit them to the cylindrical bolts (1). Secure transmission pump (2) using cylindrical bolts. Torque to 46 Nm (34 pound feet).

Secure converter bell housing (1) using hex bolts (2). Torque to 65 Nm (48 pound feet).

6003-78

STEP 15

STEP 17

11.3 Engine connection (remote mount)

1 2

BILD-20 BILD-18

Bolt input shaft (1) to flex plate (2) using hex bolts (3). Torque to 115 Nm (85 pound feet).

Install ball bearing (1) and secure it using V-ring (2).

STEP 18

NOTE: Wet threads of hex bolts with Loctite (Type No. 262).

STEP 16 1

3 BILD-21

Put cover (1) onto the converter and press it until contact is made.

BILD-19

Secure flex plate (1) to converter (3) using hex bolts (2). Torque to 115 Nm (85 pound feet).

NOTE: Support the pressure sleeve (S) on the bearing inner ring.

STEP 19

NOTE: Wet threads of hex bolts with Loctite (Type No. 262).

1 2

BILD-22

Press screen sheet (1) onto the input flange (2).

6003-79

STEP 20

STEP 22 2 1

BILD-23

BILD-25

Heat flange inner diameter to approximately +120° C (+248° F).

Secure input flange (3) using washer (1) and hex bolts (2). Oil hex bolts before assembly. Torque to 34 Nm (25 pound feet).

STEP 21

NOTE: Always use new hex bolts.

STEP 23

BILD-24

Mount input flange (1) until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

2 BILD-26

Position converter using a suitable lifting device until the cover (1) is in contact with the converter bell housing (2).

6003-80

STEP 24

STEP 2

2 3 BILD-27

BILD-02

Bolt converter bell housing (1) to cover (2) using cylindrical bolts and hex nuts (3). Torque to 46 Nm (34 pound feet).

Attach cover using hex bolts (1). Torque to 23 Nm (17 pound feet).

NOTE: Pay attention to radial installation position markings made during disassembly (see arrows).

12.0 Reassembly - Emergency steering pump STEP 1 12.1 Version without emergency steering pump

BILD-01

Install adjusting bolts (S) and assemble seal (1) and cover (2).

6003-81

13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug

STEP 2 4

STEP 1 1

5 1 BILD-02

Mount oil drain plug with O-ring (1) and torque to 80 Nm (59 pound feet). Attach oil level tube (2) with seal to the housing front section and secure it using hex bolts (3). - torque to 34 Nm (25 pound feet). Fasten dipstick (4) in oil level tube. Attach identification plate (5) to the housing front section.

7 5

8 BILD-01

Mount inductive sensors (1,2 and 3) with O-rings and torque to 30 Nm (22 pound feet). 1. Inductive sensor - turbine speed 2. Inductive sensor - speed/central gear chain 3. Inductive sensor - engine speed. Mount breather (4) and torque to 12 Nm (106 pound inches). Mount speed sensor (Hall sensor) - output speed (5) with O-ring. Secure it using a cylindrical bolt (6) and torque to 23 Nm (17 pound feet). Mount plug (7) with O-ring and torque to 80 Nm (59 pound feet). Attach cover (8) with seal to the housing front section securing it with hex bolts (9), torque to 23 Nm (17 pound feet).

NOTE: Use Loctite (type No. MS 9360).

6003-82

14.0 Reassembly Electro-hydraulic control with proportional valves STEP 1 Main pressure valve 16+2 bar

Pressure reducing valve 9 bar

Wiring harness

B B Cover

Cover

Valve block

Housing

CHAPTER 14 - FIG. 1.PNG

Electro-hydraulic Control NOTE: Different versions regarding the wiring harness position are possible. Please observe the vehicle manufacturer’s specifications. The following sketches show the sectional views of the electro-hydraulic control.

Housing

6003-83

STEP 2 Proportional valve P5 Vibration damper

Pressure controller Follow-on slide CHAPTER 14 - FIG. 2.PNG

STEP 3 Main pressure valve 16+2 bar

Wiring harness

Valve block

Pressure reducing valve 9 bar

Duct plate

CHAPTER 14 - FIG. 3.PNG

Main Pressure Valve

STEP 4 14.1 Fitting of electric control

BILD-04

NOTE: Check all single parts for damage and replace if required. Ensure free travel of the moving parts in the valve block before installation. Pistons can be exchanged individually. Before installation, oil single parts. With the concave side facing upward, insert orifice (1) until contact is made.

6003-84

STEP 5

STEP 7 2

3 S

BILD-05

NOTE: See arrows for installation position. This Step shows the following single parts: 1. Pressure reducing compression spring)

valve

(1x,

BILD-07

Fit adjusting bolts 380001577 (S). Mount seal (1) and housing (2). Then position housing equally using the adjusting bolts until contact is made.

piston

and

STEP 8

2. Vibration damper (3x, piston and compression spring)

3. Follow-on slide (3x, piston and compression spring)

STEP 6

BILD-08

Bring housing (1) into contact position using the Torx bolts. This preloads the pistons, allowing removal of the cylindrical pins (assembly aid).

STEP 9 BILD-06

Install the single parts shown in Step 5. Preload compression springs of the follow-on slides and temporarily secure pistons using 5.0 mm diameter cylindrical pins (S).

BILD-09

Secure housing using the Torx bolts (1) and torque to 5.5 Nm (49 pound inches).

6003-85

STEP 10

STEP 12 1

3 2

BILD-10

BILD-12

Mount pressure controllers with O-ring (1) and secure them using securing plates (2) and Torx bolts (3). Torque to 5.5 Nm (49 pound inches).

Install the single parts shown in Step 11. Preload the compression springs of the follow-on slides and temporarily fasten the pistons using the 5.0 mm diameter cylindrical pins (S).

NOTE: Install securing plate with the claw side facing downward. Pay attention to the radial installation position of pressure controllers.

Install two adjusting bolts (S). Assemble flat gasket (1) and housing cover. Place the housing cover equally until contact by using the adjusting bolts.

STEP 11 STEP 13

1 1

2 BILD-11

Preassemble the opposite side with the following single parts: 1. Main pressure valve compression spring)

(1x,

Piston

and

2. Vibration damper (3x, Piston and compression spring) 3. Follow-on slide (3x, Piston and compression spring).

BILD-13

Preload the pistons with Torx bolts and remove the cylindrical pins (assembly aid) again. Then secure the housing cover using Torx bolts (1). Torque to 5.5 Nm (49 pound inches).

6003-86

STEP 14

STEP 16

BILD-14

BILD-16

Mount the pressure regulators with O-ring (1) and fasten them using securing plates and cap screws. Torque to 5.5 Nm (49 pound inches).

Install flat gasket (1) and assemble the plug socket with the slot facing the lug of the cover until it makes contact. Secure the cover using cap screws and torque to 5.5 Nm (49 pound inches).

NOTE: Install the securing plate with the neck facing downward. Observe radial installation position of the pressure regulators.

STEP 17 1

STEP 15 1

BILD-17

BILD-15

Assemble the wiring harness (1) and connect the pressure regulators. NOTE: See Step 1 for installation position of pressure regulators. Pay attention to the installation position of the wiring harness - see markings made during disassembly.

Secure the wiring harness using the retaining clamp (1). Install the opposite cover. NOTE: For version with torque converter lock-up clutch solenoid valve, go to Steps 29 & 30.

STEP 18 S

BILD-18

Install two adjusting bolts (S).

6003-87

STEP 19

STEP 21 1

BILD-19

BILD-21

Flush-mount screens (1) into the holes of the sealing plate, see arrows.

Position duct plate (1) and secure it equally using Torx bolts (2). Torque to 10.5 Nm (93 pound inches).

NOTE: Pay attention to the installation position, screens should face upwards toward the duct plate.

STEP 22

STEP 20 2

1 3

BILD-22

BILD-20

Attach sealing plate (1) and duct plate (2). Screens (3) should face upward.

Install bolt plugs with O-rings (1) and torque them to 6 Nm (53 pound inches).

STEP 23

NOTE: Do not re-assemble the seal plate after opening the threaded joint shift unit/duct plate. In case of repair, always mount a new seal plate.

BILD-23

Insert converter safety valve (1) into the housing hole until contact is made.

6003-88

STEP 24

STEP 26 2

BILD-24

BILD-26

Mount stud bolts (1) and torque to 15 Nm (133 pound inches).

Mount compression spring (4), piston (3) and switch (2) with new O-ring. Torque to 30 Nm (22 pound feet).

NOTE: Wet bolt-in thread with Loctite (Type No. 243). Position seal (2) and duct plate (3) on the rear housing until contact is made.

1. Filter differential pressure valve 2. Switch with O-ring 3. Piston 4. Compression spring

NOTE: Use assembly grease.

STEP 27

STEP 25

S 2

3 2

1 BILD-27 BILD-25

Secure duct plate (1) using Torx bolts (2) and hex nuts (3). Torque to 23 Nm (17 pound inches). Mount plug (4) with new O-ring and torque to 30 Nm (22 pound feet).

Fit two adjusting bolts (S). Mount sealing plate (1) and electro-hydraulic control unit (2). NOTE: Do not re-assemble the seal plate after opening the threaded joint of the shift unit/gearbox housing. In the case of repair, a new seal plate must be mounted.

6003-89

STEP 28

STEP 30 1

3 2 4

2 1

BILD-28

BILD-30

Secure electro-hydraulic control unit (1) evenly using Torx bolts (2) and torque them to 9.5 Nm (84 pound inches).

Secure pressure controller (1) using cylindrical bolts (2) and torque to 10 Nm (89 pound inches). Fit bolt necks (3) with O-ring and torque to 25 Nm (18 pound feet). Fit plug (4) with O-ring and torque to 10 Nm (89 pound inches).

NOTE: For version with torque converter lock-up clutch solenoid valve, go to Steps 31 and 32.

NOTE: Go back to Step 18.

STEP 29 14.2 Version with torque converter lock-up clutch solenoid valve

STEP 31 Pipe - System pressure to lock-up clutch valve.

3 2

2 3 1 BILD-29

BILD-31

Position seal (1) and secure connecting housing (2) using Torx bolts (3). Tightening torque 5.5 Nm (49 pound inches).

Secure pipe (1) with hollow bolt (2) and bolt nut (3). Fit O-ring on to hollow bolt (2), insert it into the eye of the pipe and torque to 45 Nm (33 pound feet). Attach bolt nut (3) and torque to 35 Nm (26 pound feet).

NOTE: Pay attention to installation position of connection housing, see markings applied during disassembly.

6003-90

STEP 32

STEP 34

Pipe - System pressure from lock-up clutch valve to lock-up clutch.

4 1 2

BILD-34

Install new filter element. BILD-32

Insert screw-in sleeve (1) and torque to 45 Nm (33 pound feet). NOTE: Wet bolt-in thread with Loctite (Type No. 243). Secure pipe (2) with nuts (3 and 4). Torque nut (3) to 35 Nm (26 pound feet). Torque nut (4) to 45 Nm (33 pound feet).

STEP 33 14.3 Fitting of filter (pressure filter)

1 BILD-33

Secure filter head (1) with new O-rings to the rear housing using Torx bolts (2). Torque to 34 Nm (25 pound feet).

NOTE: Before putting the transmission into operation, fill it with oil according to operators manual.

MULTITRAC MT-L 3075 II / 3085 II / 3095 II AXLES

6004

Section 6004

6004-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Multi-disc Differential DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Multi-disc Differential DL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 6 8 9 9 14 14 15 15 18 18 20 21 23 23 27 29 33 33 40 40 42 42

6004-3

SPECIAL TOOLS Planetary bearing puller collet set ............................................................................................................... CAS2881 Brake housing seal installer......................................................................................................................... CAS2880 Differential bearing cone puller collet set..................................................................................................... CAS2871 Differential bearing preload wrench ............................................................................................................. CAS2851 Brake housing inner bearing cup installer ................................................................................................... CAS2877 Brake housing outer bearing cup installer ................................................................................................... CAS2878 Brake housing inner bearing cup installer ................................................................................................... CAS2879 Wear ring installer adapter .......................................................................................................................... CAS2874 Wear ring installer adapter ......................................................................................................................... CAS2875 Pinion depth gauge set................................................................................................................................ CAS2872 Pinion depth gauge block ............................................................................................................................ CAS2873 Puller body and screw ................................................................................................................................. CAS2882 Support bracket ........................................................................................................................................... CAS2883 Slide hammer puller adapter ..................................................................................................................... CAS10846 Slide hammer ..............................................................................................................................................OEM4252 Replacer ...................................................................................................................................................... CAS2297 Magnetic base with indicator ................................................................................................................... CAS10066A Heat gun .................................................................................................................................................... CAS10810 Lifting sling...................................................................................................................................................OEM4106 Engine stand................................................................................................................................................OEM4135 Snap ring pliers............................................................................................................................................OEM6484 Snap ring pliers............................................................................................................................................OEM6177 Snap ring pliers............................................................................................................................................OEM6492 Step plate set (includes 8061, 8067, and 8073) ..........................................................................................OEM4288 Step plate ............................................................................................................................................................8061 Step plate ............................................................................................................................................................8067 Step plate ............................................................................................................................................................8073 Hexagonal Wrench 105 mm ..............................................................................................................SPX 380003004

6004-4

GEAR TOOTH CONTACT PATTERNS Ideal Tooth Contact Pattern

Pinion Distance Must Be Increased

BS01D011

BS01D009

COAST SIDE (CONCAVE)

BS01D013 BS01D012

COAST SIDE (CONCAVE)

DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

6004-5

Pinion Distance Must Be Decreased

BS01D016 BS01D010

BS01D015

COAST SIDE (CONCAVE)

DRIVE SIDE (CONVEX)

6004-6

LUBRICATION 721F Limited Slip Front Axle 4

5 4

3 1

2 RH11C089.PNG

1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)

RH11C090.PNG

3. OIL FILLER HOLE 4. BRAKE BLEEDER

5. BLEEDER

721F Locking Differential Front Axle 4

5 4

2 3 1

2 RH11C091.PNG

1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)

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3. OIL FILLER HOLE 4. BRAKE BLEEDER

5. BLEEDER

721F Limited Slip Rear Axle 4

5 4

2 3 1 2 LTD SLIP REAR I.PNG

1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)

LTD SLIP REAR II.PNG

3. OIL FILLER HOLE 4. BRAKE BLEEDER

5. BLEEDER

6004-7

721F Open Differential Rear Axle 5

2 3 2 RH11C093.PNG

1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)

1 RH11C094.PNG

3. OIL FILLER HOLE 4. BRAKE BLEEDER

5. BLEEDER

6004-8

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BD00M234

BS00M071

NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a changed braking behavior. A wear measurement has to be made on both wheel ends. Remove plug, actuate brake and determine dimension “X” using a feeler gauge. If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced. Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).

6004-9

OUTPUT AND BRAKE Disassembly

STEP 3

NOTE: Tools and axle shown in the following images may appear slightly different than the tools and axle you may have. The use of the tools and disassembly/assembly of axle is the same regardless of appearance.

STEP 1

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Remove plug and drain oil from outputs. NOTE: Use a suitable container for collection of oil and abide by all local environmental laws for proper handling and disposal.

STEP 4 1-01.PNG

Use a suitable lifting device and attach axle to assembly stand. NOTE: Only heavy duty axle version uses wheel mounting studs.

STEP 2

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Remove bleeder valve to avoid damage during output and axle housing separation.

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Remove plug and drain oil from differential carrier. NOTE: Use a suitable container for collection of oil and abide by all local environmental laws for proper handling and disposal.

6004-10

STEP 5

STEP 8

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Attach load carrying device 380002303 to output assembly. Remove hex bolts and separate output from axle housing.

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Use a lever to remove output shaft cover.

STEP 9

WARNING: Attach load carrying device with a wheel nut.

STEP 6

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Remove locking bolts and releasing cover.

STEP 10 1-06.PNG

Pull stub shaft and sun gear shaft. NOTE: Watch for loose shim(s).

STEP 7

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Use puller and press planetary carrier out of output shaft profile.

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Attach output to suitable assembly stand.

6004-11

STEP 11

STEP 14

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Use a suitable lifting device and lift planetary carrier out of brake housing.

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Pull off planetary gears.

STEP 15 STEP 12

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With a suitable puller remove tapered roller bearing from planetary carrier.

Lift end plate out of brake housing.

STEP 16

STEP 13

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Lift disk package out of brake housing. 1-13.PNG

Remove retaining rings.

6004-12

STEP 17

STEP 20

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Remove hex bolts, releasing cover and cup spring.

STEP 18

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1. Brake housing 2. Guide ring 3. Back-up ring 4. Piston seal 5. Piston seal 1-18.PNG

Mount bleeder valve. Use compressed air to remove piston from brake housing.

STEP 19

6. Back-up ring 7. Slide ring seal (Metal face seal - HD option only or combi seal standard version) 8. Output shaft

STEP 21

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If necessary, remove guide ring, back-up rings and grooved rings from annular grooves of brake housing (arrows). NOTE: For installation position of single parts, see Step 20.

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Use a suitable lifting device. Lift brake housing from output shaft.

6004-13

STEP 22

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Depending on version, use a lever to remove slide ring seal or shaft seal (combi seal version) from brake housing. If needed, remove both bearing outer rings.

STEP 23

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For slide ring seal version, use a lever to remove slide ring seal from output shaft. For combi seal version, check screening plate for wear marks. If required, separate it from output shaft.

STEP 24

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Use a puller to remove tapered roller bearing from output shaft.

6004-14

AXLE HOUSING Disassembly

STEP 3

STEP 1

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Remove screw neck. 2-01.PNG

Secure axle housing to suitable lifting device. Remove hex bolts. Separate axle housing from axle drive housing

STEP 4

NOTE: Watch out for releasing differential.

STEP 2

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Pull bearing outer ring from bearing hole and remove shim. Remove O-ring (see arrow).

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Loosen threaded connections and remove releasing brake tube.

6004-15

INPUT Disassembly

STEP 3

STEP 1

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Remove piston (arrow) from axle housing. 3-01.PNG

Lift differential from axle drive housing using a suitable lifting device.

NOTE: Step is necessary only for DHL version.

STEP 4

NOTE: Disassembly of differential is covered in differential section.

STEP 2

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Use compressed air to remove piston

3-02.PNG

Pull bearing outer ring (arrow) from housing and remove shim.

6004-16

STEP 5

STEP 7

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Heat slotted nut with a hot air blower. NOTE: Slotted nut is secured with Loctite (Type no. 262).

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Remove input flange from pinion. Use a lever to remove shaft sea.

STEP 8

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 6

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Press input pinion from axle drive housing and remove releasing tapered roller bearing.

STEP 9 3-06.PNG

Remove slotted nut and shim behind it. Use slotted n u t w r e n c h C A S 2 8 4 2 a n d c l a m p i n g d ev i c e 380001546.

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Remove spacer ring and pull tapered roller bearing from input pinion.

6004-17

STEP 10

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If needed, remove bearing outer rings from axle drive housing.

6004-18

DIFFERENTIAL Disassembly Multi-disk Differential Lock DHL-2400

STEP 4

STEP 1

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Preload housing cover/compression spring using a press. Disengage retaining ring. Remove sliding sleeve and compression spring from housing cover. 4-01.PNG

Remove axial roller cage (arrow).

STEP 5

STEP 2

2 1

3 4 5

4-05.PNG

Remove single parts. 4-02.PNG

Pull both tapered roller bearings from differential.

1. Pressure piece 2. Cage

STEP 3

3. Lever (12x) 4. Disk carrier 5. Disk package

4-03.PNG

Preload differential using a press. Remove hex bolts and releasing housing cover.

6004-19

STEP 6

STEP 9

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4-09.PNG

Preload differential using a press. Remove locking bolts and housing cover.

Remove both shor t differential axles. Remove releasing spider gears and thrust washers from differential housing.

STEP 7 STEP 10

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Remove axle bevel gear with thrust washers from differential housing.

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Remove long differential axle, releasing spider gears and thrust washers from differential housing.

STEP 8 STEP 11

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Force out both slotted pins.

4-11.PNG

Remove axle bevel gear and shim.

6004-20

STEP 12

STEP 15

4-12.PNG

Press crown wheel from differential carrier.

4-15.PNG

Preload differential using a press. Remove locking bolts and housing cover.

Disassembly Differential D-2400

STEP 16

STEP 13

4-16.PNG

Pull both tapered roller bearings from differential.

Remove axle bevel gear with thrust washers from differential housing.

STEP 14

STEP 17

4-13.PNG

4-17.PNG

4-14.PNG

Preload differential using a press. Remove hex bolts and releasing housing cover.

Force out both slotted pins.

6004-21

STEP 18

STEP 21

4-18.PNG

Force out both shor t differential axles. Remove releasing spider gears with thrust washers from differential housing.

STEP 19

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Press crown wheel from differential carrier.

Disassembly Multi-disc Differential DL-2400 STEP 22

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Pull long differential axle. Remove releasing spider gears with thrust washers from differential housing.

STEP 20

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Pull both tapered roller bearings from differential.

STEP 23

4-20.PNG

Remove axle bevel gear and shim.

4-23.PNG

Preload differential with a press. Remove locking screws and housing cover.

6004-22

STEP 24

STEP 27

4-24.PNG

4-27.PNG

Remove axle bevel gear with pressure ring, disc package and thr ust washers from differential housing.

Remove pressure ring, disc package and thrust washers from the differential housing.

STEP 28 STEP 25

4-28.PNG 4-25.PNG

Remove spider shafts and axle bevel gears from differential housing.

STEP 26

4-26.PNG

Remove second axle bevel gear.

Press crown wheel from the differential carrier.

6004-23

DIFFERENTIAL Reassembly Multi-disk Differential Lock DHL-2400

STEP 3

STEP 1 S

5-03.PNG

Insert axle bevel gear.

5-01.PNG

STEP 4

Mount two M16 x 1.5 locating pins (S) and press heated crown wheel onto differential housing until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 2

5-04.PNG

I ns e r t s p i d e r g e a r s w i t h t h r u s t wa s he r s i n t o differential housing. Secure them with long spider shaft. NOTE: Thrust washers must be positioned with tabs (arrow) located in recesses of differential housing.

5-02.PNG

Insert thrust washers into differential housing.

6004-24

STEP 5 1

STEP 7 2

5-05.PNG

In s e r t spi der gear s wi t h th r us t wa s h e r s i nto differential housing. Attach them with two shor t spider shafts.

5-07.PNG

Mount second axle bevel gear.

STEP 8

NOTE: Thrust washers must be positioned with tabs (1) located in recesses of differential housing. Pay attention to radial installation position of spider shaft attaching holes (2).

STEP 6

5-08.PNG

Position thrust washers in housing cover with grease.

STEP 9

5-06.PNG

Secure short spider shafts with slotted pins. NOTE: Flush mount slotted pins.

5-09.PNG

Mount M16 x 1.5 adjusting bolts and insert housing cover until contact with differential housing is made. Preload differential using a press and secure with new locking bolts. Torque to 400 Nm (295 pound feet).

6004-25

STEP 10

STEP 12

5-10.PNG

5-12.JPG

Install compression spring onto sliding sleeve.

Setting of disc package

STEP 11

Premount single parts according to illustration. 1. Housing cover 2. Pressure piece 3. Cage 4. Lever (12x) 5. Disk carrier 6. Pressure ring 7. Inner discs 8. Outer discs (optional) 9. Snap ring. 5-11.PNG

Insert premounted sliding sleeve into housing cover. Preload compression spring with a press and engage retaining ring into annular groove of sliding sleeve.

NOTE: For number of discs and disc arrangement, refer to related spare parts list.

6004-26

STEP 13

STEP 15

5-13.PNG

5-15.PNG

Preload disk package with an axial force of F = 50 +30 KN. Then check setting dimension “A” = 1.05 +/-0.1 mm (0.041 +/-0.004 in) from collar of differential cover to plane face of outer disc (also see sketch in step 14).

Position housing cover onto pressure piece (arrow). Insert two hex bolts into housing cover to radially attach disc package.

STEP 16

NOTE: Any deviation from specified setting dimension must be corrected with a corresponding outer disk. NOTE: Special tools pressure piece and load cell are to be determined. Contact special tools.

STEP 14

5-16.PNG

Use a suitable lifting device. Position premounted differential onto housing cover and temporarily attach with hex bolts.

STEP 17 5-14.JPG

A = Setting dimension = 1.05 +/- 0.1 mm (0.041 +/-0.004 in) B = Contact face. NOTE: To obtain correct measuring result, housing cover may only be supported on contact face (B). Ensure that assembly stand is only supported on disk package and not on disk carrier.

5-17.PNG

Preload differential with a press and pressure piece. Final tighten housing cover with hex bolts. Torque to 185 Nm (136 pound feet).

6004-27

Reassembly Differential D-2400

STEP 18

STEP 20

5-18.PNG

Heat both tapered roller bearings and insert until contact is made. Adjust tapered roller bearing after cooling down. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 19

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Mount locating pins and press heated crown wheel onto differential housing until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 21

5-19.PNG

Attach axial roller cage to sliding sleeve with grease.

5-21.PNG

Insert thrust washer into differential housing.

STEP 22

5-22.PNG

Insert axle bevel gear.

6004-28

STEP 23

STEP 25

5-23.PNG

5-25.PNG

In s e r t spi der gear s wi t h th r us t wa s h e r s i nto differential housing. Secure them with long spider shaft.

Secure short spider shafts with slotted pins.

NOTE: Thrust washers must be positioned with tabs (arrow) located in recesses of differential housing.

STEP 26

NOTE: Flush mount slotted pins.

STEP 24 1

5-26.PNG

Mount second axle bevel gear. 5-24.PNG

STEP 27

In s e r t spi der gear s wi t h th r us t wa s h e r s i nto differential housing. Secure them with two short spider shafts. NOTE: Thrust washers must be positioned with tabs (1) located in recesses of differential housing. Pay attention to radial installation position of spider shafts securing holes (2).

5-27.PNG

Secure thrust washers into housing cover with grease.

6004-29

STEP 28

STEP 30

5-28.PNG

5-30.PNG

Mount two adjusting bolts and insert housing cover until contact with differential housing is obtained. Preload differential using a press. Secure with new locking bolts. Torque to 400 Nm (295 pound feet).

Heat both tapered roller bearings and insert until contact is made. Adjust tapered roller bearing after cooling down.

STEP 29

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

Reassembly Multi-disc Differential DL-2400 STEP 31 S

5-29.PNG

Attach housing cover and preload differential with a suitable press. Secure housing cover with hex bolts and torque to 185 Nm (136 pound feet).

5-31.PNG

6004-30

STEP 32

STEP 34

5-32.PNG

5-34.PNG

Insert thrust washer into differential housing.

Install pressure ring.

STEP 33

STEP 35

5-33.PNG

5-35.PNG

Mount outer and inner discs in alternating order starting with an outer disk.

Install axle bevel gear until contact is made. Then install inner discs with teeth.

NOTE: The installation clearance of internal parts is corrected by mounting outer discs of different thicknesses.

STEP 36

NOTE: The difference in thickness between the left and right disc package must be less than 0.1 mm (0.004 in.).

5-36.PNG

Preassemble the differential spider and insert it into the differential housing/pressure ring.

6004-31

STEP 37

STEP 39

5-37.PNG

Install second axle bevel gear.

5-39.PNG

Mount outer and inner discs in alternating order starting with an inner disc.

STEP 38

NOTE: The installation clearance of internal parts is corrected by mounting outer discs of different thicknesses. NOTE: The difference in thickness between the left and right disc package must be less than 0.1 mm (0.004 in.).

STEP 40

5-38.PNG

Install second thrust ring into differential housing.

5-40.PNG

Determine the installation clearance 0.2 to 0.7 mm (0.008 to 0.028 in.). Measure dimension I from the mounting face of the differential housing to the plane face of the outer disc. Dimension I e.g. 44.30 mm (1.744 in.).

6004-32

STEP 41

STEP 43

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5-43.PNG

Measure Dimension II, from the contact face of the outer disc to the mounting face on the housing cover. Dimension II e.g. 43.95 mm (1.730 in.)

Mount two M16 x 1.5 adjusting bolts and inser t housing cover until contact with differential housing is made. Preload differential with a press. Secure with new locking bolts and torque to 400 Nm (295 lb ft.)

Calculation Example:

STEP 44

Dimension I - 44.30 mm (1.744 in.) Dimension II - 43.95 mm (1.730 in.) Difference + disc clearance - 0.35 mm (0.013 in.) NOTE: Any deviation from the required installation clearance must be corrected with corresponding outer discs: s = 2.7 mm (0.106 in.), s = 2.9 mm (0.114 in.), s = 3.0 mm (0.118 in.), s = 3.1 mm (0.122 in.), s = 3.2 mm (0.126 in.), s = 3.3 mm (0.130 in.), s = 3.5 mm (0.138). NOTE: Make sure the difference in thickness between the left and right disc package is less than 0.1 mm (0.004 in.).

5-44.PNG

STEP 42

5-42.PNG

Secure thrust washers into housing cover with grease.

6004-33

INPUT Reassembly Input

STEP 3

STEP 1 Determination of shim thickness to obtain a correct contact pattern

221.10

6-03.PNG

Determine dimension III (bearing width). Dimension III e.g. 39.10 mm (1.54 in). Calculation Example “A”: 6-01.PNG

R e a d d i m e n s i o n I f r o m a x l e d r i ve h o u s i n g . Dimension I e.g. 221.10 mm (8.70 in) NOTE: If crown wheel or input pinion are damaged, both parts must be replaced together. When installing a complete new bevel gear set, look for identical mating number of input pinion and crown wheel.

Dimension I: 221.10 mm (8.70 in) Dimension II: -181.00 (7.13 in) Dimension III: -39.10 (1.54 in) Difference = shim s = 1.00 mm (0.04 in)

STEP 4 Reassembly of input pinion

NOTE: Measuring procedures must be done accurately. Inaccurate measurements lead to incorrect contact pattern requiring additional disassembly and reassembly of input pinion and differential.

STEP 2 181.0 +/- 0

6-04.PNG

Undercool external bearing and insert it into axle drive housing until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts. 6-02.PNG

Read dimension II from pinion. Dimension II e.g. 181.00 mm (7.13 in)

6004-34

STEP 5

STEP 7

6-05.PNG

6-07.PNG

Insert shim into housing hole size e.g. s = 1.00 mm (0.04 in).

Heat tapered roller bearing and insert it into input pinion until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.

STEP 6

STEP 8 Setting of rolling torque of input pinion bearing without shaft seal 1.5 to 3.0 Nm (13.3 to 26.6 pound inches)

6-06.PNG

Undercool internal bearing outer ring and bring it into contact position in housing hole using 380100001 assembly tool. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts. 6-08.PNG

Insert spacer e.g. s = 8.18 mm (0.32 in) NOTE: Based on experience, necessary rolling torque is obtained by reusing the spacer removed during disassembly e.g. s = 8.18 (0.32 in). NOTE: A later check of rolling torque is needed.

6004-35

STEP 9

STEP 11

6-09.PNG

6-11.PNG

Insert preassembled input pinion into axle drive housing. Insert heated tapered roller bearing until contact is made.

Insert input flange and secure it with disk and slotted nut. Torque to 1200 Nm (885 pound feet). Use CAS2842 slotted nut wrench and 380001546 clamping device.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.

NOTE: Temporarily mount slotted nut without Loctite. While tightening, rotate input pinion several times in both directions.

STEP 10 STEP 12

6-10.PNG

Press protection plate onto input flange until contact is made. NOTE: Do not fit shaft seal until contact pattern has been checked as shown in shown in step 24.

6-12.PNG

Check rolling torque. It should be 1.5 to 3.0 Nm (13 to 27 pound inches) without a shaft seal. NOTE: When installing new bearings try to achieve upper value of rolling torque. NOTE: In cases of rolling torque measurement deviations, correct with a corresponding spacer as specified - go back to Step 8. For insufficient rolling torque - install thinner spacer ring. Excessive rolling torque - install a thicker spacer ring.

6004-36

STEP 13

STEP 15 Determination of shims for setting of bearing rolling torque (differential housing) and backlash (bevel gear set)

6-13.PNG

Grease O-rings and insert them into annular grooves of piston. NOTE: Steps 13 and 14 are only need for versions with DHL.

STEP 14

101

+/-0 6-15.PNG

Determine required shims on the basis of read value (deviation/test dimension) and corresponding specifications of the following table: (KRS - SET RIGHT) (KRS = bevel gear set): Deviation see crown wheel rear side. The test dimension “101” is stamped into crown wheel rear side. If no +/- deviation is indicated, this value corresponds to actual value “0” in the following table. According to this value, the required shims are allocated in table.

6-14.PNG

Inser t piston (arrow) into bearing housing until contact is made.

Any +/- deviation of test dimension caused by production is also marked on the crown wheel rear side (e.g. - 20 or - 10 or 10 or 20). In accordance with this deviation, required shims are allocated in the table.

STEP 16

6-16.JPG

1 = Axle housing 2 = Shim (crown wheel side) 3 = Shim (differential carrier side) 4 = Axle housing

6004-37

Shims for differential D/DL and DHL-2400 in ZF axles MT-L 3085/3095 II Crown wheel marking Deviation

-20

-10

-0.2

-0.1

0.1

0.7

0.8

0.9

1.0

84395193

84354725

84354726

84354727

84476078

84330538

84330539

84330540

1.3

1.2

1.1

1.0

84476080

84330542

84330541

84330540

Shim

Diff. cage side Shim thickness Shim DHL 2400 Order no. Shim D/DL 2400 Order no. Shim Crown wheel side Shim thickness Shim D/DL/DHL 2400 Order no.

STEP 17

STEP 18

6-17.PNG

6-18.PNG

Insert selected shim e.g. s = 0.9 mm (0.04 in) into hole of axle housing and adjust bearing outer ring (arrow) until contact is obtained.

Cover some drive and coast flanks of crown wheel with marking ink. Insert premounted differential into axle drive housing.

6004-38

STEP 19

STEP 21

6-19.PNG

6-21.PNG

Insert selected shim e.g. s = 1.1 mm (0.04 in) into hole of axle housing and adjust bearing outer ring until contact is made.

Leak test differential lock. Pressurize lock p = 1 bar (15 psi), close shut-off valve and remove air line. No noticeable pressure loss should occur within 10 seconds.

STEP 20

NOTE: This operation is only necessary for version with DHL.

S STEP 22

6-20.PNG

Mount two M20 locating pins (S) and bring axle housing into contact position with axle drive housing using a suitable lifting device. Temporarily attach axle housing with hex bolts. Torque to 560 Nm (413 pound feet). NOTE: Test mount axle housing without O-ring.

6-22.PNG

In both directions, several times, rotate input flange to roll crown wheel over input pinion. Remove axle housing and lift differential out of axle drive housing. Compare obtained contact pattern with contact pattern examples at the beginning of this section. NOTE: If tooth contact pattern differs, an incorrect shim size was selected in Step 5. This must be corrected.

6004-39

STEP 23

STEP 25

6-23.PNG

6-25.PNG

After contact pattern check, insert differential into axle drive housing again.

Using CAS2841 driver tool, mount shaft seal with seal lip facing oil chamber.

STEP 24

NOTE: Exact installation position of seal is obtained using specified driver tool.

Reassembly of shaft seal (Step 24 to 26)

NOTE: Wet outer diameter of shaft seal with mineral spirits just before installation. Fill space between seal and dust lip with grease.

STEP 26

6-24.PNG

Remove slotted nut and pull input flange from input pinion. Use CAS2842 slotted nut wrench and 380001546 clamping device. 6-26.PNG

Insert input flange and secure it using disc and slotted nut. Torque to 1200 Nm (885 pound feet). USe CAS2842 slotted nut wrench and 380001546 clamping device. NOTE: Cover threads of slotted nut with Loctite (Type no. 262).

6004-40

AXLE HOUSING Reassembly

STEP 3

STEP 1

7-03.PNG

Mount fitting and torque to 36 Nm (27 pound feet). 7-01.PNG

STEP 4

Grease O-ring and insert it into axle housing.

STEP 2 S

7-04.PNG

7-02.PNG

Mount two M20 locating pins and bring axle housing into contact position with axle drive housing using a suitable lifting device. Secure axle housing using hex bolts. Torque to 560 Nm (413 pound feet).

Grease O-ring. Inser t it into annular groove of parking brake tube.

STEP 5

WARNING: After axle housing assembly, secure axle with clamping brackets (S).

7-05.PNG

Mount brake tube with threaded connection and hex nut (arrow). Torque to 100 Nm (74 pound feet).

6004-41

STEP 6

7-06.PNG

Install plug and new O-ring. Torque to 50 Nm (37 pound feet).

6004-42

OUTPUT AND BRAKE Reassembly

STEP 3

STEP 1

8-03.PNG

Version with slide ring seal shown in Step 3 and 4 8-01.PNG

Pull wheel stud into output shaft until contact is made. NOTE: Special tool may only be used for repairs when exchanging individual wheel studs with mounted output shaft. For new output shaft, use a press.

Wet O-ring of slide ring seal and locating hole with mineral spirits. Snap new slide ring seal (part 1) into output shaft.

STEP 4

NOTE: Only heavy duty axle version uses wheel mounting studs.

STEP 2

8-04.PNG

Then mount new slide ring seal (part 2) into brake housing. NOTE: For installation position of seal, see Step 12.

8-02.PNG

Heat tapered roller bearing and insert it onto output shaft until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.

NOTE: Surface of slide ring seal may not have any grooves, scratches or other damage. Make sure sealing surface is parallel to housing face. O-rings must be mounted evenly into locating hole and must not bulge out. WARNING: Risk of injury - metal rings have extremely sharp edges. Wear protective gloves.

6004-43

STEP 5

STEP 7

8-05.PNG

8-07.PNG

Insert both bearing outer rings (arrows) into brake housing until contact is made.

Heat slide bushing and position it at collar of output shaft. Then position slide bushing with CAS2860 pressure ring.

STEP 6

NOTE: Exact installation position is obtained when using specified pressure ring. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.

STEP 8

8-06.JPG

Steps 6 to 8 are for the Version with combi seal Illustration shows installation position of combi seal. 1. Output shaft 2. Brake housing 3. Combi seal consisting of: a = Shaft seal, b = Screening plate.

8-08.PNG

Insert shaft seal into brake housing using CAS2880 driver tool. NOTE: Exact installation position is obtained when using specified driver tool. Make note of installation position (Step 6). Wet outer diameter of shaft seal with mineral spirits before assembly.

6004-44

STEP 9

STEP 11

8-09.PNG

8-11.PNG

Use suitable lifting device and insert premounted brake housing over output shaft until contact is made.

Clean annular groove of brake housing with mineral spirits. Insert guide ring into annular grove (go to step 12). Secure it with Loctite (type no. 415) at its ends (arrows).

NOTE: Before clamping seal rings (slide ring seal) to installation dimension, clean sliding surfaces and apply an oil film. A leather cloth soaked in oil is recommended for this step.

WARNING: Upon installation, orifice of guide ring must show upwards - 12 o’clock position.

STEP 10

8-10.PNG

Insert back-up rings and grooved rings into annular grooves of brake housing (arrows). NOTE: For installation position, go to Step 12.

NOTE: Full circumference of guide ring must be in an exact contact position.

6004-45

STEP 12

STEP 14

8-14.PNG

Insert piston into brake housing and install with fabricated fixing device until contact is made. NOTE: Sufficiently oil seal surface of piston/back-up rings, grooved rings and guide ring (W-10 oils are to be used).

STEP 15 8-12.JPG

1. Brake housing 2. Guide ring 3. Back-up ring 4. Grooved ring 5. Grooved ring 6. Back-up ring 7. Slide ring seal 8. Output shaft 8-15.PNG

STEP 13

Insert disk and cup spring with convex side facing upwards into piston.

STEP 16

8-13.PNG

Flush-mount slotted pins into holes of piston. 8-16.PNG

Insert cover and secure it by means of hex bolts. Torque to 34 Nm (25 pound feet).

6004-46

STEP 17

STEP 20 2 3 1

8-17.PNG

Insert outer and inner disks. NOTE: For number of disks and disk arrangement, refer to related spare parts list.

STEP 18

8-20.PNG

Insert cylindrical roller bearing into planetary gear. To do this, press cylindrical roller bearing (1) through packaging sleeve (2) until snap ring (3) engages into annular groove of planetary gear (4). NOTE: Use packaging sleeve to facilitate assembly.

STEP 21

8-18.PNG

Insert end plate. 8-21.PNG

STEP 19

Heat bear ing inner r ings. Inser t premounted planetary gears with large radius facing planetary carrier (downwards) until contact is made. Secure planetary gears using retaining rings.

NOTE: Adjust bearing inner rings after cooling. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.

8-19.JPG

Press stop bolt (1) into planetary carrier (2) until contact is obtained.

6004-47

STEP 22

STEP 24

8-22.PNG

8-24.PNG

Heat tapered roller bearing and install it on planetary carrier until contact is made.

Align disk package centrally and radially. Insert planetary carrier into teeth of output shaft using a suitable lifting device.

WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.

STEP 25

STEP 23 1

8-25.PNG

8-23.PNG

Wet contact face of bearing inner ring (1) and profile teeth (2) in output shaft with anti-corrosive agent.

Bring planetary carrier into contact position with c ove r a n d o l d l o ck i n g b o l t s r e m ove d d u r i n g disassembly. Then remove locking bolts.

6004-48

STEP 26

STEP 29

8-26.PNG

8-29.PNG

Pivot output 90 degrees. Insert disk and secure planetary carrier with new locking bolts.

Set axial play of sun gear shaft to 0.5 to 2.0 mm (0.02 to 0.08 in). Determine dimension I, distance from mounting face of brake housing to front face of stop bolt.

NOTE: Tighten locking bolts successively with a tightening torque of 200 Nm (148 pound feet). Then, retighten with a torque of 500 Nm (369 pound feet).

STEP 27

STEP 30

8-27.PNG

Install O-ring on cover.

8-30.PNG

Insert stub shaft into teeth of axle bevel gear until contact is made.

STEP 28

NOTE: Be aware of installation position. Mount stub shaft side with long teeth towards differential.

8-28.PNG

Install cover into output shaft until fully seated.

Dimension I e.g. 19.75 mm (0.78 in).

6004-49

STEP 31

STEP 33

8-31.PNG

8-33.PNG

Insert sun gear shaft until contact is made.

Insert sun gear shaft into planetary carrier.

STEP 32

STEP 34

8-32.PNG

8-34.PNG

Measure dimension II, from front face of sun gear shaft to mounting surface of axle housing.

Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease into sun gear shaft.

Dimension II e.g. 17.15 mm (0.68 in)

STEP 35

CALCULATION EXAMPLE: Dimension I: 19.75 mm (0.78 in) Dimension II: 17.15 mm (0.68 in) Difference: 2.60 mm (0.10 in) Required axial play e.g.: 1.00 mm (0.04 in) Difference = shim e.g. s = 1.60 mm (0.06 in)

8-35.PNG

Insert O-ring with grease into countersink of brake housing.

6004-50

STEP 36

STEP 39

8-36.PNG

Grease O-ring and install it in axle housing.

8-39.PNG

Check brake hydraulics for leakage. Before starting test bleed brake hydraulics. Pressurize brake temporarily 5 times with a max pressure of p = 100 bar (1450 psi).

STEP 37

High-pressure test: Build up test pressure p = 100-10 bar maximum and close connection to pump via shut-off valve. A maximum pressure drop of 2% or 2 bar (29 psi) is permissible during a 5 minute test period. Low-pressure test: Reduce test pressure p = 5 bar (73 psi) and close shut-off valve. No pressure drop is allowed during a 5 minute test period. Test media: 8-37.PNG

Mount adjusting bolts and use 380002303 lifting device to bring output into contact position with axle housing. Secure output using hex bolts. Torque to 390 Nm (288 pound feet).

Engine oils SAE 10-W corresponds to MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils type A, Suffic A Dexron of II D.

NOTE: Attach lifting device with wheel stud.

STEP 38

8-40.PNG

Check operability of DHL. Build up maximum pressure p = 20 bar (290 psi) and close connection to pump via shut-off valve. 8-38.PNG

Mount bleeder valve (arrow).

Lock on: When rotating input flange, both outputs must have same direction of rotation.

6004-51 Lock off: When rota tin g inp ut flang e, on e side ha s no movement or rotates in opposite direction. NOTE: Before axle operation, fill with oil according to lubrication and maintenance instructions.

6004-52

DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS

6005

Section 6005

6005-2

TABLE OF CONTENTS SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 5 6 6 8 8 10 10 10 11 11 11 12 12 12 13 13 13

6005-3

SPECIAL TORQUES Coupler to Flywheel Bolts...................................................................................... 53 to 62 Nm (39 to 46 pound feet) Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet) Engine Drive Shaft to Coupler Bolts (821F/921F 5-Speed Transmission)........... 86 to 126 Nm (63 to 93 pound feet) Engine Drive Shaft to Transmission Bolts.............................................................. 75 to 81 Nm (55 to 60 pound feet) Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet) Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet) Lock Nut for Yoke on Front Drive Shaft.......................................................... 339 to 375 Nm (250 to 275 pound feet)

6005-4

FRONT DRIVE SHAFT Removal

STEP 5

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

Loosen the set screws that secure the center bearing to the front drive shaft.

STEP 6 Remove any paint or rust from the rear of the front drive shaft and apply WD40 or similar oil to loosen any rust between the inner race and the front drive shaft.

STEP 1

STEP 7

BD03A166

Loosen and remove the bolts and straps that fasten the center drive shaft to the yoke of the front drive shaft.

STEP 2

BD03A167

Loosen and remove the bolts and straps that fasten the front drive shaft to the front axle.

STEP 8 Use a prybar to disengage the front drive shaft from the front axle and remove the front drive shaft from the machine. NOTE: If necessary, use a brass hammer to drive the front drive shaft out of the center bearing.

BD03A183

Remove the lock nut that fastens the yoke to the front drive shaft.

STEP 3 Make an alignment mark on the yoke and the end of the front drive shaft to make sure that the yoke is installed correctly.

STEP 4 Use an acceptable puller and remove the yoke from the end of the front drive shaft.

6005-5

FRONT DRIVE SHAFT Installation

STEP 14

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

STEP 9 Apply antiseize compound to the bearing area of the front drive shaft.

STEP 10 Place the front drive shaft into position in the center bearing of the machine. BD03A183

STEP 11

Install the lock nut and washer which fastens the yoke to the front drive shaft. Tighten the lock nut to a torque of 339 to 375 Nm (250 to 275 pound feet).

STEP 15 Tighten the set screws that secure the center bearing to the front drive shaft alternately until they stop turning and the hex head socket wrench starts to spring.

STEP 16 BD03A167

Install the bolts and straps that fasten the front drive shaft to the front axle. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 12 Apply antiseize compound to the splines on the front drive shaft.

STEP 13 Install the yoke to the front drive shaft, making sure the alignment marks made during removal are aligned. NOTE: If a new front drive shaft has been installed, make sure the yoke being installed is 90° to the yoke on the other end of the front drive shaft.

BD03A166

Install the bolts and straps that fasten the front drive shaft to the center drive shaft. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

6005-6

CENTER BEARING Removal

STEP 19

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

STEP 17

BD03A183

Loosen and remove the lock nut that fastens the yoke to the front drive shaft.

STEP 20 BD03A166

Loosen and remove the bolts and straps that fasten the center drive shaft to the front drive shaft.

Make an alignment mark on the yoke and the front drive shaft to be sure that the yoke is installed correctly.

STEP 21

STEP 18

Use an acceptable puller and remove the yoke from the end of the front drive shaft.

STEP 22 Remove any paint or rust from the rear of the front drive shaft and apply WD40 or similar oil to loosen any rust between the inner race and the front drive shaft.

STEP 23 Loosen the set screws that secure the center bearing to the front drive shaft. BD03A183

Loosen and remove the lubrication hose from the center bearing.

6005-7

STEP 24

BD03A183

Loosen and remove the bolts, washers and nuts that fasten the bearing housing to the front frame.

STEP 25 Install two longer bolts, at least 3 inches, to hold the bearing housing during removal. Use an acceptable puller to remove the bearing housing from the front drive shaft.

6005-8

CENTER BEARING Installation

STEP 29

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured. NOTE: The center bearing and the bearing housing are not serviced separately. If the center bearing is worn or damaged or if the bearing housing is cracked, a new center bearing and bearing housing must be used.

STEP 26 Apply antiseize compound to the bearing area of the front drive shaft.

STEP 27 Install the bearing housing so that the lubrication fitting is at the top.

BC05M214

Turn the set screw down to the shaft and then back it off 1/4th turn and lock it with the jam nut. Repeat the procedure with the other set screw.

STEP 30 Apply antiseize compound to the splines on the front drive shaft. Install the yoke to the front drive shaft, making sure the alignment marks made during removal are aligned.

STEP 28

STEP 31

BD03A183

Apply Loctite 242 to bolt threads. Install the bolts, washers and nuts that fasten the bearing housing to the front frame. Tighten the bolts to a torque of 99 to 128 Nm (73 to 94 pound feet). BD03A183

Install the washer and lock nut that fasten the yoke to the front drive shaft. Tighten the lock nut to a torque of 339 to 375 Nm (250 to 275 pound feet).

6005-9

STEP 32

BD03A166

Install the straps and bolts that fasten the center drive shaft to the yoke on the front drive shaft. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 33 Install the lubrication hose into the fitting on the bearing housing.

STEP 34 Lubr icate the center bear ing with the grease specified in Section 1002.

6005-10

CENTER DRIVE SHAFT Removal

Installation

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

STEP 35

STEP 39

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten the center drive shaft to the yoke of the front drive shaft.

Hold the center drive shaft in position and install the bolts and straps that fasten the center drive shaft to the transmission. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

STEP 36 Use a prybar to disengage the center drive shaft from the yoke of the front drive shaft.

STEP 40

STEP 37

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten the center drive shaft to the transmission.

STEP 38 Hold the center drive shaft and remove from the machine.

Install the bolts and straps that fasten the center drive shaft to the yoke of the front drive shaft. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

6005-11

REAR DRIVE SHAFT Removal

Installation

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

STEP 41

STEP 45

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten the rear drive shaft to the transmission.

STEP 42

Hold the rear drive shaft into position and install the bolts and straps that fasten the rear drive shaft to the rear axle. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

Use a prybar to disengage the rear drive shaft from the transmission.

STEP 46

STEP 43

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten the rear drive shaft to the rear axle.

STEP 44 Hold the rear drive shaft and remove from the machine.

Install the bolts and straps that fasten the rear drive shaft to the transmission. Tighten the bolts to a torque of 75 to 81 Nm (55 to 60 pound feet).

6005-12

ENGINE DRIVE SHAFT Removal

Installation

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

STEP 47

STEP 50

BD01D342

Remove and discard the bolts and straps that fasten the engine drive shaft to the transmission.

Place the engine drive shaft into position on the transmission and install new straps and bolts. Tighten the bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

IMPORTANT: The bolts and straps that fasten the engine drive shaft to the transmission must be replaced when removed.

STEP 51

STEP 48

BD03A172 BD03A172

Loosen, remove and discard the bolts that fasten the engine drive shaft to the engine.

STEP 49 Remove the engine drive shaft from the machine.

Install new bolts that fasten the engine drive shaft to the engine. Tighten bolts to a torque of 53 to 62 Nm (39 to 46 pound feet). For 821F/921F machines equipped with 5-Speed transmissions, tighten bolts to a torque of 86 to 126 Nm (63 to 93 lb ft.). NOTE: The bolts that fasten the engine drive shaft to the engine must be replaced when removed.

6005-13

UNIVERSAL JOINTS Removal

Installation

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured.

NOTE: The 921F Series machines use mechanical style yokes (no bearing straps) and may appear different from the machine pictured. NOTE: The bearing race and journal that make up the universal joint are not serviced separately. If the bearing race or journal is worn or damaged, a new universal joint must be used.

STEP 52 Remove the drive shaft from the machine.

STEP 53 STEP 55 2

Clean the slots in the yoke of the drive shaft.

STEP 56 Install the universal joint and install the bearings (2) and the rings (1). Refer to the photo in Step 53.

STEP 57 Install the drive shaft.

BD01F304

1. RING

2. BEARING

Remove the ring (1) and the bearing (2) from the drive shaft. NOTE: The above photo shows the drive shaft on the machine and is for reference of the ring and bearing only.

STEP 54 Remove the universal joint from the drive shaft.

6005-14

Section 6006

6006

WHEELS AND TIRES

6006-2

TABLE OF CONTENTS WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 3 4

6006-3

WHEELS AND BOLTS General Information

Torque Specification

The wheel bolts must be tightened after every 20 hours of operation until the wheel bolts stay tight:

Tighten the wheel bolts to 278 Nm (205 lb ft.) in the sequence shown in Figure 1 or Figure 2. Then use a final torque of 640 - 720 Nm (475 - 530 lb ft.) in the same sequence.

A. If the machine is new. B. If a wheel has been removed and installed.

FRONT TIRE PRESSURES 23.5 x 25 12 ply L2 .............................................................................................................................345 kPa(50 psi) 23.5 x 25 12 ply L3 ............................................................................................................................345 kPa (50 psi) 23.5R25 L2 ....................................................................................................................... 276 - 448 kPa (40 - 65 psi) 23.5R25 Radial L3............................................................................................................ 276 - 448 kPa (40 - 65 psi)

REAR TIRE PRESSURES 23.5 x 25 12 ply L2 .............................................................................................................................276 kPa(40 psi) 23.5 x 25 12 ply L3 ............................................................................................................................276 kPa (40 psi) 23.5R25 L2 ......................................................................................................................... 207 - 276kPa (30 - 40psi) 23.5R25 Radial L3................................................................................................................207 - 276kPa (30 - 40psi

CHANGING TIRES The split rim wheels used on this machine can be dangerous. When inflating a tire on the machine, use a self-locking nozzle and stand at the front or rear of the tire. When inflating a tire off the machine, put the wheel in a tire inflation cage. The retaining ring and rim can come off with enough force to result in death to a person in front of the rim. 48-44

1. Have a qualified tire mechanic service the split rim wheels used on this machine. 2. The correct tire equipment, especially a tire inflation cage, is required. Using the wrong procedure for a split rim wheel can result in death. IMPORTANT: When installing a Michelin tire, lubricate the tire with a tire mounting lubricant and inflate the tire to 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated on the rim. Then decrease the pressure to the specified pressure.

6006-4

INSTALLING A WHEEL 1. Make sure the mounting surfaces of the rim and axle flange are clean and free of dirt and grease. 2. Install the wheel, hardened washers and wheel bolts or nuts depending on axle configuration. THe 721F/821F Heavy Duty Axles and all 921F axles have wheel studs on the axles and use wheel nuts. 3. Use a hand wrench (not an impact) to tighten the wheel b olts to pu ll the wheel against the planetar y housing. DO NOT use an impact wrench to tighten the wheel bolts. 4. Tighten the wheel bolts to 278 Nm (205 lb ft.) in the sequence shown in Figure 1, Figure 2 or Figure 3. Then tighten to final torque of 640 - 720 Nm (475 - 530 lb ft.).

84324413_205.TIF

FIGURE 2. 821F SERIES WHEEL NUT/BOLT TORQUE SEQUENCE

3 4 5

11 7

9 B0987A88.TIF

FIGURE 1. 721F SERIES WHEEL NUT/BOLT TORQUE SEQUENCE

OROR201007RCIL10WHL288BAL1.TIF

FIGURE 3. 921F SERIES WHEEL NUT/BOLT TORQUE SEQUENCE

Stud Mounted Wheels (If equipped) Machines equipped with optional heavy duty axles have a stud mounted wheel. The heavy duty axle incorporates a stud and nut assembly. Torque Rates First tighten nuts/bolts using correct sequence. Initially tighten to 278 Nm (205 lb ft.) Then tighten to final torque of 640 - 720 Nm (475 - 530 lb ft.).

7 - UNDERCARRIAGE HYDRAULICS 8 - UPPERSTRUCTURE HYDRAULICS 9 - UPPERSTRUCTURE

721F Tier 4 Wheel Loader

SERVICE MANUAL

Part number 84487560 1st edition English April 2011

7001 Section 7001 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS

7001-2

TABLE OF CONTENTS BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 5 7 7 7 9 9 9

7001-3

4 7

2 8

BC05M136

1. 2. 3. 4.

FRONT AXLE REAR AXLE BRAKE VALVE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

FRONT ACCUMULATOR REAR ACCUMULATOR BRAKE PUMP CONNECTOR TO FAN VALVE

COMPONENT LOCATION ILLUSTRATION 721F STANDARD AXLES

7001-4

7 9

5 6

BC05M136

1. FRONT AXLE 2. REAR AXLE 3. BRAKE VALVE 4. PARKING BRAKE ACCUMULATOR 5. FRONT ACCUMULATOR

6. 7. 8. 9.

REAR ACCUMULATOR BRAKE PUMP CONNECTOR TO FAN VALVE FRONT AXLE DAMPING ACCUMULATOR 10. REAR AXLE DAMPING ACCUMULATOR

COMPONENT LOCATION ILLUSTRATION 721F HEAVY DUTY AXLES

7001-5

BRAKE VALVE Removal

Installation

1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine.

1. Install the brake valve (1) in the cab or canopy. Refer to the illustration on page 6.

2. Put blocks on both sides of each tire to prevent machine movement.

2. Remove the plugs from the hydraulic lines and connect the hydraulic lines to the brake valve (1).

3. Make sure the brake accumulators are completely discharged. Push down and release the brake pedals at least 30 times.

3. Stop the vacuum pump and remove.

4. Turn the master disconnect switch to the OFF position. 5. Remove the cab skirts located under the cab or canopy. 6. To release the pressure on the parking brake accumulator, the line at the accumulator must be SLOWLY cracked open. A pan will be needed to catch the hydraulic oil. 7. Connect a drain hose to the quick disconnect couplings in each brake circuit to release any pressure in the brake circuit. 8. Clean the brake valve (1) and lines, refer to the illustration on page 6. 9. Put identification tags on all electrical and hydraulic lines that are connected to the brake valve (1). 10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump 11. Disconnect the lines from the brake valve (1) and put plugs in each line. 12. Remove the brake valve (1).

4. Connect all of the electrical connections. 5. Turn the master disconnect switch to the ON position. 6. Bleed the brake system. See Section 7002. 7. Install the cab skirts. 8. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

7001-6

1 6 2

3 9

BC05M137

1. 2. 3. 4. 5.

BRAKE VALVE REAR ACCUMULATOR LINE PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE

6. 7. 8. 9. 10.

FRONT BRAKE LINE REAR BRAKE LINE FRONT ACCUMULATOR RETURN TO TANK PARKING BRAKE ACCUMULATOR

BRAKE VALVE ILLUSTRATION

7001-7

SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS Removal NOTE: 721F machines equipped with Heavy Duty Axles include brake Damping Accumulators located on the front axle (9) and frame (10). See illustration on page 4. 1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine. 2. Put blocks on both sides of each tire to prevent machine movement. 3. Make sure the service brake accumulators (1), the parking brake accumulator (2), and brake damping accumulators (9) and (10) are completely discharged. Push down and release the brake pedal at least 30. 4. Turn the master disconnect switch to the OFF position. 5. Remove the left cab skirt located under the cab or canopy to gain access to accumulators. 6. To release the pressure on the parking brake accumulator, the line at the accumulator must be SLOWLY cracked open. A pan will be needed to catch the hydraulic oil. 7. Connect a drain hose to the quick disconnect couplings in each brake circuit to release any pressure in the brake circuit. 8. Clean the brake accumulators (1), parking brake accumulator (2), brake damping accumulators (9) and (10) and lines. Refer to illustrations on pages 4 and 8. 9. Put identification tags on the line that is connected to the parking brake accumulator (2). 10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 11. Disconnect the accumulators (1).

tubes

from

both

brake

12. Loosen the clamp stud (8) on the accumulator clamp (7). 13. Remove the accumulators accumulator clamps (7).

(1)

from

the

14. Install plugs in the tubes. 15. Disconnect the accumulator (2).

hose

from

parking

brake

16. Remove the nut (3), remove the parking brake accumulator (2). 17. Install a plug in the hose.

18. Disconnect the hose from brake damping accumulators (9) and (10). See illustration on page 4. 19. Remove brake damping accumulators from machine. 20. Install plugs in hoses.

Installation NOTE: 721F machines equipped with Heavy Duty Axles include brake Damping Accumulators located on the front axle (9) and frame (10). See illustration on page 4. 1. Mount the accumulators (1) in the accumulators clamps (7), do not tighten clamps at this time. Refer to illustration on page 8. 2. Connect the tubes to both brake accumulators (1) and tighten. 3. Tighten accumulator clamp studs (7) to 17Nm (13 pound feet). 4. Install the parking brake accumulator (2) into the bracket. 5. Install the nut (3) and tighten. 6. Connect the line accumulator (2).

the

parking

brake

7. Install the brake damping accumulators (9) and (10). 8. Connect the lines to the brake damping accumulators (9) and (10). 9. Stop the vacuum pump and remove. 10. Install the left cab skirt. 11. Turn the master disconnect switch to the ON position. 12. Bleed the brake system. See Section 7002. 13. Refer to Section 7008 and perform the Parking Brake Test Procedure. 14. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

7001-8

5 6 4

8 8

7 1

1 BC05M138

1. 2. 3. 4.

BRAKE ACCUMULATORS PARKING BRAKE ACCUMULATOR MOUNTING NUT HOSE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

TUBE FRONT BRAKE ACCUMULATOR TUBE REAR BRAKE ACCUMULATOR CLAMP ACCUMULATOR CLAMP STUD

BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

7001-9

BRAKE PUMP Installation

Removal 1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine. 2. Put blocks on both sides of each tire to prevent machine movement. 3. Turn the master disconnect switch to the OFF position. 4. Clean the brake pump (1) and lines, refer to the illustration on page 10. 5. Put identification tags the lines connected to the brake pump (1).

that

are

6. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump.

1. Install gear (6) onto the pump shaft, install washer (7) and slotted nut (8), torque nut to 70 to 79 Nm (52 to 58 pound feet). Refer to the illustration on page 10. 2. Install the cotter pin (9). 3. Install the brake pump (1), mounting bolts (2) and washers (3). 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to 48 pound feet). 5. Remove the plugs or caps and connect the lines to the brake pump (1). 6. Stop the vacuum pump and remove.

7. Disconnect the lines from the brake pump (1) and put plugs in each line.

7. Turn the master disconnect switch to the ON position.

8. Remove the mounting bolts (2) and washers (3) from the brake pump (1) and remove the brake pump (1).

8. Bleed the brake system. See Section 7002. 9. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

7001-10

9 6

3 2 4

BC05M139

1. BRAKE PUMP 2. MOUNTING BOLT (2) 3. WASHER (2)

4. SUCTION HOSE 5. PRESSURE HOSE 6. DRIVE GEAR

7. WASHER 8. SLOTTED NUT 9. COTTER PIN

BRAKE PUMP ILLUSTRATION

7001-11

NOTES

7001-12

HYDRAULIC BRAKE TROUBLESHOOTING

7002

Section 7002

7002-2

ABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 5 6 7 7 8 9 10

7002-3

SPECIFICATIONS Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar (11 to 12 gpm at 2500 psi at 2000 rpm) Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi) Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi) Accumulator valve cut out pressure....................................................................... 190 to 196 bar (2755 to 2845 psi) Brake warning pressure switch (normally closed) opening set point ......................106 to 115 bar (1530 to 1670 psi) Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi) Brake light pressure switch (normally open) closing set point .............................. 5 to 6 bar increasing (75 to 85 psi) Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi) Modulation pressure rear brake cylinders...................................................................78 to 85 bar (1130 to 1230 psi)

SPECIAL TOOLS

G 94L95

CAS-10899 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN. BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

7002-4

TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM NOTE: The hydraulic brake schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual. 1. Check the oil level in the hydraulic reservoir; add oil as necessary. 2. Push and release the brake pedal many times with the engine stopped to remove all hydraulic pressure from the brake system until there is no pressure on the pedal. 3. Install two 207 bar (3000 psi) pressure gauges to front and rear hydraulic brake accumulator test ports, refer to page 7 for the locations of the test ports. 4. Make sure that the pressure gauge hoses are long enough so the gauges can be read while sitting in the operators seat. NOTE: The gauges can not be connected to the test ports if hydraulic pressure remains in the system. 5. Start the engine. Run the engine at low idle while reading the pressure gauges. The alar ms (buzzer, master warning light and brake pressure war ning light) should shut off when the accumulator with the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi), approximately 40 seconds at any engine speed. 6. After the alarms stop, run the machine at high idle to finish charging the accumulators. The pressure must increase on both gauges until 190 to 196 bar (2757 to 2843 psi) is reached. This is the accumulator valve cut-out pressure. It is normal for the pressure to drop slightly once the cut-out pressure is reached. 7. With the engine running at high idle, push and release the brake pedal rapidly while reading the drop in pressure on the gauges. The pressure drops may not be equal, but as the lowest pressure reaches 157 to 167 bar (2280 to 2420 psi), the system pressure must start to increase. This is the valve cut in pressure.

8. Stop the engine. Turn the ignition switch to the ON position. Push and release the brake several times while reading the pressure on the gauges. Each push and release of the pedal will result in a slight drop in pressure, but not necessarily equal on the two gauges. As the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi) the brake warning lamp and alarm buzzer must actuate. If the warning lamp and alarm buzzer fail to work, test the low brake pressure warning switches and electrical circuit. If the warning lamp and alarm buzzer actuate at a higher or lower pressure than specified, test the low brake pressure war ning switches and replace as needed. 9. As the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi) the brake warning lamp and alarm buzzer must actuate. If the warning lamp and alarm buzzer fail to work, test the low brake pressure warning switches and electrical circuit. If the warning lamp and alarm buzzer actuate at a higher or lower pressure than specified, test the low brake pressure warning switches and replace as needed. 10. After the low brake pressure light activates, press the brake pedal eight more times. 11. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi). 12. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete. 13. If the pressures are not within the required specifications, then the brake system must be bled. 14. After bleeding the brake system, perform the brake system check again.

NOTE: The brake cut-in and cut-out pressures of the brake system charge valve are factory preset and are not adjustable.

15. Continue to slowly push and release the brake pedal several times until the gauge pressure suddenly drops to zero. The last pressure reading before the drop to zero is the nitrogen charge pressure in the accumulator. Test the pressure in both accumulators. If the pressure is below 48 to 59 bar (700 to 850 psi), charge or replace the accumulator(s) (see page 5).

NOTE: If the pressure on one of the pressure gauges is lower than specified, the problem can be a bad accumulator valve.

NOTE: Nominal temperature of 20° C (68° F), colder temperature will reduce pressure, hotter temperature will increase pressure.

7002-5

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine.

B. Push down and release the brake pedal many times to release the pressure. 2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit. 3. Close valves B and C on the nitrogen charging kit, refer to the illustration.

4. Turn the stem out of valve F until the stem stops. 94L95

5. Remove the cap screws and guard from the accumulator. 6. Remove the cap from the accumulator valve stem. 7. Connect valve F to the accumulator valve stem.

NITROGEN CHARGING KIT

8. Make sure that valve D is open. 9. Turn the stem into valve F and read the pressure gauge E. 10. The pressure must be 48 to 59 bar (700 to 850 psi). If the pressure is too low, charge the accumulator with dry nitrogen.

CHARGING THE ACCUMULATOR WITH DRY NITROGEN NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator. 1. Close (turn counterclockwise) valve A and open valve B. Close valves C and D. 2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the accumulator valve stem. 3. Connect the nitrogen charging kit to a dry nitrogen tank. 4. Slowly turn valve A clockwise and read gauge E until the pressure is 48 to 59 bar (700 to 850 psi). Stop turning valve A.

5. If the pressure increases above 59 bar (850 psi), quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure. 6. Connect valve F to the accumulator valve stem. Turn the stem into valve F until the stem stops m o v i n g a n d o p e n va l ve D t o c h a r g e t h e accumulator. 7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving. 8. Close valve B and disconnect the nitrogen charging kit from the accumulator valve stem. 9. Install the cap on the accumulator valve stem. I n s t a l l t h e g u a r d a n d c a p s c r ew s o n t h e accumulator.

7002-6

BLEEDING THE BRAKE SYSTEM 1. Check the level of hydraulic fluid in the reservoir. Add fluid to the reservoir if necessary. IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

8. Start the engine and run at low idle. 9. Push the brake pedal all the way down and slowly release for one cycle. 10. Close all four wheel end bleed screws. 11. Fully depress the brake pedal three times in 5 second cycles. 12. With the brake pedal partially depressed, open the bleed screw on the left front axle. Hold the brake pedal in position until the oil is clear (no bubbles). Close the bleed screw. 13. Open the bleed screw on the right front axle. Repeat step 12.

14. Open the bleed screw on the left rear axle. Repeat step 12.

BD03A092

1. SAFETY LINK

2. Raise loader arms and install the safety link (1) for safe access to the front axle bleed screws. 3. Apply the parking brake. 4. Keep the engine speed at high idle until both brake accumulators are fully charged. NOTE: This will be approximately 30 seconds after the low brake pressure light goes out. 5. Stop the engine. 6. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps). 7. Remove the plastic and rubber caps from each wheel end and slowly open all four bleed screws. NOTE: Attach a hose to the bleed screws to prevent spilling any fluids.

15. Open the bleed screw on the right rear axle. Repeat step 12. 16. Replace all bleed screws, caps and plugs. 17. Check the hydraulic fluid and add as necessary.

7002-7

BRAKE MODULATION PRESSURE CHECK

4 BD06F145

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

Testing the Brake Modulation Pressure 1. Make sure the hydraulic accumulator cut-in and cut-out pressures are correct. Refer to page 4 of this section.

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

6. Start the engine. 7. Operate the machine at low idle and watch the pressure gauges on the brake accumulators until the gauges rise above 170 bar (2645 psi). 8. Apply and hold the brakes for 10 to 15 seconds.

2. Stop the engine. Pump the brake pedal until there is no pressure in the brake system.

9. Make a note of the pressure on the gauges for the front and rear brakes.

3. Remove the cab skirts to gain access to the brake test ports.

10. The front brake pressure should read 80 to 87 bar (1160 to 1260 psi). This is the modulation pressure for the front axle.

4. Connect two 207 bar (3000 psi) pressure gauges to the front brake test port (1) and the rear brake test port (2). 5. Connect two 207 bar (3000 psi) pressure gauges to the front brake accumulator test port (4) and the rear brake accumulator test port (3).

11. The rear brake pressure should read 78 to 85 bar (1130 to 1230 psi). This is the modulation pressure for the rear axle 12. If the pressures are not within the specified ra n g e, i t w i l l b e n e c e s s a r y t o a d j u s t t h e modulation pressures.

7002-8

Adjusting the Brake Modulation Pressure NOTE: The adjusting bolt to adjust the modulation pressure is located under the cab, under the brake pedal.

1. Remove the tamper evident cover (1). NOTE: This is a tamper evident cover and it will be necessary to install a new cover after the modulation pressure is adjusted. 2. Turn the adjusting bolt to adjust the modulation pressure. NOTE: The rear brake modulation pressure cannot be adjusted separately from the front brake modulation pressure. 3. Repeat steps 5 through 11 in the Testing the Brake Modulation Pressure procedure. 4. Repeat these steps until the brake modulation pressure is within the specified range.

BD00N121

7002-9

SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) 1

4 BD06F145

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

NOTE: Prior to doing this procedure make sure that the accumulator pressures are correct. 1. Check the level of the hydraulic fluid in the reservoir, add as needed.

6. Start the engine and let idle until both the front and rear accumulators 3 and 4 are fully charged. The accumulators are fully charged at 190 to 196 bar (2755 to 2842 psi). 7. Stop the engine. 8. Push the brake pedal down slowly, allowing for full piston actuation. NOTE: Depress the brake pedal at the rate of three strokes per minute. 9. Continue pressing the brake pedal down. The low brake pressure light should activate when the pressure reaches 106 to 115 bar (1530 to 1670 psi). After the low brake pressure light activates, press the brake pedal eight more times.

1 BD00M030

1. ARTICULATION LOCK

2. Install the articulation lock (1) before doing this test. 3. Remove the left side cab skirt to gain access to the brake accumulator test ports. 4. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps). 5. Connect two 207 bar (3000 psi) pressure gauges to the test ports 3 and 4.

10. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi). 11. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete. 12. If the pressures are not within the required specifications, then the brake system must be bled. 13. After bleeding the brake system, perform the brake system check again.

7002-10

BRAKE PUMP OUTPUT TEST 1. Connect the flowmeter to the brake pump as shown, refer to the illustration below. 2. Make sure the load control of the flowmeter is open. Start the engine. Run the engine at full throttle. Make sure the oil is at operating temperature.

3. Measure the flow at 0 bar (0 psi). Record the flow reading. Slowly close the load valve on the flowmeter and read the flow at 170 bar (2500 psi). Record the flow reading. 4. Divide the flow reading at 170 bar (2500 psi) by the reading at 0 bar (0 psi). Multiply the result by 100. This is the percent efficiency of the pump. If the efficiency of the pump is less than 85%, repair or replace the pump.

5 NOTE

4 3 2

BS03B021

1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD 2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. FILTERS NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

7002-11

NOTES

7002-12

BRAKE PUMP

7003

Section 7003

7003-2

TABLE OF CONTENTS BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 4 4

7003-3

14 17

15 16

18 10 19 7

8 9 11 12 7

5 4 2

1 BC06F594

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

RETAINING RING SEAL RETAINER 0-RING OUTER LIP SEAL INNER LIP SEAL SHAFT END COVER HOUSING QUAD RING

8. 9. 10. 11. 12. 13.

BACKUP SEAL CHANNEL SEAL DOWEL PIN THRUST PLATE GEAR HOUSING PORT END COVER HOUSING PUMP ILLUSTRATION

14. 15. 16. 17. 18. 19.

WASHER BOLT DRIVEN GEAR DRIVE GEAR DRIVE SCREW NAME PLATE

7003-4

BRAKE PUMP Disassembly 1. Secure the pump by the port end cover (13) in a soft jawed vise. 2. Draw a line the length of the pump to assist during assemble. 3. Loosen and remove bolts (15). 4. Tap the shaft end cover housing (6) with soft hammer to loosen it, remove the shaft end cover housing (6). 5. Remove the backup seal (8), channel seal (9), and thrust plate (11). 6. Remove the drive gear (17) from the gear housing (12). 7. Remove the driven gear (16) from the gear housing (12). 8. Tap the gear housing (12) with a soft hammer to loosen it, remove the gear housing (12). 9. Remove the backup seal (8), channel seal (9), and thrust plate (11). 10. Remove the retaining ring (1) form the shaft end cover housing (6). 11. Remove the seal retainer (2), O-ring (3), and outer lip seal (4) from the shaft end cover housing (6). 12. Remove the inner lip seal (5) from the shaft end cover housing (6).

Inspection 1. Discard all seals and quad rings. Clean all parts in cleaning solvent. Check all machined surfaces for damage or wear. 2. Hold a straightedge across each gear housing and use a feeler gauge to measure the amount of wear caused by the gear teeth in the gear pocket. If the wear in any gear pocket is more than 0.18 MM. (0.007 inch), use a new gear housing. 3. Inspect the thrust plates for scoring, pitting, or other damage. 4. Inspect the gears for wear and damage. There must be no scoring on the gear hubs or on the outside edges of the gear teeth. There must be no more than 0.05 MM. (0.002 inch) wear in the seal area of the drive shaft. If any gear must be discarded, you must use a new hydraulic pump.

Assembly 1. Install a new lip seal (3) into the seal retainer (2) so the lip of the seal will be facing away from the gears when the seal retainer (2) is installed into the shaft end cover housing (6). 2. Install a new lip seal (4) into the shaft end cover housing (6) with the lip of the seal facing towards the gears. 3. Install a new O-ring (3) onto the seal retainer (2), lubricate the O-ring with hydraulic oil. 4. Press the seal retainer (2) into the shaft end cover housing (6) and install the retaining ring (1). 5. Place the shaft end housing (6), facing down, into a soft jawed vise. 6. Install new backup seals (8) and channel seals (9) into the thrust plates (11). 7. Place a thrust plate (11) onto the shaft end cover housing (6). IMPORTANT: Be sure to place the thrust plate (11) onto the shaft end cover housing (6) in the position shown in the illustration on page 3. 8. Lubricate the driven gear (16) with hydraulic oil, slide the driven gear (16) through the thrust plate (11) into the shaft end cover housing (6). 9. Lubricate the drive gear (17) with hydraulic oil, slide the drive gear (17) through the thrust plate (11) into the shaft end cover housing (6). 10. Install a new quad ring (7) into the gear housing (12). Check that dowel pins (10) are in place either in the gear housing (12) or the shaft end cover housing (6). 11. Align the marks made during disassembly, carefully place the gear housing (12) onto the gears. 12. Slide the thrust plate (11) onto the shafts of the gears. IMPORTANT: Be sure to place the thrust plate (11) onto the gears in the position shown in the illustration on page 3. 13. Install a new quad ring (7) into the gear housing (12). Check that dowel pins (10) are in place either in the gear housing (12) or the port end cover housing (13). 14. Align the marks made during disassembly, place the port housing (12) onto the gear housing (12). 15. Install bolts (15) with clean and dry threads, washers (14). Torque bolts to 192 ± 5.5 Nm (141.5 ± 4 pound feet).

BRAKE ACCUMULATORS

7004

Section 7004

7004-2

TABLE OF CONTENTS SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 4

7004-3

SPECIAL TOOL E

C F

G D

A 94L95

CAS10899 NITROGEN CHARGING KIT

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR 1. Remove cover from accumulator charge port. Loosen the Allen screw in the charge port.

6. Connect valve F to the valve stem on the adapter.

NOTE: Do not turn the Allen screw more than 1/8 of a turn or gas will escape uncontrolled.

7. Turn the T-handle inward on valve F to engage the pin in the valve stem, open valve G.

2. Install adapter on accumulator, use the CAS10899 nitrogen charging kit to discharge the accumulator, refer to illustrations above. The tool must be disconnected from the nitrogen tank.

8. Open valve D and check the charge pressure on gauge E.

3. Close valves B, C and D. 4. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise. 5. Turn the T-handle on valve F fully out.

9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem and remove adapter.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine. B. Push down and release the brake pedal 21 times to release the pressure. 2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit. 3. Close valves B and C on the nitrogen charging kit, refer to the illustration. 4. Turn the stem out of valve F until the stem stops.

5. Remove the cap from the accumulator. Loosen the Allen screw in the charge port. NOTE: Do not turn the Allen screw more than 1/8 of a turn or gas will escape uncontrolled. 6. Connect adapter to accumulator. 7. Connect valve F to the adapter valve stem. 8. Make sure that valve D and G are open. 9. Turn the stem into valve F and read the pressure gauge E. NOTE: See chart below for pressure readings. 10. If the pressure is too low, charge the accumulator with dry nitrogen.

7004-4

6. Connect valve F to the adapter valve stem. Turn the stem into valve F until the stem stops moving and open valve G and D to charge the accumulator.

1. Close (turn counterclockwise) valve A and open valve B. Close valves C, D, and G.

7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving and close valve G.

2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the adapter valve stem. 3. Connect the nitrogen charging kit to a dry nitrogen tank. 4. Slowly turn valve A clockwise and read gauge E until the pressure is equal to charge pressure required for accumulator being charged. Stop turning valve A. 5. If the pressure increases above required pressure, quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure.

8. Close valve B and disconnect the nitrogen charging kit from the adapter valve stem, remove the adapter. 9. Torque the Allen screw to 20 Nm (15 lb-ft), install the cover on the accumulator valve stem.

TEMPERATURE 0° C 32° F 5° C 41° F 10° C 50° F 15° C 59° F 20° C 68° F 25° C 77° F 30° C 86° F 35° C 95° F 40° C 104° F

CHARGE PRESSURE 51.2 BAR 743 PSI 52.2 BAR 757 PSI 53.1 BAR 770 PSI 54.1 BAR 784 PSI 55.0 BAR 798 PSI 55.9 BAR 811 PSI 56.9 BAR 825 PSI 57.8 BAR 839 PSI 58.8 BAR 852 PSI

TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR

Section 7008

7008

PARKING BRAKE

7008-2

TABLE OF CONTENTS PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 5

7008-3

PARKING BRAKE Disassembly

STEP 7

STEP 1 Park the machine on a hard level surface and lower the loader bucket to the ground.

STEP 2 Place wheel chocks on each wheel to prevent machine movement.

STEP 3 BD03A185

Loosen the jam nut, tur n adjusting bolt counterclockwise until the brake pads are loose.

STEP 8

BD01F143

Install the articulation lock.

STEP 4 Place the master disconnect switch in the OFF position.

STEP 5

BD03A186

Pump the brake pedal at least 30 times to discharge the accumulators.

Remove the retainer pin and brake pin.

STEP 9

STEP 6

BD03A187 BD03A184

Loosen and remove the cover from the parking brake.

Remove the two brake pads from the parking brake assembly.

7008-4

Inspection

STEP 14 Disengage the parking brake.

STEP 10 Clean and inspect all parts for wear and damage. Inspect the brake disc for wear and damage. Replace all parts that are worn or damaged.

NOTE: Hydraulic pressure will not be applied to the parking brake until the parking brake rocker switch is turned off, the service brakes applied and the transmission is put into gear. A. Place the parking brake rocker switch in the OFF position.

Assembly

B. Apply the service brake and put the machine into gear.

STEP 11

C. The parking brake light on the cluster will turn off at this time. Place the transmission back into neutral before proceeding.

STEP 15

BD03A187

Install the two brake pads in the parking brake assembly.

STEP 12 BD0CA185

Turn the adjusting bolt clockwise until both brake pads contact the brake disc, then turn the adjusting bolt counterclockwise one turn. Tighten the jam nut to secure the adjusting bolt.

STEP 16 Install the cover on the parking brake.

STEP 17 BD03A186

Install the brake pins and retainer pins.

STEP 13 Place the master disconnect switch to the on position. Start the machine and run the engine at low idle with the bucket resting on the ground. IMPORTANT: It will be necessary to have an assistant help for this procedure. An operator must be present in the cab at all times to apply the service brakes and shut down the machine in the event of mechanical failure.

Perfor m the Parking Brake Test Procedure as described in this section.

STEP 18 Return the articulation lock to the operating position.

7008-5

PARKING BRAKE TEST PROCEDURE STEP 19

STEP 24

While testing, the machine must be on a clear level surface with the bucket in the travel position. WARNING: Always know the location of all workers in your area. Warn them before you start working the machine. Always keep all other persons away from your area. Serious injury or death can result if you do not follow these instructions. SA015

STEP 20 Start the machine and run the engine at low idle in third gear neutral.

STEP 21 Place the Transmission-Auto switch to the manual position.

RCPH10WH381BAH

Use up or down arrow and highlight test park brake and press the confirm key to enter selection.

STEP 22 Place the Parking Brake switch to the ON position.

STEP 23

BD06F143

Monitor will display Test Park Brake if all conditions are met to test the brake, press the enter key.

BD06F141

Press and hold the enter key for 2 to 3 seconds until the instrument cluster monitor display changes to the select screen.

NOTE: If all conditions are not met to test the brake the monitor will display the condition that needs corrected prior to proceeding.

STEP 25 Monitor will display Test Park Brake Ready.

STEP 26 Shift the gear selector into third gear forward and slowly increase the engine speed to wide open throttle.

STEP 27 Verify that the machine does not move.

STEP 28 Reduce the engine speed to low idle and return the transmission neutral.

7008-6

STEP 29 Shift the gear selector to third gear reverse and slowly increase the engine speed to wide open throttle.

STEP 30 Verify that the machine does not move.

STEP 31 Reduce the engine speed to low idle and return the transmission to neutral.

STEP 32

BD06F141

Press the escape switch on the key pad to exit the test mode.

STEP 33 If any machine movement was detected, the parking brake must be adjusted, see procedures this section.

8001 Section 8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

8001-2

TABLE OF CONTENTS LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 6 8 8 9 11 12 12 13 13 14 15 15 17 17 18 20 20 22 24 24 25 26 26 27 28 28 29 30 30 31 32 32 32

8001-3

LOADER CONTROL VALVE Removal

STEP 5

STEP 1 Park the machine on a level surface. IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

STEP 2

BD06H198

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

STEP 6 Loosen the filler cap on the reservoir to release the air pressure in the reservoir. BD03A092

Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 3

STEP 7 Drain the hydraulic reservoir.

STEP 8

Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

STEP 4 Place the master disconnect switch in the OFF position. BD03A093

Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

8001-4 REAR OF MACHINE

6 7 5

3 2

BC05M094

1. GREEN WHITE GREEN 2. RED WHITE GREEN 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN WHITE GREEN 6. RED WHITE GREEN HYDRAULIC VALVE PILOT LINE CONNECTIONS

7. GREEN BLACK GREEN 8. RED BLACK GREEN 9.

8001-5

1 3 4

BC05M093

1. DUMP LINE 2. ROLLBACK LINE 3. LOWER LINE LEFT

4. RAISE LINE RIGHT 5. LOADER VALVE

6. LOWER LINE RIGHT 7. RAISE LINE LEFT

LOADER CONTROL VALVE LINE CONNECTIONS

8001-6

Installation

STEP 9 Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and 6) from the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding. Install a plug in each hose and a cap on each fitting.

IMPORTANT: Before installing the fittings or connecting the tubes to the fittings, install new O-rings on the fittings.

STEP 16

NOTE: Line 1, 2, 5, and 6 will need to be tagged as right or left of valve.

STEP 10 Loosen and remove tilt cylinder lines (1 and 2). Install a plug in each line and a cap on each fitting.

STEP 11 Loosen and remove lines (3 and 4). Install a plug in each line and a cap on each fitting.

STEP 12

BC05M096

Loosen and remove lines (6 and 7). Install a plug in each line and a cap on each fitting.

Install and align the loader control valve with the valve mounting plate.

STEP 13

STEP 17

Loosen and remove supply and return lines. Install a plug in each line and a cap on each fitting.

Install the bolts and washers that fasten the loader control valve to the valve mounting plate. Tighten the bolts.

STEP 14 Attach proper lifting equipment to lift loader control valve.

STEP 18

STEP 15

STEP 19

Tighten the left lift cylinder lines (6 and 7).

Install and tighten the supply and return lines.

STEP 20 Install and tighten right lift cylinder lines (3 and 4).

STEP 21 Install and tighten tilt cylinder lines (1 and 2).

STEP 22 BC05M096

Loosen and remove the three bolts and washers that hold the loader control valve to the valve mounting plate. Remove the loader control valve.

Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and 6) to the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding.

8001-7

STEP 23

STEP 27

Fill the hydraulic reservoir with oil. Refer to Section 1002 for the correct oil.

Run engine at half throttle.

STEP 28 STEP 24 Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.

STEP 29 Stop the engine and check for leaks.

STEP 25 Place the master disconnect switch in the ON position.

STEP 30

STEP 26

STEP 31

Install the access cover on the front of the machine.

Check the level of the hydraulic oil and add hydraulic oil as required.

BD03A092

Raise the loader arms and remove the safety link.

8001-8

REMOTE CONTROL VALVE Removal

STEP 37

STEP 32 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

BD06F208

Open and remove the access panel.

STEP 33 Place the master disconnect switch in the OFF position.

STEP 38

STEP 34 Unlatch and open the right hand side access door.

STEP 35 Lift the access door up and remove the access door from the pins.

STEP 36 BD06F209

Remove the front access panel.

STEP 39

BD06F207

Unlatch and open the window on the right hand side.

BD06F210

Disconnect the electrical connectors for the remote control valve.

STEP 40 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

8001-9

STEP 41

Installation

Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings.

STEP 45

STEP 42 Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.

STEP 43 Loosen and remove the screws that fasten the remote control valve to the hydraulic control tower.

STEP 44 Remove the remote control valve from the hydraulic control tower.

Install new O-rings on the adapters for the remote control valve.

STEP 46 Install the remote control valve and screws in the hydraulic control tower and tighten the screws.

STEP 47 Install the cover over the remote control valve and install the screws and washers.

STEP 48 Remove the plugs from the hoses and the caps from the fittings and connect the hydraulic hoses to the fittings according to the identification tags. (Refer to illustrations on pages 11, 12, and 13 as necessary.

STEP 49 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 50

BD06F210

Connect the electrical connectors for the remote control valve.

STEP 51 Place the master disconnect switch in the ON position.

STEP 52 Start the engine and run the engine at low idle.

STEP 53 Check to see that the remote control valve works correctly.

8001-10

STEP 54

STEP 57

Check for hydraulic oil leakage at the remote control valve.

STEP 55 Check the level of hydraulic oil in the reservoir and add as required.

STEP 56

BD06F208

Install and close the access panel.

STEP 58

BD06F209

Position the access panel on the ROPS cab or the ROPS canopy and install and tighten the screw.

BD06F207

Close the right hand window.

8001-11

8 4 6 7

1 5

5 2

1 8

3 6

4 BC05M092

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN BLACK GREEN 6. RED BLACK GREEN

7. GREEN WHITE GREEN 8. RED WHITE GREEN

JOYSTICK AND 2 LEVER HOSE COLOR CODING

8001-12

4 3

4 6

2 7

7 1

5 BC05M091

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

3 LEVER HOSE COLOR CODING

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

JOYSTICK AND 1 LEVER HOSE COLOR CODING

8001-13

1 5 4

2 1

3 2

3 4

5 BC05M090

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

2 LEVER HOSE COLOR CODING

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

JOYSTICK HOSE COLOR CODING

8001-14

HYDRAULIC PUMP

10 15

4 5 6 4

5 8

15 6

2 3 14 11 9 12

BC05M095

1. 2. 3. 4.

PUMP MAIN HYDRAULIC MOUNT BOLTS DRAIN HOSE BOLT

5. 6. 7. 8.

SPLIT FLANGE 9. STEERING HIGH PRESSURE TUBE 10. CLAMPS HOSE SUCTION 11. STEERING LOAD SENSE HOSE HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE

13. 14. 15. 16.

LOADER HIGH PRESSURE STEERING PRIORITY MANIFOLD CLAMPS FITTINGS

8001-15

Removal NOTE: When disconnecting hydraulic fittings, plug hoses and cap fittings to prevent entry of foreign matter into hydraulic system.

STEP 59 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 69 Connect lifting equipment to hydraulic pump (1). Take up all slack in lifting equipment. Remove four mounting bolts (2) and washers securing pump to transmission. Pull hydraulic pump from transmission and remove from loader. Remove and discard O-ring from pump.

Installation NOTE: Install new O-rings where required.

STEP 60 Place the master disconnect switch in the OFF position.

STEP 61 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 62 Refer to Section 9007 and remove the ROPS cab or ROPS canopy.

STEP 63 Remove eight bolts (4) and washers. Remove four split flanges (5). Disconnect tubes (6) with suction hoses (7) from hydraulic pump. Remove and discard O-ring face seals from flange heads of tubes.

STEP 70 Install new O-ring on hydraulic pump flange. Move pump into position and install in transmission. Install four washers and bolts (2) to secure pump (1) to transmission, tighten the bolts. Disconnect lifting equipment from pump.

STEP 71 Connect pump pressure hoses (9 and 13) to steering priority manifold (14).

STEP 72 Connect drain hose (3).

STEP 73 Connect load sense hoses (11 and 12).

STEP 74 STEP 64

Install and connect case drain hoses (8).

Loosen clamps (10). Tag and disconnect suction hoses (7) from hydraulic reservoir and remove from machine.

STEP 75

STEP 65 Tag and disconnect case drain hoses (8) from fittings (16); remove hoses (8). Remove and discard O-ring face seals from fittings.

STEP 66 Tag and disconnect load sense hoses (11 and 12). Remove and discard O-ring face seals from fittings.

STEP 67 Tag and disconnect drain hose (3). Remove and discard O-ring face seals from fittings.

STEP 68 Tag and disconnect pump pressure hoses (9 and 13) from steering priority manifold (14). Remove and discard O-ring face seals from flange heads of hoses.

Install suction hoses (7), tighten clamps (10) to 10 to 11 Nm (90 to 100 pound inches).

STEP 76 Install four split flanges (5). Install eight bolts (4) and washers, tighten bolts (4) to 73 to 90 Nm (53.8 to 66.3 pound feet).

STEP 77 Refer to Section 9007 and install the ROPS cab or ROPS canopy.

STEP 78 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 79 Place the master disconnect switch in the ON position.

8001-16

STEP 80

STEP 81

Start the engine and run the engine at low idle for two minutes.

Stop the engine and check for hydraulic oil leakage at the hydraulic pump.

NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.

STEP 82 Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

8001-17

LIFT CYLINDERS Removal

STEP 87

STEP 83 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF. BD01D709

STEP 84 Relieve the pressure in the ride control accumulator with the manual bleeder valve located at the rear of the front chassis.

Loosen and remove the bolt, washer and spacer that hold the pivot pin for the yoke.

STEP 88

STEP 85 Loosen the filler cap on the hydraulic reservoir to release any pressure.

STEP 86

BD01D711

Use a proper lifting device and secure a strap around the lift cylinder.

STEP 89 BD01D708

Tag and disconnect the hoses on each side of the lift cylinder. Install plugs in the hoses and caps on the fittings.

BD01D712

Remove the pivot pin from the yoke end of the lift cylinder.

8001-18

Installation

STEP 90

STEP 93 Apply antiseize compound to the bores in the front frame and the yoke on the piston rod.

STEP 94

BD01D710

Loosen and remove the bolt, washer and spacer that hold the pivot pin at the closed end of the lift cylinder.

STEP 91 BD01D714

Use a proper lifting device and position the lift cylinder on the machine.

STEP 95

BD01D713

Remove the pivot pin from the closed end of the lift cylinder.

STEP 92 Remove the lift cylinder from the machine BD01D713

Align the closed end of the lift cylinder with the front frame and install the pivot pin.

8001-19

STEP 96

STEP 99

BD01D710

Align the pivot pin with the front frame and install the spacer, washer and bolt. Tighten the bolt.

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 100 STEP 97

BD01D709 BD01D708

Remove the caps and plugs and connect the hoses to the lift cylinder.

Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.

STEP 101 STEP 98 If the yoke of the lift cylinder is not aligned with the loader frame, have another person start and run the engine at low idle and use the loader control lever to SLOWLY move the yoke into alignment with the loader frame.

SLOWLY extend and retract the piston rod three times to remove any air from the lift cylinders.

STEP 102 Lubricate the pivot pins with molydisulfide grease.

STEP 103 Check the level of hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-20

BUCKET CYLINDER - Z-BAR LOADER Removal

STEP 108

STEP 104 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 105 With the engine stopped, move the bucket control lever to release pressure in the bucket circuit.

STEP 106 BD01D695

Loosen and remove the two bolts that fasten the mounting bracket to the machine. Remove the mounting bracket.

STEP 109

BD01D694

Disconnect the proximity switch connector from the wiring harness connector.

STEP 107 BD01D697

Loosen and remove the two bolts that fasten the mounting bracket for the proximity switch to the bucket cylinder. Remove the mounting bracket and switch.

BD01D696

Loosen and remove the two bolts that fasten the target bar to the mounting bracket. Remove the target bar.

8001-21

STEP 110

STEP 113

BD01D699

BD01D701

Disconnect the hoses from each side of the bucket cylinder. Install plugs in the hoses and caps on the fittings.

Remove the pivot pin from the rod end of the bucket cylinder.

STEP 114 STEP 111

BD01D704 BD01D700

Use acceptable equipment to hold the bucket cylinder.

STEP 112

Remove the pivot pin from the head end of the bucket cylinder. NOTE: It is not necessary to remove the grease line from the pivot pin unless the pivot pin is to be replaced.

STEP 115

BD01D698

Loosen and remove the bolt, washer and spacer that fasten the pivot pin from both ends of the bucket cylinder.

BD01D706

Raise the bucket cylinder and remove the cylinder from the machine.

8001-22

Installation

STEP 120

STEP 116 Apply antisieze compound to the bores in the front frame and the bores in the loader arm for the bucket cylinder.

STEP 117

BD01D699

Connect the hoses to each side of the bucket cylinder.

STEP 121

Use acceptable lifting equipment to lower the bucket cylinder into position.

If the rod end of the bucket cylinder is not aligned with the bellcrank, have another person start the engine and run the engine at low idle and use the bucket control lever to SLOWLY move the piston rod eye into alignment with the bellcrank.

STEP 118

STEP 122

BD01D706

Install the pivot pin and stop the engine.

STEP 123

BD01D704

Install the pivot pin to the head end of the bucket cylinder. BD01D698

STEP 119 Install the spacer, washer and bolt that fasten the pivot pin to the front frame. Tighten the bolt. NOTE: If a new pivot pin is being installed, connect the grease line to the pivot pin.

Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.

8001-23

STEP 124

STEP 127

BD01D697

BD01D694

Install the two bolts that fasten the mounting bracket for the switch to the bucket cylinder.

Connect the proximity switch connector to the wiring harness connector.

STEP 125

STEP 128 See Section 9006 for the adjustment procedure for adjusting the proximity switch.

STEP 129 Start and run the engine at low idle.

STEP 130 SLOWLY extend and retract the piston rod three times to remove any air from the bucket cylinder.

STEP 131 Lubricate the pivot pins with molydisulfide grease. BD01D695

Install the two bolts for the mounting bracket for the target bar.

STEP 126

BD01D696

Install the two bolts that fasten the target bar to the mounting bracket.

STEP 132 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-24

OIL COOLER Removal

STEP 138

STEP 133 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

STEP 134 Place the master disconnect switch in the OFF position.

STEP 135 Raise the engine hood and remove the shield on the right side of the machine between the tire and the oil cooler.

STEP 136

BD03A154

Disconnect the top hose and install a plug in the hose and a cap on the fitting.

STEP 139

BD03A120

Have assistant hold side panel in raised position, remove two mounting screws, remove side panel.

STEP 137 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

BD03A179

Loosen and remove the bolt and washer that fasten the oil cooler to the cooling frame.

STEP 140

BD06H195

Disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting. Remove the two mounting nuts, remove the oil cooler from the machine.

8001-25

Installation

STEP 144

STEP 141

BD03A120

BD06H195

Place the oil cooler in position in the cooling frame. Connect the lower hose to the oil cooler, install and tighten the two mounting nuts.

STEP 142

Have assistant hold side panel in raised position, install and tighten two mounting screws.

STEP 145 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 146 Place the master disconnect switch in the ON position.

STEP 147 Start the engine and run the engine at low idle for two minutes. Stop the engine and check for hydraulic oil leakage at the ports on the oil cooler.

STEP 148 Install the shield between the right rear tire and the oil cooler and tighten the two bolts holding the shield. BD03A179

Install the bolt and washer that fasten the oil cooler to the cooling frame

STEP 143

BD03A154

Connect the hose to the top of the oil cooler.

STEP 149 Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

8001-26

RIDE CONTROL ACCUMULATOR Removal

STEP 153

STEP 150 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

BD06H196

Disconnect the hose from the elbow at the bottom of the ride control accumulator. Install a plug in the hose and a cap on the fitting.

STEP 151

STEP 154

BD06H198

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

STEP 152 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

BD06H197

Loosen and remove the nuts and washers from the U-bolt. Remove the U-bolt.

STEP 155 Loosen and remove the two bolts that fasten the accumulator bracket to the front frame. Remove the ride control accumulator from the machine.

8001-27

Installation

STEP 159

STEP 156 Place the ride control accumulator in position on the front frame.

STEP 157 Install the two bolts that fasten the accumulator bracket to the front frame. Tighten the bolts.

STEP 158 BD06H196

Remove the caps and plugs and install the hose on the elbow at the bottom of the r ide control accumulator.

STEP 160 Turn off and disconnect the vacuum pump from the hydraulic reservoir.

STEP 161 BD06H197

Install the U-bolt, washers and nuts. Tighten the nuts.

Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 162 Refer to Section 8002 Testing the Ride Control for the proper charging of the accumulator to check for leaks.

STEP 163 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-28

RIDE CONTROL VALVE Removal

STEP 166

STEP 164 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 167 Place the master disconnect switch in the OFF position.

STEP 168 Disconnect the electrical connector on top of the ride control valve.

STEP 169

STEP 165

Tag and disconnect the hoses from the ride control valve. Install a plug in the hoses and caps on fittings.

STEP 170 Loosen and remove the two bolts and washers that fasten the ride control valve to the frame.

STEP 171 Remove the ride control valve from the machine.

STEP 172 BD06H198

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

Remove and discard all O-rings.

8001-29

Installation

STEP 178

STEP 173

Connect the electrical connector to the ride control valve.

Install the ride control valve in position on the front frame.

STEP 179

STEP 174

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

Install the washers and bolts through the frame and into the ride control valve. Tighten the bolts.

STEP 180

STEP 175

Place the master disconnect switch in the ON position.

STEP 181 Start and run the engine at low idle for two minutes.

STEP 182 Stop the engine and check for hydraulic oil leakage at the ride control valve.

STEP 183

BD06H198

Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 176 Lubricate and install new O-rings.

STEP 177 Connect the hoses to the ride control valve.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

STEP 184 Refer to Section 8002 and perform the Ride Control Test Procedure.

8001-30

FAN REVERSING VALVE Removal

STEP 188

STEP 185 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

2 1

BD03A174

STEP 186 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

Tag and disconnect the fan forward hose (1) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan reverse hose (2) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 187

STEP 189

4 BD03A173

BD03A174

Disconnect the electrical connector for the fan reversing valve.

Tag and disconnect the fan valve return hose (3) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan valve supply hose (4) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 190 Loosen and remove the nuts, washers and bolts.

STEP 191 Remove the fan reversing valve from the machine.

STEP 192 Remove and discard all O-rings from the fittings.

8001-31

Installation

STEP 198

STEP 193 Place the fan reversing valve into position on the machine.

STEP 194 Lubricate and install new O-rings in the fittings.

STEP 195 Install the bolts, washers and nuts. Tighten the nuts.

STEP 196 BD03A174

Connect the electrical connector for the fan reversing valve.

STEP 199 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 200

Check the level of the hydraulic oil in the reservoir.

4 BD03A173

STEP 201

Connect the fan valve supply hose (4) to the fitting on the fan reversing valve. Connect the fan valve return hose (3) to the elbow on the fan reversing valve.

Start the engine and run the engine at low idle for two minutes.

STEP 197

Stop the engine and check for hydraulic oil leakage at the fan reversing valve.

STEP 202

STEP 203 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

2 1

BD03A174

Connect the fan reverse hose (2) to the fitting on the fan reversing valve. Connect the fan forward hose (1) to the fitting on the fan reversing valve.

8001-32

THERMAL VALVE Removal

Installation

STEP 204

STEP 208

Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

Place the thermal valve into position on the machine.

IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

Lubricate and install new O-rings in the fittings.

STEP 205 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 209 STEP 210 Install the bolts, washers and nuts. Tighten the nuts.

STEP 211 Connect the hoses to the thermal valve, remove and discard tags.

STEP 212 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 213

STEP 206

Check the level of the hydraulic oil in the reservoir.

STEP 214 Start the engine and run the engine at low idle for two minutes.

STEP 215 Stop the engine and check for hydraulic oil leakage at the thermal valve.

STEP 216 BD06F211

Tag and disconnect the hoses from the thermal valve. Install a plug in the hose and a cap on the fitting.

STEP 207 Remove the mounting bolts from the thermal valve, remove the valve from the machine.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

8002

Section 8002

8002-2

TABLE OF CONTENTS 721F - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 5 5 5 6 6 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15 16 17 17 18 20 20 20 21 22

8002-3

721F - SPECIFICATIONS Manufacturer........................................................................................................................................ Bosch-Rexroth High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 2500 psi, at 2000rpm) Low pressure pump (furthest from transmission) .................................................. 86 L/min at 172 bar, at 2000 r/min (22.6 gpm at 2500 psi, at 2000rpm) Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi) Circuit relief valve pressure setting Auxiliary A and B port.................................................................................................................290 bar (4200 psi) Bucket A port..............................................................................................................................152 bar (2200 psi) Bucket B port..............................................................................................................................290 bar (4200 psi) Pilot accumulator pressure .............................................................................................13 to 15 bar (188 to 218 psi) Steering relief valve pressure setting ............................................................................................. See Section 5002 Brake accumulator pressure .......................................................................................................... See Section 7002 NOTE: Both pump sections provide flow for both the steering and loader functions.

8002-4

SPECIAL TOOLS

B877168V

633L95

CAS-1808 FLOWMETER FITTING KIT

CAS-1904 PRESSURE FITTING KIT

B877895M

632L95

CAS-10090 HAND PUMP

CAS-1906 PRESSURE FITTING KIT

B877558M

B785789M

CAS-10280 FLOWMETER

CAS-1804 PRESSURE FITTING KIT

8002-5

TROUBLESHOOTING PROCEDURE Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts. Check the oil level in the hydraulic reservoir. Is the oil level correct?.

Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.

See Page 18. Do the flow meter test of the hydraulic pump.

Adjust the limit pressure. See page 11 in this section.

Yes Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.

Problems in All Circuits Replace the return line hydraulic filter. See Section 2002. Do the stall test to see if the engine is good. See Section 8003 and check for contaminated oil. Is the oil contaminated? Yes See Section 8003 and clean or replace the oil.

Problem in All Loader Circuits See Page 11 and check the pressure setting of the limit pressure in the loader control valve. Is the pressure setting correct?

Problem in the Braking Circuit See Section 7002 and check the braking circuit.

8002-6

Problem in a Single Loader Circuit Star t and run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

The loader control valve is damaged. See Section 8005 and repair the loader control valve

See Section 8006 and repair the cylinder.

See Section 8005. Disassemble the loader control valve and che ck for wor n or damaged parts.

Repair the component as necessary.

See the Ride Control Test Procedure page 21 in this section.

Yes Check the cylinder piston packing. Is the packing good? Yes See Page 20. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly? Yes The problem is repaired.

Problem in the Steering Circuit See Section 5002 and check the steering circuit. Is the steering circuit good? Yes See Page 13. Do the Steering Pump Limit Pressure Test and Adjustment

Problem in the Ride Control Lift ar ms rapidly and continuously sink towards the ground. Yes Check the manual bleed valve for the ride control accumulator to be sure that it is closed.

8002-7

TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check

STEP 3

STEP 1

BD06G180

1 BD00M041

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

●

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle. B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

BD06F148

1. TEST PORT (LOAD SENSE) 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to the test port (2) located on the priority valve, and one on the pump load-sense pressure tap (1 closest to transmission). IMPORTANT: Do not steer or operate loader controls while the gauges are connected, gauges could be damaged.

STEP 4 Start the engine and run at low idle.

STEP 5 Make sure all of the controls are in the neutral position and record the readings on the test gauges (1) and (2).

STEP 6 Subtract the reading of the test port (1) from the reading of the test port (2).

STEP 7

The difference between the two readings should be 24 to 27 bar (350 to 390 psi).

8002-8

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

Adjusting the High Pressure Pump Differential Pressure STEP 9 The load-sense adjusting screw is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the load-sense pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

8002-9

TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check

STEP 3

STEP 1

BD06G180

1 2 BD00M041

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on. ●

BD06F148

To measure the oil temperature with the instrument cluster:

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

1. TEST PORT (LOAD SENSE) 2. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges, one to the test port (2) located on the priority valve, and one on the pump load-sense pressure tap (1 furthest from the transmission). IMPORTANT: Do not steer of operate loader controls while the gauges are connected, gauges could be damaged.

STEP 4 Start the engine and run at low idle.

STEP 5 Make sure all of the controls are in the neutral position and record the readings on the test gauges (1) and (2).

STEP 6 Subtract the reading of the test port (1) from the reading of the test port (2).

STEP 7

The difference between the two readings should be 25 to 28 bar (360 to 400 psi).

8002-10

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump differential pressure.

Adjusting the Low Pressure Pump Differential Pressure STEP 9 The differential adjusting screw is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the differential pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

8002-11

TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

●

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle.

1 BD00M041

1. ARTICULATION LOCK

B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e r a i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

Install articulation lock (1).

STEP 2

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

STEP 4

Run the engine at full throttle.

STEP 5 Roll the loader bucket back against the stops.

STEP 6 Record the reading on the test gauge. BD06F148

1. TEST PORT (LOAD LIMIT)

STEP 7 Reading should be 248 to 255 bar (3600 to 3700 psi).

Connect a 345 bar (5000 psi) test gauge to the test port (1), located on the priority valve.

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump limit pressure.

8002-12

Adjusting the Loader Limit Pressure

STEP 9 The limit adjusting screw is located on the left side of the loader valve. Tur n the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 35 bar (500 psi).

BD06H193

8002-13

TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

●

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle.

1 BD00M041

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

STEP 4

Start the engine and run at full throttle.

STEP 5 Steer hard in either direction over relief pressure.

STEP 6 Record the reading on the test gauge. BD06F148

1. TEST PORT (LOAD LIMIT)

STEP 7 Reading should be 239 to 243 bar (3465 to 3525 psi).

Connect a 345 bar (5000 psi) test gauge to the test port (1), located on the priority valve.

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the steering limit pressure.

8002-14

Adjusting the Steering Limit Pressure

STEP 9 The steering priority valve is located on the hydraulic p u m p, t h e a d j u s t i n g va l ve i s l o c a t e d o n t h e transmission side of the priority valve. Turning the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure.

BD06F147

1. STEERING LIMIT VALVE

8002-15

TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

●

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle.

1 BD00M041

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

STEP 4 Start the engine and run at full throttle.

STEP 5 Roll the loader bucket back against the stops.

STEP 6 Record the reading on the test gauge. BD06F148

1. TEST PORT (PUMP PRESSURE)

STEP 7 Reading should be 198 to 202 bar (2870 to 2930 psi).

Connect two 345 bar (5000 psi) test gauge to the test port (1) located on the large hydraulic tube on the bottom of the pump.

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump cutoff pressure.

8002-16

Adjusting the Loader Pump Cutoff Pressure STEP 9

BD06G179

The unloading adjuster is the longer of the two adjusters on the loader pump. Tur n the screw clockwise to increase the cutoff pressure. Turning the screw counterclockwise will decrease the cutoff pressure. NOTE: The adjusting screw is located just above the steering priority valve on the pump furthest from the transmission.

8002-17

TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE NOTE: This pressure is factory preset and is not adjustable.

Pressure Check

STEP 6 Open the right side compartment to gain access to the loader control handle.

STEP 7 STEP 1 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the oil temperature with the instrument cluster: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

●

To heat the hydraulic oil do the following:

Attach a gauge capable of reading 70 bar (1000 psi) to the test port under loader control handle.

STEP 8 Start and run the machine at low idle, hold the bucket control lever in the ROLLBACK position to increase the system pressure.

STEP 9 A pressure reading of 29.5 to 39.5 bar (425 to 575 psi) should be obtained, if pressure is not as specified do the following steps.

A. Start the engine and run at full throttle. B. Hold the bucket control lever in the RO L L B AC K p o s i t i o n w h i l e ra i s i n g a n d lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

STEP 2 Raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position.

STEP 3 Repeatedly put the loader control lever into “FLOAT” position and back to neutral.

STEP 4 The system should allow a minimum of 10 actuations into float and still cause the lift arms to come down. NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists, proceed to next step.

STEP 5 Start machine and lower the bucket to the ground and turn off the engine. Turn the ignition switch to the “RUN” position, operate the pilots controls a minimum of 30 strokes to relieve any pressure in the system.

STEP 10 Lower the bucket to the ground and turn off the engine. Turn the ignition switch to the “RUN” position.

STEP 11 Operate the pilot controls several times until the gauge pressure suddenly drops to zero. The last pressure reading before the drop to zero is the nitrogen charge pressure in the accumulator. If the pressure is below 13 to 15 bar (188 to 218 psi), replace the accumulator. If accumulator test is good, go to next step.

STEP 12 Replace the pilot controls, see section 8001, retest the system, if test fails go to next step.

STEP 13 Replace the loader control valve, see section 8001, retest the system.

8002-18

HIGH PRESSURE PUMP FLOW TEST NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 7 of this section.

STEP 1 Connect the flow meter (3) by disconnecting the inlet hose (6) to the valve supply tube (13), installing a cap (12) on the fitting at the valve supply tube (13). Refer to illustration on page 19.

STEP 6 Using the temperature gauge on the flow meter, continue to run the engine at high idle until the temperature of the hydraulic oil is at least 52°C to 60°C (125°F to 140°F).

STEP 7 Run the engine at low idle, fully open the flow meter valve.

STEP 2

STEP 8

Disconnect the load sense hose (7) and install a cap (12) the fitting at the loader valve (15).

Open the needle valve (8) and operate the engine at 2000 rpm. At 0 bar (0 psi) the flow should be 250 to 255 L/min (66 to 67.4 gpm).

NOTE: This is the line that returns to the pump compensator valve.

STEP 9 STEP 3 Connect a “T” fitting (10) into the loader control valve inlet hose (6) and to the flow meter inlet hose (11).

Close the flow meter valve slowly and read the flow at 34.5 bar (500 psi) the flow should be 249 to 255 L/min (65.8 to 66.8 gpm).

STEP 4

STEP 10

Use a union (9) and connect an in line needle valve (8) to the open port in the “T” fitting (10), connect the load sense hose (7) to the needle valve (8).

Close the flow meter valve slowly and read the flow at 2000 psi @ 2000 rpm. The flow should read 244.5 to 247.5 L/min (64.6 to 65.4 gpm).

STEP 5

STEP 11

Make sure that the flow meter valve and the installed needle valve are in the open position. Start and run the engine at high idle, slowly close the flow meter valve until a pressure reading of 103 bar (1500 psi) is obtained.

Continue to close the flow meter valve slowly, at approximately 2900 psi the flow should drop significantly, this will be the low pressure pump destroking.

STEP 12 Continue slowly closing the flow meter valve until 3500 psi is reached. The flow should read between 120 to 122 L/min (31.6 and 32.1 gpm).

STEP 13 If any of the pump flow readings are not within specifications, the pump may be out of calibration and Technical Support Services should be contacted.

8002-19

3 5 6 11 12

7 10 9 12 8

14 15

BS06G117

1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE 2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP 3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY 4. PUMPS 9. UNION 14. ELBOW M14 ORB 5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

8002-20

TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES Pressure Check

STEP 4

STEP 1

Remove the safety strut and lower the bucket to the floor. Shut off the engine. Find an easy place to disconnect the line for the circuit to be tested.

Circuit relief valves are located as shown below.

STEP 5

4 1

Connect the hand pump to the disconnected line that goes to the loader control valve.

STEP 6 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).

STEP 7 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 8 Compare the reading to the specifications on Page 3.

STEP 9 1

If the pressure is not correct, adjust the circuit relief valve.

1 3

Adjustment

BS03B022

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

CIRCUIT RELIEF VALVES PUMP LIMIT PRESSURE ADJUSTMENT BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL LOADER CONTROL VALVE

STEP 2 Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 3 Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

STEP 1 Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

8002-21

TESTING THE RIDE CONTROL STEP 1

STEP 6

Move the machine to a clear level surface with clearance for full lift arm and bucket movement.

Dump the bucket until it hits the dump stops. Hold the bucket in the dump position for 5 to 10 seconds.

STEP 2 Install the ar ticulation lock, star t the machine, activate the parking brake.

STEP 3 With the pilot controller in neutral, set the ride control rocker switch on the right side console to the “Always On” position and observe the switch lamp, the lamp should illuminate.

STEP 4 Set the ride control rocker switch to the “Off” position and observe the switch lamp, the lamp should go out. NOTE: This indicates that the switch is operating correctly and has power, if the switch does not illuminate see section 4002 and troubleshoot the electrical system for the ride control.

STEP 5 Raise the lift arms to the top of their travel and dump the bucket.

NOTE: This will charge the ride control accumulator.

STEP 7 Lower the lift arms and roll the bucket back to a carry position. Do not leave the lift arms or the bucket on their stops, place the pilot control lever in the neutral position.

STEP 8 Set the ride control rocker switch to the “Always On” position. The lift arms should rise 15 to 30 cm (6 to 12 inches) with an empty bucket. NOTE: Test results will be for a machine with a empty factory bucket and no attachments.

STEP 9 If there is little or no lift arm raise, the test may have been done too slowly. The elapsed time between step 6 and step 8 should not exceed six seconds. NOTE: If test was done to slowly repeat in the allotted time.

STEP 10 If test was completed in the allotted time and the lift arms still do not rise, test the nitrogen charge in the accumulator, see section 8013.

8002-22

HYDRAULIC COMPONENT LOCATIONS 5 6

7 9 4

2 3

11 15 14 16 19 18 17

12 13

BC00N140

1. REAR BRAKE CYLINDERS 2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER 3. BRAKE ACCUMULATORS 4. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC COUPLERS 5. BRAKE LIGHT PRESSURE SWITCH 6. BRAKE WARNING PRESSURE SWITCH 7. BRAKE AND ACCUMULATOR CHARGING VALVE 8. LIFT CYLINDERS 9. BUCKET CYLINDER (TILT CYLINDER) 10. RIDE CONTROL ACCUMULATOR

11. FRONT BRAKE CYLINDERS 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND RIDE CONTROL VALVE (OPTIONAL) 13. PARKING BRAKE CYLINDER 14. STEERING PRESSURE DIAGNOSTIC COUPLER 15. STEERING PRIORITY VALVE 16. STEERING CYLINDERS 17. AUXILIARY STEERING PUMP AND MOTOR 18. AUXILIARY STEERING PRIORITY VALVE 19. AUXILIARY STEERING PRESSURE SWITCH

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for reference.

8002-23

23 24 21 22

30 31

32 33 34

BC00N140

20. 21. 22. 23. 24. 25. 26. 27.

FAN DRIVE MOTOR HYDRAULIC RESERVOIR BREATHER HYDRAULIC RESERVOIR PILOT PRESSURE DIAGNOSTIC COUPLER PILOT CONTROL VALVE PILOT PRESSURE ACCUMULATOR LOADER CONTROL VALVE PARKING BRAKE ACCUMULATOR

28. 29. 30. 31. 32. 33. 34.

PUMP PRESSURE DIAGNOSTIC COUPLER LOAD SENSING DIAGNOSTIC COUPLER IMPLEMENT HYDRAULIC PUMP HYDRAULIC FILTER HYDRAULIC COOLER BRAKE HYDRAULIC PUMP FAN VALVE

NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for reference.

8002-24

NOTES

CLEANING THE HYDRAULIC SYSTEM

8003

Section 8003

8003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 7

8003-3

SPECIAL TOOLS

806128

CAS10508, fitting kit.

806127

CAS101162A, filter unit, portable.

TR98H032

CAS10192, vacuum pump.

8003-4

GENERAL INFORMATION Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1. When you drain the oil or disconnect any line.

1. Cylinder rod seals leak. 2. Control valve spools do not return to neutral. 3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot.

2. When you disassemble a component.

5. Pump gears, housing, and other parts wear rapidly.

3. From normal wear of the hydraulic components.

6. Relief valves or check valves held open by dirt.

4. From damaged or worn seals.

7. Quick failure of components that have been repaired.

5. From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems.

8. Cycle times are slow; machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.

TYPES OF CONTAMINATION There are two types of contamination, microscopic and visible. 1. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. 2. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e problems: A. Cylinder rod seal leak. B. Control valve NEUTRAL.

spools

not

return

C. The hydraulic system has a high operating temperature.

3. Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: A. Particles of metal or dirt in the oil. B. Air in the oil C. The oil is dark and thick. D. The oil has an odor of burned oil. E. Water in the oil. See page 7.

8003-5

CLEANING THE HYDRAULIC SYSTEM 1. Prepare the portable filter on page 3 by doing the following steps: A. Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. B. Remove the filter element from the portable filter. C. Remove all hydraulic oil from the portable filter. D. Clean the inside of the housing for the filter element. 2. You must know whether the contamination is microscopic or visible. See types of contamination on page 4. 3. If the contamination is microscopic: A. Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If needed, change the hydraulic oil. See Section 1002 for specifications. Change the hydraulic filter. B. Do steps 6 through 35. 4. If the contamination is visible:

8. Using the fitting kit shown on page 3, install the valve in the hole for the drain plug. Make sure that the valve is closed. 9. Stop the vacuum pump. 10. Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug. 11. Disconnect the vacuum pump from the hydraulic reservoir air breather hose. Remove the filler cap. 12. Install the outlet hose for the portable filter in the hydraulic reservoir filler neck. 13. Open the valve that is installed in the hole for the drain plug. 14. Move the switch for the portable filter to the ON position. Start and run the engine at 1500 rpm (r/min). 15. Run the portable filter for 10 minutes. 16. Continue to run the portable filter. Increase the engine speed to full throttle. Heat the oil to operating temperature by doing the following steps:

A. Change the hydraulic oil and hydraulic filter. See Section 1002 for specifications.

A. Hold the blade control lever in the TILT position for five seconds.

B. Do steps 5 through 35.

B. Return the blade control lever NEUTRAL position for five seconds.

5. Check the amount of contamination in the hydraulic system by doing the following steps: A. Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. B. If, in your judgment, the damage to the cylinders was caused by sever contamination and is not the result of normal wear, it is necessary to remove, clean and repair valves, pump, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Remove the breather from the reservoir and connect the vacuum pump to the opening. Start the vacuum pump. 7. Loosen and remove the drain plug from the reservoir.

the

C. Repeat steps A and B until the oil in the hydraulic system is at operating temperature. 17. Continue to run the engine at full throttle. Continue to run the portable filter. 18. Operate each hydraulic circuit to completely extend and retract the cylinders. Continue to operate each hydraulic circuit two times, one after the other for 45 minutes. 19. Decrease the engine speed to low idle. 20. Continue to run the portable filter for 10 minutes. 21. Stop the portable filter. 22. Stop the engine. 23. Remove the hose from the hydraulic reservoir.

8003-6 24. Close the valve that is installed in the hole for the drain plug. 25. Disconnect the inlet hose for the portable filter from the valve. Remove the outlet hose from the reservoir filler neck and replace filler cap.

30. Stop the vacuum pump. Disconnect the vacuum pump from the opening in the reservoir and install the breather. 31. Remove the hydraulic filter elements from the machine.

26. Connect a vacuum pump to the breather hose of the hydraulic reservoir.

32. Install new hydraulic filter elements on the machine.

27. Start the vacuum pump.

33. Start the engine. Check for oil leakage around the new hydraulic filters.

28. Remove the valve from the hole for the drain plug. 29. Install the drain plug.

34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r specifications.

8003-7

FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1. Start and run the engine at 1500 rpm (r/min). 2. Completely retract the cylinders of all attachments on the machine. Angle the blade to the right, the right cylinder will be fully retracted and the left will be fully extended. Stop the engine. WARNING: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before proceeding to the next step! 39-4

13. Slowly move each control lever in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 14. Stop the engine. 15. Connect the system line to the CLOSED end of each cylinder. 16. Connect a suitable drain line to the OPEN end of each cylinder and place the other end in an acceptable container for contaminated oil. 17. Start the engine and run the engine at low idle.

NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.

18. Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the OPEN end of the cylinders.

3. Move each control lever in both directions to release pressure in the hydraulic circuits.

NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.

4. Loosen and remove the filler cap from the reservoir. 5. Drain the hydraulic oil from the reservoir.

19. Support any attachments that will be in the RAISED position.

A. See Section 1002 for capacity specifications.

20. Stop the engine.

B. Have available acceptable equipment to drain the hydraulic oil.

21. Disconnect the drain lines and connect the system lines to the cylinders.

C. Remove the drain plug from the bottom of the reservoir.

22. Check the oil level in the hydraulic reservoir. Add o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r specifications.

6. Remove the hydraulic filter elements from the machine.

23. Install the filler cap on the reservoir.

7. Install new hydraulic filter elements on the machine.

24. Remove the hydraulic filter elements from the machine.

8. Install the drain plug in the bottom of the reservoir.

25. Install new hydraulic filter elements on the machine.

9. Fill the hydraulic reservoir with hydraulic fluid. See Section 1002 for specifications.

26. Start and run the engine at 1500 rpm (r/min), operate each hydraulic circuit to completely extend and retract the cylinders.

10. Disconnect the line from the OPEN end and CLOSED end of each cylinder. 11. Be sure all control levers are in the NEUTRAL position. 12. Start and run the engine at low idle. IMPORTANT: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13.

27. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

8003-8

NOTES

HYDRAULIC PUMP

8004

Section 8004

8004-2

TABLE OF CONTENTS PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 9 11

8004-3

PUMP SPECIFICATIONS Manufacturer................................................................................................................................................... Rexroth High pressure pump (steering pump next to transmission) ................................. 120 L/min at 170 bar, at 2000 r/min (31.6 U.S. gpm at 2500 psi at 2000rpm) Low pressure pump (loader pump farthermost from transmission) ....................... 86 L/min at 170 bar, at 2000 r/min (22.5 U.S. gpm at 2500 psi at 2000rpm) Rotation ................................................................................................. Clockwise as seen from the end of the shaft Special torques Pump end cover bolts...................................................................................................165 Nm (121.5 pound-feet) Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet) Control piston plug ..............................................................................................................90 Nm (66 pound-feet)

PREPARING THE EQUIPMENT PUMP FOR USE Do the following procedure any time you install a new or overhauled equipment pump: 1. Start and run the engine at half throttle for three minutes. 2. With the engine running at half throttle, move the bucket control lever into roll back position. Hold the bucket control lever in this position until the bucket stops moving. 3. Hold the bucket control lever in the roll back position for five seconds. Then put the bucket control lever in the NEUTRAL position for five seconds.

4. Repeat Step 3 for three minutes. 5. Increase the engine speed to full throttle and repeat Steps 3 and 4. 6. Stop the engine and check for leaks. 7. Replace the hydraulic filter.

8004-4

EQUIPMENT PUMP 7

6 4

5 4 3

10 1

11 12 13 21

20 19 18 14

30 29 15 26

BC06F550

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SNAP RING SEAL MAIN BODY O-RING PLUG CONTROL VALVE CAP SCREW PISTON ROD CONTROL PISTON SHAFT

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

TAPERED BEARING BEARING RACE SHIM SPRING HALF BEARING SWASH PLATE PISTONS RETAINING PLATE BALL CYLINDER

21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

PRESSURE PINS BACKUP PLATE SPRING SNAP RING PORT PLATE SHIM TAPERED BEARING BEARING RACE DOWEL PIN END COVER

8004-5

Disassembly

STEP 3

STEP 1 Remove all dirt, oil, and grease from the exterior of the equipment pump.

STEP 2

BC06F552

Remove the control valve.

STEP 4

BC06F551

Put alignment marks on the end cover and housing.

BC06F553

Remove the four bolts.

8004-6

STEP 5

STEP 6

BC06F555

BC06F554

Remove the end cover. NOTE: Watch for the flow plate, it can be stuck to either the end cover or pump body.

Use a suitable bearing race puller and pull the bearing race from the end cover. NOTE: Do not damage the sealing surfaces.

8004-7

STEP 7

STEP 9

BC06F558

Remove plug, pull control piston using a suitable tool as shown. NOTE: Do not use a magnet to pull the piston.

STEP 10 BC06F556

Remove the bearing and shim.

STEP 8

BC06F559

Remove the piston rod and swash plate. Turn the swash plate slightly to break it free from the bearings. BC06F557

Remove the rotary group from the housing in a horizontal position.

8004-8

STEP 11

STEP 14

BC06F560

Remove the bearing and spring.

STEP 12 BC06F563

Use a suitable bearing race puller and pull the bearing race from the housing.

STEP 15

BC06F561

Remove the shaft and bearing.

STEP 13

BC06F564

Remove the shim and plug.

BC06F562

Remove the retaining ring an seal.

8004-9

Inspection

STEP 19

STEP 16 Clean all parts in cleaning solvent. Be careful not to remove the alignment mar ks made dur ing disassembly.

STEP 17

BC06F567

Check the bearing surface.

STEP 20

BC06F565

Check for wear on the splines, seal areas for grooves, bearing areas for scaring, and key set.

STEP 18

BC06F568

Check that the retaining plate is free of grooves and that there is no sign of wear.

STEP 21

BC06F566

Check the surface that the pistons contact for grooves and scaring.

BC06F569

Check the sliding surface for scratches or metal deposits, check the tightness of the cup on the piston. NOTE: If a piston needs to be replaced, all of the pistons must be replaced.

8004-10

STEP 22

STEP 24

BC06F570

Check the cylinder bores and splines for damage.

STEP 23

BC06F572

Check cylinder surface for grooves, wear, embedded particles. Check flow plate for scratches or wear.

STEP 25

BC06F571

Check ball for grooves and wear.

BC06F573

Check mounting surface for the flow plate for damage.

8004-11

Assembly

STEP 27

STEP 26

BC06F575

BC06F574

Install the plug in the housing and tighten to 127 Nm (93.5 pound-feet). Install shim and press in the bearing race.

Put the shaft and bearing in the housing.

STEP 28

BC06F576

Press in a new race into the end cover.

8004-12

STEP 29

STEP 31

BC06F579

Install the seal and retaining ring.

STEP 32 BC06F577

Install the end cover, 4 bolts and hand tighten.

STEP 30

BC06F578

A bearing pre load of 0.05 mm (0.002 inch) must be obtained, add remove shims from bear ing as required.

BC06F580

Put new bearings in the housing. Install the reaction spring.

8004-13

STEP 33

STEP 34

BC06F582

Install the piston into the housing with flat surface out. Lubricate the O-ring and install the plug, tighten the plug to 90 Nm (66 pound-feet).

STEP 35

BC06F581

Install the swash plate into the housing, work the swash plate from side to side to seat it in the bearings and spring. Install the piston rod.

BC06F583

Use grease to hold the pressure pins into position, install the spacer, spring and snap ring.

8004-14

STEP 36

STEP 39

BC06F584

Use a suitable compressor, compress the spring and install the snap ring.

STEP 37

BC06F585

BC06F587

Place the ball onto the pressure pins, install the pistons into the retaining plate.

Hold the pistons in the rotating housing using an O-ring, install the rotating group into the housing, remove the O-ring.

STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil, install the piston into the rotating housing.

8004-15

STEP 40

STEP 41

BC06F588

Use the shim that was required for the bearing pre load in step 30. Install the shim and bearing onto the shaft.

BC06F589

Install a new O-ring on the end cover, place the flow plate onto the rotating group with aligning notch up. Place the end cover onto the housing, make sure that the aligning pin in the end cover aligns with the slot in the flow plate.

8004-16

STEP 42

STEP 43

BC06F591

Use new O-rings, install and tighten the control valve.

BC06F590

Instal and tighten the four bolts to 165 Nm (121.5 pound-feet).

Section 8005

8005

LOADER CONTROL VALVE

8005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6 7 8 9 14 14 18 18

8005-3

SPECIFICATIONS Manufacturer................................................................................................................................................... Rexroth Special Torques End plate mounting bolts.................................................................................................. 70 Nm (51.5 pound feet) Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound inches) Allen head plugs.............................................................................................................. 240 Nm (177 pound feet) Allen head locking screw................................................................................................ 100 Nm (73.7 pound feet) Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches) Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches) Anticavitation valves ....................................................................................................... 100 Nm (73.7 pound feet) Combination anticavitation and circuit relief ................................................................. 200 Nm (147.5 pound feet) Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi) Circuit relief valve pressure setting Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi) Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi) Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)

8005-4

1 2 4 3 5 22 6 6

20 19

8 18

10 11

6 15

14 8 12

BS03C033

1. BOLT 2. WASHER 3. LOCKING SCREWS 4. PLATE 5. REGENERATION RELIEF VALVE 6. O-RINGS

7. LOAD SENSE SHUTTLE CHECK 8. ANTICAVITATION AND CIRCUIT RELIEF

13. FLOAT SOLENOID

18. LOAD CHECK

14. PLUG

19. FLOW LIMIT VALVE

10. FLOW COMPENSATOR SPOOL

15. REGENERATION CHECK VALVE 16. LOCKING SCREW

21. CONE

11. HOUSING

17. SPRING

22. LOCKING SCREW

9. LOAD SENSE BLEED DOWN ORIFICE

12. PLUG 2 SPOOL VALVE HOUSING CONFIGURATION

20. PRESSURE RELIEF VALVE

8005-5

25 24 23 28

6 31

29 30

6 6 33 31

34 6 34

33 32

23 23 35

29 BC06F593

6. 23. 24. 25. 26.

O-RINGS SPRING RETAINER SPRING SPRING COVER

27. 28. 29. 30. 31.

BOLT PISTON CAP NUT JAM NUT PISTON

32. 33. 34. 35.

2 SPOOL VALVE SPOOL CONFIGURATION

BOLT COVER ADJUSTING ROD SPOOL

8005-6

37 BS03C036

36. HOUSING

37. ANTICAVITATION AND CIRCUIT RELIEF 3 SPOOL MOUNTING CONFIGURATION

8005-7

38 39

BS03C035

38. NUT

39. STUD

4 SPOOL MOUNTING CONFIGURATION

8005-8

30 33 6

23 24 23

33 31

23 24

6 34

BS03C037

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION 6. 23. 24. 29. 30.

O-RINGS SPRING RETAINER SPRING CAP NUT JAM NUT

31. 32. 33. 34. 35.

PISTON BOLT COVER ADJUSTING ROD SPOOL

8005-9

DISSASEMBLY STEP 1

STEP 7

Remove valve from machine, see section 8001.

Remove pressure relief valve (20).

STEP 2

STEP 8

Remove bolts (27), cover (26), springs (24 and 25), and spring retainer (23).

Remove flow limit valve (19).

STEP 9 STEP 3 Remove bolts (32), covers (33), spring (24), and spring retainer (23).

Remove locking screw (16), spring (17), and cone (18).

STEP 10 STEP 4

Remove regeneration check valve (15).

Use wooden dowel or brass drift and push spools (35) from housing (11).

STEP 11

IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.

Remove locking screw (14).

NOTE: Repeat steps 3 and 4 for a 3 and 4 spool valve configuration.

Remove load sense shuttle check valve (7).

STEP 5

Remove locking screws (12).

Remove anticavitation valves (5, 8, 10, and 13). NOTE: Repeat step for a 3 and 4 spool anticavitation valves (37).

STEP 6 Remove locking screw (22) and cone (21).

STEP 12 STEP 13 STEP 14 Remove pilot pressure reducing valve (9).

STEP 15 Remove bolts (1) and washers (2), remove plate (4) from housing (11). NOTE: For 4 spool configuration remove nut (38) from stud (39), remove housings (36) from housing (11).

8005-10

STEP 16

STEP 18 2 1 2

BS03C025

BS03C027

Remove and discard O-rings and thrust rings from pilot pressure reducing valve (9).

Remove and discard O-rings and thrust ring from locking screw (14).

1. O-RINGS

2. THRUST RINGS

1. O-RINGS

2. THRUST RING

STEP 17 STEP 19

1 2

1 1

BS03C026

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from flow limit valve (19).

BS03C028

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Remove and discard O-rings, thrust ring, and spool seal from anticavitation valve (5).

8005-11

STEP 20

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).

STEP 21 1 1 2 1 2

1 BS03C030

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).

8005-12

STEP 22 1

2 1

BS03C031

1. O-RINGS

2. COIL

Remove and discard O-rings and thrust rings from anticavitation valve (13).

8005-13

STEP 23

1 1

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).

8005-14

INSPECTION 1. Discard all O-rings, thrust rings, and spool seals. 2. Clean all parts in cleaning solvent. 3. Check the spools and the spool bores for damage and wear.

4. Check the parts of the pressure relief valve, anticavitation valves, and the anticavitation and circuit relief valves. Use new parts as necessary. Inspect the other parts of the control valve. If any of the parts are damaged, install new parts.

ASSEMBLY STEP 1

4 A

See Note

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 37). Torque relief valve (A) into anticavitation valve to 200 Nm (147.5 pound feet). NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in direction of arrow.

8005-15

STEP 2 1

2 1

A 1

BS03C031

1. O-RINGS

2. COIL

Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).

STEP 3 1 1 2 1 2

BS03C030

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm (73.7 pound feet).

8005-16

STEP 4

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (20).

8005-17

STEP 5

STEP 8 2

1 1

2 BS03C025

BS03C028

Install new O-rings and thrust rings on pilot pressure reducing valve (9).

Install new O-rings, thrust ring, and spool seal on anticavitation valve (5).

STEP 6

STEP 9

1. O-RINGS

2. THRUST RINGS

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Install and torque regeneration check valve (15) to 100 Nm (73.7 pound feet).

STEP 10 Install and torque locking screw (14) to 100 Nm (73.7 pound feet).

2 1

STEP 11

Install and tighten load sense shuttle check valve (7).

STEP 12 BS03C026

1. O-RINGS

2. THRUST RINGS

Install and torque locking screws (12) to 240 Nm (177 pound feet).

Install new O-rings and thrust rings on flow limit valve (19).

STEP 13

STEP 7

Install and torque pilot pressure reducing valve (9) to 60 Nm (44 pound feet).

STEP 14 1

Install new O-rings on housing (11). Install plate (4), bolts (1) and washers (2), onto housing (11). Torque bolts to 70 Nm (51.5 pound feet).

NOTE: For 4 spool configuration install new O-rings between housings (36) and housing (11), install nuts (38) on studs (39). Torque nuts to 70 Nm (51.5 pound feet).

STEP 15 BS03C027

Install anticavitation valves (5, 10, and 13) and torque to 100 Nm (73.7 pound feet).

Install new O-rings and thrust ring on locking screw (14).

NOTE: Repeat step for a 3 and 4 spool anticavitation valves (37).

1. O-RINGS

2. THRUST RING

8005-18

STEP 16

Circuit Relief Pressure Test

Install anticavitation valves (8) and torque to 200 Nm (147.5 pound feet).

STEP 1

STEP 17

Connect the hand pump to the port for anticavitation and circuit relief valves (21).

Install and torque flow limit valve (19) to 20 to 25 Nm (177 to 221 pound inches).

STEP 18 Install cone (18), spring (17), locking screw (16). Torque locking screw to 100 Nm (73.7 pound feet).

STEP 19 Install cone (21) and locking screw (22). Torque locking screw to 40 Nm (30 pound feet).

NOTE: Repeat steps for machines configured with a 3 or 4 spool valve.

that

are

STEP 2 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).

STEP 3

STEP 20

Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

Lubricate spools with hydraulic oil and push spools (35) into housing (11).

STEP 4

IMPORTANT: Do not force spools into housing.

Compare the reading to the specifications on Page 3.

STEP 21

STEP 5

Install spring retainers (23), springs (24), covers (33), and bolts (32). Torque bolts to 10.4 Nm (92 pound inches).

If the pressure is not correct, adjust the circuit relief valve.

NOTE: Repeat steps 18 and 19 for a 3 and 4 spool valve configuration.

Circuit Relief Adjustment STEP 1

STEP 22 Install spring retainers (23), spring (24 and 25), cover (26), and bolts (27). Torque bolts to 6 Nm (53 pound inches). NOTE: Prior to installation in the machine, circuit reliefs can be tested.

Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).

STEP 2 STEP 23 Install valve in machine, see section 8001.

STEP 24 Check loader limit pressure, see section 8002.

Check the pressure again. Repeat the adjustment as necessary.

Section 8006

8006

CYLINDERS

8006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 4 4 6 7 7 7 9 11 11 11 12 12 12

8006-3

SPECIFICATIONS Approximate weight Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds) Bucket Cylinder........................................................................................................................199.2 kg (439 pounds)

SPECIAL TORQUES Gland Bolts Bucket Cylinder .......................................................................420 to 500 Nm (310 to 368.8 pound-feet) Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet) Piston Bolt for Lift Cylinders................................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet) Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)

SPECIAL TOOLS Torque Multiplier ......................................................................................................................................... CAS-1039

8006-4

LIFT CYLINDER Disassembly

Inspection

1. Clean exterior of cylinder. If hoses were removed with cylinder, remove hoses from cylinder.

1. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying.

2. Fasten tube (1) in an acceptable repair stand or other holding equipment. Do not damage tube (1).

2. Check to be sure that piston rod (13) is straight. If piston rod is not straight, replace it with a new piston rod.

3. Loosen and remove self-tapping screw (12).

3. Shine a light inside tube (1) and check for deep grooves and other damage. If there is any damage to tube, replace with a new tube.

4. Use a spanner wrench to loosen and remove gland (4) from tube (1). 5. Pull piston rod (13) straight out of tube (1) to prevent damage to tube. 6. Fasten piston rod eye or yoke in a vise and put a support under piston rod (13) near piston (15). Put a shop cloth between support and piston rod to prevent damage to piston rod. 7. Use a torque multiplier, CAS-1039, to loosen and remove bolt (14) that fastens piston (15) to piston rod (13). 8. Remove piston (15) from piston rod (13). 9. Remove gland (4) from piston rod (13). 10. Remove and discard seal (16), ring (17), and wear ring (18) from piston (15). 11. Remove and discard O-ring (10), backup ring (9), O-ring (11), wiper (5), rod seal (6), buffer seal (7), and bushing (8) from gland (4).

4. Remove any small scratches on piston rod (13) or inside tube (1) with emery cloth of medium grit. Use emery cloth with a rotary motion. 5. Inspect bushings (2) in tube eye. Replace as required. 6. Inspect gland (4) for rust. Clean and remove rust as necessary. 7. Inspect gland end of tube (1) for sharp edges that may cut gland O-ring (11) and remove as necessary. 8. Inspect piston (15) for damage and wear. If piston is damaged or worn, replace with a new piston.

8006-5

5 6 7 4 8 11 9 10 15

17 16 18 14 1 3 2

2 3

BC05J002

1. 2. 3. 4. 5.

TUBE BUSHING WIPER GLAND WIPER

6. 7. 8. 9. 10.

ROD SEAL BUFFER SEAL BUSHING BACKUP RING O-RING

11. 12. 13. 14. 15.

O-RING SCREW ROD BOLT PISTON

LIFT CYLINDER

16. SEAL 17. RING 18. WEAR RING

8006-6

Assembly

17. Install a new ring (17) in the other groove on the outside of the piston (15).

NOTE: If a new gland is being used, put part number of cylinder on new gland.

18. Install a new seal (16) on top of ring (17).

1. Install bushing (8) in gland (4). 2. Install rod seal (6) in gland (4). Rod seal is to be installed so that lips of seal are toward bushing (8). Rod seal (6) can be difficult to install. 3. Install buffer seal (7) in gland (4). The side of buffer seal with groove must be toward bushing (8). 4. Install a new wiper (5) in gland (4). Lips of wiper must be toward outside end of gland (4). 5. Install a new O-ring (11) in groove on OD of gland (4). 6. Install a new backup ring (9) in groove on OD of gland (4). If both sides of backup ring are not flat, side that is not flat must be toward small end of gland (4). 7. Install a new O-ring (10) next to backup ring (9) in groove on outside of gland (4). O-ring must be toward small end of gland. 8. Fasten piston rod (13) eye or yoke in vise. 9. Remove any marks and sharp edges on chamfer at end of piston rod (13). Make sure that piston rod is clean. 10. Lubricate bore of gland (4) and piston rod (13) with clean oil. 11. Push gland (4) onto piston rod (13). If necessary, use a soft hammer to drive gland onto piston rod. 12. Put a support below and near end of piston rod (13). Use a shop cloth between support and the piston rod to prevent damage to piston rod. 13. Start piston (15) onto piston rod (13). 14. Clean the threads on the end of the piston rod (13) and the threads of the bolt (14) using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to piston rod threads 6.3 mm (1/4 inch) from open end of piston rod so that there is 13 mm (1/2 inch) of Loctite 242 on piston rod threads. DO NOT apply Loctite to first 6.3 mm (1/4 inch) of piston rod threads. 15. Install bolt (14) into piston rod (13). Tighten bolt to a torque of 2830 to 3220 Nm (2087 to 2374.9 pound-feet). A torque multiplier can be used to help torque the bolt. 16. Install a new wear ring (18) in wide groove on outside of piston (15).

19. Fasten tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to tube. 20. Lubricate inside of the tube (1) and piston (15) with clean oil. 21. Push piston (15) straight into tube (1). 22. When the piston (15) is in smooth part of tube (1), start gland (4) into tube. 23. Lubricate O-rings (10 and 11) on gland (4) with clean oil. 24. Turn gland (4) into tube (1). Tighten gland to a torque of 135 to 542 Nm (100 to 400 pound-feet). 25. If the original parts are being assembled: A. Tighten gland to a torque of 135 to 542 Nm (100 to 400 pound-feet). B. Install and tighten self-tapping screw (12) to a torque of 2.3 Nm (20 inch-pounds). C. If, after tightening gland, the self-tapping screw (12) holes are not aligned, a new hole for self-tapping screw must be drilled. See Step 26. 26. If a new gland (4) or a new tube (1) are being assembled: A. Tighten gland (4) to 135 to 542 Nm (100 to 400 pound-feet). B. Use a No. 27 drill bit and drill a hole half in gland (4) and half in tube (1). Drill to a depth of 11 mm (7/16 inch). Do not drill within 13 mm (1/2 inch) of a hole for gland wrench. C. Install and tighten self-tapping screw (12) to a torque of 2.3 Nm (20 inch-pounds). 27. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.

8006-7

BUCKET CYLINDERS Disassembly 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Do not damage the tube (1). 3. Loosen and remove the cap screws (2) and hardened washers (18) from the gland (3) and the tube (1). 4. Pull the piston rod (4) straight out of the tube (1) to prevent damage to the tube (1). 5. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (4) near the piston (7). Put a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4). 6. Remove the retaining ring (10) that fastens the pin (11) in the piston (7) and piston rod (4). 7. Remove the pin (11) from the piston (7) and the piston rod (4). 8. Turn the piston (7) off the piston rod (4) and remove the piston (7). 9. Remove the gland (3) from the piston rod (4). 10. Remove the seal (6) from the OD of the piston (7). 11. Remove the wear ring (5) from the OD of the piston (7). 12. Remove the backup rings (8) and the O-ring (9) from the ID of the piston (7). 13. Remove the O-ring (16), backup ring (15), wiper (12), wide seal (13), narrow seal (14), and bushing (17) from the gland (3).

Inspection 1. Discard the parts that were removed from the piston and the gland. 2. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying. 3. Check to be sure that the piston rod is straight. If the piston rod is not straight, replace it with a new piston rod. 4. Illuminate the inside of the tube for deep grooves and other damage. If there is any damage to the tube, replace it with a new tube. 5. Remove any small scratches on the piston rod or inside the tube with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the bushings in the piston rod eye or yoke and the tube. Replace as required. 7. Inspect the gland for rust and clean and remove rust as necessary. 8. Inspect the gland end of the tube for sharp edges that will cut the gland O-ring and remove as necessary. 9. Inspect the piston for damage and wear. If the piston is damaged or worn, replace it with a new piston.

8006-8

19 20 19

4 2 18 3 17

16 11 7

13 14

8 8

6 1

5 10

20 19 BC05M026

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

TUBE CAP SCREW GLAND PISTON ROD WEAR RING SEAL

7. 8. 9. 10. 11.

PISTON BACKUP RING O-RING RETAINING RING PIN

12. 13. 14. 15. 16.

WIPER WIDE SEAL NARROW SEAL BACKUP RING O-RING

BUCKET CYLINDER

17. 18. 19. 20.

BUSHING HARDENED WASHER SEAL BUSHING

8006-9

Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland.

11. Install a new backup ring (8) in the groove in the ID of the piston (7). If both sides of the backup ring (8) are not flat, the side that is not flat must be toward the O-ring (9).

1. Install the bushing (17) in the gland (3), refer to illustration on page 8.

12. Install a new O-ring (9) in the groove in the ID of the piston (7) next to the backup ring (8).

2. Install the wide seal (13) in the gland (3). The wide seal (13) is to be installed so that the lips of the wide seal (13) are toward the bushing (17). The wide seal (13) can be difficult to install.

13. Install the other new backup ring (8) in the groove in the ID of the piston (7) next to the O-ring (9). If both sides of the backup ring (8) are not flat, the side that is not flat must be toward the O-ring (9).

3. Install a new wiper (12) in the gland (3). The lips of the wiper (12) must be toward the outside end of the gland (3). 4. Install the narrow seal (14) in the gland (3). The side of the narrow seal (14) with the groove must be toward the bushing (17). 5. Install a new backup ring (15) in the groove on the outside of the gland (3). If both sides of the backup ring (15) are not flat, the side that is not flat must be toward the small end of the gland (3). 6. Install the O-ring (16) next to the backup ring (15) in the groove on the outside of the gland (3). The O-ring (16) must be toward the small end of the gland (3).

14. Lubricate the ID of the piston (7) with clean oil. 15. Start the piston (7) onto the piston rod (4). Turn the piston (7) onto the piston rod (4) until the piston (7) is seated against the shoulder of the piston rod (4). 16. If none of the holes in the piston (7) align with the holes in the piston rod (4), turn the piston (7) counterclockwise until one of the holes in the piston (7) aligns with one of holes in the piston rod (4). Do not turn the piston (7) more than 90 degrees.

7. Remove any marks and sharp edges on the chamfer at the end of the piston rod (4). Make sure that the piston rod (4) is clean.

8. Lubricate the bore of the gland (3) and the piston rod (4) with clean oil. 9. Push the gland (3) onto the piston rod (4). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (4). 10. Put a support below and near the end of the piston rod (4). Use a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4).

4 GS98J804 PISTON AND PISTON ROD HOLE ALIGNMENT

17. Install the pin (11) in the piston (7) and the piston rod (4). 18. Install the retaining ring (10) in the pin (11).

8006-10 19. Install a new wear ring (5) in the wide groove on the OD of the piston (7). 20. Install a new seal (6) in the groove on the OD of the piston (7).

27. Tighten the cap screws (2) in the sequence shown. Torque to 420 to 500 Nm (310 to 368.8 pound-feet).

21. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (1). 22. Lubricate the inside of the tube (1) and the outside of the piston (7) with clean oil. 23. Push the piston (7) straight into the tube (1). 24. Lubricate the O-ring (16) on the gland (3) with clean oil. 25. Push the gland into the tube (1) and align the holes in the tube (1). 26. Install the cap screws (2) and hardened washers (18). BC05M027

TUBE AND GLAND HOLE ALIGNMENT

8006-11

REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Removal 1. Put piston tube (4) in a press. 2. Use an acceptable driver to press wipers (1) and bushings (2) out of piston tube (4) eye.

3. Clean bore for bushings (2) in tube (4) eye.

Installation 4

1. Use an acceptable driver to press new bushings (2) into tube (4) eye. Bushings shall be recessed 8 mm (0.315 inch) in tube eye. 2. Use an acceptable driver to install wipers (1) until flush with tube (4) eye. The lips of wipers must be toward outside of bore.

2 1 2

BS01C003

1. WIPER 2. BUSHING

3. PISTON ROD YOKE 4. TUBE

BUSHING AND WIPER REMOVAL AND REPLACEMENT LIFT CYLINDERS

8006-12

REPLACING BUSHINGS FOR THE BUCKET CYLINDER Removal

1. Put piston rod eye (3) in a press. 2. Use an acceptable driver to press wipers (1) and bushing (2) out of piston rod eye (3). 3. Put tube (4) in a press. 4. Use an acceptable driver to press bushings (2) out of tube (4) eye.

2 1

1 2

5. Clean bore for bushings (2) in piston rod eye (3) and tube (4) eye.

Installation

4 1 2

1. Use an acceptable driver to press new bushings (2) into piston rod eye (3) until recessed 8 mm (0.315 inch). 2. Use an acceptable driver to install wipers (1) until flush with piston rod eye (3). The lips of the wipers (1) must be towards outside of bore.

3. Use an acceptable driver to press new bushings (2) into tube (4) eye until recessed 8 mm (0.315 inch). 4. Use an acceptable driver to install wipers (1) until flush with tube (4) eye. The lips of wipers (1) must be towards outside of bore.

1 BS03B201

1. WIPER 2. BUSHING

3. PISTON ROD EYE 4. TUBE

BUSHING AND WIPER REMOVAL AND REPLACEMENT BUCKET CYLINDERS

Section 8007

8007

COUPLER SOLENOID LOCKING VALVE

8007-2

TABLE OF CONTENTS coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3

8007-3

COUPLER SOLENOID LOCKING VALVE Disassembly

STEP 11 Install solenoid (2) on valve cartridge (3).

STEP 1 Clean exterior of valve.

STEP 12 Install nut (1) to secure solenoid (2).

STEP 2 Remove nut (1) and solenoid (2) from valve cartridge (3).

STEP 3 Remove valve cartridge (3) from valve housing (7).

STEP 4 Remove and discard all O-rings (4 and 5) and back-up rings (6).

Cleaning and Inspection STEP 5

Immerse valve cartridge (3) and valve housing (7) in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of valve cartridge and housing and to ensure that all passage ways and bores are clear.

4 6

STEP 6

Check valve cartridge for (3) for cracks, breaks, chipping, or other damage. Replace if any of these conditions are seen.

6 6 5

STEP 7

Check bores in valve housing (7) for deep scratches, gouges, and other damage. Replace valve if any of these conditions are seen.

5 7

STEP 8 Connect an ohmmeter across terminals of solenoid (2) connector. Replace solenoid (2) and valve cartridge (3) if ohmmeter indicates short or open circuit.

Assembly STEP 9 Install new O-rings (4 and 5) and back-up rings (6) as shown.

STEP 10 Lubricate O-rings (4 and 5) using clean oil then install valve cartridge (3) in valve housing (7).

GS98J818

1. 2. 3. 4.

NUT SOLENOID VALVE CARTRIDGE O-RING

5. O-RING 6. BACKUP RING 7. VALVE HOUSING

8007-4

NOTES

RIDE CONTROL ACCUMULATOR

8013

Section 8013

8013-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 5 5 5 5 7

8013-3

SPECIFICATIONS Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8 Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch) Ride Control Accumulator Maximum Operating Pressure ...........................................................248.4 bar (3600 psi)

ACCUMULATOR SPECIAL TORQUES Accumulator Gas Charging Valve Cap .................................................................................13.6 Nm (10 pound-feet) Gas Charging Valve.............................................................................................88 to 102 Nm (65 to 75 pound-feet) Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches) Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)

SPECIAL TOOLS

94L95

CAS10899 NITROGEN ACCUMULATOR CHARGING KIT

B786441M

CAS1456 GLAND WRENCH

8013-4

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

94L95

CAS10899 NITROGEN CHARGING KIT

1. Use the CAS-10899 Nitrogen Charging Kit to d i s c h a r g e t h e a c c u m u l a t o r, r e fe r t o t h e illustration above. The tool must be disconnected from the nitrogen tank. 2. Close valves B, C and D. 3. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve F fully out. 5. Remove the guard and valve assembly cap from the accumulator. 6. Connect valve F to the valve stem on the accumulator.

7. Turn the T-handle inward on valve F to engage the pin in the valve stem. 8. Open valve D and check the charge pressure on gauge E. 9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem. 11. The accumulator can now be disassembled.

8013-5

ACCUMULATOR Assembly

Disassembly NOTE: Refer to Section 8001 for the proper procedure for the removal of the ride control accumulator. WA R N I N G : D O N O T a t t e m p t t o disassemble any accumulator until the nitrogen charge is properly discharged. SM386

1. Fasten the body (1) in a vise. Be careful not to damage the body (1), refer to the illustration on page 6. 2. Remove the screws (9) and guard (11) from the body (1). 3. Remove the pressure valve (12) from the body (1). 4. Remove and discard the O-ring (10) from the pressure valve (12). 5. Loosen and remove the cap (8) from the body (1). 6. Loosen and remove the gland (3) from the body (1).

1. Fasten the body (1) in a vise. Be careful not to damage the body (1). Refer to the illustration on page 6. 2. Install a new wear ring (5), O-ring (7) and backup ring (6) on the piston (4). 3. Lubricate the bore of the body (1) and the piston (4) with clean oil. 4. Start the piston (4) into the body (1), round surface first. Then push the piston (4) farther into the body (1). NOTE: The piston (4) must be installed squarely and slowly into the body (1). Once the piston (4) is started straight into the bore of the body (1), use a hammer and wood block to gently tap the piston into the polished area of the bore. Keep force on the piston (4) while tapping into the bore or damage may occur to the O-ring. 5. Install and tighten the cap (8) into the body (1). 6. Install new seals (2) on the gland (3).

7. Remove the piston (4) from the body (1).

7. Lubricate the seals (2) with clean oil and start the gland (3) into the body (1).

8. Remove and discard the wear ring (5), O-ring (7) and the backup ring (6) from the piston (4).

8. Tighten the gland (3).

9. Remove the seals (2) from the gland (3).

9. Install a new O-ring (10) on the pressure valve (12).

Inspection 1. Clean body (1), gland (3), cap (8) and piston (4) in cleaning solvent, refer to the illustration on page 6. 2. Inspect the piston (4) for cracks, burrs or other damage. 3. Inspect the bore of the body (1) for scratches or scoring using a light. NOTE: Minor scratches or scoring in the bore of the body (1) can be removed using crocus cloth. 4. Inspect the pressure valve (12) and replace as needed.

10. Install the pressure valve (12) in the body (1). 11. Install the guard (11), screws (9) in the body (1). 12. Charge the accumulator with dry nitrogen according to instructions on page 7. WA R N I N G : U s e o n l y n i t r o g e n w h e n charging the accumulator. DO NOT use air or oxygen that will cause an explosion. SM115A

8013-6

2 3

BS01B224

1. 2. 3. 4.

BODY SEALS (2) GLAND PISTON

5. 6. 7. 8.

WEAR RING BACKUP RING O-RING CAP

9. 10. 11. 12.

SCREW O-RING GUARD PRESSURE VALVE

RIDE CONTROL ACCUMULATOR ILLUSTRATION

8013-7

CHARGING THE ACCUMULATOR WITH NITROGEN

3 GS98N801

1. VALVE C 2. TO NITROGEN TANK 3. VALVE A

4. VALVE B 5. VALVE D 6. TO ACCUMULATOR

NITROGEN CHARGING KIT CAS10899

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. M253A

WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar (450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M406

WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration. IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high pressure (10 bar/150 psi and above) applications.

8013-8 1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to the illustration on page 7. 2. Open valve B by turning it out all the way to the left (counterclockwise). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the two cap screws (9) and the protection bracket (11) from the body (1) on the accumulator, refer to the illustration on pages 6. 8. Remove the valve cap from the pressure valve (12) on the accumulator. 9. Back off the needle valve on the accumulator end of the charging hose by tur ning it counterclockwise to the maximum amount. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve. 10. Install the charging hose fitting onto the accumulator pressure valve (12). 11. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

12. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, slightly open the needle valve on the accumulator charge hose. By regulating the needle valve, fill the accumulator to pressure according to temperature chart below. Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. TEMPERATURE 10° C 50° F 13° C 55° F 16° C 60° F 18° C 65° F 21° C 70° F 24° C 75° F 27° C 80° F 29° C 85° F 32° C 90° F 35° C 95° F 38° C 100° F

CHARGE PRESSURE 1606 KPA 233 PSI 1634 KPA 237 PSI 1669 KPA 242 PSI 1696 KPA 246 PSI 1724 KPA 250 PSI 1751 KPA 254 PSI 1779 KPA 258 PSI 1813 KPA 263 PSI 1841 KPA 267 PSI 1868 KPA 271 PSI 1896 KPA 275 PSI

TEMPERATURE/CHARGE PRESSURE RIDE CONTROL ACCUMULATOR

13. Close valve B by turning to the right (clockwise). After a few minutes, check the accumulator for leakage. 14. Back off the needle valve on the accumulator end of the charging hose by tur ning it counterclockwise the maximum amount. This will p r eve n t n it r o g e n f r o m e s c a p i n g f r o m t h e accumulator as the hose is removed. Remove the charging hose from the accumulator pressure valve (12). 15. Install the valve cap onto the pressure valve (12) on the accumulator. 16. Install the protection bracket (11) over the pressure valve (12) and secure it with cap screws (9). 17. Remove the charging hose from the nitrogen supply tank.

RIDE CONTROL VALVE

8014

Section 8014

8014-2

TABLE OF CONTENTS RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4

8014-3

RIDE CONTROL VALVE 9

13 12

7 15

5 4

3 2

BC05B015.

1. 2. 3. 4. 5.

PLUG CAP SCREW BUSHING SPRING CARRIER SPRING

6. 7. 8. 9.

SPRING SPOOL PLUG PLUG

10. 11. 12. 13.

Dissasembly

ACCUMULATOR DRAIN SCREW PLUG SOLENOID ORFICE

14. 15. 16. 17.

POPPET ORFICE VALVE BLOCK RELIEF VALVE

STEP 8 Remove the pressure relief valve (17).

STEP 1 Remove ride control valve, refer to section 8001.

STEP 2

Inspection 1. Discard all O-rings.

Remove plugs (1), (8), (9), and (11).

2. Clean all parts in cleaning solvent.

STEP 3

3. Check the spools and the spool bores for damage and wear.

Remove the solenoid (12).

4. Check the parts of the pressure relief valve.

STEP 4 Remove the spool (7) from the valve block (16).

STEP 5 Remove cap screw (2), bushing (3), spring carrier (4), springs (5 & 6) from spool (7).

STEP 6 Remove orifice (13), poppet (14), and orifice (15).

STEP 7 Remove accumulator drain screw (10).

If any of the parts are damaged, install new parts.

8014-4

Assembly

STEP 6

STEP 1 Install new O-rings.

Install springs (5 &6), spring carrier (4), bushing (3), cap screw (2) onto spool (7) and torque cap screw (2) to 5.5 Nm (48.5 lb-in).

STEP 2

STEP 7

Install and torque pressure relief valve (17) to 50 Nm (37 lb-ft).

Install spool (7) into valve block (16).

STEP 3

Install and torque plug (1) to 270 Nm (199 lb-ft).

Install and torque accumulator drain screw (10) to 3.5 Nm (31 lb-in). Install the plug for accumulator drain screw and torque to 7 Nm (62 lb-in).

STEP 9

STEP 4 Install and torque orifice (15) to 15 Nm (11 lb-ft), install poppet (14), install and torque orifice (13) to 15 Nm (11 lb-ft).

STEP 8

Install plug (8) and torque to 140 Nm (103 lb-ft), plug (9) and torque to 30 Nm (22 lb-ft), and plug (11) and torque to 90 Nm (66 lb-ft).

STEP 10 Install the ride control valve in the machine, see section 8001.

STEP 5 Install and torque solenoid valve to 12 Nm (106 lb-in).

STEP 11 Test the ride control system, see section 8002.

AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A REFRIGERANT

9002

Section 9002

9002-2

TABLE OF CONTENTS SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 6 6 8 8 9 10 11 12 12 13 13 13 14 14 15 16 16 17 17 18 18 18 19 19 20 20 21 22 22 23 23 24 24 25 25 26

9002-3

ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC’s) which are harmful to the earth’s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes. B. See a physician immediately. 2. A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is necessary to service the air conditioner system. Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.

3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system, if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can for m a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.

9002-4

299L7C

BELT TENSION TOOL CAS-10808

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, OEM-1415

A22090 109L7

ELECTRONIC LEAK DETECTOR OEM-1437 SAFETY GOGGLES CAS-10073-3

9002-5

OPERATION The refrigerant, still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The expansion valve then causes a restriction in flow of refrigerant to the evaporator core. The evap orator mete rs refr ig erant flow based on evaporator heat load.

The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser, receiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as a closed system. The air conditioner system is charged with HFC-134a refrigerant.

As the refrigerant flows through the evaporator core, the refrigerant is heated by the air around and flowing through the evaporator fins. The combination of increased heat and decreased pressure causes the air flow through the evaporator fins to become very cool and the liquid refrigerant to become a low pressure gas. The cooled air then passes from the evaporator to the cab for the operator’s comfort.

The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant and sends it in the form of a high pressure gas to the condenser. The air flow through the c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.

The electrical circuit of the air conditioning system consists of a fan speed control, temperature control, one (1) relay, a blower motor, blower resistor, A.C. compressor clutch, A.C. low pressure switch, A.C. high pressure switch, and A.C. warning light.

The high pressure refrigerant liquid then flows from t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e receiver-drier is a container filled with moisture removing material, which removes any moisture that may have entered the air conditioner system in order to prevent corrosion of the internal components of the air conditioner system.

3 5 4

208L95

1. EXPANSION VALVE 2. EVAPORATOR

3. COMPRESSOR 4. CONDENSER

5. RECEIVER-DRIER

9002-6

TROUBLESHOOTING Perform a visual inspection of the machine. Check the following and correct as necessary: 1. - Obtain service history if possible.

5. - Are there heavy accumulations of oil, or oily dust around the fittings, indicating refrigerant leakage? 6. - Are air ducts undamaged, sealed properly and in position?

2. - Is compressor drive belt in place and tensioned? 3. - Are grille screens, fan blades, condenser, air filter, and evaporator unobstructed?

7. - Condensate drain hoses and check valves present and unobstructed?

4. - Are there any sharp bends or kinks in the hoses?

Problem: No Cooling Compressor Runs

Yes Internal System Problem See Pressure Testing, Page 13

Mechanical - See Mechanical Compressor Check Page 8 Electrical - See Blower and Compressor Clutch Check Page 9

9002-7

Problem: Not Enough Cooling

Problem: Erratic Cooling

MECHANICAL HEATER

See Mechanical Compressor Check Page 8.

Make sure the heater control is OFF and that there is no coolant flow through the heater core. ELECTRICAL See Blower and Compressor Clutch Check - Blower Motor Check, Blower Switch Check and Compressor Clutch Check on Page 9. SEAL Make sure the sealing material is correctly in place. INTERNAL SYSTEM PROBLEMS See Pressure Testing, Page 13. MECHANICAL See Mechanical Compressor Check page 8. See Evaporator Heater Core Check Page 12.

Problem: System Makes Noise

ELECTRICAL See Blower and Compressor Clutch Check on Page 9. MECHANICAL See Mechanical Compressor Check Page 8. See Blower Motor Check Page 9. REFRIGERANT See Cab Temperature Check Page 10. ELECTRICAL See Compressor Clutch Check Page 9. INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

9002-8

SYSTEM CHECKS Mechanical Compressor Check Compressor and Fan Belts

1. Too much belt wear - replace a worn belt, because a worn belt will cause too much slippage.

Compressor Mounting Brackets

1. Loose bracket mounting bolts - tighten the bolts to the correct torque. 2. Bracket has cracks or breaks - replace the bracket.

Compressor Clutch

1. The compressor belt will slip on the compressor pulley if there is compressor seizure. Remove the compressor for service or replacement. 2. Remove the dust cover and check the air gap on the compressor clutch. The gap b e t w e e n t h e f r o n t p l a t e a n d p u l l ey assembly must be 0.41 to 0.79 mm. 3. Use a socket wrench to slowly rotate the compressor clockwise. Compressor rotation should be smooth and not require much effort.

Pulley and Belt Alignment

1. The compressor pulley and the compressor drive pulley must be aligned within 1.6 mm (1/16 inch) of each other. Use a straight edge to check pulley alignment. Adjust the compressor mounting bracket if needed.

9002-9

Blower and Compressor Clutch Check NOTE: Check supply voltage with compressor lead plugged in and engaged. Voltage drops will not be apparent without current flow. Compressor Clutch

1. If there is electrical system voltage to the clutch, check for excessive voltage drop in the ground circuit, then see Section 9004 and replace the compressor.

Low and High Pressure Switches

1. See Section 4002 and check the high and low pressure switches.

Blower Fuse (10 amp)

1. Check for damaged blower fuse.

Blower Fan Switch

1. Check switch operation. Switch must give four different blower speeds: OFF, Low, High, and Purge. 2. Check for loose connections or broken wires. Repair or replace as necessary. 3. Check resistor board.

Blower Motor

1. Check the wiring to the blower motor. Make repairs or replace items as necessary. 2. Check motor ground wire. Make sure motor ground wire is making good contact with mounting bracket.

1. With key in ON position, turn switch to maximum cold. Compressor clutch must engage.

Temperature Control Switch

NOTE: Blower must be operating, since electrical power to temperature control switch is received from blower switch. 2. Turn the blower off. Disconnect the wires from the temperature control. Using an ohmmeter, check the continuity between switch ter minals. If continuity is not present when switch is on maximum cold, replace switch.

9002-10

Cab Temperature Check Air Louvers

1. Make sure louvers and recirculation vents are fully open for most efficient air conditioning operation. Defrost louvers must be closed. 2. Check blower; blower must be running.

ATTENTION: Use caution when feeling hoses. Hoses become very hot. Check temperature by slowly reaching for hose and touching briefly several times with finger tips, increasing the duration with each touch. Air Conditioning

1. Feel the air conditioning hoses. The high pressure hoses (small line) must be warmer than the low pressure hose (large line). 2. If no temperature difference, the system is low on refrigerant, or compressor is not working correctly.

1. Put a thermometer in the air duct behind the seat and r u n t h e c o m p r e s s o r fo r f i v e m i n u t e s t o m a k e temperature stable. Refer to page 12. 2. Duct temperature must be below 25° C (72° F) if the system is operating at maximum efficiency. Duct Temperature

Temperature Sensing Probe Check

NOTE: Ambient temperature must be 27 to 43° C (80 to 110° F). 3. If temperature is above 25° C (72° F), system is low on refr igerant, there is a restr iction in the system, compressor is not working correctly, or air ducts are not sealed correctly.

1. Turn the engine OFF, key switch ON, blower switch ON and temperature control switch turned fully clockwise. 2. Remove the temperature sensing probe from the evaporator. Refer to Section 9004. 3. Put the end of the temperature sensing probe in a container with ice and water. 4. When the sensing tube has cooled to the temperature of the ice and water mixture, the temperature control switch should interrupt the current flow to the compressor. Check for current at the control switch terminals as on previous page. If current is not interrupted then replace the control switch.

9002-11

Visual and Leak Check Compressor Hoses

1. Make sure that all hose connections are tight. 2. Check hoses for bends or cracks. Replace all hoses that have damage.

1. Shut off the engine.

Leak Finding Check

WARNING: When refrigerant comes in contact with an open flame, it can form dangerous gas. Never breathe these fumes. 2. Use electronic leak detector OEM -1437 to inspect all connections. Use instructions from manufacturer of leak finding tool. NOTE: When checking compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise. NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 3. Repair all leaks and recharge the system. See Section 9003.

Condenser

1. Make sure the condenser is clean and the seals are in place. Make sure condenser fans run when temperature control switch is ON.

9002-12

Evaporator/Heater Core Check Make sure heater valve is closed

Evaporator/Heater Core

1. See Section 9004 for access to the evaporator/heater core. 2. Inspect the fins on the evaporator/heater core. All the fins that have bends or damage must be made straight. 3. Inspect the evaporator/heater core for r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e compressed air or a brush and vacuum cleaner. If the core is wet or filled with mud, flush the core with water using a hose without pressure. Make sure the water drains freely from the evaporator/heater core. DO NOT USE STEAM. WARNING: Do not steam clean any air conditioning systems parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode.

Evaporator/Heater Core Sealing

1. See Section 9004 for access to the evaporator/heater core. 2. Make sure seals are in place so blower will pull air only through the evaporator/heater core and not around the evaporator/heater core.

Filters

1. Make sure the filters are clean.

9002-13

PRESSURE TESTING Manifold Gauge Set NOTE: The gauge set is not accurate enough to optimize an existing charge of HFC-134a. The best use of the gauge set is to determine whether undercharge or overcharge exists, and then evacuate, reclaim and recharge system with the recommended quantity (charge) of HFC-134a. The manifold gauge set is the most important tool used to service the air conditioning system. The manifold gauge set is used to measure the high and low pressures of the system, as a tool to troubleshoot for correct refrigerant charge quantity, system diagnosis, and operating efficiency. The manifold gauge set can read both the high (discharge) and low (suction) sides at the same time, since pressure must be compared in order to make a diagnosis of system operation. LOW PRESSURE GAUGE - The low pressure gauge is a compound gauge. It is best used to judge eva cuat io n effe ctiven ess. A vac uum rea ding indicates a system malfunction. For this reason, it is necessar y to use a compound gauge that will indicate both pressure and vacuum.

During normal operation the low pressure gauge must always indicate from 10 to 35 psi (0.7 to 2.4 bar) after the system has run 10 to 15 minutes. HIGH PRESSURE GAUGE - The high pressure gauge is used to indicate pressures in the high side of the system. The gauge must indicate from 0 to 400 psi (0 to 27.6 bar) minimum. During normal operation, the high pressure gauge will normally indicate from 120 to 310 psi (8.3 to 21.4 bar). See pressure-temperature chart on page 14.

Pressure Test Connection C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r conditioning system as shown. Make sure that both valves in the manifold gauge set are closed.

9002-14

PRESSURE-TEMPERATURE CHART AMBIENT

NORMAL LOW

NORMAL HIGH

AIR LOUVER (BEHIND SEAT) MAXIMUM TEMP. TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) °F (°C) psi (bar) psi (bar) 80 (27)

9 to 12

145 to 165

(0.62 to 0.83)

(10 to 11.53)

11 to 15

190 to 210

(0.76 to 1.04)

(13.10 to 14.48)

16 to 18

210 to 230

(1.10 to 1.24)

(14.48 to 15.86)

17 to 19

235 to 255

(1.17 to 1.31)

(16.2 to 17.58)

20 to 21

260 to 280

(1.38 to 1.45)

(17.93 to 19.31)

22 to 24

290 to 310

(1.93 to 2.14)

(20 to 21.37)

90 (32) 95 (35) 100 (38) 105 (41) 110 (43)

The pressure-temperature chart is based on the following conditions: NOTE: High humidity will cause higher air louver temperatures and dramatic increase in suction pressure. The table shown represents readings taken in low relative humidity. Adjust the chart according to local conditions.

55 (14) 61 (18) 63 (20) 66 (22) 68 (23) 72 (25)

2. All panels and access doors installed and closed. 3. Cab filters clean and installed. 4. Heater valve at engine closed. 5. Measurements taken 15 minutes after startup.

1. Engine at 1500 RPM, no load, fan speed & temperature control at max setting, A/C switch ON, all louvers and doors open

QUICK REFERENCE TROUBLESHOOTING CHART PROBLEM

LOW PRESSURE GAUGE

HIGH PRESSURE GAUGE

SEE PAGE

NO COOLING

VERY LOW

NO COOLING

HIGH

NOT ENOUGH COOLING

NORMAL TO HIGH

NORMAL

NOT ENOUGH COOLING

LOW

NOT ENOUGH COOLING

HIGH

LOW

NOT ENOUGH COOLING

HIGH

INTERMITTENT COOLING

NORMAL

NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

9002-15

A/C RECOVERY AND CHARGING STATION CONNECTIONS STEP 1

STEP 4

Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.

Connect the hose from the high pressure gauge to the port on the discharge hose.

WARNING: Do not steam clean any air conditioning system parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode. SM104A

WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid r e f ri g er a n t i n y o u r ey e s c o u l d c a u s e blindness. SM105A

STEP 5

STEP 2

Make sure the charging station manifold gauge valves are in the closed position.

Connect the hoses from the test gauges to the service ports by turning the knurled knobs on the depressors.

STEP 6

STEP 3 Connect the hose from the low pressure gauge to the port on the suction hose.

Start the engine and run at 1500 RPM maximum speed. Operate the air conditioner system at maximum cooling setting and blower speed for 15 minutes with the cab door open. Observe the test gauges and check the chart on page 13 against the gauge readings.

9002-16

PROBLEM: NO COOLING

VERY LOW

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of No Refrigerant or Low Refrigerant Charge: 1. Leak test the system, see Page 11. It may be necessary to add refrigerant. See Section 9003. 2. Evacuate and reclaim remaining refrigerant from system. See Section 9003. 3. Repair system leaks as needed. Follow the given repair procedure. A. Discharge air from evaporator warm. B. Compressor does not run, or cycles off rapidly after start-up. (A/C warning light in cab should illuminate).

Yes

4. Check level of oil in compressor - possible for compressor to have an oil loss. 5. Remove air and moisture from the system. Replace Receiver-Drier. See Section 9004. 6. Charge system with new refrigerant. See Section 9003. 7. Continue performance possible problems.

test for other

9002-17

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of Large Quantity of Air in System: 1. Evacuate and reclaim refrigerant from system. See Section 9003. 2. Replace receiver-drier. Discharge air from evaporator warm

Yes

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine fan belt and proper condenser fan operation. 2. Check to see that condenser is clean and unobstructed and that the fins are straight. 3. Check system for too much refrigerant. Evacuate, reclaim and recharge refrigerant until gauge pressure is normal. See Section 9003. A. Liquid line (between evaporator and condenser) is very hot. B. Discharge air from evaporator warm.

4. Remove and check condenser for restrictions caused by oil or reduced heat transfer. A. Remove refrigerant from the system. See Section 9003. B. Use compressed condenser.

air

remove

oil

from

C. Replace receiver-drier. D. Remove moisture and charge the system. See section 9003. 5. Continue the performance test for other possible problems.

9002-18

Expansion Valve Malfunctioning - Indications: A. Discharge air from heater/evaporator warm. B. Much condensation on suction hose at compressor. C. Much condensation outlet.

See Section 9004 and replace the expansion valve.

evaporator

Refrigerant Contamination: 1. See table below and check stable saturation pressures at given temperature to determine if contamination exists. A. Measure pressure from gauge on reclamation unit. B. Measure temperature from refrigerant in reclamation tank. If refrigerant has been in reclamation unit for some time, use ambient temperature. The numbers in the table represent the boiling point for HFC-134a.

Refrigerant Contamination

C. Pressure readings below range given in chart indicate contaminated refrigerant. IMPORTANT: Do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance with all applicable laws and local procedure.

HFC-134a Stable Saturation Pressure/ Temperature Chart Temperature ° F (° C)

Pressure PSIG (Bar)

50 (10) 55 (13) 60 (16) 65 (18) 70 (21) 75 (24) 80 (27) 85 (29) 90 (32) 95 (35) 100 (38) 102 (39) 104 (40) 106 (41) 108 (42) 110 (43) 112 (44) 114 (46) 116 (47) 118 (48) 120 (49)

45 (3.1) 51 (3.5) 57 (3.9) 64 (4.4) 71 (4.9) 78 (5.4) 88 (6.1) 95 (6.6) 104 (7.2) 114 (7.9) 124 (8.6) 129 (8.9) 133 (9.2) 138 (9.5) 142 (9.8) 147 (10.1) 152 (10.5) 157 (10.8) 162 (11.2) 167 (11.5) 172 (11.9)

9002-19

PROBLEM: NOT ENOUGH COOLING

NORMAL TO SLIGHTLY HIGH

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Air in the System - Indications: 1. Test system for leaks. See page 11. Possible leak has let air enter; check compressor seal carefully. 2. Discharge system of refrigerant. See Section 9003. A. Suction line warm to your hand.

3. Repair system leak as necessary.

B. Discharge air from heater/evaporator only a little cool.

4. Replace receiver-drier. 5. Check compressor oil level. 6. Remove air and moisture from the system. See Section 9003. 7. Charge system with new refrigerant. See Section 9003.

9002-20

LOW

LO W

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Not Enough Refrigerant - Indications: 1. Leak test system - system has a loss of refrigerant. NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7 to 29.5 grams) of refrigerant between seasons. A. If leak is found, go to Step 2. B. If no leak is found, go to Step 6. 2. Discharge refrigerant from system. See Section 9003. A. Discharge air from evaporator cool or warm - not cold.

3. Repair system leaks as needed. 4. Check oil level in compressor - It is possible for compressor to lose oil. 5. Remove air and moisture from the system. Replace Receiver-Drier. See Section 9004. 6. Charge system with new refrigerant. See Section 9003.

High Side Restriction - Indications: A. Discharge air from heater/evaporator only a little cool. B. Condensation receiver-drier.

frost

C. Liquid line to receiver-drier cool, with frost or condensation. NOTE: The frost will form downstream from or at the point of the restriction

1. Discharge refrigerant from system-restriction in receiver-drier or liquid line must be removed. 2. Remove and replace part with restriction. 3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

9002-21

Expansion Valve Not Operating - Indications: A. Discharge air from evaporator warm or cool - not cold. B. Condensation or frost on expansion valve outlet. C. Inlet end of expansion valve is warm.

1. Expansion valve outlet with condensation or frost is an indication of a restriction in the expansion valve. Replace expansion valve. See Section 9004. 2. Inlet end of expansion valve is warm (not hot), indicating expansion valve is not completely open. If the valve is stuck closed, there will be little or no flow of refrigerant through the valve. Replace expansion valve. See Section 9004.

9002-22

HIGH

LOW

SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Compressor Turning But Not Pumping Properly - Indications: 1. Discharge refrigerant from system. See Section 9003. 2. Remove the compressor from the machine. See Section 9004. 3. Remove and replace compressor because there is indication of internal leak in compressor. A. System is fully charged.

4. Replace compressor.

B. Cool discharge air from evaporator.

5. Replace receiver-drier if: A. System has been opened before. B. Receiver-drier has been used two or more years. See Section 9004 for receiver-drier replacement. 6. Charge the system with refrigerant. See Section 9003.

Expansion Valve Stuck Open Expansion Valve Stuck Open

1. Replace expansion valve. See Section 9004.

9002-23

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and proper condenser fan operation. 2. Check to see that condenser is clean and that the fins are straight. 3. Check system for too much refrigerant. A. Remove refrigerant from system until gauge pressure is below normal. See Section 9003. A. Liquid line very hot. B. Discharge air from evaporator warm.

B. Add refrigerant until gauge pressures are normal. See Section 9003. C. If there is still a problem, do step 4. 4. Remove and inspect condenser for restrictions caused by oil or reduced heat transfer. A. Discharge refrigerant from system. See Section 9003. B. Use compressed air to remove oil from condenser. C. Replace receiver-drier. See Section 9004.

Air in the System - Indications: 1. Discharge refrigerant from system. See Section 9003. 2. Replace receiver-drier. Warm discharge air from evaporator.

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

9002-24

PROBLEM: INTERMITTENT COOLING

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Moisture in the System - Indications: 1. Discharge system of refrigerant. If too much moisture enters the orifice of the expansion valve, the freezing of this moisture can stop refrigerant flow. See Section 9003.

Cooling is acceptable during cool part of day but not acceptable during hot part of day.

2. Replace receiver-drier. The moisture removing material could be full to capacity with moisture. See Section 9004. 3. Remove air and moisture from the system. See Section 9003. NOTE: The time needed to remove a large amount of moisture will be two to three hours minimum. 4. Charge system with new refrigerant. See Section 9003.

9002-25

PROBLEM: NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Too Much Refrigerant in System - Indications: A. Cool discharge air from heater/evaporator. B. Compressor makes noise.

1. Remove refrigerant from system until gauge readings are below normal. See Section 9003. 2. Add new refrigerant until gauge readings are normal. See Section 9003.

9002-26

TUBE CONNECTIONS TORQUE CHART TUBING SIZE

3/8 inch

1/2 inch

5/8 inch

THREAD SIZE

M10 -1.25

5/8-18

3/4-18 OR 3/4-16

7/8-18 OR 7/8-14

1-14

STEEL TO STEEL

31-36 Nm

40-46 Nm

45-52 Nm

ALUMINUM TO BRASS

10-14 Nm

24-30 Nm

30-37 Nm

45-52 Nm

NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used. IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these connections are easily distorted.

AIR CONDITIONER SYSTEM SERVICE

9003

Section 9003

9003-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 7 10

9003-3

SPECIFICATIONS Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION OEM-1415

109L7

SAFETY GOGGLES CAS-10073-3

9003-4

SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable and easiest to work with of the refrigerants now used in air conditioning systems. Refrigerant HFC-134a does not contain chlorofluorocarbons (CFC’s) which are harmful to the Earth’s ozone layer. Safety procedures must be followed when working with refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes. B. See a physician immediately. 2. A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is necessary to service the air conditioner system. Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.

9003-5

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY Recovered refr igerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it.

STEP 3

If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding.

STEP 1

A22114

Open the high and low valves.

STEP 4

BD03A213

Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.

STEP 2 A22107

Make certain the refrigerant tank gas and liquid valves are open.

BD03B001

With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports. Connect the hose from the low pressure gauge to the port on the suction hose. Turn in valve depressor. Connect the hose from the high pressure gauge to the por t on the discharge hose. Tur n in valve depressor.

9003-6

STEP 5

STEP 7

A22112

A22110

Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the recovery start switch.

Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely.

The compressor will shut OFF automatically when recovery is complete. Wait for 5 minutes and observe the manifold pressure gauges for a pressure rise. If pressure rises above 0 psi (0 bar), depress the hold/cont switch. Then wait for the compressor to automatically shut OFF.

STEP 8

STEP 6

A22111

Fill the A/C compressor with fresh SP-20 PAG oil equal to the amount in the reservoir.

STEP 9 A22108

Drain the oil separator of the A/C system oil. Open the air purge valve long enough to let some of the compressor discharge pressure back into the separator.

BD03A213

Remove the hoses from the service ports and install the caps.

9003-7

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING IMPORTANT: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system. A. The system has been opened for service before. B. Receiver-drier has operated two or more years. C. Disassembly of compressor shows small particles of moisture removing material (gold or brown particles).

Air and moisture are removed from the system by a va c u u m p u m p. A v a c u u m p u m p i s t h e o n l y equipment made to lower the pressure enough to change the moisture to vapor that can be removed from the system. NOTE: Refer to the vacuum pump manufacturer’s user manual for additional information.

STEP 11

D. Large system leak (broken hose, break in line). E. Too much air or moisture in system. F. Removal of compressor caused the system to be open (uncapped) longer than 5 minutes.

STEP 10 A22113

Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the vacuum key. Program a minimum of 45 minutes and press the Enter key. The display will flash once indicating the programmed data has been accepted.

STEP 12 BD03B001

With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports as follows: 1. Connect the hose from the low pressure gauge to the port on the suction hose. 2. Connect the hose from the high pressure gauge to the port on the discharge hose. 3. Turn in both thumbscrews to depress the service valves. Removal of air and moisture from the system is necessary after the refrigerant has been removed after the system has been opened for maintenance. Air enters the system when the system is opened. Air has moisture that must be removed to prevent damage to the system components. NOTE: The pump on the reclamation unit will not pull a sufficient vacuum to remove air and moisture.

A22115

Press the Charge key. “Program” and “Charge” will appear on the display.

9003-8

STEP 13

STEP 16

A22113

A22123

Program 3.5 lbs and press the enter key. The display will flash once indicating the programmed data has been accepted.

Press the Vacuum key. “Automatic” will appear on the display. Vacuum will appear on the display and after a slight delay, the vacuum pump will star t. The display will show the amount of time programmed and begin a countdown to zero.

STEP 14

When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 to 29-1/2 inches of mercury (Hg). The low pressure gauge must not increase faster than one inch of mercury (Hg) in 10 minutes. A previously charged, l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m compressor oil and raise system pressure under vacuum. If the system will not hold vacuum, a leak exists that must be corrected before recharging can begin. See Section 9002 in the manual for a leak test. A22114

Fully open the low and high pressure valves.

STEP 17

STEP 15

A22113 A22107

Open the red (vapor) and blue (liquid) valves on the tank.

Press the charge key to begin refrigerant charging. “Automatic” and “Charge” will appear on the display. The display shows the programmed amount and counts down to zero as charging proceeds. When charging is completed, the display shows “CPL”.

9003-9

STEP 18

STEP 21

A22114

BD03B001

Completely close the high and low pressure manifold valves.

Stop the engine, close any open valves and carefully remove the manifold gauge hoses.

ATTENTION: Check the OEM equipment manual before performing Step 19 to avoid damaging the recovery unit. The pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the valves accidently open or if either or both valves are opened while the A/C system is operating.

STEP 22

STEP 19 Start the engine and run at 1500 RPM. Operate the air conditioner system at maximum cooling setting and blower speed with the doors and windows open. NOTE: The compressor will not operate if the system pressure is too low or too high. The pressure indicator lamp will illuminate when the relay is actuated by a low or high pressure and the compressor clutch will disengage. To restart the compressor, the air conditioner control or blower switch must be turned to the OFF position and then to the ON position.

STEP 20

A22117

Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system. See chart on Page 9002-9 for temperature and pressure variations.

BD03B213

Install the caps on the service ports on the suction and discharge hoses.

9003-10

PRESSURE - TEMPERATURE CHART NORMAL LOW NORMAL HIGH AMBIENT TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) psi (bar) psi (bar)

AIR LOUVER MAXIMUM TEMP. °F (°C)

80 (27)

9 to 12 (0.62 to 0.83)

145 to 165 (10 to 11.5)

55 (14)

90 (32)

11 to 15 (0.76 to 1.04)

190 to 210 (13.1 to 14.5)

61 (18)

95 (35)

16 to 18 (1.10 to 1.24)

210 to 230 (14.5 to 15.8)

63 (20)

100 (38)

17 to 19 (1.17 to 1.31)

235 to 255 (16.2 to 17.6)

66 (22)

105 (41)

20 to 21 (1.38 to 1.45)

260 to 280 (17.9 to 19.3)

68 (23)

110 (43)

22 to 24 (1.93 to 2.14)

290 to 310 (20 to 21.4)

72 (25)

The pressure-temperature chart is based on the following conditions: 1. Engine operating at 1500 RPM 2. No engine load 3. Fan speed control in maximum position and all louvers open. 4. Cab temperature control set to maximum cooling.

5. Both cab doors open 6. All panels and access doors installed and closed. 7. Cab filters clean and installed. 8. Heater valve at engine closed. 9. Measurements taken 15 minutes after start-up.

REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS

9004

Section 9004

9004-2

TABLE OF CONTENTS SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 5 6 8 9 14 19 19 20

9004-3

SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC’s) which are harmful to the earth’s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes. B. See a physician immediately. 2. A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is necessary to service the air conditioner system. Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.

3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can for m a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.

9004-4

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION OEM-1415

BS03H012

SAFETY GOGGLES CAS-10073-3

9004-5

COMPRESSOR Removal

STEP 4

STEP 1 Place the master disconnect switch in the OFF position.

STEP 2 Discharge the air conditioning system according to the instructions in Section 9003.

STEP 3 BD06F116

Remove the fan belt.

STEP 5

BD06F113

BD06F117

Disconnect the low pressure line from the suction port and the high pressure line from the discharge p o r t o n t h e c o m p r e s s o r. I m m e d i a t e l y i n s t a l l protective caps on the open ports and lines.

BD06F114

Loosen and remove the four bolts holding the protective shield. Remove the shield.

9004-6

Installation

STEP 6

STEP 9 Place the compressor into position on the machine.

STEP 10

BD06F117

Disconnect the compressor clutch wire from the engine harness assembly.

STEP 7 BD06F117

Install the three bolts to mount the compressor.

STEP 11

BD06F117

Loosen and remove the three compressor mounting bolts.

STEP 8 Remove the compressor from the machine.

BD06F117

Connect the compressor clutch wire to the engine harness assembly.

9004-7

STEP 12

STEP 13 Carefully remove the protective cap, install a new O-ring, and connect the low pressure line to the suction port on the compressor.

STEP 14 Install the belt.

STEP 15 Install the protective shield.

STEP 16 BD06F117

Slowly remove the protective cap, install a new O-ring, and connect the high pressure line to the discharge port on the compressor. IMPORTANT: Use caution when removing cap as new compressors have internal pressure when shipped.

Charge the air conditioning system according to the instructions in Section 9003.

9004-8

EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS 3

7 4

2 1 8 9

18 17 12

16 15

BS06G118

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

EVAPORATOR UPPER BOX PPE COVER PPE SOLENOID DRIVER UPPER BOX BOLT

7. 8. 9. 10. 11. 12.

WASHER GROMMET HEATER CORE HEATER VALVE 24V THERMOSTAT LOWER BOX

13. 14. 15. 16. 17. 18.

LOWER BOX PPE EXPANSION VALVE BLOWER RECIRCULATING VAIN RECIRCULATING MOTOR RESISTOR BLOWER MOTOR

9004-9

Removal

STEP 23

STEP 17 Park the machine on a level surface and lower the bucket to the floor.

STEP 18 If changing any air conditioning components, discharge the air conditioning system according to the instructions in Section 9003.

STEP 19 BD06G212

Open the cover on the cooler.

STEP 24

BD02N160

If changing the heater core, put a 37 liter (10 gallon) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

BD06G213

Remove the four screws securing the air vent, remove the vent cover.

STEP 20 Place the master disconnect in the OFF position.

STEP 25

STEP 21 Disconnect the wiring harness from the operator’s seat (if equipped with air seat option).

STEP 22

BD06G214

Remove the three screws securing the cooler to the cab, remove the cooler.

STEP 26 BD06G202

Remove the four bolts that fasten the operator’s seat to the upper box, remove the seat from the machine.

Fold the rubber mat over to gain access to the upper box mounting bolts.

9004-10

STEP 27

STEP 30

BD06G215

Remove the six bolts securing the upper box.

BD06G217

G o i n g t h r o u g h th e i n s i d e f i l t e r a r e a fe e l th e recirculating vain to make sure is is in the outside air, “closed”, position.

STEP 28

STEP 31

BD06G216

Remove two screws, one on each side of the upper box, securing the upper box to the lower box.

BD06G218

STEP 29

The above photo shows that the recirculating vain is not in the outside air “closed” position.

Place the air selector on the control panel to outside air.

STEP 32

NOTE: In step 30 and 33 the upper box is shown removed for clarity only, these steps must be done prior to removing the upper box.

BD06G240

Use a screw driver and disconnect the linkage.

9004-11

STEP 33

STEP 36

BD06G219

Close the vain so the upper cover can be removed.

BD06G203

Disconnect the solenoid driver.

STEP 34 Remove the upper box up and rest it against the console.

STEP 37

NOTE: The wiring harness for the HVAC system goes through the upper cover, by resting the cover against the console the wiring harness will not need to be removed.

STEP 35

BD06G236

Remove the upper PPE from the heater and air conditioning cores. NOTE: If testing on the electrical components are required the solenoid driver can be reconnected once the upper PPE is removed.

BD06G220

Pull the wiring harness loose from the upper PPE.

9004-12 NOTE: If replacing the heater control valve, heater core, air conditioning expansion valve, air conditioning evaporator core do steps 38 through 47, if replacing electrical components go to step 48.

STEP 40

STEP 38

BD06G206

Remove the thermostat probe and clamp from the evaporator core.

STEP 41 BD06G204

Remove the right side cab skirt.

STEP 39

BD06G237

Disconnect the electrical connectors from the thermostat control.

STEP 42 BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

Fasten identification tags on the hoses. Disconnect the hoses for the heater core and evaporator core, install plugs in the hoses and caps on the fittings.

BD06G236

Disconnect the electrical connectors from the heater control valve.

9004-13

STEP 43

STEP 49

Pull the heater core and evaporator core from the lower box PPE.

STEP 44 Remove the expansion valve from the evaporator core.

STEP 45 Remove and discard the O-rings from the openings in the expansion valve.

STEP 46 Remove the screws from the heater core and remove the control valve.

STEP 47 Remove and discard the O-rings from the heater control valve.

BD06G208

D i s c o n n e c t t h e e l e c t r i c a l c o n n e c t o r fo r t h e recirculating vain motor, disconnect the linkage from the vain. Remove the mounting screws and remove the motor.

STEP 50

STEP 48 1

3 2 BD06G209 BD06G207

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

Remove the fans from the lower PPE, disconnect the electrical connectors. Remove the two mounting screws for the resistor, remove the resistor.

1. FAN SPEED AND A/C SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

R e m ove t h e sw i t c h p a n e l f r o m t h e c o n s o l e. Disconnect the electrical connectors and remove switches as required.

9004-14

Installation

STEP 53

STEP 51 1

1 2

3 3 2

BD06G207

BD06G209

1. FAN SPEED SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

Re place switches and connect the electr ical connectors as required. Install the switch panel in the console.

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

Install the resistor, install the two mounting screws and tighten. Install the fans in the lower PPE, connect the electrical connectors.

STEP 54 Install new O-rings on the heater control valve.

STEP 52 STEP 55 Install the control valve, install and tighten the screws to the heater core.

STEP 56 Install new O-rings on the openings of the expansion valve.

STEP 57 Install the heater core and evaporator core into the lower box PPE. BD06G208

STEP 58

Install the motor and install the mounting screws and tighten. Connect the electrical connector for the recirculating vain motor, connect the linkage to the vain.

BD06G236

Connect the electrical connectors to the heater control valve.

9004-15

STEP 59

STEP 61

BD06G237

Connect the electrical connectors to the thermostat control.

STEP 60

BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

Remove the plugs from the hoses and the caps from the fittings. Install new O-rings in the evaporator fittings, connect the heater and evaporator hoses. Remove and discard identification tags that were used during disassemble.

STEP 62

BD06G206

Install the thermostat probe coil and clamp to the evaporator core “cold” tube.

BD06G204

Install the right side cab skirt.

STEP 63

BD06G238

Install the upper PPE on the heater and air conditioning cores.

9004-16

STEP 64

STEP 67

BD06G210. BD06G203

Connect the solenoid driver.

Make sure that the recirculating vain is in the closed position. IMPORTANT: This photo shows it in the open position and the upper box will not go back into position without damaging the recirculating vain.

STEP 65

STEP 68

BD06G239

Push the wiring harness into the preformed notches in the upper PPE.

BD06G241

STEP 66

Set the upper box into position on the heater and evaporator cores.

Place the air selector on the control panel to outside air.

STEP 69

BD06G216

Install two screws, one on each side of the upper box securing the upper box to the lower box.

9004-17

STEP 70

STEP 74

BD06G242

BD06G214

Install the insolation panel in the center of the upper box.

Install and tighten the three screws securing the cooler to the cab.

STEP 71

STEP 75

BD06G215

BD06G213

Install and tighten the six bolts securing the upper box.

Install the vent cover, install and tighten the four screws securing the air vent.

STEP 72

STEP 76

BD06G243

Install the right rear floor mat into the cab, if machine is equipped with air ride seat make sure to pull the wiring up above the mat for the seat.

STEP 73 Install the remainder of the floor mat.

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).

9004-18

STEP 77

STEP 79

Connect the wiring connector to the operator’s seat (if equipped with air seat option).

Charge the air conditioning system according to the instructions in Section 9003.

STEP 78 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

9004-19

CONDENSER AND RECIEVER DRIER Removal

STEP 85

STEP 80 Park the machine on a level surface and lower the bucket to the ground.

STEP 81 Place the master disconnect switch in the OFF position.

STEP 82 Discharge the air conditioning system according to the instructions in Section 9003. BS03A107

Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d disconnect the hoses from the condenser.

STEP 83

STEP 86

Install plugs in the hoses and caps on the fittings.

STEP 87

BD01D142

1. COVER

2. CONDENSER

Open the cover (1) to gain access to the condenser (2).

STEP 84 BS03A109

Loosen the bolts that fasten the condenser to the bracket, pivot the condenser and remove the bolts and condenser.

BD03A109

The condenser is connected to a bracket which pivots on the cooling frame. Pivot the condenser to gain access to the hoses.

9004-20

Installation

STEP 88

STEP 91 Put the condenser in position on the bracket.

STEP 92

BD06G211

Fa s t e n i d e n t i f i c a t i o n t a g s o n t h e h o s e s a n d disconnect the hoses from the receiver drier.

STEP 89 Install plugs in the hoses and caps on the fittings.

STEP 90 Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket.

BS03A109

Install the bolts that fasten the condenser to the bracket, pivot the condenser down and tighten the bolts.

STEP 93

BS03A107

Pivot the condenser to gain access to the hoses.

STEP 94 Remove the plugs from the hoses and the caps from the fittings. Install new O-rings and connect the hoses to the fittings. Remove and discard identification tags that were used during disassemble.

STEP 95 Pivot the condenser down and close the cover.

STEP 96 Mount the receiver drier and bracket, install and tighten the mounting bolt.

9004-21

STEP 97

STEP 98 Charge the air conditioning system according to the instructions in Section 9003.

STEP 99 Place the master disconnect switch in the ON position.

BD06G211

Remove plugs from the hoses and caps from the fittings, install new O-rings and connect the hoses to the fittings, connect the trinary switch. Remove and discard identification tags that were used during disassemble.

9004-22

NOTES

Section 9006

9006

LOADER

9006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 4 5 7 9

9006-3

SPECIFICATIONS Special Torques Bolts for the Bucket Teeth ........................................................................1315 to 1480 Nm (970 to 1090 pound-feet)

BUCKET TEETH Replacement of the Tooth Points 3

1. Use a hammer and punch to drive the retaining pin (1) for the tooth point (2) out of the tooth shank (3), refer to the illustration on this page.

2. Remove the tooth point (2). 3. Install a new tooth point (2) on the tooth shank (3). 4. Install the retaining pin (1) into the tooth point (2) and tooth shank (3). Make sure the shoulder on the retaining pin is toward the cutting edge. Use a hammer to hit the retaining pin (1) until the retaining pin (1) is even with the outside of the tooth shank (3).

7 8

3 2

6 10

Replacement of the Bucket Teeth 1. Loosen and remove the nuts (4), hardened washers (5), and bolts (6) from the bucket teeth.

9 7

NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off. 2. Remove the tooth.

B0740A88J

3. Install the new tooth on the bucket cutting edge (7). 4. Use new nuts (4), hardened washers (5), and bolts (6) for the tooth being installed. 5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to 1090 pound-feet).

Replacement of the Bucket Corner Teeth 1. Loosen and remove the nuts (9) and bolts (8) from the bucket corner teeth (10). NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off. 2. Remove the corner tooth (10). 3. Install the new corner tooth (10) on the bucket cutting edge (7). 4. Use new nuts (9) and bolts (8) for the corner tooth being installed. 5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to 1090 pound-feet).

1. 2. 3. 4. 5.

RETAINING RING TOOTH POINT TOOTH SHANK NUT HARDENED WASHER

6. 7. 8. 9. 10.

BOLT CUTTING EDGE PLOW BOLT NUT CORNER TOOTH

BUCKET TEETH ILLUSTRATION

9006-4

RETURN TO DIG ADJUSTMENT

2 6 1

3 4

BS01C083

1. TARGET MOUNTING BRACKET 2. BUCKET CYLINDER

3. TARGET BAR 4. PROXIMITY SWITCH MOUNTING BRACKET

5. PROXIMITY SWITCH 6. PROXIMITY SWITCH GUARD

RETURN TO DIG ADJUSTMENT ILLUSTRATION

IMPORTANT: Before adjusting the return-to-dig, make sure that the target bar on the bucket linkage is not damaged. Slowly roll back and dump the bucket and make sure that the target bar stays the same distance from the switch. The switch mounting bracket protects the switch. Make sure the target bar cannot touch the switch when the bucket is dumped. 1. Park the machine on a level surface. Raise the lift arms until they are approximately horizontal and dump the bucket. Lower the bucket until the bucket edge is on the ground. 2. Apply the parking brake and stop the engine. 3. Loosen the bolts holding the target mounting bracket (1) to the tilt cylinder eye. Align the target mounting bracket (1) parallel to the tilt cylinder (2). Tighten the bolts, refer to the illustration on this page. 4. Loosen the bolts holding the proximity switch mounting bracket (4) to the tilt cylinder (2). Position the proximity switch (5) parallel to the target bar (3) and tighten the bolts. 5. Adjust the proximity switch (5) out towards the target bar (3), until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. Torque the jam nut to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). NOTE: The proximity switch (5) must not protrude past the proximity switch guard (6). 6. Start the engine, position the bucket to the correct digging angle and stop the engine.

7. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). Slide the target bar (3) towards the proximity switch (5) until the face of the proximity switch (5) is completely covered. 8. Align the target bar (3) parallel to the tilt cylinder (2) and tighten the bolts. 9. Turn the ignition switch to the ON position. Do NOT start the engine. 10. Place the bucket control lever in the ROLLBACK position. 11. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). 12. Slide the target bar (3) slowly away from the proximity switch (5), until the control lever returns to the center position. Tighten the bolts holding the target bar (3). 13. Check to make sure that the 3.2 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained. 14. Start the engine. 15. Place the detent switch in the ON position and place the return to travel/float detent switch to the TRAVEL position. 16. Raise the lift arms approximately horizontal, and put the bucket in the fully dumped position. 17. Place the loader control lever in the ROLLBACK position, and verify that the electromagnet holds it in that position until the end of the target bar (3) passes in front of the proximity switch (5). 18. Lower the lift arms and verify that the bucket is at the correct digging angle.

9006-5

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

5 6

3 2 1

BS01C081

1. TARGET MOUNTING PLATE 2. HEIGHT CONTROL TARGET

3. PROXIMITY SWITCH 4. LIFT ARM

5. RETURN TO TRAVEL TARGET 6. FRONT CHASSIS (TOP LEFT HAND SIDE)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

1. Park the machine on a level surface. 2. Start the engine and apply the parking brake. 3. Lower the lift arms and place the bucket flat on the ground. 4. Stop the engine. NOTE: To avoid damage to the proximity switch (3), it must be adjusted back to clear everything on the lift arm as it passes. Refer to the illustration on this page. WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operators compar tment, always suppor t or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine. CSM105

5. Position the return to travel target (5) opposite the proximity switch (3) and tighten it to the target mounting plate (1).

6. Adjust the proximity switch (3) out towards the return to travel target (5) until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. 7. Lock the proximity switch (3) in this position with the jam nut. Torque the jam nut to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).

9006-6

2 A

3 B

BS01C082

1. HEIGHT CONTROL TARGET

2. RETURN TO TRAVEL TARGET

3. TARGET MOUNTING PLATE

MACHINE

APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT

721F Z-Bar

54 mm (2.1 inches)

380 mm (15.0 inches)

48 mm (1.9 inches)

3302 mm (130 inches)

721F XT

51 mm (2.0 inches)

403 mm (15.9 inches)

43 mm (1.7 inches)

3302 mm (130.0 inches)

721F XR

58 mm (2.3 inches)

461 mm (18.1 inches)

54 mm (2.1 inches)

4000 mm (157.48 inches)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

8. Refer to the table and the illustration on this page. Position the height control target (1) on the target mounting plate (3) using the table above.

13. Place the detent switch in the ON position, and set the return to travel/float detent switch to the return to travel position.

NOTE: The higher the height control target (1) is positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are raised.

14. Place the loader control lever in the raise position and verify that the electromagnet holds it in that position until the height control target (2) passes in front of the proximity switch (3). Refer to the illustration on page 5.

9. Tighten the height control target (1). 10. Position the return to travel target (2) using the table above. NOTE: The higher the return to travel target (2) is positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are lowered. 11. Check to make sure the proximity switch (3) and all of the mounting bolts are tight. Refer to the illustration on page 5. 12. Start the engine.

15. With the lift arms still raised, place the loader control lever in the lower position and verify that the electromagnet holds it in that position until the return to travel target (5) passes in front of the proximity switch (3). Refer to the illustration on page 5. 16. Repeat steps 8 through 15 until the desired heights are reached. 17. Lower the bucket to the ground and stop the engine.

9006-7

REMOVING THE LOADER FRAME 1. Park the machine on a level surface and apply the parking brake. Roll the bucket all the way forward and lower the bucket to the floor. Stop the engine. 2. Loosen the filler plug in the reservoir to release the air in the reservoir. 3. Fasten a chain hoist to the cross member (1) of the loader frame (2), refer to the illustration on page 8.

17. Loosen and remove the bolt (19), flat washer (20) and spacer (21) that fasten the pivot pin (9 or 10) to the front frame. 18. Raise the loader frame slightly. Use an acceptable driver and drive the pivot pin (9 or 10) out of the front frame. Do not lose the washers (18) and wipers (22) between the front frame and the loader frame (2).

4. Loosen and remove the bolt (12), flat washer (13), and spacer (14) that fasten the pivot pin (3) to the piston rod yoke of the right lift cylinder (4). 5. Use an acceptable driver and drive the pivot pin (3) out of the piston rod yoke of the right lift cylinder (4). Do not remove the driver. 6. Repeat Steps 4 and 5 for the left lift cylinder (6). 7. Start the engine. Roll the bucket back and lower the bucket so that the bucket is flat on the floor and fasten the chain hoist to a lift cylinder (4 or 6). 8. Raise the lift cylinder (4 or 6) slightly and remove the driver.

BD01G009

19. Remove the proximity switch cover. Left-hand side of the machine only.

9. Repeat steps 7 and 8 for the other lift cylinder (4 or 6). 10. Connect the chain hoist to the bucket cylinder (8). 11. Loosen and remove the bolt (15), flat washer (16), and spacer (17) that fasten the pivot pin (7) for the piston rod eye of the bucket cylinder (8) to the bell crank (11).

1 2

12. Use an acceptable driver and drive the pivot pin (7) out of the piston rod eye of the bucket cylinder (8). BD01G010

13. Raise the bucket cylinder (8) and use a chain or other acceptable holding equipment to hold the bucket cylinder (8) in place. 14. If the machine is equipped with auxiliary hydraulics, disconnect the two hoses from the tubes at the bracket on the right side of the loader frame (2). Install caps on the hoses and plugs in the tube fittings. 15. If the machine is equipped with front lamps, loosen and remove the cap screws and lock washers that fasten the lamp brackets to the front frame. Put the lamp brackets on the fenders. 16. Connect the chain hoist to the loader frame (2).

1. ELECTRICAL CONNECTION

2. PROXIMITY SWITCH

20. Disconnect the electrical connector (1), remove the lock nut from the proximity switch (2) and remove the proximity sw itch (2) fr om the machine. Left-hand side of the machine only. 21. Repeat Steps 17 and 18 for the other pivot pin (9 or 10). 22. Raise the loader frame (2) out of the front frame. Carefully move the machine out of the loader frame (2).

9006-8

20 18

8 16 6

2 11

1 21

5 4

14 5

12 3 13 23

BS01G022

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

CROSS MEMBER LOADER FRAME PIVOT PIN LIFT CYLINDER PIVOT PIN LIFT CYLINDER

7. 8. 9. 10. 11. 12.

PIVOT PIN BUCKET CYLINDER PIVOT PIN PIVOT PIN BELL CRANK BOLT

13. 14. 15. 16. 17. 18.

WASHER SPACER BOLT WASHER SPACER WASHER

LOADER FRAME ILLUSTRATION

19. 20. 21. 22. 23.

BOLT WASHER SPACER WIPER DUMP LINK

9006-9

INSTALLING THE LOADER FRAME 1. Apply antiseize compound to the inner bores and outer bores for the pivot pins of the front frame, refer to the illustration on page 8. 2. Move the machine into alignment with the loader frame (2). 3. Lower the loader frame (2) into alignment with the front frame. 4. Apply antiseize compound to the pivot pins (9 and 10) that fasten the loader frame (2) to the front frame. 5. Start the pivot pins (9 and 10) into the front frame. Install the washers (18) and new wipers (22) between the loader frame (2) and the front frame. 6. Install the pivot pins (9 and 10) all the way. 7. Install the bolt (19), washer (20) and spacer (21) that fasten the pivot pins (9 and 10). Tighten the bolt. 8. Install the proximity switch and cover. Left-hand side of the machine only. 9. Disconnect the chain hoist from the loader frame (2). 10. If the machine is equipped with front lamps, hold the front lamps in place and install the cap screws and lock washers that fasten the front lamps to the front frame. Tighten the cap screws. 11. If the machine is equipped with auxiliary hydraulics, remove the plugs from the tube fittings and the caps from the hoses. Connect the hoses to the tubes. 12. Connect the chain hoist to the bucket cylinder (8) and lower the bucket cylinder (8). 13. Start the engine and run the engine at low idle. 14. Have another person help you at this time. Move the bucket control lever as required to align the piston rod eye of the bucket cylinder (8) with the bell crank (11). Stop the engine. IMPORTANT: D o n o t u s e yo u r f i n g e r s t o check the alignment of the cylinder rod. Personal injury can be the result. 48-88

15. Install the pivot pin (7) in the bell crank (11) and the piston rod eye of the bucket cylinder (8). 16. Install the bolt (15), washer (16), and spacer (17) that fasten the pivot pin (7). Tighten the bolt.

17. Disconnect the chain hoist from the bucket cylinder (8). 18. Fasten the chain hoist to one of the lift cylinders (4 or 6). 19. Raise the piston rod yoke of the lift cylinder (4 or 6) so the piston rod yoke is aligned with the loader frame (2). 20. Install a driver in the piston rod yoke and the loader frame (2). 21. Repeat Steps 18, 19, and 20 for the other lift cylinder (4 or 6). 22. Disconnect the chain hoist from the lift cylinder (4 or 6). 23. Start the engine. Raise the loader frame and roll the bucket all the way forward. Lower the bucket to the floor. Stop the engine. 24. Fasten the chain hoist to the cross member (1) of the loader frame (2). 25. Start the engine and run the engine at low idle. 26. Have another person help you at this time. Move the lift control lever as required to align the piston rod yoke of one of the lift cylinders (4 or 6) with the loader frame (2). IMPORTANT: D o n o t u s e yo u r f i n g e r s t o check the alignment of the cylinder rod. Personal injury can be the result. 48-88

27. Remove the driver and install the pivot pin (3). 28. Install the bolt (12), washer (13), and spacer(14) that fasten the pivot pin (3). Tighten the bolt. 29. Repeat Steps 26, 27, and 28 for the other lift cylinder (4 or 6). Stop the engine. 30. Lubricate the pivot pins with molydisulfide grease. 31. Disconnect the chain hoist from the cross member (1) of the loader frame (2). 32. Tighten the filler plug in the reservoir. 33. If the machine is equipped with auxiliary hydraulics, start the engine and run the engine at low idle. 34. Slowly extend and retract the clam cylinders four times to remove air from the auxiliary circuit. 35. Stop the engine, check the level of the oil in the reservoir, and check for leaks. Add oil to the reservoir as required.

9006-10

NOTES

Section 9007

9007

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF)

9007-2

TABLE OF CONTENTS ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 9

9007-3

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) Attention

The Rollover Protective Structure (ROPS) or Cab S t r u c t u r a l Fr a m e ( C S F ) i s a s p e c i a l s a fe t y component of your machine.

After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site operation: ●

The ROPS or CSF structure MUST be replaced.

●

The ROPS or CSF mounting or suspension, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

●

All damaged parts MUST be replaced.

DO NOT attach any device to the ROPS or CSF for pulling purposes. The ROPS or CSF is a certified structural support and any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS or CSF MUST be replaced so that it will provide the same protection as a new ROPS or CSF.

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS OR CAB STRUCTURAL FRAME.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY After every 500 hours of operation or every six months, whichever comes first, do the following: 1. Check the torque on the CSF cab or ROPS canopy mounting bolts; torque should be 773 to 854 Nm (570 to 630 lb-ft). If necessary, tighten the bolts to the correct torque. 2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators seat mounting bolts; torque should be 73 to 87 Nm (54 to 64 lb-ft). If necessary, tighten the bolts to the correct torque. Replace parts that are worn or damaged. WARNING: Grade 8 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those shown in the parts catalog. 47-27A

WARNING: Do not install attachments that will make the total weight of the machine more than the weight shown in the maximum gross vehicle weight section of the ROPS serial number plate. 47-26 WARNING: Do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE ROPS. 47-25

9007-4

CSF CAB AND ROPS CANOPY Removal

STEP 5

NOTE: Procedures and photos in following steps cover in detail removal and installation of CSF structure. Removal and installation of ROPS is similar to removal and installation of CSF structure.

STEP 1 Park machine on a level surface and lower bucket to floor. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

BD06G191

Remove skirting under each side and front of cab.

STEP 2

STEP 6

BD01F143

Put articulation lock in LOCKED position.

BD06G186

Remove the ducts from the machine.

STEP 3

STEP 7

Put battery disconnect switch in OFF position.

STEP 4

BD06G189

BD01F184

If machine is equipped with a heater, put a 40 liters (10 Gallons) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.

At RH rear, bottom of cab, disconnect ground strap from rear chassis.

9007-5

STEP 8

STEP 11

BD06G194

BD06G192

If machine is equipped with windshield washers, identify, tag, and disconnect front and rear windshield washer nozzle hoses from supply hoses.

Identify, tag, and disconnect hoses from steering control valve. Plug hoses and cap steering control valve fittings to prevent entry of foreign matter into hydraulic system.

STEP 9 STEP 12 2

BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

BD06F207

Unlatch and open the window on the right hand side.

If machine is equipped with a heater disconnect heater hoses (3), if machine is equipped with air conditioning discharge the air conditioning system, see section 9003, and disconnect the air conditioning hoses (2), cap and plug lines and fittings.

STEP 13

STEP 10

BD06F208

Open and remove the access panel.

BD06G193

Disconnect throttle connector and the air duct.

9007-6

STEP 14

STEP 19

BD06F209

Remove the front access panel.

BD06G187

Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment

STEP 15

STEP 20

BD06F210

Disconnect the electrical connectors for the remote control valve.

BD06G188

STEP 16

Raise floor mat up and away from brake pedal to gain access to mounting hardware.

Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 21

STEP 17 Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings to prevent entry of foreign matter into hydraulic system.

STEP 18 Push the hoses out of the bottom of the cab with the rubber gromment. BD06G185

Remove hardware securing brake valve to cab floor. Let brake valve rest on the frame.

9007-7

STEP 22

STEP 25 Slowly raise cab from rear chassis. Check that all tie straps and clamps have been removed and all hoses, tubes, and wires are disconnected and free. Check that brake valve with hoses attached are free and clear of cab. Remove the ROPS or CSF from the machine. Lower ROPS or CSF onto wooden blocks to prevent damaging cab or canopy.

BD06G184

Install lifting eyes in threaded holes at top of the cab.

STEP 23 Connect lifting equipment to cab at lifting eyes. Take up all slack in lifting equipment.

STEP 24 Remove nuts, bolts, and washers securing cab to rear chassis.

9007-8

1 2

4 4 5 5 6 6 BC06G031

1. NUT 2. WASHER 3. RUBBER MOUNT

4. RUBBER MOUNT 5. WASHER 6. BOLT

9007-9

Installation

STEP 32

STEP 26 Check rubber mounts (3 an 4) for deterioration, tears, defor mation, or other damage; replace rubber mounts as necessary.

STEP 27

BD06G188

Position floor mat.

STEP 33

BD01D388

Position cab over rear chassis then put wood blocks under brake valve. Slowly lower cab onto rear chassis making sure that brake valve is positioned so that brake pedal enters into cab. Remove wood blocks as cab is lowered onto brake valve.

STEP 28 Install washers, bolts, and nuts to secure cab to rear chassis. Tighten bolts to a torque of 773 to 854 Nm (570 to 630 pound feet)

STEP 29

BD06G192

Remove plugs from hoses and caps from fittings. Connect hoses to steering control valve following tags installed during removal. Remove and discard tags.

Disconnect lifting equipment from cab.

STEP 34

STEP 30 Remove lifting eyes.

STEP 31

BD06G193

Connect throttle connector and mount air duct.

BD06G185

Align mounting holes in brake valve with associated holes in cab or canopy floor. Install hardware to secure brake valve to floor.

9007-10

STEP 35

STEP 38 2

BD06G186

BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

Install the ducts on the machine.

STEP 36

If machine is equipped with a heater, remove plugs from hoses and caps from fittings, connect heater hoses (3), if machine is equipped with air conditioning, remove plugs from hoses and caps from fittings, connect air conditioning hoses (2), charge the air conditioning system, see section 9003.

STEP 39 Remove plugs from hoses and caps from fittings. Connect hoses to joystick and two-lever controller and install in hose mounting grommet halves as shown on pages 11, 12, and 13. BD06G189

At RH rear, bottom of cab, connect ground strap to rear chassis.

STEP 37

BD06G194

If machine is equipped with windshield washers, connect front and rear windshield washer nozzle hoses following tags installed during removal. Remove and discard tags.

9007-11

8 4 6 7

1 5

5 2

1 8

3 6

4 BC05M092

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN BLACK GREEN 6. RED BLACK GREEN

7. GREEN WHITE GREEN 8. RED WHITE GREEN

JOYSTICK AND 2 LEVER HOSE COLOR CODING

9007-12

4 3

4 6

2 7

7 1

5 BC05M091

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

3 LEVER HOSE COLOR CODING

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

JOYSTICK AND 1 LEVER HOSE COLOR CODING

9007-13

1 5 4

2 1

3 2

3 4

5 BC05M090

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

2 LEVER HOSE COLOR CODING

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

JOYSTICK HOSE COLOR CODING

9007-14

STEP 40

STEP 43

BD06F210

Connect the electrical connectors for the remote control valve.

BD06F208

Install and close the access panel.

STEP 44 STEP 41

BD06F209

Place the access panel into position, install and tighten the screw.

STEP 42

BD06F207

Close the right hand window.

STEP 45

BD06G187

Connect wiring harness connectors.

BD06G191

Install skirting under each side and front of cab.

9007-15

STEP 46

STEP 49 Start engine and run engine at low idle. Run engine at operating temperature for approximately five minutes to completely mix Ethylene Glycol and water. When coolant is at operating temperature, stop engine. When engine has cooled, check coolant level at reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. BD01F184

If machine is equipped with a heater and coolant was drained, check that coolant drain cap is tight.

STEP 47 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Install radiator cap. Fill coolant reservoir up to FULL mark on reservoir.

STEP 48 Put battery disconnect switch in ON position.

STEP 50 Put articulation lock in OPERATING position.

9007-16

NOTES

Section 9010

9010

CAB GLASS INSTALLATION

9010-2

TABLE OF CONTENTS PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3

PREPARATION FOR GLASS REPLACEMENT 1. Remove all of the damaged glass section and the silicone sealant from the window frame 2. Remove all the adhesive from the window frame. 3. The window frame recesses must be free of oil and dust. Clean the frame with rubbing alcohol with a clean rag. Do not reuse the rag.

5. Clean the new glass section. Apply a 25 mm (1 inch) wide band of glass primer (349-110) to the black ceramic painted edges of the window. 6. When replacing a front window section, a silicone forming tool is needed, refer to Figure 2. Use the template and instructions provided to make the tool.

4. Apply a 25 mm (1 inch) wide band of metal primer (349-108) to the window recesses.

GLASS INSTALLATION NOTE: Once the adhesive is applied, the glass must be installed within 5 minutes. If the glass is not installed within the 5 minute period, the adhesive must be removed and applied again. 1. Apply a 10 mm (3/8 inch) diameter bead of adhesive (345-135) to the pr imed surface approximately 12 mm (1/2 inch) from edge. 2. The adhesive may be applied either to the primed glass or to the primed metal frame. DO NOT apply the adhesive to both the glass and the frame.

3. For front glass installations install a glass spacer 12 mm (1/2 inch) from each corner on bottom edge of each glass section, refer to Figure 3. 4. Install the glass. The glass edges must not contact the metal frame at any point. 5. For front glass installations position the glass to maintain a uniform 3 mm (1/8 inch) gap between front and front side glass sections.

NOTE: When replacing two or more sections of the front glass apply extra adhesive in corners, refer to Figure 3.

SILICONE SEALANT APPLICATION - FRONT WINDOWS 1. Clean the edges of the front center and front side windows. Use glass cleaning primer. 2. Apply masking tape to the inside edge of each glass section next to the gap. 3. Apply the polyester tape on top of the masking tape across the inside side gap. Do not push the tape into the gap. 4. Apply masking tape to the outside edge of each glass section. Align the edge of the tape with edge of glass on both sections. 5. The tape must be smooth to get the best result when using the silicone forming tool.

6. Fill the joint with the clear silicone sealant (114328A1), refer to Figure 1. The silicone must completely penetrate and fill the gap between the glass sections. The sealant must extend at least 1.5 mm (1/16 inch) above the outside surface of the glass section for the length of the gap. Be sure the sealant fills against the adhesive at each end of the joint. 7. Remove the polyester tape from the inside joint. 8. Remove the extra silicone from the outside joint by carefully sliding the forming tool down the length of the joint. The tool must remain in contact with the glass sections during this process. Refer to Figure 2 for for ming tool template.

9010-4

9. Remove all the silicone from the forming tool immediately after use.

10. Remove the outside tape from the glass sections. 11. Remove the extra silicone sealant from the inside joint by carefully sliding the forming tool down the length of the joint. 12. Remove all the silicone from the forming tool immediately after use.

13. Remove the inside joint masking tape.

4 498L93

1. FRONT RH SIDE GLASS 2. FRONT CENTER GLASS

3. SILICONE BEFORE SMOOTHING 4. SILICONE AFTER SMOOTHING

FIGURE 1. SILICONE APPLICATION

NOTE: Make the forming tool from 10 mm (3/8 inch) plexiglass, or wood. Sand all radius and edges smooth.

14. If two or more glass sections are being replaced, use the procedure on the second joint. 15. Apply the gray silicone sealant above the front center, front side or rear windows for additional leak protection. 16. Apply the gray silicone sealant (345-174) down approximately 50 mm (2 inches) from the top on each front side window replaced, refer to Figure 3. 17. Apply the gray silicone sealant (345-174) down approximately 50 mm (2 inches) from the top edge of the rear glass, if replaced.

6 MM (1/2 INCH) R

120°

4 MM (3/16 INCH) R

FIGURE 2. SILICONE FORMING TOOL TEMPLATE

496L93

9010-5

2 1 3 4

6 1

497L93

1. SIDE GLASS ADHESIVE 2. CENTER GLASS ADHESIVE

4. RIGHT HAND SIDE GLASS SPACER LOCATIONS 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES) FROM TOP OF FRONT SIDE GLASS 3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF CENTER AND SIDE PANELS CENTER GLASS FIGURE 3 SILICONE APPLICATION

NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set.

9010-6

NOTES

Section 9020

9020

REAR VIEW CAMERA INSTALLATION AND REMOVAL

9020-2

TABLE OF CONTENTS Rear view camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation - Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation - Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 7

9020-3

REAR VIEW CAMERA Installation - Camera

STEP 5

STEP 1

CAMERA TO EXTENSION CABLE SAFETY LOCK

Park machine on a level surface and lower bucket to ground. Put articulation lock in LOCKED position.

Route the camera cable down through the grill screen hole and connect to the extension cable.

STEP 6

STEP 2

EXTENSION CABLE ROUTING 1 RAISE HOOD

Raise the engine hood and turn the master switch to the off position.

Route the extension cable on the left side of the hood and tie wrap to the existing harness.

STEP 7

STEP 3 Drill the camera bracket mounting holes in the screen per Camera mounting - Illustration 1. (3 holes, 6.6 mm in screen if necessary)

STEP 4 Assemble and mount the camera brackets as shown in Camera mounting - Ilustration 1. Route the camera harness through the screen.

EXTENSION CABLE ROUTING 2

Route cable down left side and under fan to the right side of the Wheel Loader. Pull cable and tie wrap through firewall to the bottom of the fuse box.

9020-4

STEP 8

STEP 11

EXTENSION CABLE TO FUSE BOX

Pull cable up through existing hole into the fuse box.

STEP 9

CAMERA TO MONITOR CONNECTORS

In the fuse box connect the extension cable from the camera to the CA1 cable from the monitor. Tie wrap to secure cable.

STEP 12

MONITOR MOUNTING

Attach the mounting bar to Cab right post per Monitor mounting - Illustration 2. Install the display arm and monitor as shown and tighten all nuts.

STEP 10

POWER TO SYSTEM

Connect the remaining monitor connector to the “MON” connector in the fuse box. Tie wrap to secure cable.

STEP 13 Install the 5A fuse to F19 in the ECA fuse panel. Always install the correct fuse size.

For additional information see the camera manual included with the camera kit.

JUNCTION BOX UNDER SEAT

Install the access plate and route the cable with the engine harness. The monitor cable will run through the grommet on the access plate and up to the monitor per Plate access mounting - Illustration 3.

9020-5

Installation - Monitor Camera mounting - Illustration 1

84336466(1)

Monitor mounting - Illustration 2

84336466(2)

9020-6 Plate access mounting - Illustration 3

84336466(3)

Parts List - Illustration 4

84336466(4)

9020-7

Removal

STEP 4

STEP 1

CAMERA ON GRILL BOTTOMVIEW SAFETY LOCK

Park machine on a level surface and lower bucket to ground. Put articulation lock in LOCKED position.

Remove the mounting bolts holding the bracket to the grill screen, and remove the camera.

STEP 5

STEP 2

RAISE HOOD

MONITOR MOUNTING BACKSIDE

Raise the engine hood and turn the master switch to the off position.

Unplug the monitor cable and loosen the handle on display arm. Remove monitor.

STEP 3

CAMERA TO EXTENSION CABLE

Disconnect camera from the extension cable.

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