821F 921F Tier 2 Wheel Loader
SERVICE MANUAL
Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.
Part number 84487581 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
M4
36 to 48
4 to 5
M5
84 to 96
9 to 11
M6
132 to 156
15 to 18
M8
324 to 384
37 to 43
PoundFeet
Newton metres
Newton metres
M4
24 to 36
3 to 4
Size
M5
60 to 72
7 to 8
M10
54 to 64
73 to 87
M6
96 to 108
11 to 12
M12
93 to 112
125 to 150
M8
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 821F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921F - CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 4 5 6 6 6 6 7 9
1002-3
821F - 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.......................................................................................................................... 30 liters (32 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 Hydraulic System Hydraulic Reservoir Refill Capacity ..........................................................................90.8 liters (24.0 U.S. Gallons) Total System Capacity............................................................................................... 178 liters (47.0 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Front...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Type of Lubricant ............................................................................................................................. Case Nexplore 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
921F - 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.......................................................................................................................... 30 liters (32 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 288 liters (76 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 Hydraulic System Hydraulic Reservoir Refill Capacity ........................................................................... 110 liters (29.0 U.S. Gallons) Total System Capacity............................................................................................... 200 liters (53.0 U.S. Gallons) Type of Oil ..............................................................................................................Case AKCELA Hy-Tran Ultra® Transmission Refill Capacity with Filter Change ................................................................................ 34.1 liters (36 U.S. Quarts) Type of Oil ....................................................................................................................................... Case Nexplore Axles Capacity Front...................................................................................................................... 42.0 liters (44.4 U.S. Quarts) Rear ...................................................................................................................... 40.0 liters (42.3 U.S. Quarts) Type of Lubricant............................................................................................................................. Case Nexplore 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.
1002-5
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
1002-6
TRANSMISSION TEMPERATURE CHART
RCPH10WHL435BAH3
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%
1002-7
MAINTENANCE SCHEDULE
Variable Periodic (*)
2
Radiator Coolant Level
*
13
Tires
*
16
Hydraulic Filter
*
12
Alternator, AC, Drive Belt
*
31
Air cleaner
*
19
Bleed Fuel Filter of Condensation
XX
Fire extinguisher
*
Check Engine Oil Level
10
Every 10 Hours 1
Check Engine Coolant Level
50
3
Check Transmission Oil Level
50
Check Hydraulic Oil Level
50
Grease Bucket Mounting Fittings
50
7
Grease machine and attachments
50
16
Change Engine Oil and Filters
100
18
Replace Fuel Filters
100
Change Hydraulic Filter
100
25
Change Oil in Axles
100
13
Check wheel torque
8
Lubricate The Steering Cylinder Pivots - Rod And Closed End (4 Fittings)
100
Grease Front Drive Shaft Support Bearing
100
Every 100 Hours 9
100
10
Lubricate Loader Lift & Cylinder Pivots (10) Z-bar
100
10
Lubricate Loader Lift & Cylinder Pivots (18) XT
100
11
Check Cab Air Filter
14
Check Tire Pressure & Wheel Torque
12
Check Drive Belt
XX
Trans Clutch Calibration (See Section 6002)
14
Check Axle Oil Level
500
15
Check Battery Electrolyte Level
500
16
Change Engine Oil and Filter
XX
Check ROPS
18
Drain Fuel Tank Condensation & Water Separator
19
Replace Fuel Filter
250 4
250 250
250
1000
500 500 500 500
ADJUST
REPLACE
LUBRICATE
DRAIN
CHANGE
CLEAN
5&6
First 100 Hours 20
Every 500 Hours
* *
13
Every 50 Hours 4
Every 250 Hours
SERVICE POINTS
CHECK
ITEM NUMBER
SERVICE INTERVAL
Initial Service
FREQUENCY IN HOURS
1002-8
Every 1000 Hours
Every 1500 Hours
Every 2000 Hours
Every 6000 Hours
20
Replace Hydraulic Oil filter
1000
21
Grease Articulation Fittings
24
Change crankcase filter
23
Replace Drive Belt
11
Replace Cab Air Filter
26
Change Transmission Oil and Filter
XX
Check Injector Calibration
XX
Check Valve Adjustment (Engine Manual)
1000
XX
Trans Clutch Calibration (See Section 6002)
1000
21
Change Front & Rear Axle Oil
1500
26
Change Transmission Oil and Filter
1500
29
Change Hydraulic Oil
2000
30
Change Coolant
2000
31
Replace Engine Air Cleaner
32
Lubricate cab and door
XX
Valve Clearance (Engine Manual)
XX
Engine Injectors (Engine Manual)
6000
XX
Fuel Pump (Engine Manual)
6000
1000 1000
1000
1000 1000 1000
2000 2000 2000
6000
1002-9
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.
1002-10
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
BY
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
BY
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 30 liter (32 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
1
2
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
2
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
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
2
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
1
2
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
1
3
2 3
4 5 6
1
4
2
5
3
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
1
2
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
3
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
1
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
2
1
BD03A225
Install the crankcase ventilation hose and tighten the clamp on air cleaner intake hose.
BD03A227
STEP 73
2
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
2
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)
Y X (MM) (MM)
Y X (MM) (MM)
1
19
21
14
41
9
61
5
2
19
22
14
42
9
62
5
3
18
23
14
43
9
63
4
4
18
24
13
44
9
64
4
5
18
25
13
45
9
65
4
6
18
26
13
46
8
66
4
7
17
27
13
47
8
67
3
8
17
28
12
48
8
68
3
9
17
29
12
49
8
69
3
10
17
30
12
50
7
70
3
11
16
31
12
51
7
71
2
12
16
32
12
52
7
72
2
13
16
33
11
53
7
73
2
14
16
34
11
54
6
74
2
15
16
35
11
55
6
75
2
16
15
36
11
56
6
76
1
17
15
37
10
57
6
77
1
18
15
38
10
58
6
78
1
19
15
39
10
59
5
79
1
20
14
40
10
60
5
80
0
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 of the 821F with 90.8 liters (24.0 U.S. gallons) of Case AKCELA Hy-Tran Ultra® fluid. Fill the reservoir of the 921F with 110 liters (29.0 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 30 liters (32 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 30.0 liter (32.0 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
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
2
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).
2
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 30 liters (32.0 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 821F SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921F 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 4 5 7 7 7 8 9 9 9 9 9 10 10
2002-3
821F 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 2155 rpm C. Converter Stall ............................................................................................................................1883 to 1963 rpm D. Hydraulic Stall .............................................................................................................................1883 to 1963 rpm E. Converter & Hydraulic Stall .........................................................................................................1497 to 1577 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 2155 rpm C. Converter Stall ............................................................................................................................1860 to 1900 rpm D. Hydraulic Stall .............................................................................................................................1923 to 2003 rpm E. Converter & Hydraulic Stall .........................................................................................................1524 to 1604 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
921F 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 2155 rpm C. Converter Stall ............................................................................................................................1900 to 1940 rpm D. Hydraulic Stall .............................................................................................................................1860 to 1940 rpm E. Converter & Hydraulic Stall .........................................................................................................1525 to 1605 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 .............................................................................................................2135 to 2185 rpm C. Converter Stall ............................................................................................................................1945 to 1985 rpm D. Hydraulic Stall .............................................................................................................................2017 to 2097 rpm E. Converter & Hydraulic Stall .........................................................................................................1531 to 1611 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.
2002-5
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.
2002-6
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.
2002-7
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:
3. To measure the oil temperature with the instrument cluster:
A. Press the up or down arrow key.
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).
2002-8
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.
2002-9
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.
2002-10
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.
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
2
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.
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
2
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
1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 45 45 45 46 47 47 47 48 48 48 48 49 49 50 50 50 51 52 52 52 53 53 53 53 54 54 55 56 56 57 58 59 59 60 60 61 61 61 62 62 62 63 64 64 65 65 66 66 66 67 67 67
4002-3 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Warning (AIC) Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4002-4 Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JOYSTICK STEERING/ MISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................................................................... .................................................................................... .................................................................................... .................................................................................... .................................................................................... .................................................................................... .................................................................................... .................................................................................... .................................................................................... Rear View Camera / Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Lock Switch (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Lock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockup Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick PVRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FNR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Sense Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick STR Switch (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JSS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FNR Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124 124 124 124 124 125 126 126 126 126 127 127 127 128 128 128 128 129 130 130 130 131 132 133 133 133 133 134 135 135 135 135 135 135 135 135 135 135 135 136 136 136 136 136 136 136 137 137 137 137 137 137 137 137 138
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
1
W 0.8 GXL Twist
JMP1, JSS Load Sense
A
JMP2, JSS Load Sense
C
2
Bk 0.8 GXL Twist
JMP1, JSS Load Sense
B
JMP2, JSS Load Sense
A
14
Alternator D+
Lg 1.0 SXL
AD, Alternator D+
1
ENG, Engine Cab1
26
30
Battery Sensing
R 1.0 SXL
Alt_5 Alternator D+
2
AB_5 Alternator B+
1
31
EDC Relay Control
OR 0.8 GXL
EDC7, Engine Controller
13
SPL_EDC4, Ultrasonic
A
42
Work Lights Switched Fused Pwr R 2.0 GXL
SPL-WL, Ultrasonic
A
ECC, Elect Center C
A2
44
Brake Lt Control Power
T 1.0 SXL
BTM_C, Cab bottom bulkhd
J
PBL, Brake Light Press Switch
2
49
Back Lt Power
DU1.0 GXL
D-OR, Diode OR
C
SPL-BCK-LGT, Spl Back Lgt Pwr
A
52
Fan Reverse LSD
W 0.8 TXL
AIC-1, Adv Instr Clust 1
23
ECB, Electrical Center B
B8
56
Fan Control PWM
W 0.8 TXL
CAB-E, Cab Engine
23
AIC-1, Adv Instr Clust 1
26
57
Pin Engage Sol Pwr
W 1.0 SXL
FRONT, Cab Front Chassis
17
YPE, Pin Engage Jumper
A
58
Ride Control Sol Pwr
W 1.0 SXL
PRBF, Rollback Press Sw
A
YRC, Ride Control Option
1
64
Horn Power
Or 1.0 SXL
FRONT, Cab Front Chassis
13
HN1, Horn Power
1
460
Fan Speed Sensor Signal
Y 1.0 SXL
Eng, Engine-Cab1
16
FSS, Fan Speed Sens
1
016B
Pedal Sensor Grnd
DU 0.8 GXL
BTM_C, Cab Bottom Bulkhd
D
BPP, Pedal Position
6
017A
Fan Speed Sensor GND
BK 1.0 SXL
GND_ENG7, Tranny, Cool Temp
1
FSS, Fan Speed Sens
2
0D_C
DIAG2 GRND
BK 0.8 GXL
DIA_2, Diagnostic
A
GND_CAB_SPL, Cab Grnd Splice
D
0_29
RTT/Float GND
BK 0.8 GXL
SFL, Return to Travel SW
4
SPL_BCK_LT_GD2, SPL_BACK LGT GRND
K
0 29
RTT/Float Ground
Bk 0.8 GXL
SFL, Return To Travel Sw
4
SPL-BCK-LT-GD2, Spl Back Lgt Gnd
K
0 AA
Proximity Switch Grnd
Bk 1.0 SXL
PXH, Height Control RTT
B
SPL-A2, Ultrasonic
A
0 AB
Proximity Switch Grnd
Bk 1.0 SXL
SPL-A2, Ultrasonic
A
GND-FC, Ground A
1
0 AC
Proximity Switch Grnd
Bk 1.0 SXL
PXF, RTD
B
SPL-A2, Ultrasonic
A
0 AD
Ride Control Ground
Bk 1.0 SXL
YRC, Ride Control Option
2
SPL-A1, Ultrasonic
A
0 AE
Pin Engage Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
A
YPE, Pin Engage Jumper
B
0 AF
Horn Ground
Bk 1.0 SXL
HN2, Horn Ground
1
SPL-A1, Ultrasonic
A
0 AG
Front Chassis Ground
Bk 2.0 SXL
SPL-A1, Ultrasonic
A
GND-FC, Ground A
1
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 AH
RH Front Lights Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
A
LRF, Lights RH
1
0 AJ
LH Front Lights Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
A
LLF, Lights LH
1
0 AK
Park Brake/Warning Ground
Bk 1.0 SXL
SPL-A4, Ultrasonic
A
BTM_E, CAB BTTOM
2
0 AL
Brake Warning Press Sw Gnd
Bk 1.0 SXL
PBW, Brake Warn Press Sw
2
SPL-A4, Ultrasonic
A
0 AM
RTD Grnd
Bk 1.0 SXL
PXM, RTD
B
PXT, RTD
B
0 AN
Park Brake Solenoid Ground
Bk 1.0 SXL
YPB, Park Brake Solenoid
2
SPL-A4, Ultrasonic
A
0 AP
Front To Rear Chassis Ground
Bk 5.0 SXL
GND-S1, Ground A
1
GND-S2, Ground A
1
0 AS
GRND, JOYSTICK
Bk 1.0 GXL
JSS_FRM, JSS Frame to CAB
G
SPL_JSS_17, Ultrasonic
A
0 AT
GRND, JSS VLV
Bk 1.0 GXL
JSS_Valve, JSS HYD Valve
3
SPL_JSS_17, Ultrasonic
A
0 AU
GRND, Pilot Dump
Bk 1.0 GXL
SPL_JSS_17, Ultrasonic
A
JSS_PIL_DUMP, JSS Pilot Dump
2
0 AV
GRND
Bk 1.0 GXL
SPL_JSS_17, Ultrasonic
A
GND_JSS, Ground_A
1
0 AW
Pin Engage GND
Bk 1.0 SXL
YPE1, Pin Engage Jumper
B
YPE2, Pin_Engage_OPT
B
0B
Front Washer Ground
Bk 1.0 SXL
FWW, Front Washer
2
SPL-ENG-GRD, Gnd Spl 6 Pck
E
0 B1
Back Light Ground
Bk 0.8 GXL
SPC, Pilot Control Switch
7
SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck
B
0 B2
Back Light Ground
Bk 0.8 GXL
SFL, Return To Travel Switch
7
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
B
0 B3
Back Light Ground
Bk 0.8 GXL
SHC, Height Control Switch
7
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
C
0 B4
Back Light Ground
Bk 0.8 GXL
SRTD, Detent Switch
7
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
D
0 B5
Back Light Ground
Bk 0.8 GXL
SPE, Pin Engage Switch
9
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
E
0 B6
Cab2 Ground
Bk 1.0 GXL
SPL_BCK_LT_GD, SPL Back Lght GRND
D
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
F
0 B7
Back Light Ground
Bk 0.8 GXL
SFC, Fan Control Switch
7
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
M
0 B8
Front Wiper Motor Ground
Bk 0.8 GXL
GND_CAB2, Ground_A
1
FWMG, Wiper Ground
A
0 B10 Hood Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Grnd 6 Pck
E
GND-CAB2, Ground A
1
0 B11 Back Light Ground
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
L
SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck
F
0 B12 Hood Down Relay Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Grnd 6 Pck
A
ECC, Elect Center C
C4
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
Connector
K = Pink U = Blue Y = Yellow
To Connector Cav
Connector
Cav
0 B13 Back Light Ground
Bk 1.0 GXL
SPL-BCK-LT-GD, Spl Bk Lt Grnd
A
SPL_WL1, Ultrasonic
A
0 B14 Back Light Ground
Bk 0.8 GXL
SWL, Work Lights Switch
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
B
0 B15 Back Light Ground
Bk 0.8 GXL
SBE, Beacon Switch
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
C
0 B16 Hood Down Control Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Grnd 6 Pck
B
ECC, Elect CNTR C
B4
0 B17 Back Light Ground
Bk 0.8 GXL
STA, Trans Auto Switch
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
E
0 B18 Back Light Ground
Bk 0.8 GXL
SDC, Declutch Switch
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
F
0 B19 Back Light Ground
Bk 0.8 GXL
SDR, Driving Lights Switch
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
G
0 B20 Back Light Ground
Bk 0.8 GXL
SRC, Ride Control Switch
7
SPL-BCK-LT-GD2, Spl Bk Lt Grnd
J
0 B21 Back Light Ground
Bk 0.8 GXL
SBU, Backup Alarm Disc Sw
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
J
0 B22 Hood Up Relay Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Gnd 6 Pck
C
ECC, Elect CNTR C
0 B23 Back Light Ground
Bk 0.8 GXL
SRWP, Rear Wiper Switch
7
SPL-BCK-LT-GD, Spl Bk Lt Grnd
L
0 B24 Back Light Ground
Bk 0.8 GXL
SHZ, Hazard Switch
7
SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck
C
0 B25 Hood Up Control Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Gnd 6 Pck
D
ECC, Elect CNTR C
B2
0 B26 Buzzer/Switch Pad Ground
Bk 0.8 GXL
SPL-BUZ, Ultrasonic
A
GND_CAB2, Ground A
1
0 B27 Buzzer Ground
Bk 0.8 GXL
SPL-BUZ, Ultrasonic
A
BUZ, AIC Buzzer
2
0 B28 Switch Pad Ground
Bk 0.8 TXL
SW-PD, Switch Pad
10
SPL-BUZ, Ultrasonic
A
0 B29 RTT/Float Ground
Bk 0.8 GXL
SPB, Parking Brake Switch
7
SPL-PED-BL-GD, Spl Bk Lt Grnd 6 Pck
E
0 B31 SDA GND
Bk 0.8 GXL
SPL_BCK_LT_GD2, SPL_BACK LGT GRND
A
SDA, Diff Lock Switch
7
0 B32 Back Light GND
Bk 0.8 GXL
SRP, Work Lights SW
7
SPL_BCK_LT_GD, SPL Back Lght GD
M
0 BA
Bk 5.0 SXL.
GND-PDST, Ground A
1
GND-PDST2, Ground A
1
0 BAC EDC7 Ground
Bk 2.0 SXL
SPL-EDC1, Ultrasonic
A
GND-ENG2, WIF, EDC
1
0 BAE EDC7 Sender Ground
Bk 1.0 SXL
RECT, Engine Coolant Temp
B
GND-ENG7, Tranny, Cool Temp
1
0 BAG Hood Grounds (EURO)
Bk 1.0 SXL
GND-ENG4, Rear Lighting
1
E-HD, Trans Hood
c
0 BAG Hood Grounds (NA) N
Bk 1.0 SXL
ENG-H, Engine to Hood
1
GND-ENG4, Rear Lighting
1
Pedestal Gnd Strap
C2
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 BAR WIF Body Ground
Bk 1.0 SXL
GND-WIF, Gnd WIF Ring Term
1
GND-ENG6, Dedicated
1
0 BAT Crank Request FGND
Bk 1.0 SXL
Eng, Engine-CAB1
6
GND_ENG2, WIF, EDC
1
0 BAU EVGT_2 GND
Bk 1.0 SXL
Turbo, Eng Dash_Turbo
5
GND_ENG2, WIF, EDC
1
0 BB
Bk 1.0 SXL
YFR, Fan Reverse Sol Opt
2
SPL-FAN, Ultrasonic
A
0 BBA JOYSTICK GROUND
Bk 0.8 GXL
SPL_JSS_1, Ultrasonic
A
SJS, Joystick_Control_SW
4
0 BBB JOYSTICK GROUND
Bk 0.8 GXL
SJS, Joystick_Control_SW
7
SPL_JSS_1, Ultrasonic
A
0 BBC JOYSTICK GROUND
Bk 0.8 GXL
GND_CAB_SPL2, SPL Back LGHT GD
F
SPL_JSS_1, Ultrasonic
A
0 BBD JOYSTICK GROUND
Bk 0.8 GXL
JSS_CAB, JSS CAB
8
SPL_JSS_1, Ultrasonic
A
0 BBE JOYSTICK GROUND
Bk 0.8 GXL
SJS_Joystick_Control_SW
9
SPL_JSS_1, Ultrasonic
A
0 BBR Ground
Bk 1.0 SXL
ENG_B, CAB BTTOM
2
GND_ENG3, SPLC_PK, WSHR MTR
1
0 BC
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
11
0 BD
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
10
0 BE
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
5
0 BF
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
6
0 BG
AIC Power Ground
Bk 0.8 GXL
ENG, Engine Cab1
19
GND-ENG6, Dedicated
1
0 BH
AIC Power Ground Red
Bk 0.8 GXL
ENG, Engine Cab1
20
GND-ENG6, Dedicated
1
0 BJ
AIC Sensor Ground
Bk 0.8 GXL
ENG, Engine Cab1
17
GND-ENG6, Dedicated
1
0 BL
Rear Washer Ground
Bk 1.0 SXL
RWW, Rear Washer
2
SPL-ENG, Ultrasonic
A
0 BM
Engine Splice Grounds
Bk 1.0 SXL
SPL_ENG, Ultrasonic
A
GND-ENG3, SPLC-PK, Washer Motor
1
0 BP
WIF Sensor Ground
Bk 1.0 SXL
GND-ENG2, WIF, EDC
1
WIF, Water In Fuel Sensor
2
0 BQ
Fan Speed PWM Sol Grd
Bk 1.0 SXL
YFN, Fan PWM Solenoid
B
SPL-FAN, Ultrasonic
A
0 BR
RH Rear Light Ground (EURO)
Bk 1.0 SXL
LRR-E, RH Rear Comb Lamp
5
GND-ENG4, Rear Lighting
1
Bk 1.0 SXL
LLR, LH Rear Comb Lamp
1
SPL-J1, Ultrasonic
A
Fan Reverse Solenoid Ground
0 BR N LH Rear Light Ground (NA) 0 BS
Fan Control Ground
Bk 1.0 SXL
SPL-FAN, Ultrasonic
A
SPL-ENG, Ultrasonic
A
0 BT
LH Rear Light Ground (EURO)
Bk 1.0 SXL
LLR-E, LH Rear Comb Lamp
5
GND-ENG4, Rear Lighting
1
Bk 1.0 SXL
LRR, RH Rear Comb Lamp
1
SPL-J1, Ultrasonic
A
0 BT N RH Rear Light Ground (NA) 0 BU
Fuel Level Sender Ground
Bk 1.0 SXL
RFLG, Fuel Send Ground
1
GND-ENG7, Tranny, Cool Temp
1
0 BV
Grid Heater Control Grnd
Bk 0.8 TXL
GHC, Grid Heater Relay
2
EDC7, Engine Controller
75
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
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 BW
Water Separator Htr Ground
Bk 2.0 SXL
GND-ENG1, Start, FFH, WAT_SEP_HTR
1
WSH, Water Separator Heater
A
0 BX
Fuel Filter Heater Ground
Bk 2.0 SXL
FFH, Fuel Filter Heater
B
GND-ENG1, Start, FFH, WAT_SEP_HTR
1
0 BY
Air Filter Restriction Sw Grd
Bk 1.0 SXL
SPL_ENG, Ultrasonic
A
PAF, Air Filter Restriction Sw
2
0 BZ
Fuel Level Sender GND
Bk 1.0 SXL
RFL_23, Fuel_Level_Send
B
GND_ENG7, Tranny, Cool Temp
1
0 CA
Sec. Steering Signal Ground
Bk 1.0 SXL
SSM, Sec. Steering Mod
11
SPL-SEC Ultrasonic
A
0 CB
Sec. Steering Signal Ground
Bk 1.0 SXL
SSM, Sec. Steering Mod
12
SPL-SEC Ultrasonic
A
0 CC
Sec. Steering Press Sw Ground
Bk 1.0 SXL
PSS, Sec. Steer Press Switch
B
SPL-SEC Ultrasonic
A
0 CD
Sec. Steering Splice Ground
Bk 1.0 SXL
SPL_SEC, Ultrasonic
A
GND-SSMOD, Sec Str Chas Gnd
1
0 CE
Sec. Steering Chassis Ground
Bk 1.0 SXL
SSM, Sec. Steering Mod
4
GND-SSMOD, Sec. Str Chas Gnd
1
0 CF
Sec. Steering Sol Ground
Bk 1.0 SXL
YSS, Sec. Strg Sol
2
SPL-SEC, Ultrasonic
A
0 CG
Sec STR Flyback GND
Bk 1.0 SXL
245F, SEC_STR_FLYBACK
1
SSD, SEC_STR_Diode
B
0 CH
Sec STR Flyback GND
Bk 1.0 SXL
245F, SEC_STR_FLYBACK
1
SSD, SEC_STR_Diode
A
0 DA
AIC Chassis Ground
Bk 0.8 TXL
GND-PDST1, Ground A
1
AIC-2, Advanced Inst Cluster 2
22
0 DAP Back Light Ground
Bk 0.8 GXL
STE, Trans Enable Switch
7
SPL-BCK-LT-GD, Splice Back Light Ground
K
0 DAV TECM Diagnostic Ground
Bk 0.8 GXL
108F, Diagnostic connector
3
GND-CAB3D, Ground A
1
0 DB
AIC Power Ground Red
Bk 0.8 TXL
CAB-E, Cab Engine
20
AIC-2, ADV Instr Cluster 2
15
0 DD
Work Lights Grnd
Bk 2.0 GXL
SPL_WL1, Ultrasonic
A
GND_CAB1, Ground A
1
0 DE
Neutral Start Relay Control Grd
Bk 0.8 GXL
GND_CAB_SPL2, SPL Back Light GD
G
ECB, Elect Center B
B4
0 DF
Crank Request Relay Control Ground
Bk 0.8 GXL
CAB_E, CAB-Engine
6
ECB, Elect Center B
B6
0 DG
Cab Splice Grounds
Bk 1.0 GXL
GND-CAB-SPL, Cab Grd Spl
F
GND-CAB3, Ground C
1
0 DH
Diagnostic Connector Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
M
DIA, Diagnostic
A
0 DJ
AC Relay Control Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
K
ECD, Elect Center D
B10
0 DK
Seat Compressor Motor Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
J
SC, Seat Comp Motor
B
0 DM
Speed Sensor Grounds
Bk 0.8 TXL
CAB-T, Cab Transmission
11
TECM, Trans
3
0 DN
Output Speed Sensor Ground
Bk 0.8 TXL
CAB-T, Cab Transmission
28
TECM, Trans
4
0 DP
DIAG TECM Ground
Bk 0.8 TXL
GND-CAB3D, Ground A
1
TECM, Trans
1
0 DQ
DIAG TECM Ground
Bk 0.8 TXL
GND-CAB3D, Ground A
1
TECM, Trans
2
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
0 DR
Roof Splice Grounds
0 DS
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 GXL
CAB-RF, Cab to Roof Conn.
F
GND-CAB1, Ground A
1
Roof Splice Grounds
Bk 1.0 GXL
CAB-RF, Cab to Roof Conn.
G
GND-CAB1, Ground A
1
0 DT
Front Wiper/Washer Sw Grd
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
G
SFWW, Front Wiper/Washer
2
0 DU
Pilot Pressure Sol Grd
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
L
YPP, Pilot Press Sol
B
0 DV
Cigar Lighter Ground
Bk 3.0 SXL
CL, Cigar Lighter
2
GND-CAB3, Ground C
1
0 DW
AIC Power Ground
Bk 0.8 TXL
CAB-E, Cab Engine
19
AIC-1, Adv Instr Cluster 1
12
0 DX
AIC Sensor Ground
Bk 0.8 TXL
CAB-E, Cab Engine
17
AIC-1, Adv Instr Cluster 1
6
0 DY
Roof Splice GNDs
Bk 1.0 GXL
SPL_WL1, Ultrasonic
A
CAB_RF, CAB to Roof Connection
B
0 DZ
Work Lights GRND
Bk 2.0 GXL
SPL_WL1, Ultrasonic
A
CAB_RF, CAB to Roof Connection
A
0 EA
PWR Relay GND
Bk 0.8 GXL
ECB, Elect CNTR B
C2
SPL_SD3, Ultrasonic
A
0 EB
Ignition Relay Control Ground
Bk 0.8 GXL
SPL_SD3, Ultrasonic
A
PRM-C1, PRM Signal
B
0 EC
ACC Relay Control Ground
Bk 0.8 GXL
SPL_SD3, Ultrasonic
A
PRM-B1, PRM Signal
B
0 ED
HVAC Grounds
Bk 3.0 SXL
HVAC2, HVAC2
2
GND-CAB4, Ground C
1
0 EE
DIODE Suppression Grounds
Bk 0.8 GXL
GND-CAB-SPL, Cab Grnd Spl
A
140M, DIODE Module
C
0 EF
Brake Lights Relay Ctrl Grnd
Bk 0.8 GXL
GND-CAB-SPL2, Spl Back Light Ground
M
ECC, Elec CNTR D
A1
0 EG
Flasher Module Ground
Bk 0.8 GXL
FLSHR, Flasher Module
4
GND-CAB-SPL2, Spl Back Light Ground
L
0 EH
Flasher Module Ground
Bk 0.8 GXL
FLSHR, Flasher Module
3
GND-CAB-SPL2, Spl Back Light Ground
K
0 EJ
Power Converter Ground
Bk 1.0 GXL
CNV, 24V to 12V Pwr Convert
3
GND-CAB4, Ground C
1
0 EK
AUX Power Outlet 1 Grnd
Bk 1.0 GXL
PO1, Power Outlet
C
GND-CAB5, Ground C
1
0 EL
AUX Power Outlet 2 Grnd
Bk 1.0 GXL
PO2, Power Outlet
C
GND-CAB5, Ground C
1
0 EM
Radio Ground
Bk 0.8 GXL
CAB-RF, Cab to Roof Conn.
M
GND-CAB-SPL, Cab Grnd Spl
B
0 EN
Radio Ground
Bk 0.8 GXL
ROOF, Roof to Cab Conn.
M
RAD, Radio Power
8
0 EP
Horn Switch Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
C
SRHSTLK, RH Stalk Switch
31
0 EQ
Splice Pack GND-CAB-SPL2 Grnd
Bk 0.8 GXL
GND-CAB-SPL2, Spl Back Light Ground
H
GND-CAB6, Start, FFH, Water Sep Htr
1
0 ER
Power Converter Grnd
Bk 1.0 GXL
CNV, 24V to 12V Pwr Conv
6
GND-CAB4, Ground C
1
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
Connector
K = Pink U = Blue Y = Yellow
To Connector Cav
Wire
Circuit
0 ES
Grid Heater Ground
Bk 19.0 SXL
GH-1, Grid Heater
1
0 ET
Power Relay GND
Bk 0.8 GXL
ECB, Elect CNTR B
0 EU
PWR Converter RLY CTRL GND Bk 0.8 GXL
0 EV
IGN Latch GND
0 EW
Connector
Cav
GND-GH1, STRT, FFH, Water Sep Htr
1
D2
SPL_SDL, Ultrasonic
A
SPL_SD3, Ultrasonic
A
PRM_A2, PRM Signal
B
Bk 0.8 GXL
ECB, Elect CNTR B
B2
SPL_SD1, Ultrasonic
A
Power Relay GND
Bk 0.8 GXL
ECB, Elect CNTR B
B1
GND_CAB_SPL2, SPL Back LGHT GD
E
0 EY
Power Relay GND
Bk 0.8 GXL
ECD, Elec CNTR D
A4
SPl_SD1, Ultrasonic
A
0 EZ
Power Relay Control
W 0.8 GXL
ECD, Elec CNTR D
A3
AIC_1, ADV Instr Cluster 1
22
Bk 2.0 SXL
GND_CB, Ground, On Cooling Box
1
GND_GL, Ground, Rear Grill
1
0G 0 GB
Starter Relay Control Ground
Bk 1.0 SXL
SRC-1, Relay
2
GND-ENG1, STRT, FFH, Water Sep Htr
1
0 HD
Speed Sensor Grounds
Bk 1.0 SXL
TRANS, Cab Transmission
11
SPL-H2, Ultrasonic
A
0 HE
Output Speed Sensor Grnd
Bk 1.0 SXL
TRANS, Cab Transmission
28
OSS, Out Speed Sensor
1
0 HF
Engine Speed Sensor Grnd
Bk 0.8 GXL Twist
ESS, Engine Speed Sensor
2
SPL-H2, Ultrasonic
A
0 HG
Inter Speed Sensor Grnd
Bk 0.8 GXL Twist
ISS, Inter Speed Sensor
2
SPL-H2, Ultrasonic
A
0 HH
Turbine Speed Sensor Grnd
Bk 0.8 GXL Twist
TSS, Turbine Speed Sensor
2
SPL-H2, Ultrasonic
A
0 HL
Redundant Brake Switch Grnd
Bk 1.0 SXL
PRB2, Redundant Brake Sw
B
GND_TRANS, Ground_Trans
1
0 HM
Redundant Brake Switch Grnd
Bk 1.0 SXL
PRB1, Redundant Brake Sw
B
GND_TRANS, Ground_Trans
1
0 HR
HYD FLTR SW Grnd
Bk 1.0 SXL
PHF9, HYD_FLTR_RES_SW
1
GND_TRANS, Ground_Trans
1
0 HW
Hot Ground
Bk 1.0 SXL
HOT, Hydraulic Oil Temp Send
B
GND_TRANS, Ground_Trans
1
0J
Start Lockout RLY GND
Bk 0.8 GXL
ECC, Elect CNTR C
B10
GND_CAB_SPL2, SPL Back LGHT GD
A
0 JA
Hood Grounds (EURO)
Bk 1.0 SXL
HD-E, Hood Trans
C
SPL-J1, Ultrasonic
A
Bk 1.0 SXL
HD-N, Hood to Engine
1
SPL-J1, Ultrasonic
A
0 JA N Hood Grounds (NA) 0 JB
Backup Alarm Grnd
Bk 1.0 SXL
BU1, Backup Alarm Grnd
1
SPL-J1, Ultrasonic
A
0 JC
License Plate Light Grnd
Bk 1.0 SXL
LPL, Lic Plate Light
B
SPL-J1, Ultrasonic
A
0K
Camera GND
BK 0.8 GXL
GND_CAB_SPL2, SPL Back LGHT GD
C
Mon, Camera/Monitor
2
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
AA3
GND_CAB_SPL2, SPL Back LGHT GD
B
TEL, Telematics
H
CABE2, CAB to ENG2 Bulkhd
G
Bk 2.0 GXL
ENG2, ENG Bulkhd 2
G
DC2_A, Disconnect-Battery
1
Rear Wiper Motor Grnd
Bk 1.0 GXL
SPL-ROOF, Spl Rood Grnd
C
RWMG, Rear Wiper Motor Grnd
1
0 MB
Dome Light Grnd
Bk 0.8 GXL
LDM3, Dome Light Grnd
1
SPL-ROOF, Spl Rood Grnd
B
0 MC
Beacon Light Grnd
Bk 1.0 GXL
LBEGRD, Light Beacon Grnd
1
SPL-ROOF, Spl Rood Grnd
A
0 ME
LH Rear Work Light Grnd
Bk 1.0 GXL
LLRW, LH Rear Work Light
2
SPL_WR, Ultrasonic
A
0 MF
RH Rear Work Light Grnd
Bk 1.0 GXL
LRRW, RH Rear Work Light
2
SPL_WR, Ultrasonic
A
0 MG
RH Front Work Light Grnd
Bk 1.0 GXL
LRFS, Front_WK_LT_OPT
2
SPL_WRK2, Ultrasonic
A
0 MH
Rear Work Light Grnd
Bk 1.0 GXL
Roof, Roof to CAB Connection
B
SPL_WR, Ultrasonic
A
0 MJ
RH Front Work Light Grnd
Bk 1.0 GXL
LRFW, RH Front Work Light
2
SPL_WK, Ultrasonic
A
0 MK
Roof Grounds
Bk 1.0 GXL
ROOF, Roof to Cab Conn.
G
SPL-ROOF, Spl Rood Grnd
E
0 ML
RH Front Work Light Grnd
Bk 1.0 GXL
SPL_WRK2, Ultrasonic
A
LRFR, Front_EWK_LT_OPT
2
0 MN
Roof Grounds
Bk 1.0 GXL
ROOF, Roof to Cab Conn.
F
SPL-ROOF, Spl Rood Grnd
D
0 MP
RH Front Work Light Grnd
Bk 1.0 GXL
SPL_WRK2, Ultrasonic
A
LRFO, Front_WK_LT_OPT
2
0 MU
LH Front Work Light Grnd
Bk 1.0 GXL
LLFW, LH Front Work Light
2
SPL_WK, Ultrasonic
A
0 MV
RH Front Work Light Grnd
Bk 2.0 SXL
Roof, Roof to CAB Connection
A
SPL_WK, Ultrasonic
A
0 NA
Hood Grounds (EU)
Bk 1.0 SXL
HD_9, Hood to ENG
1
SPL_B1
A
0 NB
Master Disconnect Grnd
Bk 62.0 SGR
DC2, Discon Black Grnd
1
STTR-GRN, Grid Heater Fuse
1
0 NC
Battery Disconnect
Bk 62.0 SGR
BT4, Discon Black Grnd
1
DC1, Disconnect Battery
1
0 ND
SSM Ground
Bk 62.0 SGR
242F, Chassis Grnd Sec. Strg Motor
1
GND-SSCHAS, SSM Ground Cable
1
0 NE
Hood Grounds (EU)
Bk 1.0 SXL
SPL_B1
A
LLR_9, LH_Rear_Comb_LT
5
0 NF
Hood Grounds (EU)
Bk 1.0 SXL
SPL_B1
A
LLR_9, RH_Rear_Comb_LT
5
0 NG
Hood Grounds (EU)
Bk 1.0 SXL
SPL_B1
A
SPL_J1, Ultrasonic
A
0 PA
Left Speaker Grnd
Bk 0.8 GXL
LSPK, Left Speaker
B
SPK, Speaker
8
0 PB
Right Speaker Grnd
Bk 0.8 GXL
RSPK, Right Speaker
B
SPK, Speaker
2
0 RD
Ride Control Grnd
Bk 1.0 SXL
YRC_J, Ride CNTRL_Jumper
2
YRC_J2, Ride_Control_OPT
2
0 KA
IGN PWR Control GND
Bk 0.8 GXL
ECD, Elec CNTR D
Telematics GRND
BK 2.0 GXL
0 LD
Telematics GND
0 MA
0L
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 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 SC
GRND, Joystick
Bk 0.8 GXL
JSS_ARM, JSS Armrest to CAB
7
PVRES, JSS Joystick
V
0 SD
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
CAB_ARM, CAB to Armrest
7
0 SE
GRND
Bk 0.8 TXL
SPL_JSS_10, Ultrasonic
A
CAN_MOD_2, JSS can mod
10
0 SF
GRND
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
Cab to JSS Frame
G
0 SG
Common
Bk 0.8 GXL
SPL_JSS_10, Ultrasonic
A
Arm_Pos, Arm position
1
0 SH
GRND, CAN MOD
Bk 0.8 GXL
JSS_ARM, JSS Armrest to cab
2
SPL_JSS_10, Ultrasonic
A
0 SJ
GRND, CAN MOD
Bk 0.8 GXL
SPL_JSS_9, Ultrasonic
A
CAB_ARM, Cab to Armrest
2
0 SK
GRND, CAN MOD
Bk 0.8 GXL
CAB_ARM_FRM, Cab to Arm to Frm
8
SPL_JSS_9, Ultrasonic
A
0 SL
Ground
Bk 0.8 GXL
JSS_RLY, Relay K2
87A
SPL_JSS_9, Ultrasonic
A
0 SM
GRND, Joystick
Bk 0.8 GXL
JSS_CNT, JSS Controller
10
SPL_JSS_20, Ultrasonic
A
0 SN
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_20, Ultrasonic
A
JSS_CNT, JSS Controller
11
0 SP
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
R1, Resistor
0 SR
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
JSS_CNT, JSS Controller
15
0 SS
GRND, Joystick
Bk 0.8 GXL
JSS_197F, Main_CAB_FNR
1
FNR_RLY, Relay K2
87A
0 ST
GRND, Joystick
Bk 0.8 GXL
FNR_RLY, Relay K2
85
SPL_JSS_9, Ultrasonic
A
0 SU
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_20, Ultrasonic
A
SPL_JSS_9, Ultrasonic
A
12ACC Ignition Switch ACC Power
W 0.8 GXL
S-KEY, Ignition Switch
4
SPL-ACC, Ultrasonic
A
12ACC ACC PRM Control Power B
W 0.8 GXL
SPL-ACC, Ultrasonic
A
PRM-B1, PRM Signal
A
12ACC Power Converter PRM Control C Power
W 0.8 GXL
SPL-ACC, Ultrasonic
A
PRM-A2, PRM Signal
A
12V Pwr To Outlet 1
Or 1.0 GXL
PO1, Power Outlet
A
ECB, Elect Center B
AA1
12V A 12V Pwr To Outlet 2
Or 1.0 GXL
PO2, Power Outlet
A
ECB, Elect Center B
AA2
12V B 12V Fused Pwr to Radio
Or 1.0 GXL
CAB-RF, Cab to Roof Conn.
N
ECB, Elect Center B
AA9
12V C 12V Switched Power
Or 2.0 GXL
CNV, 24V to 12V Pwr Conver
5
SPL-12V, Ultrasonic
A
12V D Plug 1 12V Switched Power
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A1
12V E Plug 2 12V Switched Power
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A2
12V F Radio 12V Switched Power
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A9
12V G 2 Way Radio 12V Switched Pwr
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A10
12V
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
12V H 12V Fused Power to Radio
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
ROOF, Roof to Cab Conn.
N
SPL-RAD, Ultrasonic
A
12V HA
12V Fused Power to Radio
Or 0.8 GXL
SPL-RAD, Ultrasonic
A
RAD, Radio Power
7
12V HB
12V Fused Power to Radio
Or 0.8 GXL
SPL-RAD, Ultrasonic
A
RAD, Radio Power
4
13A
EVGT Relay
Or 0.8 TXL
Evgt_4, EVGT
C
EDC7, Engine Controller
51
13B
EVGT Relay PWR
Or 1.0 GXL
Turbo, ENG Dash_Turbo
6
EVGT_4, EVGT
A
13C
Fuel Shutoff Fused Power
Or 1.0 SXL
DC3, Fuel Solenoid Disc
1
DISC, Disconnect Engine
A
13C A Fuel Shutoff Fused Power
Or 1.0 SXL
ENG-D, Disc Harness
A
ENG, Engine Cab1
21
13C B Fuel Shutoff Fused Power
Or 1.0 SXL
CAB-E, Cab Engine
21
ECA, Elect Center A
A9
Ignition Switch Pwr
Or 1.0 GXL
S-KEY, Ignition Switch
3
SPL-PK1, Slice 3-4 Way
E
13K A Ignition Switch Pwr
Or 1.0 GXL
TDM, Time Delay Module
5
SPL-PK1, Slice 3-4 Way
G
13K B Ignition Switch Pwr
Or 1.0 GXL
SPL-PK1, Slice 3-4 Way
F
PRM-A1, PRM Signal
A
13K C Ignition Switch Pwr
Or 1.0 GXL
SPL-PK1, Slice 3-4 Way
H
ECB, Elect Center B
D1
Fuel Shutoff Fused Power
Or 1.0 SXL
DC4, Fuel Sol Disconnect
1
DISC, Disconnect Engine
B
13M A Fuel Shutoff Fused Power
Or 0.8 TXL
ENG-D, Disconnect Harness
B
EDC7, Engine Controller
40
13K
13M
14 5
Alternator D+
LG 1.0 SXL
ENG, Engine-CAB1
26
ALT_5, Alternator D+
3
14 A
Alternator D+
LG 0.8 GXL
SPL_ALT, Ultrasonic
A
215F, Alternator Resistor
1
14 AB Alternator D+
LG 0.8 GXL
SPL_ALT, Ultrasonic
A
CAB_E, CAB-Engine
26
14 AC Alternator Running
LG 0.8 GXL
SPL_ALT, Ultrasonic
A
TEL, Telematics
D
16R C FNR Reverse Signal
LU 0.8 GXL
JSS_197M, FNR-Main_CAB
4
RVS_DIODE, Diode ASSY
C
17P A Switch Pad Power From AIC Pwr Or 0.8 TXL
SW-PD, Switch Pad
9
SPL_SW_PD, Ultrasonic
A
17P B SW Pad PWR from AIC PWR
Or 0.8 TXL
SPL_SW_PD, Ultrasonic
A
AIC_1, ADV Instr Cluster 1
25
17P C B+ CAN MOD
Or 0.8 GXL
SPL_SW_PD,Ultrasonic
A
JSS_CAB, JSS CAB
2
17P D B+ CAN MOD
Or 0.8 GXL
SPL_JSS_18, Ultrasonic
A
CAB_ARM, Cab to Armrest
4
17P E B+ CAN MOD
Bk 0.8 TXL
JSS_ARM, JSS Armrest to CAB
4
CAN_MOD_2, JSS CAN MOD
9
17P F B+ JSS Controller
Or 0.8 GXL
SPL_JSS_18, Ultrasonic
A
JSS_CNT, JSS Controller
3
17P G B+ Joystick
Or 0.8 GXL
SPL_JSS_18, Ultrasonic
A
CAB_ARM_FRM, Cab to Arm to Frm
2
LH High Beam Fused Power
Or 2.0 SXL
FRONT, Cab Front Chassis
6
LLF, Lights LH
3
18B A LH High Beam Fused Power
Or 2.0 GXL
CAB-F, Cab Front Chassis
6
ECB, Elect Center B
18B
AA3
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 18C
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
RH High Beam Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
16
LRF, Lights RH
18C A RH High Beam Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
16
ECB, Elect Center B
LH Low Beam Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
14
LLF, Lights LH
18D A LH Low Beam Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
14
ECB, Elect Center B
RH Low Beam Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
15
LRF, Lights RH
18E A RH Low Beam Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
15
ECB, Elect Center B
LH Position/Tail Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
10
LLF, Lights LH
4
18F A LH Position/Tail Fused Power
Or 0.8 GXL
CABE2, CAB to ENG2 Bulkhd
M
SPL-POS-L, Ultrasonic
A
LH Position/Tail Fused Power
Or 1.0 SXL
ENG2, ENG Bulkhd 2
M
ENG-H, Engine to Hood
6
18F B LH Position/Tail Fused Power
Or 1.0 SXL
ENG2, ENG Bulkhd 2
M
LLR-E, LH Rear Comb Light
3
LH Position/Tail Fused Power
Or 1.0 SXL
HD-N, Hood to Engine
6
LLR-N LH Rear Combination Light
3
18F C LH Position/Tail Fused Power
Or 1.0 GXL
SPL-POS-L, Ultrasonic
A
ECB, Electric Center B
AA7
18F E LH Position/Tail Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
10
SPL-POS-L, Ultrasonic
A
18F F LH Position/Tail Fused Power
Or 1.0 SXL
HD-9, Hood to Engine
6
LLR-9, LH Rear Comb Light
3
RH Position/Tail Fused Power
Or 1.0 GXL
SPL-POS-R, Ultrasonic
A
ECB, Elect Center B
18G A RH Position/Tail Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
5
LRF, Lights RH
4
RH Position/Tail Fused Power
Or 1.0 SXL
SPL-POS-NA, Ultrasonic
A
LRR, RH Rear Combination Light
3
18G D Licence Plate Light Fused Pwr
Or 1.0 SXL
SPL-POS, Ultrasonic
A
E-HD, Trans Hood
A
18G E Licence Plate Light Fused Pwr
Or 0.8 GXL
HD-E, Hood Trans
A
LPL, Licence Plate Light
A
Licence Plate Light Fused Pwr
Or 1.0 SXL
LPL, Licence Plate Light
A
SPL-POS-NA, Ultrasonic
A
18G F RH Position/Tail Fused Power
Or 0.8 GXL
CABE2, CAB to ENG2 Bulkhd
N
SPL-POS-R, Ultrasonic
A
18G G RH Position/Tail Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
5
SPL-POS-R, Ultrasonic
A
18G H RH Position/Tail Fused Power
Or 1.0 SXL
ENG2, Engine Bulkhd 2
N
SPL-POS, Ultrasonic
A
RH Position/Tail Fused Power
Or 1.0 SXL
ENG2, Engine Bulkhd 2
N
ENG-H, Engine to Hood
5
18G J RH Position/Tail Fused Power
Or 1.0 SXL
LRR-E, RH Rear Combination Light
3
SPL-POS, Ultrasonic
A
Or 1.0 SXL
HD-N, Hood to Engine
5
SPL-POS-NA, Ultrasonic
A
18D
18E
18F
18F AN
18F BN
18G
18G CN
18G EN
18G HN
18G JN
RH Position/Tail Fused Power
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
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
18G K RH Position/Tail Fused Power
Or 1.0 SXL
HD-9, Hood to Engine
5
SPL-P9,
A
18G L LIC Plate Fused Power
Or 1.0 SXL
SPL-P9,
A
LPL, LIC_PLATE_LIGHT
A
18G M RH Position/Tail Fused Power
Or 1.0 SXL
SPL-P9,
A
LRR-9, RH Rear Combination Light
3
18J B EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
3
18J C EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
2
18J D EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
8
18J E EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
9
18J F
Or 3.0 GXL
PRM_D1, PRM Output
A
SPL-EDC4, Ultrasonic
A
18J H Water In Fuel Sensor Fused Pwr Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
WIF, Water In Fuel Sensor
3
18K A Diagnostic Fused Power
Or 0.8 GXL
ECC, Elect CNTR C
A9
SPL_PK1, Splice 3-4 way
K
18K B Diag Fused B+
Or 0.8 GXL
SPL_PK1, Splice 3-4 way
L
DIA_2, Diagnostic
B
18K C Telematics FSD Power
Or 0.8 GXL
SPL_PK1, Splice 3-4 way
M
TEL, Telematics
A
18K D Diag Fused B+
Or 0.8 GXL
SPL_PK1, Splice 3-4 way
J
DIA, Diagnostic
B
Blower Motor Fused Power
Or 3.0 GXL
SPL-BLWR, Ultrasonic
A
ECA, Elect Center A
C1
18N A Blower Motor Fused Power
Or 0.8 GXL
SPL-BLWR, Ultrasonic
A
HVAC1, HVAC1
2
18N B Blower Motor Fused Power
Or 3.0 GXL
SPL-BLWR, Ultrasonic
A
HVAC2, HVAC2
1
18S A B+, JSS Fused
Or 0.8 GXL
ECA, Elect CNTR A
A2
SPL_JSS_3, Ultrasonic
A
18S B B+, JSS Fused
Or 0.8 GXL
SPL_JSS_3, Ultrasonic
A
SJS, Joystick_Control_SW
2
18S C B+, JSS Fused
Or 0.8 GXL
JSS_CAB, JSS CAB
11
SPL_JSS_3, Ultrasonic
A
18S D B+, JSS Fused
Or 0.8 GXL
CAB_FRM, CAB to JSS Frame
J
CAB_ARM_FRM, CAB to ARM to FRM
11
18S E B+, JSS Fused
Or 1.0 SXL
JSS_PIL_PR, JSS Pilot Pressure
A
JSS_FRM, JSS Frame to Cab
J
TRANS, Transmisson-CAB
29
OSS, Out Speed Sensor
3
18N
19A
EDC7 Fused Power
Output Speed Sensor Fused Pwr Or 1.0 SXL
19A A Brake Declutch Sw Fused Pwr
Or 1.0 SXL
TRANS, Transmisson-CAB
24
PBD, Dec. Pressure Switch
A
19A B FNR Switched Fused Power
Or 0.8 GXL
197M, FNR Main Cab
1
SPL-FNR, Ultrasonic
A
19A C FNR Switched Fused Power
Or 0.8 GXL
197F, Main Cab FNR
1
SPL-TRNS-PWR, Trans Pwr
F
19A D Trans Enable Switch Fused Pwr
Or 0.8 GXL
STE, Trans Enable Switch
2
SPL-D15, Ultrasonic
A
19A E AIC Fused Power
Or 0.8 GXL
STE, Trans Enable Switch
10
SPL-D15, Ultrasonic
A
19A F Trans Enable Switch Fused Pwr
Or 0.8 GXL
SPL-TRNS-PWR, Trans Pwr
B
SPL-D15, Ultrasonic
A
19A G FNR Sw Fused Power
Or 0.8 GXL
SPL-FNR, Ultrasonic
A
SFNR, FNR Switch
8
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
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
19A H Trans Shifter Fused Power
Or 0.8 GXL
TS1, Transmission Shifter
A
SPL-TRNS-PWR, Trans Pwr
M
19A K TECM Fused Power
Or 0.8 TXL
SPL-TRANS-PWR, Trans Pwr
J
TECM, Trans
45
19A L Park Brake Switched Fused Pwr
Or 0.8 GXL
SPB, Parking Brake Switch
2
SPL-PBS, Ultrasonic
A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL
CAB-T, Cab Transmission
29
SPL-TRNS-PWR, Trans Power
K
19A N Trans Fused Power
Or 1.0 GXL
SPL-TRANS-PWR, Trans Pwr
A
ECA, Elect Center A
A1
19A P Backup Alarm Relay Control Fused Power
Or 1.0 GXL
SPL-TRANS-PWR, Trans Pwr
G
ECD, Elect Center D
AA10
19A Q Trans/Auto Switch Fused Power
Or 0.8 GXL
STA, Trans Auto Switch
2
SPL-TRANS-PWR, Trans Pwr
C
19A R Declutch Switch Fused Power
Or 0.8 GXL
SDC, Declutch Switch
2
SPL-TRANS-PWR, Trans Pwr
H
19A T Brake Declutch Switch Fused Power
Or 0.8 GXL
CAB-T, Cab-Transmission
24
SPL-TRANS-PWR, Trans Pwr
D
19A U Trans Kick Down Switch Fused Power
Or 0.8 GXL
SPL-FNR, Ultrasonic
A
20M, Trans Kick Down
1
19A V FNR Switch Fused Power
Or 0.8 GXL
SFNR, FNR Switch
5
SPL-FNR, Ultrasonic
A
19A W Diagnostic Conn. Fused Power
Or 0.8 GXL
108F, Diagnostic Connector
1
SPL-TRANS-PWR, Trans Pwr
E
Or 0.8 GXL
SRHSTLK, RH Stalk Switch
49a
ECA, Elect Center A
A8
19B A FNR SW Fused PWR
W 0.8 GXL
FNR_RLY, Relay K2
30
JSS_197M, FNR-MAIN_CAB
1
19B B FNR SW Fused PWR
Or 0.8 GXL
CAB_FNR, MAIN_CAB_FNR
1
FNR_RLY, Relay K2
87
19B C FNR SW Fused PWR
Or 0.8 GXL
ARM_FNR, FNR-MAIN_CAB
1
SPL_AJ, Ultrasonic
A
19B D FNR SW Fused PWR
Or 0.8 GXL
21M, Trans_KICK-DOWN
1
SPL_AJ, Ultrasonic
A
19B E FNR SW Fused PWR
Or 0.8 GXL
SAJ, FNR_SWITCH
5
SPL_AJ, Ultrasonic
A
19B F FNR SW Fused PWR
Or 0.8 GXL
SAJ, FNR_SWITCH
8
SPL_AJ, Ultrasonic
A
19C A Pilot Ctrl Fused Pwr
Or 1.0 GXL
SPL-D24, Ultrasonic
A
ECA, Elect Center A
A5
19C B Pilot Ctrl Fused Pwr
Or 1.0 GXL
SPL-D24, Ultrasonic
A
ECD, Elect Center D
B5
19C C Pilot Ctrl Fused Pwr
Or 0.8 GXL
SPL-D24, Ultrasonic
A
ECD, Elect Center D
D5
19C D Ride Control SW Fused Pwr
Or 1.0 GXL
SPL-D24, Ultrasonic
A
SRC, Ride Control Switch
2
19C E Pilot Control SW FSD Pwr
Or 0.8 GXL
SPL-D24, Ultrasonic
A
TEL, Telematics
C
19C F Pilot Control SW Fused Pwr
Or 0.8 GXL
SPL-D24, Ultrasonic
A
SPC, Pilot_Control_Switch
2
19D A Parking Brake Relay Fused Pwr
Or 1.0 GXL
SPL-PBS, Ultrasonic
A
ECA, Elect Center A
A6
19D B Parking Brake Relay Fused Pwr
Or 0.8 GXL
SPL-PBS, Ultrasonic
A
ECB, Elect Center B
D9
19B
Turn Signal Fused Power
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
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
19D C Parking Brake Relay Fused Pwr
Or 1.0 GXL
SPL-PBS, Ultrasonic
A
ECB, Elect Center B
B9
19E A AIC Wake Up Ignition
Or 0.8 TXL
SPL_AP, Ultrasonic
A
ECA, Elect Center A
A3
19H
Backup Alarm B+
Or 1.0 GXL
ECA, Elect Center A
C4
ECD, Elect Center D
A10
19J
Front Wiper Fused Pwr
Or 0.8 GXL
SPL-PK3, Splice 3-4 Way
K
ECA, Elect Center A
C2
19J A Front Wiper Motor Fused Pwr
Or 0.8 GXL
SPL-PK3, Splice 3-4 Way
M
FWM, Front Wiper Motor
C
19J B Front Wip Wash Sw Fused Pwr
Or 0.8 GXL
SFWW, Front Wiper/Washer
5
SPL-PK3, Splice 3-4 Way
J
19J C Front Wiper Relay Fused Power
Or 0.8 GXL
SPL-PK3, Splice 3-4 Way
L
SPL-FW, Ultrasonic
A
19J D Front Wiper Relay Fused Power
Or 0.8 GXL
SPL-FW, Ultrasonic
A
ECD, Elect Center D
D1
19J E Front Wiper Relay Fused Power
Or 0.8 GXL
SPL-FW, Ultrasonic
A
ECD, Elect Center D
B1
Or 0.8 GXL
SPL-FW, Ultrasonic
A
ECD, Elect Center D
D3
Or 0.8 GXL
SPL-FW, Ultrasonic
A
K-WCO, Wiper Cutout
86
Or 1.0 GXL
SPL-RWW, Ultrasonic
A
ECA, Elect Center A
C3
19K A Rear Wiper Sw Fused Pwr
Or 1.0 GXL
SRWP, Rear Wiper Sw
3
SPL-RWW, Ultrasonic
A
19K B Rear Wip Wash Fused Pwr
Or 0.8 GXL
SRWP, Rear Wiper Sw
5
SPL-RWW, Ultrasonic
A
19K C Rear Wiper Motor Fused Pwr
Or 1.0 GXL
CAB-RF, Cab to Roof Connect
J
SPL-RWW, Ultrasonic
A
19K D Rear Wiper Motor Fused Pwr
Or 1.0 SXL
ROOF, Roof to Cab Connect
J
RWM, rear Wiper Motor
C
Pwr Converter Fused Power
Or 3.0 GXL
PRM-E1, PRM Output
C
SPL-CNV, Ultrasonic
A
19L A Pwr Converter Fused Power
Or 2.0 GXL
CNV, 24V to 12V Pwr Conver
1
SPL-CNV, Ultrasonic
A
19L B Pwr Converter Fused Power
Or 2.0 GXL
CNV, 24V to 12V Pwr Conver
2
SPL-CNV, Ultrasonic
A
Sec. Steering Accessory Fused Pwr
Or 0.8 GXL
CAB-T, Cab Transmission
3
ECA, Elect Center A
C7
19M A Sec. Steering Accessory Fused Pwr
Or 1.0 SXL
TRANS, Cab Transmission
3
TR-SS, Sec. Steering Module Opt
A
19M C Sec. Steering Accessory Fused Pwr
Or 1.0 SXL
SSM, Sec. Steering Module
7
SS-TR, Sec. Steering Mod Trans
A
19J F
Front Wiper Relay LS Control Fused Power
19J G Wiper Cutout Relay Fused Pwr 19K
19L
19M
Rear Wiper Fused Pwr
19N
Seat Compressor Fused Pwr
Or 1.0 GXL
SC, Seat Compressor Motor
A
ECA, Elect Center A
C6
19P
Pin Engage/Fan Fused Pwr
Or 0.8 GXL
SPL-PIN, Spl Back Lgt Pwr
B
ECA, Elect Center A
A7
19P A Pin Engage Sw Fused Pwr
Or 0.8 GXL
SPE, Pin Engage Sw
2
SPL-PIN, Spl Back Lgt Pwr
A
19P C Fan Rev Sw Fused Pwr
Or 0.8 GXL
SFC, Fan Control Switch
5
SPL-PIN, Spl Back Lgt Pwr
C
19P D Fan Rev Relay Fused Pwr
Or 0.8 GXL
SPL-PIN, Spl Back Lgt Pwr
E
ECB, Elect Center B
D7
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
19P E Fan Rev Relay Fused 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
Or 0.8 GXL
SPL-PIN, Spl Back Lgt Pwr
F
ECB, Elect Center B
B7
19R
Sec. Steering Ign Fused Pwr
Or 0.8 GXL
DM, Diode OR
C
SPL-2 Ultrasonic
A
19RR
Sec. Steering Ign Fused Pwr
Or 0.8 GXL
DM, Diode OR
A
ECA, Elect Center A
A4
19R A Sec. Steering Ign Fused Pwr
Or 1.0 SXL
TRANS, Cab Transmission
4
TR-SS, Sec. Steering Module Opt
B
19R C Sec. Steering Ign Fused Pwr
Or 1.0 SXL
SSM, Sec. Steering Module
1
SS-TR, Sec. Steering Mod Trans
B
19R D Alternator Resistor Fused Pwr
Or 0.8 GXL
SPL-2, Ultrasonic
A
216F, Alternator Resistor
1
19R E Sec. Steering Ign Fused Pwr
Or 0.8 GXL
SPL-2, Ultrasonic
A
CAB-T, Cab Transmission
4
19S1
Sec. Steering Fused Pwr
Or 3.0 GXL
PRM_A1, PRM Output
A
SPL_19S, Ultrasonic
A
19S2
Sec. Steering Fused Pw
Or 1.0 GXL
SPL_19S, Ultrasonic
A
CAB_T, Cab-Transmission
26
19S1 E Sec. Steering Fused Pwr
Or 1.0 SXL
TRANS, Cab Transmission
26
TR-SS, Sec. Steering Module Opt
E
19S1 X Sec. Steering Fused Pwr
Or 1.0 SXL
SSM, Sec. Steering Module
3
SS-TR, Sec. Steering Module Trans
E
19S B AIC Delay Fused Power
Or 0.8 GXL
SPL-DKY3, Ultrasonic
A
ECC, Elect Center C
A8
19S C AIC Delay Fused Power
Or 0.8 TXL
SPL-DKY3, Ultrasonic
A
AIC-2, Advanced Instr Cluster 2
20
19S D AIC Delay Fused Power
Or 0.8 TXL
SPL-DKY3, Ultrasonic
A
AIC-2, Advanced Instr Cluster 2
14
19S E AIC BATT B+
Or 1.0 GXL
SPL_AP, Ultrasonic
A
AIC_1, ADV Instr Cluster 1
1
19S F AIC BATT B+
Or 1.0 GXL
SPL_AP, Ultrasonic
A
AIC_2, ADV Instr Cluster 2
21
19T A Fused_Batt_Pwr
Or 0.8 TXL
TECM, Trans
23
SPL_D17, Ultrasonic
A
19T B Fused_Batt_Pwr
Or 0.8 TXL
TECM, Trans
68
SPL_D17, Ultrasonic
A
19T C Fused_Batt_Pwr
Or 0.8 TXL
ECC, Elect CNTR C
A10
SPL_D17, Ultrasonic
A
Horn Relay Fused Power
Or 0.8 GXL
SPL-HRN, Ultrasonic
A
ECC, Elect CNTR C
A6
19U A Horn Relay Fused Power
Or 0.8 GXL
SPL-HRN, Ultrasonic
A
ECC, Elect CNTR C
B7
19U B Beacon Dome Lt Fused Pwr
Or 1.0 GXL
SPL-LT, Ultrasonic
A
ECC, Elect CNTR C
A1
19U C Dome Lt Fused Pwr
Or 0.8 GXL
ROOF, Roof to Cab Connection
D
LDM1, Dome Light B+
1
19U D Dome Lt Fused Pwr
Or 0.8 GXL
CAB-RF, Cab to Roof Connection
D
SPL-LT, Ultrasonic
A
19U E Horn Relay Fused Power
Or 0.8 GXL
SPL-HRN, Ultrasonic
A
ECC, Elect CNTR C
D7
19U F Door Sw Fused Power
Or 0.8 GXL
ROOF, Roof to Cab Connection
P
DS, Door Switch
A
19U G Door Sw Fused Power
Or 0.8 GXL
CAB-RF, Cab to Roof Connection
P
SPL-LT, Ultrasonic
A
19U
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
19U H Beacon Switch Fused 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
Or 1.0 GXL
SBE, Beacon Switch
2
SPL-LT, Ultrasonic
A
19W
Cigar Lighter Pwr
Or 3.0 GXL
CL, Cigar Lighter
1
ECC, Elect CNTR A
C8
19Y
Hood control Fused Power
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A
ECC, Elect CNTR C
A7
19Y A Hood Up Relay Fused Power
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A
ECC, Elect CNTR C
D2
19Y B Hood Down Relay Fused Power
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A
ECC, Elect CNTR C
D4
19Y C Hood Switch Fused Power
Or 1.0 GXL
CABE2, Cab to Eng2 Bulkhd
T
SPL-HOOD, Ultrasonic
A
19Y D Hood Switch Fused Power
Or 1.0 GXL
ENG2, Engine Bulkhd 2
T
HD, Hood Switch
B
Driving Lights Sw Fused Power
Or 1.0 GXL
SPL_DR, Ultrasonic
A
ECC, Elect CNTR C
A3
19Z A Driving Lights Sw Fused Power
Or 1.0 GXL
SDR, Driving Lights Sw
2
SPL_DR, Ultrasonic
A
19Z B Driving Lights Sw Fused Power
Or 1.0 GXL
SDR, Driving Lights Sw
5
SPL_DR, Ultrasonic
A
19Z C High Beam Flash Fused Power
Or 1.0 GXL
SRHSTLK, RH Stalk Switch
56d
SPL_DR, Ultrasonic
A
Cab CB Protected Power
R 19.0 SXL
P_C3, B+ Pwr FRM PRMD
1
CBPW, Cab Power
1
1CB A Cab CB Protected Power
R 19.0 SXL
P-A3, B+ Power
1
CAB-PW, Cab Power
1
19Z
1CB
1DM
Time Delay/Ign Sw Fused Pwr
R 1.0 GXL
ECC, Elect CNTR C
A5
S_Key, Ignition_Switch
1
1 AA
Brake Lt Sw Pwr
R 1.0 SXL
BTM_C, Cab Bottom Bulkhd
K
PBL, Brake Light Press Switch
1
1B
EVGT Relay PWR
R 1.0 GXL
EVGT_3, EVGT_Fuse
B
EVGT_4, EVGT
D
1 BA
Alternator B+
R 13.0 SXL
AB+, Alternator B+
1
B2 Starter Power
1
1 BB
Starter Solenoid Pwr
R 8.0 SXL
193 Starter Relay
1
194 Starter Signal
1
1 BE
Grid Htr Pwr
R 19.0 SXL
115 Grid Htr Pwr
1
GH, Grid Htr
1
1 BF
Alternator B+
R 13.0 SXL
AB_5, Alternator B+
1
B6, Starter Power
1
1 BG
B+ PWR PRMC
R 19.0 SXL
B5, Starter PWR Stud
1
P_C1, B+ PWR FRM PRMD
1
1C
ECC Bat Power
R 8.0 GXL
P-A1, B+ Power
1
L1-ECC, ECC Battery Power
1
1 DR
Brake Light Switch Power
R 1.0 GXL
CAB-B, Cab Front Chassis
K
SPL-FLSHR-PWR, Ultrasonic
A
1 DU
Flasher Module Pwr
R 1.0 GXL
FLSHR, Flasher Module
1
SPL-FLSHR-PWR, Ultrasonic
A
1 DV
Brake Lights/Flasher Bat Pwr
R 2.0 GXL
SPL-FLSHR-PWR, Ultrasonic
A
ECC, Elec CNTR C
A4
1 DW
Brake Lt Relay Bat Pwr
R 1.0 GXL
SPL-FLSHR-PWR, Ultrasonic
A
ECD, Elec CNTR D
A2
Grid heater Fuse Bat Power
R 19.0 SXL
P-C2, B+ Power from PRMD
1
GHF1, Grid Heater Fuse
1
1 GA
Filter Htr Pwr
R 3.0 SXL
PRM-D1, PRM Output
C
SPL-HTR, Ultrasonic
A
1 GB
Fuel Filter Htr Pwr
R 2.0 SXL
SPL-HTR, Ultrasonic
A
FFH, Fuel Filter Heater
A
1E
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
1 GC
Water Sep Htr Pwr
R 2.0 SXL
SPL-HTR, Ultrasonic
A
WSH, Water Separator Heater
B
1 KA
Hazard Switch Pwr
R 1.0 GXL
SHZ, Hazard Switch
2
SPL-FLSHR-PWR, Ultrasonic
A
1 NA
Battery Crossover
R 62.0 SGR
BT3, Starter Battery
1
BT2, Disconnect Battery
1
1 NB
Battery Starter
R 62.0 SGR
BT1, Battery Starter
1
B3, Starter Battery
1
1 NC
B+ Power PRMC
R 19.0 SXL
B1, Starter Power Stud
1
P-C1, B+ Power From PRMC
1
1 ND
SSM Power
R 62.0 SGR
244F Starter Sec. Strg Mtr
1
B4, Starter Power
1
1 NE
Battery STRTR
R 62.0 SGR
B7, Starter-Battery
1
BT1, Battery_Starter
1
1 NF
SSM PWR
R 62.0 SGR
B8, Starter_Power
1
244F, Starter-sec_STRG_MTR
1
1T
EVGT_3 PWR
R 1.0 SXL
P_C6, B+ PWR FRM PRMD
1
EVGT_3, EVGT_FUSE
A
1Y
Grid Heater Fused Power
R 19.0 SXL
GHF3, Grid heater Fuse
1
GHF4, Grid Heater
1
1Z
Starter Relay Battery Power
R 8.0 SXL
P-C4, B+, Power From PRMC
1
195, Starter Relay Power
1
20G A EDC7 ESO-K Interface
W 0.8 TXL
ENG, Engine Cab1
31
EDC7, Engine Controller
89
20G B EDC7 ESO-K Interface
W 0.8 GXL
CAB-E, Cab Engine
31
DIA, Diagnostic
E
Neutral Start Relay Output
W 0.8 GXL
SPL-CR, Ultrasonic
A
ECB, Elect Center B
D4
21C A Neutral Start Relay Output
W 0.8 GXL
SPL-CR, Ultrasonic
A
ECB, Elect Center B
D5
21C B Neutral Start Relay Output
W 0.8 GXL
SPL-CR, Ultrasonic
A
ECD, Elect Center D
A6
Starter Relay Signal
W 1.0 SXL
SRC-1, Relay
1
ENG, Engine Cab1
15
21D A Starter Relay Signal
W 0.8 GXL
CAB_E, Cab-Engine
15
ECD, Elect Center D
AA5
Key Switch Crank
W 0.8 GXL
ECB, Elect CNTR B
D6
ECC, Elect Center C
B9
21E A Key Switch Crank
W 0.8 TXL
ENG, Engine Cab1
27
EDC7, Engine Controller
32
21E B Key Switch Crank
W 0.8 GXL
ECC, Elect CNTR C
C10
CAB_E, Cab-Engine
27
EDC7 Digital Ground
W 0.8 GXL
CAB-E, Cab Engine
11
ECB, Elect Center B
B5
21F A EDC7 Digital Ground
W 0.8 GXL
ENG, Engine Cab
11
SPL-EDC3, Ultrasonic
A
21F B EDC7 Digital Ground
W 0.8 TXL
SPL-EDC3, Ultrasonic
A
EDC7, Engine Controller
29
21F C EDC7 Digital Ground
W 0.8 TXL
ENG_B, CAB BTTOM
1
SPL-EDC3, Ultrasonic
A
21F D EDC7 Digital Ground
W 0.8 TXL
RTHP, Throttle Pedal
1
BTM_E, CAB BTTOM
1
EDC7 Crank Control relay
W 0.8 GXL
CAB-E, Cab Engine
3
ECD, Elect Center D
AA6
21G A EDC7 Crank Control relay
W 0.8 TXL
ENG, Engine Cab1
3
EDC7, Engine Controller
37
Crank control relay LSD
W 0.8 GXL
CAB-E, Cab Engine
4
ECD, Elect Center D
A5
21H A Crank control relay LSD
W 0.8 TXL
ENG, Engine Cab1
4
EDC7, Engine Controller
17
W 0.8 GXL
ECC, Elect CNTR C
D9
TEL, Telematics
S
21C
21D
21E
21F
21G
21H
21J
Restart Prevent
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 21K
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
Ign Sw Start Signal
W 0.8 GXL
S-KEY, Ignition Switch
2
SPL-CRK, Ultrasonic
A
21K A Ign Sw Start Signal
W 0.8 TXL
SPL-CRK, Ultrasonic
A
AIC-2, Adv Instrument Cluster 2
17
21K B Ign Sw Start Signal
W 0.8 GXL
SPL-CRK, Ultrasonic
A
ECB, Elect Center B
B3
22A
Declutch SW
DU 0.8 TXL
SDC, Declutch_Switch
3
TECM, Trans
21
22B
Pedal Sensor +5V
K 0.8 TXL
TECM, Trans
37
CAB_B, Cab BTM Bulkhd
B
22C
Pedal POS Signal
Y 0.8 TXL
TECM, Trans
38
CAB_B, Cab BTM Bulkhd
C
22D
Pedal Sensor Grnd
LU 0.8 TXL
TECM, Trans
24
CAB_B, Cab BTM Bulkhd
A
22E
Pedal Sensor +5V
K 0.8 TXL
BTM_C, Cab Bottom Bulkhd
B
BPP, Pedal Position
2
22F
Pedal POS Signal
Y 0.8 GXL
BTM_C, Cab Bottom Bulkhd
C
BPP, Pedal Position
3
22G
Pedal Sensor Grnd
LU 0.8 GXL
BTM_C, Cab Bottom Bulkhd
A
BPP, Pedal Position
1
24B
Throttle Signal
W 0.8 TXL
ENG_B, Cab BTTOM
3
EDC7, Engine Controller
79
24B A Throttle Signal
W 0.8 TXL
RTHP, Throttle Pedal
3
BTM+E, Cab BTTOM
3
Low Idle Sw
W 0.8 TXL
ENG_B, Cab BTTOM
6
EDC7, Engine Controller
48
24L A Low Idle Sw
W 0.8 TXL
RTHP, Throttle Pedal
6
BTM_E, Cab BTTOM
6
Throttle Grnd
W 0.8 TXL
ENG_B, Cab BTTOM
4
EDC7, Engine Controller
78
24R A Throttle Grnd
W 0.8 TXL
RTHP, Throttle Pedal
4
BTM_E, Cab BTTOM
4
Throttle Supply
W 0.8 TXL
ENG_B, Cab BTTOM
5
EDC7, Engine Controller
77
24S A Throttle Supply
W 0.8 TXL
RTHP, Throttle Pedal
5
BTM_E, Cab BTTOM
5
24T B TC Lockup SOL GND
LU 1.0 SXL
TRANS, Cab Transmission
25
YLS, TC_Lockup_Valve
2
255E
Pedal Sensor +5V
K 0.8 TXL
BTM_C, Cab Bottom Bulkhd
E
BPP, Pedal Position
5
25A
Eng Speed Sig
LU 0.8 GXL Twist
TRANS, Cab Transmission
7
ESS, Engine speed Sensor
1
25A A Eng Speed Sig
LU 0.8 TXL
TECM, Trans
19
Cab+T, Cab-Transmission
7
Int Speed Sig
LU 0.8 GXL Twist
TRANS, Cab Transmission
9
ISS, Int Speed Sensor
1
25B A Int Speed Sig
LU 0.8 TXL
TECM, Trans
42
Cab+T, Cab-Transmission
9
Turbine Speed Sig
LU 0.8 GXL Twist
TRANS, Cab Transmission
8
TSS, Turbine Speed Sensor
1
25C A Turbine Speed Sig
LU 0.8 TXL
TECM, Trans
41
Cab+T, Cab-Transmission
8
Output Speed Sig
LU 1.0 SXL
TRANS, Cab Transmission
10
OSS, Output Speed Sensor
2
25D A Output Speed Sig
LU 0.8 TXL
TECM, Trans
62
Cab+T, Cab-Transmission
10
LU 0.8 TXL
TS1, Transmission Shifter
B
TECM, Trans
43
24L
24R
24S
25B
25C
25D
25F
Forward Signal
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 25G
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
LU 1.0 SXL
Trans, Transmission-Cab
14
PBD, Declutch Pressure Switch
B
25G A Brake Declutch Switch CTRL
LU 0.8 GXL
CAB-T, Cab Transmission
14
SPL-DC, Ultrasonic
A
25G B Brake Declutch Switch CTRL
LU 0.8 GXL
SDC, Declutch Switch
1
SPL-DC, Ultrasonic
A
25G C Brake Declutch Switch CTRL
LU 0.8 TXL
SPL-DC, Ultrasonic
A
TECM, Trans
66
Brake Declutch Switch
25H
Trans Auto Signal
LU 0.8 TXL
STA, Trans Auto Switch
3
TECM, Trans
29
25J
Trans Sol Valve Y6
LU 0.8 TXL
TRANS, Cab Transmission
21
TRC, Trans Control
6
25J A Trans Sol Valve Y6
LU 0.8 TXL
CAB-T, Cab Transmission
21
TECM, Trans
51
Trans Sol Valve Y1
LU 0.8 TXL
TRANS, Cab Transmission
16
TRC, Trans Control
1
25K 9 Trans Sol Valve Y2
LU 0.8 TXL
TRANS, Cab Transmission
16
TRC, Trans Control
2
25K A Trans Sol Valve Y1
LU 0.8 TXL
CAB-T, Cab Transmission
16
TECM, Trans
56
25K
25L
Trans Sol Valve Y2
LU 0.8 TXL
TRANS, Cab Transmission
17
TRC, Trans Control
2
25L 9
Trans Sol Valve Y1
LU 0.8 TXL
TRANS, Cab Transmission
17
TRC, Trans Control
1
25L A Trans Sol Valve Y2
LU 0.8 TXL
CAB-T, Cab Transmission
17
TECM, Trans
10
25M
Trans Sol Valve Y3
LU 0.8 TXL
TRANS, Cab Transmission
18
TRC, Trans Control
3
25M A Trans Sol Valve Y3
LU 0.8 TXL
CAB-T, Cab Transmission
18
TECM, Trans
32
Trans Sol Valve Y4
LU 0.8 TXL
TRANS, Cab Transmission
19
TRC, Trans Control
4
25N A Trans Sol Valve Y4
LU 0.8 TXL
CAB-T, Cab Transmission
19
TECM, Trans
55
Trans Sol Valve Y5
LU 0.8 TXL
TRANS, Cab Transmission
20
TRC, Trans Control
5
25P A Trans Sol Valve Y5
LU 0.8 TXL
CAB-T, Cab Transmission
20
TECM, Trans
9
Reverse Signal
LU 0.8 TXL
TS1, Transmission Shifter
C
TECM, Trans
64
25R A TC Lockup SOL Power
LU 0.8 TXL
TECM, Trans
50
CAB_T, Cab-Transmission
15
25R B TC Lockup SOL Power
LU 1.0 SXL
Trans, Transmission-CAB
15
YLS, TC_Lockup_Valve
1
Output Sw Power VPS1
LU 0.8 TXL
TRANS, Cab Transmission
22
TRC, Transmission Control
7
25S A Output Sw Power VPS1
LU 0.8 TXL
CAB-T, Cab Transmission
22
SPL D12, Ultrasonic
A
25S B Output Sw Power VPS1
LU 0.8 TXL
SPL D12 Ultrasonic
A
TECM, Trans
12
25S C Output Sw Power VPS1
LU 0.8 TXL
SPL D12 Ultrasonic
A
TECM, Trans
13
Neutral Signal
LU 0.8 GXL
SPL-NEU, Ultrasonic
A
ECB, Elect Center B
D3
25T A TC Lockup SOL GND
W 0.8 TXL
SPL_D19, Ultrasonic
A
CAB_T, Cab-Transmission
25
25T B Neutral Signal
LU 0.8 GXL
TS1, Transmission Shifter
D
SPL-NEU, Ultrasonic
A
25T C Neutral Signal
LU 0.8 TXL
SPL-NEU, Ultrasonic
A
TECM, Trans
67
25W
LU 0.8 TXL
TS2, Transmission Shifter
B
TECM, Trans
65
25N
25P
25R
25S
25T
3rd And 4th Gear Signal
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 25Y
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
Trans Kick Down Signal
LU 0.8 GXL
TS2, Transmission Shifter
D
SPL D11, Ultrasonic
A
25Y A Trans Kick Down Signal
LU 0.8 TXL
SPL D11, Ultrasonic
A
TECM, Trans
22
25Y B Trans Kick Down Signal
LU 0.8 GXL
197F, Main Cab FNR
6
SPL D11, Ultrasonic
A
25Y C Trans Kick Down Signal
LU 0.8 GXL
20M, Trans Kick Down
2
197M, FNR Main Cab
6
25Y D Trans Kick Down Signal
LU 0.8 GXL
KD_Diode, Diode ASSY
C
JSS_197M, FNR-Main_Cab
6
25Y E Trans Kick Down Signal
LU 0.8 GXL
CAB_FNR, Main_Cab_Fnr
6
KD_Diode, Diode ASSY
B
25Y F Trans Kick Down Signal
LU 0.8 GXL
KD_Diode, Diode ASSY
A
JSS_197F, Main_Cab_Fnr
6
25Y G Trans Kick Down Signal
LU 0.8 SXL
21M, Trans_Kick-Down
2
ARM_FNR, Fnr-Main_Cab
6
LU 0.8 TXL
TS2, Transmission Shifter
C
TECM, Trans
63
26E A Trans Enable Signal
LU 0.8 TXL
STE, Trans Enable Switch
3
TECM, Trans
31
26F A FNR Forward Signal
LU 0.8 GXL
197M, FNR Main Cab
2
SFNR, FNR Switch
6
26F B FNR Forward Signal
LU 0.8 TXL
197F, Main Cab FNR
2
TECM, Trans
20
26F C FNR Forward Signal
LU 0.8 GXL
FWD_DIODE, Diode ASSY
C
JSS_197M, FNR-Main_Cab
2
26F D FNR Forward Signal
LU 0.8 GXL
JSS_197F, Main_Cab_Fnr
2
FWD_DIODE, Diode ASSY
A
26F E FNR Forward Signal
LU 0.8 GXL
CAB_FNR, Main_Cab_Fnr
2
FWD_DIODE, Diode ASSY
B
26F F FNR Forward Signal
LU 0.8 GXL
SAJ, FNR_Switch
6
ARM_FNR, FNR-Main_Cab
2
25Z
1st And 4th Gear Signal
26J
FNR Switch Jumper
LU 0.8 GXL
SFNR, FNR Switch
2
SFNR, FNR Switch
4
26K
FNR Switch Jumper
LU 0.8 GXL
SAJ, FNR_Switch
2
SAJ, FNR_Switch
4
26N A FNR Neutral Signal
LU 0.8 GXL
SFNR, FNR Switch
3
197M, FNR Main Cab
3
26N B FNR Neutral Signal
LU 0.8 TXL
197F, Main Cab FNR
3
TECM, Trans
44
26N C FNR Neutral Signal
LU 0.8 GXL
JSS_197M, FNR-Main_Cab
3
NTRL_DIODE, Diode ASSY
C
26N D FNR Neutral Signal
LU 0.8 GXL
JSS_197F, Main_Cab_Fnr
3
NTRL_DIODE, Diode ASSY
A
26N E FNR Neutral Signal
LU 0.8 GXL
NTRL_DIODE, Diode Assy
B
CAB_FNR, Main_Cab_Fnr
3
26N F FNR Neutral Signal
LU 0.8 GXL
SAJ, FNR_Switch
3
ARM_FNR, FNR-Main_Cab
3
26R A FNR Reverse Signal
LU 0.8 GXL
SFNR, FNR Switch
1
197M, FNR Main Cab
4
26R B FNR Reverse Signal
LU 0.8 TXL
197F, Main Cab FNR
4
TECM, Trans
30
26R D FNR Reverse Signal
LU 0.8 GXL
JSS_197F, Main_Cab_Fnr
4
RVS_DIODE, Diode ASSY
A
26R E FNR Reverse Signal
LU 0.8 GXL
CAB_FNR, Main_Cab_Fnr
4
RVS_DIODE, Diode ASSY
B
26R F FNR Reverse Signal
LU 0.8 GXL
SAJ, FNR_Switch
1
ARM_FNR, Fnr-Main_Cab
4
28F
Fuel FLTR HTR RLY CTRL
W 0.8 TXL
PRM-D2,PRM Signal
A
EDC7, Engine Controller
36
28G
Grid Heater Source Dr.
W 1.0 GXL
GHC, Grid Htr Relay
1
EDC7, Engine Controller
12
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
31A
EVGT Relay B+
Or 0.8 GXL
EVGT_4, EVGT
B
SPL_EDC4, Ultrasonic
A
31B
Filter Heater Control
Or 0.8 GXL
PRM_D2, PRM Signal
B
SPL_EDC4, Ultrasonic
A
31F
Air Filter Rest Sw Signal
Y 1.0 SXL
ENG, Engine Cab1
28
PAF, Air Filter Rest Sw
1
31F A Air Filter Rest Sw Signal
Y 0.8 TXL
CAB-E, Cab Engine
28
SW-PD, Switch Pad
5
31H
Hyd Filter Rest Sw Signal
Y 1.0 SXL
TRANS, Cab Transmission
23
PHF, Hyd Oil Filter Rest Sw
1
31H9
HYD FLTR RST SW 9
Y 1.0 SXL
TRANS, Cab Transmission
23
PHF9, HYD_FLTR_RES_SW
2
Y 0.8 TXL
SW-PD, Switch Pad
4
CAB-T, Cab Transmission
23
31H A Hyd Filter Rest Sw Signal 31L
Pilot Control Switch High
Y 0.8 TXL
SPC, Pilot Control Switch
3
AIC-2, Advance Instr Cluster 2
18
32F
Trans Filter Maint Sw
Y 1.0 SXL
TRANS, Cab Transmission
31
FM, Filter Maint Sw
1
32F A Trans Filter Maint Sw
Y 0.8 TXL
CAB-T, Cab Transmission
31
TECM, Trans
17
32J A Trans Enable Indiction
Y 0.8 GXL
SFNR, FNR Switch
7
197M FNR Main Cab
5
32J C Trans Enable Indiction
Y 0.8 GXL
STE, Trans Enable Switch
9
SPL-D16, Ultrasonic
A
32J D Trans Enable Indiction
Y 0.8 TXL
SPL-D16, Ultrasonic
A
TECM, Trans
5
32J E Trans Enable Indiction
Y 0.8 GXL
197F, Main Cab FNR
5
SPL-D16, Ultrasonic
A
32J F
Trans Enable Indiction
Y 0.8 GXL
SPL_JSS_21, Ultrasonic
A
JSS_197M, FNR-Main_Cab
5
32J G Trans Enable Indiction
Y 0.8 GXL
JSS_197F, Main_Cab_Fnr
5
SPL_JSS_21, Ultrasonic
A
32J H Trans Enable Indiction
Y 0.8 GXL
CAB_FNR, Main_Cab_Fnr
5
SPL_JSS_21, Ultrasonic
A
32J J
Trans Enable Indiction
Y 0.8 GXL
SAJ, FNR_Switch
7
ARM_FNR, Fnr-Main_Cab
5
33P
Brake Warning Press Low
Y 1.0 SXL
BTM_C, Cab Bottom Bulkhd
L
PBW, Brake Warning Press Sw
1
33P A Brake Warning Press Low
Y 0.8 TXL
CAB_B, Cab BTM Bulkhd
L
AIC-2, Advance Instr Cluster 2
5
33R
Redundant Brake Accumulator Pressure Low
Y 0.8 TXL
CAB-T, Cab Transmission
1
AIC-2, Advance Instr Cluster 2
4
33R A
Redundant Brake Accumulator Pressure Low
Y 1.0 SXL
TRANS, Cab Transmission
1
SPL-RD, Ultrasonic
A
33R B Redundant Brake Accumulator Pressure Low
Y 1.0 SXL
SPL-RD, Ultrasonic
A
PRB2, Redundant Brake Switch
A
33R C Redundant Brake Accumulator Pressure Low
Y 1.0 SXL
SPL-RD, Ultrasonic
A
PRB1, Redundant Brake Switch
A
Y 0.8 TXL
SPB, Parking Brake Switch
3
AIC-2, Advance Instr Cluster 2
6
34A A Diff Lock SW B+
Or 0.8 GXL
SDA, Diff Lock Switch
2
SPL_PBS, Ultrasonic
A
34A B Diff Lock SW SIG B+
Or 0.8 GXL
SDA, Diff Lock Switch
2
SPL_PBS, Ultrasonic
A
34A C Diff Lock SOL B+
W 0.8 TXL
SPL_D19, Ultrasonic
A
CAB_T, Cab-Transmission
2
33U
Parking Brake Switch
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
34A D Diff Lock SOL B+
Or 1.0 SXL
TRANS, Transmission-Cab
27
YDL, Diff Lock Solenoid
1
34A E Diff Lock SOL B+
Or 1.0 SXL
YDL_1, Diff Lock Solenoid
1
YDL_2, Diff Lock Solenoid
1
34B
Diff Lock SW SIG
LU 0.8 TXL
SDA, Diff Lock Switch
3
TECM, Trans
35
34C
Diff Lock SOL GND
LU 0.8 TXL
TECM, Trans
11
CAB_T, Cab-Transmission
27
34C A Diff Lock SOL GND
LU 1.0 SXL
TRANS, Transmission-Cab
2
YDL, Diff Lock Solenoid
2
34C D Diff Lock SOL GND
LU 1.0 SXL
YDL_1, Diff Lock Solenoid
2
YDL_2, Diff Lock Solenoid
2
LU 0.8 TXL
TECM, Trans
59
SDM, Diff Lock Switch
1
35A 9 Backup Alarm RLY OUT
Bk 1.0 SXL
HD-9, Hood to Engine
7
BU2, Backup_Alarm
1
35A A Backup Alarm
Y 0.8 GXL
SPL_35A, Ultrasonic
A
ECD, Elect Control D
AA9
35A B Backup Alarm Disable Switch
Y 0.8 GXL
SBU, Backup Alarm Dis Sw
2
SPL_35A, Ultrasonic
A
35A C Backup Alarm Relay Out
Y 0.8 GXL
SPL_35A, Ultrasonic
A
CABE2, Cab to Eng2 Bulkhd
L
35A D Backup Alarm Relay Out
Y 0.8 GXL
209M, Backup Alarm Dis Jump
A
SPL_35A, Ultrasonic
A
35A E Backup Alarm Relay Out
Y 0.8 SXL
209F, Backup Alarm Dis Jump
1
SPL-D8-C1, Ultrasonic
A
35A F Backup Alarm Relay Out
Y 0.8 SXL
CABE2, Cab to Eng2 Bulkhd
K
SPL-D8-C1, Ultrasonic
A
35A G Backup Alarm Relay Out
Y 0.8 SXL
ENG2, Eng Bulkhd 2
K
E-HD, Trans Hood
B
Backup Alarm Relay Out
Y 1.0 SXL
ENG2, Eng Bulkhd 2
K
ENG-H, Engine to Hood
7
35A H Backup Alarm Relay Out
Y 1.0 SXL
HD-E, Hood Trans
B
BU2, Backup Alarm
1
Y 1.0 SXL
HD-N, Hood to Engine
7
BU2, Backup Alarm
1
35A J Reverse Light
K 1.0 SXL
ENG2, Eng Bulkhd 2
L
SPL-A1A, Ultrasonic
A
35A K Reverse Light
K 1.0 SXL
SPL-A1A, Ultrasonic
A
LRR-E, RH rear Comb Light
4
35A L Reverse Light
K 1.0 SXL
SPL-A1A, Ultrasonic
A
LLR-E, LH rear Comb Light
4
35A M Reverse Signal
K 1.0 SXL
SPL-35A, Ultrasonic
A
MON, Camera/Monitor
3
35A N Reverse Light
K 1.0 SXL
SPL-REV
A
LLR-9, LH Rear Comb Light
4
35A O Reverse Light
K 1.0 SXL
HD_9, Hood to Eng
8
SPL_REV
A
35A P Reverse Light
K 1.0 SXL
LRR-9, RH rear Comb Light
4
SPL-REV
A
35A R Backup Alarm Relay Out
Y 1.0 SXL
ENG2, Eng Bulkhd 2
L
ENG-H, Engine to Hood
8
34D
35A GN
35A HN
Diff Lock SW SIG
Backup Alarm Relay Out
35B
AIC Buzzer HSD
W 0.8 TXL
BUZ, AIC Buzzer
1
AIC-1, Advance Instr Cluster 1
13
35C
Backup Alarm Relay Control
Y 0.8 TXL
TECM, Trans
7
ECD, Elect Center D
A9
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
35R C Backup Alarm Sw
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
Y 0.8 GXL
SBU, Backup Alarm Dis Sw
1
SPL-D8-C1, Ultrasonic
A
35W
Water In Fuel Indicator
W 0.8 TXL
WIF, Water In Fuel Sensor
1
EDC7, Engine Controller
42
35X
Sec. Str Low Press Sig
Y 0.8 TXL
CAB-T, Cab Transmission
6
AIC-2, Advance Instr Cluster 2
11
35X A Sec. Str Low Press Sig
Y 1.0 SXL
SPL-C3, Ultrasonic
A
PSS, Sec. Steering Press Sw
C
35X B Sec. Str Low Press Sig
Y 1.0 SXL
TRANS, Cab Transmission
6
TR-SS, Sec. Steering Mod Option
C
35X C Sec. Str Low Press Sig
Y 1.0 SXL
SPL-C3, Ultrasonic
A
SS-TR, SS Module Trans
C
35X D Sec. Str Low Press Sig
Y 1.0 SXL
SSM, Sec. Steering Module
8
SPL-C3, Ultrasonic
A
Radiator Cool Temp Signal
P 1.0 SXL
ENG, Engine Cab1
5
RECT, Engine Coolant Temp
A
36C A Radiator Cool Temp Signal
P 0.8 TXL
CAB-E, Cab Engine
5
AIC-1, Advance Instr Cluster 1
11
Fuel Level Analog
P 1.0 SXL
ENG, Engine Cab1
1
RFL, Fuel Sender
1
36F A Fuel Level Analog
P 0.8 TXL
CAB-E, Cab Engine
1
AIC-1, Advance Instr Cluster 1
2
Torque Conv Output Temp Signal
P 1.0 SXL
TRANS, Cab Transmission
13
TCOT, TCO Sender
1
36G A Torque Conv Output Temp Signal
P 0.8 TXL
CAB-T, Cab Transmission
13
TECM, Trans
49
Hydraulic Oil Temp
P 1.0 SXL
TRANS, Cab Transmission
30
HOT, Hydraulic Oil Temp Sender
A
36H A Hydraulic Oil Temp
P 0.8 TXL
CAB-T, Cab Transmission
30
AIC-1, Advance Instr Cluster 1
9
Fuel Level Analog
P 1.0 SXL
ENG, Engine-Cab1
1
RFL_23, Fuel_Level_Send
A
36R A Trans Temps/Filter Return
P 1.0 SXL
TRANS, Cab Transmission
12
SPL H1, Ultrasonic
A
36R B Trans Filter Maint Sw Return
P 1.0 SXL
SPL H1, Ultrasonic
A
FM, Filter Maint Switch
2
36R C Valve Body Temp Return
P 0.8 TXL
SPL H1, Ultrasonic
A
TRC, Trans Control
9
36R D TCO Temp Return
P 1.0 SXL
SPL H1, Ultrasonic
A
TCOT, TCO Sender
2
36R E Trans Temps/Filter Return
P 0.8 TXL
CAB-T, Cab Transmission
12
TECM, Trans
46
Valve Body Temp Sig
P 0.8 TXL
TRANS, Cab Transmission
5
TRC, Trans Control
8
36T A Valve Body Temp Sig
P 0.8 TXL
CAB-T, Cab Transmission
5
TECM, Trans
39
37D A Diagnostic Signal
P 0.8 TXL
108F, Diagnostic Connector
2
TECM, Trans
15
36C
36F
36G
36H
36J
36T
37E
Diagnostic Signal Switched
P 0.8 TXL
108F, Diagnostic Connector
4
TECM, Trans
18
401B
Pedal POS Signal
Y 0.8 GXL
BTM_C, Cab Bottom Bulkhd
F
BPP, Pedal Position
4
41H A High Beam Pwr
Or 1.0 GXL
SRHSTLK, RH Stalk Switch
56a
SPL_HB, Ultrasonic
A
41H B High Beam LH Pwr
Or 0.8 GXL
SPL_HB, Ultrasonic
A
ECB, Elect Center B
A3
41H C High Beam RH Pwr
Or 0.8 GXL
SPL_HB, Ultrasonic
A
ECB, Elect Center B
A4
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
41H D High Beam 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
Or 0.8 TXL
SW-PD, Switch Pad
1
SPL_HB, Ultrasonic
A
Or 1.0 GXL
SDR, Driving Lights Switch
6
SRHSTLK, RH Stalk Switch
56
41L A Low Beam Power
Or 1.0 GXL
SRHSTLK, RH Stalk Switch
56b
SPL-LB, Ultrasonic
A
41L B Low Beam LH Power
Or 0.8 GXL
SPL-LB, Ultrasonic
A
ECB, Elect Center B
A6
41L C Low Beam RH Power
Or 0.8 GXL
SPL-LB, Ultrasonic
A
ECB, Elect Center B
A5
K 1.0 GXL
SDR, Driving Lights Switch
3
SPL_PR, Ultrasonic
A
41T A Position Lights RH Switched Pwr K 1.0 GXL
SPL_PR, Ultrasonic
A
ECB, Elect Center B
A8
41T B Position Lights LH Switched Pwr K 1.0 GXL
SPL_PR, Ultrasonic
A
ECB, Elect Center B
A7
41T C Position Lights Switched Pwr
K 1.0 GXL
D-OR, Diode OR
B
SPL_PR, Ultrasonic
A
42C A Front Work Lights Fused Pwr
DU 2.0 GXL
CAB-RF, Cab to Roof Conn.
H
SPL_42C, Ultrasonic
A
42C C Front Work Lights Fused Pwr
DU 2.0 GXL
SPL_42C, Ultrasonic
A
SWL, Work Lights SW
3
42C D Front Work Lights Fused Pwr
DU 1.0 GXL
SPL_42C, Ultrasonic
A
D-OR, Diode OR
A
42C F Front Work Lights Fused Pwr
DU 2.0 GXL
ROOF, Roof to Cab Conn.
H
SPL-WRKF, Ultrasonic
A
42C G RH Front Work Lights Fused Pwr DU 1.0 GXL
SPL-WRKF, Ultrasonic
A
LRFW, RH Front Work Light
1
42C H LH Front Work Lights Fused Pwr DU 1.0 GXL
SPL-WRKF, Ultrasonic
A
LLFW, LH Front Work Light
1
42R A RH Front Work Lights Fuse Pwr
DU 1.0 GXL
LRFS, Front_WK_LT_OPT
1
SPL_WRK1, Ultrasonic
A
42R B RH Front Work Lights Fuse Pwr
DU 1.0 GXL
SPL_WRK1, Ultrasonic
A
LRFR, Front_WK_LT_OPT
1
42R C Rear Work Lights Fused Pwr
DU 2.0 GXL
CAB-RF, Cab to Roof Conn.
S
SWL, Work Lights SW
6
42R F Rear Work Lights Fused Pwr
DU 2.0 GXL
ROOF, Roof to Cab Conn.
S
SPL-WRKR, Ultrasonic
A
42R G RH Rear Work Lt Fused Pwr
DU 1.0 GXL
SPL-WRKR, Ultrasonic
A
LRRW, RH Rear Work Light
1
42R H LH Rear Work Lt Fused Pwr
DU 1.0 GXL
SPL-WRKR, Ultrasonic
A
LLRW, LH Rear Work Light
1
42R K RH Front Work Lights Fuse Pwr
DU 1.0 GXL
SPL_WRK1, Ultrasonic
A
LRFO, Front_WK_LT_OPT
1
41J
41T
Driving Light Power
Position Lights Switched Pwr
42 A
Work Lights Fused Power
R 2.0 GXL
SWL, Work Lights Switch
2
SPL-WL, Ultrasonic
A
42 B
Work Lights Fused Power
R 1.0 GXL
SWL, Work Lights Switch
5
SPL-WL, Ultrasonic
A
43S A Door Open Signal
W 0.8 GXL
CAB-RF, Cab to Roof Conn.
R
AIC_2, ADV Instr Cluster 2
2
43S B Door Open Signal
W 0.8 GXL
ROOF, Roof to Cab Conn.
R
DS, Door Switch
B
43 A
Dome Light Auto Mode
DU 0.8 TXL
CAB-RF, Cab to Roof Conn.
C
AIC-1, Adv Instrument Cluster 1
7
43 B
Dome Light Auto Mode
DU 0.8 GXL
ROOF, Roof to Cab Conn.
C
LDM2, Dome Light Auto
1
44A A Brake Light Relay Out
T 0.8 GXL
CABE2, Cab to Eng2 Bulkhd
S
ECD, Elect CNTR D
AA1
44A D Brake Light Relay Out
T 1.0 SXL
ENG2, Eng Bulkhd2
S
SPL-B8, Ultrasonic
A
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 44A DN
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
Brake Light Relay Out
T 1.0 SXL
ENG2, Eng Bulkhd2
S
ENG-H, Engine to Hood
2
44A E Brake Light Relay Out
T 1.0 SXL
LLR-E, LH Rear Comb Light
1
SPL-B8, Ultrasonic
A
Brake Light Relay Out
T 1.0 SXL
HD-N, Hood to Engine
2
SPL-J2-N, Ultrasonic
A
44A F Brake Light Relay Out
T 1.0 SXL
LRR-E, RH Rear Comb Light
1
SPL-B8, Ultrasonic
A
44A EN
44A FN
Brake Light Relay Out
T 1.0 SXL
LLR-N, LH Rear Comb Light
2
SPL-J2-N, Ultrasonic
A
44A GN
Brake Light Relay Out
T 1.0 SXL
LRR-N, RH Rear Comb Light
2
SPL-J2-N, Ultrasonic
A
44A J Brake Light Relay Out
T 1.0 SXL
SPL-L1
A
HD-9, Hood to Engine
2
44A K Brake Light Relay Out
T 1.0 SXL
SPL-L1
A
LRR-9, RH Rear Comb Light
1
44A L Brake Light Relay Out
T 1.0 SXL
LLR-9, LH Rear Comb Light
1
SPL-L1
A
44 A
T 0.8 GXL
CAB-B, Cab BTM Bulkhd
J
ECD, Elec CNTR D
45A A Left Turn Switch Power
N 0.8 GXL
FLSHR, Flasher Module
9
SRHSTLK, RH Stalk Switch
L
45B A Right Turn Switch Power
N 0.8 GXL
FLSHR, Flasher Module
10
SRHSTLK, RH Stalk Switch
R
Brake Light Control Power
AA2
45H
Hazard Switch Power
N 0.8 GXL
FLSHR, Flasher Module
11
SHZ, Hazard Switch
3
45L
Left Turn Signal
N 1.0 SXL
FRONT, Cab Front Chassis
2
LLF, Lights LH
5
45L A Left Turn Signal
N 1.0 SXL
ENG2, Eng Bulkhd 2
R
LLR-E, LH Rear Comb Light
2
45L AN Left Turn Signal
N 1.0 SXL
ENG2, Eng Bulkhd 2
R
ENG-H, Engine to Hood
3
45L B Left Turn Signal
N 0.8 GXL
CABE2, Cab to Eng2 Bulkhd
R
SPL-PK3, Splice 3-4 Way
D
45L BN Left Turn Signal
N 1.0 SXL
HD-N, Hood to Engine
3
LLR, LH Rear Comb Light
4
45L C Left Turn Signal
N 0.8 GXL
CAB-F, Cab Front Chassis
2
SPL-PK3, Splice 3-4 Way
C
45L D Left Turn Signal
N 0.8 GXL
FLSHR, Flasher Module
8
SPL-PK3, Splice 3-4 Way
B
45L E Left Turn Signal
N 0.8 TXL
SPL-PK3, Splice 3-4 Way
A
AIC-2, Adv Instrument Cluster 2
9
45L N Left Turn Signal
N 1.0 SXL
HD_9, Hood to Eng
3
LLR_9, LH_Rear_Comb_LT
2
45N A Flasher OPP Side Control
N 0.8 GXL
FLSHR, Flasher Module
2
64F, Flasher Connector
1
45N B Flasher OPP Side Control
N 0.8 GXL
FLSHR, Flasher Module
12
64M, Flasher Connector
1
Right Turn Signal
N 1.0 SXL
FRONT, Cab Front Chassis
3
LRF, Lights RH
5
45R 9 Right Turn Signal
N 1.0 SXL
HD-9, Hood to Engine
4
LRR-9, RH Rear Comb Light
2
45R A Right Turn Signal
N 1.0 SXL
ENG2, Eng Bulkhd 2
P
LRR-E, RH Rear Comb Light
2
45R
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 45R AN
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
Right Turn Signal
N 1.0 SXL
ENG2, Eng Bulkhd 2
P
ENG-H, Engine to Hood
4
45R B Right Turn Signal
N 0.8 GXL
CABE2, Cab to Eng2 Bulkhd
P
SPL-PK3, Splice 3-4 Way
H
Right Turn Signal
N 1.0 SXL
HD-N, Hood to Engine
4
LRR, RH Rear Comb Light
C
45R C Right Turn Signal
N 0.8 TXL
SPL-PK3, Splice 3-4 Way
E
AIC-2, Adv Instrument Cluster 2
10
45R D Right Turn Signal
N 0.8 GXL
CAB-F, Cab Front Chassis
3
SPL-PK3, Splice 3-4 Way
G
45R E Right Turn Signal
N 0.8 GXL
FLSHR, Flasher Module
7
SPL-PK3, Splice 3-4 Way
F
46 C
Beacon Switched Power
K 1.0 GXL
CAB-RF, Cab to Roof Conn.
E
SBE, Beacon Switch
3
46 D
Beacon Switched Power
K 1.0 GXL
ROOF, Roof to Cab Conn.
E
LBEPWR, Light Beacon power
1
49A
Back Light Power
S 0.8 GXL
HVAC1, HVAC1
3
SPL-BCK-LGT, Spl Back Lgt Pwr
F
49S
Back Light Power
S 0.8 GXL
STA, Trans Auto Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
J
49 A
Back Light Power
S 0.8 GXL
SWL, Work Lights Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
M
49 B
Back Light Power
S 0.8 GXL
SBE, Beacon Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
L
49 C
Back Light Power
S 0.8 GXL
SRWP, Rear Wiper Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
C
49 D
Back Light Power
S 0.8 GXL
SHZ, Hazard SWitch
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
C
49 E
Back Light Power
S 0.8 GXL
SPL-BCK-LGT2, Spl Back Lgt Pwr
A
SPL-BCK-LGT, Spl Back Lgt Pwr
K
49 F
Back Light Power
S 0.8 GXL
SPE, Pin Engage Switch
10
SPL-BCK-LGT2, Spl Back Lgt Pwr
F
49 G
Back Light Power
S 0.8 GXL
SRC, Ride control Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
K
49 H
Back Light Power
S 0.8 GXL
STE, Trans Enable Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
D
49 J
Back Light Power
S 0.8 GXL
SRTD, Detent Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
C
49 K
Back Light Power
S 0.8 GXL
SFL, Return to Travel Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
E
49 L
Back Light Power
S 0.8 GXL
SBU, Back Up Alarm Dis Sw
8
SPL-BCK-LGT, Spl Back Lgt Pwr
E
49 M
Back Light Power
S 0.8 GXL
SHC, Height Control Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
D
49 N
Back Light Power
S 0.8 GXL
SPC, Pilot Control Switch
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
B
49 P
Back Light Power
S 0.8 GXL
SDR, Driving Lights Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
G
45R BN
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
49 Q
Back Light Power
S 0.8 GXL
SFC, Fan Control Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
G
49 R
Back Light Power
S 0.8 GXL
SDC, Declutch Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
H
49 S
Back Light Power
S 0.8 GXL
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
F
SPL-BCK-LGT2, Spl Back Lgt Pwr
M
49 T
Back Light Power
S 0.8 GXL
SFWW, Front Wiper/Washer
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
H
49 V
Back Light Power
S 0.8 GXL
SPB, Parking Brake Switch
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
E
49 W
JSS Backlight
S 0.8 GXL
SJS, Joystick_Control_SW
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
A
49 X
Back Light AIC
S 0.8 TXL
SW_PD, Switch Pad
3
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
D
49 Z
Back Light Power
S 0.8 GXL
SPL_BCK_LGT2, Spl_Back Lgt Pwr
J
SDA, Diff Lock Switch
8
51B A JSS ACT SW
W 0.8 GXL
SPL_JSS_2, Ultrasonic
A
SJS, Joystick_Control_SW
3
51B B JSS ACT SW
W 0.8 GXL
SJS, Joystick_Control_SW
6
SPL_JSS_2, Ultrasonic
A
51B C JSS ACT SW
W 0.8 GXL
JSS_CAB, JSS Cab
5
SPL_JSS_2, Ultrasonic
A
51B D JSS ACT SW
W 1.0 SXL
CAB_ARM_FRM, Cab to Arm to Frm
5
SPL_JSS_7, Ultrasonic
A
51B E B+, JSS
W 0.8 GXL
JSS_RLY, Relay K2
86
SPL_JSS_7, Ultrasonic
A
51B G B+, JSS
W 0.8 GXL
SPL_JSS_7, Ultrasonic
A
JSS_RLY, Relay K2
87
51B H JSS ACT SW
W 0.8 GXL
SPL_JSS_7, Ultrasonic
A
CAB_ARM, Cab to Armrest
6
51B J JSS ACT SW
Bk 0.8 TXL
JSS_ARM, JSS Armrest to Cab
6
CAN_MOD_2, JSS Can Mod
1
51B K JSS Power
W 0.8 GXL
FNR_RLY, Relay K2
86
SPL_JSS_4, Ultrasonic
A
51C A JSS ACT BTN
Y 0.8 GXL
JSS_VAB, JSS Cab
10
SJS, Joystick_Control_SW
5
51C B JSS ACT BTN
Y 0.8 GXL
CAB_ARM_FRM, Cab to Arm to Frm
10
JSS_CNT, JSS Controller
13
51D A GRND, Relay CTRL
Bk 0.8 GXL
JSS_CAB, JSS Cab
4
AIC_1, ADV Instr Cluster 1
21
51D B GRND, Relay CTRL
Bk 0.8 GXL
CAB_ARM_FRM, Cab to Arm to Frm
4
JSS_RLY, Relay K2
85
51E A Armrest Lower
Or 0.8 GXL
JSS_CNT, JSS Controller
6
CAB_ARM, Cab to Armrest
3
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
51E B Armrest Lower
Or 0.8 GXL
JSS_ARM, JSS Armrest to Cab
3
ARM_POS, Arm Position
3
51F A LS Press Sw SIG
G 1.0 GXL
JSS_LS, JSS Load Sense
B
JSS_FRM, JSS Frame to Cab
A
51F B LS Press Sw
G 0.8 GXL
CAB_FRM, Cab to JSS Frame
A
JSS_CNT, JSS Controller
16
51H B Joystick Signal
Y 0.8 GXL
JSS_CNT, JSS Controller
4
CAB_ARM, Cab to Armrest
10
51H C Joystick Signal
Y 0.8 GXL
JSS_ARM, JSS Armrest to Cab
10
PVRES, JSS Joystick
T
51J A Valve Alarm
P 0.8 GXL
SPL_JSS_11, Ultrasonic
A
CAB_FRM, Cab to JSS Frame
B
51J B Valve Alarm
P 0.8 GXL
JSS_CNT, JSS Controller
12
SPL_JSS_11, Ultrasonic
A
51J C JSS Alarm
P 1.0 GXL
JSS_VALVE, JSS HYD Valve
2
JSS_FRM, JSS Frame to Cab
B
51J D Valve Alarm
P 0.8 GXL
SPL_JSS_11, Ultrasonic
A
R1, Resistor
51K B Pilot Press SW
G 0.8 GXL
CAB_FRM, Cab to JSS Frame
C
JSS_CNT, JSS Controller
8
51K C Pilot Press SW SIG
G 1.0 GXL
JSS_PIL_PR, JSS Pilot Pressure
B
JSS_FRM, JSS Frame to Cab
C
Joystick Signal
Y 1.0 GXL
JSS_VALVE, JSS HYD Valve
1
JSS_FRM, JSS Frame to Cab
D
51L A Joystick Signal
Y 0.8 GXL
JSS_CNT, JSS Controller
7
CAB_FRM, Cab to JSS Frame
D
51NC
NC Neutral SW
Bk 0.8 TXL
PVRES, JSS Joystick
W
CAN_MOD_2, JSS Can Mod
3
51NO NO Neutral SW
Y 0.8 GXL
JSS_ARM, JSS Armrest to Cab
11
PVRES, JSS Joystick
U
51NO NO Neutral SW A
P 0.8 GXL
CAB_ARM, Cab to Armrest
11
JSS_CNT, JSS Controller
14
51PW JSS Power H
W 1.0 SXL
SPL_JSS_16, Ultrasonic
A
JSS_FRM, JSS Frame to Cab
H
51PW JSS Power J
W 1.0 SXL
JSS_LS, JSS Load Sense
A
SPL_JSS_16, Ultrasonic
A
51PW JSS Power K
W 1.0 SXL
SPL_JSS_16, Ultrasonic
A
JSS_PIL_DUMP, JSS Pilot Dump
1
51PW JSS Power M
W 0.8 GXL
SPL_JSS_6, Ultrasonic
A
CAB_ARM_FRM, Cab to Arm to Frm
9
51PW JSS Power N
W 0.8 GXL
JSS_CAB, JSS Cab
9
SJS, Joystick_Control_SW
10
51PW JSS Power P
W 0.8 GXL
JSS_RLY, Relay K2
30
SPL_JSS_4, Ultrasonic
A
51L
CS0
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
51PW JSS Power Q
W 0.8 GXL
JSS_CNT, JSS Controller
9
SPL_JSS_4, Ultrasonic
A
51PW JSS Power R
W 0.8 GXL
SPL_JSS_6, Ultrasonic
A
CAB_ARM, Cab to Armrest
8
51PW JSS Power S
W 0.8 GXL
SPL_JSS_13, Ultrasonic
A
JSS_ARM, JSS Armrest to Cab
8
51PW JSS Power T
W 0.8 GXL
SPL_JSS_6, Ultrasonic
A
CAB_FRM, Cab to JSS Frame
H
51PW JSS Power U
Bk 0.8 TXL
SPL_JSS_13, Ultrasonic
A
CAN_MOD_2, JSS Can Mod
2
51PW JSS Power V
W 0.8 GXL
SPL_JSS_13, Ultrasonic
A
PVRES, JSS Joystick
S
51PW JSS Power W
W 0.8 GXL
SPL_JSS_6, Ultrasonic
A
SPL_JSS_4, Ultrasonic
A
51P A SEC STR High Press
W 1.0 SXL
SSM, SEC STR MOD
9
PSS, Sec Str Press Switch
A
Bk 0.8 TXL
ARM_POS, Arm Position
2
CAN_MOD_2, JSS Can Mod
5
51S A JSS Okay PWR
W 0.8 GXL
JSS_CNT, JSS Controller
5
SPL_JSS_5, Ultrasonic
A
51S B JSS Okay PWR
W 0.8 GXL
CAB_ARM, Cab to Armrest
9
SPL_JSS_5, Ultrasonic
A
51S C JSS Okay PWR
W 0.8 GXL
SPL_JSS_15, Ultrasonic
A
JSS_ARM, JSS Armrest to Cab
9
51S D JSS Okay PWR
Bk 0.8 TXL
CAN_MOD_2, JSS Can Mod
4
SPL_JSS_15, Ultrasonic
A
51S E JSS Okay PWR
W 0.8 GXL
PVRES, JSS Joystick
R
SPL_JSS_15, Ultrasonic
A
51S F JSS Okay PWR
W 0.8 GXL
CAB_FRM, Cab to JSS Frame
F
SPL_JSS_5, Ultrasonic
A
51S J JSS Okay PWR
W 1.0 SXL
JSS_VALVE, JSS HYD Valve
4
JSS_FRM, JSS Frame to Cab
F
51 A
Sec. Str Motor Control
W 1.0 SXL
SSM, Sec. Steer Module
2
SPL-SS, Ultrasonic
A
51 B
Sec. Str Motor Control
W 1.0 SXL
SPL-SS, Ultrasonic
A
SSS, SS Mag Switch
1
51 C
Sec. Str Sol Control
W 1.0 SXL
SPL-SS, Ultrasonic
A
YSS, Sec. Steering Solenoid
1
51 D
Sec. Str Flyback
W 1.0 SXL
SSS, SS Mag Switch
1
SSD, SEC_STR_Diode
C
52AU
Fan Reverse Auto
W 0.8 TXL
SFC, Fan Control Switch
3
AIC-2, Adv Instrument Cluster 2
8
52A A Fan Reverse Relay Out
W 1.0 GXL
CAB-E, Cab Engine
22
ECB, Elect Center B
52A B Fan Reverse Relay Out
W 1.0 SXL
ENG, Engine Cab1
22
YFR, Fan Rev Solenoid Option
51R
Armrest Raise
52C
Parking Brake Solenoid LSD
W 0.8 TXL
AIC-1, Adv Instrument Cluster 1
14
ECB, Elect Center B
52J
Fan Control Switch Jumper
W 0.8 GXL
SFC, Fan Control Switch
4
SFC, Fan Control Switch
D8 1 B10 2
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
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
Wire
Circuit
52M
Fan Reverse Manual
W 0.8 TXL
SFC, Fan Control Switch
6
AIC-2, Adv Instrument Cluster 2
7
52P
Parking Brk Relay Out
W 1.0 SXL
BTM_C, Cab Bottom Bulkhd
M
YPB, Park Brake Solenoid
1
52P A Parking Brk Relay Out
W 0.8 GXL
CAB-B, Cab BTM Bulkhd
M
SPL-PTM, Ultrasonic
A
52P B Parking Brk Relay Out
W 0.8 GXL
SPL-PB, Ultrasonic
A
ECB, Elect Center B
D10
53A
RTD Switch Power
W 0.8 GXL
SRTD, Detent Switch
3
EM, RTD Height Control RTT
3
53B
RTD Signal
W 1.0 SXL
FRONT, Cab Front Chassis
12
PXF, RTD
A
53B A RTD Signal
W 1.0 SXL
PXM, RTD
A
PXT, RTD
A
53B B RTD Signal
W 0.8 GXL
EM, RTD Height Control RTT
4
CAB-F, Cab Front Chassis
12
53C A Pilot Control Solenoid LSD
W 0.8 TXL
AIC-1, Adv Instrument Cluster 1
20
ECD, Elect Center D
B6
53P A Pilot Control Relay Out
W 0.8 GXL
SPL-D25, Ultrasonic
A
YPP, Pilot Pressure Solenoid
A
53P B Pilot Control Relay Out
W 0.8 GXL
SFL, Return to Travel Switch
2
SPL-D25, Ultrasonic
A
53P C Pilot Control Relay Out
W 1.0 GXL
SPL-D25, Ultrasonic
A
ECD, Elect Center D
D6
53P D Pilot Control Relay Out
W 0.8 GXL
SHC, Height Control Switch
2
SPL-D25, Ultrasonic
A
53P E Pilot Control Relay Out
W 0.8 GXL
SRTD, Detent Switch
2
SPL-D25, Ultrasonic
A
53P F Pilot Control Relay Out
W 0.8 GXL
CAB-F, Cab Front Chassis
9
SPL-D25, Ultrasonic
A
53P G Pilot Control Relay Out
W 1.0 SXL
FRONT, Cab Front Chassis
9
SPL-A3, Ultrasonic
A
53P H Pilot Control Relay Out
W 1.0 SXL
SPL-A3, Ultrasonic
A
PXF, RTD
C
53P I
Pilot Control Relay Out
W 1.0 SXL
PXM, RTD
C
PXT, RTD
C
53P J Pilot Control Relay Out
W 1.0 SXL
SPL-A3, Ultrasonic
A
PXH, Height Control RTT
C
54A
Height Control Switch Power
W 0.8 GXL
SHC, Height Control Switch
6
EM, RTD Height Control RTT
2
54B
HC RTT Control Signal
W 1.0 SXL
FRONT, Cab Front Chassis
11
PXH, Height Control RTT
A
54B A HC RTT Control Signal
W 0.8 GXL
CAB-F, Cab Front Chassis
11
SPL-D1, Ultrasonic
A
54B B HC RTT Control Signal
W 0.8 GXL
EM, RTD Height Control RTT
5
SPL-D1, Ultrasonic
A
54B C HC RTT Control Signal
W 0.8 GXL
SFL, Return to Travel Switch
6
SPL-D1, Ultrasonic
A
55A A RTT Float Sw Power
W 0.8 GXL
EM, RTD Height Control RTT
1
SPL-RTT, Ultrasonic
A
55A B RTT Float Sw Power
W 0.8 GXL
SFL, Return to Travel Switch
1
SPL-RTT, Ultrasonic
A
55A C RTT Float Sw Power
W 0.8 GXL
SFL, Return to Travel Switch
3
SPL-RTT, Ultrasonic
A
55B
RTT Float Switch Control
W 0.8 GXL
SFL, Return to Travel Switch
5
EM, RTD Height Control RTT
6
56 A
Fan Control PWM
W 1.0 SXL
ENG, Engine Cab1
23
YFN, Fan PWM Solenoid
A
57 A
Pin Engage Sol Pwr
W 0.8 GXL
CAB-F, Cab Front Chassis
17
SPL-PINE, Ultrasonic
A
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
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
Wire
Circuit
57 B
Pin Engage Sol Pwr
W 0.8 GXL
SPE, Pin Engage Switch
1
SPL-PINE, Ultrasonic
A
57 C
Pin Engage Sol Pwr
W 0.8 TXL
SPL-PINE, Ultrasonic
A
AIC-2, Adv Instrument Cluster 2
16
57 D
Pin Engage Sol Pwr
W 1.0 SXL
YPE1, PIN Engage Jumper
A
YPE2, Pin_Engage_OPT
A
58C
Ride Control Switch Jumper
W 0.8 GXL
SRC, Ride Control Switch
5
SRC, Ride Control Switch
3
58H A Power VPS2
W 0.8 TXL
TECM, Trans
8
SPL_D19, Ultrasonic
A
58H B Power VPSL
W 0.8 TXL
SPL_D19, Ultrasonic
A
TECM, Trans
53
58H C Power
W 0.8 GXL
ECD,Elec CNTR D
D7
SPL_D19, Ultrasonic
A
58L
Ride Control Relay LSD
Bk 0.8 TXL
TECM, Trans
57
ECD, Elect Center D
B8
58T
Ride Control Relay Sw Pwr
W 0.8 GXL
SRC, Ride Control Switch
4
ECD, Elect Center D
B7
58 A
Ride Control Sol Pwr
W 1.0 SXL
202M, Rollback Jumper
A
202M, Rollback Jumper
B
58 B
Ride Control Sol Pwr
W 1.0 SXL
FRONT, Cab Front Chassis
18
PRBF, Rollback Pressure Switch
B
58 C
Ride Control Sol Pwr
W 0.8 GXL
CAB-F, Cab Front Chassis
18
SPL-D26, Ultrasonic
A
58 D
Ride Control Sol Pwr
W 0.8 GXL
140M, Diode Module
D
SPL-D26, Ultrasonic
A
58 E
Ride Control Sol Pwr
W 0.8 GXL
SPL-D26, Ultrasonic
A
ECD, Elect Center D
D8
58 F
Ride Control Sol Pwr
W 0.8 GXL
SRC, Ride Control Switch
6
SPL-D26, Ultrasonic
A
58 G
Ride Control Sol Pwr
W 1.0 SXL
Front, FRNT_CHAS_CAB
18
YRC, Ride_Control_OPT
1
58 H
Ride Control Signal
W 1.0 SXL
YRC_J, Ride CNTR_Jumper
1
YRC_J2, Ride_Control_OPT
1
59D
Hood Relay Control Down
W 1.0 GXL
CABE2, Cab to Eng2 Bulkhd
V
ECC, Elect CNTR C
D3
59D A Hood Relay Control Down
W 1.0 SXL
ENG2, Eng Bulkhd 2
V
HD, Hood Switch
A
Hood Relay Control Up
W 1.0 GXL
CABE2, Cab to Eng2 Bulkhd
X
ECC, Elect CNTR C
D1
59U A Hood Relay Control Up
W 1.0 SXL
ENG2, Eng Bulkhd 2
X
HD, Hood Switch
C
Hood Down Relay Out
W 1.0 GXL
CABE2, Cab to Eng2 Bulkhd
U
ECC, Elect CNTR C
B3
60D A Hood Down Relay Out
W 1.0 SXL
ENG2, Eng Bulkhd 2
U
HDM, Hood Lift Motor
2
Hood Up Relay Out
W 1.0 GXL
CABE2, Cab to Eng2 Bulkhd
W
ECC, Elect CNTR C
B1
60U A Hood Up Relay Out
W 1.0 SXL
ENG2, Eng Bulkhd 2
W
HDM, Hood Lift Motor
1
W 1.0 SXL
ENG, Engine Cab1
30
SPL_ACP, Ultrasonic
A
61A B Trinary Press Sw Input
W 0.8 GXL
SPL_AC, Ultrasonic
A
CAB_E, Cab-Engine
30
61A C AC Switch Input
W 1.0 SXL
SPL_ACP, Ultrasonic
A
ENG_B, Cab Bttom
8
61A D AC Switch Input
W 1.0 SXL
SPL_ACP, Ultrasonic
A
PRH, AC High Press SW
A
61A E AC Switch Input
W 1.0 SXL
PRL, AC Low Press SW
A
BTM_E, Cab Bttom
8
61A F Trinary Press Sw Input
W 0.8 GXL
HVAC1, HVAC1
1
SPL_AC Ultrasonic
A
59U
60D
60U
61A
AC Press SW input
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
61A G Trinary Press Sw Input
W 0.8 GXL
ECD, Elec CNTR D
B9
SPL_AC Ultrasonic
A
61B A AC Signal
W 0.8 GXL
HVAC1, HVAC1
4
AIC_2, ADV Instr Cluster2
12
AC Relay Out
Or 0.8 GXL
CAB-E, Cab Engine
2
ECD, Elect Center D
61C A AC Relay Out
Or 1.0 SXL
ENG, Engine Cab1
2
ACT, AC Comp Clutch
1
AC Relay Control
W 1.0 SXL
ENG, Engine Cab1
29
SPL_ACS Ultrasonic
A
61R B AC Relay Control
W 0.8 GXL
CAB-E, Cab Engine
29
ECD, Elect Center D
D9
61R C AC Switch Output
W 1.0 SXL
SPL_ACS, Ultrasonic
A
ENG_B, Cab Bttom
7
61R D AC Switch Output
W 1.0 SXL
SPL_ACS, Ultrasonic
A
PRH, AC High Press SW
B
61R E AC Switch Output
W 1.0 SXL
PRL, AC Low Press SW
B
BTM_E, Cab Bttom
7
61C
61R
C10
63C
Front Wiper Park Control
W 0.8 GXL
FWM, Front Wiper Motor
D
ECD, Elect Center D
C4
63C2
Front Wiper Park Control
W 0.8 GXL
ECD, Elect Center D
D4
ECD, Elect Center D
C2
63C3
Front Wiper Park Control
W 0.8 GXL
K-WCO, Wiper Cutout
87a
ECD, Elect Center D
B3
63HC
Front Wiper High Speed Rly Ctrl
W 0.8 GXL
SFWW, Front Wiper/Washer
9
SPL-HC, Ultrasonic
A
63HC Wiper Cutout Relay Control A
W 0.8 GXL
SPL-HC, Ultrasonic
A
K-WCO, Wiper Cutout
85
63HC Front Wiper Rly High Speed B
W 0.8 GXL
SPL-HC, Ultrasonic
A
ECD, Elect Center D
B2
63H A Front Wiper High Speed Rly Out
W 0.8 GXL
FMW, Front Wiper Motor
A
SPL-WHS, Ultrasonic
A
63H B Front Wiper Rly High Speed
W 0.8 GXL
SPL-WHS, Ultrasonic
A
ECD, Elect Center D
D2
63H C Front Wiper High Speed Rly Out
W 0.8 GXL
140M, Diode Module
A
SPL-WHS, Ultrasonic
A
63LC
Front Wiper Low Speed Rly Ctrl
W 0.8 GXL
SFWW, Front Wiper/Washer
3
ECD, Elect Center D
B4
63L A Front Wiper Low Speed Rly Out
W 0.8 GXL
FMW, Front Wiper Motor
B
SPL-WLS, Ultrasonic
A
63L B Front Wiper Low Speed Rly Out
W 0.8 GXL
K-WCO, Wiper Cutout
30
SPL-WLS, Ultrasonic
A
63L C Front Wiper Low Speed Rly Out
W 0.8 GXL
140M, Diode Module
B
SPL-WLS, Ultrasonic
A
63W
Front Washer Pump
W 0.8 GXL
CAB-E, Cab Engine
25
SFWW, Front Wiper/Washer
7
63W A Front Washer Pump
W 1.0 SXL
ENG, Engine Cab1
25
FWW, Front Washer
1
64C
Horn Relay Control
Or 0.8 GXL
SRHSTLK, RH Stalk Switch
31b
ECC, Elect CNTR C
B8
64 A
Horn Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
13
ECC, Elect CNTR C
D8
65L
Left Speaker
Or 0.8 GXL
LSPK, Left Speaker
A
SPK, Speaker
7
65R
Right Speaker
Or 0.8 GXL
RSPK, Right Speaker
A
SPK, Speaker
1
66A
RR Camera PWR
OR 0.8 GXL
ECA, Elect CNTR A
C9
MON, Camera/Monitor
1
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
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
67A
Park Brake Signl
OR 0.8 GXL
TEL, Telematics
67B
Start Lockout
OR 0.8 GXL
ECC, Elect CNTR C
68C
Rear Wiper Park Control
Or 1.0 GXL
CAB-RF, Cab to Roof Conn.
68C A Rear Wiper Park Control
Or 1.0 GXL
Rear Wiper Switch Power
K = Pink U = Blue Y = Yellow
To Connector Cav
Connector
Cav
E
SPL_PTM, Ultrasonic
A
D10
SRP, Work Lights SW
8
K
SRWP, Rear Wiper Switch
1
ROOF, Roof to Cab Conn.
K
RWM, Rear Wiper Motor
D
Or 1.0 GXL
SRWP, Rear Wiper Switch
2
SPL-3, Ultrasonic
A
68L A Rear Wiper Switch Power
Or 1.0 GXL
ROOF, Roof to Cab Conn.
L
RWM, Rear Wiper Motor
B
68L B Rear Wiper Switch Power
Or 1.0 GXL
CAB-RF, Cab to Roof Conn.
L
SPL-3, Ultrasonic
A
68L C Rear Wiper Switch Power
Or 1.0 GXL
140M, Diode Module
F
SPL-3, Ultrasonic
A
68W
Rear Washer Pump
W 0.8 GXL
CAB-E, Cab Engine
24
SRWP, Rear Wiper Switch
6
68W A Rear Washer Pump
W 1.0 SXL
ENG, Engine Cab
24
RWW, Rear Washer
1
CAN1 CAN HI H
Y 0.8 TXL twist
ENG, Engine-Cab1
14
EDC7, Engine Controller
35
G 0.8 TXL twist
ENG, Engine-Cab1
13
EDC7, Engine Controller
34
JSS_ARM, Jss Armrest to Cab
1
CAN_MOD_2, JSS Can Mod
7
CAB_ARM_FRM, Cab to Arm to Frm
12
CAB_ARM, Cab to Armrest
1
7
JSS_CNT, JSS Controller
1
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
G 0.8 TXL twist
JSS_ARM, JSS Armrest to Cab
12
CAN_MOD_2, Jss Can Mod
8
G 0.8 TXL twist
CAB_ARM, Cab to Armrest
12
CAB_ARM_FRM, Cab to Arm to Frm
1
CAB_ARM_FRM, Cab to Arm to Frm
6
JSS_CNT, Jss Controller
2
Y 0.8 TXL TWIST
ENG, Engine-Cab1
14
SPL_CAN_DH, Ultrasonic
A
Y 0.8 GXL twist
TERM_CAN_2, Can Bulk Head
B
SPL_CAN_HV, Ultrasonic
A
CANS LA CAN LO, CAN MOD2 CANS LB CAN LO, CAN MOD2 CANS LD CAN LO, CAN MOD3
CAN H CAN High CAN H2
CAN2 HI, Term
G 0.8 TXL twist
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
K = Pink U = Blue Y = Yellow
To Connector
Connector
Cav
Connector
Cav
CAN HA
CAN High
Y 0.8 TXL TWIST
SPL-CAN-JS_HI, Ultrasonic
A
SPL_CAN_GH, Ultrasonic
A
CAN HB
CAN High
Y 0.8 TXL TWIST
SPL-CAN-DIAG, Ultrasonic
A
DIA, Diagnostic
C
CAN HC
CAN High
Y 0.8 TXL TWIST
SPL-CAN-TRANS, Ultrasonic
A
SPL-CAN-DIAG, Ultrasonic
A
CAN HD
CAN High
Y 0.8 TXL TWIST
SPL-CAN-TRANS, Ultrasonic
A
TECM, Trans
25
CAN HE
CAN High
Y 0.8 TXL TWIST
SPL-CAN, Ultrasonic
A
SPL-CAN-TRANS, Ultrasonic
A
CAN HF
CAN High
Y 0.8 TXL TWIST
SW-PD, Switch Pad
7
SPL-CAN, Ultrasonic
A
CAN HG
CAN High
Y 0.8 TXL TWIST
SPL-CAN, Ultrasonic
A
AIC-1, Adv Instrument Cluster 1
3
CAN HH
CAN High
Y 0.8 TXL TWIST
SPL_CAN_TEL, Ultrasonic
A
TEL, Telematics
M
CAN HJ
CAN High
Y 0.8 TXL TWIST
SPL_CAN_TEL, Ultrasonic
A
SPL_CAN_JS_H2, Ultrasonic
A
CAN HK
CAN HI, EDC
Y 0.8 GXL twist
SPL-CAN-DH, Ultrasonic
A
EDC7, Engine Controller
35
CAN HL
CAN High
Y 0.8 TXL TWIST
SPL_CAN_TEL, Ultrasonic
A
SPL_CAN_DIAG, Ultrasonic
A
CAN HM
CAN2 HI, EDC
Y 0.8 GXL TWIST
SPL-CAN-GH, Ultrasonic
A
CAB_E, Cab-Engine
14
CAN HN
CAN High
Y 0.8 TXL TWIST
SPL_CAN_JS_HI, Ultrasonic
A
SPL_CAN_JS_H2, Ultrasonic
A
CAN HO
CAN2 HI, Diag2
Y 0.8 GXL TWIST
SPL_CAN_GH, Ultrasonic
A
DIA_2, Diagnostic
C
CAN HP
CAN HI, Can Mod2
Y 0.8 GXL TWIST
SPL_CAN_JS_HI, Ultrasonic
A
JSS_CAB, JSS Cab
12
CAN HR
CAN HI, Can Mod3
Y 0.8 GXL TWIST
SPL_CAN_JS_H2, Ultrasonic
A
JSS_CAB, JSS Cab
7
CAN HW
CAN2 HI, EVGT
Y 0.8 TXL TWIST
SPL_CAN_HV, Ultrasonic
A
Turbo, ENG Dash_Turbo
7
CAN HZ
CAN2 HI
Y 0.8 GXL TWIST
SPL_CAN_HV, Ultrasonic
A
SPL_CAN_HT, Ultrasonic
A
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
CAN L CAN Low
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
ENG, Engine-CAB1
13
SPL_CAN_DL, Ultrasonic
A
CAN L2
CAN 2 LO, TERM
G 0.8 GXL TWIST
Term_CAN_2, CAN Bluk Head
A
SPL_CAN_LV, Ultrasonic
A
CAN LA
CAN Low
G 0.8 TXL TWIST
SPL-CAN-JS-L1, Ultrasonic
A
SPL_CAN_GL, Ultrasonic
A
CAN LB
CAN Low
G 0.8 TXL TWIST
SPL-CAN-DIAG-L, Ultrasonic
A
DIA, Diagnostic
D
CAN LC
CAN Low
G 0.8 TXL TWIST
SPL-CAN-TRANS-L, Ultrasonic
A
SPL-CAN-DIAG-L, Ultrasonic
A
CAN LD
CAN Low
G 0.8 TXL TWIST
TECM, Trans
26
SPL-CAN-TRANS-L, Ultrasonic
A
CAN LE
CAN Low
G 0.8 TXL TWIST
SPL-CAN-L, Ultrasonic
A
SPL-CAN-TRANS-L, Ultrasonic
A
CAN LF
CAN Low
G 0.8 TXL TWIST
SW-PD, Switch Pad
8
SPL-CAN-L, Ultrasonic
A
CAN LG
CAN Low
G 0.8 TXL TWIST
SPL-CAN-L, Ultrasonic
A
AIC-1, Adv Instrument Cluster 1
4
CAN LH
CAN Low
G 0.8 TXL TWIST
SPL_CAN_TEL2, Ultrasonic
A
SPL_CAN_JS_L2, Ultrasonic
A
CAN LJ
CAN LO, EDC
G 0.8 GXL TWIST
EDC7, Engine Controller
34
SPL_CAN_DL, Ultrasonic
A
CAN LL
CAN2 LO, EDC
G 0.8 GXL TWIST
SPL-CAN-GL, Ultrasonic
A
CAB_E, Cab-Engine
13
CAN LM
CAN Low
G 0.8 TXL TWIST
SPL_CAN_TEL2, Ultrasonic
A
TEL, Telematics
N
CAN LP
CAN Low, Can Mod3
G 0.8 GXL TWIST
SPL_CAN_JS_L1, Ultrasonic
A
JSS_CAB, JSS Cab
1
CAN LQ
CAN Low
G 0.8 TXL TWIST
SPL_CAN_JS_L1, Ultrasonic
A
SPL_CAN_JS_L2, Ultrasonic
A
CAN LR
CAN Low, Can Mod2
G 0.8 GXL TWIST
SPL_CAN_JS_L2, Ultrasonic
A
JSS_CAB, JSS Cab
6
CAN LW
CAN LO, EVGT
G 0.8 TXL TWIST
SPL_CAN_LV, Ultrasonic
A
Turbo, Eng Dash_Turbo
1
CAN LX
CAN2 LO, Diag2
G 0.8 GXL TWIST
SPL_CAN_GL, Ultrasonic
A
DIA_2, Diagnostic
D
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
K = Pink U = Blue Y = Yellow
To Connector
Connector
Cav
Connector
Cav
CAN LY
CAN Low
G 0.8 TXL TWIST
SPL_CAN_TEL2, Ultrasonic
A
SPL_CAN_DIAG_L, Ultrasonic
A
CAN LZ
CAN 2 LO
G 0.8 GXL TWIST
SPL_CAN_LV, Ultrasonic
A
SPL_CAN_LT, Ultrasonic
A
ECC L1
Beacon/Dome Light L1 ECC
BUSS
L1-ECC, ECC Batt Power
1
ECC, Elect CNTR C
L1-1
J1
Trans ECM Power
ECA-BUSS
ECA-L1, B+ Power
cs01
ECA, Elect Center A
L1
J2
Trans ECM Power
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J3
Emergency Steer AIC Power
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J4
Emergency Steer AIC Power
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J5
Emergency Steer Plt EM Dtnts
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J6
Pltem Dtnts Park Brk Sol
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J7
Park Brake Solenoid Horn
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J8
Fan Reverse Turn Signal
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J9
Turn Signal Engine Shut Down
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J11
Blower Motor Power
ECA-BUSS
ECA, Elect Center A
L2
PRMB_L1, B+ Power
cs01
J12
Blower Motor Front Wiper Washer
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J13
Front Wiper Rear Wiper Washer
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J14
Rear Wiper Washer Backup
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J15
Backup AC
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J17
Seat Comp EMG Strtr
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J18
Diagnostic Power
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J19
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J10 ECC
BUSS
ECC, Elect Center C
L1-9
ECC, Elect Center C
L1-10
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
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
K = Pink U = Blue Y = Yellow
To Connector
Connector
Cav
Connector
Cav
J6 ECC
Delay Power Horn
ECC-BUSS
ECC, Elect Center C
L1-5
ECC, Elect Center C
L1-6
J7 ECC
Horn HOD Control
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
5
RAD-J1, Radio Power
8
RAD2 12V Fused Power to Radio
W 0.8 GXL
RAD-J3, Radio Jumper
12
RAD-J1, Radio Power
7
RAD3 12V Fused Power to Radio
W 0.8 GXL
RAD-J3, Radio Jumper
7
RAD-J1, Radio Power
4
RAD4 Left Speaker Ground
W 0.8 GXL
RAD-J3, Radio Jumper
3
RAD-J2, Speaker
8
RAD5 Left Speaker
W 0.8 GXL
RAD-J3, Radio Jumper
10
RAD-J2, Speaker
7
RAD6 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
4
RAD-J2, Speaker
6
RAD7 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
11
RAD-J2, Speaker
5
RAD8 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
2
RAD-J2, Speaker
4
RAD9 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
9
RAD-J2, Speaker
3
RAD10 Right Speaker Ground
W 0.8 GXL
RAD-J3, Radio Jumper
1
RAD-J2, Speaker
2
RAD11 Right Speaker
W 0.8 GXL
RAD-J3, Radio Jumper
8
RAD-J2, Speaker
1
4002-45
UNDERSTANDING THE TROUBLESHOOTING TABLES 1 – Alternator
1
Check Points
Correct Reading
2
Check the 10 ampere fuse at location 3 and 4C in the fuse block. Terminal for wire 1A to ground
3
Good 12 volts
4
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.
5
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.
4002-46
STARTING AND CHARGING SYSTEMS
9 3
5
8
10
2
1
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.
4002-47
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.
4002-48
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 –
4002-49
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.
4002-50
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 –
4002-51
POWER RELAY MODULES AND COLD STARTING SYSTEMS
20 21
17
16
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.
4002-52
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 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-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.
4002-53
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 –
4002-54
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.
4002-55
ENGINE CONTROLLER
24
22
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.
4002-56
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
4002-57
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.
4002-58
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE 28 30
25 26 31 32
27 29
33
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.
4002-59
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.
4002-60
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.
4002-61
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.
4002-62
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.
4002-63
PILOT CONTROL - RIDE CONTROL - FAN CONTROL
43 44
35 37 39
36
40 41
38
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.
4002-64
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.
4002-65
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).
4002-66
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.
4002-67
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.
4002-68
TRANSMISSION
46
48
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.
4002-69
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
4002-70
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE
66 62 63
67 69
65
68
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.
4002-71
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.
4002-72
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.
4002-73
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).
4002-74
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.
4002-75
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.
4002-76
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.
4002-77
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.
4002-78 ]
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).
4002-79
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).
4002-80
77 –
4002-81
BACK UP ALARM CONTROLS
79
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.
4002-82
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.
4002-83
LIGHTS - 01
87 82 85 81
83
86
88
80 84
89
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.
4002-84
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.
4002-85
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.
4002-86
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.
4002-87
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.
4002-88
LIGHTS - 02
93 94
95
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.
4002-89
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.
4002-90
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.
4002-91
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.
4002-92
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.
4002-93
LIGHTS - 03 AND HORN
96 99
97
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.
4002-94
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.
4002-95
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.
4002-96
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.
4002-97
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.
4002-98
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.
4002-99
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.
4002-100
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.
4002-101
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.
4002-102
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.
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. If machine is a TUV model, depress back-up alarm switch to turn LED ON (back-up alarm enabled). Terminal for wire 35A-H to ground
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.
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. If machine is a TUV model, depress back-up alarm switch to turn LED ON (back-up alarm enabled). Terminal for wire 35A to ground
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.
4002-103
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.
4002-104
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.
4002-105
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.
4002-106
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.
4002-107
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.
4002-108
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.
4002-109
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.
4002-110
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.
4002-111
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).
4002-112
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.
4002-113
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.
4002-114
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.
4002-115
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.
4002-116
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.
4002-117
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).
4002-118
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.
4002-119
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.
4002-120
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.
4002-121
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.
4002-122
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.
4002-123
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.
4002-124
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.
4002-125
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.
4002-126
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.
4002-127
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.
4002-128
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.
4002-129
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.
4002-130
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.
4002-131
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.
4002-132
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.
4002-133
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
4002-134
JOYSTICK STEERING/ MISC
170
RCPH10WHL094FAH
161. 162. 163. 164. 165.
166. 167. 168. 169.
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
161 – 162 – 163 – 164 – 165 – 166 – 167 – 168 – 169 – 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) Check Points
Correct Reading
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.
4002-136
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
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.
4002-137
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.
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.
4002-138
CONNECTORS CONNECTOR 108F - DIAGNOSTIC CONNECTOR
291663A1
CONNECTOR 197F - MAIN CAB FNR
CONNECTOR 140M - DIODE MODULE 225350C1
245488C1
4002-139 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
4002-140 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
4002-141 CONNECTOR AIC2 - ADV INSTRUMENT CLUSTER 2
CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH
8602417
CONNECTOR AIC1 - ADV INSTRUMENT CLUSTER 87419488
87410948
4002-142
4002-143
CONNECTOR BUZ - AIC BUZZER
222136A1
4002-144
4002-145 CONNECTOR CAB-RF - CAB TO ROOF CONNECTION
CONNECTOR CAB-T - CAB TO TRANMISSION
380839A1
388710A1
4002-146 CONNECTOR CL - CIGAR LIGHTER
3227856R1
CONNECTOR CNV - 24V TO 12V POWER CONVERTER
225351C1
4002-147 CONNECTOR DM - DIODE OR CONNECTOR D-OR - DIODE OR
245485C1
245485C1
CONNECTOR DISC - DISCONNECT ENGINE
245482C1
4002-148 CONNECTOR DNS-DRIVER
411311A1
4002-149 CONNECTOR DS - DOOR SWITCH
CONNECTOR EM - HEIGHT CONT RTT RTD
245482C1
225351C1
CONNECTOR E-HD - TRANSMISSION HOOD
245485C1
4002-150 CONNECTOR ECA - ELECTRICAL CENTER A
87315248
4002-151
4002-152 CONNECTOR ECB - ELECTRICAL CENTER B
87312843
4002-153
4002-154 CONNECTOR ECC - WORK LIGHTS
87315249
4002-155
4002-156 CONNECTOR ECD - ELECTRICAL CENTER D
87312843
4002-157
4002-158 CONNECTOR EDC7 - ENGINE CONTROLLER
BOSCH-89-POLE
4002-159 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
4002-160 CONNECTOR FLSHR - FLASHER MODULE
225389C1
CONNECTOR FM - FILTER MAINTENANCE SWITCH
CONNECTOR FWM - FRONT WIPER MOTOR
371614A1
245715C1
4002-161 CONNECTOR FWMG - FRONT WIPER MOTOR GROUND
CONNECTOR GHC - GRID HEATER RELAY
3227856R1 245480C1
CONNECTOR FWW - FRONT WASHER
3227856R1
4002-162 CONNECTOR - CAB GROUND SPLICE
87324393
CONNECTOR - SPLICE BACK LIGHT GROUND
87324393
4002-163
4002-164 CONNECTOR HD - HOOD SWITCH
245485C1
CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS
245484C1
4002-165 CONNECTOR HD-N - HOOD TO ENGINE
225319C1
CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER
194788A1
CONNECTOR HDM - HOOD LIFT MOTOR
225316C1
4002-166 CONNECTOR HVAC2 - HVAC2
87552622
CONNECTOR ISS - INT-SPEED-SENSOR
291718A1
4002-167
4002-168 CONNECTOR LLF - LH FRONT LIGHTS
CONNECTOR LLR-E - LH REAR COMBINATION LAMP
225351C1 225351C1
CONNECTOR LPL - LICENSE PLATE LAMP
245482C1
4002-169 CONNECTOR LRF - RH FRONT LAMP
CONNECTOR LRR-E - RH REAR COMBINATION LAMP
225351C1
225351C1
CONNECTOR LSPK - LEFT SPEAKER
195552A1
4002-170 CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH
291718A1
CONNECTOR OSS - OUTPUT SPEED SENSOR
291719A1
CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH
245482C1
4002-171 CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH
CONNECTOR PO1 - POWER OUTLET
222136A1 12176446
CONNECTOR PO2 - POWER OUTLET
12176446
4002-172 CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH
245483C1
4002-173 CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH
CONNECTOR PXF - RTD
245485C1 245485C1
4002-174 CONNECTOR RAD - RADIO POWER
CONNECTOR RAD-J2 - SPEAKER
292495A1
292501A1
CONNECTOR RAD-J1 - RADIO POWER
CONNECTOR RAD-J3 - RADIO JUMPER
411311A1 292497A1
4002-175 CONNECTOR RECT - ENGINE COOLANT TEMPERATURE
194788A1
CONNECTOR ROOF - ROOF TO CAB CONNECTION
388708A1
CONNECTOR RSPK - RIGHT SPEAKER
195552A1
4002-176 CONNECTOR RTHP - THROTTLE PEDAL
CONNECTOR RWMG - REAR WIPER MOTOR GROUND
225351C1 245480C1
CONNECTOR RWW - REAR WASHER
CONNECTOR RWM - REAR WIPER MOTOR
3227856R1
245715C1
4002-177 CONNECTOR S-KEY - IGNITION SWITCH TO PEDESTAL HARNESS
CONNECTOR SC - SEAT COMPRESSOR MOTOR
245482C1
225253C1
CONNECTOR SBE - BEACON SWITCH
CONNECTOR SDC - DECLUTCH SWITCH
382391A1
382391A1
4002-178 CONNECTOR SDR - DRIVING LIGHTS SWITCH
382391A1
CONNECTOR SFWW - REAR WIPER AND WASHER SWITCH
87345132
CONNECTOR SHC - HEIGHT CONTROL SWITCH
382391A1
4002-179 CONNECTOR SPK - SPEAKER
292494A1
CONNECTOR SPB - PARKING BRAKE SWITCH
382391A1
4002-180 CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT GD
87324393
CONNECTOR SPL-BCK-LGT
87324393
4002-181 CONNECTOR SPL-PED-BL - SPL BACK LIGHT POWER 6 PACK
CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
87324462 87324391
4002-182 CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY
CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER
87324462 87324393
CONNECTOR SRC - RIDE CONTROL SWITCH
382391A1
4002-183 CONNECTOR SRC-1 - STARTER RELAY
CONNECTOR SRTD - DETENT SWITCH
225316C1 382391A1
CONNECTOR SRHSTLK - RH STALK SWITCH
87318288
4002-184 CONNECTOR SS-TR - SS-MOD-TRANS
CONNECTOR STA - TRANSMISSION AUTO SWITCH
245489C1
382391A1
CONNECTOR SSM - SECONDARY STEERING MODULE
225389C1
4002-185 CONNECTOR SWL - WORK LIGHTS SWITCH
CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER
382391A1
291718A1
4002-186 CONNECTOR TECM - TRANSMISSION
411398a1
4002-187 CONNECTOR TRANS - CAB TO TRANSMISSION CONNECTOR TR-SS - SEC-STR-MOD-OPT
380838A1
245488C1
4002-188 CONNECTOR TRC - TRANSMISSION CONTROL
CONNECTOR TS2 - TRANSMISSION SHIFTER
245487C1
371566A1
CONNECTOR TSS - TURBINE SPEED SENSOR
CONNECTOR TS1 - TRANSMISSION SHIFTER 291718A1
245486C1
4002-189 CONNECTOR WF - WATER IN FUEL SENSOR
8602416
CONNECTOR WSH - WATER SEPARATOR HEATER
CONNECTOR YFN - FNA PWM SOLENOID
182069A1
256340A1
4002-190 CONNECTOR YFR - FAN REVERSING SOLENOID
225316C1
CONNECTOR YPP - PILOT PRESSURE SOLENOID
245482C1
CONNECTOR YPE - PIN ENGAGE
CONNECTOR YRC - RIDE CONTROL OPT
245482C1
291718A1
4002-191
CONNECTOR YSS - SECONDARY STEERING SOLENOID
225316C1
4002-192
NOTES
INDEX OF FUNCTIONS
SHT
SHT
SHT
ECD
SHT
6
BACKUP ALARM
5 , 14
5
COLOR ABBREVIATIONS 70 62
SHT
SHT
SHT
SHT
SHT
SHT
71
SHT
LARGE CONNECTOR LIST SHEET
INDEX / WIRE INFORMATION
1
SHEET
SHEET
CONNECTOR LIST
SHEET
SHEET
2
SHEET
SHEET
CONNECTOR LIST
SHEET
3
3
18
13
21
14
15
20 5 9
_ 2
8
158 1 10
4
Relay in location F5/F6
160
Relay in location F3\F4 6
16
11
17 159
COLD START
POWER DISTRIBUTION
IGNITION SWITCH
4
ENGINE CONTROL
5
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
93
95
78 91
North American models European and International models 101
100
101
100
Turn Signal
Driving Lights
Light/ Horn
79
Horn
94
103 96
97
102
LIGHTING 1
BACKUP ALARM
6
89
81
88
87 80
86
85
84
170
83
82
LIGHTING 2
7
172
54 173
171 55
57 59
56
174
46
47 45
61 48 58 49
50 51
52
53 60
TRANSMISSION CONTROLS
8
63
64
68
74 72 67
65 75 69 73
76
66
INSTRUMENT CLUSTER
9
25
35 36
26
29
33
31
32
98 27
37
99
39
28
40
34
38
30
41 42 44
43
MACHINE CONTROLS
10
113
155 154 104
108
105 114
106
115 107
117
109 156
111
116 112 113
157
110 118
HOOD LIFT
11
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
8
8
185
176
179
178
181
182 180
183
JOYSTICK STEERING (FOR PL18 & PL23 ONLY)
186
13
145
144 143 146
147
148
153 149
150
152 151
STANDARD HVAC
14
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
15
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
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
# 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
# 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
REAR VIEW CAMERA/MONITOR DIFFERENTIAL LOCK SWITCH (MANUAL) DIFFERENTIAL LOCK SWITCH DIFFERENTIAL LOCK SOLENOID LOCKUP SOLENOID JOYSTICK PVRES TRANSMISSION KICK DOWN SWITCH
COMPONENT NUMBERING INFORMATION
16
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.
1
2
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.
2
1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 4 4 5 6 9 11 11 12 12 12 12 14 18 18 18 19 23 42 50
.
4005-3
INSTRUMENT CLUSTER
1
2
3
4
5
6
7
8
9
10
11
15 14
13
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 BD06F202.TIF
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
A
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.
C
NOTE: Pressing the escape key will return the LCD back to the normal driving screen.
B
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. RCPH10WHL533AAH.PNG
Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed and fuel level.
4005-7
BD06F169
RCPH10WHL534AAH.PNG
Info 2 will be displayed next. The Info 2 screen will display coolant temperature, engine oil temperature in either Fahrenheit or Celsius and oil pressure in BAR or 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
RCPH10WHL531AAH.PNG
Push the down button again for the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil and sump oil.
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).
RCPH10WHL584AAH.PNG
Transmission selections Max gear Min gear
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
in
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 seven, 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
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.
A
5. 5000 to 5999 eltro-hydraulic system errors.
C
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.
B
D 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.
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 lower threshold limit.
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.
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.
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
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
Sensor supply voltage 2 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 3 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
3286
Sensor supply voltage 3 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
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).
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
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.
4005-42
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
4005-43 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 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.
4005-44 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
4005-45 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
4005-46 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.
4005-47 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).
4005-48 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
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.
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.
4005-49 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.
4005-50
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.
4005-51 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
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.
HourMeter Failure - One of two copies are wrong
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.
9162
HourMeter Failure - Pre-crank and after-crank check are wrong
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.
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.
9160
9161
4005-52
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
6
7
5
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
1
2
3 6
7
4
5
4
8
3
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
6
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
9
10
8 7 6 5 4 3
11
2 12
1
1
13 14 15
11
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
1
2
3
4
5
6
7
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.
1
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
is
at
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.
6
2. A remote starter switch.
7
3. A tachometer to check the armature speed. 4. A Sun Electric VAT-33 Starting and Charging System Tester.
8
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).
2
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.
4
3
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.
1
2. Repeat pressure test procedure. 3. If necessary, adjust the limit valve again until within the specified range.
2
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
2
3
4
5
6
7
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
15
16
17 16
18 8 9
19 13 12 11 10
7
3
4
5
6
1
14
2
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
1
2 3
4
5
1
6
2
7 5 8
10 6
9 5
12
16
11 6
8 13 6 2
14
1 5
8 15
2
2
1
1
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.
19
41. Remove the bearing retainer (13) and shims (8). 42. Remove the lower bearing spacer (11) from the top of the lower pivot.
20
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.
21
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
18
19 26
24
49. Use an acceptable driver to press the seal (6) out of each bearing retainer (7 and 13).
25
21
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).
7
17
18
19
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.
27
9
BC06A125.
21
22
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).
21
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
21
18
25
40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13).
19
24 29
23
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.
21
18
19 29 30
12
BC06A121
17
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
8
10
9
11 16
12
1 13 3
17
4
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:
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
●
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.
3
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:
4
1
5
2
●
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 OFF
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
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 ON
JSS OFF
JSS ON
F-N-R conditions
JSS ON JSS F-N-R = neutral.
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.
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 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.
JSS / AUX F-N-R disabled.
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
11
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
18
1842
JSS Valve Alarm Open Circuit
19
1843
JSS Pilot Pressure is High
20
1844
JSS Pilot Pressure Switch Short to Ground
21
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
TO
T
LX
PP A
B
T2
P
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
5
1
7
10
8
3
4
11
9
6
2
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
11
Remove all dirt and grease from the steering system valves and adjacent area. IMPORTANT: disassembly.
Tag
all
connections
prior
to
9 10
STEP 3 1
W190-4R072
3
Remove nut (11) from the stud (9) to release the chassis grounding cable (1).
2 STEP 5 4
7
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).
1
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
2
6 4
7 3
8
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
3
STEP 9
1
4
10 2 W190-4R075
9
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
2
3
4
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
9
W190-4R080
To remove the armrest harness (9), see page 33.
5009-14
Installation
STEP 14
STEP 12 1 3 2 4
7
12 14 13 16 15
8
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
1
5
1
11
6
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
11
2
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.
1
STEP 17 W190-4R073
Connect connector (1) to the joystick harness (2).
STEP 19
14
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
3
4
5
2 W190-4R087
Connect interface connector (4) of the joystick harness (2), connect the armrest harness (3) to connector (5).
5009-17
8
14
D C
20 19
12 11 10
27 28 15 F
29
E Detail C view from D
13
18
1 21 2
9
22 A
3 7
Detail E view from F
16
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
20 21
19
27
8
8
22 22
8 22
29
22 21
28
13
26 24 25
16 23
2 84419913 sht 13
WIRING DIAGRAM OF THE JOYSTICK STEERING SYSTEM
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
5
4
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
4
1
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
1
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
8
STEP 14
7
1
9
10
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”.
5
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.
3
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).
1
STEP 21
W190-4R023
Install the firing (1) into port “LS”. Tighten the fitting to 45 N m (33 pound feet).
2
STEP 24
W190-4R021
Install fitting (2) into port “P”. Tighten the fitting to 170 N m (125 pound feet).
2
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
10
11
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
1
4 3
7
8 5 5
2
6
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
1
11 10 7
8
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
1
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).
3
2
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
10
16
30
13
10
See table 2 7 18
31
25
C 6
27 22 24
12
8
8 2
5 23 22 17 1 15 20 19
19 21 Detail “A”
G
B
34
6 3
F See table 2
A
4 View from “C”
W190-4R033
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM - Table 1
5009-28
9
28 29
11 10 10
13 Detail J 35
J 11 13 36 16
D H
30
30
Detail D view from H
14
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
30
10
10
16
7
31 25
22 24
13
C
12
8
8 6
*
2
5 23 17 27 22
G
1
15
20 19 21 19
F *
B
A
7
6
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
18
11
32 13 10
Detail D
36 11
Detail E
J
32 16
30 Detail F view from G
14
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
1
9
2
15
19
18 16
8
21
YPP
UNLOCK
LOCK
11
A1
20
P
T
16B
12
X1 MX
B1
16A
20D
20A
T
280 bar
14 16C R
4
20C
F
R1
13
13A
20B
2
13F
X
3
16D 1
13E
B
2
P
5 13D
3
A
16E
13B
1
240±8% L/min
240±8% L/min OPTION
B3
ø2.0
A3
a3
ø0.8
Pst
528789
)(
898999
30 bar
22H
22C
22E
290 bar
936718
22E
S2
22D
936718
S1
R901007569
859551
22J
290 bar
936725
224±3 bar
847160
R901075587
22D
22E
22E
TP1: UNLOADING PUMP PRESSURE TP9: PILOT PRESSURE SUPPLY
868050
20±8% L/min
280±8% L/min BOOM
B2
ø2.0
A2
22C
290 bar
936718
290 bar
TP2: IMPLEMENT LOAD SENSE TP5: STEERING PUMP PRESSURE
936718
22D
737012
TP3: STEERING LOAD SENSE
22B
22F
22G
329140
MT1
TP7: REAR BRAKE ACCUMULATOR
8-10.8 bar
TP6: FRONT BRAKE ACCUMULATOR
45A
44
ø2.0
ø0.8
868050
b3
B2
A2
899039
ø2.0
22K
234 bar
35
234
TANK
bar
45B
Note 2
EF
LS
LS IMPL
.64
.8
24
CF 24A
P
45D
T
M1
35A
T
30
G1 34
X2
LS
33 33A
34A
CF
32 27
30B
2
23
T 1
0.31
0.31
46 24C
46
29
36
33B
34B
Note 1
ST
30A
240 bar
40
SLS
24B
LS
0.7
35C
35B
G2
X1
L
IN
R
M1
162 bar
22K
45
43
M2
P
45B
b2
45C
ø0.8
b1
280±8% A1 L/min
22
M2
23cc
22C
10
TP10: FRONT BRAKE TO AXLE
42
528789
R901075585
T
528789
1.2
TP11: REAR BRAKE TO AXLE
22K
765876
11
7
22K
Mp
LS
17
A1
P
22A
a1
0.6
R2
pst
T2
ø0.8
13C
868050
B
BUCKET
N
B1 280±8% L/min
T1' 6
a2
T1
23cc
33C
34C
R
3
30C
0.75
P
T
28A 41
L1 L2
39
S1
S2
28
P
T
P
33D
34D
L
LS
1.8 L4
L3
31
28C
28B
p
26 11 cc
25
38
37
37
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 821F (Note: Joystick steering section the same for 921F)
T
5009-32
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM - 821F
5009-33
JOYSTICK STEERING SYSTEM ARMREST Removal
STEP 3
STEP 1 3 2
1
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
8
3
7
4
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
12
7
1
10
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
5
5
4
6
7 1
3
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).
4
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.
1
3
5
4
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
7
8
2
11 3
1
4 9 2
7 5
6
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
8
9
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
3
1
5 7
2
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
7
1 2
3
4
5
8
6
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
6
1 3 4 8 W190-4R054
Position the armrest support plate (8) on the seat runners (6).
STEP 25
5
6
7
W190-4R056
1
2
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
10
9
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
11
5
9
6 7
8
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
8
12
4
1
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
11
6
4
5
5 2
3
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
2
9
W190-4R066
Install the CAN module (1) in the seat (2) on the armrest.
STEP 40 8
7
5
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
14
9
10
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
5
17 W190-4R107
4
Insert the “Kick-Down” button (16) on the armrest (15) and secure it with the nut (17).
7
6
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
1
4
5
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
1
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
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. 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
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.
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
1. With the engine at low idle, with all the controls in neutral and JSS ON, steer the unit completely to the left.
1
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
3
2 1
C B 1 3
4
2 2
2
1
1
5
5 7
6
1 5
5
1
2
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 and all 821F/921F machines are equipped with brake damping accumulators.
IMG_1998 RESIZED.JPG
Disconnect differential lock hose. NOTE: Locking front differential is available on 721F, 821F and 921F 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 heavy duty axles and all 821F/921F axles have 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.
821FXR-8818.PNG
Remove wheel nuts/bolts and washers from front wheels. Remove both wheels from front axle. NOTE: 721F and 821F (pictured) heavy duty axles and all 921F axles have wheel studs on the axles and use wheel nuts.
6001-15
Front Axle Mounting
1 2
5
3
4
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
84324413205.TIF
821F 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).
STEP 17
0R0R201007RCIL10WHL288BAL[1].TIF
921F Torque Pattern 821FXR-8818.PNG
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.
STEP 18
NOTE: 721F and 821F (pictured) heavy duty axles and all 921F axles have wheel studs on the axles and use wheel nuts. NOTE: 821F units (pictured) use a 16 hole mounting pattern. 921F units use a 20 hole mounting pattern.
IMG_2121.PNG
Remove jack from front axle.
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
Connect differential lock hose.
STEP 21
NOTE: Locking front differential is available on 721F, 821F and 921F 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 and all 821F/921F machines 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
A
A
821FXR-8818.PNG
IMG_2133.PNG
Remove 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 and 821F (pictured) heavy duty axles and all 921F axles have wheel studs on the axles and use wheel nuts.
6001-21
Rear Axle Mounting
5 4 2
3
1
7
5 1 2 6
8 9
7
4
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.
A
STEP 12 5
5
B
8 6
3
PIVOT BUSHING 2.PNG
A
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
6
4
A
8
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).
84324413 205.TIF
821F Torque Pattern
STEP 17
821FXR-8818.PNG
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. NOTE: 721F and 821F (pictured) heavy duty axles and all 921F axles have wheel studs on the axles and use wheel nuts. NOTE: 821F units (pictured) use a 16 hole mounting pattern. 921F units (pictured) use a 20 hole mounting pattern.
0R0R201007RCIL10WHL288BAL[1].TIF
921F Torque Pattern
6001-24
STEP 18
STEP 20
821FXR-8818.PNG
BD03A162
Remove hydraulic jack supporting rear axle and jack stands supporting loader.
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).
STEP 19 STEP 21 If necessary, fill axle with Standard Multi-G Hydraulic oil.
STEP 22 Refer to Section 7002 and bleed brakes.
STEP 23 Place articulation lock in OPERATING position.
BD03A169
Install a new O-ring face seal in elbow. Connect brake hose to elbow.
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
4
1 3
2
5
12
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
5
15
6
14 8 13
7
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
2
2
2
2
3
1
4
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
1
2
3
4
5 9 10 8
6
7
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
2
1
1
3
7
6
5
4
4
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
52
Behind the Converter - Opening Pressure 2.5 bar (36 psi)
M14x1.5
53
Clutch Forward 16+2 bar (232 + 29 psi)
KV M10x1
B
55
Clutch Reverse 16+2 bar (232 + 29 psi)
KR M10x1
E
56
Clutch 16+2 bar (232 + 29 psi)
K1 M10x1
D
57
Clutch 16+2 bar (232 + 29 psi)
K2 M10x1
A
58
Clutch 16+2 bar (232 + 29 psi)
K3 M10x1
C
60
Clutch 16+2 bar (232 + 29 psi)
K4 M10x1
F
63
Behind the Converter Temperature 100° C, Short Time 120° C
M14x1/5
65
System Pressure 16+2 bar (232 + 29 psi)
M10x1
K
Measuring Points for Delivery Rates 15
Connection to the Heat Exchanger
1 5/16” - 12 UNF-2B
16
Connection from the Heat Exchanger
1 5/16” - 12 UNF-2B
Inductive Transmitter and Speed Sensor 21
Inductive Transmitter for Turbine Speed
34
M18x1.5
Output Speed Sensor
47
Inductive Transmitter for Central Gear Train Speed
M18x1.5
48
Inductive Transmitter for Engine Speed
M18x1.5
Connections 49
Plug Connection on the Hydraulic Control Unit
68
System Pressure
M16x1.5
G
69
Pilot Pressure
M16x1.5
J
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
LP
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
A
A
19A_H
43
45
forward
V
yellow
-
B
25F
44
43
reverse
R
pink
-
C
25R
45
64
neutral
N
gray
-
D
25T_B
46
67
gear2(3-4)
B2
green
B
-
25W
48
65
gear1(1-2)
B1
blue
C
-
25Z
49
63
downshift
DS
purple
D
-
25Y
50
22
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
56
Y1
K4
1
25K
16
A1P2
10
Y2
KR
2
25L
17
A1P3
32
Y3
K1
3
25M
18
A1P4
55
Y4
K3
4
25N
19
A1P5
9
Y5
KV
5
25P
20
A1P6
51
Y6
K2
6
25J
21
VPSI
12,13
all Y
all K
7
25S
22
TEMP
39
TEMP
none
8
36T
5
TEMP
46
TEMP
none
9
36R
12
6002-21
NOTES
6002-22
4 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.0 Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 8.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches . . . . . . . . . . . 65 10.0 Outputs and closure parts pump shaft (PTO-shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 12.0 Reassembly - Emergency steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug . . . . . . . . . . . . . . . . 80 14.0 Reassembly Electro-hydraulic control with proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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
STEP 1 1.1 Removal of filter
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.
of
oil
according
to
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
3
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.
STEP 5
Remove differential pressure switch (1) from fine filter duct plate (4). 1. Switch with O-ring 2. Piston 3. Compression spring.
STEP 7 S
2
2
1
1 BILD-05
Remove gear-shift control assembly (1) and sealing plate (2). Adjusting bolts M6 (S).
BILD-07
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
3
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
2
1
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
1
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
1
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
2.0 Inductive sensor Hall effect sensor, breather, oil filler and oil drain plug STEP 1 3
4 5 6
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 1 3.1 Engine connection (remote mount)
1 2
2 1 BILD-03 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).
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.
of
STEP 2 STEP 2
1 2
BILD-04 BILD-02
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.
6003-10
STEP 3
STEP 6 1
2
BILD-05
Remove output flange.
BILD-08
Remove hex bolts (1) and flex plate (2) from converter.
STEP 4 STEP 7 2 1
3
BILD-06
Press input shaft and converter out of cover (ball bearing).
STEP 5 1
2
BILD-07
Remove retaining ring (1) and ball bearing (2).
BILD-09
Remove hex bolts (1) and flex plate (2) from input shaft (3).
6003-11
STEP 8
STEP 10
3.2 Oil pressure pump
2 1 2
1
BILD-12 BILD-10
Loosen bolted connection (1) between converter bell housing and oil feed housing. Remove converter bell housing (2).
Separate oil pressure pump (1) from oil feed housing (2).
STEP 11
STEP 9 1 1
2
21
BILD-13
Remove O-ring (1) and cylindrical bolts (2). BILD-11
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. NOTE: Separate oil feed housing together with oil pressure pump from front transmission housing.
6003-12
STEP 12
STEP 14 3.3 Converter back-pressure valve
1 2 2 3
1 4 BILD-14
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.
BILD-16
With a screwdriver, release the converter safety valve (1) pressure and remove the locking plate (2).
1. Cover
STEP 15
2. Inner rotor 3. Outer rotor 4. Pump housing
STEP 13 1
2
3
1
BILD-17
Remove individual parts of converter safety valve which are released.
2
1. Pressure plate BILD-15
Remove shaft seal (1) from the pump housing (2).
2. Compression spring 3. Piston
6003-13
STEP 16
4.0 Emergency steering pump STEP 1 4.1 Version without emergency steering pump
2 1
1 BILD-18
Remove temperature sensor (1).
STEP 17
BILD-01
Remove hex bolts (1), cover (2) and seals.
5.0 Outputs and closure parts pump shaft (PTO-shaft)
1
5.1 Output flange on converter side (Standard version)
2
STEP 1 1 BILD-19
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.
BILD-01
Remove hex bolts (1), washer and O-ring.
6003-14
STEP 2
STEP 5 2
1 1
2
BILD-02
BILD-13
Pull off output flange (1) and remove shaft seal (2).
Remove hex bolts (2) and parking brake (1).
5.2 Output flange on output side with parking brake FSG-88
STEP 6
STEP 3 2 2
1
1
BILD-14
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.
Remove hex bolts (1) of bolted brake disc/output flange connection and remove brake disc (2).
STEP 7 2
3
1
STEP 4
BILD-15
Remove hex bolts (1), washer and O-ring. Remove output flange (2) and shaft seal. Remove cylinder bolt with washer (3). BILD-12
Remove hex nut with open end wrench.
6003-15
6.0 Removal of input shaft, output shaft, pump shaft (PTO -shaft) and clutches
STEP 3
STEP 1
1 2
1
2
BILD-03
Remove output shaft (1) and lower oil screen sheet (2) from housing. 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 4 2 1
STEP 2 1
BILD-04
Remove all rectangular rings (1) from the clutches and all O-rings (2) from the oil tubes.
STEP 5 BILD-02
Loosen bolted connection (1) of oil screen sheets.
1
2 BILD-05
Use a suitable lifting device to lower rear housing section (1) into contact position with front housing section (2).
6003-16
STEP 6
STEP 8 1
1 2
1
BILD-06
BILD-08
Secure all clutches K1, K2, K3 and K4 by using 380001557 handle (1).
Remove cylindrical bolts of oil tubes (1) from the front housing.
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 9
NOTE: Due to the installation conditions, the removal of single clutches without using the special tool is not possible.
2
STEP 7 1 BILD-09
1
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.
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 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 10
STEP 12 1
2
BILD-10
BILD-12
Remove bearing outer rings (arrows) from the front housing.
Press ball bearing (1) off the pump shaft. Snap out rectangular ring (2).
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
STEP 11 5 4
1
3
BILD-13
Lift the clutches out of the housing in numerical order as described in the legend.
2
1. K1 clutch
1
2. K2 clutch BILD-11
Disengage retaining ring (1) and remove pump shafts (2).
3. K3 clutch (Version with emergency steering pump) 4. K4 clutch 5. KR clutch 6. KV clutch 7. Input shaft
6003-18
STEP 14
7.0 Clutches KV/KR/K1/K2/K3/K4 input and output shaft. STEP 1 2
6
4
5
3 1 BILD-14
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.
7 BILD-01
1. K1 clutch 2. K2 clutch 3. K3 clutch 4. K4 clutch 5. KR clutch
STEP 15
6. KV clutch 7. Input shaft.
1
STEP 2
2
7.1 KV clutch
1
2
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. BILD-02
Remove stud bolt (1) and snap out piston ring (2).
6003-19
STEP 3
STEP 6
1
BILD-03
BILD- 06
Pull tapered roller bearing off the shaft using special tool CAS2798.
Secure idler gear (1) using a cut-off device and pull it off the clutch shaft.
STEP 4
STEP 7 1
1 3
2
BILD-04
Snap out retaining ring (1).
BILD-07
Snap retaining ring (1) out of the idler gear (2) and remove ball bearing (3).
STEP 5 STEP 8 1
2 1
BILD-05
Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 11-16.
BILD-08
Remove needle cage (1) from the shaft (2).
6003-20
STEP 9
STEP 12 1
1
2 2 3 BILD-09
BILD-12
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 10
STEP 13
1
BILD-10
BILD-13
Pull tapered roller bearing off shaft with special tool CAS2798.
Preload compression spring with special tool 380001556 and unsnap L-ring (1).
STEP 11
STEP 14 1
1
2 3
BILD-11
Unsnap snap ring (1).
BILD-14
Remove support shim (1), compression spring (2) and washer (3).
6003-21
STEP 15
STEP 2
1
BILD-15
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 16
STEP 3 1 1
2
BILD-16
BILD-03
Remove both O-rings (1 and 2).
Snap out retaining ring (1).
STEP 1
STEP 4
7.2 KR clutch
1
2
1
BILD-04 BILD-01
Remove stud bolt (1) and snap out piston ring (2).
Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 10-15.
6003-22
STEP 5
STEP 8 1
1
2
BILD- 05
BILD-08
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 6
STEP 9 1 3
2
BILD-06
BILD-09
Snap retaining ring (1) out of the idler gear (2) and remove ball bearing (3).
Pull tapered roller bearing off shaft using special tool CAS2798.
STEP 7
STEP 10 1 1
2
BILD-10
BILD-07
Remove needle cage (1) from the shaft (2).
Unsnap snap ring (1).
6003-23
STEP 11
STEP 14 1 1
2
3 BILD-11
BILD-14
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 12
STEP 15
1 2
1
BILD-12
Preload compression spring with special tool 380001556 and unsnap L-ring (1).
BILD-15
Remove both O-rings (1 and 2).
STEP 1 STEP 13
7.3 K1 clutch
1
1
2
2 3
BILD-13
Remove support shim (1), compression spring (2) and washer (3).
BILD-01
Remove stud bolt (1) and snap out piston ring (2).
6003-24
STEP 2
STEP 5 1 3 2
BILD-02
BILD-05
Pull tapered roller bearing off the shaft with special tool CAS2798.
Take off idler gear (1), remove needle cage (2) and axial bearing assembly (3).
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
1
1
2
BILD-04
Remove axial bearing assembly (1).
BILD-07
Turn shaft (2) 180 degrees and snap out piston ring (1).
6003-25
STEP 8
STEP 11
1
BILD-08
BILD-11
Pull tapered roller bearing off the shaft with special tool CAS2798.
Preload cup springs using special tool 380001556 and unsnap L-ring (1).
STEP 9
STEP 12 1 1
BILD-09
BILD-12
Unsnap snap ring (1).
Remove cup spring package (1).
STEP 10
STEP 13 1 1
2
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.
6003-26
STEP 14
STEP 3 1 1
2
BILD-14
BILD-03
Remove both O-rings (1 and 2).
Snap out retaining ring (1).
STEP 1
STEP 4
7.4 K2 clutch
1
1 2
BILD-04 BILD-01
Remove stud bolt (1) and snap out piston ring (2).
Remove axial bearing assembly (1).
STEP 5
STEP 2 1 3 2
BILD-05 BILD-02
Pull tapered roller bearing off the shaft using special tool CAS2798.
Remove idler gear (1), needle cage (2) and axial bearing assembly (3).
6003-27
STEP 6
STEP 9 1
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).
STEP 11
STEP 8
1
BILD-11 BILD-08
Pull tapered roller bearing off the shaft using special tool CAS2798.
Preload cup springs using special tool 380001556 and unsnap L-ring (1).
6003-28
STEP 12
STEP 1 7.5 K3 clutch
1 1
BILD-12
Remove cup spring package (1).
BILD-01
Snap out piston ring (1).
STEP 13
STEP 2
1
BILD-13
Using compressed air, remove the piston (1) from the disc carrier.
STEP 14
BILD-02
Pull tapered roller bearing off the shaft using special tool CAS2798.
STEP 3 1
1
2
BILD-14
Remove both O-rings (1 and 2).
BILD-03
Remove axial bearing assembly (1).
6003-29
STEP 4
STEP 7 1
3 2
BILD-04
BILD-07
Take off idler gear (1), remove needle cage (2) and axial bearing assembly (3).
Pull tapered roller bearing off the shaft using special tool CAS2798.
STEP 5
STEP 8
1
1
BILD-05
Pull clutch (1) off the shaft.
BILD-08
Unsnap snap ring (1).
NOTE: For disassembly of clutch see Steps 8-13.
STEP 9
STEP 6 1 1
2 2
3
BILD-09 BILD-06
Remove stud bolt (1) and snap out piston ring (2).
Remove end shim (1) and disc set (2) from the disc carrier (3).
6003-30
STEP 10
STEP 13
1 2
1
BILD-10
Preload cup springs using special tool 380001556 and unsnap L-ring (1).
BILD-13
Remove both O-rings (1 and 2).
STEP 1 STEP 11
7.6 K4 clutch
1 1
2
BILD-11 BILD-01
Remove cup spring package (1).
Remove stud bolt (1) and snap out piston ring (2).
STEP 12
STEP 2
1
BILD-12
Using compressed air, remove the piston (1) from the disc carrier.
BILD-02
Pull tapered roller bearing off the shaft using special tool CAS2798.
6003-31
STEP 3
STEP 6 1 1
2
3 BILD-03
Snap out retaining ring (1).
BILD-06
Remove needle cage (1) and axial bearing assembly (2).
STEP 4
NOTE: The gear (3) cannot be removed, it is a shrink fit.
STEP 7 1
1
2
BILD-04
Pull clutch (1) off the shaft. NOTE: For disassembly of clutch see Steps 9-14. BILD-07
STEP 5
Turn shaft (2) by 180 degrees and snap out piston ring (1).
1 STEP 8
2
BILD-05
Remove axial bearing assembly (1) and idler gear (2). BILD-08
Pull tapered roller bearing off the shaft using special tool CAS2798.
6003-32
STEP 9
STEP 12
1
1
BILD-09
BILD-12
Unsnap snap ring (1).
Remove cup spring package (1).
STEP 10
STEP 13 1 1
2
3
BILD-10
BILD-13
Remove end shim (1) and disc set (2) out of the disc carrier (3).
Using compressed air, remove the piston (1) from the disc carrier.
STEP 11
STEP 14
1 2
1
BILD-11
Preload cup springs using special tool 380001556 and unsnap L-ring (1).
BILD-14
Remove both O-rings (1 and 2).
6003-33
STEP 1
STEP 3
7.7 Input shaft
1
2 1
BILD-03 BILD-01
Snap out piston ring (1). Turbine wheel shaft and drive gear (2) are secured by a snap ring. NOTE: When separated, the snap ring will be destroyed.
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
STEP 2
1 BILD-02
BILD-01
Pull tapered roller bearing off drive gear using special tool CAS2798.
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.
6003-34
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
3
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.
1
BILD-05
Press pre-assembled idler gear (1) onto the shaft until contact occurs.
6003-35
STEP 6
STEP 9 4 3 1
2 1 S
1
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.
S
BILD-08
Use special tool 380001556 (S) to place piston into the disc carrier.
6003-36
STEP 11
STEP 12 1
2
3
5 6
2
3
7 4 1
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 20. 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.
6003-37
STEP 14
STEP 16
F
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
R
F
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 (0.083 to 0.165 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
1
BILD-20
Secure clutch (1) using retaining ring (2).
6003-38
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
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.
6003-39
STEP 1
STEP 4
8.2 KR Clutch
3 2
1
BILD-04 BILD-01
Heat bearing to approximately +120° C (+248° F).
STEP 5
STEP 2
1
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.
6003-40
STEP 7
STEP 10
1
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
S
2
3
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
4
2. Compression spring
3
3. Support shim 4. L-Ring
2
5. Disc carrier
1
6. Drain valve (piston) 7. Piston with O-Rings.
S
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.
6003-41
STEP 12
STEP 14
F 2
3
1
4
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 20.
F
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 (0.083 to 0.165 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.
6003-42
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
1
R
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.
WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.
STEP 21 STEP 18 2 2
1
1
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).
6003-43
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
1
1
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.
2
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.
6003-44
STEP 3
STEP 6 2 1 1
3 2
S
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
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 the annular grove.
NOTE: Observe installation position.
STEP 5
NOTE: Always use a new L-ring.
S
BILD-05
Use special tool 380001556 (S) to place piston into the disc carrier.
6003-45
STEP 8
STEP 10 1
2 1
3
2
4
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
F
STEP 9
2
3
BILD-12
4
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 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.
Press on end plate (F) approximately 100 N = 10 kg and set dial indicator to “zero”.
6003-46
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 (0.083 to 0.165 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
2
STEP 13
1
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.
6003-47
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
3
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
2
2
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).
6003-48
STEP 23
STEP 2 1
2
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.
6003-49
STEP 4
STEP 7
1 S1
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 into the annular grove.
NOTE: Observe installation position.
STEP 5
NOTE: Always use a new L-ring.
STEP 8 1
S
2
3
4
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
2. L-Ring 3. Disc carrier 4. Piston with O-rings
1
S
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.
6003-50
STEP 9
STEP 11
F 2
3
1
4
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 14.
F
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-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.) see Step 9.
1
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 (0.083 to 0.165 in.).
2
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.
6003-51
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
R
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
3
1
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.
6003-52
STEP 19
STEP 22 2
1
2
1
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).
6003-53
STEP 2
STEP 4 3
2 1
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.
2
NOTE: Check function of the drain valve (3). There must be no jamming of the ball.
1
S
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.
6003-54
STEP 7
STEP 9
2 S1
S2
3
4
1
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-09
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 14.
2
NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version.
3
NOTE: The actual installed clutch and disc arrangement must be taken from the corresponding spare parts list. The spare parts list is binding.
4
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.
6003-55
STEP 11
STEP 13
F
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
1
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 (0.083 to 0.165 in.).
BILD-15
Mount clutch (1) until contact is made. WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.
6003-56
STEP 15
STEP 18 3
3 2
2
1
1
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
R
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).
6003-57
STEP 21
STEP 1 8.6 K4 Clutch
2
1
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
1
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.
6003-58
STEP 3
STEP 5 2
1
2
1
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).
1
BILD-07
Mount idler gear (1).
6003-59
STEP 8
STEP 10 3 2 1
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.
2
1
S
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.
6003-60
STEP 13
STEP 15
3 S2 S1
2
4
1
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 (6 pcs)
NOTE: Always use a new L-ring.
3. Outer discs (6 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 12.
2
3
NOTE: Different clutch disc arrangements with relevant disc clearance can be installed depending on the parts list version.
4
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
1
2
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.
6003-61
STEP 17
STEP 19
F
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
L
R
1
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 0.065 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 (0.083 to 0.165 in.).
WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.
STEP 21
1
BILD-21
Secure clutch using retaining ring (1).
6003-62
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
2
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.
6003-63
STEP 2
STEP 5
1
BILD-02
BILD-05
Secure drive gear using retaining ring (1).
Heat bearing to approximately +120° C (+248° F).
STEP 3
STEP 6
1
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
1
1
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).
6003-64
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).
6003-65
STEP 4
9.0 Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches STEP 1
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).
1
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.
1
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.
6003-66
STEP 3 3
STEP 5 3 1
1
2
2
4
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.
6003-67
STEP 7
STEP 9 1
3
4
1 8
5
6 7
2
2
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.
1
STEP 8 2 1 BILD-10
3
Mount K3 clutch (1).
STEP 11
1
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).
6003-68
STEP 12
STEP 15
1
7
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.
2
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
3
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
1
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.
6003-69
STEP 17
STEP 20 4
2
3
1
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.
2
NOTE: Be sure that both oil tubes are aligned with the holes in the rear housing.
1
BILD-19
Position screen sheet (1). Install pre-assembled output shaft (2).
6003-70
STEP 22
STEP 24 1
3
1
2
1
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
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.
6003-71
10.0 Outputs and closure parts pump shaft (PTO-shaft)
STEP 3
STEP 1
1
3
2
10.1 Output flange output side with brake FSG-88
S
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
3
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.
6003-72
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 (0.02 to 0.06 in), Nominal clearance: 1.0 mm (0.04 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
S
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.
6003-73
STEP 9
STEP 11 2 1
3
3
1
4
2
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.
6003-74
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
1
STEP 1 11.1 Converter back-pressure valve
1
BILD-03
Mount temperature sensor (1) with O-ring. Torque to 25 Nm (18 pound feet).
2
3
5
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
3
The Step shows the single parts of the converter back-pressure valve. 1. Oil feed housing
1
2. Piston
2
3. Compression spring 4. Pressure plate
S
5. Locking plate. NOTE: Install pressure plate (4), with the pin (6 mm diameter) facing towards the locking plate (1).
S
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).
6003-75
STEP 5
STEP 8 1 1 S
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
1
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.
6003-76
STEP 10
STEP 13 1
2
1
2
2
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
1
2
S
BILD-14 BILD-11
Mount pre-assembled pump with driver (S) until contact is made.
STEP 12
1
2
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).
6003-77
STEP 15
STEP 17
11.3 Engine connection (remote mount)
1
2
1 2
3
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).
S
STEP 16 1
1
2
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).
6003-78
STEP 20
STEP 22 2 1
3
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
1
1
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).
6003-79
STEP 24
STEP 2
1
1
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
2
1
S
BILD-01
Install adjusting bolts (S) and assemble seal (1) and cover (2).
6003-80
13.0 Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug
STEP 2 4
STEP 1 1
2
3
4
2
3
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.
6
7 5
9
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 inces). 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).
6003-81
14.0 Reassembly Electro-hydraulic control with proportional valves STEP 1 Main pressure valve 16+2 bar
Pressure reducing valve 9 bar
Wiring harness
A
A
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
6003-82
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
1
1
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.
6003-83
STEP 5
STEP 7 2
1
S
3 S
2
1
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)
1
3. Follow-on slide (3x, piston and compression spring)
STEP 6
BILD-08
S
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).
1
BILD-09
Secure housing using the Torx bolts (1) and torque to 5.5 Nm (49 pound inches).
6003-84
STEP 10
STEP 12 1
3 2
1
S
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
3
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).
6003-85
STEP 14
STEP 16
1
1
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.
STEP 18 S
BILD-18
Install two adjusting bolts (S).
6003-86
STEP 19
STEP 21 1
1
1
2
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
1
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.
1
BILD-23
Insert converter safety valve (1) into the housing hole until contact is made.
6003-87
STEP 24
STEP 26 2
1
1
3
2
3
4
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
4
1
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 feet). 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.
6003-88
STEP 28
STEP 30
2 1
BILD-28
Secure electro-hydraulic control unit (1) evenly using Torx bolts (2) and torque them to 9.5 Nm (84 pound inches). NOTE: For version with torque converter lock-up clutch solenoid valve, go to Steps 31 and 32.
STEP 29 14.3 Fitting of filter (pressure filter)
2
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).
BILD-34
Install new filter element. NOTE: Before putting the transmission into operation, fill it with oil according to operators manual.
MULTITRAC MT-L 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 821F Limited Slip Front Axle 4
5 4
2 3 1
2 RH11C095.PNG
1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)
RH11C096.PNG
3. OIL FILLER HOLE 4. BRAKE BLEEDER
5. BLEEDER
821F Locking Differential Front Axle 4
5 4
2 3 1
2 RH11C099.PNG
1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)
RH11C100.PNG
3. OIL FILLER HOLE 4. BRAKE BLEEDER
5. BLEEDER
821F Limited Slip Rear Axle 5
4
4
2 3 2 RH11C097.PNG
1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)
1 RH11C098.PNG
3. OIL FILLER HOLE 4. BRAKE BLEEDER
5. BLEEDER
6004-7
821F/921F Open Differential Rear Axle 4
5 4
2 3 2 RH11C101.PNG
1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)
1 RH11C102.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
1-03.PNG
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
1-04.PNG
Remove bleeder valve to avoid damage during output and axle housing separation.
1-02.PNG
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
1-05.PNG
Attach load carrying device 380002303 to output assembly. Remove hex bolts and separate output from axle housing.
1-08.PNG
Use a lever to remove output shaft cover.
STEP 9
WARNING: Attach load carrying device with a wheel nut.
STEP 6
1-09.PNG
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
1-10.PNG
Use puller and press planetary carrier out of output shaft profile.
1-07.PNG
Attach output to suitable assembly stand.
6004-11
STEP 11
STEP 14
1-11.PNG
Use a suitable lifting device and lift planetary carrier out of brake housing.
1-14.PNG
Pull off planetary gears.
STEP 15 STEP 12
1-15.PNG 1-12.PNG
With a suitable puller remove tapered roller bearing from planetary carrier.
Lift end plate out of brake housing.
STEP 16
STEP 13
1-16.PNG
Lift disk package out of brake housing. 1-13.PNG
Remove retaining rings.
6004-12
STEP 17
STEP 20
1-17.PNG
Remove hex bolts, releasing cover and cup spring.
STEP 18
1-20.JPG
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
1-19.PNG
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.
1-21.PNG
Use a suitable lifting device. Lift brake housing from output shaft.
6004-13
STEP 22
1-22.PNG
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
1-23.PNG
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
1-24.PNG
Use a puller to remove tapered roller bearing from output shaft.
6004-14
AXLE HOUSING Disassembly
STEP 3
STEP 1
2-03.PNG
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
2-04.PNG
Pull bearing outer ring from bearing hole and remove shim. Remove O-ring (see arrow).
2-02.PNG
Loosen threaded connections and remove releasing brake tube.
6004-15
INPUT Disassembly
STEP 3
STEP 1
3-03.PNG
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
3-04.PNG
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
3-05.PNG
Heat slotted nut with a hot air blower. NOTE: Slotted nut is secured with Loctite (Type no. 262).
3-07.PNG
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
3-08.PNG
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.
3-09.PNG
Remove spacer ring and pull tapered roller bearing from input pinion.
STEP 10
6004-17
3-10.PNG
If needed, remove bearing outer rings from axle drive housing.
6004-18
DIFFERENTIAL Disassembly Multi-disk Differential Lock DHL-2400
STEP 4
STEP 1
4-04.PNG
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
4-06.PNG
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
4-07.PNG
Remove axle bevel gear with thrust washers from differential housing.
4-10.PNG
Remove long differential axle, releasing spider gears and thrust washers from differential housing.
STEP 8 STEP 11
4-08.PNG
Force out both slotted pins.
4-11.PNG
Remove axle bevel gear and shim.
STEP 12
6004-20
STEP 15
4-12.PNG
Press crown wheel from differential carrier.
4-15.PNG
Disassembly Differential D-2400
Preload differential using a press. Remove locking bolts and housing cover.
STEP 16
STEP 13
4-16.PNG 4-13.PNG
Pull both tapered roller bearings from differential.
STEP 14
Remove axle bevel gear with thrust washers from differential housing.
STEP 17
4-14.PNG
Preload differential using a press. Remove hex bolts and releasing housing cover.
4-17.PNG
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
4-21.PNG
Press crown wheel from differential carrier.
Disassembly Multi-disc Differential DL-2400 STEP 22
4-19.PNG
Pull long differential axle. Remove releasing spider gears with thrust washers from differential housing.
STEP 20
4-22.PNG
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
5-20.PNG
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
2
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
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.
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
5-41.PNG
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
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.
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
-
10
-0.2
-0.1
0
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.
STEP 19
6004-38
STEP 21
6-19.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.
STEP 20
6-21.PNG
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. 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
4
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
1
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.
2
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
2
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
MULTITRAC MT-L 3105 II AXLE
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Multi-disk Differential Lock DHL-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Differential D-2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 4 6 7 8 8 13 13 14 14 17 17 19 21 21 25 28 28 36 36 38 38
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 921F Open Differential Front Axle 4
5 4
2 3 1
2 RH11C105.PNG
1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)
RH11C106.PNG
3. OIL FILLER HOLE 4. BRAKE BLEEDER
5. BLEEDER
921F Locking Differential Front Axle 4
5 4
2 3 2 RH11C103.PNG
1. OIL DRAIN HOLE (AXLE CASING) 2. OIL DRAIN HOLE (OUTPUTS)
1 RH11C104.PNGBS00M070
3. OIL FILLER HOLE 4. BRAKE BLEEDER
5. BLEEDER
6004-7
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).
6004-8
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 the axle is the same regardless of appearance.
STEP 1
1-03.PNG
Remove plugs 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.
STEP 2
1-04.PNG
Remove bleeder valves to avoid damage when separating outputs.
1-02.PNG
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.
6004-9
STEP 5
STEP 8
1-05.PNG
Attach lifting device 380002303 to output assembly. Loosen hex bolts and separate output assembly from axle housing.
1-08.PNG
Use a lever to remove output shaft cover.
STEP 9
WARNING: Attach load carrying device with wheel nut.
STEP 6
1-09.PNG
Remove locking bolts and releasing cover.
STEP 10 1-06.PNG
Pull stub shaft and sun gear shaft from output. NOTE: Look for loose shim(s).
STEP 7
1-10.PNG
Using a two-armed puller, press planetary carrier from profile of output shaft.
1-07.PNG
Attach output to suitable work stand.
6004-10
STEP 11
STEP 14
1-11.PNG
Use a suitable lifting device. Lift planetary carrier out of brake housing.
1-14.PNG
Pull off planetary gears.
STEP 15 STEP 12
1-15.PNG 1-12.PNG
Lift end plate out of brake housing.
Pull tapered roller bearing from planetary carrier.
STEP 16 STEP 13
1-16.PNG 1-13.PNG
Remove retaining rings.
Lift disk package out of brake housing.
6004-11
STEP 17
STEP 20
1-17.PNG
Remove hex bolts, releasing cover and cup spring.
STEP 18
1-20.JPG
1. Brake housing 2. Guide ring 3. Back-up ring 4. Piston seal 5. Piston seal 1-18.PNG
Mount breather valve. Use compressed air to remove piston from brake housing.
STEP 19
6. Back-up ring 7. Metal Face Seal (Heavy Duty Option) Combi Seal (Standard) 8. Output shaft
STEP 21
1-19.PNG
If needed, remove guide ring, back-up rings and grooved rings from annular grooves of brake housing (see arrows). NOTE: For position of single parts, see Step 20.
1-21.PNG
Use a suitable lifting device. Lift brake housing from output shaft.
6004-12
STEP 22
1-22.PNG
Use levers to remove slide ring seal from brake housing. If needed, remove both bearing outer rings.
STEP 23
1-23.PNG
Use levers to remove slide ring seal from output shaft.
STEP 24
1-24.PNG
Pull tapered roller bearing from output shaft.
6004-13
AXLE HOUSING Disassembly
STEP 3
STEP 1
2-03.PNG
Remove screw neck. 2-01.PNG
Secure axle housing to suitable lifting device. Loosen hex bolts. Separate axle housing from drive housing
STEP 4
NOTE: Be aware of possible release of differential.
STEP 2
2-04.PNG
Pull bearing outer ring and remove shim behind. Then remove O-ring (arrow).
2-02.PNG
Loosen threaded connections and remove brake release tube.
6004-14
INPUT Disassembly
STEP 3
STEP 1
3-03.PNG
Remove piston (arrow) from axle housing. 3-01.PNG
Use a suitable lifting device and pull differential from axle drive housing.
NOTE: Step is only necessary for DHL version.
STEP 4
NOTE: Disassembly of differential is covered in differential section.
STEP 2
3-04.PNG
Use compressed air to remove piston.
3-02.PNG
Pull bearing outer ring (arrow) from housing and remove shim.
6004-15
STEP 5
STEP 7
3-05.PNG
Heat slotted nut. NOTE: Slotted nut is secured with Loctite (Type no. 262).
3-07.PNG
Pull input flange from pinion. Use a lever to remove shaft seal.
STEP 8
WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.
STEP 6
3-08.PNG
Press input pinion from axle drive housing and remove releasing tapered roller bearing.
STEP 9 3-06.PNG
Remove slotted nut and shim using special wrench CAS2842 and clamping device 380001546.
3-09.PNG
Remove spacer ring and pull tapered roller bearing from input pinion.
6004-16
STEP 10
3-10.PNG
If needed, remove both bearing outer rings from axle drive housing.
6004-17
DIFFERENTIAL Disassembly Multi-disk Differential Lock DHL-2400
STEP 4
STEP 1
4-04.PNG
Preload housing cover/compression spring with a press and 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.
6004-18
STEP 6
STEP 9
4-06.PNG
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
4-07.PNG
Remove axle bevel gear and thrust washers from differential housing.
4-10.PNG
Remove long differential axle, spider gears and thrust washers from differential housing.
STEP 8 STEP 11
4-08.PNG
Remove both slotted pins.
4-11.PNG
Remove axle bevel gear and shim.
6004-19
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
4-13JPG
4-17.PNG
4-14.PNG
Preload differential using a press. Remove hex bolts and releasing housing cover.
Force out both slotted pins.
6004-20
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
4-19.PNG
Pull long differential axle. Remove releasing spider gears with thrust washers from differential housing.
STEP 20
4-20.PNG
Remove axle bevel gear and shim.
4-21.PNG
Press crown wheel from differential carrier.
6004-21
DIFFERENTIAL Reassembly Multi-disk Differential Lock DHL-2400
STEP 3
STEP 1 5
S
5-03.PNG
Insert axle bevel gear.
5-01.PNG
STEP 4
Mount two locating pins (S). 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 washer into differential housing.
6004-22
STEP 5
STEP 7
1 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
Secure thrust washers into 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 two adjusting bolts (S) 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).
6004-23
STEP 10
STEP 12 Setting of disc package
5-10.PNG
Install compression spring onto sliding sleeve. 5-12.JPG
Premount single parts according to illustration.
STEP 11
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.
6004-24
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 (0.04 +/- 0.003 in) from collar of differential cover to plane face of outer disc (also see illustration in step 14).
Position housing cover onto dealer fabricated 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 tooling to be determined. Contact Special Tools for assistance.
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 (0.04 +/0.003 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 using a press and pressure piece. Final tighten housing cover with hex bolts. Torque to 185 Nm (136 pound feet).
6004-25
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
5-20.PNG
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 (arrow) to sliding sleeve with grease.
5-21.PNG
Insert thrust washer into differential housing.
STEP 22
5-22.PNG
Insert axle bevel gear.
6004-26
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
2
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.
6004-27
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
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).
WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.
6004-28
INPUT Reassembly
STEP 3
STEP 1 Determination of shim thickness to obtain a correct contact pattern
6-03.PNG
Determine dimension III (bearing width). Dimension III e.g. 42.60 mm (1.67 in). Calculation Example “A”: 6-01.PNG
Dimension I: 245.60 mm (9.67 in)
NOTE: If crown wheel or input pinion are damaged, both parts must be replaced together. In case of an installation of a complete new bevel gear set, pay attention to an identical mating number on input pinion and crown wheel.
Dimension II: -202.00 mm (7.95 in)
NOTE: The following measuring procedures must be completed accurately. Inaccurate measurements lead to incorrect contact pattern requiring additional disassembly and reassembly of input pinion and differential.
STEP 4 Reassembly of input pinion
Dimension III: -42.60 mm (1.68 in) Difference = shim s = 1.00 mm (0.04 in)
Read dimension I (arrow) from axle drive housing. Dimension I e.g. 245.60 mm (9.67 in).
STEP 2
6-04.PNG
Cool external bearing. With a driver tool, 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 pinion dimension (arrow), Dimension II. Dimension II e.g. 202.00 mm (7.95 in).
6004-29
STEP 5
STEP 7
6-05.PNG
6-07.PNG
Insert determined shim size e.g. s = 1.00 mm (0.04 in) into housing hole.
Heat tapered roller bearing. Insert it onto 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 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
Cool internal bearing outer ring. Bring it into contact position within housing hole using 380100001 assembly fixture. 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 when reusing the spacer removed during disassembly e.g. s = 8.18 mm (0.32 in). NOTE: A later check of tolling torque is needed.
6004-30
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). Uses slotted nut wrench CAS2842 and clamping device 380001564.
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 (arrow) 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 (13.3 to 26.6 pound inches) without shaft seal. NOTE: When installing new bearings try to achieve upper value of rolling torque. NOTE: In case of deviations from needed rolling torque, correct with a corresponding spacer as specified in Step 8. For insufficient rolling torque install thinner spacer ring. Excessive rolling torque install a thicker spacer ring.
6004-31
STEP 13
STEP 15 Determination of shims for setting bearing rolling torque (differential housing) and backlash (bevel gear set)
6-13.PNG
Grease O-rings (arrows) and insert them into annular grooves of piston. NOTE: Steps 13 and 14 are only necessary for DHL versions.
STEP 14
6-15.PNG
Determine required shims on the basis of the read value (deviation /te st dimension) and the corresponding specifications of the following table: (KRS - SET - RIGHT) (KRS = bevel gear set): For deviation, see rear side of crown wheel. The test dimension “106” is stamped into the crown wheel rear side. If no + or - deviation is indicated, this value corresponds to actual value “0” in the table below. According to this value, the required shims are allocated in the table below.
6-14.PNG
Inser t piston (arrow) into bearing housing until contact is made.
Any + or - deviation of the 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, the required shims are allocated in the following table.
STEP 16
6-16.JPG
1 = Axle housing 2 = Shim (crown wheel side) 3 = Shim (differential carrier side) 4 = Axle housing
6004-32
Shims for differential D/DL and DHL-2400 in ZF axles MT-L 3105 II Crown wheel
-20
-10
-
10
Deviation
-0.2
-0.1
0
0.1
Shim
0.8
0.9
1.0
1.1
84354725
84354726
84354727
84354728
1.2
1.1
1.0
0.9
84354730
84354728
84354727
84354726
marking
Diff. cage side Shim thickness Shim Order no. Shim Crown wheel side Shim thickness Shim Order no.
6004-33
STEP 17
STEP 20
6-17.PNG
6-20.PNG
Insert selected shim e.g. s = 1.0 mm (0.04 in) into hole of axle housing and adjust bearing outer ring (arrow) until contact is obtained.
Mount two locating pins 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).
STEP 18
NOTE: Test mount axle housing without O-ring.
STEP 21
6-18.PNG
Cover some drive and coast flanks of crown wheel with marking ink. Insert premounted differential into axle drive housing.
6-21.PNG
Leakage test of lock
STEP 19
Pressurize lock p = 1 bar (14.5 psi), close shut-off valve and remove air line. No noticeable pressure loss is allowed to occur within 10 seconds. NOTE: This operation is only necessary for version with DHL.
6-19.PNG
Insert selected shim e.g. s = 1.0 mm (0.04 in) into hole of axle housing and adjust bearing outer ring (arrow) until contact is made.
6004-34
STEP 22
STEP 24 Reassembly of shaft seal (Steps 24 to 26)
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 patter examples at the beginning of this section. NOTE: If a contact pattern deviation exists, a measuring error was made during shim size determination (Step 5). This must be corrected.
6-24.PNG
Loosen slotted nut using CAS2842 slotted nut wrench with 380001564 clamping device and pull input flange from input pinion.
STEP 25
STEP 23
6-25.PNG
Use driver tool CAS2841 to mount shaft seal with seal lip facing oil chamber. 6-23.PNG
After contact pattern check, insert differential into axle drive housing again.
NOTE: Exact installation position of seal is obtained when using specified driver tool. NOTE: Wet outer diameter of shaft seal with mineral spirits just before installation. Fill space between seal and dust lip with grease.
6004-35
STEP 26
6-26.PNG
Insert input flange and secure with disc and slotted nut using slotted nut wrench CAS2842 and clamping device 380001564. Torque to 1200 Nm (885 pound feet). NOTE: Cover threads of slotted nut with Loctite (Type no. 262).
6004-36
AXLE HOUSING Reassembly
STEP 3
STEP 1
7-03.PNG
Mount fitting. Torque to 36 Nm (27 pound feet). 7-01.PNG
Grease O-ring (arrow) insert it into axle housing.
STEP 4
STEP 2
7-04.PNG
7-02.PNG
Mount M20 locating pins. Use a suitable lifting device and bring axle housing into contact position with axle drive housing. Secure axle housing with hex bolts. Torque to 560 Nm (413 pound feet).
Grease O-ring. Insert it into annular groove of brake tube (arrow).
STEP 5
WARNING: After assembling axle housing secure axle with clamping brackets.
7-05.PNG
Mount brake tube with threaded connection and hex nut (arrow). Torque to 100 Nm (74 pound feet).
6004-37
STEP 6
7-06.PNG
Install plug and new O-ring. Torque to 50 Nm (37 pound feet).
6004-38
OUTPUT AND BRAKE Reassembly
STEP 3
STEP 1
8-03.PNG
8-01.PNG
Pull wheel stud into output shaft until contact is made.
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: A special tool should be used for repairs when exchanging individual wheel studs with a mounted output shaft. On a new output shaft, mount wheel studs with a press.
STEP 2
8-04.PNG
Mount new slide ring seal (part 2) into brake housing. NOTE: For installation position of seal, go to Step 9.
8-02.PNG
Heat tapered roller bearing and insert it into 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 that 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.
6004-39
STEP 5
STEP 7
8-05.PNG
8-07.PNG
Insert both bearing outer rings (arrows) into brake housing until contact is made.
Insert back-up rings and grooved rings into annular grooves of brake housing (arrows). NOTE: For installation position, go to Step 9.
STEP 6
STEP 8
8-06.PNG
Use a suitable lifting device and insert premounted brake housing over output shaft until contact is made. 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.
8-08.PNG
Clean annular groove of brake housing with mineral spirits. Insert guide ring into annular grove (go to Step 9). Secure it with Loctite (type no. 415) at its ends (arrows). NOTE: Full circumference of guide ring must be in an exact contact position. WARNING: Upon installation, orifice of guide ring must show upwards - 12 o’clock position.
6004-40
STEP 9
STEP 11
8-11.PNG
Insert piston into brake housing and install with dealer fabricated fixing device until contact is made. NOTE: Sufficiently oil seal surface of piston/back-up rings, grooved rings and guide ring with W-10 oils.
STEP 12 8-09.JPG
1. Brake housing 2. Guide ring 3. Back-up ring 4. Piston seal 5. Piston seal 6. Back-up ring 7. Metal Face Seal (Heavy Duty Option) Combi Seal (Standard) 8-12.PNG
8. Output shaft
Insert disk and cup spring with convex side showing upwards into piston.
STEP 10 STEP 13
8-10.PNG
Flush-mount slotted pins into holes of piston.
8-13.PNG
Insert cover and secure it with hex bolts. Torque to 34 Nm (25 pound feet).
6004-41
STEP 14
STEP 17
2 1
3 4
8-14.PNG
Insert outer and inner disks. NOTE: For number of disks and disk arrangement, refer to related spare parts list.
STEP 15
8-17.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 18
8-15.PNG
Insert end plate. 8-18.PNG
STEP 16
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 with retaining rings.
2 1
NOTE: Adjust bearing inner rings after cooling. WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.
8-16.JPG
Press stop bolt (1) into planetary carrier (2) until contact is obtained.
6004-42
STEP 19
STEP 21
8-19.PNG
8-21.PNG
Heat tapered roller bearing. Install it on planetary carrier until contact is made.
Align disk package centrally and radially. Heat output shaft. Use a suitable lifting device to insert planetary carrier into teeth of output shaft.
WARNING: Always wear protective gloves to prevent burning your hands when handling heated parts.
WARNING: Always wear protective gloves to prevent burning your hands when handling heated or cooled parts.
STEP 20 STEP 22 2 1
8-20.PNG
Wet contact face of bearing inner ring (1) and profile teeth (2) in output shaft with anti-corrosive agent.
8-22.PNG
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. Remove old locking bolts.
6004-43
STEP 23
STEP 25
8-23.PNG
Pivot output 90 degrees. Insert disk and secure planetary carrier with new locking bolts. NOTE: Tighten locking bolts successively with a tightening torque of 200 Nm (148 pound feet). Then, retighten locking bolts successively with a torque of 500 Nm (369 pound feet).
8-25.PNG
Insert cover into output shaft until contact is made.
STEP 26
STEP 24 2
8-26.PNG
Set axial play of sun gear shaft 0.5 to 2.0 mm (0.02 to 0.08 in). Use a straight edge to determine dimension I, from mounting face of brake housing to front face of stop bolt.
1 8-24.PNG
Install new O-ring (1) and cover. Wet contact face (2) with Terostat - MS 9360. NOTE: Curing period for Terostat is greater than 24-hours.
Dimension I e.g. 40.80 mm (1.61 in)
6004-44
STEP 27
STEP 29
8-27.PNG
8-29.PNG
Insert stub shaft into teeth of axle bevel gear until contact is made.
Using a straight edge measure dimension II, from front face of sun gear shaft to mounting surface of axle housing.
NOTE: Be aware of installation position. Mount stub shaft with long teeth towards differential.
Dimension II e.g. 38.20 mm (1.50 in) CALCULATION EXAMPLE:
STEP 28
Dimension I: 40.80 mm (1.61 in) Dimension II: 38.20 mm (1.50 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)
STEP 30
8-28.PNG
Insert sun gear shaft until contact is made.
8-30.PNG
Insert sun gear shaft into planetary carrier.
6004-45
STEP 31
STEP 34
8-314.PNG
8-34.PNG
Insert shim(s) e.g. s = 1.60 mm (0.06 in) with grease into sun gear shaft.
M o u n t a d j u s t i n g b o l ts a n d u s e l i f t i n g d ev i c e 380002303 to bring output into contact position with axle housing. Secure output using hex bolts. Torque to 560 Nm (413 pound feet).
STEP 32
NOTE: Attach load carrying device with wheel stud.
STEP 35
8-32.PNG
Attach O-ring (arrow) with grease into countersink of brake housing. 8-35.PNG
STEP 33
Mount bleeder valve (arrow).
8-33.PNG
Grease O-ring (arrow) and install it in axle housing.
6004-46
STEP 36
Differential Lock off: When ro tatin g inp ut flan ge, 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.
8-36.PNG
Check brake hydraulics for leakage. Before starting test bleed hydraulic system. Pressurize brake temporarily (5x) with a max pressure of p = 100 bar (1450 psi). High-pressure test: Build up test pressure p = 100 -10 bar maximum and close connection to HP 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: 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.
8-37.PNG
Check operability of DHL. Build up maximum pressure p = 20 bar (290 psi) and close connection to pump via shut-off valve. Differential Lock on: When rotating input flange, both outputs must have same direction of rotation.
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.
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.
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.
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
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.
1
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.).
1
84324413_205.TIF
8
10
FIGURE 2. 821F SERIES WHEEL NUT/BOLT TORQUE SEQUENCE
12
6
3 4 5
11 7
2
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.).
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 4 4 6 6 6 8 8 8
7001-3
3
4
7 9
5 6
1
10
8 2
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
7001-4
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 5.
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 5. 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.
7001-5
1 6 2
7
3 9
4
10
8
5
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
7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS Removal NOTE: 821F and 921F machines are now equipped with brake Damping Accumulators located on the front axle (9) and frame (10). See illustration on page 3. 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 3 and 7. 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 3. 19. Remove brake damping accumulators from machine. 20. Install plugs in hoses.
Installation NOTE: 821F and 921F machines are now equipped with brake Damping Accumulators located on the front axle (9) and frame (10). See illustration on page 3. 1. Mount the accumulators (1) in the accumulators clamps (7), do not tighten clamps at this time. Refer to illustration on page 7. 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).
to
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.
7001-7
2
3
5 6 4
7
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
7001-8
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 9. 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 9. 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.
7001-9
9 6
8
7
1
5
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
7001-10
NOTES
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.
E
C
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.
F
D
B
A
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.
1
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
1
2
3
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.
1
BD00N121
7002-9
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) 1
2
3
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
6
1
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
10
18 10 19 7
13
8 9 11 12 7
8
9
10
11
5 4 2
6
3
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
B
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
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.
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
8
6 7 5
1
3 2
4
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
2
1 3 4
5
6
7
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
3
8 4 6 7
1 5
2
7
8
7
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
5
5
7
1
4 3
4 6
3
1
2 7
7
6
3
6
2
7 1
2
4
7
7 1
2
6
3
5
4
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
5
6
4
6
3
2 1
3 2
1
2
6
3 4
1
2
6
3
5
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
7
4 5 6 4
16
5 8
15 6
1
13
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
3
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
3
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 821F - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921F - 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 6 6 6 6 7 7 7 8 8 9 10 10 11 12 12 13 14 14 15 16 16 17 18 18 19 21 21 21 22 23
8002-3
821F - SPECIFICATIONS Manufacturer........................................................................................................................................ Bosch-Rexroth High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 3600 psi at 2000rpm) Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 2000 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..............................................................................................................................290 bar (4200 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
921F - SPECIFICATIONS Manufacturer ....................................................................................................................................... Bosch-Rexroth High pressure pump (closest to transmission) ............................................... 170 L/min at 24822 kPa, at 2000 r/min (44.9 gpm at 3600 psi at 2000rpm) Low pressure pump (furthest from transmission) ........................................... 120 L/min at 24822 kPa, at 2000 r/min (31.6 gpm at 2000 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..............................................................................................................................290 bar (4200 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.
8002-5
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
8002-6
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?.
No
Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.
No
See Page 19. Do the flow meter test of the hydraulic pump.
No
Adjust the limit pressure. See page 12 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 12 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.
8002-7
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?
No
The loader control valve is damaged. See Section 8005 and repair the loader control valve
No
See Section 8006 and repair the cylinder.
No
See Section 8005. Disassemble the loader c o n t r o l va l ve a n d c h e ck fo r wo r n o r damaged parts.
No
Repair the component as necessary.
No
See the Ride Control Test Procedure page 22 in this section.
Yes Check the cylinder piston packing. Is the packing good? Yes See Page 21. 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 14. 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.
8002-8
TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check
STEP 3
STEP 1
1
BD06G180
1 BD00M041
2
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).
8002-9
STEP 7 The difference between the two readings should be 24 to 27 bar (350 to 390 psi).
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).
8002-10
TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check
STEP 3
STEP 1
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:
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.
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).
8002-11
STEP 7 The difference between the two readings should be 25 to 28 bar (360 to 400 psi).
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).
8002-12
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
1
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.
8002-13
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
8002-14
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
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
1
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.
8002-15
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.
1
BD06F147
1. STEERING LIMIT VALVE
8002-16
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
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.
1
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.
8002-17
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.
8002-18
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.
8002-19
HIGH PRESSURE PUMP FLOW TEST NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 8 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 20.
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.
8002-20
1
2
4
3 5 6 11 12
13
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
8002-21
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.
3
STEP 5
4 1
1
5
2
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.
6
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
4
5
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.
8002-22
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.
8002-23
HYDRAULIC COMPONENT LOCATIONS 5 6
8
7 9 4
10
2 3
8
11 15 14 16 19 18 17
12 13
1
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.
8002-24
23 24 21 22
26
25
20
30 31
29
28
27
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.
8002-25
NOTES
8002-26
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
do
not
return
to
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.
in
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 821F - PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921F - PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 3 3 4 5 9 11
8004-3
821F - PUMP SPECIFICATIONS Manufacturer........................................................................................................................................ Bosch-Rexroth High pressure pump (closest to transmission) .................................................... 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 3600 psi at 2000rpm) Low pressure pump (furthest from transmission) ................................................ 120 L/min at 172 bar, at 2000 r/min (31.6 gpm at 2000 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)
921F - PUMP SPECIFICATIONS ) Manufacturer........................................................................................................................................ Bosch-Rexroth High pressure pump (closest to transmission) ............................................... 170 L/min at 24822 kPa, at 2000 r/min (44.9 gpm at 3600 psi at 2000rpm) Low pressure pump (furthest from transmission) ........................................... 120 L/min at 24822 kPa, at 2000 r/min (31.6 gpm at 2000 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
9
8
5
6 4
5 4 3
10 1
2
11 12 13 21
22
23
24
20 19 18 14
17
15
16
30 29 15 26
27
28
25
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
21
7
6
20 19
8 18
6
17
9
16
10 11
6 15
14 8 12
12
13
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
26
27
25 24 23 28
6 31
29 30
6 6 33 31
34 6 34
6
24
33 32
24
23 23 35
30
32
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
36
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
31
29
30 33 6
34
6
23 24 23
32
35
33 31
23 24
6 34
6
29
32
30
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
1
1
1
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
2
1 2
1
1 1
2
BS03C026
1. O-RINGS
3
1
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
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
1
1
BS03C031
1. O-RINGS
2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (13).
8005-13
STEP 23
3
2
4
1
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
3
4 A
2
1
1
See Note
1
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
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
2
A
1
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
1 1
3
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).
2
STEP 10 Install and torque locking screw (14) to 100 Nm (73.7 pound feet).
2 1
STEP 11
1
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).
2
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).
1
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
13
5 6 7 4 8 11 9 10 15
12
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
15
12
16 11 7
13 14
8 8
9
6 1
5 10
19
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
11
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.
10
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
3. Clean bore for bushings (2) in tube (4) eye.
1
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
3
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.
2
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).
1
STEP 3 Remove valve cartridge (3) from valve housing (7).
2
STEP 4 Remove and discard all O-rings (4 and 5) and back-up rings (6).
Cleaning and Inspection STEP 5
3
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
5
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
6
6
Check bores in valve housing (7) for deep scratches, gouges, and other damage. Replace valve if any of these conditions are seen.
5 7
6
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
E
C
F
D
A
B
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
1
5
2 3
6
7
4
9
8
10
9
11
12
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
1
2
6
5
4
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
10
11
8
13 12
7 15
6
14
5 4
16
3 2
17
1
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
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.
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.
1
2
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
No
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
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
VERY LOW
16
NO COOLING
HIGH
HIGH
17
NOT ENOUGH COOLING
NORMAL TO HIGH
NORMAL
19
NOT ENOUGH COOLING
LOW
LOW
20
NOT ENOUGH COOLING
HIGH
LOW
22
NOT ENOUGH COOLING
HIGH
HIGH
23
INTERMITTENT COOLING
NORMAL
NORMAL
24
NOISE IN SYSTEM
NORMAL TO HIGH
HIGH
25
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
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
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
to
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.
on
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.
or
frost
on
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
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
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
31-36 Nm
40-46 Nm
45-52 Nm
45-52 Nm
ALUMINUM TO BRASS
10-14 Nm
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.
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.
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
6
5
7 4
2 1 8 9
10
18 17 12
14
11
13
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
2
3
1
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
2
3
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
2
3
1
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
1
Install plugs in the hoses and caps on the fittings.
2
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
5
4
1
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
1
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
5
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
4
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
1
BS01C082
1. HEIGHT CONTROL TARGET
2. RETURN TO TRAVEL TARGET
3. TARGET MOUNTING PLATE
MACHINE
A
APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT
B
APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT
821F Z-Bar
56 mm (2.2 inches)
414 mm (16.3 inches)
42 mm (1.6 inches)
3302 mm (130 inches)
821F XR
70 mm (2.76 inches)
587 mm (23.11inches)
61 mm (2.4 inches)
4000 mm (157.48 inches)
921F Z-Bar
56 mm (2.2 inches)
414 mm (16.3 inches)
42 mm (1.6 inches)
3302 mm (130 inches)
921F XR
70 mm (2.76 inches)
587 mm (23.11inches)
61 mm (2.4 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
10
19
18
22
20 18
8 16 6
9
7
15
17
2 11
1 21
5 4
5
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
3
1
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
1 2
3
3
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
3
1
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
3
8 4 6 7
1 5
2
7
8
7
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
5
5
7
1
4 3
4 6
3
1
2 7
7
6
3
6
2
7 1
2
4
7
7 1
2
6
3
5
4
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
5
6
4
6
3
2 1
3 2
1
2
6
3 4
1
2
6
3
5
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. Cooling system capacity is 36.9 liters (9.75 U.S. Gallons). 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
1
9. Remove all the silicone from the forming tool immediately after use.
2
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.
3
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°
120°
4 MM (3/16 INCH) R
FIGURE 2. SILICONE FORMING TOOL TEMPLATE
496L93
9010-5
5
2 1 3 4
6 1
2
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.
9020-8
INDEX OF FUNCTIONS
SHT
SHT
SHT
ECD
SHT
SHEET
SHEET
SHEET
SHEET
6
BACKUP ALARM
5 , 14
5
COLOR ABBREVIATIONS 70 62
SHT
SHT
SHT
SHT
SHT
SHT
71
SHT
LARGE CONNECTOR LIST SHEET
INDEX / WIRE INFORMATION SHEET
SHEET
CONNECTOR LIST
1
2
SHEET
3
18
13
21
14
15
20 5 9
_ 2
8
158 1 10
4
Relay in location F5/F6
160
Relay in location F3\F4 6
16
11
17 159
CONNECTOR LIST
3
COLD START
4 IGNITION SWITCH POWER DISTRIBUTION ELECTRICAL SCHEMATIC SIDE 1 721F, 821F, 921F TIER 2 WHEEL LOADER Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419915
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
93
95
78 91
North American models European and International models 101
101
100
100
Turn Signal
Driving Lights
Light/ Horn
79
Horn
94
103 96
97
102
5
ENGINE CONTROL
LIGHTING 1
6
BACKUP ALARM
172
89
54 173
171
81
55
57 59
56 88
87 174
80
86 46
47 45
61 48 58 49 85 50 84 51
52
170
53
83
60 82
LIGHTING 2
7
TRANSMISSION CONTROLS ELECTRICAL SCHEMATIC 721F, 821F, 921F TIER 2 WHEEL LOADER
8 SIDE 2
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419915
25
35 36
26
63
29
33 64
31
32
68
98
74
27
72 37
67
65
99
75 69 73
39
28
76 40
34
38
66
30
41 42 44
43
9
INSTRUMENT CLUSTER
10
MACHINE CONTROLS
121 113 122
155
129
154
122 126
104
128
108
130
105 114
106
125
124
123
119
115 107
117
109 156
111
116 112 113
Note: Telematics for future models
127 157
110 118 R S
HOOD LIFT
11
HVAC
R S
AIR SEAT
RADIO POWER/CONVERTER 12 ELECTRICAL SCHEMATIC 721F, 821F, 921F TIER 2 WHEEL LOADER
SIDE 3
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419915
145
144 143 146 184
177 175
147
8
8 148
185
176
179
153 150
149
152 151
178
181
182 180
183
JOYSTICK STEERING (FOR PL18 & PL23 ONLY)
186
13
STANDARD HVAC
14
COMPONENT NUMBERS
721F, 821F, 921F Tier 4 Wheel Loader ELECTRICAL SCHEMATIC LEGEND INDICATES CONSTANT POWER INDICATES SWITCH IS INDICATES SWITCH IS
POWER WHEN KEY ON POWER WHEN KEY IN START POSITION POWER RELAY A POWER RELAY B POWER RELAY C POWER RELAY D ILLUMINATION
ELECTRICAL WIRING INFORMATION
15
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
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
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
# 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
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
7 8 8 8 8 13 13
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
# 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
REAR VIEW CAMERA/MONITOR DIFFERENTIAL LOCK SWITCH (MANUAL) DIFFERENTIAL LOCK SWITCH DIFFERENTIAL LOCK SOLENOID LOCKUP SOLENOID JOYSTICK PVRES TRANSMISSION KICK DOWN SWITCH
COMPONENT NUMBERING INFORMATION ELECTRICAL SCHEMATIC 721F, 821F, 921F TIER 2 WHEEL LOADER
16 SIDE 4
Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419915
1
9
2
15
19
18 16
8
YPP
UNLOCK
LOCK
11
21
A1
20
P
T
16B
MX B1
16A
12
X1
20D
20A
T
280 bar
14 16C R
4
20C
F
R1
13
13A
20B
2
13F
X
3
16D 1
13E
B
2
P
5 13D
3
A
16E
13B
1
240±8% L/min
240±8% L/min OPTION
B3
ø2.0
A3
a3
528789
)(
898999
30 bar
22H
22C
22E
35
234 bar
Note 2
LS IMPL
.64
.8 45B
EF
LS
ø2.0
ø0.8
868050
b3
B2
A2 ø2.0
24
CF 24A
P
45D
T
M1
35A
T
30
G1 34
LS
X2
33
34A
33A
34B
33B
CF
32 27
30B
2
24C
23
T 1
0.31
0.31
46
46
29
36
Note 1
ST
30A
240 bar
40
SLS
24B
LS
0.7
35C
35B
G2
X1
L
bar
TANK
M1
899039
234
IN
R
162 bar
22K
45
43
M2
22K
45B
45A
44
P
b2
45C
ø0.8
b1
280±8% A1 L/min
22
M2
23cc
33C
34C
R
3
30C P
T
41
L1 L2
S1
S2
L4
L3
31 11 cc
T
COMPONENTS 1
37
NOTES
CIRCUIT DIAGRAM LEGEND PUMP SUPPLY
CHECK VALVE
RESTRICTOR
FILTER OR SCREEN
OIL COOLER
28C
26
38
COMPONENT NUMBER
T
28B
p
25
SHOWS CIRCUIT CONNECTED
P
1.8
39
#
28
P
33D
34D
L
LS
0.75 28A
SHOWS CIRCUIT CROSSING NOT CONNECTED
290 bar
936718
22E
S2
22D
936718
S1
R901007569
859551
22J
290 bar
936725
224±3 bar
847160
R901075587
22D
22E
22E
TP1: UNLOADING PUMP PRESSURE TP9: PILOT PRESSURE SUPPLY
868050
280±8% L/min BOOM
B2 22C
290 bar
TP5: STEERING PUMP PRESSURE
936718
290 bar
TP2: IMPLEMENT LOAD SENSE
936718
22D
737012
TP3: STEERING LOAD SENSE
22B
22F
22G
329140
TP7: REAR BRAKE ACCUMULATOR
8-10.8 bar
MT1
TP6: FRONT BRAKE ACCUMULATOR
ø0.8
20±8% L/min
A2
Pst 22C
10
TP10: FRONT BRAKE TO AXLE
23cc
528789
528789
T
R901075585
11
TP11: REAR BRAKE TO AXLE
42
ø2.0
765876 1.2
7
22K
Mp
LS
17
A1
P
22A
a1
0.6
R2
pst
T2
22K
868050
13C
ø0.8
6
B
BUCKET
N
B1 280±8% L/min
T1'
a2
T1
CIRCUIT
LOAD SENSE
COMPONENT
PILOT LINE TYPES
Note 1 : Optional Check Valve for Ride Control Only Note 2 : Check and Relief Valves not used with Fan Reverser
37
Rear Axle Brakes Modulation Pressure 68 to 75 bar (985 to 1090 PSI) 2 Front Axle Brakes Modulation Pressure 70 to 77 bar (1015 to 1115 PSI) 3 Brake Damping Accumulators 0.16 liter (0.17 quart) 7 bar (102 PSI) Precharge 4 Parking Brake 5 Brake Signal, 5-speed transmission 6 Brake Declutch Switch, 4-speed transmission Electrical Connector PBD 24 bar (350 PSI) 7 Brake Light Switch 4.1 bar (60 PSI) Increasing 8 Parking Brake Accumulator 0.16 liter (0.17 quart) 96 bar (1390 PSI) Precharge 9 Front Brake Accumulator 3.5 liter (3.7 quart) 70 bar (1015 PSI) Precharge 10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 3.5 liter (3.7 quart) 70 bar (1015 PSI) Precharge
CONVERSION INFORMATION 1 bar = 14.5 pounds per square inch (PSI) 1 liter per minute = .264 gallons per minute
11 Redundant Accumulator Pressure Switches Electrical Connectors PRB1, PRB2 Rising < 91 bar (< 1320 PSI) Falling 70 to 84 bar (1015 to 1220 PSI) 12 Low Brake Pressure Warning Switch Alarm OFF 138 bar (2000 PSI) Increasing Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 13 Brake Valve 13A Parking Brake Solenoid Electrical Connector YPB 13B Front Brake Valve 13C Rear Brake Valve 13D Accumulator Isolation Check Valve 13E Accumulator Charging Spool 13F Priority Valve Cut-In Pressure 157 to 167 bar (2275 to 2420 PSI) Cut-Out Pressure 190 to 196 bar (2755 to 2845 PSI) 14 Coupler Locking Valve 15 Coupler Locking Cylinders 16 Pilot Control Valve 16A Pilot ON/OFF Solenoid Electrical Connector YPP 16B Bucket Pilot Control
16C 16D 16E 17
18 19 20 20A 20B 20C 20D 21
22 22A 22B 22C 22D 22E
Lift Pilot Control Auxiliary Hydraulics Pilot Control 1 Auxiliary Hydraulics Pilot Control 2 Pilot Control Accumulator 0.75 liter (0.79 quart) 13.8 bar (200 PSI) Precharge Bucket Cylinder Z-Bar Lift Cylinders Ride Control Valve Ride Control Solenoid Electrical Connector YRC Ride Control Spool Valve Manual Bleed Valve Pressure Relief Valve 280 bar (4060 PSI) Ride Control Accumulator 3.78 liter (4 quart) 14.5 bar (210 PSI) Precharge Loader Valve Load Sense Shuttle Valve Regeneration Relief Valve Flow Compensator Spool Regeneration Check Valve Circuit Relief Valve with Anti-Cavitation
22F Pilot Pressure Reducing Valve 29 to 40 bar (420 to 580 PSI) 22G Pilot Pressure Relief 22H Load Sense Signal Bleed Down Orifice 22J Loader Main Relief 22K Shuttle Check Valve 23 Steering Cylinders 24 Steering Control Valve 24A Steering Spool 24B Gerotor Pump 24C Circuit Relief Valve 25 Steering Back Pressure Valve 8 to 10 bar (115 to 145 PSI) 26 Steering Back Pressure Sensor Joystick Steering Only 27 Joystick Steering Load Sense Resolver 28 Joystick Steering Valve 28A Control Spool 28B Pressure Reducer 28C Pilot Dump Valve 29 Auxiliary Steering Accumulator 0.32 liter (0.34 quart) 60 bar (870 PSI) Precharge 30 Auxiliary Steering Control Valve
30A Auxiliary Steering Activation Solenoid Electrical Connector YSS 30B Relief Valve 240 bar (3480 PSI) 30C Priority Spool 31 Auxiliary Steering Pump 32 Auxiliary Steering Pressure Switch Electrical Connector PSS 33 Second Pump (Farthest from Transmission) 120 LPM (31.6 GPM) Cut Off 280 bar (4060 PSI) Delta 24 to 26 bar (350 to 375 PSI) 33A Compensator Differential Pressure Spool 33B Compensator High Pressure Cutoff Spool 33C Control Piston with Spring 33D Rotating Group with Swash Plate 34 First Pump (Closest to Transmission) 120 LPM (31.6 GPM) Cut Off 280 bar (4060 PSI) Delta 28 to 30 bar (405 to 435 PSI) 34A Compensator Differential Pressure Spool 34B Compensator High Pressure Cutoff Spool 34C Control Piston with Spring 34D Rotating Group with Swash Plate 35 Priority Valve
35A Priority Spool 35B Differential Pressure Relief 40 bar (580 PSI) 35C Steering Relief 216 bar (3130 PSI) 36 Brake Pump 37 100 Mesh Strainers 38 Hydraulic Reservoir 90 liter 39 Reservoir Vent 100 mesh 0.03 bar check 0.35 bar relief 40 Filter Electrical Connector PHF 10 micron media Bypass 3.4 bar (50 PSI) Warning Switch 2.7 bar (40 PSI) 41 Oil Cooler Thermal Valve 2.4 to 3.6 bar (35 to 52 PSI) Bypass 42 Hydraulic Oil Cooler 43 Oil Cooler Fan
44 Standard Fan Valve 162 bar (2350 PSI) 45 Fan Reversing and Variable Valve 45A Crossover Relief 234 bar (3395 PSI) 45B Reversing Spools 45C Pulse Width Modulation (PWM) Relief Valve 165 bar (2390 PSI) 45D ON/OFF Reversing Solenoid Electrical Connector YFR 46 Steering Cylinder Relief Valves 345 bar (5000 PSI)
HYDRAULIC SCHEMATIC 821F WHEEL LOADER Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419918.
1
9
2
19
18
15
21
16
8
A1
UNLOCK
LOCK
11
P
20
16B
X1 MX
B1
16A
12
T
20D
T
20A
14
280 bar
16C
R 4
20C
F
R1
13
13A
2
X
3
13F
20B 16D
1
13E
A
16E
13D
3
B
2
P
5
13B
1
22D
22E
OPTION
B3 240±8% L/min
A3 240±8% L/min
ø2.0
528789
22C
22D
22E
290 bar
936718
936718
290 bar
S1
R901007569
22J
859551
898999
30 bar
22H
22E
S2
22E
TP9: PILOT PRESSURE SUPPLY
936725
TP1: UNLOADING PUMP PRESSURE
)(
224±3 bar
R901075587
290 bar
936718
290 bar
TP5: STEERING PUMP PRESSURE
936718
22E
737012
TP3: LOAD SENSE SIGNAL
22D
329140
MT1
8-10.8 bar
TP10: FRONT BRAKE TO AXLE
22F
847160
22C 22G
TP7: REAR BRAKE ACCUMULATOR
868050
ø0.8
BOOM
Pst 528789
528789
R901075585
T
22C
10
TP6: FRONT BRAKE ACCUMULATOR
a3
B2 280±8% L/min
20±8% L/min
A2
ø2.0
868050
Mp
LS 11
TP11: REAR BRAKE TO AXLE
22K
765876 1.2
7
A1
22A
P
17
a1
0.6
R2
pst
13C
T2
22K
ø0.8
6
B
BUCKET
N
B1 280±8% L/min
T1'
a2
T1
M2
23cc
162 BAR
234 bar
IN
35
234 bar
TANK
M1
ø2.0
ø0.8
868050
b3
B2
A2 ø2.0
899039
45
EF
LS
LS IMPL
0.64 45B
Note 2
0.47
LS2
45D
35A
T
M1
G1 34
X1
35B
G2
24
CF
L
43
22K
LS1
P
T
30
SLS
ST
32
CF
X2
27
30A
34A
33A
34B
33B
240 bar 30B
2
46 23
T 1
0.31
0.31
24B
24C
LS
0.7
35C
33
46
29
36 40
Note 1
LS
24A
R
42
22K
45B
45A
44
P
b2
45C
M2
ø0.8
b1
280±8% A1 L/min
22
23cc
33C
34C
R
3
30C
28A 41
34D
L1 L2
S1
P
T
P
33D
S2
28
LS
0.75
P
T
L
1.8 L4 L3
31
39
28C
28B
p
26 11 cc
25
T
38
COMPONENTS 1
37
NOTES
CIRCUIT DIAGRAM LEGEND PUMP SUPPLY
# SHOWS CIRCUIT CROSSING NOT CONNECTED
SHOWS CIRCUIT CONNECTED
COMPONENT NUMBER
CHECK VALVE
RESTRICTOR
FILTER OR SCREEN
OIL COOLER
CIRCUIT
LOAD SENSE
COMPONENT
PILOT LINE TYPES
Note 1 : Optional Check Valve for Ride Control Only Note 2 : Check and Relief Valves not used with Fan Reverser
37
Rear Axle Brakes Modulation Pressure 68 to 75 bar (985 to 1090 PSI) 2 Front Axle Brakes Modulation Pressure 70 to 77 bar (1015 to 1115 PSI) 3 Brake Damping Accumulators 0.16 liter (0.17 quart) 7 bar (102 PSI) Precharge 4 Parking Brake 5 Brake Signal, 5-speed transmission 6 Brake Declutch Switch, 4-speed transmission Electrical Connector PBD 24 bar (350 PSI) 7 Brake Light Switch 4.1 bar (60 PSI) Increasing 8 Parking Brake Accumulator 0.16 liter (0.17 quart) 96 bar (1390 PSI) Precharge 9 Front Brake Accumulator 3.5 liter (3.7 quart) 70 bar (1015 PSI) Precharge 10 Rear Brake Accumulator, 3.5 liter, 70 bar precharge 3.5 liter (3.7 quart) 70 bar (1015 PSI) Precharge
CONVERSION INFORMATION 1 bar = 14.5 pounds per square inch (PSI) 1 liter per minute = .264 gallons per minute
11 Redundant Accumulator Pressure Switches Electrical Connectors PRB1, PRB2 Rising < 91 bar (< 1320 PSI) Falling 70 to 84 bar (1015 to 1220 PSI) 12 Low Brake Pressure Warning Switch Alarm OFF 138 bar (2000 PSI) Increasing Alarm ON 115 to 129 bar (1670 to 1870 PSI) Decreasing 13 Brake Valve 13A Parking Brake Solenoid Electrical Connector YPB 13B Front Brake Valve 13C Rear Brake Valve 13D Accumulator Isolation Check Valve 13E Accumulator Charging Spool 13F Priority Valve Cut-In Pressure 157 to 167 bar (2275 to 2420 PSI) Cut-Out Pressure 190 to 196 bar (2755 to 2845 PSI) 14 Coupler Locking Valve 15 Coupler Locking Cylinders 16 Pilot Control Valve 16A Pilot ON/OFF Solenoid Electrical Connector YPP 16B Bucket Pilot Control
16C 16D 16E 17
18 19 20 20A 20B 20C 20D 21
22 22A 22B 22C 22D 22E
Lift Pilot Control Auxiliary Hydraulics Pilot Control 1 Auxiliary Hydraulics Pilot Control 2 Pilot Control Accumulator 0.75 liter (0.79 quart) 13.8 bar (200 PSI) Precharge Bucket Cylinder Z-Bar Lift Cylinders Ride Control Valve Ride Control Solenoid Electrical Connector YRC Ride Control Spool Valve Manual Bleed Valve Pressure Relief Valve 280 bar (4060 PSI) Ride Control Accumulator 3.78 liter (4 quart) 14.5 bar (210 PSI) Precharge Loader Valve Load Sense Shuttle Valve Regeneration Relief Valve Flow Compensator Spool Regeneration Check Valve Circuit Relief Valve with Anti-Cavitation
22F Pilot Pressure Reducing Valve 29 to 40 bar (420 to 580 PSI) 22G Pilot Pressure Relief 22H Load Sense Signal Bleed Down Orifice 22J Loader Main Relief 22K Shuttle Check Valve 23 Steering Cylinders 24 Steering Control Valve 24A Steering Spool 24B Gerotor Pump 24C Circuit Relief Valve 25 Steering Back Pressure Valve 8 to 10 bar (115 to 145 PSI) 26 Steering Back Pressure Sensor Joystick Steering Only 27 Joystick Steering Load Sense Resolver 28 Joystick Steering Valve 28A Control Spool 28B Pressure Reducer 28C Pilot Dump Valve 29 Auxiliary Steering Accumulator 0.32 liter (0.34 quart) 60 bar (870 PSI) Precharge
30 Auxiliary Steering Control Valve 30A Auxiliary Steering Activation Solenoid Electrical Connector YSS 30B Relief Valve 240 bar (3480 PSI) 30C Priority Spool 31 Auxiliary Steering Pump 32 Auxiliary Steering Pressure Switch Electrical Connector PSS 33 Second Pump (Farthest from Transmission) 120 LPM (31.6 GPM) Cut Off 280 bar (4060 PSI) Delta 21 to 23 bar (305 to 335 PSI) 33A Compensator Differential Pressure Spool 33B Compensator High Pressure Cutoff Spool 33C Control Piston with Spring 33D Rotating Group with Swash Plate 34 First Pump (Closest to Transmission) 162 LPM (42.7 GPM) Cut Off 280 bar (4060 PSI) Delta 24 to 26 bar (350 to 380 PSI) 34A Compensator Differential Pressure Spool 34B Compensator High Pressure Cutoff Spool 34C Control Piston with Spring 34D Rotating Group with Swash Plate
35 Priority Valve 35A Priority Spool 35B Differential Pressure Relief 40 bar (580 PSI) 35C Steering Relief 216 bar (3130 PSI) 36 Brake Pump 37 100 Mesh Strainers 38 Hydraulic Reservoir 108.5 liter 39 Reservoir Vent 100 mesh 0.03 bar check 0.35 bar relief 40 Filter Electrical Connector PHF 10 micron media Bypass 3.4 bar (50 PSI) Warning Switch 2.7 bar (40 PSI) 41 Oil Cooler Thermal Valve 2.4 to 3.6 bar (35 to 52 PSI) Bypass
42 Hydraulic Oil Cooler 43 Oil Cooler Fan 44 Standard Fan Valve 162 bar (2350 PSI) 45 Fan Reversing and Variable Valve 45A Crossover Relief 234 bar (3395 PSI) 45B Reversing Spools 45C Pulse Width Modulation (PWM) Relief Valve 165 bar (2390 PSI) 45D ON/OFF Reversing Solenoid Electrical Connector YFR 46 Steering Cylinder Relief Valves 345 bar (5000 PSI)
HYDRAULIC SCHEMATIC 921F WHEEL LOADER Additional copies of this Schematic can be ordered through Technical Publications Distribution System. Part # RAC 84419921.