Protection of electronic modules during welding operations

Protection of electronic modules during welding operations

The following procedure must be followed when performing welding operations to avoid damage to electronic assemblies (e.g. instrument panel, keypad, engine......).

Shut off the engine. Turn the electrical system keyswitch to position 0 (ignition OFF) and remove the key. Disconnect the negative and the positive leads from the battery (see also: “Removing and installing the batteries”).

Unplug electronic module connectors

At several places, the connectors of electronic components must be unplugged.

Gearbox control unit “EST37A” (XA1) and front-wheel drive control “FWD” (XA8.1)

1. Remove the panel (Fig. 1). Loosen the 3 hex socket head screws and store them in a safe place. 2. Draw back retaining clamp (1, Fig. 2) and unplug connector (2) from the EST unit (A, Fig. 2) by pulling it upwards. Do not forget to disengage the lug at the front end of the connector. 3. Release and unplug connector (B, Fig. 2) in the same way as described above.

Fig. 2

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Fig. 1

Instrument panel connections

Fig. 4

1. The instrument panel is located under the trimming behind the steering wheel. The trimming is fixed to the steering column by 4 screws (Fig. 4). 2. Unplug connectors (1 + 2, Fig. 5) from the AIC.

Fig. 6

Connectors in the driver’s cab

The connectors (A, B, Fig. 7) are located at the right rear under the floor plate of the driver’s cab. The connector (C, Fig. 8) is located at the rear left of the floor plate in the driver’s cab. 1. Open the engine hood and engage in service position II (see “Opening the engine hood”). 2. Unlock and withdraw connectors (A, B, Fig. 7) and (C, Fig. 8).

Fig. 5

Engine control unit

The connectors of the engine control unit are located on the left side of the engine under the hood. (A, B, C, Fig. 6). 1. Open the engine hood (see “Opening the engine hood”). 2. Draw back retaining clamp (1, Fig. 6) and unplug connector (2) of the engine control unit (A, B, Fig. 6) by pulling it out of the socket. Do not forget to disengage the lug at the front end of the connector (C, Fig. 6).

Fig. 7

Fig. 8

Alternator connector

Unlock the hooks (1, Fig. 9) and pull out the alternator plug (2). After all these steps have been completed welding operations on the machine can begin (read and observe the instructions in: “Welding operations, safety instructions” and “Welding instructions”). When welding operations are finished, restore all connections to the electronic components. Do this by following the steps described above in reverse order.

Failure to follow this procedure will invalidate all liability and warranty claims for any damage caused.

Fig. 9

PART 5 – ANNEX

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Operating instructions Target group Part 1 INTRODUCTION BASIC SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel

Operating personnel must have the knowledge about the operation and the employment of this or comparable machines.

Part 3 INSPECTION AND SERVICING Inspection and servicing personnel

Inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Part 4 REPAIR WORK

Part 5 APPENDIX

Repair personnel

Repair personnel must have the know-how and experience relevant to the repair of this or comparable machines.

Operating personnel + Inspection and servicing personnel + Repair personnel