New Holland W110C Tier 4 Wheel Loader Service Manual (84581910B) New Holland W110C - PDF Download by www.heydownloads.com

SERVICE MANUAL W110C Tier 4 Wheel loader

Print No. 84581910B

W110C Loader 84581910B

Use for Repair Manual

W110C Wheel Loader Repair Manual 84581910B

Table of Contents Description General

Section No. Tab 1

Section Index - General Standard Torque Specifications

1001

Fluids and Lubricants

1002

Metric Conversion Chart

1003

Engines

Tab 2

Section Index - Engines Engine and Radiator Removal and Installation

2000

Stall Tests

2002

After Cooler

2003

SCR System Sensors

2020

SCR Catalyst

2030

Engine Intake Temperature/Humidity Sensor

2040

DEF/ADBLUE Heater Control Valve

2050

DEF/ADBLUE DNOx Supply Module

2060

DEF/ADBLUE Dosing Injector

2070

DEF/ADBLUE Supply Tank

2080

DEF/ADBLUE Supply Tank Level and Temperature Sensor/Pick-up and Heater

2090

DEF/ADBLUE Supply Filters

2100

For Engine Repair, See the Engine Service Manual 84392403

Fuel System

Tab 3

Section Index - Fuel System For Fuel System Repair, See the Engine Service Manual 84392403

Electrical

Tab 4

Section Index - Electrical Removal and Installation of Starter and Alternator

4001

Electrical Specifications and Troubleshooting

4002

Batteries

4003

Instrument Cluster

4005

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84581910B

W110C Wheel Loader Repair Manual 84581910B

Table of Contents Description Steering

Section No. Tab 5

Section Index - Steering Removal and Installation of Steering Components

5001

Steering Specifications, Pressure Checks, and Troubleshooting

5002

Steering Cylinders

5005

Center Pivot

5006

Auxiliary Steering Motor and Pump

5008

Power Train

Tab 6

Section Index - Power Train Removal and Installation of Power Train Components

6001

Transmission Specifications, Pressure Checks, and Troubleshooting

6002

Transmission

6003

Front Axle

6004

Rear Axle

6004

Drive Shafts, Center Bearing, and Universal Joints

6005

Wheels and Tires

6006

Transmission Control Valve

6007

Brakes

Tab 7

Section Index - Brakes Removal and Installation of Brake Components

7001

Hydraulic Brake Troubleshooting

7002

Brake Pump

7003

Brake Accumulators

7004

Parking Brake

7008

Hydraulics

Tab 8

Section Index - Hydraulics How to Read Hydraulic Schematics

8000

Removal and Installation of Hydraulic Components

8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

Cleaning the Hydraulic System

8003

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84581910B

W110C Wheel Loader Repair Manual 84581910B

Table of Contents Description

Section No.

Loader Control Valve

8005

Cylinders

8006

Coupler Solenoid Locking Valve

8007

Ride Control Accumulator

8013

Ride Control Valve

8014

Mounted Equipment

Tab 9

Section Index - Mounted Equipment Air Conditioning Troubleshooting and System Checks

9002

Air Conditioner System Service Removal And Installation Of Air Conditioning And Heater Components

9003

Loader

9006

Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF)

9007

Cab Glass Installation

9010

Electrical Schematic Foldouts and Hydraulic Schematic Foldout

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84581910B

9004

In Rear Pocket

SECTION INDEX

GENERAL Section Title

Section Number

Standard Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

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

Size

PoundFeet

Newton metres

3/4 inch

380 to 456

515 to 618

7/16 inch

54 to 64

73 to 87

7/8 inch

600 to 720

814 to 976

1/2 inch

80 to 96

109 to 130

1.0 inch

900 to 1080

1220 to 1465

9/16 inch

110 to 132

149 to 179

1-1/8 inch

1280 to 1440

1736 to 1953

5/8 inch

150 to 180

203 to 244

1-1/4 inch

1820 to 2000

2468 to 2712

3/4 inch

270 to 324

366 to 439

1-3/8 inch

2380 to 2720

3227 to 3688

7/8 inch

400 to 480

542 to 651

1-1/2 inch

3160 to 3560

4285 to 4827

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

NOTE: Use thick nuts with Grade 8 bolts.

1001-4

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

Grade 8.8 Bolts, Nuts, and Studs 8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs 10.9

Size

PoundInches

Newton metres

36 to 48

4 to 5

84 to 96

9 to 11

132 to 156

15 to 18

324 to 384

37 to 43

PoundFeet

Newton metres

24 to 36

3 to 4

Size

60 to 72

7 to 8

M10

54 to 64

73 to 87

96 to 108

11 to 12

M12

93 to 112

125 to 150

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Grade 12.9 Bolts, Nuts, and Studs 12.9

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

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

1/4 inch 6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch 6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch 7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch 7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch 9.5 mm

9/16-18

120 to 300

14 to 34

3/8 inch 9.5 mm

9/16-18

300 to 480

34 to 54

1/2 inch 12.7 mm

3/4-16

180 to 504

20 to 57

1/2 inch 12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch 15.9 mm

7/8-14

300 to 696

34 to 79 Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

3/4 inch 19.0 mm

1-1/16-12

40 to 80

54 to 108

3/4 inch 19.0 mm

1-1/16-12

80 to 128

108 to 174

7/8 inch 22.2 mm

1-3/16-12

60 to 100

81 to 135

7/8 inch 22.2 mm

1-3/16-12

100 to 160

136 to 216

1.0 inch 25.4 mm

1-5/16-12

75 to 117

102 to 158

1.0 inch 25.4 mm

1-5/16-12

117 to 187

159 to 253

1-1/4 inch 31.8 mm

1-5/8-12

125 to 165

169 to 223

1-1/4 inch 31.8 mm

1-5/8-12

165 to 264

224 to 357

1-1/2 inch 38.1 mm

1-7/8-12

210 to 250

285 to 338

1-1/2 inch 38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts PoundInches

Newton metres

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

1001-6

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

O-ring Face Seal End Nom. SAE Dash Size

Tube OD

Thread Size

PoundInches

Newton metres

Thread Size

PoundInches

Newton metres

-4

1/4 inch 6.4 mm

9/16-18

120 to 144

14 to 16

7/16-20

204 to 240

23 to 27

-6

3/8 inch 9.5 mm

11/16-16

216 to 240

24 to 27

9/16-18

300 to 360

34 to 41

-8

1/2 inch 12.7 mm

13/16-16

384 to 480

43 to 54

3/4-16

540 to 600

61 to 68

Thread Size

PoundFeet

Newton metres

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

-10

Nom. SAE Dash Size

5/8 inch 15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread Size

PoundFeet

Newton metres

1-3/16-12

95 to 100

129 to 136

-12

3/4 inch 19.0 mm

1-3/16-12

65 to 80

90 to 110

1-5/16-12

115 to 125

156 to 169

-14

7/8 inch 22.2 mm

1-3/16-12

65 to 80

90 to 110

1-5/8-12

150 to 160

203 to 217

-16

1.0 inch 25.4 mm

1-7/16-12

92 to 105

125 to 140

1-7/8-12

190 to 200

258 to 271

-20

1-1/4 inch 31.8 mm

1-11/16-12

125 to 140

170 to 190

-24

1-1/2 inch 38.1 mm

2-12

150 to 180

200 to 254

FLUIDS AND LUBRICANTS

1002

Section 1002

1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 What is Selective Catalytic Reduction (SCR)?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Selective Catalytic Reduction (SCR) - Basic instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1002-3

CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change ..................................................................................... 10.9 liters (11.5 U.S. Quarts) Total system capacity ............................................................................................... 11.8 liters (12.5 U.S. Quarts) Type of oil .......AMBRA UNITEK CJ-4 ENGINE OIL (SAE 15W-40) - see engine oil recommendations on page 4 Engine Cooling System Capacity....................................................................................................................... 22 liters (23.2 U.S. Quarts) Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol Fuel Tank Capacity ...................................................................................................................... 189 liters (50 U.S. Gallons) Type of Fuel............................................................................................. See Diesel fuel specifications on page 5 Hydraulic System Hydraulic Reservoir Refill Capacity ..........................................................................56.8 liters (15.0 U.S. Gallons) Total System Capacity............................................................................................113.6 liters (30.0 U.S. Gallons) Type of Oil ............................................................................................................... AMBRA Hydrosystem 46HV® Transmission Refill Capacity with Filter Change ............................................................................. 18.9 liters (35.9 U.S. Quarts) Type of Oil ......................................AMBRA MULTI G 134TM HYDRAULIC TANSMISSION OIL (SAE 10W-30) Axles Capacity Standard Front ......................................................................................................... 22 liters (23.2 U.S. Quarts) Standard Rear.......................................................................................................... 22 liters (23.2 U.S. Quarts) Optional Front .......................................................................................................... 22 liters (23.2 U.S. Quarts) Optional Rear........................................................................................................... 22 liters (23.2 U.S. Quarts) Type of Lubricant................................................... AMBRA MULTI G 134TM HYDRAULIC TANSMISSION OIL DEF (Diesel Exhaust Fluid) Total Capacity Urea Tank ....................................................................................... 28.6 liters (10.20 U.S. Gallons) NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil. Brake System Type of Fluid (Same as Hydraulic System).................................................................. AMBRA Hydrosystem 46HV® Grease Fittings Grease fittings as required by maintenance schedule.................................................................. AMBRA GR 75 MD

1002-4

ENGINE OIL RECOMMENDATIONS AMBRA UNITEK CJ-4 ENGINE OIL (SAE 15W-40) engine oil is recommended for use in your engine. AMBRA UNITEK CJ-4 ENGINE OIL (SAE 15W-40) engine Oil will lubricate your engine correctly under all operating conditions. If AMBRA UNITEK CJ-4 ENGINE OIL (SAE 15W-40) Multi-Viscosity Oil is not available, use only oil meeting API engine oil service category CI-4. S e e t he c h ar t b e l ow fo r recommended viscosity at ambient air temperature ranges. NOTE: Do not put performance additives or other oil additive products in the engine RH99K130 crankcase. The oil change intervals given in this manual are according to tests with AMBRA UNITEK CJ-4 ENGINE OIL (SAE 15W-40) lubricants.

WHL201213

1002-5

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

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

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

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

1002-6

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

• Keep

container tightly closed.

• Keep

container in a cool, well-ventilated area.

• Keep

away from heat and direct sunlight.

How does Selective Catalytic Reduction (SCR) work?

Thawing •

During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue® solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue® solution.

The machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue®. The machine will still function until the DEF/AdBlue® begins to flow. The SCR system will then function normally.

•

Do not heat DEF/AdBlue® for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life.

During cold engine operation at low engine coolant and ambient air temperatures, water vapor will be visible from the exhaust when the engine operates. This water vapor will resemble steam or light white smoke and will dissipate as the engine and machine components warm and is considered normal.

IMPORTANT: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue®. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue® mixture will lessen its ability to perform correctly and may cause damage to the SCR components.

NOTE: After engine shutdown, the SCR system will perform a purge cycle, which permits the supply module to continue to run for up to 70 seconds. This is to be considered normal and requires no action from the operator.

Handling and supply of additives, if any •

Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, impervious gloves are recommended. Follow the precautions listed in the SAFETY INFORMATION chapter when handling any service fluid.

•

No additives are required.

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

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

between -11 °C (12 °F) and 30 °C (86 °F).

only an approved DEF/AdBlue® container.

IMPORTANT: Contaminated DEF/AdBlue® can affect the performance of your machine. Follow all instructions in this manual when handling DEF/AdBlue®.

Shelf life Constant ambient minimum shelf life

storage

temperature

and

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

1002-7 NOTE: The main factors taken into account to define the shelf life in the previous figures are the ambient storage temperature and the initial alkalinity of DEF/AdBlue®. The difference in evaporation between vented and non-vented storage containers is an additional factor. NOTE: The information in this table is for reference only and has been provided by the International Organization for Standardization, Document number ISO 22241-3 Diesel engines - NOx reduction agent AUS 32 - Part 3: Handling, transportation and storage. Disposal •

Dispose of DEF/AdBlue® and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal.

For machines sold in California CNH must warrant the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owner’s manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owner’s manual for other warranty information. The diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, and other emission-related assemblies.

Disposal DEF

Diesel Exhaust Fluid

ISO

International Organization for Standardization

MSDS

Material Safety Data Sheet

NOx

Nitrogen Oxide

PPE

Pe r s o n a l Equipment

SCR

Selective Catalytic Reduction

ULSD

Ultra Low Sulfur Diesel

Protective

1002-8

SELECTIVE CATALYTIC REDUCTION (SCR) - BASIC INSTRUCTIONS Requirements The operator must mai n tain appropr iate DEF/AdBlue® levels at all times. The SCR system is compatible with up to 7% bio-diesel fuel.

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

screen in the filler neck will not be damaged.

•

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

•

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

• DEF/AdBlue®

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

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

Diesel Exhaust consumption

Fluid

(DEF)/AdBlue®

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

1002-9

MAINTENANCE SCHEDULE Model W110C

Daily inspection Every 10 Hours

General

Engine Oil

Bucket/attachment grease fittings

Initial 100 Hours

Hydraulic oil level

Every 250 Hours

Transmission oil level

Engine Coolant

Wheel torque

Fuel prefilter

Every 500 Hours

Every 1000 Hours

Every 1500 Hours

X X

Grease lift arm

Grease drive shaft slip joints

Cab air filter

Drive belt

X X

Engine oil filter

Replace fuel prefilter

Fuel filter

Fuel tank sediment

Axle oil level

Battery fluid level

Pivot points

Articulation fittings

Hydraulic oil level

Drive belt

Cab air filter

Replacing the engine breather filter

Change front and rear axle oil

Transmission fluid and filter

Clean breather

Calibrating the gear box

Transmission declutch pressure adjustment

Hydraulic oil and filters

Engine coolant

Every 2000 Hours

Engine air filters

Frame and cab - lubricate Engine valve clearance

X X

Fuel pre-filter

Air conditioning condenser

Height control and return to travel

As required

ADJUST

Grease fittings

Wheels and tires

DRAIN FLUID

X X

Fuel filter

Every 100 Hours

CLEANING

Grease machine and attachments

Every 50 Hours

REPLACE

GREASE

SERVICE POINTS CHECK

SERVICE INTERVAL

CHANGE FLUID

FREQUENCY IN HOURS

Return to dig Parking brake

X X

Secondary steering

Cab service

1002-10 Battery service

Electrical System

Battery electrolyte level

Auxiliary battery connections

Battery removal and installation

Fuses and relays

Work lights

Driving lights

Additional features

MAINTENANCE POINTS Model W110C 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.

METRIC CONVERSION CHART

1003

Section 1003

1003-2

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

1003-3

CONVERSION FACTORS Metric to U.S. MULTIPLY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

Force:

newton newton

3.596 942 0.224 809

ounce force pound force

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C +32

degree F

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

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

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

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

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

1003-4

U.S. to Metric MULTIPLY

TO OBTAIN

Area:

square foot acre

0.092 903 0.404 686

square meter hectare

Force:

ounce force pound force

0.278 014 4.448 222

newton newton

Length:

inch foot mile

25.4 * 0.304 8 * 1.609 344 *

millimeter meter kilometer

Mass:

pound ounce

0.453 592 28.35

kilogram gram

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Power:

horsepower

0.745 700

kilowatt

Pressure:

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

6.894 757 0.069 0.070 303

kilopascal bar kg/sq. cm

Temperature:

degree F

1.8 F - 32

degree C

Torque:

pound/inch pound/foot

0.112 985 1.355 818

newton meter newton meter

Velocity:

miles/hr.

1.609 344 *

kilometer/hr.

Volume:

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

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

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

Volume/Time:

gallon/min.

3.785 412

litre/min.

* = exact

SECTION INDEX

ENGINES Section Title

Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002 After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003

FOR ENGINE REPAIR, SEE THE ENGINE REPAIR MANUAL 84392403

Section 2000

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

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

3 3 11 20 20 23

2000-3

ENGINE Removal STEP 1

W110R381

STEP 5 BD03A040

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

STEP 2 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 W110R383

Re move bo th b att er y c over s an d disc on ne ct batteries from the machine.

STEP 6

1 W110R381

The master switch disconnect is located under the hood on the left read side of the machine. Raise the hood put master disconnect switch in OFF position.

W110R382

Loosen the screw (1) and open the access cover (2).

2000-4

STEP 7

STEP 9

4 3

BD02N160

BD07N564-01

Put a container capable of holding at least 22.7 liter (6.0 gallon) below radiator drain. Remove radiator cap (4). Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap. Put a container capable of holding at least 12.3 liter (13 U.S. quarts) below engine oil drain. Remove cap (3) and drain oil into container. Install cap after oil has drained.

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

STEP 10

NOTE: After draining oil disconnect drain hose from frame for removal with engine.

STEP 8

BD07N597-01

Remove the right front lift cylinder from the hood. Repeat the procedure for the left hand side.

STEP 11

BD03A231

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

W110R384

Remove the rear lift cylinder from the machine.

2000-5

STEP 12

STEP 15

W110R385

W110R386

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

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

STEP 16

STEP 13

1 BD07N569-01 BD07N567-01

Have another person balance the hood, and remove the hood hinge mounting bolts (1) located outside the hood by the cab (2) from the cooler frame. Repeat procedure for the other side.

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

STEP 17

STEP 14

W110R387

Loosen clamps on turbocharger and air cleaner, remove the intake hose. BD03A232

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

2000-6

STEP 18

STEP 21

BD07N570-01 W110R388

Remove the air cleaner by removing the four bolts.

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

STEP 19

STEP 22

W110R389

W110R391

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

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

STEP 20

STEP 23

W110R390

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

W110R392

Loosen the exhaust clamp from the turbocharger.

2000-7

STEP 24

3 W110R393

Disconnect the electrical connector (3) from exhaust sensor (1) before the SCR catalist (2).

STEP 25 4

1 W110R394

Disconnect the electrical connector (1) from exhaust temperature sensor (2) after the SCR catalist. Tag and disconnect two hoses from Dosing Unit Injector (3) and disconnect electrical connector (4).

STEP 26 2

W110R411

Disconnect NOx sensor module (1) from machine wiring harness. Remove hex bolts (2) securing NOx sensor module to mounting support bracket and remove module.

2000-8

STEP 27

STEP 28

Loosen two bolt clamp muffler (6) from brackets (5-20). Remove eight mounting bolts (10) from brackets (4) on left side and right side (4 on each side). Remove muffler SCR (7) from brackets.

Remove the four mounting bolts 17-15 - two on each side and remove the support muffler left and right (1-2).

8 A

10 9

4 13 12 9 2

14 15 14 16 14 17

18 23 8 W110R397

Muffler installation 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Support, Muffler - RH Support, Muffler - LH Bracket, Muffler - RH Bracket, Muffler - LH Bracket Clamp Muffler Muffler, SCR Pipe exhaust system Washer, 10.5x18x1.6 mm Bolt, M10x20 Bolt, M10x25 Nut, M10

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Bolt, M10x30 Washer, 13.5x24x2.5 mm Bolt, M12x50 Bolt, M12x65 Bolt, M12x45 Clamp Strap, Retaining Bracket Washer, 9x21x2.5 mm Bolt, M8x25 Seal

2000-9

1 11 12 9 12 10 9 3

14 17

21 22

W110R397

STEP 29

STEP 30

W230R423

W230R424

Remove from the bottom on Electronic Control Unit DENOX Urea supply the electrical connections.

Remove from the rear on Electronic Control Unit DENOX Urea supply the wiring harness.

2000-10

STEP 31

STEP 33

BD07N577-01

BD07N600-01

Loosen clamps and remove lower cooler hose from the engine.

STEP 34

BD07N573-01

Remove the four mounting bolts from the belt cover, remove the cover. Disconnect the master switch wiring. NOTE: After removing the belt cover remove the cover mounting brackets from the machine frame.

BD07N579-01

STEP 32

W110R395

BD07N576-01

Remove the drive belt from the engine.

If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness connectors from air compressor clutch connector (1). R e m o ve t h e t w o m o u n t i n g b o l t s ( 2 ) fo r t h e compressor and set the compressor on the left battery cover.

2000-11

STEP 35

STEP 37

1 2 3 BD07N575-01

Tag and disconnect the wiring from the alternator.

STEP 36

BD07N581-01

Tag and remove the wires from the starter solenoid (2), remove the ground cable and ground strap (3) from the starter. Then remove the two mounting bolts (1). NOTE: Move the starter cables away from the engine, move the wiring harness away from the engine.

STEP 38

BD07N580-01

BD07N599-01

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

2 BD07N582-01

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

2000-12

STEP 39

STEP 40 1

BD07N596-01

BD07N585-01

Tag and remove the grid heater cable.

STEP 41 2

BD07N583-01

BD07N586-01

Disconnect the wiring harness from the EDC 7 controller.

NOTE: Lifting up on the lever will release the connector from the controller.

STEP 42

BD07N584-01

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.

BD07N591-01

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

2000-13

STEP 43

STEP 46 2

1 BD07N598-01

BD03A172

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

STEP 47

STEP 44

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 engine oil drain hose with the engine.

STEP 48 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.

BD07N588-01

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.

STEP 45

BD07N589-01

Remove the lower cover for the drive shaft.

2000-14

Installation

1 2 3

4 5

W110R468

ENGINE INSTALLATION 1. ENGINE MOUNT BOLT, 3. INSOLATOR UPPER 244-298 NM (182-220 LB-FT) 2. WASHER 4. INSOLATOR LOWER

STEP 49 If engine rubber isolators require replacement, remove and discard isolators (3 and 4). Install new rubber isolator (4), then rubber isolator (3).

5. WASHER

7. NUT

6. WASHER

8. REMOTE OIL DRAIN HOSE

9. OIL FILL TUBE

STEP 50 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.

2000-15

STEP 51

STEP 56

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

STEP 52 Disconnect lifting equipment from engine lifting brackets.

STEP 53 Connect engine oil drain hose to frame bracket.

STEP 54 BD07N588-01

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.

STEP 57 2

BD03A172

At front of engine, position drive shaft on engine coupling. Install six bolts to secure drive shaft to engine coupling. Apply Loctite 242 to threads and tighten the six bolts to a torque of 53 to 62 Nm (39 to 46 lb-ft).

STEP 55

1 BD07N598-01

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

STEP 58

BD07N589-01

Install the lower cover for the drive shaft.

BD07N591-01

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

2000-16

STEP 59

BD07N583-01

BD07N586-01

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

STEP 60

BD07N584-01

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

STEP 62 BD07N585-01

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

STEP 61

BD07N599-01

Connect the engine coolant vent hose.

BD07N596-01

2000-17

STEP 63

STEP 65

1 2 3 BD07N581-01

BD07N575-01

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

STEP 66 1

BS08A030

Install the wires (2) to the starter solenoid, install the ground cable and ground strap (3), to the starter. Torque starter mounting nuts (1) to 40 to 50 Nm (29 to 37 pound-feet). Remove and discard tags.

BD07N579-01

NOTE: If the starter mounting studs (4) have to be replaced apply Loctite 747 primer to studs and holes and apply Loctite 271 to each stud and hole and torque to 19 to 29 Nm (14 to 21 pound-feet).

STEP 64

1 W110R395

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

2 BD07N582-01

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

2000-18

STEP 67

STEP 69

BD07N577-01

BD07N600-01

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).

STEP 68 1

BD07N573-01

Install the cover mounting brackets to the machine frame. Install the belt cover, install the four mounting bolts for the belt cover.. BD07N576-01

STEP 70 1

W230R427 BS08A051

DRIVE BELT ROUTING W/O AC (SEPARATE BELT FOR AC)

Install the drive belt (1) on the pulleys. If equipped with air conditioning install belt (2). NOTE: A/C compressor belt tension: A. Tension for a new belt is 45 Kg (100 lbs.). B. Tension for a belt used more than 20 hours is 41 Kg (90 lbs).

Install the suppor t muffler (1), install the four mounting bolts (2, two on each side). Install the support muffler (2).

2000-19

STEP 71

STEP 73 2

W110R396

W110R411

Place the muffler on the brackets. Install the eight mounting bolts (four on each side). Tighten the bolts to a torque of 28.9 to 35.3 Nm (21.3 to 26 lb-ft).

Install NOx sensor module (1) and secure it to mounting suppor t bracket using hex bolt (2). Reconnect machine wiring harness to NOx sensor module.

STEP 72

STEP 74

4 8

18 2

W110R398

NOTE: Position exhaust tube into place using muffler inlet and fixture. So that flexible tube is halfway between fully extended and fully compressed lengths.

Reconnect the hoses on Dosing Unit Injector (3) and reconnect electrical connector (4). Reconnect the electrical sensor connector (1).

Tighten the clamp on the exhaust pipe (8) (torque muffler clamp 6.0 Nm/53 lbs-in).

STEP 75

W110R394

3 W110R393

Reconnect the electrical connector (3).

2000-20

STEP 76

STEP 79

BD07N570-01 W110R388

Place air cleaner on bracket. Install four mounting bolts in air cleaner and tighten.

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

STEP 80

STEP 77

W110R389 W110R392

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

STEP 78

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

STEP 81

W110R391

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

W110R387

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

2000-21

STEP 82

STEP 85

1 BD07N569-01

BD07N567-01

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

Have another person balance the hood. Install the hood hinge mounting bolts (1) to the cooler frame (2) located outside the hood by the cab from the cooler frame. Repeat procedure for the other side.

STEP 83

STEP 86

W110R387

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

BD07N597-01

Install the right front lift cylinder from the hood. Repeat the procedure for the left hand side.

STEP 84

STEP 87

BD03A232

Carefully raise and place hood over loader. NOTE: Refer to step 8 and 9 of removal for lifting procedure.

W110R384

Install the rear lift cylinder on the machine.

2000-22

STEP 88

STEP 93

W110R385 BD07N562-01

Connect hood wiring harness connector and backup alarm connector to the rear chassis wiring harness and remove tags.

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

STEP 89

STEP 94 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. BD02N160

Check and make sure that drain caps are tight.

STEP 95 Lower the hood.

STEP 90 Install a new oil filter on engine. Fill engine with 11.8 liters (12.5 quarts) of AMBRA Unitek CJ-4 Engine Oil (SAE 15W-40).

STEP 91 If hydraulic reservoir was drained, fill reservoir with 113.6 liters (30.0 gallons) of AMBRA Hydrosystem 46 Hv.

STEP 92 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 22 liters (5.8 gallons). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 96 Put articulation lock in OPERATING position.

2000-23

RADIATOR Removal

STEP 4

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

STEP 2

2 BD03A231

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

STEP 5 BD03A040

Put articulation lock in LOCKED position.

STEP 3

BD07N564-01

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

STEP 6 BD07N563-01

Put master disconnect switch in OFF position.

BD07N597-01

Remove the right front lift cylinder from the hood. Repeat the procedure for the left hand side.

2000-24

STEP 7

STEP 10

BD03A232 W110R384

Remove the rear lift cylinder from the machine.

STEP 8

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

STEP 11

W110R385

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

STEP 9

1 BD07N567-01

Have another person balance the hood, and remove the hood hinge mounting bolts (1) located outside the hood by the cab (2) from the cooler frame. Repeat procedure for the other side.

BD02N160

Put a 22.7 liter (6 gallon) container below radiator drain. Remove radiator cap then remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

2000-25

STEP 12

STEP 15

BD03A109

BD03A113

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

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

STEP 13

STEP 16

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 14

BD06F129

Loose and remove the lower radiator hose from the radiator.

2000-26

Installation

STEP 20

STEP 17 Move radiator into position above cooling frame. Carefully lower radiator while guiding it into position in cooling frame.

STEP 18

BD06F129

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

STEP 21 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 19

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 22

BD03A113

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

BD02N160

Check that coolant drain cap is tight.

2000-27

STEP 23

STEP 27

Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 22 liter (5.8 gallon). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 24 1 1

BD07N567-01

Have another person balance the hood. Install the hood hinge mounting bolts (1) to the cooler frame (2) located outside the hood by the cab from the cooler frame. Repeat procedure for the other side.

STEP 28 BD03A231

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

STEP 25

BD07N597-01

Install the right front lift cylinder from the hood. Repeat the procedure for the left hand side.

STEP 29 BD07N564-01

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

STEP 26

W110R384

Install the rear lift cylinder on the machine.

BD03A232

Carefully raise and place hood over loader.

2000-28

STEP 30

STEP 32 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. BD07N566-01

Connect hood wiring harness connector and backup alarm connector to the rear chassis wiring harness and remove tags.

STEP 31

BD07N562-01

Put master disconnect switch in ON position.

STEP 33 Put articulation lock in OPERATING position.

STALL TEST

2002

Section 2002

2002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 3 3 5 5 5 6 7 7 7 7 7 8 8

2002-3

SPECIFICATIONS Low idle ..........................................................................................................................................1020 to 1080 rpm Alternate low idle .................................................................................................................................870 to 930 rpm Cold low idle ....................................................................................................................................1170 to 1230 rpm In gear low idle in boost mode (see note)........................................................................................1050 to 1150 rpm Full throttle (no load)........................................................................................................................2074 to 2244 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: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this accelerated level until the transmission is placed back into neutral for two seconds.

Stall Speeds Torque converter..............................................................................................................................1950 to 2030 rpm Hydraulic system .............................................................................................................................1900 to 2100 rpm Torque converter and hydraulic system together.............................................................................1400 to 1600 rpm

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

2002-4

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

BD06F027

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

BD06F188

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

BD06F184

BD06F183

3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPMâ&#x20AC;&#x2122;s, speed, and fuel level.

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

2002-5

BD06F169

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

BD06F170

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

2002-6

PROCEDURE TO HEAT THE OIL Torque Converter

Hydraulic System

1. Sit in the seat.

1. Apply the parking brake.

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

2. Start the engine and run at full throttle.

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

A. Press the up or down arrow key.

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

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

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

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

2002-7

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

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

BD06H038

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

2002-8

PERFORMING STALL TESTS Test No. 1 - Torque Converter and Hydraulic Stall Together 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. 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. 5. Turn the transmission control lever to third gear. 6. Increase the engine speed to full throttle. 7. 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. 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.

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. 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. 5. Turn the transmission control lever to third gear. 6. Increase the engine speed to full throttle. 7. Check the engine speed. 8. Decrease the engine speed to low idle. 9. Place the transmission in neutral and apply the parking brake. 10. Stop the engine.

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

2002-9

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

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

2002-10 NOTES:

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

STEP 5

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

STEP 2 Raise hood. Install â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; 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.

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

STEP 4

STEP 6

BD03A119-01

W110R400

BD03A109-01

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

W110R399

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

NOTE: If the leak source has not been located, remove and test the after cooler.

2003-4

AFTERCOOLER REMOVAL Removal

STEP 3

STEP 1

W110R399

Loosen clamps and remove air cooler outlet hose. W110R400

Loosen clamps and remove turbocharger outlet components. Loosen clamps and remove air cooler inlet hose.

STEP 4

STEP 2

BD03112-01

Raise air conditioning/air cooler cover. Support cover with appropriate lifting device. Remove cover support latch. BD03A119-01

Loosen clamps and remove Intake hose.

STEP 5

BD03A111-01

Remove three cover mounting bolts and lift cover off.

2003-5

STEP 6

STEP 9

BD03A109-01

Unlatch air conditioning condenser clamp.

BD03A113-01

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

STEP 7

STEP 10 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 11

BD03A107-01

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 8

BD03A111-01

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

BD03A117-01

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

2003-6

Leak Test

Installation STEP 1

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.

BD03A111-01

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

BD03A113-01

Install two side mounting bolts

STEP 3

BD03A117-01

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

2003-7

STEP 4

STEP 7

BD03A107-01

W110R400

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

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

STEP 5

STEP 8

BD03112-01

BD03A119-01

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

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

STEP 6

BD03A111-01

Install three cover mounting bolts.

2003-8

STEP 9

STEP 10 Install â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 11 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).

W110R399

Tighten clamps at air cooler outlet.

Section 2020

2020

SCR SYSTEM SENSORS

2020-2

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

3 3 4 5 6 7 9

2020-3

SCR SYSTEM SENSORS Upstream Exhaust Temperature Sensor Removal

STEP 4

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

STEP 1

W110R404

Loosen hex nut on sensor (1). Remove temperature sensor from exhaust system. W110R381

Raise the engine hood compartment.

STEP 5

STEP 2

BD07N563-01

Turn master electric switch to the “off” position.

STEP 3 1 2

W110R403

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

W110R405

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

2020-4

Upstream Exhaust Temperature Sensor Reinstall

Downstream Exhaust Temperature Sensor Removal

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

STEP 1

STEP 1 1 2

W110R403

W110R381

Install temperature sensor (1) into exhaust pipe.

Raise the engine hood compartment.

STEP 2

BD07N563-01

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

BD07N563-01

Turn master electric switch to the “off” position.

STEP 3

W110R406

Locate the exhaust temperature sensor (1) on exhaust system after catalyst. Loosen hex nut and remove sensor from exhaust system.

2020-5

STEP 4 Remove any wire ties securing wiring harness to machine and disconnect sensor from wiring harness.

STEP 5

Downstream Exhaust Temperature Sensor Reinstall NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.”

STEP 1

W110R407

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

W110R406

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

STEP 2 Reconnect sensor to machine wiring harness.

STEP 3

BD07N563-01

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

2020-6

NOx Sensor Removal

STEP 4

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

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

STEP 1

STEP 5

W110R381

Raise the hood using controls located behind the access cover. W110R409

STEP 2

Loosen hex nut on NOx sensor.

STEP 6

BD07N563-01

Turn master electric switch to the “off” position.

STEP 3 W110R410

Remove NOx sensor from exhaust system.

W110R408

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

2020-7

NOx Sensor Reinstall

STEP 7

NOTE: Do not use impact wrenches on the exhaust system unless the sensors are removed.â&#x20AC;?

STEP 1 1

W110R411

Locate NOx sensor module (1) and disconnect NOx sensor module from machine wiring harness.

STEP 8 Remove hex bolts (2) securing NOx sensor module to mounting support bracket and remove module. W110R410

STEP 9

Install NOx sensor into exhaust system.

STEP 2

W110R412

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

W110R419

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

2020-8

STEP 3 2

W110R411

Install NOx sensor module (1) and secure it to mounting support bracket using hex bolts (2). NOx sensor module torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.).

STEP 4 Reconnect machine wiring harness to NOx sensor module.

STEP 5 Secure NOx sensor wire harness with P-clip to catalyst mounting support bracket using hex bolts. Secure wire harness with wire ties where appropriate.

STEP 6

BD07N563-01

Turn master electric switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault code. Start engine and check to see if problem has been corrected.

Section 2030

2030

SCR CATALYST

2030-2

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

2030-3

SCR CATALYST Removal

STEP 4

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

STEP 1

W110R413

Loosen hex nut on sensor (1). W110R381

Raise the hood using controls located behind the access cover.

STEP 5

STEP 2

W110R405 BD07N563-01

Turn master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

STEP 3 2

W110R414

Locate the SCR catalyst (1) and the upstream exhaust gas temperature sensor (2).

Remove upstream exhaust gas temperature sensor.

2030-4

STEP 6

STEP 7 Attach a suitable lifting device and lift strap to the SCR catalyst (1).

STEP 8

Remove clamp (2), gasket (3) at SCR catalyst and mixing pipe connection (4). Discard clamp and gasket.

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

STEP 9

W110R414

Remove four hex bolts (5) from mounting support brackets from SCR catalyst (left and right side).

Locate the downstream NOx sensor (1) and exhaust gas temperature sensor (2) after the SCR catalyst. Loosen hex nut and remove downstream exhaust temperature sensor (2). Loosen hex nut on NOx sensor (1) and remove it from exhaust system.

5 1

2 3 4

W110R469

2030-5

Installation

STEP 10

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

STEP 1 Attach mounting support bracket (right and left) to SCR catalyst.

STEP 2

W110R416

Lift SCR catalyst from machine.

STEP 11 Loosen four hex bolt (6) and remove bolt mounting support bracket from SCR catalyst.

W110R416

Attach a suitable lifting device and lift strap to the SCR catalyst. Move SCR (1) catalyst into position within the wheel loader.

STEP 3 Install hex bolts (6) into SCR catalyst through left mounting support bracket. NOTE: Leave hex bolts loose until final positioning of SCR catalyst is completed.

STEP 4 Install hex bolts (5) into front mounting support brackets. NOTE: Leave hex bolts loose until final positioning of SCR catalyst is completed.

2030-6

STEP 5

W110R418

Install new gasket and clamp on connection between SCR catalyst and mixing pipe. Clamp torque 6 Nm (53 lb in.). Tighten all hex bolts to secure SCR catalyst to mounting support brackets. NOTE: Gasket and clamp should be replaced every time connection is disassembled. The gasket alignment sleeve press fits into mixing pipe or muffler, whichever fits better. NOTE: It might be necessary to loosen the turbo clamp, brackets and U-bolts to gain proper alignment of components.

5 1

2 3 4

2030-7 W110R469

STEP 6

W110R419

Install NOx sensor into exhaust pipe downstream of SCR catalyst. Sensor torque 40 to 60 Nm (30 to 44 lb ft.). Install downstream exhaust gas temperature sensor into exhaust pipe after SCR catalyst. Sensor torque 40 to 50 Nm (30 to 36 lb ft.).

STEP 7

W110R414

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

STEP 8

BD07N563-01

Turn the master electric switch to the â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault code. Start machine and check for exhaust leaks. Confirm problem has been corrected.

2030-8 NOTES:

Section 2040

2040

ENGINE INTAKE TEMPERATURE/HUMIDITY SENSOR

2040-2

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

2040-3

INTAKE TEMPERATURE/HUMIDITY SENSOR Removal

STEP 4

STEP 1

W110R421 W110R381

Raise the engine compartment hood.

Disconnect wiring harness plug.

STEP 5

STEP 2

BD07N563-01

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

W110R422

Remove hex bolts.

STEP 6

STEP 3

W110R423 W110R420

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

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

2040-4

Installation

STEP 3

STEP 1

W110R421

Reconnect wiring harness plug. W110R423

Remove plug covering hole in intake pipe. Insert sensor.

STEP 4

STEP 2

BD07N563-01

Turn master electric switch â&#x20AC;&#x153;onâ&#x20AC;?. Clear any fault code. Start machine and confirm that problem has been corrected. Lower the engine compartment hood. W110R422

Secure sensor with hex bolts.

Section 2050

2050

DEF/ADBLUE HEATER CONTROL VALVE

2050-2

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

2050-3

DEF/ADBLUE HEATER CONTROL VALVE Removal

STEP 3

STEP 1

W110R382

W110R381

Raise the engine compartment hood.

STEP 2

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

STEP 4

BD07N563-01

Turn master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

W110R424

Locate DEF/AdBlue Heater Control valve on the right hand side of the engine.

2050-4

STEP 5

STEP 7

W110R427 W110R425

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

STEP 6

Remove three hex bolts securing heater control valve (1) to mounting support bracket (3).

STEP 8

W110R426

Using a small flat blade screw driver, pull up on the fitting retaining clip and disconnect the coolant inlet/outlet lines from the heater control valve (1).

W110R470

Remove heater control valve from machine.

2050-5

Installation

STEP 3

STEP 1

BD07N563-01

W110R427

Position DEF/AdBlue heater control valve on the mounting support bracket and secure it with hex bolts (Torque 18 ± 2 Nm).

STEP 2

W110R425

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

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

2050-6 NOTES:

Section 2060

2060

DEF/ADBLUE DNOx SUPPLY MODULE

2060-2

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

2060-3

DEF/ADBLUE DNOX SUPPLY MODULE Removal

STEP 4

STEP 1

2 1 3

W110R429 W110R381

Raise the engine compartment hood.

STEP 2

Remove the fenders pouels (2-3) mark supply and return line (4) connection locations for reference during reassembly.

STEP 5

BD07N563-01

Turn the master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

STEP 3

W270R113

Fr o m t h e b o t t o m o f t h e m o d u l e d i s c o n n e c t DEF/AdBlue supply and return lines from underneath DNOx supply module. NOTE: To disconnect fittings, squirt water into the fitting connection to lubricate the O-ring. Squeeze the locking tabs together while slightly pushing the fitting ends together and then pulling them apart. If the fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be used. NOTE: Use compressed air and water to clean debris from supply and return line connections. W110R428

Locate the DEF/AD BLUE DNOx supply Module (1) on the right side of engine.

2060-4

Installation

STEP 6

STEP 1 1

W270R114

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

STEP 7

W270R676

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

STEP 2

W270R675

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

W270R114

Fit the DNOx supply module into mounting support bracket and secure with hex bolts. Bolts torque 24 Âą 4 Nm (17.7 Âą l Lb ft).

2060-5

STEP 3

STEP 4

W270R113

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

W270R112

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

STEP 5

BD07N563-01

Reinstall the fender panels. Turn master switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start engine. Check for fluid leaks at connections. Confirm problem has been corrected. Close engine compartment hood.

2060-6 NOTES:

Section 2070

2070

DEF/ADBLUE DOSING INJECTOR

2070-2

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

2070-3

DEF/ADBLUE DOSING INJECTOR Removal

STEP 3

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

STEP 1

W110R430

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

W110R381

Raise the hood using controls located behind the access cover.

STEP 2

NOTE: The dosing injector is located in the exhaust system upstream from the SCR catalyst and downstream of the turbocharger. NOTE: Cover openings to prevent debris entering system.

STEP 4

BD07N563-01

Turn master electric switch â&#x20AC;&#x153;offâ&#x20AC;?.

W110R431

Disconnect dosing injector wiring harness.

2070-4

STEP 5

STEP 7 2

1 W110R432

W110R434

Mark location of DEF/AdBlue supply and return lines (1-2) for reference dur ing reassembl y. Remove DEF/AdBlue supply and return lines. Cap lines to prevent debris from entering the system.

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

STEP 8

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

STEP 6

W110R435

Inspect dosing injector and service or replace as recommended.

W110R433

Remove (3) bolts securing dosing injector into mixing pipe.

2070-5

Installation

STEP 3

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

STEP 1

1 W110R432

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

W110R434

Remove cover from exhaust system and install dosing injector.

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

STEP 4

NOTE: Use markings made during disassembly to determined proper positioning.

STEP 2

BD07N563-01

W110R433

Secure dosing injector to exhaust pipe. Torque screws (3) to 6,5 to 7,5 Nm (57 to 66 lb in.).

Turn master electric switch to â&#x20AC;&#x153;onâ&#x20AC;?. Clear any fault code. Start machine. Check for leaks at DEF/AdBlue, exhaust and intake system connections. Confirm problem has been corrected. Lower the engine compartment hood.

2070-6 NOTES:

Section 2080

2080

DEF/ADBLUE SUPPLY TANK

2080-2

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

2080-3

DEF/ADBLUE SUPPLY TANK Removal

STEP 3

STEP 1

W110R436

W110R381

Raise the engine compartment hood.

STEP 2

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

STEP 4

BD07N563-01

Turn master electric switch â&#x20AC;&#x153;offâ&#x20AC;?.

W110R437

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

2080-4

STEP 5

STEP 7

W110R438

W110R440

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

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

STEP 8

STEP 6

1 W110R439

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

W110R441

Remove hex bolts and panel (1-2-3) to access supply tank.

2080-5

STEP 9

STEP 11

W110R442

W110R444

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

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

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

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

STEP 12

STEP 10

W110R445

W110R443

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

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

2080-6

Removal

STEP 13

STEP 1 1

W110R448

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

STEP 14 1

W110R452

Install DEF/AdBlue supply tank into the machine frame cradle and secure it using hex bolts (2) on bottom of tank and hex bolt (1) upper suppor t mounting bracket.

STEP 2

W110R452

Remove two hex bolts (1) from mounting support bracket above tank and two hex bolt from bottom right of tank. Lift tank up and out of its cradle in the wheel loader frame.

W110R448

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

2080-7

STEP 3

STEP 6

W110R445

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

STEP 4 2

W110R441

Reinstall access panel (1-2-3) and secure using hex bolts.

STEP 7 W110R443

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

STEP 5

W110R454

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

W110R442

Replace rubber boot (1) protective cover.

2080-8

STEP 8

W110R440

Reinstall filler neck assembly onto supply tank.

STEP 9

W110R439

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

STEP 10

BD07N563-01

Turn master electric power switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start machine and check for DEF/AdBlue and coolant leaks. Confirm that the problem has been corrected. Lower the engine compartment hood.

Section 2090

2090

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

2090-2

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

2090-3

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

STEP 3

STEP 1

W110R382

W110R381

Raise the engine compartment hood.

STEP 2

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

BD07N563-01

Turn master electric switch to the “off” position.

2090-4

STEP 4

STEP 6

W110R442

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

W110R446

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

STEP 5

W110R447

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

2090-5

STEP 7

STEP 10

W110R443

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

STEP 8

W110R450

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

5 4 1 W110R444

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

3 2

STEP 9

W110R453

Urea tank illustration: 1. Tank - 2. Ring - 3. Neek, filler urea tank - 4. Screw hex M4X12 - 5. Cap - 6. Sender unit - DEF. W110R449

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

2090-6

Installation

STEP 3

STEP 1

W110R443

W110R451

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

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

STEP 4

STEP 2

W110R447

W110R449

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

Reinstall protective rubber boot cover. Refill engine cooling system.

2090-7

STEP 5

BD07N562-01

Turn master electric switch to the â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start the machine and check for engine coolant and DEF/AdBlue leaks. Confirm that problem has been corrected.

STEP 6

W110R446

Reinstall tank access cover and secure with hex bolts. Lower the engine compartment hood.

2090-8 NOTES:

Section 2100

2100

DEF/ADBLUE SUPPLY FILTERS

2100-2

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

3 3 4 5 6 7 8

2100-3

DEF/ADBLUE SUPPLY FILTERS Removal Supply Tank Filler Neck Screen

STEP 3

STEP 1

BD07N563-01

Turn master electric switch to the “off” position.

STEP 4 W110R381

Raise the engine compartment hood.

STEP 2

W110R456

Open access cover and remove filler cap from filler neck of supply tank. W110R455

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

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

2100-4

STEP 5

STEP 7

W110R439

W110R457

Remove bolts securing filler cap/neck screen assembly.

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

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

STEP 6

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

Installation Supply Tank Filler Neck Screen STEP 1 1 2 W110R440

Remove filler cap/neck screen assembly and O-ring. Pull upwards while twisting assembly left and right. NOTE: Cap opening of supply tank to prevent debris from entering tank. W110R458

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

2100-5

Removal Supply Line Screen

STEP 2

STEP 1

W110R459

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

W110R460

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

STEP 3

STEP 2

W110R439

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

STEP 4

W110R381

Raise the engine compartment hood.

STEP 3

BD07N562-01

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

BD07N563-01

Turn master electric switch to the “off” position.

2100-6

STEP 4

STEP 6 2

1 4 W110R463 W110R461

Loosen hex bolts (4) and remove the cover (3). Locate supply line filter screen housing within supply line between supply tank (1) and DNOx supply module (2). NOTE: Use compressed air and water to clean debris from around screen assembly.

Remove filter screen from housing with needle nose pliers. Rinse filter screen with water to remove accumulated debris. NOTE: If filter screen is damaged, replace it.

Installation Supply Line Screen STEP 1

STEP 5

W110R463

Install filter screen into supply line filter housing. W110R462

To open fitting, push fitting together, squeeze locking tabs slightly, and then pull apart.

STEP 2

NOTE: Squirt water into fitting connection to lubricate O-ring. If fitting will not release, but is free to rotate, O-ring is likely stuck and additional water should be used to free connection. NOTE: Use a suitable container to catch any fluid discharged during hose and filter disassembly.

W110R462

Reconnect supply line coupling.

2100-7

STEP 3

STEP 2

BD07N562-01

W110R381

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

Raise the hood using controls located behind the access cover.

Removal DNOx Supply Module Filter

STEP 3

STEP 1

BD07N563-01

Turn master electric switch to the “off” position.

STEP 4 W110R460

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

1 4 W110R461

Loosen hex bolts (4) and remove the cover (3). Locate the DNOx supply module (2). The filter element assembly is located on the underside of the module. NOTE: Clean dirt and debris from filter element housing using compressed air and water.

2100-8

STEP 5

STEP 7 1

W110R466 W110R464

Squirt water into fitting connections to lubricate O-r ings. Disconnect fittings by pushing them together. Then squeeze locking tabs and pull fitting down and off. NOTE: If the fitting will not release, but is free to rotate, the O-ring is likely stuck and lubrication of the O-ring should be repeated.

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

Removal DNOx Supply Module Filter STEP 1

STEP 6 1

W110R466

W110R465

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

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

2100-9

STEP 2

STEP 5

W110R467

BD07N562-01

Lubricate filter element O-ring on control module side.

Turn master electric switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.

NOTE: Lubricate O-ring with petroleum jelly.

STEP 3

W110R465

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

STEP 4

W110R468

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

2100-10 NOTES:

SECTION INDEX

FUEL SYSTEM Section Title

Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE REPAIR MANUAL 84392403

SECTION INDEX

ELECTRICAL Section Title

Section Number

Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001 Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005

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

BD07N581-01

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

STEP 5 BD07N563-01

Raise the engine compartment hood, place the master disconnect switch in the OFF position.

STEP 3 2

1 BD07N581-01

Remove the ground cable and ground strap (1) from the starter, remove the starter mounting bolts (2), remove the stater.

W110R469

Loosen clamp on air cleaner intake hose and remove. Remove the air cleaner by removing the four bolts.

4001-4

Installation

STEP 8

STEP 6

2 BD07N581-01

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

STEP 9 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 7 BD07N562-01

Place the master disconnect switch in the ON position. Lower the engine compartment hood.

1 BD07N581-01

Position the star ter on the machine, attach the ground cable and ground strap (1). Torque the two nuts (2) to 40 to 50 Nm (29 to 37 pound-feet).

4001-5

ALTERNATOR Removal

STEP 4

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

STEP 2

BD07N600-01

BD07N563-01

Raise the engine compartment hood, place the master disconnect switch in the OFF position.

STEP 3 W110R470

Remove four belt cover mounting bolts, remove cover.

STEP 5

BD07N575-01

Disconnect wires from the alternator.

BD07N576-01

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

BD07N607-01

Place alternator into engine, install mounting bolts for alternator and tighten (62-72 Nm).

STEP 8

BS08A050

Remove mounting bolts for alternator, remove alternator.

BD07N576-01

Use a wrench to move the belt tensioner, install the belt. NOTE: Belt routing instructions are on belt cover. See belt routing on page 8.

4001-7

STEP 9

STEP 10

BD07N600-01

BD07N575-01

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

STEP 11

W110R470

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

BD07N562-01

Place the master disconnect switch in the ON position. Lower the engine compartment hood.

4001-8

BELT INSTALLATION

BS08A051

WITH OUT AIR CONDITIONING

BD07N606-01

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, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module B, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module C, For Fuel Filter Heater and Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 8 46 46 46 47 48 48 48 49 49 49 49 50 50 51 52 53 53 53 54 54 54 55 55 56 57 57 58 59 60 60 61 61 62 62 62 63 63 63 64 65 65 66 66 67 67 67 68 68 68 69 70

4002-3 Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4002-4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4002-5 Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Recirculation Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 124 124 125 126 126 126 126 127 127 127 128 128 128 128 136

4002-6

NOTES

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 Pressure Switch (Closed With Normal System Pressure) Opens With Pressure .............................................................................Below 20.7 ± 0.7 bar (300.22 ± 10.1 psi) Closed With Pressure ............................................................................. Above 27.6 ± 0.7 bar (400.3 ± 10.1 psi) Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi) Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 115 to 129 bar (1667 to 1870 psi) Brake Redundant Pressure Switches (Normally Open) Closing Set point...70 to 84 bar decreasing (1015 to 1218 psi) Brake Lamp Pressure Switch (Normally Open) Closing Set point..................................... 4.1 bar increasing (59 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 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 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

Alternator D+

Lg 1.0 SXL

AD, Alternator D+

ENG, Engine Cab

Battery sensing

R 1.0 SXL

ALT_5, Alternator D+

AB_5, Alternator B+

EDC Relay CNTL

OR 0.8 GXL

EDC7, Engine controller

SPL_EDC4, Ultrasonic

Doser valve B+

R 0.8 GXL

DNOX2, NOX Controller

DEFDM, Doser metering VLV

Work Lights Switched Fused Pwr R 2.0 GXL

SPL-WL, Ultrasonic

ECC, ELect CNTR C

Brake Lt Control Power

T 1.0 SXL

BTM_C, CAB Bottom bulkhd

PBL, Brake Light Press Switch

Back Lt Power

DU1.0 GXL

D-OR, Diode OR

SPL-BCK-LGT, Spl Back Lgt Pwr

Fan Reverse LSD

W 0.8 TXL

AIC-1, Adv Instr Clust 1

ECB, Electrical Center B

Fan Control PWM

W 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Clust 1

Pin Engage Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

YPE, Pin Engage Option

Ride Control Sol Pwr

W 1.0 SXL

PRBF, Rollback Press Sw

YRC, Ride Control Option

Horn Power

Or 1.0 SXL

FRONT, Cab Front Chassis

HN1, Horn Power

460

Fan speed sensor signal

Y 1.0 SXL

FSS, Fan_speed_sens

ENG, Engine-CAB1

016B

Pedal Sensor Grnd

DU 0.8 GXL

BTM_C, CAB BOTTOM BULKHD

BPP, Pedal position

017A

Fan speed sensor GND

BK 1.0 SXL

GND_ENG7, Tranny, cool temp

FSS, Fan_speed_sens

OD_C DIAG2 GRND

BK 0.8 GXL

DIA_2, Diagnostic

GND_CAB_SPL, CAB GRND SPLICE

OE_A Exht temp up GND

BK 0.8 GXL

UTS, Upstream temp sense

DNOX2, NOX Controller

0 29

RTT/Float Ground

Bk 0.8 GXL

SFL, Return To Travel Sw

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

0 AA

Proximity Switch Grnd

Bk 1.0 SXL

PXH, Height Control RTT

SPL-A2, Ultrasonic

0 AB

Proximity Switch Grnd

Bk 1.0 SXL

SPL-A2, Ultrasonic

GND-FC, Ground A

0 AC

Proximity Switch Grnd

Bk 1.0 SXL

PXF, RTD

SPL-A2, Ultrasonic

0 AD

Ride Control Ground

Bk 1.0 SXL

YRC, Ride Control Option

SPL-A1, Ultrasonic

0 AE

Pin Engage Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

YPE, Pin Engage Option

0 AF

Horn Ground

Bk 1.0 SXL

HN2, Horn Ground

SPL-A1, Ultrasonic

0 AG

Front Chassis Ground

Bk 2.0 SXL

SPL-A1, Ultrasonic

GND-FC, Ground A

0 AH

RH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LRF, Lights RH

0 AJ

LH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LLF, Lights LH

4002-9

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

0 AK

Park Brake/Warning Ground

Bk 1.0 SXL

SPL-A4, Ultrasonic

BTM_E, CAB BOTTOM

0 AL

Brake Warning Press Sw Gnd

Bk 1.0 SXL

PBW, Brake Warn Press Sw

SPL-A4, Ultrasonic

0 AM

RTD Grnd

Bk 1.0 SXL

PXM, RTD

PXT, RTD

0 AN

Park Brake Solenoid Ground

Bk 1.0 SXL

YPB, Park Brake Solenoid

SPL-A4, Ultrasonic

0 AP

Front To Rear Chassis Ground

Bk 5.0 SXL

GND-S1, Ground A

GND-S2, Ground A

0_AS

GRND, Joystick

BK 1.0 GXL

JSS_FRM, JSS Frame to cab

SPL_JSS_17, Ultrasonic

0_AT

GRND, JSS VLV

BK 1.0 GXL

JSS_Valve, JSS HYD Valve

SPL_JSS_17, Ultrasonic

0_AU

GRND, Pilot dump

BK 1.0 GXL

SPL_JSS_17, Ultrasonic

JSS_PIL_Dump, JSS Pilot dump

0_AV

GRND

BK 1.0 GXL

SPL_JSS_17, Ultrasonic

GND_JSS, Ground_A

BK 1.0 SXL

YPE1, PIN Engage jumper

YPE2, PIN_Engage_OPT

0_AW PIN Engage GND 0B

Front Washer Ground

Bk 1.0 SXL

FWW, Front Washer

SPL_ENG, ULTRASONIC

0 B1

Back Light Ground

Bk 0.8 GXL

SPC, Pilot Control Switch

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

0 B2

Back Light Ground

Bk 0.8 GXL

SFL, Return To Travel Switch

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

0 B3

Back Light Ground

Bk 0.8 GXL

SHC, Height Control Switch

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

0 B4

Back Light Ground

Bk 0.8 GXL

SRTD, Detent Switch

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

0 B5

Back Light Ground

Bk 0.8 GXL

SPE, Pin Engage Switch

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

0 B6

Cab2 Ground

Bk 1.0 GXL

SPL_BCK_LT_GD, SPL BACK LGHT GD

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

0 B7

Back Light Ground

Bk 0.8 GXL

SFC, Fan Control Switch

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

0 B8

Front Wiper Motor Ground

Bk 0.8 GXL

GND_CAB2, GROUND_A

FWMG, Wiper Ground

0 B10 Hood Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

GND-CAB2, Ground A

0 B11 Back Light Ground

Bk 0.8 GXL

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

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

0 B12 Hood Down Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

ECC, Work Lights

0 B13 Back Light Ground

Bk 1.0 GXL

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

SPL_WL1, ULTRASONIC

0 B14 Back Light Ground

Bk 0.8 GXL

SWL, Work Lights Switch

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

4002-10

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

0 B15 Back Light Ground

Bk 0.8 GXL

SBE, Beacon Switch

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

0 B16 Hood Down Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

ECC, ELECT CNTR C

0 B17 Back Light Ground

Bk 0.8 GXL

STA, Trans Auto Switch

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

0 B18 Back Light Ground

Bk 0.8 GXL

SDC, Declutch Switch

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

0 B19 Back Light Ground

Bk 0.8 GXL

SDR, Driving Lights Switch

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

0 B20 Back Light Ground

Bk 0.8 GXL

SRC, Ride Control Switch

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

0 B21 Back Light Ground

Bk 1.0 GXL

SBU, Backup Alarm Disc Sw

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

0 B22 Hood Up Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

ECC, ELECT CNTR C

0 B23 Back Light Ground

Bk 0.8 GXL

SRWP, Rear Wiper Switch

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

0 B24 Back Light Ground

Bk 0.8 GXL

SHZ, Hazard Switch

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

0 B25 Hood Up Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

ECC, ELECT CNTR C

0 B26 Buzzer/Switch Pad Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

GND_CAB2, Ground_A

0 B27 Buzzer Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

BUZ, AIC Buzzer

0 B28 Switch Pad Ground

Bk 0.8 TXL

SW-PD, Switch Pad

SPL-BUZ, Ultrasonic

0 B29 RTT/Float Ground

Bk 0.8 GXL

SPB, Parking Brake Switch

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

0_B31 SDA GND

BK 0.8 GXL

SPL_BCK_LT_GD2, SPL_Back LGT GRND

SDA, Diff lock switch

0_B32 Back light GND

BK 0.8 GXL

SRP, Work lights SW

SPL_BCK_LT_GD, SPL Back lght GD

Bk 5.0 SXL.

GND-PDST, Ground A

GND-PDST2, Ground A

0 BAC EDC7 Ground

Bk 2.0 SXL

SPL-EDC1, Ultrasonic

GND-ENG2, WIF, EDC

0 BAE EDC7 Sender Ground

Bk 1.0 SXL

RECT, Engine Coolant Temp

GND-ENG7, Tranny, Cool Temp

0 BAG Hood Grounds (EURO)

Bk 1.0 SXL

GND-ENG4, Rear Lighting

E-HD, Trans Hood

0 BAG Hood Grounds (NA) N

Bk 1.0 SXL

ENG-H, Engine to Hood

GND-ENG4, Rear Lighting

0 BAR WIF Body Ground

Bk 1.0 SXL

GND-WIF, Gnd WIF Ring Term

GND-ENG6, Dedicated

0_BAT Crank request GND

BK 1.0 SXL

ENG, Engine-CAB1

GND_ENG2, WIF, EDC

0 BA

Pedestal Gnd Strap

4002-11

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

0_BAU EVGT_2 GND

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

BK 1.0 SXL

Turbo, ENG DASH_Turbo

GND_ENG2, WIF, EDC

Bk 1.0 SXL

YFR, Fan Reverse Sol Opt

SPL-FAN, Ultrasonic

0_BBA Joystick ground

BK 0.8 GXL

SPL_JSS_1, Ultrasonic

SJS, Joystick_control_SW

0_BBB Joystick ground

BK 0.8 GXL

SJS, Joystick_control_SW

SPL_JSS_1, Ultrasonic

0_BBC Joystick ground

BK 0.8 GXL

GND_CAB_SPL2, SPL Back lght GD

SPL_JSS_1, Ultrasonic

0_BBD Joystick ground

BK 0.8 GXL

JSS_Cab, JSS Cab

SPL_JSS_1, Ultrasonic

0_BBE Joystick ground

BK 0.8 GXL

SJS, Joystick_control_SW

SPL_JSS_1, Ultrasonic

0_BBF DNOX2 Module GND

BK 2.0 SXL

SPL_DCUG, Ultrasonic

DC1_A, Disconect-battery

0_BBR Ground

BK 1.0 SXL

ENG_B, Cab bottom

GND_ENG3, SPLC_PK, WSHR MTR

0_BC

EDC7 GND

BK 1.0 GXL

SPL_EDC1, Ultrasonic

EDC7, Engine controller

0 BD

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BE

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BF

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BG

AIC Power Ground

Bk 0.8 GXL

ENG, Engine Cab

GND-ENG6, Dedicated

0 BH

AIC Power Ground Red

Bk 0.8 GXL

ENG, Engine Cab

GND-ENG6, Dedicated

0 BJ

AIC Sensor Ground

Bk 0.8 GXL

ENG, Engine Cab

GND-ENG6, Dedicated

0 BL

Rear Washer Ground

Bk 1.0 SXL

RWW, Rear Washer

SPL_ENG, Ultrasonic

0 BM

Engine Splice Grounds

Bk 1.0 SXL

SPL_ENG, Ultrasonic

GND-ENG3, SPLC-PK, Washer Motor

0 BP

WIF Sensor Ground

Bk 1.0 SXL

GND-ENG2, WIF, EDC

WIF, Water In Fuel Sensor

0 BQ

Fan Speed PWM Sol Grd

Bk 1.0 SXL

YFN, Fan PWM Solenoid

SPL-FAN, Ultrasonic

0 BR

RH Rear Light Ground (EURO)

Bk 1.0 SXL

LRR-E, RH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LLR-N, LH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BB

Fan Reverse Solenoid Ground

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

Fan Control Ground

Bk 1.0 SXL

SPL-FAN, Ultrasonic

SPL_ENG, Ultrasonic

0 BT

LH Rear Light Ground (EURO)

Bk 1.0 SXL

LLR-E, LH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LRR-N, RH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BT N RH Rear Light Ground (NA) 0 BU

Fuel Level Sender Ground

Bk 1.0 SXL

RFLG, Fuel Send Ground

GND-ENG7, Tranny, Cool Temp

0 BV

Grid Heater Control Grnd

Bk 0.8 TXL

GHC, Grid Heater Relay

EDC7, Engine Controller

0 BW

Water Separator Htr Ground

Bk 2.0 SXL

GND-ENG1, Start, FFH, WSH

WSH, Water Separator Heater

4002-12

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

0 BX

Fuel Filter Heater Ground

Bk 2.0 SXL

FFH, Fuel Filter Heater

GND_ENG1, STRT, FFH, WAT_SEP_HTR

0 BY

Air Filter Restriction Sw Grd

Bk 1.0 SXL

SPL_ENG, Ultrasonic

PAF, Air Filter Restriction Sw

0 BZ

Fuel level sender GND

Bk 1.0 SXL

RFL_23, Fuel_level_send

GND_ENG7, Tranny, cool temp

0 CA

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

SPL_SEC, Ultrasonic

0 CB

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

SPL_SEC, Ultrasonic

0 CC

Sec. Steering Press Sw Ground

Bk 1.0 SXL

PSS, Sec. Steer Press Switch

SPL_SEC, Ultrasonic

0 CD

Sec. Steering Splice Ground

Bk 1.0 SXL

SPL_SEC, Ultrasonic

GND_SSMOD, SEC STR Chasis GND

0 CE

Sec. Steering Chassis Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

GND-SSMOD, Sec. Str Chas Gnd

0 CF

Sec. Steering Sol Ground

Bk 1.0 SXL

YSS, Sec. Strg Sol

SPL_SEC, Ultrasonic

0_CG SEC STR Flyback GND

BK 1.0 SXL

245F, SEC_STR_Flyback

SSD, SEC_STR_Diode

0_CH

SEC STR Flyback GND

BK 1.0 SXL

245F, SEC_STR_Flyback

SSD, SEC_STR_Diode

0 DA

AIC Chassis Ground

Bk 0.8 TXL

GND-PDST1, Ground A

AIC-2, Advanced Inst Cluster 2

0 DAP Back Light Ground

S 0.8 GXL

STE, Trans Enable Switch

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

0 DAV TECM Diagnostic Ground

Bk 0.8 GXL

108F, Diagnostic connector

GND-CAB3D, Ground A

0 DB

AIC Power Ground Red

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-2, And Instr Cluster 2

0 DD

Work Lights GRND

BK 2.0 GXL

SPL_WL1, Ultrasonic

ECC, ELECT CNTR C

0 DE

Neutral Start Relay Control Grd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

ECB, Elect Center B

0 DF

Crank Request Relay Control Ground

Bk 0.8 GXL

Cab_E, Cab-Engine

ECB, Elect Center B

0 DG

Cab Splice Grounds

Bk 1.0 GXL

GND-CAB-SPL, Cab Grd Spl

GND-CAB3, Ground C

0 DH

Diagnostic Connector Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

DIA, Diagnostic

0 DJ

AC Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

ECD, Elect Center D

B10

0 DK

Seat Compressor Motor Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SC, Seat Comp Motor

0 DL

Work Lights GRND

BK 2.0 GXL

ECC, ELECT CNTR C

GND_Cab1, Ground_A

0 DM

Speed Sensor Grounds

Bk 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

0 DN

Output Speed Sensor Ground

Bk 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

0 DP

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DQ

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

4002-13

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

0 DR

Roof Splice Grounds

0 DS

2.0 mm 5.0 mm 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

Cavity

Connector

Cavity

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DT

Front Wiper/Washer Sw Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SFWW, Front Wiper/Washer

0 DU

Pilot Pressure Sol Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

YPP, Pilot Press Sol

0 DV

Cigar Lighter Ground

Bk 3.0 SXL

CL, Cigar Lighter

GND-CAB3, Ground C

0 DW

AIC Power Ground

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Cluster 1

0 DX

AIC Sensor Ground

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Cluster 1

0 DY

Roof Splice GNDS

BK 1.0 GXL

SPL_WL1, Ultrasonic

Cab_RF, Cab to Roof Connection

0_DZ

Work Lights GRND

BK 2.0 GXL

Cab_RF, Cab to Roof Conn.

SPL_WL1, Ultrasonic

0 EA

PWR Relay GND

BK0_8-GXL

ECB, Elect CNTR B

SPL_SD3

0 EB

Ignition Relay Control Ground

Bk 0.8 GXL

SPL_SD3

PRM-C1, PRM Signal

0 EC

ACC Relay Control Ground

Bk 0.8 GXL

SPL_SD3

PRM-B1, PRM Signal

0 ED

HVAC Grounds

Bk 3.0 SXL

HVAC2, HVAC2

GND-CAB4, Ground C

0 EE

DIODE Suppression Grounds

Bk 0.8 GXL

GND-CAB-SPL, Cab Grnd Spl

140M, DIODE Module

0 EF

Brake Lights Relay Ctrl Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

ECD, ELEC CNTR D

0 EG

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light Ground

0 EH

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light Ground

0 EJ

Power Converter Ground

Bk 1.0 GXL

CNV, 24V to 12V Pwr Convert

GND-CAB4, Ground C

0 EK

AUX Power Outlet 1 Grnd

Bk 1.0 GXL

PO1, Power Outlet

GND-CAB5, Ground C

0 EL

AUX Power Outlet 2 Grnd

Bk 1.0 GXL

PO2, Power Outlet

GND-CAB5, Ground C

0 EM

Radio Ground

Bk 0.8 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB-SPL, Cab Grnd Spl

0 EN

Radio Ground

Bk 0.8 GXL

ROOF, Roof to Cab Conn.

RAD, Radio Power

0 EP

Horn Switch Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SRHSTLK, RH Stalk Switch

0 EQ

Splice Pack GND-CAB-SPL2 Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

GND-CAB6, Start, FFH, Water Sep Htr

0 ER

Power Converter Grnd

Bk 1.0 GXL

CNV, 24V to 12V Pwr Conv

GND-CAB4, Ground C

0 ES

Grid Heater Ground

Bk 19.0 SXL

GH-1, Grid Heater

GND-GH1, STRT, FFH, Water Sep Htr

4002-14

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

0 ET

Power Relat GND

0 EU

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

ECB, ELECT CNTR B

SPL_SD1

PWR Converter RLY CTRL GND BK 0.8 GXL

SPL_SD3

PRM_A2, PRM Signal

0 EV

IGN Latch GND

BK 0.8 GXL

ECB, ELECT CNTR B

SPL_SD1

0 EW

Power Relay GND

BK 0.8 GXL

GND_Cab_SPL2, SPL Back Light GD

ECB, ELECT CNTR B

0 EY

Power Relay GND

BK 0.8 GXL

SPL_SD1

ECD, ELEC CNTR D

0 EZ

Power Relay Control

W 0.8 GXL

ECD, ELEC CNTR D

AIC_1, ADV Instr Cluster 1

0 GB

Starter Relay Control Ground

Bk 1.0 SXL

SRC-1, Relay

GND-ENG1, STRT, FFH, Water Sep Htr

0 HD

Speed Sensor Grounds

Bk 1.0 SXL

TRANS, Cab Transmission

SPL-H2, Ultrasonic

0 HE

Output Speed Sensor Grnd

Bk 1.0 SXL

TRANS, Cab Transmission

OSS, Out Speed Sensor

0 HF

Engine Speed Sensor Grnd

Bk 0.8 GXL Twist

ESS, Engine Speed Sensor

SPL-H2, Ultrasonic

0 HG

Inter Speed Sensor Grnd

Bk 0.8 GXL Twist

ISS, Inter Speed Sensor

SPL-H2, Ultrasonic

0 HH

Turbine Speed Sensor Grnd

Bk 0.8 GXL Twist

TSS, Turbine Speed Sensor

SPL-H2, Ultrasonic

0 HL

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB2, Redundant Brake Sw

GND_Trans, Ground_Trans

0 HM

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB1, Redundant Brake Sw

GND_Trans, Ground_Trans

0 HR

HYD FLTR SW GRND

BK 1.0 SXL

PHF9, HYD_FLTR_RES_SW

GND_Trans, Ground_Trans

0 HW

Hot Ground

Bk 1.0 SXL

HOT, Hydraulic Oil Temp Send

SPL-TRN-GRD, Spl Trans Grd

Start Lockout RLY GND

BK 0.8 GXL

ECC, ELECT CNTR C

GND_CAB_SPL2, SPL Back LGHT GD

0 JA

Hood Grounds (EURO)

Bk 1.0 SXL

HD-E, Hood Trans

SPL-J1, Ultrasonic

0 JA N Hood Grounds (NA)

Bk 1.0 SXL

HD-N, Hood to Engine

SPL-J1, Ultrasonic

0 JA T Hood Grounds (NA)

BK 1.0 SXL

HD_N_T_1, Hood to Engine

SPL_J1, Ultrasonic

BK 0.8 GXL

0 JB

Backup Alarm Grnd

Bk 1.0 SXL

BU1, Backup Alarm Grnd

SPL-J1, Ultrasonic

0 JC

License Plate Light Grnd

Bk 1.0 SXL

LPL, Lic Plate Light

SPL-J1, Ultrasonic

Camera GND

BK 0.8 GXL

GND_Cab_SPL2, SPL Back Light GD

MON, Camera/Monitor

0 KA

IGN PWR Control GND

BK0_8-GXL

ECD, ELEC CNTR D

GND_Cab_SPL2, SPL Back Light GD

AA3

4002-15

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

Telematics GRND

BK 1.0 GXL

CABE2, Cab to ENG2 BULKHD

TEL, Telematics

0 LA

DNOX2 Module GND

BK 1.0 GXL

SPL_DCUG, Ultrasonic

ENG2, ENG BULKHD 2

0 LB

DNOX2 Module GND

BK 1.0 GXL

DNOX2, NOX Controller

SPL_DCUG, Ultrasonic

0 LC

DNOX2 Module GND

BK 1.0 GXL

SPL_DCUG, Ultrasonic

DNOX2, NOX Controller

0 LD

DNOX2 Module GND

BK 2.0 SXL

DC1_A, Disconect-Battery

ENG2, ENG BULKHD 2

0 MA

Rear Wiper Motor Grnd

Bk 1.0 GXL

SPL-ROOF, Spl Rood Grnd

RWMG, Rear Wiper Motor Grnd

0 MB

Dome Light Grnd

Bk 0.8 GXL

LDM3, Dome Light Grnd

SPL-ROOF, Spl Rood Grnd

0 MC

Beacon Light Grnd

Bk 1.0 GXL

LBEGRD, Light Beacon Grnd

SPL-ROOF, Spl Rood Grnd

0 ME

LH Rear Work Light Grnd

Bk 1.0 GXL

LLRW, LH Rear Work Light

SPL_WR, Ultrasonic

0 MF

RH Rear Work Light Grnd

Bk 1.0 GXL

LRRW, RH Rear Work Light

SPL_WR, Ultrasonic

0 MG

RH Front Work Light GND

Bk 1.0 GXL

LRFS, Front_WK_LT_OPT

SPL_WRK2, Ultrasonic

0 MH

Rear Work Light GND

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL_WR, Ultrasonic

0 MJ

RH Front Work Light Grnd

Bk 1.0 GXL

LRFW, RH Front Work Light

SPL_WR, Ultrasonic

0 MK

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 ML

RH Front Work Light GND

Bk 1.0 GXL

SPL_WRK2, Ultrasonic

LRFR, Front_WK_LT_OPT

0 MN

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 MP

RH Front Work Light GND

Bk 1.0 GXL

SPL_WRK2, Ultrasonic

LRFO, Front_WK_LT_OPT

0 MU

LH Front Work Light Grnd

Bk 1.0 GXL

LLFW, LH Front Work Light

SPL_WK, Ultrasonic

0 MV

RH Front Work Light GND

Bk 2.0 SXL

SPL_WK, Ultrasonic

ROOF, Roof to Cab Connector

0 NB

Master Disconnect Grnd

Bk 62.0 SGR

DC2, Discon Black Grnd

STTR-GRN, Grid Heater Fuse

0 NC

Battery Disconnect

Bk 62.0 SGR

BT4, Discon Black Grnd

DC1, Disconnect Battery

0 ND

SSM Ground

Bk 62.0 SGR

242F, Chassis Grnd Sec. Strg Motor

GND-SSCHAS, SSM Ground Cable

0 PA

Left Speaker Grnd

Bk 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

0 PB

Right Speaker Grnd

Bk 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

0 RD

Ride Control GND

Bk 1.0 SXL

YRC_J, Ride Cntrl_Jumper

YRC_J2, Ride_Control_opt

0 SC

GRND, Joystick

Bk 0.8 GXL

JSS_Arm, JSS Armrest to Cab

PVRES, JSS Joystick

0 SD

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

Cab_Arm, Cab to Armrest

0 SE

GRND

Bk 0.8 TXL

SPL_JSS_10, Ultrasonic

CAN_MOD_2, JSS CAN MOD

0 SF

GRND

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

Cab_FRM, Cab to JSS Frame

4002-16

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

0 SG

COMMON

Bk 0.8 GXL

SPL_JSS_10, Ultrasonic

Arm_pos, Arm position

0 SH

GRND, CAN MOD

Bk 0.8 GXL

JSS_Arm, JSS Armrest to Cab

SPL_JSS_10, Ultrasonic

0 SJ

GRND, CAN MOD

Bk 0.8 GXL

SPL_JSS_9, Ultrasonic

Cab_Arm, Cab to Armrest

0 SK

GRND, CAN MOD

Bk 0.8 GXL

Cab_Arm_FRM, Cab to Arm to FRM

SPL_JSS_9, Ultrasonic

0 SL

GROUND

Bk 0.8 GXL

JSS_RLY, Relay K2

87A

SPL_JSS_9, Ultrasonic

0 SM

GRND, Joystick

Bk 0.8 GXL

JSS_CNT, JSS Controller

SPL_JSS_20, Ultrasonic

0 SN

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_20, Ultrasonic

JSS_CNT, JSS Controller

0 SP

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

R1, Resistor

0 SR

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

JSS_CNT, JSS Controller

0 SS

GRND, Joystick

Bk 0.8 GXL

JSS_197F, Main_Cab_FNR

FNR_RLY, Relay K2

87A

0 ST

GRND, Joystick

Bk 0.8 GXL

FNR_RLY, Relay K2

SPL_JSS_9, Ultrasonic

0 SU

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_20, Ultrasonic

SPL_JSS_9, Ultrasonic

DEF Sensor GND

Bk 0.8 GXL

UBJ, DEF Level Temp

DNOX2, NOX Controller

0 TA

DEF Sensor GND

LU 0.8 GXL

UBJM, DEF Level Temp

DTLTS, DEF_Tank Level Temp Sensor

EXHT Temp DWN GND

BK 0.8 SXL

DNOX2, NOX Controller

DTS, Downstream Temp Sens

12ACC Ignition Switch ACC Power

W 0.8 GXL

S-KEY, Ignition Switch

SPL-ACC, Ultrasonic

12ACC ACC PRM control Power B

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-B1, PRM Signal

12ACC Power Converter PRM Control C Power

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-A2, PRM Signal

12V Pwr To Outlet 1

Or 1.0 GXL

PO1, Power Outlet

ECD, Elect Center B

12V A 12V Pwr To Outlet 2

Or 1.0 GXL

PO2, Power Outlet

ECD, Elect Center B

12V B 12V Fused Pwr to Radio

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

ECD, Elect Center B

12V C 12V Switched Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-12V, Ultrasonic

12V D Plug 1 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center B

12V E Plug 2 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center B

12V F Radio 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center B

12V G 2 Way Radio 12V Switched Pwr

Or 1.0 GXL

SPL-12V, Ultrasonic

ECD, Elect Center B

12V H 12V Fused Power to Radio

Or 0.8 GXL

ROOF, Roof to Cab Conn.

SPL-RAD, Ultrasonic

12V

CS0

4002-17

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

12V HA

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

12V HB

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

13A

EVGT Relay

OR 0.8 TXL

EVGT_4, EVGT

EDC7, ENGINE Controller

13B

EVGT Relay PWR

OR 1.0 GXL

Turbo, ENG DASH_Turbo

EVGT_4, EVGT

13C

Fuel Shutoff Fused Power

Or 1.0 SXL

DC3, Fuel Solenoid Disc

DISC, Disconnect Engine

13C A Fuel Shutoff Fused Power

Or 1.0 SXL

ENG-D, Disc Harness

ENG, Engine Cab

13C B Fuel Shutoff Fused Power

Or 1.0 SXL

CAB-E, Cab Engine

ECA, Elect Center A

Or 1.0 GXL

S-KEY, Ignition Switch

SPL_SD2,

13K A IGN PWR Control B+

W 0.8 GXL

SPL_SD2

ECD, Elect Center D

13K B IGN PWR Latch B+

W 0.8 GXL

ECB, ELECT CNTR B

SPL_SD2

13K C Ignition Switch Pwr

Or 1.0 GXL

SPL_SD2

PRM_C1, PRM Signal

Fuel Shutoff Fused Power

Or 1.0 SXL

DC4, Fuel Sol Disconnect

DISC, Disconnect Engine

13M A Fuel Shutoff Fused Power

Or 0.8 TXL

ENG-D, Disconnect Harness

EDC7, Engine Controller

14_5

Alternator D+

LG 1.0 SXL

ALT_5, Alternator D+

ENG, Engine-Cab1

14 A

Alternator D+

LG 0.8 GXL

SPL_ALT, Ultrasonic

215F, Alternator Resistor

14 AB Alternator D+

LG 0.8 GXL

SPL_ALT, Ultrasonic

Cab_E, Cab-Engine

14 AC Altenator Running

LG 0.8 GXL

SPL_ALT, Ultrasonic

TEL, Telematics

16R C FNR reverse Signal

LU 0.8 GXL

JSS_197M, FNR-Main_Cab

RVS_Diode, Diode Assy

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

SW-PD, Switch Pad

SPL_SW_PD, Ultrasonic

17P B SW PAD PWR FR0M AIC PWR

OR 0.8 TXL

SPL_SW_PD, Ultrasonic

AIC_1, ADV INSTR Cluster 1

17P C B+, CAN Module

OR 0.8 GXL

SPL_SW_PD, Ultrasonic

JSS_Cab, JSS Cab

17P D B+, CAN Module

OR 0.8 GXL

SPL_JSS_18, Ultrasonic

Cab_Arm, Cab to Armrest

17P E B+, CAN Module

BK 0.8 TXL

JSS_Arm, JSS Armrest to Cab

CAN_MOD_2, JSS CAN MOD

17P F B+, JSS Controller

OR 0.8 GXL

SPL_JSS_18, Ultrasonic

JSS_CNT, JSS Controller

17P G B+, Joystick

OR 0.8 GXL

SPL_JSS_18, Ultrasonic

Cab_Arm_FRM, Cab to Arm to FRM

LH High Beam Fused Power

OR 2.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18B A LH High Beam Fused Power

OR 2.0 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH High Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

18C A RH High Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

13K

13M

18B

18C

Ignition Switch Pwr

AA4

AA3 3 AA4

4002-18

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 18D

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

LH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18D A LH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

18E A RH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

LH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18F A LH Position/Tail Fused Power

Or 0.8 GXL

CABE2, CAB TO ENG2 BULKHD

SPL-POS-L, Ultrasonic

LH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

18F B LH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

LLR-E, LH Rear Comb Light

Or 1.0 SXL

HD-N, Hood to Engine

LLR-N LH Rear Combination Light

18F BT LH Posn/Tail Fused PWR

OR 1.0 SXL

HD_N_T_2, Hood to Engine

LLR, LH_Rear_Comb_LT

18F C LH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-L, Ultrasonic

ECB, Electric Center B

AA7

18F E LH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-L, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-R, Ultrasonic

ECB, Elect Center B

18G A RH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

RH Position/Tail Fused Power

Or 1.0 SXL

SPL-POS-NA, Ultrasonic

LRR-N, RH Rear Combination Light

18G D Licence Plate Light Fused Pwr

Or 1.0 SXL

SPL-POS, Ultrasonic

E-HD, Trans Hood

18G E Licence Plate Light Fused Pwr

Or 0.8 GXL

HD-E, Hood Trans

LPL, Licence Plate Light

Licence Plate Light Fused Pwr

Or 1.0 SXL

LPL, Licence Plate Light

SPL-POS-NA, Ultrasonic

18G F RH Position/Tail Fused Power

Or 0.8 GXL

CABE2, CAB TO ENG2 BULKHD

SPL-POS-R, Ultrasonic

18G G RH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-R, Ultrasonic

18G H RH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

18G J RH Position/Tail Fused Power

Or 1.0 SXL

LRR-E, RH Rear Combination Light

SPL-POS, Ultrasonic

Or 1.0 SXL

HD-N, Hood to Engine

SPL-POS-NA, Ultrasonic

OR 1.0 SXL

HD_N_T_2, Hood to Engine

SPL_POS_NA, Ultrasonic

18E

18F

18F AN

18F BN

18G

18G CN

18G EN

18G HN

18G JN

LH Position/Tail Fused Power

RH Position/Tail Fused Power

18G JT RH Position/Tail Fused Power

2 AA6 2 AA5

AA8

4002-19

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

18J B EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J C EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J D EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J E EDC7 Time Delay Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J F

OR 3.0 GXL

PRM_D1, PRM OUTPUT

SPL-EDC2, Ultrasonic

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

SPL-EDC2, Ultrasonic

WIF, Water In Fuel Sensor

18K A Diagnostic Fused PWR

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

ECC, Elect Cntr C

18K B Diagnostic Fused B+

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

DIA_2, Diagnostic

18K C Telematics FSD PWR

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

TEL, Telematics

18K D Diagnostic Fused B+

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

DIA, Diagnostic

Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

ECA, Elect Center A

18N A Blower Motor Fused Power

Or 0.8 GXL

SPL-BLWR, Ultrasonic

HVAC1, HVAC1

18N B Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

HVAC2, HVAC2

18S A B+, JSS Fused

OR 0.8 GXL

SPL_JSS_3, Ultrasonic

ECA, ELECT CNTR A

18S B B+, JSS Fused

OR 0.8 GXL

SPL_JSS_3, Ultrasonic

SJS, Joystick_Control_SW

18S C B+, JSS Fused

OR 0.8 GXL

JSS_Cab, JSS Cab

SPL_JSS_3, Ultrasonic

18S D B+, JSS Fused

OR 0.8 GXL

Cab_FRM, Cab to JSS Frame

Cab_Arm_FRM, Cab to Arm to FRM

18S E B+, JSS Fused

OR 1.0 SXL

JSS_PIL_PR, JSS Pilot Pressure

JSS_FRM, JSS Frame to Cab

OR 0.8 GXL

ECA, ELECT CNTR A

A10

Cabe2, Cab to ENG2 BULKHD

18T A DNOX2 SW B+

OR 1.0 SXL

ENG2, ENG BULKHD 2

DNOX2, NOX Controller

18U A DNOX2 Module B+

OR 2.0 GXL

Cabe2, Cab to ENG2 BULKHD

PRMB_L2, B+ POWER

18U B DNOX2 BATT

OR 2.0 GXL

ENG2, ENG BULKHD 2

DNOX2, NOX Controller

18U C DNOX2 BATT

OR 2.0 GXL

Cabe2, Cab to ENG2 BULKHD

PRMB_L2, B+ POWER

18U D DNOX2 BATT

OR 2.0 GXL

DNOX2, NOX Controller

ENG2, ENG BULKHD 2

TRANS, Cab Transmission

OSS, Out Speed Sensor

18N

18T

19A

EDC7 Time Delay Fused Power

DNOX SW B+

Output Speed Sensor Fused Pwr Or 1.0 SXL

19A A Brake Declutch Sw Fused Pwr

Or 1.0 SXL

Trans, Transmission-Cab

PBD, Dec. Pressure Switch

19A B FNR Switched Fused Power

Or 0.8 GXL

197M, FNR Main Cab

SPL-FNR, Ultrasonic

19A C FNR Switched Fused Power

Or 0.8 GXL

197F, Main Cab FNR

SPL-TRNS-PWR, Trans Pwr

4002-20

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

19A D Trans Enable Switch Fused Pwr

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A E AIC Fused PWR

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A F Trans Enable Switch Fused Pwr

Or 0.8 GXL

SPL-TRNS-PWR, Trans Pwr

SPL-D15, Ultrasonic

19A G FNR Sw Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

SFNR, FNR Switch

19A H Trans Shifter Fused Power

Or 0.8 GXL

TS1, Transmission Shifter

SPL-TRNS-PWR, Trans Pwr

19A K TECM Fused Power

Or 0.8 TXL

SPL-TRANS-PWR, Trans Pwr

TECM, Trans

19A L Park Brake Switched Fused Pwr

Or 0.8 GXL

SPB, Parking Brake Switch

SPL-PB1, Ultrasonic

19A M Output Speed Sensor Fused Pwr Or 0.8 TXL

CAB-T, Cab Transmission

SPL-TRNS-PWR, Trans Power

19A N Trans Fused Power

Or 1.0 GXL

SPL-TRANS-PWR, Trans Pwr

ECA, Elect Center A

19A P Backup Alarm Relay

OR1_0-GXL

ECD, ELEC CNTR D

SPL_TRNS_PWR, TRANS_PWR

19A Q Trans/Auto Switch Fused Power

Or 0.8 GXL

STA, Trans Auto Switch

SPL-TRANS-PWR, Trans Pwr

19A R Declutch Switch Fused Power

Or 0.8 GXL

SDC, Declutch Switch

SPL-TRANS-PWR, Trans Pwr

19A T Brake Declutch Switch Fused Power

Or 0.8 GXL

CAB-T, Cab Transmission

SPL-TRANS-PWR, Trans Pwr

19A U Trans Dick Down Switch Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

20M, Trans Kick Down

19A V FNR Switch Fused Power

Or 0.8 GXL

SFNR, FNR Switch

SPL-FNR, Ultrasonic

19A W Diagnostic Conn. Fused Power

Or 0.8 GXL

108F, Diagnostic Connector

SPL-TRANS-PWR, Trans Pwr

Turn Signal Fused Power

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

49a

ECA, Elect Center A

19B A FNR Switch Fused Power

W 0.8 GXL

FNR_RLY, Relay K2

JSS_197M, FNR-Main Cab

19B B FNR Switch Fused Power

OR 0.8 GXL

Cab FNR, Main Cab FNR

FNR_RLY, Relay K2

19B C FNR Switch Fused Power

OR 0.8 GXL

Arm FNR, FNR-Main Cab

SPL_AJ, Ultrasonic

19B D FNR Switch Fused Power

OR 0.8 GXL

21M, Trans_Kick-Down

SPL_AJ, Ultrasonic

19B E FNR Switch Fused Power

OR 0.8 GXL

SAJ, FNR Switch

SPL_AJ, Ultrasonic

19B F FNR Switch Fused Power

OR 0.8 GXL

SAJ, FNR Switch

SPL_AJ, Ultrasonic

19C A Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECA, Elect Center A

19C B Pilot Ctrl Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

19C C Pilot Ctrl Fused Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

19C D Ride Control Fused Pwr

Or 1.0 GXL

SRC, Ride Control Switch

SPL-D24, Ultrasonic

19C E Pilot Control SW Fused Pwr

OR 0.8 GXL

TEL, Telematics

SPL_D24, Ultrasonic

19B

AA10

4002-21

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

19C F Pilot Control SW Fused Pwr

OR 0.8 GXL

SPC, Pilot Control Switch

SPL_D24, Ultrasonic

19D A Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECA, Elect Center A

19D B Parking Brake Relay Fused Pwr

Or 0.8 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

19D C Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

19E A AIC Wake Up Ignition

Or 0.8 TXL

SPL_AP, Ultrasonic

ECA, Elect Center A

A10

ECA, Elect Center A

19H

Backup Alarm B+

OR 1.0 GXL

ECD, ELEC CNTR D

19J

Front Wiper Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

ECA, Elect Center A

19J A Front Wiper Motor Fused Pwr

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

FWM, Front Wiper Motor

19J B Front Wip Wash Sw Fused Pwr

Or 0.8 GXL

SFWW, Front Wiper/Washer

SPL-PK3, Splice 3-4 Way

19J C Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

SPL-FW, Ultrasonic

19J D Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

19J E Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

Or 0.8 GXL

SPL-FW, Ultrasonic

K-WCO, Wiper Cutout

Or 1.0 GXL

SPL-RWW, Ultrasonic

ECA, Elect Center A

19K A Rear Wiper Sw Fused Pwr

Or 1.0 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K B Rear Wip Wash Fused Pwr

Or 0.8 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K C Rear Wiper Motor Fused Pwr

Or 1.0 GXL

CAB-RF, Cab to Roof Connect

SPL-RWW, Ultrasonic

19K D Rear Wiper Motor Fused Pwr

Or 1.0 SXL

ROOF, Roof to Cab Connect

RWM, rear Wiper Motor

Pwr Converter Fused Power

Or 2.0 GXL

PRM-E1, PRM Output

SPL-CNV, Ultrasonic

19L A Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

19L B Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

Sec. Steering Accessory Fused Pwr

Or 0.8 GXL

CAB-T, Cab Transmission

ECA, Elect Center A

19M A Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19M C Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

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

ECA, Elect Center A

19P

Pin Engage/Fan Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECA, Elect Center A

4002-22

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

19P A Pin Engage Sw Fused Pwr

Or 0.8 GXL

SPE, Pin Engage Sw

SPL-PIN, Spl Back Lgt Pwr

19P C Fan Rev Sw Fused Pwr

Or 0.8 GXL

SFC, Fan Control Switch

SPL-PIN, Spl Back Lgt Pwr

19P D Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19P E Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19R

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

SPL-2 Ultrasonic

19RR

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

ECA, Elect Center A

19R A Sec. Steering Ign Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19R C Sec. Steering Ign Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19R D Alternator Resistor Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

216F, Alternator Resistor

19R E Sec. Steering Ign Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

CAB-T, Cab Transmission

19S1

Sec. Steering Fused Pwr

Or 1.0 GXL

PRM_A1, PRM Output

CAB-T, Cab Transmission

19S1 E Sec. Steering Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19S1 X Sec. Steering Fused Pwr

R 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Module Trans

19S B AIC Delay Fused Power

Or 0.8 GXL

SPL-DKY3, Ultrasonic

ECD, Elect Center C

19S C AIC Delay Fused Power

Or 0.8 TXL

SPL-DKY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19S D AIC Delay Fused Power

Or 0.8 TXL

SPL-DKY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19S E AIC Batt B+

OR 0.8 GXL

SPL_AP, Ultrasonic

AIC_1, Advanced Instr Cluster 1

19S F AIC Batt B+

OR 0.8 GXL

SPL_AP, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19T A Fused Batt. Power

Or 0.8 TXL

TECM, Trans

SPL_D17, Ultrasonic

19T B Fused Batt. Power

OR 0.8 TXL

TECM, Trans

SPL_D17, Ultrasonic

19T C Fused Batt. Power

OR 0.8 TXL

SPL_D17, Ultrasonic

ECC, Elect Center C

A10

Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect Center C

19U A Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect Center C

19U B Beacon Dome Lt Fused Pwr

Or 1.0 GXL

SPL-LT, Ultrasonic

ECC, Elect Center C

19U C Dome Lt Fused Pwr

Or 0.8 GXL

ROOF, Roof to Cab Connection

LDM1, Dome Light B+

19U D Dome Lt Fused Pwr

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U E Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect Cntr C

19U F Door Sw Fused Power

Or 0.8 GXL

ROOF, Roof to Cab Connection

DS, Door Switch

19U

4002-23

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

19U G Door Sw Fused Power

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U H Beacon Switch Fused Power

Or 1.0 GXL

SBE, Beacon Switch

SPL-LT, Ultrasonic

19W

Cigar Lighter Pwr

Or 3.0 GXL

CL, Cigar Lighter

ECA, Elect Cntr A

19Y

Hood control Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect Cntr C

19Y A Hood Up Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect Cntr C

19Y B Hood Down Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect Cntr C

19Y C Hood Switch Fused Power

Or 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

SPL-HOOD, Ultrasonic

19Y D Hood Switch Fused Power

Or 1.0 GXL

ENG2, ENG BULKHD 2

HD, Hood Switch

Driving Lights Sw Fused Power

Or 1.0 GXL

SPL_DR, Ultrasoic

ECC, Elect Cntr C

19Z A Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL_DR, Ultrasoic

19Z B Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL_DR, Ultrasoic

19Z C High Beam Flash Fused Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56d

SPL_DR, Ultrasoic

Cab CB Protected Power

R 19.0 SXL

P C3, B+ PWR FRM PRMD

CBPW, Cab Power

1CB A Cab CB Protected Power

R 19.0 SXL

P-A3, B+ Power

CAB-PW, Cab Power

19Z

1CB

1DM

Time Delay/Ign Sw Fused Pwr

R 1.0 GXL

S_KEY, Ignition Switch

ECC, Elect Cntr C

1 AA

Brake Lt Sw Pwr

R 1.0 SXL

BTM_C, Cab Bottom BULKHD

PBL, Brake Light Press Switch

EVGT Relay Power

R 1.0 GXL

EVGT 3, EVGT Fuse

EVGT 4, EVGT

1 BA

Alternator B+

R 13.0 SXL

AB+, Alternator B+

B2 Starter Power

1 BB

Starter Solenoid Pwr

R 8.0 SXL

193 Starter Relay

194 Starter Signal

1 BE

Grid Htr Pwr

R 19.0 SXL

115 Grid Htr Pwr

GH, Grid Htr

1 BF

Alternator B+

R 13.0 SXL

AB 5, Alternator B+

B6, Starter Power

1 BG

B+ PWR PRMC

R19_0-SXL

B5, Starter Pwr Stud

P C1, B+ Pwr frm prmd

ECC Bat Power

R 8.0 GXL

P-A1, B+ Power

L1-ECC, ECC Battery Power

1 DR

Brake Light Switch Power

R 1.0 GXL

Cab B, Cab BTM Bulkhead

SPL-FLSHR-PWR, Ultrasonic

1 DU

Flasher Module Pwr

R 1.0 GXL

FLSHR, Flasher Module

SPL-FLSHR-PWR, Ultrasonic

1 DV

Brake Lights/Flasher Bat Pwr

R 2.0 GXL

SPL-FLSHR-PWR, Ultrasonic

ECC, Elect Cntr C

1 DW

Brake Lt Relay Bat Pwr

R 1.0 GXL

SPL-FLSHR-PWR, Ultrasonic

ECD, Elect Cntr D

Grid heater Fuse Bat Power

R 19.0 SXL

P-C2, B+ Power from PRMD

GHF1, Grid Heater Fuse

Filter Htr Pwr

R 3.0 SXL

PRM-D1, PRM Output

SPL-HTR, Ultrasonic

1E 1 GA

4002-24

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

1 GB

Fuel Filter Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

FFH, Fuel Filter Heater

1 GC

Water Sep Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

WSH, Water Separator Heater

1 KA

Hazard Switch Pwr

R 1.0 GXL

SHZ, Hazard Switch

SPL-FLSHR-PWR, Ultrasonic

1 NA

Battery Crossover

R 62.0 SGR

BT3, Starter Battery

BT2, Disconnect Battery

1 NB

Battery Starter

R 62.0 SGR

BT1, Battery Starter

B3, Starter Battery

1 NC

B+ Power PRMC

R 19.0 SXL

B1, Starter Power Stud

P-C1, B+ Power From PRMD

1 ND

SSM Power

R 62.0 SGR

244F Starter Sec. Strg Mtr

B4, Starter Power

1 NE

Battery Starter

R 62.0 SGR

B7, Starter Battery

BT1, Battery Starter

1 NF

SSM Pwr

R 62.0 SGR

B8, Starter Power

244F, Starter-Sec Strg Mtr

EVGT 3 Pwr

R 1.0 SXL

P C6, B+ Pwr Frm prmd

EVGT 3, EVGT Fuse

Grid Heater Fused Power

R 19.0 SXL

GHF3, Grid heater Fuse

GHF4, Grid Heater

Starter Relay Battery Power

R 8.0 SXL

P-C4, B+, Power From PRMD

195, Starter Relay Power

20G A EDC7 ESO-K Interface

W 0.8 TXL

ENG, Engine Cab

EDC7, Engine Controller

20G B EDC7 ESO-K Interface

W 0.8 GXL

CAB-E, Cab Engine

DIA, Diagnostic

Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

21C A Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

21C B Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center D

Starter Relay Signal

W 1.0 SXL

SRC-1, Relay

ENG, Engine Cab

21D A Starter Relay Signal

W 0.8 GXL

Cab E, Cab-Engine

ECB, Elect Center D

AA5

Key Switch Crank

W 0.8 GXL

ECC, Elect Cntr C

ECB, Elect Center B

21E A Key Switch Crank

W 0.8 TXL

ENG, Engine Cab

EDC7, Engine Controller

21E B Key Switch Crank

W 0.8 GXL

Cab E, Cab-Engine

ECC, Elect Cntr C

87A

EDC7 Digital Ground

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center B

21F A EDC7 Digital Ground

W 0.8 GXL

ENG, Engine Cab

SPL-EDC3, Ultrasonic

21F B EDC7 Digital Ground

W 0.8 TXL

SPL-EDC3, Ultrasonic

EDC7, Engine Controller

21F C EDC7 Digital Ground

W 0.8 TXL

ENG_B, Cab Bottom

SPL-EDC3, Ultrasonic

21F D EDC7 Digital Ground

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

EDC7 Crank Control relay

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center D

AA6

21G A EDC7 Crank Control relay

W 0.8 TXL

ENG, Engine Cab

EDC7, Engine Controller

Crank control relay LSD

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center D

21H A Crank control relay LSD

W 0.8 TXL

ENG, Engine Cab

EDC7, Engine Controller

21C

21D

21E

21F

21G

21H

4002-25

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

21J

Restart Prevent

W 0.8 GXL

ECC, Elect Cntr C

TEL, Telematics

21K

Ign Sw Start Signal

W 0.8 GXL

S-KEY, Ignition Switch

SPL-CRK, Ultrasonic

21K A Ign Sw Start Signal

W 0.8 TXL

SPL-CRK, Ultrasonic

AIC-2, Adv Instrument Cluster 2

21K B Ign Sw Start Signal

W 0.8 GXL

SPL-CRK, Ultrasonic

ECB, Elect Center B

22B

Pedal Sensor +5V

K 0.8 TXL

Cab_B, Cab BTM BULKHEAD

TECM, Trans

22C

Pedal Pos Signal

Y 0.8 TXL

TECM, Trans

Cab B, Cab BTM BULKHEAD

22D

Pedal Sensor Grnd

LU 0.8 TXL

Cab_B, Cab BTM BULKHEAD

TECM, Trans

22E

Pedal Sensor +5V

K 0.8 TXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

22F

Pedal Pos Signal

Y 0.8 GXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

22G

Pedal Sensor Grnd

LU 0.8 GXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

23A A DNOX2 Module B+

N 0.8 TXL

NOXS, NOX Sensor

ENG2, ENG BULKHD 2

23B A NOX Sensor B+

OR 0.8 GXL

CabE2, Cab to ENG2 BULKHD

ECD, Elec Cntr D

23B B NOX Sensor B+

N 0.8 GXL

CabE2, Cab to ENG2 BULKHD

ECD, Elec Cntr D

AA7

23B C NOX Relay Gnd

BK 0.8 GXL

ECD, Elec Cntr D

GND Cab_SPL, Cab Grnd Splice

23B D NOX Relay, B+

OR 0.8 GXL

CabE2, Cab to ENG2 BULKHD

ECD, Elec cntr D

23B E NOX Sensor B+

OR 1.0 GXL

SPL EDC2, Ultrasonic

ENG2, ENG BULKHD 2

23B F NOX Relay B+

OR 1.0 SXL

SPL EDC4, Ultrasonic

ENG2, ENG BULKHD 2

23D D NOX Sensor Gnd

BK 0.8 TXL

NOXS, NOX Sensor

GND ENG2, WIF, EDC

23J B DNOX2 K-Line

W 0.8 GXL

Cab E, Cab-Engine

DIA 2, Diagnostic

23K A Temp/Humd B+

K 0.8 TXL

HTS, HMDTY And AMB Temp

EDC7, Engine Controller

23K B Temp/Humd Temp

Y 0.8 GXL

HTS, HMDTY And AMB Temp

EDC7, Engine Controller

23K C Temp/Humd Humd

Y 0.8 GXL

HTS, HMDTY And AMB Temp

EDC7, Engine Controller

23K E Temp/Humd Gnd

LU 0.8 GXL

EDC7, Engine Controller

HTS, HMDTY And Amb Temp

Throttle Signal

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

24B A Throttle Signal

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

W 0.8 TXL

RTHP, Throttle Pedal

BTM_E, Cab Bottom

Throttle Grnd

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

24R A Throttle Grnd

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

24B

24L

Low Idle Sw

24L A Low Idle Switch 24R

E AA8

4002-26

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 24S

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

Throttle Supply

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

24S A Throttle Supply

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

24T B TC Lockup Sol Gnd

LU 1.0 SXL

YLS, TC Lockup Valve

Trans, Transmission-Cab

Eng Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

ESS, Engine speed Sensor

25A A Eng Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Int Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

ISS, Int Speed Sensor

25B A Int Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Turbine Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

TSS, Turbine Speed Sensor

25C A Turbine Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Output Speed Sig

LU 1.0 SXL

TRANS, Cab Transmission

OSS, Output Speed Sensor

25D A Output Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25A

25B

25C

25D

25F

Forward Signal

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

25G

Brake Declutch Switch Ctrl

LU 1.0 SXL

Trans, Transmission-Cab

PBD, Declutch Pressure Switch

25G A Brake Declutch Switch Ctrl

LU 0.8 GXL

Cab T, Cab-Transmission

SPL-DC, Ultrasonic

25G B Brake Declutch Switch Ctrl

LU 0.8 GXL

SDC, Declutch Switch

SPL-DC, Ultrasonic

25G C Brake Declutch Switch Ctrl

LU 0.8 TXL

SPL-DC, Ultrasonic

TECM, Trans

25H

Trans Auto Signal

LU 0.8 TXL

STA, Trans Auto Switch

TECM, Trans

25J

Trans Sol Valve Y6

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25J A Trans Sol Valve Y6

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K 9 Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K A Trans Sol Valve Y1

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25K

25L

Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25L 9

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25L A Trans Sol Valve Y2

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25M

Trans Sol Valve Y3

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25M A Trans Sol Valve Y3

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y4

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25N A Trans Sol Valve Y4

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25N

4002-27

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 25P

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

Trans Sol Valve Y5

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25P A Trans Sol Valve Y5

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

25R A TC Lockup Sol Power

LU 0.8 TXL

TECM, Transmission

Cab T, Cab-Transmission

25R B TC Lockup Sol Power

LU 1.0 SXL

YLS, TC Lockup Valve

Trans, Transmission-Cab

Output Sw Power VPS1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Transmission Control

25S A Output Sw Power VPS1

LU 0.8 TXL

CAB-T, Cab Transmission

SPL D12, Ultrasonic

25S B Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

25S C Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

LU 0.8 GXL

SPL-NEU, Ultrasonic

ECB, Elect Center B

25T A TC Lockup Sol Gnd

W 0.8 TXL

SPL_D19, Ultrasonic

Cab T, Cab-Transmission

25T B Neutral Signal

LU 0.8 GXL

TS1, Transmission Shifter

SPL-NEU, Ultrasonic

25T C Neutral Signal

LU 0.8 TXL

SPL-NEU, Ultrasonic

TECM, Trans

25W

3rd And 4th Gear Signal

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

25Y

Trans Kick Down Signal

LU 0.8 GXL

TS2, Transmission Shifter

SPL D11, Ultrasonic

25Y A Trans Kick Down Signal

LU 0.8 TXL

SPL D11, Ultrasonic

TECM, Trans

25Y B Trans Kick Down Signal

LU 0.8 GXL

197F, Main Cab FNR

SPL D11, Ultrasonic

25Y C Trans Kick Down Signal

LU 0.8 GXL

20M, Trans Kick Down

197M, FNR Main Cab

25Y D Trans Kick Down Signal

LU 0.8 GXL

KD_Diode, Diode Assy

JSS 197M, FNR Main Cab

25Y E Trans Kick Down Signal

LU 0.8 GXL

Cab Fnr, Main Cab Fnr

KD Diode, Diode Assy

25Y F Trans Kick Down Signal

LU 0.8 GXL

KD Diode, Diode Assy

JSS 197F, Main Cab FNR

25Y G Trans Kick Down Signal

LU 0.8 GXL

21M, Trans Kick-Down

Arm FNR, FNR-Main Cab

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

26E A Trans Enable Signal

LU 0.8 TXL

STE, Trans Enable Switch

TECM, Trans

26F A FNR Forward Signal

LU 0.8 GXL

197M, FNR Main Cab

SFNR, FNR Switch

26F B FNR Forward Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26F C FNR Forward Signal

LU 0.8 GXL

FWD Diode, Diode Assy

JSS 197M, FNR-Main Cab

26F D FNR Forward Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

FWD Diode, Diode Assy

26F E FNR Forward Signal

LU 0.8 GXL

Cab FNR, Main Cab FNR

FWD Diode, Diode Assy

26F F FNR Forward Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR Main Cab

LU 0.8 GXL

SFNR, FNR Switch

25R

25S

25T

25Z

26J

Reverse Signal

Neutral Signal

1st And 4th Gear Signal

FNR Switch Jumper

4002-28

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 26K

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

FNR Switch Jumper

LU 0.8 GXL

SAJ, FNR Switch

26N A FNR Neutral Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26N B FNR Neutral Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26N C FNR Neutral Signal

LU 0.8 GXL

JSS 197M, FNR-Main Cab

Ntrl Diode, Diode Assy

26N D FNR Neutral Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

Ntrl Diode, Diode Assy

26N E FNR Neutral Signal

LU 0.8 GXL

Ntrl Diode, Diode Assy

Cab FNR, Main Cab FNR

26N F FNR Neutral Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR-Main Cab

26R A FNR Reverse Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26R B FNR Reverse Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26R D FNR Reverse Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

RVS Diode, Diode Assy

26R E FNR Reverse Signal

LU 0.8 GXL

Cab FNR, Main Cab FNR

RVS Diode, Diode Assy

26R F FNR Reverse Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR-Main Cab

28F

Filter Htrs Relay Control

W 0.8 TXL

PRM-C2,PRM Signal

EDC7, Engine Controller

28G

Grid Heater Source Dr.

W 1.0 GXL

GHC, Grid Htr Relay

EDC7, Engine Controller

31A

EVGT Relay B+

OR 0.8 GXL

EVGT 4, EVGT

SPL EDC4, Ultrasonic

31B

Filter Heater Control

OR 0.8 GXL

PRM D2, PRM Signal

SPL EDC4, Ultrasonic

31F

Air Filter Rest Sw Signal

Y 1.0 SXL

ENG, Engine Cab

PAF, Air Filter Rest Sw

31F A Air Filter Rest Sw Signal

Y 0.8 TXL

CAB-E, Cab Engine

SW-PD, Switch Pad

31H

Hyd Filter Rest Sw Signal

Y 1.0 SXL

TRANS, Cab Transmission

PHF, Hyd Oil Filter Rest Sw

31H9

Hyd Filter Rest Sw 9

Y 1.0 SXL

Trans, Transmission Cab

PHF9, Hyd Oil Filter Rest Sw

Y 0.8 GXL

SW-PD, Switch Pad

CAB-T, Cab Transmission

31H A Hyd Filter Rest Sw Signal 31L

Pilot Control Switch High

Y 0.8 TXL

SPC, Pilot Control Switch

AIC-2, Advance Instr Cluster 2

32F

Trans Filter Maint Sw

Y 1.0 SXL

TRANS, Cab Transmission

FM, Filter Maint Sw

32F A Trans Filter Maint Sw

Y 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

32J A Trans Enable Indiction

Y 0.8 GXL

SFNR, FNR Switch

197M FNR Main Cab

32J C Trans Enable Indiction

Y 0.8 GXL

STE, Trans Enable Switch

SPL-D16, Ultrasonic

32J D Trans Enable Indiction

Y 0.8 TXL

SPL-D16, Ultrasonic

TECM, Trans

32J E Trans Enable Indiction

Y 0.8 GXL

197F, Main Cab FNR

SPL-D16, Ultrasonic

32J F

Trans Enable Indiction

Y 0.8 GXL

SPL JSS_21, Ultrasonic

JSS 197M, FNR Main Cab

32J G Trans Enable Indiction

Y 0.8 GXL

JSS 197F, Main Cab FNR

SPL JSS_21, Ultrasonic

32J H Trans Enable Indiction

Y 0.8 GXL

Cab FNR, Main Cab FNR

SPL JSS_21, Ultrasonic

4002-29

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

32J J

Trans Enable Indiction

Y 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR Main Cab

33P

Brake Warning Press Low

Y 1.0 SXL

BTM_C, Cab Bottom BULKHD

PBW, Brake Warning Press Sw

33P A Brake Warning Press Low

Y 0.8 TXL

Cab B, Cab BTM BULKHEAD

AIC-2, Advance Instr Cluster 2

Redundant Brake Accumulator Pressure Low

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

33R A Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

TRANS, Cab Transmission

SPL-RD, Ultrasonic

33R B Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB2, Redundant Brake Switch

33R C Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB1, Redundant Brake Switch

Y 0.8 TXL

SPB, Parking Brake Switch

AIC-2, Advance Instr Cluster 2

34A A Diff Lock SW B+

OR 0.8 GXL

SDA, Diff Lock Switch

SPL PBS, Ultrasonic

34A B Diff Lock SW SIG B+

OR 0.8 GXL

SDM, Diff Lock Switch

SPL PBS, Ultrasonic

34A C Diff Lock Sol B+

W 0.8 TXL

SPL D19, Ultrasonic

Cab T, CAB Transmission

34A D Diff Lock Sol B+

OR 1.0 SXL

Trans, Transmission Cab

YDL, Diff Lock Solenoid

34A E Diff Lock Sol B+

OR 1.0 SXL

YDL 1, Diff Lock Solenoid

YDL 2, Diff Lock Solenoid

33R

33U

Parking Brake Switch

34B

Diff Lock SW SIG

LU 0.8 TXL

SDA, Diff Lock Switch

TECM, Trans

34C

Diff Lock Sol GND

LU 0.8 TXL

Cab T, Cab Transmission

TECM, Trans

34C A Diff Lock Sol GND

LU 1.0 SXL

Trans, Transmission Cab

YDL, Diff Lock Solenoid

34C D Diff Lock Sol GND

LU 1.0 SXL

YDL 1, Diff Lock Solenoid

YDL 2, Diff Lock Solenoid

LU 0.8 TXL

TECM, Trans

SDM, Diff Lock Switch

35A A Backup Alarm

Y 0.8 GXL

ECD, Elec Cntr D

AA9

SPL 35A, Ultrasonic

35A B Backup Alarm Disable Switch

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL 35A, Ultrasonic

35A C Backup Alarm Relay Out

Y 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

SPL 35A, Ultrasonic

35A D Backup Alarm Relay Out

Y 0.8 GXL

209M, Backup Alarm Dis Jump

SPL 35A, Ultrasonic

35A E Backup Alarm Relay Out

Y 0.8 SXL

209F, Backup Alarm Dis Jump

SPL-D8-C1, Ultrasonic

35A F Backup Alarm Relay Out

Y 0.8 SXL

Cabe2, Cab to ENG2 BULKHD

SPL-D8-C1, Ultrasonic

35A G Backup Alarm Relay Out

Y 0.8 SXL

ENG2, ENG BULKHD 2

E-HD, Trans Hood

Y 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

34D

35A GN

Diff Lock SW SIG

Backup Alarm Relay Out

4002-30

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

35A H Backup Alarm Relay Out

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

Y 1.0 SXL

HD-E, Hood Trans

BU2, Backup Alarm

35A HN

Backup Alarm Relay Out

Y 1.0 SXL

HD-N, Hood to Engine

BU2, Backup Alarm

35A HT

Backup Alarm Relay Out

Y 1.0 SXL

HD_N_T_2, Hood to Engine

BU2, Backup Alarm

35A J Revers Light

K 1.0 SXL

ENG2, ENG BULKHD 2

SPL-A1A, Ultrasonic

35A K Revers Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LRR-E, RH rear Comb Light

35A L Revers Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LLR-E, LH rear Comb Light

35A M Reverse Signal

Y 0.8 GXL

MON, Camera/Monitor

SPL 35A, Ultrasonic

35B

AIC Buzzer HSD

W 0.8 TXL

BUZ, AIC Buzzer

AIC-1, Advance Instr Cluster 1

35C

Backup Alarm Relay Control

Y 0.8 GXL

ECD, Elec Cntr D

TECM, Trans

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL-D8-C1, Ultrasonic

35R C Backup Alarm Sw 35W

Water In Fuel Indicator

W 0.8 TXL

WIF, Water In Fuel Sensor

EDC7, Engine Controller

35X

Sec. Str Low Press Sig

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

35X A Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

PSS, Sec. Steering Press Sw

35X B Sec. Str Low Press Sig

Y 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Mod Option

35X C Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

SS-TR, SS Module Trans

35X D Sec. Str Low Press Sig

Y 1.0 SXL

SSM, Sec. Steering Module

SPL-C3, Ultrasonic

Radiator Cool Temp Signal

P 1.0 SXL

ENG, Engine Cab

RECT, Engine Coolant Temp

36C A Radiator Cool Temp Signal

P 0.8 TXL

CAB-E, Cab Engine

AIC-1, Advance Instr Cluster 1

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab

RFL, Fuel Sender

36F A Fuel Level Analog

P 0.8 TXL

CAB-E, Cab Engine

AIC-1, Advance Instr Cluster 1

Torque Conv Output Temp Signal

P 1.0 SXL

TRANS, Cab Transmission

TCOT, TCO Sender

36G A Torque Conv Output Temp Signal

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

P 1.0 SXL

TRANS, Cab Transmission

HOT, Hydraulic Oil Temp Sender

P 0.8 TXL

CAB-T, Cab Transmission

AIC-1, Advance Instr Cluster 1

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab1

RFL 23, Fuel Level Sender

36R A Trans Temps/Filter Return

P 1.0 SXL

TRANS, Cab Transmission

SPL H1, Ultrasonic

36R B Trans Filter Maint Sw Return

P 1.0 SXL

SPL H1, Ultrasonic

FM, Filter Maint Switch

36R C Valve Body Temp Return

P 0.8 TXL

SPL H1, Ultrasonic

TRC, Trans Control

36C

36F

36G

36H

Hydraulic Oil Temp Signal

36H A Hydraulic Oil Temp 36J

4002-31

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

36R D TCO Temp Return

P 1.0 SXL

SPL H1, Ultrasonic

TCOT, TCO Sender

36R E Trans Temps/Filter Return

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Valve Body Temp Sig

P 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

36T A Valve Body Temp Sig

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

37D A Diagnostic Signal

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

36T

37E

Diagnostic Signal Switched

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

38A

Doser Valve GND

LU 0.8 GXL

DNOX2, NOX Controller

DEFDM, Doser Metering Valve

38B

Def Level Sig

Y 0.8 GXL

UBJ, Def Level Temp

DNOX2, NOX Controller

38B A Def Level Sig

Y 0.8 GXL

UBJM, Def Level Temp

DTLTS, Def Tank Level Temp Sensor

38C

Tank Heat GND

LU 0.8 TXL

DNOX2, NOX Controller

THV, Tank Heater Control Valve

38D

Tank Heat B+

OR 0.8 TXL

DNOX2, NOX Controller

THV, Tank Heater Control Valve

38E

Exht Temp DWN B+

Y 0.8 GXL

DNOX2, NOX Controller

DTS, Downstream Temp Sens

38F

Exht up Signal

Y 0.8 GXL

UTS, Upstream Temp Sense

DNOX2, NOX Controller

38G

Def Temp Sig

Y 0.8 GXL

UBJ, Def Level Temp

DNOX2, NOX Controller

38G A Def Temp Sig

Y 0.8 GXL

UBJM, Def Level Temp

DTLTS, Def Tank Level Temp Sensor

38H

DNOX2 K-line

W 0.8 TXL

DNOX2, NOX Controller

ENG, Engine-Cab1

401B

Pedal Pos Signal

Y 0.8 GXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

41H A High Beam Pwr

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56a

SPL HB, Ultrasonic

41H B High Beam LH Pwr

Or 0.8 GXL

SPL HB, Ultrasonic

ECB, Elect Center B

41H C High Beam RH Pwr

Or 0.8 GXL

SPL HB, Ultrasonic

ECB, Elect Center B

41H D High Beam Pwr

Or 0.8 TXL

SW-PD, Switch Pad

SPL HB, Ultrasonic

Or 1.0 GXL

SDR, Driving Lights Switch

SRHSTLK, RH Stalk Switch

41L A Low Beam Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56b

SPL-LB, Ultrasonic

41L B Low Beam RH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

41L C Low Beam LH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

K 1.0 GXL

SDR, Driving Lights Switch

SPL PR, Ultrasonic

41T A Position Lights RH Switched Pwr K 1.0 GXL

SPL PR, Ultrasonic

ECB, Elect Center B

41T B Position Lights LH Switched Pwr K 1.0 GXL

SPL PR, Ultrasonic

ECB, Elect Center B

41T C Position Lights Switched Pwr

D-OR, Diode OR

SPL-D, Ultrasonic

41J

41T

Driving Light Power

Position Lights Switched Pwr

K 1.0 GXL

4002-32

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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

Cavity

Connector

Cavity

42C A Front Work Lights Fused Pwr

DU 1.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-PK1, Splice 3-4 Way

42C C Front Work Lights Fused Pwr

DU 1.0 GXL

SPL-PK1, Splice 3-4 Way

SWL, Work lights SW

42C D Front Work Lights Fused Pwr

DU 1.0 GXL

SPL-PK1, Splice 3-4 Way

D-OR, Diode OR

42C E Front Work Lights Fused Pwr

DU 0.8 TXL

ECC, Elect Cntr C

D WL, Diode

42C F Front Work Lights Fused Pwr

DU 2.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKF, Ultrasonic

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

SPL-WRKF, Ultrasonic

LRFW, RH Front Work Light

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

SPL-WRKF, Ultrasonic

LLFW, LH Front Work Light

42C J Front Work LTS Fused Pwr

BK 0.8 GXL

SPL BCK LGT, Splice Back Lights Pwr

D WL, Diode

42C L Front Work LTS Fused Pwr

DU 0.8 GXL

ECC, Elect Cntr C

SPL_SD3

42R A RH Front Work LTS Fused Pwr

DU 1.0 GXL

LRFS, Front Wk LT Opt

SPL Wrk1, Ultrasonic

42R B RH Front Work LTS Fused Pwr

DU 1.0 GXL

SPL Wrk1, Ultrasonic

LRFR, Front Wk LT Opt

42R C Rear Work Lights Fused Pwr

DU 1.0 GXL

CAB-RF, Cab to Roof Conn.

SWL, Work lights SW

42R F Rear Work Lights Fused Pwr

DU 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKR, Ultrasonic

42R G RH Rear Work Lt Fused Pwr

DU 1.0 SXL

SPL-WRKR, Ultrasonic

LRRW, RH Rear Work Light

42R H LH Rear Work Lt Fused Pwr

DU 1.0 SXL

SPL-WRKR, Ultrasonic

LLRW, LH Rear Work Light

42R K RH Front Work LTS Fused Pwr

DU 1.0 GXL

SPL WRK1, Ultrasonic

LRFO, Front Wk LT Opt

42 A

Work Lights Fused Power

R 2.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

42 B

Work Lights Fused Power

R 1.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

43S A Door Open Signal

W 0.8 GXL

CAB-RF, Cab to Roof Conn.

AIC 2, ADV Instr Cluster 2

43S B Door Open Signal

W 0.8 GXL

ROOF, Roof to Cab Conn.

DS, Door Switch

43 A

Dome Light Auto Mode

DU 0.8 TXL

CAB-RF, Cab to Roof Conn.

AIC-1, Adv Instrument Cluster 1

43 B

Dome Light Auto Mode

DU 0.8 GXL

ROOF, Roof to Cab Conn.

LDM2, Dome Light Auto

44A A Brake Light Relay Out

T 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

ECD, Elec Cntr D

AA1

44A D Brake Light Relay Out

T 1.0 SXL

ENG2, ENG BULKHD 2

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

44A E Brake Light Relay Out

T 1.0 SXL

LLR-E, LH Rear Comb Light

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

HD-N, Hood to Engine

SPL-J2-N, Ultrasonic

44A ET Brake Light Relay Out

T1.0 SXL

HD N_T 1, Hood to Engine

SPL-J2-N, Ultrasonic

44A F Brake Light Relay Out

T 1.0 SXL

LRR-E, RH Rear Comb Light

SPL-B8, Ultrasonic

44A DN

44A EN

4002-33

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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

Cavity

Connector

Cavity

44A FN

Brake Light Relay Out

T 1.0 SXL

LLR-N, LH Rear Comb Light

SPL-J2-N, Ultrasonic

44A GN

Brake Light Relay Out

T 1.0 SXL

LRR-N, RH Rear Comb Light

SPL-J2-N, Ultrasonic

44 A

Brake Light Control Power

T 0.8 GXL

Cab_B, Cab BTM BULKHEAD

ECD, Elec Cntr D

45A A Left Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

45B A Right Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

AA2

45H

Hazard Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SHZ, Hazard Switch

45L

Left Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

45L A Left Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

LLR-E, LH Rear Comb Light

45L AN Left Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

45L B Left Turn Signal

N 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

SPL-PK3, Splice 3-4 Way

45L BN Left Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LLR-N, LH Rear Comb Light

45L BT Left Turn Signal

N 1.0 SXL

HD-N_T 1, Hood to Engine

LLR, LH Rear Comb Light

45L C Left Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45L D Left Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

45L E Left Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45N A Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64F, Flasher Connector

45N B Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64M, Flasher Connector

Right Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

45R A Right Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

LRR-E, RH Rear Comb Light

Right Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

45R B Right Turn Signal

N 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

SPL-PK3, Splice 3-4 Way

45R

45R AN

45R BN

Right Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LRR-N, RH Rear Comb Light

45R BT

Right Turn Signal

N 1.0 SXL

HD-N_T 1, Hood to Engine

LRR, RH Rear Comb Light

45R C Right Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45R D Right Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45R E Right Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

46 C

K 1.0 GXL

CAB-RF, Cab to Roof Conn.

SBE, Beacon Switch

Beacon Switched Power

4002-34

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

46 D

Beacon Switched Power

K 1.0 GXL

ROOF, Roof to Cab Conn.

LBEPWR, Light Beacon power

49A

Back Light Power

S 0.8 GXL

HVAC1, HVAC1

SPL-BCK-LGT, Spl Back Lgt Pwr

49S

Back Light Power

S 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 A

Back Light Power

S 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 B

Back Light Power

S 0.8 GXL

SBE, Beacon Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 C

Back Light Power

S 0.8 GXL

SRWP, Rear Wiper Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 D

Back Light Power

S 0.8 GXL

SHZ, Hazard SWitch

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

49 E

Back Light Power

S 0.8 GXL

SPL-BCK-LGT2, Spl Back Lgt Pwr

SPL-BCK-LGT, Spl Back Lgt Pwr

49 F

Back Light Power

S 0.8 GXL

SPE, Pin Engage Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 G

Back Light Power

S 0.8 GXL

SRC, Ride control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 H

Back Light Power

S 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 J

Back Light Power

S 0.8 GXL

SRTD, Detent Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 K

Back Light Power

S 0.8 GXL

SFL, Return to Travel Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 L

Back Light Power

S 0.8 GXL

SBU, Back Up Alarm Dis Sw

SPL-BCK-LGT, Spl Back Lgt Pwr

49 M

Back Light Power

S 0.8 GXL

SHC, Height Control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 N

Back Light Power

S 0.8 GXL

SPC, Pilot Control Switch

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

49 P

Back Light Power

S 0.8 GXL

SDR, Driving Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 Q

Back Light Power

S 0.8 GXL

SFC, Fan Control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 R

Back Light Power

S 0.8 GXL

SDC, Declutch Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 S

Back Light Power

S 0.8 GXL

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

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 T

Back Light Power

S 0.8 GXL

SFWW, Front Wiper/Washer

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 V

Back Light Power

S 0.8 GXL

SPB, Parking Brake Switch

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

4002-35

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

49 W

JSS Back Light

S 0.8 GXL

SJS, Joystick Control SW

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

49 X

Back Light AIC

S 0.8 GXL

SW PD, Switch Pad

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

49 Z

Back Light PWR

S 0.8 GXL

SPL-BCK-LGT2, SPL_Back Lgt Pwr

SDA, Diff Lock Switch

51B A JSS ACT SW

W 0.8 GXL

SPL-JSS 2, Ultrasonic

SJS, Joystick Control SW

51B B JSS ACT SW

W 0.8 GXL

SJS, Joystick Control SW

SPL-JSS 2, Ultrasonic

51B C JSS ACT SW

W 0.8 GXL

JSS Cab, JSS Cab

SPL-JSS 2, Ultrasonic

51B D JSS ACT SW

W 0.8 GXL

Cab Arm FRM, Cab to Arm to FRM

SPL-JSS 7, Ultrasonic

51B E B+, JSS

W 0.8 GXL

JSS-RLY, Relay K2

SPL-JSS 7, Ultrasonic

51B G B+, JSS

W 0.8 GXL

SPL-JSS 7, Ultrasonic

JSS RLY, Relay K2

51B H JSS ACT SW

W 0.8 GXL

SPL-JSS 7, Ultrasonic

Cab Arm, Cab to Armrest

51B J JSS ACT SW

BK 0.8 TXL

JSS arm, JSS Armrest to Cab

CAN MOD_2, JSS CAN MOD

51B K JSS Power

W 0.8 GXL

FNR Rly, relay K2

SPL JSS_4, Ultrasonic

51C A JSS ACT BTN

Y 0.8 GXL

JSS Cab, JSS Cab

SJS, Joystick Control SW

51C B JSS ACT BTN

Y 0.8 GXL

Cab Arm FRM, Cab to Arm to FRM

JSS CNT, JSS Controller

51D A GRND, Relay Ctrl

BK 0.8 GXL

JSS Cab, JSS Cab

AIC 1, ADV Instr Cluster 1

51D B GRND, Relay Ctrl

BK 0.8 GXL

Cab Arm FRM, Cab to Arm to FRM

JSS RLY, Relay K2

51E A Armrest Lower

OR 0.8 GXL

JSS CNT, JSS Controller

Cab Arm, Cab to Armrest

51E B Armrest Lower

OR 0.8 GXL

JSS Arm, JSS Armrest to Cab

Arm Pos, Arm Position

51F A LS Press SW SIG

G 1.0 GXL

JSS LS, JSS Load Sense

JSS FRM, JSS Frame to Cab

51F B LS Press SW

G 0.8 GXL

Cab FRM, Cab to JSS Frame

JSS CNT, JSS Controller

51H B Joystick Signal

Y 0.8 GXL

JSS CNT, JSS Controller

Cab Arm, Cab to Armrest

51H C Joystick Signal

Y 0.8 GXL

JSS Arm, JSS Armrest to Cab

PVRES, JSS Joystick

51J A Valve Alarm

P 0.8 GXL

SPL JSS_11, Ultrasonic

Cab FRM, Cab to JSS frame

51J B Valve Alarm

P 0.8 GXL

JSS CNT, JSS Controller

SPL JSS 11, Ultrasonic

51J C JSS Alarm

P 1.0 GXL

JSS Valve, JSS HYD Valve

JSS FRM, JSS Frame to Cab

51J D Valve Alarm

P 0.8 GXL

SPL JSS 11, Ultrasonic

R1, Resistor

51K B Pilot Press SW

G 0.8 GXL

Cab FRM, Cab to JSS Frame

JSS CNT, JSS Controller

CS0 8

4002-36

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

G 1.0 GXL

JSS PIL PR, JSS Pilot Pressure

JSS FRM, JSS Frame to Cab

Joystick Signal

Y 1.0 GXL

JSS Valve, JSS HYD Valve

JSS FRM, JSS Frame to Cab

51L A Joystick Signal

Y 0.8 GXL

JSS CNT, JSS Controller

CAB FRM, Cab to JSS Frame

51NC

BK 0.8 TXL

PVRES, JSS Joystick

CAN MOD 2, JSS CAN MOD

51NO NC Neutral SW

Y 0.8 GXL

JSS Arm, JSS Armrest to Cab

PVRES, JSS Joystick

51NO NC Neutral SW A

P 0.8 GXL

Cab Arm, Cab to Armrest

JSS CNT, JSS Controller

51PW JSS Power H

W 1.0 SXL

SPL JSS_16, Ultrasonic

JSS FRM, JSS Frame to Cab

51PW JSS Power J

W 1.0 SXL

JSS LS, JSS Load Sense

SPL JSS 16, Ultrasonic

51PW JSS Power K

W 1.0 SXL

SPL JSS 16, Ultrasonic

JSS Pil Dump, JSS Pilot Dump

51PW JSS Power M

W 0.8 GXL

SPL JSS 6, Ultrasonic

Cab Arm FRM, Cab to Arm to FRM

51PW JSS Power N

W 0.8 GXL

JSS Cab, JSS Cab

SJS, Joystick_Control SW

51PW JSS Power P

W 0.8 GXL

JSS Rly, Relay K2

SPL JSS 4, Ultrasonic

51PW JSS Power Q

W 0.8 GXL

JSS Cnt, JSS Controller

SP JSS 4, Ultrasonic

51PW JSS Power R

W 0.8 GXL

SPL JSS 6, Ultrasonic

Cab Arm, Cab to Armrest

51PW JSS Power S

W 0.8 GXL

SPL JSS 13, Ultrasonic

JSS Arm, JSS Armrest to Cab

51PW JSS Power T

W 0.8 GXL

SPL JSS 6, Ultrasonic

Cab Frm, Cab to JSS Frame

51PW JSS Power U

BK 0.8 TXL

SPL JSS 13, Ultrasonic

Can Mod 2, JSS Can mod

51PW JSS Power V

W 0.8 GXL

SPL JSS 13, Ultrasonic

PVRES, JSS Joystick

51PW JSS Power W

W 0.8 GXL

SPL JSS 6, Ultrasonic

SPL JSS 4, Ultrasonic

51P A Sec. Str High Press

W 1.0 SXL

SSM, Sec. Steer Module

PSS, Sec. Str Pres Switch

BK 0.8 TXL

Arm Pos, Arm Position

CAN MOD 2, JSS CAN MOD

51K C Pilot Press SW SIG 51L

51R

NC Neutral SW

Armrest Raise

4002-37

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

51S A JSS Okay Pwr

W 0.8 GXL

JSS Cnt, JSS Controller

SPL JSS 5, Ultrasonic

51S B JSS Okay Pwr

W 0.8 GXL

Cab Arm, Cab to Armrest

SPL JSS 5, Ultrasonic

51S C JSS Okay Pwr

W 0.8 GXL

SPL JSS 15, Ultrasonic

JSS Arm, JSS Armrest to Cab

51S D JSS Okay Pwr

BK 0.8 TXL

CAN MOD_2, JSS CAN MOD

SPL JSS 15, Ultrasonic

51S E JSS Okay Pwr

W 0.8 GXL

PVRES, JSS Joystick

SPL JSS 15, Ultrasonic

51S F JSS Okay Pwr

W 0.8 GXL

Cab Frm, Cab to JSS Frame

SPL JSS 5, Ultrasonic

51S J JSS Okay Pwr

W 1.0 SXL

JSS Valve, JSS HYD Valve

JSS Frm, JSS Frame to Cab

51 A

Sec. Str Motor Control

W 1.0 SXL

SSM, Sec. Steer Module

SPL-SS, Ultrasonic

51 B

Sec. Str Motor Control

W 1.0 SXL

SPL-SS, Ultrasonic

SSS, SS Mag Switch

51 C

Sec. Strg Sol Control

W 1.0 SXL

SPL-SS, Ultrasonic

YSS, Sec. Steering Solenoid

51 D

Sec. Str Flyback

W 1.0 SXL

SSS, SS MAG Switch

SSD, Sec. Steering Diode

52AU

Fan Reverse Auto

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52A A Fan Reverse Relay Out

W 1.0 GXL

CAB-E, Cab Engine

ECB, Elect Center B

52A B Fan Reverse Relay Out

W 1.0 SXL

ENG, Engine Cab

YFR, Fan Rev Solenoid Option

D8 1

52C

Parking Brake Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument Cluster 1

ECB, Elect Center B

52J

Fan Control Switch Jumper

W 0.8 GXL

SFC, Fan Control Switch

52M

Fan Reverse Manual

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52P

Parking Brk Relay Out

W 1.0 SXL

BTM_C, CAB Bottom BULKHD

YPB, Park Brake Solenoid

52P A Parking Brk Relay Out

W 0.8 GXL

Cab_B, Cab BTM BULKHEAD

SPL-PB, Ultrasonic

52P B Parking Brk Relay Out

W 0.8 GXL

SPL-PB, Ultrasonic

ECB, Elect Center B

D10

B10

53A

RTD Switch Power

W 0.8 GXL

SRTD, Detent Switch

EM, RTD Height Control RTT

53B

RTD Signal

W 1.0 SXL

FRONT, Cab Front Chassis

PXF, RTD

53B A RTD Control Signal

W 1.0 SXL

PXM, RTD

PXT, RTD

53B B RTD Control Signal

W 0.8 GXL

EM, RTD Height Control RTT

CAB-F, Cab Front Chassis

53C A Pilot Control Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument Cluster 1

ECD, Elect Center D

53P A Pilot Control Relay Out

W 0.8 GXL

SPL-D25, Ultrasonic

YPP, Pilot Pressure Solenoid

53P B Pilot Control Relay Out

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D25, Ultrasonic

53P C Pilot Control Relay Out

W 1.0 GXL

SPL-D25, Ultrasonic

ECD, Elect Center D

53P D Pilot Control Relay Out

W 0.8 GXL

SHC, Height Control Switch

SPL-D25, Ultrasonic

4002-38

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

53P E Pilot Control Relay Out

W 0.8 GXL

SRTD, Detent Switch

SPL-D25, Ultrasonic

53P F Pilot Control Relay Out

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D25, Ultrasonic

53P G Pilot Control Relay Out

W 1.0 SXL

FRONT, Cab Front Chassis

SPL-A3, Ultrasonic

53P H Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXF, RTD

53P I

Pilot Control Relay Out

W 1.0 SXL

PXM, RTD

PXT, RTD

53P J Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXH, Height Control RTT

54A

Height Control Switch Power

W 0.8 GXL

SHC, Height Control Switch

EM, RTD Height Control RTT

54B

Height RTT Control Signal

W 1.0 SXL

FRONT, Cab Front Chassis

PXH, Height Control RTT

54B A Height RTT Control Signal

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D1, Ultrasonic

54B B Height RTT Control Signal

W 0.8 GXL

EM, RTD Height Control RTT

SPL-D1, Ultrasonic

54B C Height RTT Control Signal

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D1, Ultrasonic

55A A RTT Float Sw Power

W 0.8 GXL

EM, RTD Height Control RTT

SPL-RTT, Ultrasonic

55A B RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55A C RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55B

RTT Float Switch Control

W 0.8 GXL

SFL, Return to Travel Switch

EM, RTD Height Control RTT

56 A

Fan Control PWM

W 1.0 SXL

ENG, Engine Cab

YFN, Fan PWM Solenoid

57 A

Pin Engage Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PINE, Ultrasonic

57 B

Pin Engage Sol Pwr

W 0.8 GXL

SPE, Pin Engage Switch

SPL-PINE, Ultrasonic

57 C

Pin Engage Sol Pwr

W 0.8 TXL

SPL-PINE, Ultrasonic

AIC-2, Adv Instrument Cluster 2

57 D

Pin Engage Sol Pwr

W 1.0 SXL

YPE1, Pin Engage Jumper

YPE2, Pin Engage Opt

58C

Ride Control Switch Jumper

W 0.8 GXL

SRC, Ride Control Switch

58H A Pwr VPS2

W 0.8 TXL

TECM, Trans

SPL D19, Ultrasonic

58H B Power VPSL

W 0.8 TXL

SPL D19, Ultrasonic

TECM, Trans

58H C Power

W 0.8 GXL

ECD, Elec Cntr D

SPL D19, Ultrasonic

58L

Ride Control Relay LSD

Bk 0.8 TXL

TECM, Trans

ECD, Elect Center D

58T

Ride Control Relay Sw Pwr

W 0.8 GXL

SRC, Ride Control Switch

ECD, Elect Center D

58 A

Ride Control Sol Pwr

W 1.0 SXL

202M, Rollback Jumper

58 B

Ride Control Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

PRBF, Rollback Pressure Switch

58 C

Ride Control Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D26, Ultrasonic

58 D

Ride Control Sol Pwr

W 0.8 GXL

140M, Diode Module

SPL-D26, Ultrasonic

58 E

Ride Control Sol Pwr

W 0.8 GXL

SPL-D26, Ultrasonic

ECD, Elect Center D

4002-39

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

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

To Connector

Wire

Circuit

58 F

Ride Control Sol Pwr

W 0.8 GXL

SRC, Ride Control Switch

SPL-D26, Ultrasonic

58 G

Ride Control Sol Pwr

W 1.0 SXL

YRC, Ride Control Opt

Front, Frnt Chas-Cab

58 H

Ride Control Signal

W 1.0 SXL

YRC J, Ride Control Jumper

YRC J2, Ride Control Opt

59D

Hood Relay Control Down

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

59D A Hood Relay Control Down

W 1.0 SXL

ENG2, ENG BULKHD 2

HD, Hood Switch

Hood Relay Control Up

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

59U A Hood Relay Control Up

W 1.0 SXL

ENG2, ENG BULKHD 2

HD, Hood Switch

Hood Down Relay Out

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

60D A Hood Down Relay Out

W 1.0 SXL

ENG2, ENG BULKHD 2

HDM, Hood Lift Motor

Hood Up Relay Out

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

60U A Hood Up Relay Out

W 1.0 SXL

ENG2, ENG BULKHD 2

HDM, Hood Lift Motor

W 1.0 SXL

ENG, Engine Cab

SPL ACP, Ultrasonic

61A B Trinary Press Sw Input

W 0.8 GXL

CAB-E, Cab Engine

SPL AC, Ultrasonic

61A C AC Switch Input

W 1.0 SXL

SPL ACP, Ultrasonic

ENG B, Cab Bottom

61A D AC Switch Input

W 1.0 SXL

SPL ACP, Ultrasonic

PRH, AC High Press SW

61A E AC Switch Input

W 1.0 SXL

PRL, AC Low Press SW

BTM E, Cab Bottom

61A F Trinary Press SW Input

W 0.8 GXL

HVAC1, HVAC1

SPL AC, Ultrasonic

61A G Trinary Press SW Input

W 0.8 GXL

SPL AC, Ultrasonic

ECD, Elec Cntr D

61B A AC Signal

W 0.8 GXL

AIC 2, ADV Instr Cluster 2

HVAC1, HVAC1

AC Relay Out

Or 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61C A AC Relay Out

Or 1.0 SXL

ENG, Engine Cab

ACT, AC Comp Clutch

AC Relay Control

W 1.0 SXL

ENG, Engine Cab

SPL ACS, Ultrasonic

61R B AC Relay Control

W 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61R C AC Switch Output

W 1.0 SXL

SPL ACS, Ultrasonic

ENG B, Cab Bottom

61R D AC Switch Output

W 1.0 SXL

SPL ACS, Ultrasonic

PRH, AC High Press SW

61R E AC Switch Output

W 1.0 SXL

PRL, AC Low Press SW

BTM_E, Cab Bottom

59U

60D

60U

61A

61C

61R

AC Press Sw Input

Connector

K = Pink U = Blue Y = Yellow

Cavity

Connector

Cavity

C10

63C

Front Wiper Park Control

W 0.8 GXL

FWM, Front Wiper Motor

ECD, Elect Center D

63C2

Front Wiper Park Control

W 0.8 GXL

ECD, Elect Center D

63C3

Front Wiper Park Control

W 0.8 GXL

K-WCO, Wiper Cutout

87a

ECD, Elect Center D

63HC

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

SPL-HC, Ultrasonic

4002-40

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

63HC A

Wiper Cutout Relay Control

W 0.8 GXL

SPL-HC, Ultrasonic

K-WCO, Wiper Cutout

63HC B

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

ECD, Elec Cntr D

SPL HC, Ultrasonic

63H A Front Wiper High Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WHS, Ultrasonic

63H B Front Wiper High Speed Rly Out

W 0.8 GXL

ECD, Elec Cntr D

SPL WHS, Ultrasonic

63H C Front Wiper High Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WHS, Ultrasonic

63LC

Front Wiper Low Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

ECD, Elect Center D

63L A Front Wiper Low Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WLS, Ultrasonic

63L B Front Wiper Low Speed Rly Out

W 0.8 GXL

K-WCO, Wiper Cutout

SPL-WLS, Ultrasonic

63L C Front Wiper Low Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WLS, Ultrasonic

63W

Front Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

SFWW, Front Wiper/Washer

63W A Front Washer Pump

W 1.0 SXL

ENG, Engine Cab

FWW, Front Washer

64C

Horn Relay Control

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

31b

ECC, Work Lights

64 A

Horn Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECC, Work Lights

65L

Left Speaker

Or 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

65R

Right Speaker

Or 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

66A

RR Camera Pwr

OR 0.8 GXL

Mon, Camera/MOnitor

ECA, Elect Cntr A

67A

Park Brake Signl

OR 0.8 GXL

TEL, Telematics

SPL PTM, Ultrasonic

67B

Start Lockout

OR 0.8 GXL

ECC, Elect Cntr C

SRP, Work Lights SW

68C

Rear Wiper Park Control

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SRWP, Rear Wiper Switch

68C A Rear Wiper Park Control

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

Rear Wiper Switch Power

Or 1.0 GXL

SRWP, Rear Wiper Switch

SPL-3, Ultrasonic

68L A Rear Wiper Switch Power

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

68L B Rear Wiper Switch Power

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-3, Ultrasonic

68L C Rear Wiper Switch Power

Or 1.0 GXL

140M, Diode Module

SPL-3, Ultrasonic

68W

Rear Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

SRWP, Rear Wiper Switch

68W A Rear Washer Pump

W 1.0 SXL

ENG, Engine Cab

RWW, Rear Washer

CAN1 CAN HI H

Y 0.8 TXL TWIST

EDC7, Engine Controller

ENG, Engine-Cab1

CAN1 CAN LO L

G 0.8 TXL TWIST

EDC7, Engine Controller

ENG, Engine-Cab1

68L

4002-41

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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

Cavity

Connector

Cavity

CANS HA CAN HI, CAN MOD2

Y 0.8 TXL TWIST

JSS Arm, JSS Armrest to Cab

CAN MOD 2, JSS CAN MOD

CANS HB CAN HI, CAN MOD2

Y 0.8 TXL TWIST

Cab Arm FRM, Cab to Arm to FRM

Cab Arm, Cab to Armrest

CANS HD CAN HI, CAN MOD3

Y 0.8 TXL TWIST

Cab Arm FRM, Cab to Arm to FRM

JSS CNT, JSS Controller

CANS CAN LO, CAN MOD2 LA

G 0.8 TXL TWIST

JSS Arm, JSS Armrest to Cab

CAN MOD 2, JSS CAN MOD

CANS CAN LO, CAN MOD2 LB

G 0.8 TXL TWIST

Cab Arm, Cab to Armrest

Cab Arm FRM, Cab to Arm to FRM

CANS CAN HI, CAN MOD3 LD

G 0.8 TXL TWIST

Cab Arm FRM, Cab to Arm to FRM

JSS CNT, JSS Controller

CAN H CAN HIGH

Y 0.8 TXL TWIST

ENG, ENGINE-CAB1

SPL CAN DH, Ultrasonic

CAN H2

CAN2 HI, TERM

Y 0.8 GXL TWIST

TERM CAN 2, CAN Bulk Head

SPL CAN HV, Ultrasonic

CAN HA

CAN High

Y 0.8 TXL TWIST

SPL CAN_JS_H1, Ultrasonic

SPL CAN GH, Ultrasonic

CAN HB

CAN High

Y 0.8 TXL TWIST

SPL-CAN-DIAG, Ultrasonic

DIA, Diagnostic

CAN HC

CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic

SPL-CAN-DIAG, Ultrasonic

CAN HD

CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic

TECM, Trans

CAN HE

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

SPL-CAN-TRANS, Ultrasonic

CAN HF

CAN High

Y 0.8 TXL TWIST

SW-PD, Switch Pad

SPL-CAN, Ultrasonic

CAN HG

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN HH

CAN High

Y 0.8 TXL TWIST

SPL CAN TEL, Ultrasonic

TEL, Telematics

CAN HJ

CAN High

Y 0.8 TXL TWIST

SPL CAN TEL, Ultrasonic

SPL CAN JS H2, Ultrasonic

CAN HK

CAN HI, EDC

Y 0.8 GXL TWIST

SPL CAN DH, Ultrasonic

EDC7, Engine Controller

4002-42

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

CAN HL

CAN High

Y 0.8 TXL TWIST

SPL CAN TEL, Ultrasonic

SPL CAN DIAG, Ultrasonic

CAN HM

CAN2 HI, EDC

Y 0.8 GXL TWIST

Cab E, Cab-Engine

SPL-CAN-DIAG, Ultrasonic

CAN HN

CAN High

Y 0.8 TXL TWIST

SPL CAN JS H1, Ultrasonic

SPL CAN JS H2, Ultrasonic

CAN HO

CAN2 HI, DIAG2

Y 0.8 GXL TWIST

SPL CAN GH, Ultrasonic

DIA 2, Diagnostic

CAN HP

CAN HI,CAN MOD2

Y 0.8 GXL TWIST

SPL CAN JS H1, Ultrasonic

JSS Cab, JSS Cab

CAN HQ

CAN HI, DNOX2

Y 0.8 GXL TWIST

SPL CAN DH, Ultrasonic

DNOX2, NOX Controller

CAN HR

CAN HI,CAN MOD3

Y 0.8 GXL TWIST

SPL CAN JS H2, Ultrasonic

JSS Cab, JSS Cab

CAN HS

CAN2 HI, NOX

Y 0.8 GXL TWIST

SPL CAN HV, Ultrasonic

EDC7, Engine Controller

CAN HU

CAN2 HI, NOX

Y 0.8 TXL TWIST

SPL CAN HT, Ultrasonic

NOXS, NOX Sensor

CAN HV

CAN2 HI, TERM

Y 0.8 GXL TWIST

SPL CAN HT, Ultrasonic

TERM CAN 2, CAN Bulk Head

CAN HW

CAN 2 HI, EVGT

Y 0.8 TXL TWIST

SPL CAN HV, Ultrasonic

Turbo, Eng DASH Turbo

CAN HZ

CAN 2 HI

Y 0.8 GXL TWIST

SPL CAN HV, Ultrasonic

SPL CAN HT, Ultrasonic

CAN L CAN Low

G 0.8 TXL TWIST

ENG, Engine-Cab1

SPL CAN DL, Ultrasonic

CAN L2

CAN 2 LO, Term

Y 0.8 GXL TWIST

Term CAN 2, CAN Bulk Head

SPL CAN LV, Ultrasonic

CAN LA

CAN Low

G 0.8 TXL TWIST

SPL CAN JS_L1, Ultrasonic

SPL CAN GL, Ultrasonic

CAN LB

CAN Low

G 0.8 TXL TWIST

SPL-CAN-DIAG-L, Ultrasonic

DIA, Diagnostic

CAN LC

CAN Low

G 0.8 TXL TWIST

SPL-CAN-TRANS-L, Ultrasonic

SPL-CAN-DIAG-L, Ultrasonic

CAN LD

CAN Low

G 0.8 TXL TWIST

TECM, Trans

SPL-CAN-TRANS-L, Ultrasonic

4002-43

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

CAN LE

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

SPL-CAN-TRANS-L, Ultrasonic

CAN LF

CAN Low

G 0.8 TXL TWIST

SW-PD, Switch Pad

SPL-CAN-L, Ultrasonic

CAN LG

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN LH

CAN Low

G 0.8 TXL TWIST

SPL CAN TEL2, Ultrasonic

SPL CAN JS L2, Ultrasonic

CAN LJ

CAN Low, EDC

G 0.8 GXL TWIST

EDC7, Engine Controller

SPL CAN DL, Ultrasonic

CAN LK

CAN Low, DNOX2

G 0.8 GXL TWIST

SPL CAN DL, Ultrasonic

DNOX2, NOX Controller

CAN LL

CAN2 LO, EDC

G 0.8 GXL TWIST

Cab E, Cab-Engine

SPL CAN GL, Ultrasonic

CAN LM

CAN Low

G 0.8 TXL TWIST

SPL CAN TEL2, Ultrasonic

TEL, Telematics

CAN LP

CAN Low,CAN MOD3

G 0.8 GXL TWIST

SPL CAN JS L1, Ultrasonic

JSS Cab, JSS Cab

CAN LQ

CAN LOW

G 0.8 TXL TWIST

SPL CAN JS L1, Ultrasonic

SPL CAN JS L2, Ultrasonic

CAN LR

CAN Low, CAN MOD2

G 0.8 GXL TWIST

SPL CAN JS L2, Ultrasonic

JSS Cab, JSS Cab

CAN LS

CAN2 LO, NOX

G 0.8 GXL TWIST

SPL CAN LV, Ultrasonic

EDC7, Engine Controller

CAN LU

CAN2 LO, NOX

G 0.8 TXL TWIST

NOXS, NOX Sensor

SPL CAN_LT, Ultrasonic

CAN LV

CAN2 LO, Term

G 0.8 GXL TWIST

Term CAN 2, CAN Bulk Head

SPL CAN LT, Ultrasonic

CAN LW

CAN LO, EVGT

G 0.8 TXL TWIST

SPL CAN LV, Ultrasonic

Turbo, ENG DASH Turbo

CAN LX

CAN2 LO, DIAG2

G 0.8 GXL TWIST

SPL CAN GL, Ultrasonic

DIA 2, Diagnostic

CAN LY

CAN Low

G 0.8 TXL TWIST

SP CAN TEL2, Ultrasonic

SPL CAN DIAG L, Ultrasonic

CAN LZ

CAN 2 LO

G 0.8 GXL TWIST

SPL CAN LV, Ultrasonic

SPL CAN LT, Ultrasonic

4002-44

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire ECC L1

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

Beacon/Dome Light L1 ECC

BUSS

L1-ECC, ECC Batt Power

cs01

ECC, Elect Cntr C

L1-1

Trans ECM Power

ECA-BUSS

ECA-L1, B+ Power

cs01

ECA, Elect Center A

Trans ECM Power

ECA-BUSS

ECA, Elect Center A

EMG STR AIC Power

ECA-BUSS

ECA, Elect Center A

Emergency Steer AIC Power

ECA-BUSS

ECA, Elect Center A

Emergency Steer Pltem Dtnts

ECA-BUSS

ECA, Elect Center A

Pltem Dtnts Park Brk Sol

ECA-BUSS

ECA, Elect Center A

Park Brake Solenoid Horn

ECA-BUSS

ECA, Elect Center A

Fan Reverse Turn Signal

ECA-BUSS

ECA, Elect Center A

Turn Signal Engine Shut Down

ECA-BUSS

ECA, Elect Center A

J10

DNOX SW B+

ECA-BUSS

ECA, Elect Center A

J11

Blower Motor Power

ECA-BUSS

PRMB_L1, B+ Power

cs01

ECA, Elect Center A

J12

Blower Motor Front Wiper Washer

ECA-BUSS

ECA, Elect Center A

J13

Front Wiper Rear Wiper Washer

ECA-BUSS

ECA, Elect Center A

J14

Rear Wiper Washer Backup

ECA-BUSS

ECA, Elect Center A

J15

Backup AC

ECA-BUSS

ECA, Elect Center A

J17

Seat Comp EMG Strtr

ECA-BUSS

ECA, Elect Center A

J18

Diagnostic Power

ECA-BUSS

ECA, Elect Center A

J2 ECC

Beacon/Dome Lt Work Lights

ECC-BUSS

ECC, Elect Center C

L1-1

ECC, Elect Center C

L1-2

J3 ECC

Work Lights Driving Lights

ECC-BUSS

ECC, Elect Center C

L1-2

ECC, Elect Center C

L1-3

J4 ECC

Driving Lights Brake Lights

ECC-BUSS

ECC, Elect Center C

L1-3

ECC, Elect Center C

L1-4

J5 ECC

Brake Lights Delay Power

ECC-BUSS

ECC, Elect Center C

L1-4

ECC, Elect Center C

L1-5

J6 ECC

Delay Power Horn

ECC-BUSS

ECC, Elect Center C

L1-5

ECC, Elect Center C

L1-6

J7 ECC

Horn HOD Control

ECC-BUSS

ECC, Elect Center C

L1-6

ECC, Elect Center C

L1-7

RAD1 Radio Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD2 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

4002-45

Wire Identification Codes

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

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm 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 Cavity

Connector

Cavity

RAD3 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD4 Left Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD5 Left Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD6 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD7 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD8 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD9 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD10 Right Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD11 Right Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

4002-46

UNDERSTANDING THE TROUBLESHOOTING TABLES 1 â&#x20AC;&#x201C; Alternator

Check Points

Correct Reading

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

Good 12 volts

Possible Cause of Bad Reading

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

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

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

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

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

4002-47

STARTING AND CHARGING SYSTEMS

6 4 11 2

W230R606 / W230R607

1. 2. 3. 4. 5.

STARTING RELAY RESISTOR 75 OHM ALTERNATOR CRANK CONTROL RELAY BATTERIES

6. 8. 9. 10. 11.

CRANK REQUEST RELAY 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.

4002-48

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.

4002-49

4 – Crank Control Relay Located in the cab access panel for fuses and relays. Correct Reading

Check Points Terminal for wire 21H to ground

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 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. Correct Reading

Check Points Terminal for wire 0-DF to ground

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.

8 – Master Disconnect Switch Located on left sideof engine hood compartment. 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).

4002-50

9 â&#x20AC;&#x201C; 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.

10 â&#x20AC;&#x201C; 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.

4002-51

11 â&#x20AC;&#x201C; 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.

4002-52

POWER RELAY MODULES AND COLD STARTING SYSTEMS

13 14 15 W230R608 / W230R609

13. 14. 15. 16. 17.

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

18. POWER RELAY MODULE D 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.

4002-53

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 fuse or circuit.

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

24 volts

Check circuit 1CB.

Terminal for wire 12ACC-C to ground

24 volts

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

Terminal for wire 19L to ground

24 volts

Bad power relay module A.

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

Correct Reading

Possible Cause of Bad Reading

Check fuse F1, F2

Continuity

Bad fuse or circuit.

Terminal for wire 0-EC to ground

Continuity

Bad fuse or 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 fuse or 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.

4002-54

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

4002-55

20 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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.

4002-56

ENGINE CONTROLLER

W230R608 / W230R610

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.

4002-57

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

4002-58

24 â&#x20AC;&#x201C; 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.

4002-59

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE 28

25 26 31 32

27 33

34 W230R611 / W230R612

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 RETURN 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.

4002-60

25 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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.

4002-61

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. 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. 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.

4002-62

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.

4002-63

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.

4002-64

PILOT CONTROL - RIDE CONTROL - FAN CONTROL

43 44 35 37 39

36 38

40 41 42 W230R613 / W230R614

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.

4002-65

35 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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.

4002-66

37 â&#x20AC;&#x201C; 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 reversing switch in position 1. Terminal for wire 52AU to ground

24 volts

Bad fan reversing switch.

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

24 volts

Bad fan reversing 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 reversing switch are not ON with 24 volts at check point, replace fan control switch.

38 â&#x20AC;&#x201C; 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 reverse 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).

4002-67

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.

4002-68

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 reversing switch. Also check wire 52-A.

4002-69

TRANSMISSION

48 52 55 56 57 60

49 50 51

45 53 54 47 61 58 W230R615 / W230R616

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.

4002-70 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

4002-71

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE 66

62 63

67 69

64 W230R617 / W230R618

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.

4002-72

62 â&#x20AC;&#x201C; 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 11to 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 9to 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.

4002-73

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.

4002-74

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).

4002-75

69 â&#x20AC;&#x201C; 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.

4002-76

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE

70 71 74

75 76

72 73 W230R619 / W230R620

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

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.

4002-77

70 â&#x20AC;&#x201C; 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.

4002-78

71 â&#x20AC;&#x201C; 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-D-A. 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 (13).

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 18to ground

24 volts

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

4002-79 ]

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).

4002-80

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 70 bar (1015 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 70 bar (1015 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).

4002-81

BACK UP ALARM CONTROLS

78 W230R608 / W230R621

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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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

80 84

89 W230R622 / W230R623

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 â&#x20AC;&#x201C; 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

92 91 90 W230R624 / W230R625

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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 (13). 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 â&#x20AC;&#x201C; 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

98 W230R626 / W230R627

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 â&#x20AC;&#x201C; 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 LF 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 LF 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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

W230R628 / W230R629

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 â&#x20AC;&#x201C; 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-N 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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-N 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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.

24 volts

Bad back-up alarm disable switch (79). If machine is not a TUV model, check connector 209F and 209M is connected.

NOTE: If the readings are good, replace the back-up alarm.

103 – Back-up Alarm (Europe Only) Located on the left rear of the machine inside engine compartment. Check Points Terminal for wire 0-JB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

24 volts

Bad back-up alarm disable switch (79). If machine is not a TUV model, check connector 209F and 209M is connected.

NOTE: If the readings are good, replace the back-up alarm.

4002-103

CAB WINDOW WASHER AND WIPER SYSTEM 110

109

111 112 107 108

113

104 106 105 W230R630 / W230R631

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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 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 â&#x20AC;&#x201C; 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 W230R608 / W230R632

114.SECONDARY STEERING DIODES 115.SECONDARY STEERING SOLENOID 116.SECONDARY STEERING MODULE

117.SECONDARY STEERING MOTOR 118.SECONDARY STEERING PRESSUR 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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

W230R608 / W230R633

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 â&#x20AC;&#x201C; 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

W230R634 / W230R635

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

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 â&#x20AC;&#x201C; 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 â&#x20AC;&#x201C; 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 130

126

129 127

128 W230R636 / W230R637

126.SEAT COMPRESSOR AND SWITCH 127.CIGAR LIGHTER 128.AIR CONDITIONING COMPRESSOR CLUTCH REALY

129.A/C HIGH/LOW PRESSURE 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 blower 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 â&#x20AC;&#x201C; 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 blower 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. 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 â&#x20AC;&#x201C; 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 blower 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 135 136 137 140 141 137

131

139 132 133 134 138 142 W230R638 / W230R639

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

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.

138 – Mixed Air Sensor Check Points NOTE: Automatic climate control only.

4002-124

139 – Compressor Relay 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

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 143 144 145 146 147 148 137

149 150 151 152 153

W230R640 / W230R641

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. Continuity

Between DNSS2 and DNS75

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 blower switch (149) to position 4. Terminal for wire DNS65 to ground

24 volts

Check the blower switch (149).

NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blower switch (149) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower motor 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

STARTING / IGNITION SYSTEMS

158 159 160 W230R608 / W230R644

154.IGNITION POWER LATCH 155.IGNITION POWER CONTROL

156.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.

4002-130

154 – 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).

155 – 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.

156 – 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

4002-131

SCR SYSTEM/ JOYSTICK STEERING/ MISC 162

161 164 167 165

163 166 168 169

W230R608 / W230R645

157.NOX SENSOR 158.HUMIDITY AND AMBIENT TEMPERATURE SENSOR 159.NOX SENSOR (NOXS) 160.TANK HEATER CONTROL VALVE 161.DEF LEVEL AND TANK TEMPERATURE

162.UPSTREAM TEMPERATURE SENSOR 163.DOWNSTREAM TEMPERATURE SENSOR 164.DOSER METERING VALVE 165.DNOX CONTROLLER

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

4002-132

157 – NOX Sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

158 – Humidity and ambient temperature sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

159 – NOX Sensor (NOXS) Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

160 – Tank heater control valve Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

161 – DEF Level and tank temperature Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

162 – Upstream temperature sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

163 – Downstream temperature sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

164 – Doser metering valve Check Points

Correct Reading

NOTE: See SCR controller manual for details.

Possible Cause of Bad Reading

4002-133

165 – DNOX Controller Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: See SCR controller manual for details.

166 – Rear View Camera / Monitor Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: See Camera manual for details.

167 – Differential Lock Switch (Manual) Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Remove connector SDM from switch.

Between terminals 2 and 3

Normally open, Continuity when switch is closed

Bad Lock Switch.

168 – 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

169 – Differential Lock Solenoid Check Points Terminal for wire 34C-A to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and ignition switch in ON position. Terminal 1 for wire 34A-D to ground

24 volts

Bad TECM module. Also check circuit 34C.

NOTE: If the readings are good, replace the differenital lock solenoid. NOTE: See transmission section for more details.

4002-134

170 – 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.

171 – Joystick PVRES NOTE: See service manual section 5009 for Joystick steering details.

172 – Transmission Kick Down Switch NOTE: See service manual section 5009 for Joystick steering details.

173 – ARM POS NOTE: See service manual section 5009 for Joystick steering details.

174 – FNR Switch (option) NOTE: See service manual section 5009 for Joystick steering details.

175 – FNR Relay NOTE: See service manual section 5009 for Joystick steering details.

176 – Pilot Dump Valve NOTE: See service manual section 5009 for Joystick steering details.

177 – JSS Valve NOTE: See service manual section 5009 for Joystick steering details.

178 – Load Sense Pressure Sensor NOTE: See service manual section 5009 for Joystick steering details.

179 – Pilot Pressure Switch NOTE: See service manual section 5009 for Joystick steering details.

4002-135

180 – JSS Relay NOTE: See service manual section 5009 for Joystick steering details.

181 – Joystick STR Switch (option) NOTE: See service manual section 5009 for Joystick steering details.

182 – JSS Controller NOTE: See service manual section 5009 for Joystick steering details.

4002-136

CONNECTORS AIC 1, ADV INSTR CLUSTER 1

CONNECTOR AB+, ALTERNATOR B+ CAV 1

WIRE IDENT 1 BA

CIRCUIT ALTERNATOR B+

CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH

87419488

8602417

CAV 1

WIRE IDENT 61C-A

CIRCUIT AC RELAY OUT

AD, ALTERNATOR D+ CAV 1

WIRE IDENT 14

CIRCUIT ALTERNATOR D+

CAV

WIRE IDENT

CIRCUIT

19S-E

AIC BATT B+

36F-A

FUEL LEVEL ANALOG

CAN-HG

CAN HIGH

CAN-LG

CAN LOW

0-DX

AIC SENSOR GND

43-A

DOME LT AUTO MODE

36H-A

HYDRAULIC OIL TEMP

36C-A

RADITAOR COOL TEMP SGNL

0-DW

AIC POWER GND

35B

AIC BUZZER HSD

52C

PARK BRAKE SOL LSD

53C-A

PILOT CTRL SOL LSD

51D-A

GRND, RELAY CTRL

0-EZ

POWER RELAY CONTROL

FAN REVERSER LSD

17P-B

SW PAD PWR FR0M AIC PWR

FAN CONTROL PWM

4002-137 ARM POS, ARM POSITION

AIC 2, ADV INSTR CLUSTER 2 CAV

WIRE IDENT

CIRCUIT

0-SG

COMMON

51R

ARMREST RAISE

51E-B

ARMREST LOWER

B1, STARTER PWR STUD CAV 1

WIRE IDENT 1-NC

CIRCUIT B+ PWR PRMC

87410948

CAV

WIRE IDENT

B2, STARTER POWER

CIRCUIT

43S-A

DOOR OPEN SGNL

CAV

33R

RDNT BRK ACCUM PRESS LOW

33P-A

BRK WARN PRESS LOW

33U

PARK BRK SWITCH

52M

FAN REVERSE MAN

52AU

FAN REVERSE AUTO

CAV 1

45L-E

LEFT TURN SGNL

45R-C

RIGHT TURN SGNL

35X

SEC STR LOW PRESS SGNL

61B-A

AC SIGNAL

19S-D

AIC DELAY FSD PWR

0-DB

AIC POWER GND RED

57-C

PIN ENGAGE SOL PWR

21K-A

IGN SW START SIGNAL

31L

PILOT CTRL SW HIGH

19S-C

AIC DELAY FSD PWR

19S-F

AIC BATT B+

0-DA

AIC CHASSIS GND

WIRE IDENT 1-BA

CIRCUIT ALTERNATOR B+

B3, STARTER BATTERY WIRE IDENT 1-NB

CIRCUIT BATTERY STARTER

B4, STARTER POWER CAV 1

WIRE IDENT 1-ND

CIRCUIT SSM PWR

BPP, PEDAL POSITION

ARM FNR, FNR-MAIN CAB CAV

WIRE IDENT

CIRCUIT

19B-C

FNR SWITCHED PWR

26F-F

FNR FORWARD SIGNAL

26N-F

FNR NEUTRAL SIGNAL

26R-F

FNR REVERSE SIGNAL

32J-J

FNR LT SIGNAL

25Y-G

TRANS KICKDOWN SIGNAL

W230R395

CAV

WIRE IDENT

CIRCUIT

22G

PEDAL SENSOR GRND

22E

PEDAL SENSOR +5V

22F

PEDAL POS SIGNAL

401B

PEDAL POS SIGNAL

255E

PEDAL SESNOR +5V

016B

PEDAL SENSOR GRND

4002-138 BT1, BATTERY STARTER CAV

WIRE IDENT

BTM E, CAB BTTOM

CIRCUIT

1-NB

BATTERY STARTER

1-NE

BATTERY STARTER

BT2, DISCONECT BATTERY CAV 1

WIRE IDENT 1-NA

CIRCUIT BATTERY CROSSOVER

BT3, STARTER BATTERY CAV 1

WIRE IDENT 1-NA

225319C1

CAV

CIRCUIT BATTERY CROSSOVER

BT4, DISCON-BLCK GRND CAV 1

WIRE IDENT 0-NC

CIRCUIT BATTERY DISCONNECT

BTM C, CAB BOTTOM BULKHD

WIRE IDENT

CIRCUIT

21F-D

EDC7 DIGITAL GND

0-AK

PARK BRAKE/WARNING GND

24B-A

THROT SIGNAL

24R-A

THROT GND

24S-A

THROT SUPPLY

24L-A

LOW IDLE SWITCH

61R-E

AC SWITCH OUTPUT

61A-E

AC SWITCH INPUT

BU1, BACKUP ALARM GRND CAV 1

WIRE IDENT 0-JB

CIRCUIT BACKUP ALARM GND

BU2, BACKUP ALARM CAV

W230R397

CAV

WIRE IDENT

CIRCUIT

22G

PEDAL SENSOR GRND

22E

PEDAL SENSOR +5V

22C

PEDAL POS SIGNAL

22F

PEDAL POS SIGNAL

016B

PEDAL SENSOR GRND PEDAL SESNOR +5V

WIRE IDENT

CIRCUIT

35A-H

BKUP ALM RLY OUT

35A-HN

BKUP ALM RLY OUT

35A-HT

BKUP ALM RLY OUT

BUZ, AIC BUZZER CAV

WIRE IDENT

CIRCUIT

35B

AIC BUZZER HSD

0-B27

BUZZER GND

255E

401B

PEDAL POS SIGNAL

BRK LT CTRL PWR

1-AA

BRK LT SW PWR

CAV

33P

BRK WARNING PRESS LOW

52P

PARK BRK RLY OUT

CAB PW, CAB POWER WIRE IDENT 1CB-A

CIRCUIT CAB CB PROTECTED PWR

4002-139 CABE2, CAB TO ENG2 BULKHD

CAB ARM, CAB TO ARMREST

W230R398

CAV

WIRE IDENT

CIRCUIT

225389C1

CAV

WIRE IDENT

CIRCUIT

23B-D

NOX RELAY, B+

CANS-HB

CAN HI, CAN MOD2

18U-C

DNOX2 BATT

0-SJ

GRND, CAN MOD

23B-B

NOX SENSOR B+

51E-A

ARMREST LOWER

18U-A

DNOX2 MODULE B+

17P-D

B+, CAN MOD

23B-A

NOX SENSOR B+

51B-H

JSS ACT SW

0-L

TELEMATICS GRND

0-SD

GRND, JOYSTICK

18T

DNOX SW B+

51PW-R

JSS POWER

35A-F

BKUP ALM RLY OUT

51S-B

JSS OKAY PWR

35A-C

BKUP ALM RLY OUT

51H-B

JOYSTICK SIGNAL

18F-A

LH POSN/TAIL FUSED PWR

51NO-A

NO NEUTRAL SW

18G-F

RH POSN/TAIL FUSED PWR

CANS-LB

CAN LO, CAN MOD2

45R-B

RIGHT TURN SGNL

45L-B

LEFT TURN SGNL

44A-A

BRK LT RLY OUT

19Y-C

HOOD SWITCH FSD PWR

CAV

CANS-LB

CAN LO, CAN MOD2

CAB ARM FRM, CAB TO ARM TO FRM WIRE IDENT

CIRCUIT

60D

HOOD DOWN RLY OUT

59D

HOOD DOWN RLY CTRL

17P-G

B+, JOYSTICK

60U

HOOD UP RLY OUT

51D-B

GRND, RELAY CNTL

59U

HOOD UP RLY CTRL

51B-D

JSS ACT SW

CANS-LD

CAN LO, CAN MOD3

CANS-HD

CAN HI, CAN MOD3

0-SK

GRND, CAN MOD

51PW-M

JSS POWER

51C-B

JSS ACT BTN

18S-D

B+, JSS FUSED

CANS-HB

CAN HI, CAN MOD2

4002-140 CAB B, CAB BTM BULKHEAD

CAB E, CAB-ENGINE CAV

WIRE IDENT

CIRCUIT

36F-A

FUEL LEVEL ANALOG

61C

AC RELAY OUT

21G

EDC7 CRANK CTRL RLY

21H

CRANK CTRL RLY LSD

36C-A

RADITAOR COOL TEMP SGNL

0-DF

CRANK REQUEST RLY CTRL GND

21F

EDC7 DIGITAL GND

CAN-LL

CAN2 LO, EDC

CAN-HM

CAN2 HI, EDC

21D-A

STARTER RLY SIGNAL

0-DX

AIC SENSOR GND

23J-B

DNOX2 K-LINE

0-DW

AIC POWER GND

W230R396

CAV A

WIRE IDENT 22D

CIRCUIT PEDAL SENSOR GRND

22B

PEDAL SENSOR +5V

22C

PEDAL POS SIGNAL

44-A

BRK LT CTRL PWR

1-DR

BRK LT SW PWR

33P-A

BRK WARN PRESS LOW

52P-A

PARK BRK RLY OUT

CAB FNR, MAIN CAB FNR CAV

WIRE IDENT

CIRCUIT

0-DB

AIC POWER GND RED

13C-B

FUEL SHUTOFF FUSED PWR

52A-A

FAN REVERSE RLY OUT

FAN CONTROL PWM

68W

REAR WSHR PUMP

63W

FNT WASHER PUMP

14-AB

ALTERNATOR D+ KEY SWITCH CRANK

19B-B

TRANS ENA SW PWR

21E-B

26F-E

FNR FORWARD SIGNAL

31F-A

AIR FLTR REST SW SGNL

61R-B

AC RELAY CONTROL

26N-E

FNR NEUTRAL SIGNAL

26R-E

FNR REVERSE SIGNAL

61A-B

TRINARY PRESS SW INPUT

32J-H

TRANS ENABLE LT SIG

20G-B

EDC7 ISO-K INTERFACE

25Y-E

NONE

CAB F, CAB FRONT CHAS CAV

WIRE IDENT

CIRCUIT

45L-C

LEFT TURN SGNL

45R-D

RIGHT TURN SGNL

18G-G

RH POSN/TAIL FUSED PWR

18B-A

LH HIGH BEAM FUSED PWR

53P-F

PILOT CTRL RLY OUT

18F-E

LH POSN/TAIL FUSED PWR

54B-A

HC-RTT CTRL SGNL

53B-B

RTD CTRL SIGNAL

64-A

HORN POWER

18D-A

LH LOW BEAM FUSED PWR

18E-A

RH LOW BEAM FUSED PWR

18C-A

RH HIGH BEAM FUSED PWR

57-A

PIN ENGAGE SOL PWR

58-C

RIDE CTRL SOL PWR

4002-141 CAB FRM, CAB TO JSS FRAME CAV

WIRE IDENT

CAB T, CAB TRANSMISSION

CIRCUIT

51F-B

LS PRESS SW

51J-A

VALVE ALARM

51K-B

PILOT PRESS SW

51L-A

JOYSTICK SIGNAL

51S-F

JSS OKAY PWR

0-SF

GRND

51PW-T

JSS POWER

18S-D

B+, JSS FUSED

380839A1

CAV

CAB RF, CAB TO ROOF CONNECTION

388710A1

CAV A

WIRE IDENT 0-DZ

CIRCUIT WORK LIGHTS GRND

0-DY

ROOF SPLICE GNDS

43-A

DOME LT AUTO MODE

19U-D

DOME LT FSD PWR

46-C

BEACON SW PWR

0-DR

ROOF SPLICE GNDS

0-DS

ROOF SPLICE GNDS

42C-A

FNT WRK LTS FUSE PWR

19K-C

REAR WPR MOTOR FSD PWR

68C

REAR WPR PARK CTRL

68L-B

REAR WPR SW PWR

0-EM

RADIO GND

12V-B

12V FUSED PWR TO RADIO

19U-G

DOOR SW FSD PWR

43S-A

DOOR OPEN SGNL

42R-C

REAR WRK LTS FUSE PWR

WIRE IDENT

CIRCUIT

33R

RDNT BRK ACCUM PRESS LOW

34A-C

DIFF LOCK SOL B+

19M

SEC STR ACCESSORY FSD PWR

19R-E

SEC STR IGN FSD PWR

36T-A

VALVE BODY TEMP SGNL

35X

SEC STR LOW PRESS SGNL

25A-A

ENG SP SIGNAL

25C-A

TURBINE SP SIGNAL

25B-A

INT SP SIGNAL

25D-A

OUTPUT SP SIGNAL

0-DM

SPEED SENSOR GNDS

36R-E

TRANS TEMPS/FLTR RETURN

36G-A

TCO TEMP SIGNAL

25G-A

BRK DECLUTCH SW CTRL

25R-A

TC LOCKUP SOL POWER

25K-A

TRANS SOL VALVE Y1

25L-A

TRANS SOL VALVE Y2

25M-A

TRANS SOL VALVE Y3

25N-A

TRANS SOL VALVE Y4

25P-A

TRANS SOL VALVE Y5

25J-A

TRANS SOL VALVE Y6

25S-A

OUTPUT SW PWR VPS1

31H-A

HYD FLTR REST SW SGNL

19A-T

BRK DECLUTCH SW FSD PWR

25T-A

TC LOCKUP SOL GND

19S1

SEC STR FSD PWR

34C

DIFF LOCK SOL GND

0-DN

OUTPUT SPEED SENSOR GND

19A-M

OUTPUT SP SNSR FUSED PWR

36H-A

HYDRAULIC OIL TEMP

32F-A

TRANS FLTR MAINT SW

4002-142 CAN MOD 2, JSS CAN MOD

CONNECTOR CNV - 24V TO 12V POWER CONVERTER

225351C1

CAV

19L-A

POW CONVER. FUSED POW

19L-B

POW CONVER. FUSED POW

JSS ACT SW

0-EJ

WIRE IDENT 51B-J

CIRCUIT

87552623

CAV

WIRE IDENT

CIRCUIT

POW CONVERTER GROUND

51PW-U

JSS POWER

51NC

NC NEUTRAL SW

12V-C

12V SWITCHED POWER

51S-D

JSS OKAY PWR

0-ER

POW CONVERTER GROUND

51R

ARMREST RAISE

CANS-HA

CAN HI, CAN MOD2

CANS-LA

CAN LO, CAN MOD2

17P-E

B+, CAN MODULE

CAV

GRND

0-SE

NOT USED

DC1, DISCONECT BATTERY WIRE IDENT 0-NC

DC2, DISCON BLCK GRND

CBPW, CAB POWER CAV 1

WIRE IDENT 1CB

CIRCUIT BATTERY DISCONNECT

CAV

CIRCUIT CAB CB PROTECTED PWR

WIRE IDENT 0-NB

CIRCUIT MASTER DISCONNECT GND

DC3, FUEL SOL DISCONNECT

CONNECTOR CL - CIGAR LIGHTER CAV 1

WIRE IDENT 13C

CIRCUIT FUEL SHUTOFF FUSED PWR

DC4, FUEL SOL DISCONNECT CAV 1

WIRE IDENT 13M

CIRCUIT FUEL SHUTOFF FUSED PWR

DEFDM, DOSER METERING VLV 3227856R1

CAV

WIRE IDENT

CIRCUIT

19W

CIGAR LIGHTER FUSED POW

0-DV

CIGAR LIGHTER GROUND

CAV

WIRE IDENT

CIRCUIT

DOSER VALVE B+

38A

DOSER VALVE GND

4002-143 CONNECTOR DIA - DIAGNOSTIC

CONNECTOR DISC - DISCONNECT ENGINE

245482C1 310057A1

CAV

WIRE IDENT

CAV

CIRCUIT

0-DH

GROUND

18K-A

DIAGNOSTICS FUSED POWER

CAN-HB

CONTROLLER AREA NETWORK HIGH

CAN-LB

CONTROLLER AREA NETWORK LOW

20G-B

EDC7 ISO-K INTERFACE

WIRE IDENT

CIRCUIT

13C

FUEL SHUTOFF FUSED POW

13M

FUEL SHUTOFF FUSED POW

CONNECTOR DM - DIODE OR

DIA 2, DIAGNOSTIC

245485C1

CAV A

WIRE IDENT 19RR

B C 310057A1

CAV

WIRE IDENT

CIRCUIT

0D-C

DIAG2 GRND

18K-B

DIAG FUSED B+

CAN-HO

CAN2 HI, DIAG2

CAN-LX

CAN2 LO, DIAG2

23J-B

DNOX2 K-LINE

CIRCUIT SEC. STEERING IGNITION FUSED PWR NOT USED

19R

SEC. STEERING IGNITION FUSED PWR

4002-144 DNOX2, NOX CONTROLLER CAV

WIRE IDENT

DTLTS, DEF TANK LEVEL TEMP SENSOR

CIRCUIT

38D

TANK HEAT B+

18U-D

DNOX2 BATT

18U-B

DNOX2 BATT

CAN-QH

CAN HI, DNOX2

CAN-LK

CAN LO, DNOX2

38A

DOSER VALVE GND

DOSER VALVE B+

0-LB

DNOX2 MODULE GND

0-LC

DNOX2 MODULE GND

CAV

0E-A

EXHT TEMP UP GND

38B-A

DEF LEVEL SIG

38B

DEF LEVEL SIG

0-TA

DEF SENSOR GND

0-T

DEF SENSOR GND

38G-A

DEF TEMP SIG

38C

TANK HEAT GND

18T-A

DNOX2 SW B+

0-U

EXHT TEMP DWN GND

38E

EXHT TEMP DWN B+

CAV

38F

EXHT UP SIGNAL

38E

EXHT TEMP DWN B+

38G

DEF TEMP SIG

0-U

EXHT TEMP DWN GND

38H

DNOX2 K-LINE

W230R399

WIRE IDENT

CIRCUIT

DTS, DOWNSTREAM TEMP SENS WIRE IDENT

CIRCUIT

CONNECTOR D-OR - DIODE OR CONNECTOR DS - DOOR SWITCH

245485C1 245482C1

CAV

WIRE IDENT

CIRCUIT

19U-F

DOOR SWITCH FUSED POWER

43S-B

DOOR OPEN SIGNAL

CAV

WIRE IDENT

CIRCUIT

42C-D

FRONT WORK LIGHTS FUSED POWER

41T-C

POSITION LIGHTS SWITCHED POWER

BACK LIGHT POWER

4002-145 EDC7, ENGINE CONTROLLER

CAV

WIRE IDENT

CIRCUIT

CAN1-H

CAN HI

CAN-HK

CAN HI, EDC

28F

FUEL FLTR HTR RLY CTRL

21G-A

EDC7 CRANK CTRL RLY

13M-A

FUEL SHUTOFF FUSED PWR

35W

WIF INDICATOR

24L

LOW IDLE SWITCH

13A

EVGT RELAY

CAN-LS

CAN2 LO, NOX

CAN-HS

CAN2 HI, NOX

23K-A

TEMP/HUMD B+

0-BV

GRID HEATER CTRL GND

24S

THROT SUPPLY

24R

THROT GND

24B

THROT SIGNAL

20G-A

EDC7 ISO-K INTERFACE

ECA L1, B+ POWER CAV cs01

WIRE IDENT J1

CIRCUIT TRANS ECM PWR

CONNECTOR EM - HEIGHT CONTROL RTD - RTT BOSCH-89-POLE

CAV

WIRE IDENT

CIRCUIT

18J-C

EDC7 FSD PWR

18J-B

EDC7 FSD PWR

0-BE

EDC7 GND

0-BF

EDC7 GND

18J-D

EDC7 FSD PWR

18J-E

EDC7 FSD PWR

0-BD

EDC7 GND

0-BC

EDC7 GND

28G

GRID HTR SOURCE DR

EDC RELAY CNTL

21H-A

CRANK CTRL RLY LSD

23K-B

TEMP/HUMD TEMP

23K-C

TEMP/HUMD HUMD

23K-E

TEMP/HUMD GND

21F-B

EDC7 DIGITAL GND

21E-A

KEY SWITCH CRANK

CAN-LJ

CAN LO, EDC

CAN1-L

CAN LO

225351C1

CAV

WIRE IDENT

CIRCUIT

55A-A

RTT/FLOAT SWITCHED POW.

54A

HEIGHT CONTROL SWITCHED POWER

53A

RTD SWITCHED POWER

53B-B

RTD CONTROL SIGNAL

54B-B

HC-RTT CONTROL SIGNAL

55B

RTT FLOAT SWITCH CONTROL

4002-146 ENG B, CAB BOTTOM

ENG, ENGINE CAB1 CAV

WIRE IDENT

CIRCUIT

36F

FUEL LEVEL ANALOG

36J

FUEL LEVEL ANALOG

61C-A

AC RELAY OUT

21G-A

EDC7 CRANK CTRL RLY

21H-A

CRANK CTRL RLY LSD

36C

RADIATOR COOL TEMP SGNL

0-BAT

CRANK REQUEST GND

21F-A

EDC7 DIGITAL GND

CAN-L

CAN LOW

225320C1

CAV

WIRE IDENT

CIRCUIT

21F-C

EDC7 DIGITAL GND

0-BBR

GROUND

24B

THROT SIGNAL

24R

THROT GND

24S

THROT SUPPLY

24L

LOW IDLE SWITCH

61R-C

AC SWITCH OUTPUT

61A-C

AC SWITCH INPUT

CAN1-L

CAN LO

CAN-H

CAN HIGH

CAN1-H

CAN HI

21D

STRTR RLY SIGNAL

460

FAN SPEED SENSOR SIGNAL

0-BJ

AIC SENSOR GND

38H

DNOX2 K-LINE

0-BG

AIC POWER GND

0-BH

AIC POWER GND RED

13C-A

FUEL SHUTOFF FUSED PWR

52A-B

FAN REVERSE RLY OUT

56-A

FAN CONTROL PWM

68W-A

REAR WSHR PUMP

63W-A

FNT WASHER PUMP

ALTERNATOR D+

14-5

ALTERNATOR D+

21E-A

KEY SWITCH CRANK

31F

AIR FLTR REST SW SGNL

61R

AC RELAY CONTROL

61A

AC PRESS SW INPUT

20G-A

EDC7 ISO-K INTERFACE

4002-147 ECA, ELECT CNTR A

87315248

CAV A1

WIRE IDENT 19A-N

CIRCUIT TRANS FUSE PWR

18S-A

B+, JSS FUSED

19E-A

AIC WAKE UP IGN

19RR

SEC STR IGN FSD PWR

19C-A

PILOT CTRL RLY FSD PWR

19D-A

PARK BRK RLY FSD PWR

19P

PIN ENGAGE/FAN FSD PWR

19B

TURN SIGNAL FSD PWR

19C-B

FUEL SHUTOFF FUSED PWR

A10

18T

DNOX SW B+

18N

BLOWER MOTOR FUSED PWR

19J

FNT WPR FSD PWR

19K

REAR WPR FSD PWR

19H

BACKUP ALARM B+

19N

SEAT CPRSR FSD PWR

19M

SEC STR ACCESSORY FSD PWR

19W

CIGAR LIGHTER FSD PWR

66A

RR CAMERA PWR

TRANS ECM PWR

EMG STR AIC PWR

EMG STRG PLT EM DTNTS

CAV

WIRE IDENT

CIRCUIT

PLTEM DTNTS PRK BRK SOL

PRK BRK SOL HRN

FAN RVSR TURN SGNL

TURN SGNL ENG SHTDWN.

J10

DNOX SW B+

J11

BLWR MOTOR PWR

J12

BLWR MTR FRNT WIPR WASH

J13

FRNT WIPR RER WIPR WSH

J14

RER WIPR WSH BACKUP

J15

BKUP A/C

J17

SEAT COMP EMG STRTR

J18

DIAGNOSTIC PWR

4002-148 ECB, ELECT CNTR B

87312843

CAV

WIRE IDENT

CIRCUIT

CAV

0-EF

BRK LTS RLY CTRL GND

1-DW

BRAKE LT RLY BAT PWR

WIRE IDENT

CIRCUIT

63C3

FNT WPR PARK CTRL

63LC

FNT WPR LS RLY CTRL

19C-B

PILOT CTRL RLY FSD PWR

0-EZ

POWER RELAY CONTROL

0-EY

POWER RELAY GND

53C-A

PILOT CTRL SOL LSD

21H

CRANK CTRL RLY LSD

58T

RIDE CTRL RLY SW PWR

21C-B

NEUT START RLY OUTPUT

58L

RIDE CTRL RLY LSD

61A-G

TRINARY PRESS SW INPUT

23B-C

NOX RELAY GND

23B-A

NOX SENSOR B+

B10

0-DJ

AC RELAY CONTROL GND

35C

BACK UP ALRM CNTL

63C2

FNT WPR PARK CTRL

A10

19H

BACKUP ALARM B+

63C

FNT WPR PARK CTRL

61C

AC RELAY OUT

AA1

44A-A

BRK LT RLY OUT

C10

AA2

44-A

BRK LT CTRL PWR

19J-D

FNT WPR RLY FSD PWR

AA3

0-KA

IGN PWR CONTROL GND

63H-B

FNT WPR RLY HS

AA4

13K-A

IGN PWR CONTROL B+

19J-F

FNT WPR RLY LS CTRL FSD PWR

AA5

21D-A

STRTR RLY SIGNAL

63C2

FNT WPR PARK CTRL

AA6

21G

EDC7 CRANK CTRL RLY

19C-C

PILOT CTRL RLY FSD PWR

AA7

23B-B

NOX SENSOR B+

53P-C

PILOT CTRL RLY OUT

AA8

23B-D

NOX RELAY, B+

58H-C

POWER

AA9

35A-A

BACKUP ALARM

58-E

RIDE CTRL SOL PWR

AA10

19A-P

BACKUP ALARM RELAY

61R-B

AC RELAY CONTROL

19J-E

FNT WPR RLY FSD PWR

63HC-B

FNT WPR RLY HS

4002-149 ECB, ELECT CNTR D

87315249

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

21E

KEY SWITCH CRANK

0-B22

HOOD UP RELAY GND

0-J

START LOCKOUT RLY GND

0-B12

HOOD DOWN RELAY GND

21J

RESTART PREVENT

59U

HOOD UP RLY CTRL

67B

START LOCKOUT

19Y-A

HOOD UP RLY FSD PWR

59D

HOOD DOWN RLY CTRL

87A

21E-B

KEY SWITCH CRANK

19U-B

BEACON DOME LT FSD PWR

19Y-B

HOOD DOWN RLY FSD PWR

WORK LIGHTS SW FSD PWR

42C-E

FNT WRK LTS FUSE PWR

19Z

DRIVING LTS SW FSD PWR

0-DL

WORK LIGHTS GRND

19U-E

HORN RLY FSD PWR

1-DV

BRK LTS/FLASHER BAT PWR

1DM

TIME DELAY/IGN SW FSD PWR

64-A

HORN POWER

19U

HORN RLY FSD PWR

L1-1

J2-ECC

BEACON/DOME LT WORK LTS

19Y

HOOD CTRL FSD PWR

L1-1

ECC-L1

BEACON/DOME LT LI ECC

J3-ECC

WORK LTS DRIVING LTS

19S-B

AIC DELAY FSD PWR

L1-2

18K-A

DIAGNOSTIC FUSED PWR

L1-2

J2-ECC

BEACON/DOME LT WORK LTS

A10

19T-C

FUSED BATT PWR

L1-3

J4-ECC

DRIVING LTS BRK LTS

60U

HOOD UP RLY OUT

L1-3

J3-ECC

WORK LTS DRIVING LTS

J5-ECC

BRK LTS DLY PWR

0-B25

HOOD UP CONTROL GND

L1-4

60D

HOOD DOWN RLY OUT

L1-4

J4-ECC

DRIVING LTS BRK LTS

0-B16

HOOD DOWN CONTROL GND

L1-5

J6-ECC

DLY PWR HRN

0-DD

WORK LIGHTS GRND

L1-5

J5-ECC

BRK LTS DLY PWR

J7-ECC

HRN HOD CTRL

42C-L

FNT WRK LTS FUSE PWR

L1-6

19U-A

HORN RLY FSD PWR

L1-6

J6-ECC

DLY PWR HRN

64C

HORN RLY CTRL

L1-7

J7-ECC

HRN HOD CTRL

4002-150 ECC, ELECT CNTR C

87312843

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

12V-D

PLUG 1 12V SW PWR

0-DE

NEUT START RLY CTRL GND

12V-E

PLUG 2 12V SW PWR

21F

EDC7 DIGITAL GND

41H-B

HIGH BEAM LH PWR

0-DF

CRANK REQUEST RLY CTRL GND

41H-C

HIGH BEAM RH PWR

41L-C

LOW BEAM RH PWR

41L-B

LOW BEAM LH PWR

41T-B

POSN LIGHTS LH SW PWR

41T-A

POSN LIGHTS RH SW PWR

12V-F

RADIO 12V SW PWR

A10

12V-G

2 WAY RADIO 12V SW PWR

AA1

12V

12V PWR TO OUTLET 1

AA2

12V-A

12V PWR TO OUTLET 2

AA3

18B-A

LH HIGH BEAM FUSED PWR

AA4

18C-A

RH HIGH BEAM FUSED PWR

AA5

18E-A

RH LOW BEAM FUSED PWR

AA6

18D-A

LH LOW BEAM FUSED PWR

AA7

18F-C

LH POSN/TAIL FUSED PWR

AA8

18G

RH POSN/TAIL FUSED PWR

AA9

12V-B

12V FUSED PWR TO RADIO

0-EW

POWER RELAY GND

0-EV

IGN LATCH GND

21K-B

IGN SW START SIGNAL

19P-E

FAN REV RLY FSD PWR

FAN REVERSER LSD

19D-C

PARK BRK RLY FSD PWR

B10

52C

PARK BRAKE SOL LSD

0-EA

PWR RELAY GND

13K-B

IGN PWR LATCH B+

0-ET

POWER RELAT GND

25T

NEUTRAL SIGNAL

21C

NEUT START RLY OUTPUT

21C-A

NEUT START RLY OUTPUT

21E

KEY SWITCH CRANK

19P-D

FAN REV RLY FSD PWR

52A-A

FAN REVERSE RLY OUT

19D-B

PARK BRK RLY FSD PWR

D10

52P-B

PARK BRK RLY OUT

4002-151 ENG2, ENG BULKHD 2

CONNECTOR ENG-D - DISCONECT HARNESS

245483C1

CAV

WIRE IDENT

CIRCUIT

13C-A

FUEL SHUTOFF FUSED POW

13M-A

FUEL SHUTOFF FUSED POW

W230R397

CAV

WIRE IDENT

CIRCUIT

23B-F

NOX RELAY B+

18U-D

DNOX2 BATT

23A-A

DNOX2 MODULE B+

18U-B

DNOX2 BATT

23B-E

NOX SENSOR B+

0-LA

DNOX2 MODULE GND

0-LD

DNOX2 MODULE GND

18T-A

DNOX2 SW B+

35A-G

BKUP ALM RLY OUT

35A-GN

BKUP ALM RLY OUT

35A-J

REVERSE LT

18F-AN

LH POSN/TAIL FUSED PWR

18F-B

LH POSN/TAIL FUSED PWR

18G-H

RH POSN/TAIL FUSED PWR

18G-HN

RH POSN/TAIL FUSED PWR

45R-A

RIGHT TURN SGNL

45R-AN

RIGHT TURN SGNL

45L-A

LEFT TURN SGNL

45L-AN

LEFT TURN SGNL

44A-D

BRK LT RLY OUT

44A-DN

BRK LT RLY OUT

19Y-D

HOOD SWITCH FSD PWR

60D-A

HOOD DOWN RLY OUT

59D-A

HOOD DOWN RLY CTRL

60U-A

HOOD UP RLY OUT

59U-A

HOOD UP RLY CTRL

CONNECTOR ENG-H - ENGINE TO HOOD

225320C1

CAV

WIRE IDENT

CIRCUIT

0-BAG-N

HOOD GROUND (NA)

44A-DN

BRAKE LIGHT RELAY OUT

45L-AN

LEFT TURN SIGNAL

45R-AN

RIGHT TURN SIGNAL

18G-HN

RH POSITION/TAIL FUSED PWR

18F-AN

LH POSITION/TAIL FUSED PWR

35A-GN

BACKUP ALARM RELAY OUT

4002-152 CONNECTOR E-HD - TRANSMISSION HOOD

CONNECTOR FLSHR - FLASHER MODULE

245485C1

CAV

WIRE IDENT

CIRCUIT

225389C1

18G-D

LIC PLATE LIGHT FUSED PWR

35A-G

BACKUP ALARM RELAY OUT

0-BAG

HOOD GROUND (EURO)

CONNECTOR ESS - ENGINE SPEED SENSOR

CAV

WIRE IDENT

1-DU

FLASHER MODULE POWER

45N-A

FLASHER OPT. SIDE CONTR.

0-EH

FLASHER MODULE GROUND

0-EG

FLASHER MODULE GROUND

NOT USED

45R-E

RIGHT TURN SIGNAL

45L-D

LEFT TURN SIGNAL

45A-A

LEFT TURN SWITCH POWER

45B-A

RIGHT TURN SWITCH POWER

45H

HAZARD SWITCH POWER

45N-B

FLASHER OPT. SIDE CONT.

CONNECTOR FM - FILTER MAINTENANCE SWITCH

CIRCUIT

25A

ENGINE SPEED SIGNAL

0-HF

ENGINE SPEED SENSOR GROUND

CIRCUIT

291718A1

CAV

WIRE IDENT

CONNECTOR FFH - FULE FILTER HEATER

371614A1

CAV

182069A1

CAV

WIRE IDENT

CIRCUIT

1-GB

FUEL FILTER HEATER PWR

0-BX

FUEL FILTER HEATER GROUND

WIRE IDENT

CIRCUIT

32F

TRANS FILTER MAINT SW

36R-B

TRANS FM SWITCH RETURN

4002-153 CONNECTOR FWM - FRONT WIPER MOTOR

FNR RLY, RELAY K2 CAV

WIRE IDENT

CIRCUIT

19B-A

FNR SW FUSED PWR

0-ST

GRND, JOYSTICK

51B-K

JSS POWER

19B-B

TRANS ENA SW PWR

87A

0-SS

TRANS ENA SW PWR

FRONT, FRNT CHAS-CAB 245715C1

CAV

WIRE IDENT

CIRCUIT

45L

LEFT TURN SGNL

45R

RIGHT TURN SGNL

18G-A

RH POSN/TAIL FUSED PWR

18B

LH HIGH BEAM FUSED PWR

53P-G

PILOT CTRL RLY OUT

18F

LH POSN/TAIL FUSED PWR

54B

HC-RTT CTRL SGNL

53B

RTD CTRL SIGNAL

HORN POWER

18D

LH LOW BEAM FUSED PWR

18E

RH LOW BEAM FUSED PWR

18C

RH HIGH BEAM FUSED PWR

PIN ENGAGE SOL PWR

58-B

RIDE CONTROL SOL PWR

58-G

NONE

CAV

WIRE IDENT

CIRCUIT

63H-A

FRONT WIPER HIGH SPEED RLY OUT

63L-A

FRONT WIPER LOW SPEED RLY OUT

19J-A

FRONT WIPER MOTOR FUSED POWER

63C

FRONT WIPER PARK CONTROL

CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

FWD DIODE, DIODE ASSY CAV

WIRE IDENT

CIRCUIT 245480C1

26F-D

FNR FORWARD SIGNAL

26F-E

FNR FORWARD SIGNAL

26F-C

FNR FORWARD SIGNAL

CAV 1

WIRE IDENT 0-B8

CIRCUIT FRONT WIPER GROUND

4002-154 CONNECTOR FWW - FRONT WASHER

GHF3, GRID HEATER FUSE CAV 1

WIRE IDENT 1-Y

CIRCUIT GRID HTR FSD PWR

GHF4, GRID HEATER CAV 1

WIRE IDENT 1-Y

GND CAB1 , GROUND A

3227856R1

CAV

WIRE IDENT

CIRCUIT

CAV

63W-A

FRONT WASHER PUMP

0-B

FRONT WASHER GROUND

GH, GRID HEATER CAV 1

WIRE IDENT 0-ES

CIRCUIT

0-DL

WORK LIGHTS GRND

0-DR

ROOF SPLICE GNDS

0-DS

ROOF SPLICE GNDS

CIRCUIT

GND CAB2 , GROUND A

GRID HTR PWR

GH 1, GRID HEATER

WIRE IDENT

CAV

CIRCUIT GRID HTR FSD PWR

WIRE IDENT 0-ES

CIRCUIT

WIRE IDENT

CIRCUIT

0-B8

FRONT WIPER MOTOR GND

0-B10

HOOD GND

0-B26

BUZZER/SW PAD GND

GRID HTR GND

GND CAB3 , GROUND C CONNECTOR GHC - GRID HEATER RELAY

CAV

WIRE IDENT

CIRCUIT

0-DG

CAB SPLICE GNDS

0-DV

CIGAR LIGHTER GND

GND CAB3D , GROUND A CAV

3227856R1

CAV

WIRE IDENT 28G

GRID HTR SOURCE DR

0-BV

GRID HTR CONT GND

0-DP

DIAG TECM GND

0-DQ

DIAG TECM GND

0-DAV

TECM DIAGNOSTIC GND

GND CAB4 , GROUND C CAV

GHF1, GRID HEATER FUSE

WIRE IDENT 1-E

CIRCUIT

CAV

WIRE IDENT

CIRCUIT GRID HTR FUSE BAT PWR

WIRE IDENT

CIRCUIT

0-ED

HVAC GNDS

0-EJ

POWER CONVERTER GND

0-ER

POWER CONVERTER GND

4002-155 GND CAB5 , GROUND C CAV

WIRE IDENT

GND CAB SPL2, SPL BACK LGHT GD

CIRCUIT

0-EK

AUX POWER OUTLET 1 GND

0-EL

AUX POWER OUTLET 2 GND

GND CAB6, STRT, FFH, WAT SEP HTR CAV 1

WIRE IDENT 0-EQ

CIRCUIT SPLICE PACK GND CAB SPL2 GND

CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE

87324393

CAV

WIRE IDENT

CIRCUIT

0-J

START LOCKOUT RLY GND

0-KA

IGN PWR CONTROL GND

0-K

CAMERA GND

0-EW

POWER RELAY GND

0-BBC

JOYSTICK GROUND

0-DE

NEUT START RLY CTRL GND

0-EQ

SPLICE PACK GND CAB SPL2 GND

0-EH

FLASHER MODULE GND

0-EG

FLASHER MODULE GND

0-EF

BRK LTS RLY CTRL GND

87324393

CAV

WIRE IDENT

CIRCUIT

0-EE

DIODE SUPPRESSION GROUNDS

0-EM

RADIO GROUND

0-EP

HORN SWITCH GROUND

DIAG2 GROUND

NOX RELAY GROUND

0-DG

CAB SPLICE GROUNDS

0-DT

FRNT WIP/WASHER SW GND

0-DK

SEAT COMPR MOTOR GND

0-DJ

AC RELAY CONTROL GRND

0-DU

PILOT PRESS SOLEN GND

0-DH

DIAGNOSTIC CONNECTOR GROUND

GND ENG1 , STRT, FFH, WAT SEP HTR CAV

WIRE IDENT

CIRCUIT

0-BW

WATER SEP HEATER GND

0-BX

FUEL FILTER HEATER GND

0-GB

STARTER RLY CTRL GND

GND ENG2 , WIF, EDC CAV

WIRE IDENT

CIRCUIT

0-BP

WIF SENSOR GND

0-BAT

CRANK REQUEST GND

0-BAC

EDC7 GND

0-BAU

EVGT_2 GND

23D-D

NOX SENSOR GND

4002-156 GND PDST , GROUND A

GND ENG3 , SPLC PK, WSHR MTR CAV

WIRE IDENT

CIRCUIT

0-BM

ENGINE SPLICE GNDS

0-BBR

GROUND

CAV 1

WIRE IDENT 0-BA

CIRCUIT PEDESTAL GND STRAP

GND PDST1 , GROUND A GND ENG4 , REAR LIGHTING CAV CAV

WIRE IDENT

CIRCUIT

0-BAG

HOOD GROUNDS (EURO)

0-BAG-N

HOOD GROUNDS (NA)

0-BT

LH REAR LIGHT GND (EURO)

0-BR

RH REAR LIGHT GND (EURO)

WIRE IDENT 0-DA

CIRCUIT AIC CHASSIS GND

GND PDST2 , GROUND A CAV 1

WIRE IDENT 0-BA

CIRCUIT PEDESTAL GND STRAP

GND ENG6 , DEDICATED CAV

WIRE IDENT

GND S1 , GROUND A

CIRCUIT

0-BG

AIC POWER GND

0-BH

AIC POWER GND RED

0-BJ

AIC SENSOR GND

0-BAR

WIF BODY GRND

CAV 1

WIRE IDENT

CIRCUIT FRONT TO REAR CHASSIS GND

0-AP

GND S2 , GROUND A GND ENG7 , TRANNY, COOL TEMP CAV

WIRE IDENT

CIRCUIT

017A

FAN SPEED SENSOR GND

0-BAE

EDC7 SENDER GND

0-BU

FUEL LEVEL SENDER GND

0-BZ

FUEL LEVEL SENDER GND

CAV 1

WIRE IDENT 0-AP

CIRCUIT FRONT TO REAR CHASSIS GND

GND SSCHAS, SSM GROUND CABLE CAV 1

WIRE IDENT 0-ND

CIRCUIT SSM GROUND

GND FC , GROUND A CAV

WIRE IDENT

0-AG

FRONT CHASSIS GND

0-AB

PROX SW GND

GND GH1, STRT, FFH, WAT SEP HTR CAV 1

WIRE IDENT 0-ES

GND SSMOD, SEC STR CHASIS GND

CIRCUIT CAV

0-CE

SEC STEERING CHASSIS GND

0-CD

SEC STEERING SPLICE GND

GND WIF, GRND WIF RING TERM

GRID HTR GND CAV

CAV 1

WIRE IDENT 0-AV

CIRCUIT GRND

CIRCUIT

GND JSS , GROUND A

WIRE IDENT

WIRE IDENT 0-BAR

CIRCUIT WIF BODY GRND

4002-157 GND TRANS, GROUND TRANS CAV

WIRE IDENT

CONNECTOR HD-N - HOOD TO ENGINE

CIRCUIT

0-HW

HOT GROUND

0-HR

HYD FLTR SW GRND

0-HL

RED BRAKE SW GND

0-HM

RED BRAKE SW GND

CONNECTOR HD - HOOD SWITCH

225319C1

CAV

245485C1

CAV

WIRE IDENT

CIRCUIT

59D-A

HOOD RELAY CONT DOWN

19Y-D

HOOD SWITCH FUSED PWR

59U-A

HOOD RELAY CONTROL UP

CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS

WIRE IDENT

CIRCUIT

0-JA-N

HOOD GROUNDS (NA)

44A-EN

BRAKE LIGHT RELAY OUT

45L-BN

LEFT TURN SIGNAL

45R-BN

RIGHT TURN SIGNAL

18G-JN

RH POSITION/TAIL FUSED PWR

18F-BN

LH POSITION/TAIL FUSED PWR

35A-HN

BACKUP ALARM RELAY OUT

HN1, HORN PWR CAV 1

WIRE IDENT 64

CIRCUIT HORN POWER

HN2, HORN GRND CAV 1

WIRE IDENT

CIRCUIT

18G-E

LICENSE PLATE LIGHT FUSED PWR

35A-H

BACKUP ALARM RELAY OUT

0-JA

HOOD GROUND (EURO)

0-AF

CIRCUIT HORN GND

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

245484C1

CAV

WIRE IDENT

194788A1

CAV

WIRE IDENT

CIRCUIT

36H

HYDR. OIL TEMP SIGNAL

0-HW

HYDR. OIL TEMP GROUND

4002-158 HTS, HMDTY AND AMB TEMP CAV

WIRE IDENT

CONNECTOR ISS - INT-SPEED-SENSOR

CIRCUIT

23K-A

TEMP/HUMD B+

23K-B

TEMP/HUMD TEMP

23K-C

TEMP/HUMD HUMD

23K-E

TEMP/HUMD GND

HVAC1, HVAC1 CAV 1

WIRE IDENT

CIRCUIT

291718A1

61A-F

TRINARY PRESS SW INPUT

CAV

18N-A

BLOWER MOTOR FUSED PWR

25B

INT SPEED SIGNAL

49A

BACK LIGHT POWER

0-HG

INT SPEED SENSOR GROUND

61B-A

AC SIGNAL

WIRE IDENT

CIRCUIT

JSS ARM, JSS ARMREST TO CAB CONNECTOR HVAC2 - HVAC2

87552622

CAV

WIRE IDENT

CIRCUIT

0-ED

HVAC GROUNDS

18N-B

BLOWER MOTOR FUS PWR

W230R400

CAV

WIRE IDENT

CIRCUIT

CANS-HA

CAN HI, CAN MOD2

0-SH

GRND, CAN MOD

51E-B

ARMREST LOWER

17P-E

B+, CAN MODULE

51B-J

JSS ACT SW

0-SC

GRND, JOYSTICK

51PW-S

JSS POWER

51S-C

JSS OKAY PWR

51H-C

JOYSTICK SIGNAL

51NO

NO NEUTRAL SW

CANS-LA

CAN LO, CAN MOD2

4002-159 JSS CAB

JSS FRAME TO CAB CAV

225389C1

CAV

WIRE IDENT CANS-LP

CAN LOW,CAN MOD3

17P-C

B+, CAN MOD

51D-A

GRND, RELAY CTRL

51B-C

JSS ACT SW

CAN-LR

CAN LOW, CAN MOD2

CAN-HR

CAN HI,CAN MOD3

0-BBD

JOYSTICK GROUND

51PW-N

JSS POWER

51C-A

JSS ACT BTN

18S-C

B+, JSS FUSED

CAN-HP

CAN HI,CAN MOD2

JSS CONTROLLER WIRE IDENT

CIRCUIT

51F-A

LS PRESS SW SIG

51J-C

JSS ALARM

51K-C

PILOT PRESS SW SIG

51L

JOYSTICK SIGNAL

51S-J

JSS OKAY PWR

0-AS

GRND, JOYSTICK

51PW-H

JSS POWER

18S-E

B+, JSS FUSED

CIRCUIT

CAV

WIRE IDENT

JSS LOAD SENSE

245483C1

CAV

WIRE IDENT

CIRCUIT

51PW-J

JSS POWER

51F-A

LS PRESS SW SIG

CIRCUIT

JSS PILOT DUMP

CANS-HD

CAN HI, CAN MOD3

CANS-LD

CAN LO, CAN MOD3

CAV

17P-F

B+, JSS CONTROLLER

51PW-K

JSS POWER

51H-B

JOYSTICK SIGNAL

0-AU

GRND, PILOT DUMP

51S-A

JSS OKAY PWR

51E-A

ARMREST LOWER

51L-A

JOYSTICK SIGNAL

51K-B

PILOT PRESS SW

51PW-Q

JSS POWER

0-SM

GRND, JOYSTICK

0-SN

GRND, JOYSTICK

51J-B

VALVE ALARM

51C-B

JSS ACT BTN

51NO-A

NO NEUTRAL SW

0-SR

GRND, JOYSTICK

51F-B

LS PRESS SW

WIRE IDENT

CIRCUIT

JSS PILOT PRESSURE

245483C1

CAV

WIRE IDENT

CIRCUIT

18S-E

B+, JSS FUSED

51K-C

PILOT PRESS SW SIG

4002-160 RLY, RELAY K2

JSS 197M, FNR-MAIN CAB

225351C1 245731C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

19B-A

FNR SW FUSED PWR

26F-C

FNR FORWARD SIGNAL

51PW-P

JSS POWER

51D-B

GRND, RELAY CNTL

26N-C

FNR NEUT SIGNAL

51B-E

B+, JSS

16R-C

FNR REVERSE SIGNAL

51B-G

B+, JSS

32J-F

TRANS ENABLE INDICTION

87A

0-SL

GROUND

25Y-D

TRANS KICK DOWN SIGNAL

JSS 197F, MAIN CAB FNR

JSS VALVE, JSS HYD VALVE

225350C1

CAV

WIRE IDENT

239451A1

CIRCUIT

0-SS

GRND, JOYSTICK

26F-D

FNR FORWARD SIGNAL

26N-D

FNR NEUT SIGNAL

26R-D

FNR REVERSE SIGNAL

32J-G

TRANS ENABLE INDICTION

25Y-F

TRANS KICK DOWN SIGNAL

CAV

WIRE IDENT

CIRCUIT

51L

JOYSTICK SIGNAL

51J-C

JSS ALARM

0-AT

GRND, JSS VLV

51S-J

JSS OKAY PWR

4002-161 LLF, LIGHTS LH

KD DIODE, DIODE ASSY

245485C1

CAV

WIRE IDENT

CIRCUIT

225351C1

25Y-F

TRANS KICK DOWN SIGNAL

CAV

25Y-E

TRANS KICK DOWN SIGNAL

0-AJ

LH FRONT LIGHTS GND

25Y-D

TRANS KICK DOWN SIGNAL

18D

LH LOW BEAM FUSED PWR

18B

LH HIGH BEAM FUSED PWR

18F

LH POSN/TAIL FUSED PWR

45L

LEFT TURN SGNL

L1 ECC, ECC BATT PWR CAV 1

WIRE IDENT 1-C

WIRE IDENT

CIRCUIT

CIRCUIT ECC BAT PWR

CONNECTOR LLFW - LH FRONT WORK LAMP

LBEGRD, LIGHT BEACON GRND CAV 1

WIRE IDENT 0-MC

CIRCUIT BEACON LIGHT GND

LBEPWR, LIGHT BEACON PWR CAV 1

WIRE IDENT 46-D

245483C1

CIRCUIT BEACON SW PWR

CAV

WIRE IDENT

CIRCUIT

42C-H

LH FRONT WORK LAMP PWR

0-MU

LH FRONT WORK LAMP GND

LDM1, DOME LIGHT B+ CAV 1

WIRE IDENT 19U-C

CIRCUIT

CONNECTOR LLRW- LH REAR WORK LAMP

DOME LT FSD PWR

LDM2, DOME LIGHT AUTO CAV 1

WIRE IDENT 43-B

CIRCUIT DOME LT AUTO MODE

LDM3, DOME LIGHT GND

245483C1

CAV CAV 1

WIRE IDENT 0-MB

CIRCUIT DOME LIGHT GND

WIRE IDENT

CIRCUIT

42R-H

LH REAR WORK LAMP FUS PWR

0-ME

LH REAR WORK LAMP GRND

4002-162 CONNECTOR LLR-E - LH REAR COMBINATION LAMP

CONNECTOR LRF - RH FRONT COMBINATION LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

CAV

44A-E

BRAKE LIGHT RELAY OUT

45L-A

LEFT TURN SIGNAL

18F-B

LEFT TAIL FUSED POWER

35A-L

REVERSE LAMP

0-BT

LH GROUND (EURO)

225351C1

NOT USED

WIRE IDENT 0-AH

RH FRONT LIGHTS GROUND

18E

RH LOW BEAM FUSED PWR

18C

RH HIGH BEAM FUSED PWR

18G-A

RH POSIT/TAIL FUSED PWR

45R

RIGHT TURN SIGNAL

CONNECTOR LPL - LICENSE PLATE LAMP

CIRCUIT

NOT USED

CONNECTOR LRFO - FRONT WORK LAMP OPT

245482C1

CAV

WIRE IDENT

CIRCUIT

18G-E

LICENSE PLATE LAMP FUSED PWR

18G-EN

LICENSE PLATE LAMP FUSED PWR

0-JC

LICENSE PLATE LAMP GRND

245483C1

CAV

WIRE IDENT

CIRCUIT

42R-K

RH FRONT WORK LAMP FUSED PWR

0-MP

RH FRNT WORK LAMP GRND

4002-163 CONNECTOR LRFR - FRONT WORK LAMP OPT

CONNECTOR LRRW- RH REAR WORK LAMP

245483C1

CAV

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

42R-B

RH FRONT WORK LAMP FUSED PWR

42R-G

RH REAR WORK LAMP FUSED PWR

0-ML

RH FRNT WORK LAMP GRND

0-MF

RH REAR WORK LAMP GRND

CONNECTOR LRFS- FRONT WORK LAMP OPT

CONNECTOR LRR-E - RH REAR COMBINATION LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

225351C1

42R-A

RH FRONT WORK LAMP FUSED PWR

0-MG

RH FRONT WORK LAMP GRND

CONNECTOR LRFW - RH FRONT WORK LAMP

CAV

WIRE IDENT

44A-F

BRAKE LIGHT RELAY OUT

45R-A

RIGHT TURN SIGNAL

18G-J

RIGHT POSITION/TAIL FUSED PWR

35A-K

REVERSE LAMP

0-BR

CIRCUIT

GROUND (EURO) NOT USED

CONNECTOR LSPK - LEFT SPEAKER

245483C1

CAV

WIRE IDENT

CIRCUIT

42C-G

RH FRONT WORK LAMP FUSED PWR

0-MJ

RH FRONT WORK LAMP GRND

195552A1

CAV

WIRE IDENT

CIRCUIT

65L

LEFT SPEAKER SIGNAL

0-PA

LEFT SPEAKER GROUND

4002-164 NOXS, NOX SENSOR CAV

WIRE IDENT

CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

CIRCUIT

23A-A

DNOX2 MODULE B+

23D-D

NOX SENSOR GND

CAN-LU

CAN2 LO, NOX

CAN-HU

CAN2 HI, NOX

NTRL DIODE, DIODE ASSY

291718A1

CAV

WIRE IDENT

CIRCUIT

31F

AIR FILTER RESTRICTION SWITCH SIGNAL

0-BY

AIR FILTER RESTRICTION SWITCH GRND

245485C1

CAV

WIRE IDENT

CIRCUIT

P A1, B+ POWER

26N-D

FNR NEUT SIGNAL

26N-E

FNR NEUT SIGNAL

CAV

26N-C

FNR NEUT SIGNAL

WIRE IDENT 1-C

CONNECTOR OSS - OUTPUT SPEED SENSOR

CIRCUIT ECC BAT PWR

P A3, B+ POWER CAV 1

WIRE IDENT 1CB-A

CIRCUIT CAB CB PROTECTED PWR

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

291719A1

CAV

WIRE IDENT

CIRCUIT

0-HE

OUTPUT SPEED GROUND

25D

OUTPUT SPEED SIGNAL

19A

OUTPUT SPEED FUSED PWR

245482C1

CAV

WIRE IDENT

CIRCUIT

19A-A

BRAKE DECLUTCH SW FUSED PWR

25G

BRAKE DECLUTCH SWITCH CONTROL

4002-165 CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH

P C3, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1CB

CIRCUIT CAB CB PROTECTED PWR

P C4, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1-Z

PHF, HYD OIL FILT RES SW

222136A1

CAV

WIRE IDENT

CIRCUIT

CAV

1-AA

BRAKE LAMP SWITCH PWR

BRAKE LAMP CONTR PWR

CIRCUIT STRTR RLY BAT PWR

WIRE IDENT 31H

CIRCUIT HYD FLTR REST SW SGNL

CONNECTOR PO1 - POWER OUTLET

CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH

225316C1

CAV

WIRE IDENT

33P

LOW BRAKE PRESS WARNING

0-AL

BRAKE PRESS WARN SW GROUND

P C1, B+ PWR FRM PRMD CAV

WIRE IDENT

CIRCUIT

1-BG

B+ PWR PRMC

1-NC

B+ PWR PRMC

P C2, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1-E

12176446

CIRCUIT

CIRCUIT GRID HTR FUSE BAT PWR

CAV A

WIRE IDENT 12V

B C

CIRCUIT 12V PWR TO OUTLET 1 NOT USED

0-EK

AUX POWER OUTLET 1 GND

4002-166 CONNECTOR PO2 - POWER OUTLET

CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

245483C1

CAV 12176446

CAV A

WIRE IDENT 12V-A

CIRCUIT

WIRE IDENT

CIRCUIT

33R-B

RDNT BRAKE ACCUMULATOR PRESS LOW

0-HL

RED BRAKE SW GROUND

12V PWR TO OUTLET 2 NOT USED

0-EL

AUX POWER OUTLET 2 GND

CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH

PRH, AC HIGH PRESS SW

245483C1

CAV 245483C1

CAV

WIRE IDENT

CIRCUIT

61A-D

AC SWITCH INPUT

61R-D

AC SWITCH OUTPUT

WIRE IDENT

CIRCUIT

RIDE CONTR SOLENOID PWR

58-B

RIDE CONTR SOLENOID PWR

PRM A1, PRM OUTPUT

CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

256340A1 245483C1

CAV

WIRE IDENT

CAV

WIRE IDENT

CIRCUIT

19S1

SEC STR FSD PWR

19L

PWR CONVERTER FSD PWR

33R-C

RDNT BRAKE ACCUMULATOR PRESS LOW

0-HM

GROUND - TRANS

4002-167 PRM A2, PRM SIGNAL CAV

WIRE IDENT

CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

CIRCUIT

12ACC-C

PWR CONVERTER PRM CTRL PWR

0-EU

PWR CONVERTER RLY CTRL GND

CONNECTOR PRM-B1 - PRM SIGNAL 245485C1

CAV

WIRE IDENT

CIRCUIT

51P-A

SECONDARY STEER HIGH PRESSURE

0-CC

SEC. STEER PRESS SWITCH GROUND

35X-A

SECONDARY STEER LOW PRESS SIG

409084A1

CAV

WIRE IDENT

CIRCUIT

12ACC-B

ACC PRM CONTROL POWER

0-EC

ACC RELAY CONTROL GND

CONNECTOR PXF - RTD

PRM C1, PRM SIGNAL CAV

WIRE IDENT

CIRCUIT

13K-C

IGNITION SWITCH POWER

0-EB

IGNITION RELAY CTRL GND 245485C1

PRM D1, PRM OUTPUT CAV

WIRE IDENT

CIRCUIT

18J-F

EDC7 FSD PWR

1-GA

FLTR HTR PWR

CAV

WIRE IDENT

CIRCUIT

53B

RTD CTRL SIGNAL

0-AC

PROXIMITY SWITCH GROUND

53P-J

PILOT CONTROL RELAY OUT

CONNECTOR PXH - HEIGHT CONTROL RTT

PRM D2, PRM SIGNAL CAV

WIRE IDENT

CIRCUIT

28F

FUEL FLTR HTR RLY CTRL

31B

FILTER HEATER CONTROL

245485C1

CAV

WIRE IDENT

CIRCUIT

54B

RTT SIGNAL

0-AA

PROXIMITY SWITCH GROUND

53P-J

PILOT CONTROL RELAY OUT

4002-168 CONNECTOR PXM - RTD

CONNECTOR RAD - RADIO POWER

245485C1

CAV

WIRE IDENT

CIRCUIT

53B-A

RTD CONTROL SIGNAL

0-AM

RTD GROUND

CAV

53P-I

PILOT CONTROL RELAY OUT

NOT USED

292495A1

CONNECTOR PXT - RTD

WIRE IDENT

12V-HB

CIRCUIT

12V FUSED PWR TO RADIO NOT USED

NOT USED

12V-HA

12V FUSED PWR TO RADIO

0-EN

RADIO GROUND

CONNECTOR RAD-J1 - RADIO POWER 245485C1

CAV A

WIRE IDENT 53B-A

CIRCUIT RTD CONTROL SIGNAL

0-AM

RTD GROUND

53P-I

PILOT CONTROL RELAY OUT

292497A1

CAV

WIRE IDENT

CIRCUIT

NOT USED

RAD3

12V FUSED PWR TO RADIO

NOT USED

RAD2

12V FUSED PWR TO RADIO

RAD1

RADIO GROUND

4002-169 CONNECTOR RAD-J2 - SPEAKER

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

194788A1

CAV 292501A1

CAV

WIRE IDENT

CIRCUIT

RAD11

RAD10

RIGHT SPEAKER GROUND

RAD9

NOT USED

RAD8

NOT USED

RAD7

NOT USED

RAD6

NOT USED

RAD5

LEFT SPEAKER

RAD4

LEFT SPEAKER GROUND

36C

RADIATOR COOLANT TEMP SIGNAL

0-BAE

EDC7 SENDER GROUND

RFL, FUEL SENDER CAV 1

411311A1

WIRE IDENT

CIRCUIT

RAD10

RIGHT SPEAKER GROUND

RAD8

NOT USED

RAD4

LEFT SPEAKER GROUND

RAD6

NOT USED

RAD1

RADIO GROUND NOT USED

RAD3

12V FUSED PWR TO RADIO

RAD11

RIGHT SPEAKER

RAD9

NOT USED

RAD5

LEFT SPEAKER

RAD7

NOT USED

RAD2

12V FUSED POWER TO RADIO

NOT USED

WIRE IDENT 36F

CIRCUIT FUEL LEVEL ANALOG

RFLG, FUEL SEND GRND CAV

CIRCUIT

RIGHT SPEAKER

CONNECTOR RAD-J3 - RADIO JUMPER

CAV

WIRE IDENT

WIRE IDENT 0-BU

CIRCUIT FUEL LEVEL SENDER GND

4002-170 ROOF, ROOF TO CAB CONNECTION

CONNECTOR RTHP - THROTTLE PEDAL

388708A1

CAV

WIRE IDENT

CIRCUIT 225351C1

0-MV

FONT WORK LIGHT GND

0-MH

REAR WORK LIGHT GND

CAV

43-B

DOME LT AUTO MODE

19U-C

DOME LT FSD PWR

NOT USED NOT USED

46-D

BEACON SW PWR

0-MN

ROOF GROUNDS

0-MK

ROOF GROUNDS

42C-F

FNT WRK LTS FUSE PWR

WIRE IDENT 21F-D

24B-A

CIRCUIT EDC7 DIGITAL GROUND

THROTTLE SIGNAL NOT USED

24R-A

THROTTLE POS. SENS GND

19K-D

REAR WPR MOTOR FSD PWR

68C-A

REAR WPR PARK CTRL

24S-A

THROTTLE SUPPLY

68L-A

REAR WPR SW PWR

24L-A

LOW IDLE SWITCH

0-EN

RADIO GND

12V-H

12V FUSED PWR TO RADIO

19U-F

DOOR SW FSD PWR

43S-B

DOOR OPEN SGNL

CAV

42R-F

REAR WRK LTS FUSE PWR

26R-D

FNR REVERSE SIGNAL

26R-E

FNR REVERSE SIGNAL

16R-C

FNR REVERSE SIGNAL

CONNECTOR RSPK - RIGHT SPEAKER

NOT USED

RVS DIODE, DIODE ASSY WIRE IDENT

CIRCUIT

CONNECTOR RWM - REAR WIPER MOTOR

195552A1

CAV

WIRE IDENT

CIRCUIT

65R

RIGHT SPEAKER SIGNAL

0-PB

RIGHT SPEAKER GROUND 245715C1

CAV

WIRE IDENT

CIRCUIT NOT USED

68L-A

REAR WIPER SWITCH PWR

19K-D

REAR WIPER MOTR FUS PWR

68C-A

REAR WIPER PARK CONTROL

4002-171 CONNECTOR RWMG - REAR WIPER MOTOR GROUND

CONNECTOR SBE - BEACON SWITCH

382391A1 245480C1

CAV 1

WIRE IDENT 0-MA

CIRCUIT

CAV

WIRE IDENT

REAR WIPER MOTOR GRND

CONNECTOR RWW - REAR WASHER

CIRCUIT NOT USED

19U-H

BEACON SWITCH FUS PWR

46-C

BEACON SWITCHED POWER

NOT USED

0-B15

49-B

BACK LIGHT GROUND BACK LIGHT POWER

NOT USED

CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH 3227856R1

CAV

WIRE IDENT

CIRCUIT

68W-A

REAR WASHER PUMP

0-BL

REAR WASHER GROUND

382391A1

CAV

WIRE IDENT

CIRCUIT

35R-C

BACKUP ALARM SWITCH

35A-B

BACKUP ALARM DISABLE SW

NOT USED

0-B21

BACK LIGHT GROUND

49-L

BACK LIGHT POWER

NOT USED

4002-172 CONNECTOR SC - SEAT COMPRESSOR MOTOR

SDM, DIFF LOCK SWITCH CAV

WIRE IDENT

CIRCUIT

34D

DIFF LOCK SW SIG

34A-B

DIFF LOCK SW SIG B+

CONNECTOR SDR - DRIVING LIGHTS SWITCH

245482C1

CAV

WIRE IDENT

CIRCUIT

19N

SEAT COMPRESSOR FUSED PWR

0-DK

SEAT COMPRESSOR MOTOR GROUND

SDA, DIFF LOCK SWITCH 382391A1

CAV

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

34A-A

DIFF LOCK SW B+

NOT USED

34B

DIFF LOCK SW SIG

19Z-A

0-B31

SDA GND

DRIVING LIGHTS SW FUSED PWR

49-Z

BACK LIGHT PWR

41T

POSITION LIGHTS SW PWR

CONNECTOR SDC - DECLUTCH SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

25G-B

BRAKE DECLUTCH SWITCH CONTROL

19A-R

DECLUTCH SW FUSED PWR

22A

DECLUTCH SW

NOT USED

0-B18

BACK LIGHT GROUND

49-R

BACK LIGHT POWER

NOT USED

19Z-B

DRIVING LIGHTS SWITCH FUSED POWER

41J

DRIVING LIGHTS POWER

0-B19

BACK LIGHT GROUND

49-P

BACK LIGHT POWER

NOT USED

4002-173 CONNECTOR SFC - FAN CONTROL SWITCH

CONNECTOR SFNR - FNR SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

382391A1

CAV

WIRE IDENT

CIRCUIT

NOT USED

26R-A

FNR REVERSE SIGNAL

52J

FAN CONTROL SW JUMPER

26J

FNR SWITCH JUMPER

52-AU

FAN REVERSE AUTO

26N-A

FNR NEUTRAL SIGNAL

52J

FAN CONTROL SW JUMPER

26J

FNR SWITCH JUMPER

19P-C

FAN REVERSE SWITCH FUSED PWR

19A-V

FNR SWITCH FUSED POWER

26F-A

FNR FORWARD SIGNAL

52M

FAN REVERSE MANUAL

32J-A

TRANS ENABLE INDICATION

0-B7

BACK LIGHT GROUND

19A-G

FNR SWITCH FUSED POWER

49-Q

BACK LIGHT POWER

NOT USED

CONNECTOR SFWW - FRONT WIPER AND WASHER SWITCH

CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH

87345132

382391A1

CAV

WIRE IDENT

CIRCUIT

55A-B

RTT/FLOAT SWITCH POWER

53P-B

PILOT CONTROL RELAY OUT

55A-C

RTT/FLOAT SWITCH POWER

0-29

RTT/FLOAT GROUND

55B

RTT FLOAT SW CONTROL

54B-C

HC-RTT CONTROL SIGNAL

0-B2

BACK LIGHT GROUND

49-K

BACK LIGHT POWER

NOT USED

CAV

WIRE IDENT

CIRCUIT NOT USED

0-DT

FRONT WIPER/WASHER SW GND

63LC

FRNT WIP LS RELAY CONTR

19J-B

INT WIP/WAS SW FUSED PWR

4 5

NOT USED

63W

49-T

BACK LIGHT POWER

63HC

FRONT WIPER HS RELAY CONTROL

9 10

FRONT WASHER PUMP

NOT USED

4002-174 CONNECTOR SHC - HEIGHT CONTROL SWITCH

SJS, JOYSTICK CONTROL SW CAV

382391A1

CAV

WIRE IDENT

1 2

CIRCUIT

18S-B

B+, JSS FUSED

51B-A

JSS ACT SW

0-BBA

JOYSTICK GROUND

51C-A

JSS ACT BTN

51B-B

JSS ACT SW

0-BBB

JOYSTICK GROUND

49-W

JSS BACKLIGHT

0-BBE

JOYSTICK GROUND

51PW-N

JSS POWER

NOT USED 53P-D

PILOT CONTROL RELAY OUT

NOT USED

S KEY, IGNITION SWITCH CAV

CIRCUIT TIME DELAY/IGN SW FSD PWR

1DM

BACK LIGHT GROUND

21K

IGN SW START SIGNAL

13K

IGNITION SWITCH POWER

12ACC

IGNITION SW ACC POWER

54A

HC CONTROL SW PWR

0-B3

BACK LIGHT POWER

NOT USED

49-M

WIRE IDENT

CONNECTOR SPB - PARKING BRAKE SWITCH CONNECTOR SHZ - HAZARD SWITCH

382391A1 382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT NOT USED

NOT USED

19A-L

PARK BRK SW FUSED PWR

33U

PARK BRAKE SWITCH

1-KA

HAZARD SWITCH POWER

45H

HAZARD SWITCH POWER

NOT USED

0-B29

BACK LIGHT GROUND

49-v

BACK LIGHT POWER

NOT USED

7 8

0-b24 49-D

RTT/FLOAT GROUND BACK LIGHT POWER

4002-175 CONNECTOR SPC - PILOT CONTROL SWITCH

CONNECTOR SPK - SPEAKER

382391A1

CAV

WIRE IDENT

292494A1

CIRCUIT CAV

NOT USED

WIRE IDENT

CIRCUIT

19C-F

PILOT CONTROL SW FUSED PWR

31L

PILOT CONTROL SW HIGH

NOT USED

NOT USED NOT USED

65R

RIGHT SPEAKER

0-PB

RIGHT SPEAKER GROUND

NOT USED

0-B1

BACK LIGHT GROUND

65L

LEFT SPEAKER

49-N

BACK LIGHT POWER

0-PA

LEFT SPEAKER GROUND

NOT USED

CONNECTOR SPE - PIN ENGAGE SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

57-B

PIN ENGAGE SOL PWR

19P-A

PIN ENGAGE SW FUS PWR

NOT USED

0-B5

BACK LIGHT GROUND

49-F

BACK LIGHT POWER

4002-176 CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT POWER

CAV

WIRE IDENT

CIRCUIT

0-B4

BACK LIGHT GND

0-B5

BACK LIGHT GND

0-B6

BACK LIGHT GND

NOT USED

0-B20

BACK LIGHT GND

0-B29

RTT/FLOAT GND

0-B11

BACK LIGHT GND

0-B7

BACK LIGHT GND

SPL BCK LGT, SPLICE BACK LGHT PWR 87324393

CAV

WIRE IDENT

CIRCUIT

0-B13

BACK LIGHT GND

0-B14

BACK LIGHT GND

0-B15

BACK LIGHT GND

0-B6

BACK LIGHT GND

0-B17

BACK LIGHT GND

0-B18

BACK LIGHT GND

0-B19

BACK LIGHT GND

NOT USED

0-B21

BACK LIGHT GND

0-DAP

BACK LIGHT GND

0-B23

BACK LIGHT GND

CAV

0-B32

BACK LIGHT GND

BACK LIGHT POWER

42C-J

FNT WRK LTS FUSE PWR

49-C

BACK LIGHT POWER

49-H

BACK LIGHT POWER

49-L

BACK LIGHT POWER

49A

BACK LIGHT POWER

49-P

BACK LIGHT POWER

49-R

BACK LIGHT POWER

49S

BACK LIGHT POWER

49-E

BACK LIGHT POWER

49-B

BACK LIGHT POWER

49-A

BACK LIGHT POWER

87324393

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT POWER

87324393

CAV

WIRE IDENT

CIRCUIT

0-B31

SDA GROUND

0-B2

BACK LIGHT GND

0-B3

BACK LIGHT GND

WIRE IDENT

CIRCUIT

4002-177 SPL PED BL, SPL BACK LGT PWR 6 PCK

CONNECTOR SPL-PED-BL-GD - SPL BACK LIGHT POWER 6 PACK

87324391

CAV A

WIRE IDENT 49-W

87324391

CIRCUIT JSS BACKLIGHT

CAV

0-B9

WIRE IDENT NOT USED

CIRCUIT

49-N

BACK LIGHT POWER

49-D

BACK LIGHT POWER

0-B1

BACK LIGHT GROUND

49-X

BACK LIGHT AIC

0-B24

BACK LIGHT GROUND

49-V

BACK LIGHT POWER

0-B30

NOT USED

BACK LIGHT POWER

0-B29

RTT/FLOAT GROUND

0-B11

BACK LIGHT GROUND

49-S

CONNECTOR SPL-HOOD-GND - HOOD GROUND 6 PACK

CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK

87324391

CAV

WIRE IDENT

87324391

CIRCUIT

0-B12

HOOD DOWN RELAY GRND

CAV

WIRE IDENT

CIRCUIT

0-B16

HOOD DOWN CONTR GRND

19P-A

PIN ENGAGE SW FUSED PWR

19P

PIN ENGAGE/FAN FUS PWR

19P-C

RAN REVERSE SW FUS PWR

0-B22

HOOD UP RELAY GROUND

0-B25

HOOD UP CONTR GRND

0-B10

HOOD GROUND

NOT USED

19P-D

FAN REV RELAY FUS PWR

19P-E

FAN REV RELAY FUS PWR

NOT USED

4002-178 SPL PK1, SPLICE 3-4 WAY

CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

87324462

CAV

WIRE IDENT

CIRCUIT

87324462

CAV

WIRE IDENT

CIRCUIT

42C-A

FNT WRK LTS FUSE PWR

45L-E

LEFT TURN SIGNAL

42C-D

FNT WRK LTS FUSE PWR

45L-D

LEFT TURN SIGNAL

42C-C

FNT WRK LTS FUSE PWR

45L-C

LEFT TURN SIGNAL

18K-D

DIAG FUSED B+

45L-B

LEFT TURN SIGNAL

18K-A

DIAGNOSTIC FUSED PWR

45R-C

RIGHT TURN SIGNAL

18K-B

DIAG FUSED B+

45R-E

RIGHT TURN SIGNAL

18K-C

TELEMATICS FSD PWR

45R-D

RIGHT TURN SIGNAL

45R-B

RIGHT TURN SIGNAL

19J-B

FRONT WIPER/WASHER SW FUSED PWR

19J

FRONT WIPER FUSED POWER

19J-C

FRONT WIPER RELAY FUSED POWER

19J-A

FRONT WIPER MOTOR FUSED POWER

SPL BCK LGT2, SPL BACK LGT PWR

SPL ROOF, SPLICE ROOF GROUND CAV

87324462

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

0-MC

BEACON LIGHT GND

0-MB

DOME LIGHT GND

0-MA

REAR WIPER MOTOR GND

49-E

BACK LIGHT POWER

0-MN

ROOF GROUNDS

49-J

BACK LIGHT POWER

0-MK

ROOF GROUNDS

49-M

BACK LIGHT POWER

49-K

BACK LIGHT POWER

49-F

BACK LIGHT POWER

49-Q

BACK LIGHT POWER

49-Z

BACK LIGHT POWER

49-T

BACK LIGHT POWER

49-G

BACK LIGHT POWER

49-S

BACK LIGHT POWER

4002-179 CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

CONNECTOR SRC - RIDE CONTROL SWITCH

382391A1

CAV

WIRE IDENT

1 87324393

CAV

WIRE IDENT

CIRCUIT

19A-N

TRANS FUSED POWER

19A-F

TRANS ENABLE SWITCH FUSED PWR

CIRCUIT NOT USED

19C-D

RIDE CTRL SW FUSED PWR

58C

RIDE CTRL SWITCH JUMPER

58T

RIDE CTRL RELAY SW PWR

58C

RIDE CTRL SWITCH JUMPER

58-F

RIDE CTRL SOLENOID PWR

19A-Q

TRANS/AUTO SWITCH FUSED PWR

6 7

0-B20

BACK LIGHT GROUND

19A-T

BRAKE DECLUTCH SW FUSED PWR

49-G

BACK LIGHT POWER

19A-W

DIAGN CONN. FUSED PWR

19A-C

FNR SWITCH FUSED PWR

19A-P

BACKUP ALARM RLY

19A-R

DECLUTCH SW FUSED PWR

19A-K

TECM FUSED PWR

19A-M

OUTPUT SPEED SENSOR FUSED PWR

L M

NOT USED

CONNECTOR SRC-1 - STARTER RELAY

NOT USED 19A-H

TRANS SHIFTER FUSED PWR

225316C1

CAV

WIRE IDENT

CIRCUIT

21D

STARTER RELAY SIGNAL

0-GB

STARTER RELAY CONTROL GROUND

4002-180 CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

68C

REAR WIPER PARK CONTROL

68L

REAR WIPER SW PWR

19K-A

REAR WIPER SW FUSED PWR

87318288

CAV

WIRE IDENT

CIRCUIT

31b

64C

HORN RELAY CONTROL

49a

19B

TURN SIGNAL FUSED POWER

56a

41H-A

HIGH BEAM POWER

56b

41L-A

LOW BEAM POWER

56d

19Z-C

HIGH BEAM FLASH FUS PWR

0-EP

HORN SWITCH GROUND

41J

DRIVE LIGHTS POWER

45A-A

LEFT TURN SWITCH POWER

45B-A

RIGHT TURN SWITCH POWER

NOT USED

19K-B

REAR WIPER SW FUSED PWR

68W

REAR WASHER PUMP

0-B23

BACK LIGHT GROUND

49-C

BACK LIGHT POWER

NOT USED

SSD, SEC STR DIODE CONNECTOR SRTD - DETENT SWITCH

245485C1

CAV 382391A1

CAV

WIRE IDENT

CIRCUIT NOT USED

53P-E

PILOT CONTROL RELAY OUT

53A

RTD SWITCHED POWER

NOT USED

0-B4

49-J

BACK LIGHT GROUND BACK LIGHT POWER

NOT USED

WIRE IDENT

CIRCUIT

0-CH

SEC STR FLYBACK GND

0-CG

SEC STR FLYBACK GND

51-D

SEC STR FLYBACK

4002-181 CONNECTOR SS-TR - SS-MOD-TRANS

CONNECTOR SSM - SECONDARY STEERING MODULE

245489C1

CAV

225389C1

CAV

WIRE IDENT

19M-C

19R-C

SEC. STR IGNIT FUS PWR

35X-C

SEC. STR LOW PRESS SIGNAL

CIRCUIT D

19R-C

SEC. STEERING IGNITION FUSED PWR

51-A

SECOND STEER MOTOR CONTR

19S1-X

SECONDY STEER FUS PWR

0-CE

SECONDY STEER CHASSIS GRND

NOT USED

19M-C

SECONDARY STEER ACC FUSED PWR

35X-D

SECOND STEER LOW PRESS SIG

51P-A

SECONDARY STEER HIGH PRESS

SEC. STR ACCESS FUS PWR

NOT USED

19S1-X

SEC. STR FUSED POWER NOT USED

CONNECTOR STA - TRANSMISSION AUTO SWITCH

NOT USED

0-CA

SECONDARY STEER SIGNAL GRND

0-CB

SECONDARY STEER SIGNAL GRND

SSS, SS MAG SWITCH CAV

CIRCUIT

WIRE IDENT

382391A1

CAV

WIRE IDENT

CIRCUIT NOT USED

19A-Q

TRANS AUTO SW FUS PWR

25H

TRANS AUTO SIGNAL

NOT USED

CIRCUIT

NOT USED NOT USED

51-D

SEC STR FLYBACK

51-B

SEC STR MOTOR CTRL

0-B17

BACK LIGHT GROUND

49S

BACK LIGHT POWER

NOT USED

4002-182 CONNECTOR STE - TRANSMISSION ENABLE SWITCH

CONNECTOR SW-PD - SWITCH PAD

382391A1

CAV

WIRE IDENT

CIRCUIT

87552623

NOT USED

19A-D

TRANS ENABLE SW FUSED POWER

26E-A

TRANS ENABLE SIGNAL

CAV

NOT USED

41H-D

CIRCUIT HIGH BEAM POWER NOT USED

NOT USED

WIRE IDENT

49-X

BACK LIGHT AIC

31H-A

HYDRAULIC FILTER REST SW SIGNAL

31F-A

AIR FILTER REST SWITCH SIGNAL

0-DAP

BACK LIGHT GROUND

49-H

BACK LIGHT POWER

NOT USED

32J-C

TRANS ENABLE INDICTION

CAN-HF

CAN HIGH

19A-E

AIC FUSED PWR

CAN-LF

CAN LOW

17P-A

SWITCH PAD PWR FROM AIC PWR

0-B28

SWITCH PAD GROUND

CONNECTOR SWL - WORK LIGHTS SWITCH

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

382391A1

CAV

WIRE IDENT

CIRCUIT NOT USED

42-A

42C-C

WORK LIGHTS FUSED PWR FR WORK LIGHTS FUSE PWR 291718A1

NOT USED

42-B

WORK LIGHTS FUS PWR

42RC

RE WORK LIGHTS FUSE PWR

0-B14

BACK LIGHT GROUND

49-A

BACK LIGHT POWER

NOT USED

CAV

WIRE IDENT

CIRCUIT

36G

TCO TEMPERATURE SIGNAL

36R-D

TCO TEMPERATURE RETURN

4002-183 TECM, TRANS

CAV

411398A1

CAV 1

WIRE IDENT 0-DP

CIRCUIT DIAG TECM GND

WIRE IDENT

CIRCUIT

26F-B

FNR FORWARD SIGNAL

22A

DECLUTCH SW

25Y-A

TRANS KICK DOWN SIGNAL

19T-A

FUSED BATT PWR

22D

PEDAL SENSOR GRND

CAN-HD

CAN HIGH

CAN-LD

CAN LOW

25H

TRANS AUTO SIGNAL

26R-B

FNR REVERSE SIGNAL

26E-A

TRANS ENABLE SIGNAL

25M-A

TRANS SOL VALVE Y3

34B

DIFF LOCK SW SIG

22B

PEDAL SENSOR +5V

22C

PEDAL POS SIGNAL

36T-A

VALVE BODY TEMP SGNL

25C-A

TURBINE SP SIGNAL

25B-A

INT SP SIGNAL

25F

FORWARD SIGNAL

26N-B

FNR NEUT SIGNAL

19A-K

TECM FUSED PWR

36R-E

TRANS TEMPS/FLTR RETURN

36G-A

TCO TEMP SIGNAL

25R-A

TC LOCKUP SOL POWER

25J-A

TRANS SOL VALVE Y6

58H-B

POWER VPSL

25N-A

TRANS SOL VALVE Y4

25K-A

TRANS SOL VALVE Y1

58L

RIDE CTRL RLY LSD

34D

DIFF LOCK SW SIG

25D-A

OUTPUT SP SIGNAL

25Z

1ST AND 4TH GEAR SIGNAL

0-DQ

DIAG TECM GND

0-DM

SPEED SENSOR GNDS

0-DN

OUTPUT SPEED SENSOR GND

25R

REVERSE SIGNAL

32J-D

TRANS ENABLE INDICTION

25W

3RD AND 4TH GEAR SIGNAL

35C

BACK UP ALRM CNTL

25G-C

BRK DECLUTCH SW CTRL

58H-A

POWER VPS2

25T-C

NEUTRAL SIGNAL

25P-A

TRANS SOL VALVE Y5

19T-B

FUSED BATT PWR

25L-A

TRANS SOL VALVE Y2

34C

DIFF LOCK SOL GND

25S-B

OUTPUT SW PWR VPS1

25S-C

OUTPUT SW PWR VPS1

37D-A

DIAGNOSTIC SGNL

32F-A

TRANS FLTR MAINT SW

37E

DIAGN SGNL SWITCHED

25A-A

ENG SP SIGNAL

4002-184 TERM CAN 2, CAN BULK HEAD

TRANS, TRANSMISSION-CAB

380838A1

CAV

87315267

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

33R-A

RDNT BRK ACC PRESS LOW

34C-A

DIFF LOCK SOL GND

19M-A

SEC STR ACCESS FSD PWR

19R-A

SEC STR IGN FSD PWR

36T

VALVE BODY TEMP SGNL

CAN-L2

CAN 2 LO, TERM

35X-B

SEC STR LOW PRESS SGNL

CAN-LV

CAN2 LO, TERM

25A

ENG SP SIGNAL

CAN-H2

CAN2 HI, TERM

25C

TURBINE SP SIGNAL

CAN-HV

CAN2 HI, TERM

25B

INT SP SIGNAL

25D

OUTPUT SP SIGNAL

THV, TANK HEATER CONTROL VALVE

371614A1

CAV

WIRE IDENT

CIRCUIT

38C

TANK HEAT GND

38D

TANK HEAT B+

0-HD

SPEED SENSOR GNDS

36R-A

TRANS TEMPS/FLTR RETURN

36G

TCO TEMP SIGNAL

25G

BRK DECLUTCH SW CTRL

25R-B

TC LOCKUP SOL POWER

25K

TRANS SOL VALVE Y1

25K-9

TRANS SOL VALVE Y2

25L-9

TRANS SOL VALVE Y1

25L

TRANS SOL VALVE Y2

25M

TRANS SOL VALVE Y3

25N

TRANS SOL VALVE Y4

25P

TRANS SOL VALVE Y5

25J

TRANS SOL VALVE Y6

25S

OUTPUT SW PWR VPS1

31H

HYD FLTR REST SW SGNL

19A-A

BRAKE DECLUTCH SW FSD PWR

24T-B

TC LOCKUP SOL GND

19S1-E

SEC STR FSD PWR

34A-D

DIFF LOCK SOL B+

0-HE

OUTPUT SPEED SENS GND

19A

OUTPUT SP SENS FSD PWR

36H

HYDRAULIC OIL TEMP

32F

TRANS FLTR MAINT SW

4002-185 CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TR-SS - SEC-STR-MOD-OPT

245488C1 371566A1

CAV

WIRE IDENT

CIRCUIT

CAV

CIRCUIT

19M-A

SEC. STEER ACC FUS PWR

19R-A

SEC. STEERING IGNITION FUSED PWR

TRANS SOLENOID VALVE Y2

35X-B

NOT USED

25K

TRANS SOLENOID VALVE Y1

25L-9

TRANS SOLENOID VALVE Y1

25K-9

WIRE IDENT

25L

TRANS SOLENOID VALVE Y2

25M

TRANS SOLENOID VALVE Y3

25N

TRANS SOLENOID VALVE Y4

25P

TRANS SOLENOID VALVE Y5

25J

TRANS SOLENOID VALVE Y6

25S

OUTPUT SW POWER VPS1

36T

VALVE BODY TEMP SIGNAL

36R-C

VALVE BODY TEMP RETURN

NOT USED

NOT USED 19S1-E

SEC. STEER FUSED PWR NOT USED

CONNECTOR TS1 - TRANSMISSION SHIFTER

245486C1

CAV

WIRE IDENT

CIRCUIT

19A-H

TRANS SHIFTER FUSED PWR

25F

FORWARD SIGNAL

25R

REVERSE SIGNAL

25T-B

NEUTRAL SIGNAL

4002-186 CONNECTOR TS2 - TRANSMISSION SHIFTER

UBJ, DEF LEVEL TEMP

245487C1

CAV

WIRE IDENT

CIRCUIT

W230R399

CAV

WIRE IDENT

CIRCUIT

NOT USED

38B

DEF LEVEL SIG

25W

3RD AND 4TH GEAR SIGNAL

0-T

DEF SENSOR GND

25Z

1ST AND 4TH GEAR SIGNAL

38G

DEF TEMP SIG

25Y

TRANSMISSION KICK DOWN SIGNAL

UBJM, DEF LEVEL TEMP CONNECTOR TSS - TURBINE SPEED SENSOR

CAV

WIRE IDENT

CIRCUIT

38B-A

DEF LEVEL SIG

0-TA

DEF SENSOR GND

38G-A

DEF TEMP SIG

UTS, UPSTREAM TEMP SENSE CAV

WIRE IDENT

CIRCUIT

38F

EXHT UP SIGNAL

0E-A

EXHT TEMP UP GND

291718A1

CAV

WIRE IDENT

CIRCUIT

25C

TURBINE SPEED SIGNAL

0-HH

TURBINE SPEED SENS GRND

CONNECTOR WF - WATER IN FUEL SENSOR

8602416

CAV

WIRE IDENT

CIRCUIT

35W

WATER INDICATOR

0-BP

WATER SENSOR GROUND

18J-H

WATER SENSOR FUSED PWR

4002-187 CONNECTOR WSH - WATER SEPARATOR HEATER

CONNECTOR YFN - FNA PWM SOLENOID

256340A1

182069A1

CAV

WIRE IDENT

CAV

CIRCUIT

0-BW

WATER SEPARATOR HEATER GROUND

1-GC

WATER SEPARATOR HEATER POWER

WIRE IDENT

CIRCUIT

56-A

FAN CONTROL PWM

0-BQ

FAN SPEED PWM SOLEN GND

CONNECTOR YFR - FAN REVERSING SOLENOID YDL, DIFF LOCK SOLENOID CAV

WIRE IDENT

CIRCUIT

34A-D

DIFF LOCK SOL B+

34C-A

DIFF LOCK SOL GND

YDL 1, DIFF LOCK SOLENOID 225316C1

CAV

WIRE IDENT

CIRCUIT

52A-B

FAN REVERSING RELAY OUT

0-BB

FAN REVERSING SOLEN GND

YLS, TC LOCKUP VALVE 225315C1

CAV

WIRE IDENT

CIRCUIT

34A-E

DIFF LOCK SOL B+

34C-D

DIFF LOCK SOL GND

YDL 2, DIFF LOCK SOLENOID CAV

WIRE IDENT

CIRCUIT

34A-E

DIFF LOCK SOL B+

34C-D

DIFF LOCK SOL GND

CAV

WIRE IDENT

CIRCUIT

35R-B

TC LOCKUP SOL POWER

24T-B

TC LOCKUP SOL GND

4002-188 CONNECTOR YPB - PARKING BRAKE SOLENOID

CONNECTOR YPP - PILOT PRESSURE SOLENOID

245482C1

CAV 291718A1

CAV

WIRE IDENT

CIRCUIT

52P

PARKING BRAKE RELAY OUT

0-AN

PARK BRAKE SOLEN GND

WIRE IDENT

CIRCUIT

53P-A

PILOT CONTROL RELAY OUT

0-DU

PILOT PRESS SOLEN GND

CONNECTOR YRC - RIDE CONTROL OPT CONNECTOR YPE - PIN ENGAGE OPT

245482C1

CAV

WIRE IDENT

CIRCUIT

291718A1

CAV

WIRE IDENT

CIRCUIT

PIN ENGAGE SOLENOID PWR

58-G

RIDE CONTR SOLEN PWR

0-AE

PIN ENGAGE GROUND

RIDE CONTROL

0-AD

RIDE CONTROL GROUND

YPE2, PIN ENGAGE OPT YRC J, RIDE CNTRL JUMPER CAV

WIRE IDENT

CIRCUIT

58-H

RIDE CONTROL SIGNAL

0-RD

RIDE CONTROL GND

YRC J2, RIDE CONTROL OPT 245482C1

CAV

WIRE IDENT

CIRCUIT

57-D

PIN ENGAGE SOL PWR

0-AW

PIN ENGAGE GND

CAV

WIRE IDENT

CIRCUIT

58-H

RIDE CONTROL SIGNAL

0-RD

RIDE CONTROL GND

4002-189 CONNECTOR YSS - SECONDARY STEERING SOLENOID

CONNECTOR 64F - FLASHER CONNECTOR

245481C1 225316C1

CAV

WIRE IDENT

CIRCUIT

CAV 1

51-C

SEC. STEERING SOLENOID CONTROL

0-CF

SEC. STEERING SOLENOID GROUND

WIRE IDENT 45N-A

CIRCUIT FLASHER OPT SIDE CONTR

CONNECTOR 64M - FLASHER CONNECTOR

CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

245480C1

CAV A

WIRE IDENT 45N-B

CIRCUIT FLASHER OPT SIDE CONTR

225316C1

CAV

WIRE IDENT

CONNECTOR 108F - DIAGNOSTIC CONNECTOR

CIRCUIT

19A-U

TRANS KICK DOWN SW FSD PWR

25Y-C

TRANS KICK DOWN SIGNAL

21M, TRANS KICK-DOWN

291663A1

CAV

225316C1

CAV

WIRE IDENT

CIRCUIT

19B-D

FNR SW FUSED PWR

25Y-G

TRANS KICK DOWN SIGNAL

WIRE IDENT

CIRCUIT

19A-W

DIAGN CONN. FUSED PWR

37D-A

DIAGNOSTIC SIGNAL

0-DAV

DIAGNOSTIC TECM GROUND

37E

DIAGNOSTIC SIGNAL SWITCHED

4 5

NOT USED

4002-190 CONNECTOR 197F - MAIN CAB FNR

115, GRID HTR PWR CAV 1

WIRE IDENT 1-BE

CIRCUIT GRID HTR PWR

CONNECTOR 140M - DIODE MODULE

225350C1

CAV

245488C1

CAV

WIRE IDENT

CIRCUIT

63H-C

FRONT WIPER HIGH RYL OUT

63L-C

FRONT WIPER LOW RYL OUT

0-EE

DIODE SUPPRESSION GNDS

58-D

RIDE CONTROL SOLENOID PWR

D E F

WIRE IDENT

CIRCUIT

19A-C

FNR SWITCH FUSED POWER

26F-B

FNR FORWARD SIGNAL

26N-B

FNR NEUTRAL SIGNAL

26R-B

FNR REVERSE SIGNAL

32J-E

TRANS ENABLE INDIC LAMP

25Y-B

TRANS KICK DOWN SIGNAL

CONNECTOR 197M - FNR MAIN CAB

NOT USED 68L-C

REAR WIPER SWITCH PWR

193, STARTER RELAY CAV 1

WIRE IDENT 1-BB

CIRCUIT STRTR SOL PWR 225351C1

CAV

194, STARTER SIGNAL CAV 1

WIRE IDENT 1-BB

CIRCUIT STRTR SOL PWR

195, STARTER RELAY POWER CAV 1

WIRE IDENT 1-Z

CIRCUIT STRTR RLY BAT PWR

WIRE IDENT

CIRCUIT

19A-B

FNR SWITCHED FUSED POWER

26F-A

FNR FORWARD SIGNAL

26N-A

FNR NEUTRAL SIGNAL

26R-A

FNR REVERSE SIGNAL

32J-A

TRANS ENABLE INDIC LAMP

25Y-C

TRANS KICK DOWN SIGNAL

4002-191 CONNECTOR 202M - ROLLBACK JUMPER

CONNECTOR 215F - ALTERNATOR RESISTOR

245482C1

CAV

WIRE IDENT

CIRCUIT

199436A1

CAV

58-A

RIDE CONTR SOLENOID PWR

58-A

RIDE CONTR SOLENOID PWR

WIRE IDENT 14-A

CIRCUIT ALTERNATOR D+

CONNECTOR 216F - ALTERNATOR RESISTOR CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

199436A1

CAV 245481C1

CAV 1

WIRE IDENT 35A-E

WIRE IDENT 19R-D

CIRCUIT

CIRCUIT ALTERNATOR RESISTOR FUSED PWR

BACKUP ALARM RELAY OUT

245F, SEC STR FLYBACK CONNECTOR 209M - BACKUP ALARM DISABLE JUMPER

245480C1

CAV A B

WIRE IDENT 35A-D

CIRCUIT BACKUP ALARM RELAY OUT NOT USED

CAV

WIRE IDENT

CIRCUIT

0-CG

SEC STR FLYBACK GND

0-CH

SEC STR FLYBACK GND

4002-192

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 New Holland Batter y Saver and Cleaner according to the instructions on the container. New Holland Batter y Saver and Cleaner also helps prevent corrosion. If New Holland 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 New Holland Battery Saver and Cleaner or Urethane Seal Coat to the cable terminals to prevent corrosion. See the Parts Counter Catalog. DO NOT apply grease.

4003-5

BATTERY TEST NOTE: To correctly test a battery, do each part of the battery test until you know the condition of the battery.

Visual Checks 1. Make sure the cable connections are clean and tight. Clean foreign material from the top of the battery. 2. Inspect the battery case, battery posts, and cables for damage. 3. Check the electrolyte level. See Page 4. 4. If you added water to the battery, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte.

Specific Gravity Check A hydrometer is used to check the specific gravity (weight) of the electrolyte. The specific gravity is an indication of the level of charge for each cell. Hydrometers are made to show the correct specific gravity when the temperature of the electrolyte is 26.7°C (80°F). When you check the specific gravity, you must know the temperature of the electrolyte. If your hydrometer does not have a thermometer, get a thermometer to check the temperature of the electrolyte. The thermometer must indicate a high temperature of at least 52°C (120°F). 1. Remove enough electrolyte from a cell so that the float is free in the tube. NOTE: If the specific gravity cannot be checked without first adding water to the cell, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte. Then check the specific gravity. 2. Read the float. 3. Read the thermometer. If the reading is above 26.7°C (80°F) add specific gravity points to the reading for specific gravity. If the reading is below 26.5°C (80°F) subtract specific gravity points from the reading for specific gravity. See the following illustration and add or subtract specific gravity points as needed.

B790863

1. TEMPERATURE IN F

2. TEMPERATURE IN C

SPECIFIC GRAVITY CHART

4. Make a record of the corrected specific gravity reading for each cell. 5. If the difference between the high reading and the low reading is 0.050 or more, charge the battery and check the specific gravity again. If after charging, the difference is still 0.050 or more, install a new battery. 6. The corrected specific gravity reading shows the level of charge for the cell. The level of charge must be at least 75% in each of the cells. ln maintenance free batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.240 or higher. In all other batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.230 or higher. 7. If the difference between the high reading and the low reading is less than 0.050, and the level of charge is at least 75% in all of the cells, do the Capacity (Load) Test. 8. If the difference between the high reading and the low reading is less than 0.050, but the level of charge is less than 75% in any of the cells, charge the battery and check the specific gravity again. If after charging: A. The level of charge is less than 75% in any of the cells, discard the battery. B. The level of charge is at least 75% in all of the cells, do the Capacity (Load) Test.

4003-6

Capacity (Load) Test This test can be done using a variable load tester s u c h a s t h e S u n E l e c t r i c VAT- 3 3 . O t h e r t e s t equipment can be used. Connect the test equipment according to the instructions of the manufacturer of the equipment. 1. The level of charge of the battery must be at least 75%. Do the Specific Gravity Check in this section. 2. Prepare the tester (Sun Electric VAT-33 shown) for the test. A. Select the voltmeter range that will measure 1 to 18 volts. B. Make sure the load control knob is in the OFF position. C. Select the ammeter range that will measure 0 to 1000 amperes. D. Move the volt lead switch to the NT. position. 3. Connect the tester to the battery as shown.

NOTE: Never apply a load for longer than 15 seconds. After each 15 seconds, turn the load control knob to OFF for at least one minute. 4. Apply a 15 ampere load to the battery for 15 seconds. Wait at least three minutes before applying the load again. 5. Check and make a record of the temperature of the electrolyte. 6. Find the correct load for this test in Specifications in Section 4001. NOTE: The correct load is half of the cold cranking amperes at -17°C (0°F). 7. Turn the load control knob until the ammeter indicates the specified load. Keep the load for 15 seconds and read the voltmeter. Turn the load control knob to OFF. 8. Compare the test reading and the temperature of the electrolyte to the chart below. Temperature of . . . . . . . . . . . . . . . Minimum Voltage electrolyte 21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6 16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9.3 -1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 -12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 A. If the test result is equal to or more than the vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d condition. B. If the test result is less than the voltage shown, discard the battery.

B790499

1. LOAD CONTROL KNOB

2. AMMETER CLAMP (TIP OF ARROW AWAY FROM BATTERY)

4003-7

CHARGING A BATTERY WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83

The charging rate must be decreased if: 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 52Â°C (125Â°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 15.5Â°C (60Â°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

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. 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.

W270R584

The Jump Post option can be used to provide power to star t the machine if i ts batter ies 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: 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.

4003-4

NOTES

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 6 9 11 12 13 16 16 16 16 17 17 17 18 22 42 49 52

4005-3

INSTRUMENT CLUSTER 1

15 14

12 BS06H240

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 operatorâ&#x20AC;&#x2122;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 LEDâ&#x20AC;&#x2122;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

Information will be displayed in different zones on the LCD, as directed by the operator or machine. In most situations the operator or technician will be given specific information to follow if conditions are not correct. 1. In the example, above, the machine hours are d i s p l aye 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.

W230M139

The LCD Multi-Function Display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps.

2. This example, shows that the Transmission Control Lever is in Neutral. 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 zone shows the gear numerically (3th).

F 2

7.0 H

12 3 4

A A 11 22

W230R477

LCD MULTI-FUNCTION DISPLAY 4 SPEED

12 3 D

•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.

• MAX

- Maximum Power.

• STD

- Normal/Standard mode of Operation.

•

AUTO - Switches automatically Maximum and Standard Power.

• ECO

N R

- Automatic

5. This example shows the Power Boost Status.

7.0 H

•A

4 6

4. This example shows the current transmission mode that has been selected. A. If the Transmission is operating normally it will display either

R 3

A A 11 22

- Limited Power for fuel efficiency.

6. This example will show the Time in either 12 hour or 24 hour.

5 4 6

W230R476

LCD MULTI-FUNCTION DISPLAY 5 SPEED

between

4005-6

Navigating Through The LCD Multi-function Display Screens

Using The Arrow Keys At any time, during operation or with the key switch on, the operator may scroll through three information screens and two trip screens by using the arrow keys. These five screens are in a circular loop and may be reached by pressing the up or down key. The following sequence is using the down key only.

NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

D BD06F186

Located on the steering column, just to the left of the Park Switch, is the key pad. Use this key pad to move fr o m on e s c r e e n to a n o th e r, c h o o s e va r i o u s selections, monitor the machine functions, and retrieve information. All functions can be accessed in the same basic manner. A. Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to start over and begin again, plus use to check active, acknowledge errors.

BD06F188

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

B. Enter key: Use this key to confirm, yes, this is the desired function. C. Up arrow key: Use this key to scroll up to selections. D. Down arrow key: Use this key to scroll down to selections. NOTE: Arrows on the screen will indicate if selections are up or down from the current selection. NOTE: Display units can be changed by the operator. W230R435

Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPMâ&#x20AC;&#x2122;s, speed, fuel level, and the Urea level.

4005-7

W230R436

W230R438

Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Fahrenheit or Celsius, and the Urea level.

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.

W230R437

Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and the Urea level.

Info Voltage Air Turbo DefTemp DefLvl

4 V 24.2 Â°C 42 Â°C 32 % 24 W230M171

Push the down key again to display the info 4 screen. This screen display the voltage level, turbocharger air temperature, Urea temperature and Urea level.

W230R439

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

Trip 04May2008,

2 17:42

Time Fuel

Hrs 102.9 L 1000.6

Fuel/hr

L/h

9.1 BD06F172 W230M137

Highlight the trip screen you wish to set.

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.

Trip 04May2008,

BD06F187

2 17:42

Time Fuel

Hrs 102.9 L 1000.6

Fuel/hr

L/h

9.1

Press the confirm button to reset the trip selection to zero. W230M137

Press the escape key to return to the main driving screen and lock settings into memory. The screen will begin to record time and fuel usage immediately.

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.

W230M141 / BD06F188

Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to scroll through the menu’s. Items and selections in this menu are: 1. Setting Menu • •

Engine (Auto Idle, Power Mode, Eng Options, Factory Set, Auto Shutdown, Fan Gain) Transmission (Max Gear, Min Gear, ICCO ENABLE)

• Joystick

Steering (Option)

2. Display Menu • Options •

(Engine Snd, Ground Snd)

Language (English, Deutsch, Francais, Italiano, Espagnol, Portuguese)

• Units

(Metric, English, Imperial)

• Clock

(24 or 12 Hour Increments)

•

Backlight (Day Disp., Day Led, Night Disp., Night Led)

•

Factory Set (Reset, Display Setting, Confirm Please)

3. Diagnostics •

Show Errors (Red, Yellow, White, Memory) Memory 1/2

• Reset •

Errors (Reset, Confirm Please)

Cluster S/W (Software Part Number, Software Serial Number, Software ID, Software Version)

• Transmission

(SW, HW, VER, SER)

4. Service •

Calibration (Clutch Calib, Pedal Calib, Park Brake, Fan Test)

• Change • Slot

Model

Tires

For other submenu see next page. * The tests in the configuration menu should be performed only by a qualified operator or technician, as some tests require the engine to be running at high RPM’s.

Deflt

WorkIdle

STANDARD AUTO ECO

Low

Accelerated

EngOptions

(Option)

Joyst Steer

JSS_Spd

Fan Auto

Power Mode

(5 Speed)

POWERINCH ON

Min Gear

Transm.

Max Gear

MAX

Auto Idle

(4 Speed)

Transm.

Joyst. Steer

Off

Factory Set

EngOptions

Min Gear

Power Mode

Transm.

Max Gear

Engine

Auto Idle

Settings

Engine

Ground Spd

Confirm Please

Engine Settings

Reset

Factory Set

Engine Spd

OPT Options

(Option)

30 min Protection OFF

OFF

Auto Shtdwn

English Imperial

Deutsch Francais Italiano Espagnol Portugue

Units Metric

Language

Factory Set

Backlight

Clock

Units

Language

English

Economy Interval

Display OPT Options

0 2

17NOV10,Hr 1

1067 0.00

SCR Control CAN Msg Engine Timeout

MEMORY 1/2 19605 Warning

WHITE

MEMORY

Show Errors

Ver

Ldr

Backlight Day Disp. Day LED Night Disp. Night LED

1.8.0.0 3.0.2.8

87372814 84340740

Cluster HW P/N SW P/N

12 Hr 12 30 1 1 2011

Clock

RED YELLOW

Format Hour Minute Day Month Year

Settings Display Diagnostics Service

Main Menu

6057 018 121 6009 365 007

Transm.

Confirm Please

Display Settings

Reset

Factory Set

VER 932___tdz_Luc 4506JCWFw SER

SW HW

20 20 5 5

Confirm Please

ClutchCalib

Transm.

Cluster

Show Errors

Diagnostics

Calibration

Press Esc To Exit

Turn Key OFF

Now,

Change OK

420

Reset Actual PWM

735 *****

70% Speed

AdjustSpeed

Fan Speed Engage 3rdManual

PedalCalib

Test at fixed

ParkBrake Test Park Brake

Fixed 70%

Confirm Please

Fan Speed Mode

Switch to Fixed

Fan Test

20.5 Rad

Select Tires TireSize

PedalCalib

Confirm Please

Test Park Brake

ParkBrake

Slct_Tires

Push Pedal Full

Confirm Please

PedalCalib

Fan Test

ParkBrake

PedalCalib

ClutchCalib

Service Calibration

4005-10

W230R478

4005-11 SELECT SCREEN The "Display" selection screen allows time settings to be entered. Highlight "clock" and press the select button. This will allow the time settings to be changed.

W230M142

W230M143

W230M144

The "Diagnostic" selection screen allows the software screens which cannot be modified to be viewed by highlighting "cluster S/W" and pressing the confirmation button.

W230M145

Figure 4

W230M146

Figure 5

W230M147

Figure 6

Figure 1

Figure 2

Figure 3

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 page back to the main screen. Turning the machine off will also lock the settings into memory.

4005-12 SELECTING POWER MODES The power mode allows the operator to choose the most effective machine power for the current job conditions. Idling can be changed from automatic to a fixed rate. 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. Press and hold the confirm key for two seconds to arrive at the service screen.

W230M141

W230M149

Figure 9

At the screen shown above, highlight the power mode, and press the confirm key to move to the Power Mode Selection Menu.

Figure 7 W230M150

Figure 10

At the Power Mode Menu press the confirm key again to activate the selections. The highlighted section will flash to indicate a new selection can be made. Press the up or down key to select the Power Mode, and then press the confirm key. Use the escape key to return to the main driving screen and to lock the mode selection into memory. Confirming the Selected Mode

W230M148

Figure 8

The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected.

4005-13 OPTIONS AND PREFERENCE SCREENS LANGUAGE SCREEN, MEASUREMENT UNITS, AND CLOCK The LCD screen can be set with language, measurements, and/or clock preferences. Use the arrow keys to scroll to the display menu. Press the confirm key on the correct selection. Press the escape key to return to the main driving screen and lock the selection into memory. Choose the preferences desired: language in English, Spanish, Portuguese, Italian, German, French; measurement units in metric, English, or Imperial; and clock units in 12 or 24 hour cycles. 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, press the confirm key, then use the escape key to return to the main driving screen in order to lock the preference into memory.

W230M142

W230M155

W230M156

Figure 13

W230M157

Figure 14

W230M158

Figure 15

Figure 11

Figure 12

4005-14 CLOCK

DISPLAY MENU

Setting The Hour and Date

The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key until the screen rever ts to the main driving screen to lock the selection into memory. The screen display can be changed to suit working conditions. The screen will change to night function illumination when the head lamps are turned on.

Fr o m t h e d i s p l ay s c r e e n , c h o o s e t h e c l o c k 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 the 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.

W230M142

W230M159

Figure 19

W230M160

Figure 20

Figure 16

W230M143

Figure 17

W230M144

Figure 18

4005-15

Clutch Calibration After warming the oil temperature: 1. Park the machine on a firm level surface. 2. Place the NEUTRAL.

Transmission

Control

Lever

3. Set the Park Brake. 4. With the engine running, at idle, enter the Service Screen Menu and scroll to Service.

W230M175

If, conditions are not correct, an error message will appear and guide the operator or technican. There are six, if conditions not met, screens: • Not

in neutral

• Park

Brake OFF

• Machine

W230M173

Use the confirm and arrow button to scroll to the screen shown above. At this screen push the confirm button again.

moving

• Oil

temp too low

• 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

• Adjust

Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start. W230M174

This screen will prompt the operator or technican to confirm or escape.

If the process is not completed the operator or technican will be prompted to escape.

4005-16

Auto Idle Idling can be changed from automatic to a fixed rate. The fixed idle rate is defined as Standard Idle at 900 RPM. Highlight the auto idle selection by using the arrow keys, then press confirm. When you have chosen the selection, lock the selection into memory by pressing the confirm key.

RPM Engine speed in RPM will show on the display if the engine speed is running up to 550 RPMâ&#x20AC;&#x2122;s, and will disappear if the engine speed is lower than 300 RPM. W230M141

Options Menu

MPH/KPH

Use the arrow keys to choose the menu. Press the confirm key, and the options sub-menu will appear. The options menu will allow the operator to choose options for the fan, idle.

Vehicle speed will show on the display if it is up to 1.0 MPH / 1.5 KPH and will disappear if the vehicle speed is less than 0.6 MPH / 1.0 KPH.

Fan Auto The fan can be set to run at automatic or the fan will run at maximum speed. Automatic is the more common or preferred setting. It will switch between high speed, low speed, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil. The operator can choose fan speed or reversing capabilities. Highlight the fan auto selection by using the arrow keys, then press confirm. When you have chosen the selection, lock the selection into memory by pressing the confirm key.

4005-17

RETRIEVING FAULT CODES General Fault Code Identification 1. Press and hold the escape key and up arrow key for more than 2 seconds to access the fault codes.

Fault Code Grouping 1. 1000 to 1999 vehicle errors. 2. 2000 to 2999 not used. 3. 3000 to 3999 engine errors. 4. 4000 to 4999 transmission errors.

5. 5000 to 5999 eltro-hydraulic system errors.

6. 6000 to 6999 reserved. 7. 7000 to 7999 reserved. 8. 8000 to 8999 optional equipment IE: GPS. 9. 9000 to 9999 internal AIC errors.

10. 19000 to 19999 Selective Catalytic Reduction (SCR) errors. BD06F186

A. Escape key B. enter key C. up key D. down key 2. Yellow Faults, buzzer will beep once every 2 seconds: A. Operator can acknowledge it by pressing the enter key. B. The message will disappear. C. Buzzer will not beep anymore. D. Yellow lamp will stay ON. E. Fault will remain in Yellow list until it is closed. 3. Red Faults, buzzer will be continuous, alternating sounds: A. Operator can acknowledge it by pressing the enter key. B. Buzzer will change to a less stressing sound, but will remain. C. Message will remain on display with indication of URGENT STOP.

4005-18

VEHICLE FAULT CODES CODE

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

1316

Check charging system 1. Stop machine operations 2. Run engine at 1500 rpm 3. Check sending unit

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

1. Stop machine operations 2. Check charging system

4005-19 CODE

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.

Check connector of JSS valve and JSC controller.

1834

JSS controller, JSC output, SC to BAT Power is applied to one of the JSC controller outputs.

Check electrical connection for short to power. Or JSC internal relay is defective.

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.

1835

4005-20 CODE

DEFINITION

1836

JSS controller, board temperature, out of limits temperature on the JSC board is <-40C or >+85C;

1837

JSS controller, switched power, out of limits Check elect connection for electrical transients, switched power supply at JSC Pin3 is out of limit; 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

Check wiring, installation, and proper functioning of JSS valve. See electrical schematics and section 5009 for details.

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

1846

POSSIBLE STEPS FOR REPAIR Check ambient temperature or short circuit at JSC power outputs

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.

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.

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.

4005-21 CODE 1864

DEFINITION Test

POSSIBLE STEPS FOR REPAIR 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

4005-22

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 째C (86 째F). Cause: The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit.

Air intake temperature sensor - signal above range min.

3010

3011

4005-23 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

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.

4005-24 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.

3043

Vehicle speed sensing hardware conversion error

No information available at time of print.

4005-25 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3047

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.

3048

High pressure Pump relay - Short circuit to ground.

1. Faulty reading from component. 2. Wiring or circuits shorted.

3051

Battery voltage to ECM too high

Alternator voltage governor defect. Replace alternator governor device or alternator.

Battery voltage to ECM too low

Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect. Occurrence possible during cold start. Replace battery or alternator. Check ECU and wiring.

ECM afterrun was interrupted.

3060

Cylinder 1 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3061

Cylinder 1 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3062

Cylinder 1 signal low

Check the wiring and the injection signals, replace ECU

3063

Cylinder 1 short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3064

Cylinder 5 unclassified error in injector

Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible. Check the wiring and the injection signals, replace ECU

3065

Cylinder 5 injector cable short-circuit low side to battery

Short circuit in wiring with external source. Check the wiring or replace injector

3066

Cylinder 5 signal low

Check the wiring and the injection signals, replace ECU.

3052

3059

4005-26 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3067

Cylinder 5 injector cable short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3068

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

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.

4005-27 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3083

Cylinder 4 injector cable short-circuit high side to low side

Defective coil of injector. Check the wiring and replace injector

3088

Crankshaft sensor lost synchronization

Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor. Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals)

3089

Crankshaft sensor defective

Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals).

3090

Camshaft sensor lost phase

Signal interrupted do 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 do 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

4005-28 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

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

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 â&#x20AC;&#x2122;short circuit to groundâ&#x20AC;&#x2122; (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.

3104

3112

Rail pressure sensor CP3 signal above range max.

Rail pressure sensor inaccurate. Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor Short circuit of wiring to external source or defective pressure sensor, rail pressure overshoot. Check wiring and proper functioning of rail pressure sensor

4005-29 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3113

Main Relay 1 (High Pressure Pomp) short to GND

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

3114

Main Relay 1 (High Pressure Pomp) short to GND

Short circuit to ground of main relay or defective main relay. Check the wiring connecting the battery to the EDC or replace main relay

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)

4005-30 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

No information available at time of print.

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.

4005-31 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.

4005-32 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.

4005-33 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

4005-34 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

4005-35 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

4005-36 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

4005-37 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Sensor supply voltage 1 low

Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC

Sensor supply voltage 2 high

Sensor supply voltage 2 low

Sensor supply voltage 3 high

3286

Sensor supply voltage 3 low

3290

Turbo compound monitoring signal not plausible

See engine manual for details.

3297

Rail pressure governor deviation exceeded max limit with fuel delivery quantity on limit.

See engine manual for details.

3301

Rail pressure governor deviation exceeded min limit with fuel delivery quantity on limit.

See engine manual for details.

3305

Rail pressure governor deviation below min limit for speed

See engine manual for details.

3309

Rail pressure governor deviation exceeded max limit

See engine manual for details.

3313

Rail pressure drop rate is higher than expected.

See engine manual for details.

3315

Minimum number of injections not reached stop engine.

See engine manual for details.

3281

3283

3284

3285

4005-38 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3316

Minimum number of injections not reached stop engine.

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.

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

3335

Timeout of CAN message TSC1-PE Torque (when active).

Timeout of CAN message TSC1-PE Torque (when inactive).

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 See engine manual for details.

4005-39 CODE 3338

3339

DEFINITION Timeout of CAN message TSC1-VE Torque (when inactive).

Timeout of CAN message TSC1-VE Torque (when active).

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR See engine manual for details. 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.

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.

4005-40 DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

3370

Info: Torque limitation due to engine protection (against excessive torque, Engine overspeed and overheat)

See engine manual for details.

3371

Info: Torque limitation due to fuel quantity limitation because of injection system errors.

See engine manual for details.

3512

DCU State monitoring - DCU not ready in time

See engine manual for details.

3513

SCR catalyst not present - Relation of temperature behavior between both catalyst temperatures not plausible

See engine/SCR manual for details.

3517

Ambient air temperature sensor failure (of humidity sensor) - Signal too high

See engine/SCR manual for details.

3518

Ambient air temperature sensor failure (of humidity sensor) - Signal too low

See engine/SCR manual for details.

3521

NOX estimation failure - Estimated NOX signal not reliable.

See engine/SCR manual for details.

3528

NOX sensor plausibility failure - signal not plausible

See engine/SCR manual for details.

3529

NOX sensor failure - Open load

See engine/SCR manual for details.

2530

NOX sensor failure - Short circuit

See engine/SCR manual for details.

2532

NOX sensor failure - Sensor not ready in time

See engine/SCR manual for details.

2533

CAN message timeout NOX (from NOX sensor) - CAN timeout

See engine/SCR manual for details.

3537

Message DM1DCU timeout

See engine/SCR manual for details.

3541

Message SCR1 timeout

See engine/SCR manual for details.

3545

Info: SCR Dosing valve overheat protection Torque limitation level2 for SCR protection active

See engine/SCR manual for details.

3546

Info: SCR Dosing valve overheat protection Torque limitation level1 for SCR protection active

See engine/SCR manual for details.

3549

Humidity sensor signal ratio failure - Signal ratio above limit

See engine/SCR manual for details.

3550

Humidity sensor signal ratio failure - Signal ratio below limit

See engine/SCR manual for details.

3555

CAN message timeout SCR2 (from DCU) CAN timeout

See engine/SCR manual for details.

3557

Info: Humidity sensor possibly saturated with water droplets - Signal ratio above limit

See engine/SCR manual for details.

3558

Info: Humidity sensor possibly saturated with water droplets - Signal ratio below limit

See engine/SCR manual for details.

4005-41 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3561

NOX value not plausible (After treatment plausibility)

See engine/SCR manual for details.

3577

DM1DCU SPN1 message- Error in DCU active

See engine/SCR manual for details.

3581

Performance limit active due to either stage Performance limitation active

See engine/SCR manual for details.

3585

Engine shut off (after idling phase)

See engine/SCR manual for details.

3586

Plausibility check of catalyst system Temperature after catalyst not plausible

See engine/SCR manual for details.

3587

Plausibility check of catalyst system Temperature before catalyst not plausible

See engine/SCR manual for details.

3588

Plausibility check of catalyst system - Ambient temperature of humidity sensor or both catalyst temperatures not plausible

See engine/SCR manual for details.

3589

Plausibility check of catalyst system Temperature deviation between up and downstream catalyst temperature too high during operation

See engine/SCR manual for details.

3591

SCR Catalyst thermal ageing limit exceeded Main catalyst efficiency below threshold

See engine/SCR manual for details.

3593

Poor reagent quality

See engine/SCR manual for details.

3594

Indicates torque limitation due to SCR

See engine/SCR manual for details.

3599

Error path of oxidation catalyst not present: Warm up catalyst efficiency below threshold

See engine/SCR manual for details.

3602

Defect ratio between threshold limits - Catalyst temperature sensor circuit

See engine/SCR manual for details.

3611

Catalyst efficiency lower than first NOX prediction threshold level

See engine/SCR manual for details.

3612

Catalyst efficiency lower than second NOX prediction threshold level

See engine/SCR manual for details.

3613

Too high efficiency of catalyst system

See engine/SCR manual for details.

3614

SRA2EDC high effort fault

See engine/SCR manual for details.

3615

SRA2EDC initialization fault

See engine/SCR manual for details.

3616

Torque limitation due to turbo charger protection

See engine/SCR manual for details.

4005-42

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.

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.

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

4114

4116

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 output 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

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 sensor 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, does not fit other speeds 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

4181

4182

4183

4184

4185

4193

4197

4201

4202

4203

Vehicle controller time-out (CAN)

1. Check the cluster controller. 2. Check wire of CAN-Bus. 3. Check the cable to the cluster controller.

JSS timeout

1. Check Joystick steering controller. 2. Check wire of CAN-Bus. 3. Check cable to Joystick steering controller.

Engine CONF timeout

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

EEC1 timeout

1. Check EEC controller 2. Check wire of CAN-Bus 3. Check cable to EEC controller

EEC3 timeout

1. Check EEC controller 2. Check wire of CAN-Bus 3. Check cable to EEC controller

Invalid test mode signal (CAN)

1. Check the cluster controller. 2. Check wire of CAN-Bus. 3. Check the cable to the cluster controller.

AEB Request signal

1. Check I/O controller 2. Check wire of CAN-Bus 3. Check cable to I/O controller

Engine torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

Reference engine torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

Actual engine torque signal

1. Check engine controller 2. Check wire of CAN-Bus 3. Check cable to engine controller

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 1. Check EEC timeout 2. Check wire of CAN-Bus 3. Check cable to EEC controller

4206

EEC2 timeout

4209

Short circuit to battery voltage at clutch K1

4210

Short circuit to ground at clutch K1

4211

Open circuit at clutch K1

4212

Short circuit to battery voltage at clutch K2

4213

Short circuit to ground at clutch K2

4214

Open circuit at clutch K2

4215

Short circuit to battery voltage at clutch K3

4216

Short circuit to ground at clutch K3

4217

Open circuit at clutch K3

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

4225

Short circuit to battery voltage at clutch K4

4226

Short circuit to ground at clutch K4

4227

Open circuit at clutch K4

4228

Short circuit to battery voltage at clutch KV

4229

Short circuit to ground at clutch KV

4230

Open circuit at clutch KV

4231

Short circuit to battery voltage at clutch KR

4232

Short circuit to ground at clutch KR

4233

Open circuit at clutch KR

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

1. Check the cable from the TCU to the transmission control valve. 2. Check the connectors from the TCU to the transmission control valve. 3. Check the regulator resistance. 4. Check internal wire harness of the transmission control valve.

4005-46 CODE

DEFINITION

4241

Short circuit to ground a relay reverse warning alarm

4242

Short circuit to battery voltage at relay reverse warning alarm

4243

Open circuit at relay reverse warning alarm

POSSIBLE STEPS FOR REPAIR 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.

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).

4005-47 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

4292

Joystick status indicator short-circuit to ground

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.

4293

Joystick status indicator short-circuit to battery voltage

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.

4294

Joystick status indicator over current

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.

4298

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

Power supply for sensors short-circuit to battery voltage

1. Check the cables from the sensors TCU. 2. Check the connectors from the sensors to the TCU.

4306

Power supply for sensors short-circuit to ground

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

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.

4005-48 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

4323

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

4324

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 error

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

Do the transmission clutch calibration procedure.

4005-49

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.

4005-50 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

9140

LogicalError in list0

No information available at time of print.

9141

LogicalError in list1

No information available at time of print.

9142

Logical Error in list2

No information available at time of print.

9143

Logical Error in list3

No information available at time of print.

9144

Logical Error in list4

No information available at time of print.

9145

Logical Error in list5

No information available at time of print.

9146

Logical Error in list6

No information available at time of print.

9147

Logical Error in list7

No information available at time of print.

9151

Logical Error when retrieving flash data

No information available at time of print.

9152

Logical Error when retrieving flash data

No information available at time of print.

9153

Logical Error when retrieving flash data

No information available at time of print.

9154

Logical Error when retrieving flash data

No information available at time of print.

9155

Logical Error when retrieving flash data

No information available at time of print.

9156

Logical Error when retrieving flash data

No information available at time of print.

9157

Logical Error when retrieving flash data

No information available at time of print.

HourMeter Failure - Both copies are wrong

HourMeter Failure - One of two copies are wrong

9162

HourMeter Failure - Pre-crank and after-crank check are wrong

9173

SCR controller CAN timeout

No information available at time of print.

9174

SCR controller CAN did not start

No information available at time of print.

9175

CreateMbx 20ms DM1 BAM (SCR controller)

No information available at time of print.

9160

9161

4005-51 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

9176

AddMsg DM1 BAM (SCR controller)

No information available at time of print.

9177

AddMsg DM1 PCK (SCR controller)

No information available at time of print.

9178

TimeOut Packet (SCR controller)

No information available at time of print.

9179

CreateMbx 20ms DM1 Packets (SCR controller)

No information available at time of print.

9180

VCM controller CAN timeout

No information available at time of print.

9181

VCM controller CAN did not start

No information available at time of print.

9182

Wheel Loader Configuration Plausibility Failure - Wrong engine type

No information available at time of print.

4005-52

SELECTIVE CATALYTIC REDUCTION (SCR) FAULT CODES CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19001

Battery voltage evaluation - Above upper limit

1. Faulty electrical wiring or connections 2. Faulty DCU

19002

Battery voltage evaluation - Below lower limit

1. Faulty electrical wiring or connections 2. Faulty DCU

19003

Battery voltage sensing (electrical) - Above upper limit.

The selective catalytic reduction (SCR) controller has detected a high voltage condition in the voltage supply circuit. The fault becomes active when the supply voltage is greater than 36.738 for at least 0.3 s. The code will heal if the supply voltage returns to less than 36.738 V for 0.8 s. Cause: The supply voltage to the SCR controller is greater than 36.738 V. Possible failure modes: 1. Faulty electrical wiring or connections 2. Faulty Power converter 3. Faulty SCR controller

19004

Battery voltage sensing (electrical) - Below lower limit

The selective catalytic reduction (SCR) controller has detected a low voltage condition in the voltage supply circuit. The fault becomes active when the supply voltage is less than 13.143 V for at least 0.3 s. The code will heal if the supply voltage returns to greater than 13.143 V for 0.8 s. Cause: The supply voltage to the SCR controller is less than 13.143 V (13.143 V). Possible failure modes: 1. Faulty electrical wiring or connections 2. Faulty Power converter 3. Faulty SCR controller

19010

Catalyst temperature sensor circuit high - After catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19011

Catalyst temperature sensor circuit low - After catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19019

Catalyst temperature sensor circuit high - Before catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19020

Catalyst temperature sensor circuit low - Before catalyst

1. Faulty sensor 2. Faulty electrical wiring or connection 3. Faulty denox module

19021

Temperature sensor before catalyst (electrical) signal above high error threshold

No information available at time of print.

19022

Temperature sensor before catalyst (electrical) signal below low error threshold

No information available at time of print.

4005-53 CODE

19037

19038

19046

19047

19048

19055

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Reagent - pressure sensor - Short circuit high (high supply voltage)

The denox module/supply module has detected a high supply voltage for urea pressure sensors, located inside the denox module/supply module. Attempt to clear the code. If this code reoccurs, there is a problem with the supply voltage internal to denox module/supply module. Replace the denox module/supply module.

Reagent - pressure sensor - Short circuit low low supply voltage)

Reagent - pressure sensor - Open circuit

The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module. This error occurs when the sensor signal level has reached its internal limit. This error is corrected if sensor returns to its normal output. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Reagent - pressure sensor - Short circuit high (signal high)

The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module. The sensor signal level is above 5.0 V for over 700 ms. This fault will reset if the raw signal level goes below 5.0 V for over 1000 ms. Attempt to clear the code. If this code reoccurs, the sensor is defective and the denox module should be replaced.

Reagent - pressure sensor - Short circuit low (signal low)

The denox module/supply module has detected a failure of the urea pressure sensor, located inside the denox module. This error occurs when the sensor signal level is below 0.152 V for over 700 ms. This error is corrected if sensor returns to normal output for greater than 1.0 s. Ensure all connectors are secured properly on the denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module.

Reagent - temperature sensor of pump module - Short circuit high

The denox module/supply module has detected a failure of the urea temperature sensor, located inside the denox module. The sensor signal level is above 5.0 V for over 700 ms. This fault will reset if the raw signal level goes below 5.0 V for over 1000 ms. If the sensor is defective the denox module should be replaced.

4005-54 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19056

Reagent - temperature sensor of pump module - Short circuit low

The denox module/supply module has detected a failure of the urea temperature sensor, located inside the denox module. This error occurs when the sensor signal level is below 0.283 V for over 700 ms. This error is corrected if sensor returns to normal output for greater than 1.0 s. Ensure all connectors are secured properly on the denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module.

19057

UREA Temperature sensor in box (electrical) signal above high error threshold Out of range

No information available at time of print.

19058

UREA Temperature sensor in box (electrical) signal below low error threshold Out of range

No information available at time of print.

Voltage supply internal heaters 1 (UB1) electrical - Internal heating Open circuit

The denox module/supply module has sensed a fault with the voltage supply for the internal heaters, located in the supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the supply module.

Pump module - Internal heating - Short circuit high

Voltage supply 2 - tube heaters (UB2) electrical - Short circuit high

The denox module/supply module has sensed a fault with the voltage supply for the internal heaters, located in the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Voltage supply 2 - tube heaters (UB2) electrical - Short circuit low

19064

19065

19073

19074

4005-55 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Reagent - suction tube heating - open circuit

Vent valve (Reductant purge control valve) Short circuit high

The denox module/supply module has sensed a fault with the voltage supply for the coolant control valve and the reverting valve, located in the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Voltage supply 3 - Coolant control valve and reverting.valve (UB3) electrical - Short circuit low

19084

Vent valve (Reductant purge control valve) Short circuit low

If this error has occurred, there is a failure in denox module/supply module. Ensure all connectors are ensured properly on the denox module/supply module and all lines are in operable condition. If fault does not reset or reoccurs, replace denox module/supply module.

19091

12 Volt supply for dosing module - Above upper limit

1. Problem with battery or charging system 2. Denox module/supply module internal failure.

19092

12 Volt supply for dosing module - Below lower limit

1. Problem with battery or charging system 2. Denox module/supply module internal failure.

19093

Dosing valve/Pump motor - Above upper limit

No information available at time of print.

19094

Dosing valve/Pump motor - Below lower limit.

No information available at time of print.

UREA level sensor (electrical) - supply voltage error.

The dosing control unit (DCU) has detected a failure of the Internal level sensor, located inside the DCU. This error occurs when there is a short circuit or broken supply wire inside the denox module/supply module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If the fault does not reset or reoccurs, replace the DCU.

19075

19082

19083

19100

4005-56 CODE

19101

DEFINITION

Reagent - tank level sensor - Short circuit high

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The dosing control unit has sensed the level of AdBlue™/Def drops below a predetermined level. If the signal is higher than 4.7 V for 0.5 s. Cause: There is an short circuit in the AdBlue™/Def level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19102

Reagent - tank level sensor - Short circuit low

The Dosing Control Unit (DCU) has sensed the level of AdBlue™/Def has dropped below a predetermined level. If the signal is lower than 0.2 V for 0.5 s this error will occur. Cause: There is an short to ground in the AdBlue™/Def level sensor circuit. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19109

Reagent - tank temperature sensor (temperature of the reagent - solution in the tank) - Short circuit high

1. Faulty wiring 2. DEF/AdBlue® tank temperature sensor is faulty.

19110

Reagent - tank temperature sensor (temperature of the reagent - solution in the tank) - Short circuit low

1. Faulty wiring 2. DEF/AdBlue® tank temperature sensor is faulty.

19145

Reductant injector circuit high - Dosing valve

1. Dosing valve harness short to power 2. Denox module/supply module is faulty

19146

Reductant injector circuit low - Dosing valve

No information available at time of print.

19147

Reductant injector circuit/open - Dosing valve

1. Dosing valve harness open circuit 2. Dosing valve solenoid open circuit 3. Denox module/supply module is faulty

19148

Reagent - dosing nozzle - Pressure too high Dosing valve

1. Dosing valve faulty. 2. Denox module/supply module is faulty

19149

Dosing valve (electrical) - short circuit to ground.

The dosing injection valve, which is fed with AdBlue™/DEF, is an injector located on the exhaust pipe. Cause: There is a open circuit in the dosing injection valve circuit. Possible failure modes: 1. Faulty dosing injection valve. 2. Faulty electrical wiring or connections X904, X914. 3. Faulty selective catalytic reduction (SCR) controller.

4005-57 CODE

19150

DEFINITION

Dosing valve (electrical) - dosing valve permanent.”ON” - Pressure too high

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The dosing control unit (DCU) has detected an error with the dosing module. Cause: There is a short circuit in the dosing module circuit. Possible failure modes: 1. Faulty dosing valve. 2. Faulty electrical wiring or connections. 3. Faulty DCU.

19154

19155

19156

Reagent - pump - not delivering

The supply module/denox module has detected a urea pump speed sensor fault. This error occurs when the supply module/denox module has sensed all three hall sensors outputs are high for greater than 7 s. This error is corrected if all three sensors return to normal output for greater than 1 s. Ensure all connectors are secured properly on the supply module/denox module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the supply module/denox module.

Reagent - pump motor blocked

The denox module/supply module has detected this failure because the averaged pump flow is less than a predetermined flow rate, and pump control duty cycle is greater than expected as determined by the denox module/supply module. The pump is blocked internally because of contamination, frozen DEF/AdBlue®, damaged pump motor, or damaged pump flow measurement. Ensure all connectors are secured properly to thedenox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Reagent - pump - over speed

The denox module/supply module has detected this failure because the averaged pump flow is greater than a predetermined value for over 7.0 s. Check hose from DEF/AdBlue® tank to pump module. If hose is detached, reconnect hose and secure to pump. If hose is defective, replace the hose. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. Replace denox module/supply module if fault reoccurs.

4005-58 CODE

19157

19163

19164

19172

19181

19182

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Reagent - pump - not delivering

The supply module/denox module has detected a urea pump speed sensor fault. This error occurs when the supply module/denox module has sensed all three hall sensor outputs are low for greater than 7 s. This error is corrected if all three sensors return to normal output for greater than 1 s. If the fault does not reset or reoccurs, replace the supply module/ denox module.

Vent valve (Cooling control valve) - Short circuit high

The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, the power stage is switched OFF and ON again and the check is repeated for ten times. Failure is reported if test fails each time. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault does not reset or reoccurs, replace the DCU.

Vent valve (Cooling purge control valve) Open circuit

The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, there is a short internal to the pump module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault does not reset or reoccurs, replace the DCU.

Vent valve (Cooling purge control valve) Short circuit low

The dosing control unit (DCU) has detected a failure of the SCR Coolant control valve. If this error is detected, there is a internal failure to the pump module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If fault does not reset or reoccurs, replace the DCU.

Vent valve (Reverting purge control valve) Short circuit high

The denox module/supply module has detected a failure of the reverting valve, located inside the denox module/supply module. Ensure all connectors are secured properly on the denox module/supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

Vent valve (Reverting purge control valve) Short circuit low

The dosing control unit (DCU) has detected a failure of the reverting valve, located inside the supply module. Ensure all connectors are secured properly on the DCU and all lines are in operable condition. If the fault does not reset or reoccurs, replace the supply module.

4005-59 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19183

Vent valve (Reverting purge control valve) Open circuit

19184

Reverting valve electrically - Short circuit to ground

No information available at time of print.

19262

Tank heating valve - Short circuit high

A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlueÂŽ from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. Cause: A open circuit has been detected in the tank heater control valve circuit. Possible failure modes: 1. Faulty DEF tank heater control valve. 2. Faulty electrical wiring or connection. 3. Faulty denox module/supply module.

19263

19264

Tank heating valve - Short circuit low

Tank heating valve - Open circuit

A valve remote from the storage tank is used to control coolant to prevent AdBlueâ&#x201E;˘/DEF from freezing in cold temperatures. The valve will respond to a signal from the DCU based on temperature signals from the temperature sensor. A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlueÂŽ from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. Cause: A open circuit has been detected in the DEF tank heater control valve circuit. Possible failure modes: 1. Faulty DEF tank heating control valve. 2. Faulty electrical wiring or connection. 3. Faulty denox module/supply module.

4005-60 CODE

19265

DEFINITION

Tank heating valve - short circuit to ground.

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlue® from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. Cause: A short circuit has been detected in the DEF tank heater control valve circuit. Possible failure modes: 1. Faulty DEF tank heating control valve. 2. Faulty electrical wiring or connection. 3. Faulty denox module/supply module.

19289

19290

Temperature after catalyst too low

Catalyst temperature sensor circuit range/performance

A valve remote from the storage tank is used to control coolant to prevent DEF/AdBlue® from freezing in cold temperatures. The valve will respond to a signal from the denox module/supply module based on temperature signals from the temperature sensor. NOTE: After the repair has been completed, the code will still be present and active until it has been determined that the selective catalytic reduction (SCR) system is operating properly. The engine must be brought to normal operating temperature and run under load until the fault clears. If the code is still present and active after running the engine for 30 minutes, further diagnostics is necessary. Context: The selective catalytic reduction (SCR) controller has sensed the Downstream catalyst temperature sensor is giving an implausible reading. This occurs when the SCR controller senses the Downstream catalyst temperature sensor reading is less than 110 °C (230 °F) for longer than 450 s (450 s) with engine speed of greater than 800 RPM (800 RPM) and an engine load of at least 15 % (15 %). Cause: The SCR controller has sensed a low Downstream catalyst temperature sensor reading. Possible failure modes: 1. Downstream catalyst temperature sensor not installed properly.

4005-61 CODE

19298

DEFINITION

Reagent - pump - Not delivering; UREA pressure too low at system start

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR The denox module/supply module has detected the DEF/AdBlue® pressure has not reached 500 kPa within 2.5 min. Manually check DEF/AdBlue® level is filled to operating level. Check feeding tubes, connectors and O-rings in connectors for any air leaks. If error is still present, use the electronic service tool (EST) to run urea dosing system test (UDST) to troubleshoot the system further. NOTE: After the repair has been completed, the code will still be present and active until it has been determined that the selective catalytic reduction (SCR) system is operating properly. The engine must be brought to normal operating temperature and run under load until the fault clears. If the code is still present and active after running the engine for 30 minutes, further diagnostics is necessary.

19307

19316

Reagent - pressure - Above threshold; UREA pressure not plausible (urea pressure too high)

Reagent - temperature sensor of pump module - Out of range

The denox module/supply module has detected the DEF/AdBlue® pressure exceeds 6.5 bar for 30 s. Reasons for failure could be internal control valve blocked or pump speed to high. These are indications of internal failure of supply module. Use the electronic service tool (EST) to run the urea dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500 kPa, and the pump speed should not exceed 6000 RPM. Replace denox module/ supply module if values are out of range. The denox module/supply module has detected the DEF/AdBlue® temperature in module box is less than 75 °C (167°F) or greater than 9 °C (48 °F), and system is not in defreezing mode. This error occurs if, in the previous driving cycle, box temperature was less than 85 °C (185 °F) and in shutdown mode. If during the actual driving cycle the box temperature remains less than 70 °C (158 °F) for more than 10.0 s, the system goes into emergency shutdown and will not start until EEPROM is cleared. Use the electronic service tool (EST) to clear code. Verify tank heater codes are not present, and there is no temperature plausibility errors. If other errors are present, correct as well.

4005-62 CODE

19325

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

DEFINITION

Reagent - tank temperature sensor (temperature of the reagent - solution in the tank) - Out of range

The DEF/AdBlue® temperature in tank is greater than 75.0 °C (167.0 °F) for 300 s and system is not in defreezing mode. This code will heal when the temperature returns below 75.0 °C (167.0 °F) for 1.0s. Cause: The DEF/AdBlue® tank temperature is out of range. Possible failure modes: 1. Tank heating valve stuck open. 2. Check for other DEF tank heater control valve related error codes.

19334

Defreezing mode and detection errors (inlet line defreezing failed)

The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system start up. If DEF/AdBlue® pressure does not reach 390 kPa within 2.5 min the inlet line is frozen. This failure is stored after 30 repetitions with 2.5 min heating phases between the checks. Cause: The denox module/supply module has detected this error because of no DEF/AdBlue® pressure. Possible failure modes: 1. 2. 3. 4.

19335

Defreezing mode and detection errors (pressure line defreezing failed)

AdBlue™/DEF tank empty. Inlet line broken. Pump does not feed. DEF/AdBlue® box heater does not work correctly.

The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system start up, and inlet line is detected open. If DEF/AdBlue® pressure does not drop to 350 kPa within 40 s with the dosing valve open to 99.0 %, the pressure line is frozen. This failure is stored after 28 repetitions with 2.5 min heating phases between the checks. Cause: The denox module/supply module has detected this error because of no DEF/AdBlue® injection. Possible failure modes: 1. 2. 3. 4.

Dosing valve does not open Pressure line blocked Injection nozzle blocked Faulty box heater

4005-63 CODE

19336

19337

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

DEFINITION

Defreezing mode and detection errors (pressure build-up in detection mode failed); Pump module - Internal heating - Open circuit

Defreezing mode and detection errors (Back-flow line defreezing failed)

The dosing control unit (DCU) has detected this failure when ambient temperature is below 17.0 °F at system start up. The pressure line and inlet line is detected open. If DEF/AdBlue® pressure does not reach 390 kPa within 40 s with full pump speed, the system is not unfrozen. This failure is stored after 26 repetitions with 2.5 min heating phases between the checks. Check if the internal heater is working correctly. The denox module/supply module has detected this failure when ambient temperature is below 17.0 °F at system start up. The inlet and pressure line is detected open and pressure build up was OK. If DEF/AdBlue® pressure does not drop to 140 kPa within 50 s with the vent valve open to 100 %, the back flow line is frozen. This failure is stored after 24 repetitions with 2.5 min heating phases between the checks. Cause: The denox module/supply module has detected this error because of no DEF/AdBlue® back flow line is frozen. Possible failure modes: 1. 2. 3. 4.

DEF/AdBlue® tank ventilation clogged Back flow line clogged Ventilation valve does not open Back flow line frozen

Coolant control valve mechanically Mechanical defective blocked open

The dosing control unit (DCU) has detected a short circuit. If at normal operating speed the AdBlue™/DEF pressure is greater than 450 kPa, and the cooling valve is closed from 100 - 0 %, the AdBlue™/DEF pressure must rise at least 15 kPa within 2 s. Ensure all connections and connectors are secured to the DCU properly. If error is still present, there is an internal failure of the box. Replace the DCU.

19344

Coolant control valve mechanically Mechanical defective blocked closed

The dosing control unit (DCU) has detected a open circuit. If at normal operating speed the AdBlue™/DEF pressure is greater than 450 kPa, and the cooling valve is open from 0 - 100 %, the AdBlue™/DEF pressure must drop at least 15 kPa within 2 s. Ensure all connections and connectors are secured to the DCU properly. If error is still present, there is an internal failure of the box. Replace the DCU.

19352

Vent valve (Reductant purge control valve) Open circuit; reverting control valve

Possible failure modes: 1. Valve is mechanically stuck 2. System was empty, needs primed

19343

4005-64 CODE

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

DEFINITION

19361

Battery voltage evaluation - Below lower limit

Possible failure modes: 1. Problem with battery or charging system. 2. Denox module/supply module internal failure.

19362

Battery voltage evaluation - Above upper limit

Possible failure modes: 1. Problem with battery or charging system. 2. Denox module/supply module internal failure.

19370

Pump motor error during commissioning (pump not delivering); UREA pressure too low

During operation, the ventilation valve is fully opened, the pump is then set to 100 % operation until DEF/AdBlue® pressure has reached 500 kPa. The ventilation valve is then closed. If DEF/AdBlue® pressure does not reach 500kPa within 2.5 min, this error occurs. Cause: The denox module/supply module has detected the pump motor is not delivering. Possible failure modes: 1. 2. 3. 4.

19379

Temperatures not plausible during commissioning

No DEF/AdBlue® in tank System was empty, needs primed Faulty pump Faulty feeding line

The denox module/supply module has detected the temperatures are not correct within 30 min of operation. The module box temperature is less than -9 °C (16 °F) or greater than 75 °C (167 °F), or the DEF/AdBlue® tank is less than -17 °C (2 °F) or greater than 75 °C (167 °F). Bring temperature to a normal level, between 0 - 30 °C (32 - 86 °F). Possible failure modes: 1. Extreme cold ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

19415

Empty UREA tank - fluid level in tank too low

The denox module/supply module has detected the DEF/AdBlue® level is constantly less than 0.1 % for more than 25 s. Possible failure modes: 1. Tank is empty 2. Faulty level sensor

19496

Pressure - Above threshold

No information available at time of print.

19505

Plausibility of pump module temp. sensor; dynamic

No information available at time of print.

19514

Plausibility of UREA tank temp. sensor; dynamic

No information available at time of print.

4005-65 CODE

19532

19541

19550

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Back flow line blocked; dosing valve - Short circuit low

The denox module/supply module has generated this fault because it has sensed the back flow line is clogged. This fault occurs when the denox module/supply module performs the a test and determines: DEF/AdBlue® pressure is greater than 345 kPa (50 psi), pump speed greater than 300 RPM (300 RPM), downstream temperature is greater than 60 °C (140 °F), and dosing is greater than 6 % (6 %) for 20 s (20 s). If these parameters are met, the cooling valve is closed, the DEF/AdBlue® pump is stopped and the dosing valve is fully opened and the pressure is rechecked by the denox module/supply module. If the pressure is less than 30 kPa (4.35 psi), the back flow line is clogged. Ensure the lines are open and free flowing. If the lines are free of blockage, replace the denox module/supply module.

Vent valve test - Plausibility test (start-up) ; cooling control valve

The denox module/supply module has detected at start up, after opening the coolant control valve for 40 s, DEF/AdBlue® pressure is less than 150 kPa. First check that pressure and back flow line are not frozen or clogged. If all lines are open and in proper operation, the denox module/supply module has failed. Replace the denox module/supply module

Dosing nozzle - Pressure too high

NOTE: After the repair has been completed, the code will still be present and active until it has been determined that the selective catalytic reduction (SCR) system is operating properly. The engine must be brought to normal operating temperature and run under load until the fault clears. If the code is still present and active after running the engine for 30 minutes, further diagnostics is necessary. Possible failure modes: 1. Dosing nozzle blocked. 2. Crimped , or collapsed supply line to dosing nozzle.

4005-66 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Low UREA level 1 (warning) - Too low

The denox module/supply module has detected low DEF/AdBlue® level. This error occurs when the DEF/AdBlue® fluid level is too low or level sensor has faults present. Ensure the heated level sensor is connected properly. Check DEF/AdBlue® tank level is full. If fluid level is low, fill tank to proper capacity. Check for any other errors that may be present. Correct those errors first, then recheck original error has been corrected. Ensure all connectors are secured properly on the denox module/ supply module and all lines are in operable condition. If the fault does not reset or reoccurs, replace the denox module/supply module.

19568

Low UREA level 2 (warning) - Too low

19577

CAN receive frame E2SCR: (UREA quantity not in range.

Possible failure modes: 1. Controller communication error

19578

CAN receive frame E2SCR (Dosing status not in range).

Possible failure modes: 1. Controller communication error

19579

CAN receive frame E2SCR - timeout

Possible failure modes: 1. Controller communication error

19580

CAN receive frame E2SCR - too many messages

Possible failure modes: 1. Controller communication error

19581

CAN receive frame E2SCR - Serial Communication link

Possible failure modes: 1. Controller communication error

19595

CAN receive frame EEC1 (Engine torque not in range).

Possible failure modes: 1. Controller communication error

19596

CAN receive frame EEC1 (Engine speed not in range).

Possible failure modes: 1. Controller communication error

19597

CAN receive frame EEC1 - timeout

Possible failure modes: 1. Controller communication error

19598

CAN receive frame EEC1 - too many messages

Possible failure modes: 1. Controller communication error

19559

4005-67 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

19599

CAN receive frame EEC1 (Torque driver demand not in range).

Possible failure modes: 1. Controller communication error

19604

CAN receive frame ET1 (Oil temperature not in range).

Possible failure modes: 1. Controller communication error

19605

CAN receive frame ET1 - timeout

Possible failure modes: 1. Controller communication error

19606

CAN receive frame ET1 - too many messages

Possible failure modes: 1. Controller communication error

19607

CAN receive frame ET1 (Water temperature not in range).

Possible failure modes: 1. Controller communication error

UREA Tank level sensor - open circuit

Cause: There was an open circuit detected in the DEF/AdBlue® level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

UREA Tank level sensor - Short circuit high

Cause: There was an open circuit detected in the DEF/AdBlue® level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19651

UREA Tank level senor - Short circuit low

Cause: There was an open circuit detected in the DEF/AdBlue® level sensor circuit. Possible failure modes: 1. Faulty Sensor. 2. Faulty electrical wiring or connection. 3. Faulty DCU.

19652

UREA Tank level error (CAN message or electrical with real sensor) - (timeout))

No information available at time of print.

19653

UREA Tank level error (too many CAN messages)

No information available at time of print.

19654

UREA Tank level error - Open circuit

No information available at time of print.

19649

19650

4005-68 CODE

19676

19677

19678

19679

19721

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Ambient temperature CAN receive signal: (Ambient air temperature not in range)

The denox module/supply module has detected this failure because the ambient air temperature is out of range. Ambient air is measured through the denox module/supply module. If the tractor has been exposed to extreme ambient temperatures, either high or low, take steps to get tractor back into normal operating temperature range. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Ambient air temperature sensor range/performance - CAN timeout

The denox module/supply module has detected this failure because the ambient air temperature has timed out. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Ambient air temperature sensor range/performance - too many CAN messages

The denox module/supply module has detected this failure because the ambient air temperature has faulty can bus signal. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

Ambient temperature CAN receive signal: (Barometric pressure not in range)

The denox module/supply module has detected this failure because the ambient air temperature has faulty sensor range. Ensure all connectors are secured properly to the denox module/supply module and all lines are in operable condition. If fault does not reset, replace the denox module/supply module.

EEPROM/Checksum failures - EEPROM write error (P062F)

The denox module/supply module has suffered a detection error. This error indicates a defect in the dataset that is presently loaded in the denox module/supply module. If this error is present and active, reload the software dataset. If this error then reoccurs, replace the denox module/supply module.

4005-69 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

EEPROM/Checksum failures -No corresponding variant number error (P062F)

The denox module/supply module has an internal cycle counter to check if the afterrun is correctly finished. This cycle counter data is then stored in the EEPROM memory. This error indicates the denox module/supply module has attempted to store this data in a protected area of memory. If this error is present and active, first verify the denox module/supply module and other components have not been tampered with and reload the software. If this error reoccurs replace the denox module/supply module.

19723

EEPROM/Checksum failures -EEPROM communication error (P062F)

The denox module/supply module memory in EEPROM is not correct or a SPI communication error has occurred. This error indicates an internal denox module/supply module error. If this error is present and active, ensure all electrical connectors are secure and reload the denox module/supply module software. If this error reoccurs, replace the denox module/supply module.

19724

EEPROM/Checksum failures -EEPROM detection error or codierwort error (P062F)

The denox module/supply module has an internal error in software. If the code is present and active, reload the software. If this error reoccurs, replace the denox module/supply module.

19725

EEPROM/Checksum failures -Wrong EEPROM size (P062F)

The denox module/supply module has the incorrect EEPROM installed. This error would only occur during initial startup when the denox module/supply module has previously been replaced. Replace the denox module/supply module.

19730

Ignition switch - plausibility error

Possible failure modes: Faulty connector Faulty ignition switch

ECM/PCM Power relay control circuit/open main relay shut off too late

Context: The denox module/supply module has detected the main relay is not switched off within 2 s. Cause: The main relay is shutting off too late. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

ECM/PCM Power relay control circuit/open main relay short circuit

Cause: Switched power relay control circuit open. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

19722

19739

19740

4005-70 CODE

19741

19742

19748

19749

19757

19766

19775

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

ECM/PCM Power relay control circuit/open main relay open circuit

Cause: Switched power relay control circuit high. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

ECM/PCM Power relay control circuit/open main relay shut off too early

Cause: Switched power relay control circuit open. Possible failure modes: 1. Faulty relay 2. Faulty electrical wiring or connection 3. Denox module/supply module error

UREA Temperature sensor of pump module Out of range

Cause: High urea temperature in pump module. Possible failure modes: 1. Tank heating valve stuck open. 2. Check for other tank heating valve/coolant flow solenoid related error codes.

Dynamic UREA leakage test - Leakage detected

Cause: High urea temperature in pump module. Possible failure modes: 1. Tank heating valve stuck open. 2. Check for other tank heating valve/coolant flow solenoid related error codes.

Reagent - pump - Not delivering

The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue® injection control being active. Diagnose those fault codes to clear this fault. If this fault is active without any other codes active, reload the software in the DCU or replace the DCU.

Compressed air regulation valve

Plausibility of catalyst temperature sensors Plausibility error

The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue® injection temperature being active. Diagnose those fault codes to clear this fault. If this fault is active without any other codes active, reload the software in the DCU or replace the DCU.

4005-71 CODE

19784

19793

19802

19803

19804

19805

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

NOX Trap efficiency below threshold

Fluid level in UREA tank - Too low

The dosing control unit (DCU) has activated this fault due to other fault codes associated with the DEF / AdBlue® system urea low tank level. Confirm the urea tank is full. Diagnose those fault codes to clear this fault. If this fault is active without any other codes active, reload the software in the DCU or replace the DCU.

UREA Tank temperature Temp over CAN timeout

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Can communication error. 2. DEF/AdBlue® tank temperature sensor is faulty.

UREA Tank temperature - Temp over CAN: SAE J1939 Too many messages

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Extreme cold ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

UREA Tank temperature Temp over CAN: SAE J1939 erroneous signal - Open circuit

UREA Tank temperature - SRC High: Short circuit high

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Extreme hot ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

4005-72 CODE

19806

19807

19808

19813

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

UREA Tank temperature - SRC Low: Short circuit low.

UREA Tank temperature - SRC High: UREA temperature too high - Out of range

Context: The denox module/supply module has detected the urea tank temperature and denox module/supply module temperature are not in agreement. Possible failure modes: 1. Extreme hot ambient conditions. 2. DEF/AdBlue® tank temperature sensor is faulty.

UREA Tank temperature - SRC Low: UREA temperature too low - Out of range

Reagent - pump - Not delivering

Context: During operation, the ventilation valve is fully opened, the pump is then set to 100 % operation until DEF/AdBlue® pressure has reached 500 kPa. The ventilation valve is then closed. If DEF/AdBlue® pressure does not reach 500kPa within 2.5 min, this error occurs. Cause: The denox module/supply module has detected the pump motor is not delivering. Possible failure modes: 1. No DEF/AdBlue® in tank 2. System was empty, needs primed 3. Faulty pump 4. Faulty feeding line

4005-73 CODE

19817

19818

19822

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

Dosing valve - Blocked (only stuck closed)

The denox module/supply module has detected the DEF/AdBlue® pressure exceeds 6.5 bar for 30 s. Reasons for failure could be internal control valve blocked, blocked dosing valve nozzle or too high a pump speed. These are indications of internal failure of supply module. Use the electronic service tool (EST) to run the Urea dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500kPa, and the pump speed should not exceed 6000 RPM. Replace denox module/supply module if values are out of range.

Dynamic UREA leakage test - Leakage detected

The denox module/supply module has detected leakage. Visual inspect all urea lines and connections for leakage. These are indications of internal leakage of supply module. Use the electronic service tool (EST) to run the urea dosing system test (UDST) to monitor the DEF/AdBlue® pressure and pump speed. DEF/AdBlue® pressure should not exceed 500 kPa , and lower values can indicate leakage, and the pump speed should not exceed 6000 RPM. Replace denox module/supply module if values are out of range.

Dynamic UREA leakage test - Leakage detected

4005-74

NOTES

Section 4006

4006

REAR VIEW CAMERA AND MONITOR

4006-2

TABLE OF CONTENTS REAR VIEW CAMERA AND MONITOR (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Components of the rear view camera and monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation the rear view camera and monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4006-3 REAR VIEW CAMERA AND MONITOR (OPTIONAL) The rear view back-up camera reduces vehicle blind spots during reversing operations. It assists operators when backing for loading operations and offers a view of other equipment, obstacles, and/or personnel in the work area. Refer to the camera manufacture's instructions for correct operation of the camera monitor. The camera monitor is mounted in the operator's compartment and the camera eye is located behind the rear grille. The camera eye has built in moisture resistance for equipment that operates in harsh environments. The camera is available for yourauthorized dealer. W230M181

W230M182

4006-4

COMPONENTS OF THE REAR VIEW CAMERA AND MONITOR 1. Bar mounting 2. Monitor arm mount 3. Plate access monitor adaptor 4. Monitor 5. Mounting bracket rear camera 6. Rear camera 7. Washer 8. Bolt 9. Washer 10. Nut 11. Washer 12. Screw 13. Washer 14. Screw 15. Nut 16. Cab right hand console 17. Washer 18. Screw 19. Latch 20. Rivet 21. Nut 22. Grommet 23. Strap cable

4006-5

13 14

4 12 11 17

16 W230R490

INSTALLATION THE REAR VIEW CAMERA AND MONITOR

4006-6

SECTION INDEX

STEERING Section Title

Section Number

Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001 Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005 Center Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006 Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5008 Joystick Steering System (JSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5009

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 6 6 6 8 8 8 10 10 10 12 12 12

5001-3

STEERING CONTROL VALVE Removal

STEP 8

NOTE: When disconnecting hydraulic fittings, plug hoses and cap fittings to prevent entry of foreign matter into hydraulic system.

STEP 1 Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine.

STEP 2 Put master disconnect the master switch in OFF position.

BD07B099

Pull floor mat away from the column.

STEP 3

STEP 9

Remove the front skirt from the cab or canopy.

STEP 4 Remove all dirt and grease from steering control valve.

STEP 5 Remove hydraulic reservoir fill cap, attach a vacuum pump to the reservoir, start the pump.

STEP 6 Tag hoses connected to steering control valve. BD07B100

STEP 7

Remove the mounting screws from the lower trim.

STEP 10

BD06G262

Disconnect five hoses from steering control valve, cap or plug the fittings and hoses, turn off the vacuum pump.

BD07B101

Tilt the steering wheel and remove the mounting screws from lower trim, remove the trim.

5001-4

Installation

STEP 11

STEP 12 1

BD07B102

Remove the four mounting bolts (4) for the steering control valve (5), two shown and two in the front. IMPORTANT: Have an assistant support and remove the valve while removing the mounting bolts.

BD07B141

Put the rubber bushing (1) on the spacer (3) with the tapered end towards the steering valve. Rubber bushing (2) is mounted between the cab and the steering valve.

STEP 13 15

Put one rubber bushing on the sleeve and place in the mounting hole and hold in place, have an assistant push the other rubber bushing onto the sleeve.

STEP 14

Have an assistant push the valve into place while turning the steering shaft, this will engage the splines.

STEP 15 2

BD07B102

W110R557

Install and tighten the four mounting bolts (4) for the steering control valve (5), two shown and two in the front. Torque 50 Nm (37 ft-lbs). NOTE: Finger tighten all bolts before tightening, check for proper wheel operation after tightening.

5001-5

STEP 16

STEP 19

BD07B101

BD06G262

Install the lower trim onto the column, tilt the steering wheel and install and tighten the mounting screws.

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 17

STEP 20 Remove the vacuum pump from the reservoir, install and tighten the reservoir fill cap.

STEP 21 Put battery disconnect switch in ON position. 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. BD07B100

STEP 22

Install and tighten the mounting screws into the lower trim.

Install the front skirt onto the cab or canopy.

STEP 18

Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

BD07B099

Put floor mat back into position on the cab floor.

STEP 23

5001-6

AUXILIARY 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 auxiliary steering priority valve and adjacent area. See illustration on page 7. 4. Remove hydraulic reservoir fill cap. 5. Connect a vacuum pump to hydraulic reservoir. 6. Start vacuum pump. 7. Tag and disconnect tank return tube (8) from the priority valve. Install a cap on the elbow and a plug in the tube. 8. Stop the vacuum pump. 9. Tag and disconnect the wiring from the steering solenoid (16). 10. Tag and disconnect the wiring from the pressure switch (5). 11. Tag and disconnect load sensing hose (3) from auxiliary steering priority valve (14). Install a cap on the elbow and a plug in the hose. 12. Tag and disconnect load sensing hose (4) from the priority valve (14). Install a cap on the elbow and a plug in the hose. 13. Tag and disconnect steering pressure hose (1) from priority valve (14). Install a cap on the fitting and a plug in the hose. 14. Tag and disconnect pressure hose (7) from priority valve (14). Install a cap on the fitting and a plug in the hose. 15. Tag and disconnect pressure hose (11) from priority valve (14). Install a cap on the fitting and a plug in the hose. 16. Support auxiliary steering priority valve (14). Remove cap screws. 17. Remove auxiliary steering priority valve (14).

Installation 1. Install and tighten cap screws. 2. Connect and tighten pressure hose (11). 3. Connect and tighten pressure hose (7). 4. Connect and tighten steering pressure hose (1). 5. Connect and tighten steering load sensing hose (4). 6. Connect and tighten load sensing hose (3). 7. Connect electrical connector to the pressure switch (5). 8. Connect electrical connector to the steering solenoid (16). 9. Start vacuum pump. 10. Connect and tighten tank return tube (8). 11. Stop vacuum pump. Disconnect vacuum pump from hydraulic reservoir. 12. Install fill cap on hydraulic reservoir. 13. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks. 14. Check to make sure priority valve operates correctly. See Section 5002. 15. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

5001-7

6 5

8 9

13 11 10

12 W110R558

7 3

17 14

16 8 11 BS08A015

1. 2. 3. 4. 5. 6. 7. 8. 9.

STEERING PRESSURE HOSE STEERING CONTROL VALVE STEERING LOAD SENSING HOSE TO STEERING VALVE STEERING LOAD SENSING HOSE TO PRIORITY VALVE STEERING PRESSURE SWITCH LOADER VALVE PRESSURE HOSE PUMP OUTPUT TANK RETURN HOSE AUXILIARY STEERING PUMP MOTOR

10. 11. 12. 13. 14. 15. 16. 17.

STEERING SUCTION HOSE STEERING PRESSURE HOSE TO STARTER POSITIVE CABLE FILTER IN HYDRAULIC TANK PRIORITY VALVE CONTROL MODULE STEERING SOLENOID VALVE CHECK VALVE

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

5001-8

AUXILIARY STEERING PUMP AND MOTOR Removal 1. Park loader on level ground with enough clearance around the machine to allow you to completely steer from side to side. Lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine,

6. Connect ground cable (4) to ground stud of auxiliary steering pump and motor (1) following tag installed during removal. 7. Connect positive cable (5) to B+ stud of auxiliary steering pump and motor (1) following tag installed during removal.

2. Put master disconnect switch in OFF position.

8. Connect wire (6) to auxiliary steering pump and motor following tag installed during removal.

3. Tag and disconnect wire (6) from auxiliary steering pump and motor solenoid. See illustration on page 9.

9. Put master disconnect switch in ON position.

4. Tag and disconnect positive cable (5) from B+ stud of auxiliary steering pump and motor (1). 5. Tag and disconnect ground cable (4) from ground stud of auxiliary steering pump and motor (1). 6. Remove hydraulic reservoir fill cap. 7. Connect a vacuum pump to hydraulic reservoir. 8. Start vacuum pump. 9. Disconnect suction hose (2). Install a plug in suction hose and cap on fitting. 10. Stop vacuum pump. 11. Disconnect pressure hose (3). Install a plug in suction hose and cap on fitting. 12. Support auxiliary steering pump and motor (1). Remove nuts, cap screws, and washers securing auxiliary steering pump and motor (1). 13. Remove auxiliary steering pump and motor (1).

Installation 1. Position auxiliary steering pump and motor (1) on its mounting plate, have an assistant install cap screws, washers, and nuts to secure auxiliary steering pump and motor (1), tighten the nuts. See illustration on page 9. 2. Remove plug from pressure hose (3) and cap from elbow. Connect pressure hose to the auxiliary steering pump and motor (1). 3. Start vacuum pump. 4. Remove plug from suction hose (2) and cap from elbow. Connect suction hose to elbow installed in auxiliary steering pump and motor (1). 5. Stop and disconnect vacuum pump. Install fill cap in hydraulic reservoir.

10. Start and run engine at low idle and raise bucket 500 mm (20 inches) above ground. Check that auxiliary steering light on instrument cluster is OFF. IMPORTANT: In following Steps, do not run auxiliary steering pump and motor continuously for more than 20 seconds at a time without a two minute cool down. 11. 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 instr ument cluster is ON and auxiliar y steering pump and motor is operating. 12. Turn steering wheel full left into the end of travel, and hold the pump at high pressure for 4-5 seconds to confirm no leakage to the pressure switch. Then full r ight to confir m that the secondary steering system is working and there is no binding in the steering. 13. Restart engine to build steering pressure. Confirm that auxiliary steering light and auxiliary steering pump and motor is operating. After about three seconds motor should stop operating and auxiliary steering light should go out. 14. Let engine run and allow batteries to recharge for a minimum of 10 minutes. WARNING: Do not turn the key switch off if the machine is steered against either the right or left hand steering stop. The steering wheel may kick back.

5001-9

4 2

3 BS08A013

6 3 4

1 2 5 BS08A014

1. AUXILIARY STEERING PUMP AND MOTOR 2. SUCTION HOSE 3. PRESSURE HOSE

4. GROUND CABLE 5. POSITIVE CABLE (TO STARTER) 6. WIRE TO CONTROL MODULE

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

5001-10

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 (12) from steering cylinders (11). See illustration on page 11. 3. Disconnect hydraulic hoses (13, 14, 15, and 16) from steering cylinders (11). 4. Install a plug in each hose (13, 14, 15, and 16) to prevent entry of foreign matter. 5. Remove locknut (10). 6. Remove shoulder bolt (7). 7. Remove pin (6). 8. Remove washers (9). 9. Remove bolt (3), washer (4), and spacer (5) securing pivot pin (2) at rear of steering cylinders (11). 10. Use a suitable driver and drive pivot pin (2) out of steering cylinder (11). 11. Remove washer(s) (1) 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 (1) are installed between steering cylinder (11) and rear frame. See illustration on page 11. NOTE: Install a washer (1) on top and bottom of steering cylinders (11) if possible. If only one washer (1) can be installed, place washer (1) at bottom of steering cylinders (11). 2. Make sure washers (9) are installed between steer ing cylinders (11) and front frame of machine. 3. Install the pivot pin (2) to secure rear of steering cylinders (11) to machine frame. Install spacer (5), washer (4), and bolt (3) to secure pivot pin (2). 4. Tighten bolt (3). 5. Install pin (6) in front of steering cylinders (11). Make sure that washers (9) are installed in correct position. 6. Install shoulder bolt (7) and new locknut (10) in steering cylinders (11) rod end and pin (6). Tighten locknut (10). NOTE: Shoulder bolt (7) should turn freely in hole after tightening. 7. Connect hose assemblies (13, 14, 15, and 16) to steering cylinders (11). 8. Connect grease hoses (12) 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.

5001-11

8 10 11

BS08A009

15 16 11 12

14 13 11 8 BS08A010

1. 2. 3. 4.

WASHER PIVOT PIN BOLT WASHER

5. 6. 7. 8.

SPACER PIN SHOULDER BOLT GREASE FITTING

9. 10. 11. 12.

WASHER LOCKNUT STEERING CYLINDER GREASE HOSE

STEERING CYLINDER ILLUSTRATION

13. 14. 15. 16.

HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY

5001-12

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 (5) from the pressure relief valve. 3. Remove the nuts, bolts and spacers from the pressure relief valve, 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.

5001-13

1 2 3

6 5

BS08A008

1. STEERING CONTROL VALVE 2. RETURN HOSE 3. CONNECTOR M27 ORB

4. RELIEF VALVE 5. RETURN HOSE TO FILTERS 6. RETURN MANIFOLD

STEERING BACK PRESSURE VALVE ILLUSTRATION

5001-14

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 RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 5 5 6 7 7 9 10

5002-3

SPECIAL TOOLS

B785789

380001731 FLOWMETER

B009638

380001739 PRESSURE TEST FITTING KIT

B797157

380001740 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.

3. 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.

4. Test the steering cylinders for leakage, refer to instructions on page 10. If a steering cylinder is leaking, repair or replace the steering cylinder.

2. Do the steering relief valve pressure test. Refer to page 7. If the pressure is above or below specifications, adjust the steering relief valve in the loader control valve.

5002-4

AUXILIARY STEERING SYSTEM PUMP TEST Equipment Required 1. 380001731 Flowmeter 2. 380001740 Flowmeter fitting kit

Test Procedure 1

BB830300

1. AMMETER CLAMP

6. Connect the ammeter clamp (1) to the cable as in illustration above.

7. Make sure that the parking brake is applied and the bucket is on the floor. BD00M030

1. ARTICULATION LOCK

1. Install 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 of the Auxiliar y Steering Pump from the Steering Priority Valve.

8. Make sure that temperature.

the

oil

operating

9. Make sure that the load valve for the flowmeter is open (zero pressure). 10. Start and run the engine. 11. Stop the engine and turn the key back to the On position. 12. Turn the steering wheel, this will activate the auxiliary steering pump.

3. Install a plug into the hose.

13. Turn the load valve on the flowmeter towards CLOSED until the pressure is 104 bar (1500 psi).

4. Connect the inlet of the flowmeter to the outlet fitting on the Steering Priority Valve.

14. Read the flowmeter and ammeter gauges and record the readings.

5. Install the outlet hose of the flowmeter in the hydraulic reservoir and hold in place with wire.

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 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.

1 4

2. A remote starter switch. 3. A tachometer to check the armature speed. 4. A Sun Electric VAT-33 Starting and Charging System Tester.

Test Procedure 1. Remove the connector that is between the ter minals on the magnetic switch and the auxiliary steering motor.

5 B790852

1. 2. 3. 4. 5.

REMOTE STARTER SWITCH TESTER AUXILIARY STEERING MOTOR AMMETER CLAMP 24 VOLT BATTERY SYSTEM

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 in Figure 3.

5. Push the button on the remote starter switch (1) and look at the voltmeter in the tester. 6. Turn the load control (8) until the voltmeter (7) indicates 24 volts. Refer to figure 4. Look at the ammeter (6) in the tester. Make a record of the ammeter indication. 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).

B795328

6. AMMETER 7. VOLTMETER 8. LOAD CONTROL

5002-6

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. 2. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was higher than 30 amperes, possible causes include the following: A. Damaged bearings. B. Loose pole shoes. C. A short circuit in the armature coil. The a r m a t u r e c o i l m u s t b e c h e cke d o n a n armature tester after the motor is disassembled. D. A ground connection in the field coil. 3. If the armature did not turn and the ammeter indication was higher than 30 amperes, possible causes include the following: A. The motor terminal is in contact with the field frame. B. A damaged bearing that will not let the armature turn.

4. If the armature did not turn, and the ammeter indication was zero amperes, possible causes include the following: A. An open field coil. B. An open armature coil. After the motor is disassembled, look at the commutator on the armature. If the commutator is badly burned, the armature coil is probably open. C. Broken brush springs or worn brush springs. 5. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was less than 30 amperes, possible causes include the following: A. Bad connections between the brushes and the field coil. B. Dirty commutator. 6. If the armature speed was 6950 r/min (rpm) or more and the ammeter indication was more than 30 amperes, there is probably a short circuit in the field coil. A short circuit in the field coil is difficult to find. It is recommended that a new field frame assembly be installed.

5002-7

STEERING RELIEF VALVE NOTE: The pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and Adjusting the Pump Differential Pressure.

Pressure Setting Test

1 1 BD03A092 BD03A092

1. SAFETY LINK

1. Install the safety link (1) and lower the loader arms slowly, until the safety link is supporting the loader arms.

1. SAFETY LINK

3. Remove the safety link (1) and lower the loader arms to the ground. 4. Stop the engine.

1 1 BD00M030 BD00M041

1. ARTICULATION LOCK

1. COVER PLATE

5. Install articulation lock (1). 2. Remove the cover plate (1) to gain access to the loader control valve.

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.

5002-8 6. Make sure that the temperature of the hydraulic oil is at least 52° C (125° F). 7. To measure the temperature of the oil using the instrument panel: A. Press the program switch (left side of the program/reset switch). B. Press the up count switch to function 008. C. Return the program switch to the OFF (center) position. 8. Apply the parking brake.

1 2

9. Start and run the engine at full throttle. 10. Hold the bucket control lever in the rollback position. 11. Hold the lift lever in the “FLOAT” position. 12. Continue holding until the specified temperature of the oil is reached. 13. Stop the engine. 14. Remove the cap on the hydraulic reservoir to release any pressure in the hydraulic system.

BD00N018

1. LOADER CONTROL VALVE 2. PUMP PRESSURE TEST PORT

15. Remove the dust cap from the test port (2). 16. Connect a 345 bar (5000 psi) pressure gauge to the test port (2) on the front of the loader control valve (1). 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. 17. Start the engine and operate the machine at full throttle. 18. With the articulation lock still in place, turn and hold the steering wheel for a hard right turn. 19. Continue holding the steering wheel, and read the pressure gauge. 20. The pressure gauge must indicate 239 to 243 bar (3465 to 3523 psi). If the pressure is not correct, adjust the steering relief valve.

5002-9

Pressure Setting Adjustment

1 1 BD03A092 BD03A092

1. SAFETY LINK

1. Install the safety link (1) before adjusting the steering relief valve.

1. SAFETY LINK

3. Remove the safety link (1), and lower the loader arms to the ground. 4. If the pressure gauge is still connected, repeat steps 17 through 20 in the Pressure Setting Test Procedure. If the pressure gauge is not connected, do the entire Pressure Setting Test Procedure. 5. If necessary, adjust the relief valve again until the relief valve is within the specified range. 6. Stop the engine before removing the pressure gauge.

2 1 BS01A046

1. LOADER CONTROL VALVE 2. STEERING RELIEF VALVE

2. Turn the adjusting screw clockwise to increase the pressure setting. Turn the adjusting screw counterclockwise to decrease the pressure setting. NOTE: 1/4 turn of the adjusting screw will change the pressure by approximately 35 bar (500 psi).

5002-10

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.

Section 5006

5006

CENTER PIVOT

5005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 5

5005-3

SPECIFICATIONS Torque for piston cap screw...........................................................................585 to 720 Nm (431 to 531 pound-feet) Torque for gland.............................................................................................339 to 475 Nm (250 to 350 pound-feet)

STEERING CYLINDER Disassembly

Inspection

1. Fasten the tube (1) in a vise. Be careful not to damage the tube (1). Refer to the illustration on page 4.

1. Discard the O-ring (6), backup ring (7), seal (4), seal (5), wiper (9), and guide (8) from the gland (3). Refer to the illustration on page 4.

2. Loosen and remove the gland (3) from the tube (1).

2. Discard the seal (12), backup ring (13), and wear ring (14) that were removed from the piston (11).

3. Pull the piston (11) straight out of the tube (1).

3. Clean all parts in cleaning solvent.

4. Fasten the yoke on the piston rod (10) in the vise and put a support below the piston rod (10) near the piston (11). Use a shop cloth between the suppor t and the piston rod (10) to prevent damage to the piston rod (10).

4. Check to be sure that the piston rod (10) is straight. If the piston rod (10) is bent, install a new piston rod (10).

5. Loosen and remove the bolt (15) that hold the piston (11). 6. Remove the piston (11) from the piston rod (10). 7. Remove the seal (12), backup ring (13), and wear ring (14) from the piston (11). 8. Remove the gland (3) from the piston rod (10). 9. Remove the O-ring (6), backup ring (7), seal (4), seal (5), wiper (9), and guide (8) from the gland (3).

5. Inspect the inside of the tube (1) for deep grooves and other damage. If there is any damage to the tube (1), a new tube (1) must be used. 6. Remove small scratches on the piston rod (10) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion. 7. Inspect the bushings (2) and replace as required.

5005-4

9 4 5 3 7 6 8 11 12 13 14 15 1

BS01B202

5005-5 1. 2. 3. 4. 5. 6.

TUBE BUSHING GLAND SEAL SEAL O-RING

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

BACKUP RING GUIDE WIPER PISTON ROD PISTON SEAL

13. 14. 15. 16.

BACKUP RING WEAR RING BOLT REMOTE GREASE HOSE FITTING

STEERING CYLINDER ILLUSTRATION

Assembly 1. Install the seal (4) in the gland (3). The seal (4) must be installed so that the lips of the seal (4) are toward the small end of the gland (3). The seal (4) can be difficult to install. Use tools that will not damage the seal (4). Refer to the illustration on page 4.

12. Install a new backup ring (13) on the piston (11). 13. Install a new seal (12) over the backup ring (13).

3. Install the guide (8) in the gland (3).

14. Clean the threads on the end of the piston rod (10) and the threads of the bolt (15) using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to the piston rod threads 1/4 inch from the open end of the piston rod so that there is 1/2 inch of Loctite 242 on the piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads.

4. Install the wiper (9) in the gland (3).

15. Install the bolt (15) in the piston (11).

5. Install the O-ring (6) on the gland (3). The O-ring (6) must be toward the small end of the gland (3).

16. Install the piston (11) on the piston rod (10) and start the bolt (15) into the piston rod (10).

6. Install the backup ring (7) on the gland (3). The backup ring (7) must be toward the large end of the gland (3). If the backup ring (7) is not flat on both sides, the side that is not flat must be toward the O-ring (6).

17. Tighten the bolt (15) according to torque specifications listed on page 2.

7. Fasten the yoke on the piston rod (10) in the vise.

19. Apply petroleum jelly to the O-ring (6) and backup ring (7) on the gland (3) and to the sealing surface in the tube (1).

2. Install the seal (5) in the gland (3).

8. Lubricate the piston rod (10) and the bore in the gland (3) with clean hydraulic oil. NOTE: If a new gland (3) is being installed, write the part number of the cylinder on the gland (3). 9. Push the gland (3) onto the piston rod (10). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (10). 10. Put the support below and near the end of the piston rod (10). Put a cloth between the support and the piston rod (10) to prevent damage to the piston rod (10). 11. Install a new wear ring (14) on the piston (11).

18. Fasten the tube (1) in the vise. Be careful not to damage the tube (1).

20. Lubricate the piston (11) and the inside of the tube (1) with clean hydraulic oil. 21. Push the piston (11) straight into the tube (1). Be careful not to damage the wear ring (14) and seal (12) on the piston (11). 22. When the piston (11) is in the smooth part of the tube (1), start the gland (3) into the tube (1). 23. Tighten the gland (3) to 339 to 475 Nm (250 to 350 pound-feet).

5005-6

NOTES

Section 5006

5006

CENTER PIVOT

5006-2

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 .........................................................................New Holland AMBRA GR 75 MD grease Steering cylinder rod eyes.......................................................................New Holland AMBRA GR 75 MD grease FLUIDS Hydraulic system reservoir .................................................................New Holland AMBRA Hydrosystem 46HVÂ®

SPECIAL TOOLS 380001730....................................................................................................................... Hand pump (hydraulic ram) 380001734....................................................................................................................................... 10 ton ram (long) 380001735........................................................................................................... Puller set, includes 24827 leg ends 380001736................................................................................ Bearing cup and seal puller, includes 24850 adapter 380001729.............................................................................................................................. Vacuum pump (12 volt) 380001744................................................................................. *Top bearing driver, bottom bearing driver and plate * (Requires screw, two nuts, and two washers from 380001735)

BC06A174

380001744 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 (18), washer (17), and spacer (16) that fasten the upper pivot pin (15) to the rear chassis (5).

13. Disconnect the hoses for the steering cylinder.

31. Use a prybar to remove the upper pivot pin (15).

14. Install caps on the fittings and plugs in the hoses.

32. Loosen and remove the bolts (31-32) and washers (30-6) that fasten the lower pin plate (22) 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 (7) and washers (6) that fasten the lower pin plate (3) 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 (4), see Special Tools in this section.

5006-5

18 17

16 5 UPPER REAR CHASSIS ARTICULATION PLATE

14 13

6 33 12 25 26 24 2

LOWER UPPER REAR CHASSIS ARTICULATION PLATE

FRONT CHASSIS

1 28 29 27 3

UPPER LOWER REAR CHASSIS ARTICULATION PLATE

33 5

7 19 20 21 6

31 34

30 W110R559

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

BEARING LOWER PIVOT BEARING UPPER PIVOT RETAINER, LOWER PIVOT SPACER, LOWER BEARING SEAL LOWER WASHER 13.5X24X3 mm

10. 11. 12. 13. 14. 15.

PIN, LOWER PIVOT SEAL UPPER, LOWER RETAINER UPPER PIVOT SEAL UPPER BOLT M12X1.75X80 PIN/W UPPER PIVOT

19. 20. 21. 22. 23. 24.

SHIM PIVOT CHASSIS (0.25) 28. SHIM PIVOT CHASSIS (0.1) 29. SHIM PIVOT CHASSIS (0.5) 30. PLATE LOWER PIN ZINC PLATE31. BOLT M12X30 SHIM UPPER PIVOT (0.1) 33.

7. BOLT M12X100 16. SPACER 25. SHIM UPPER PIVOT (0.5) 8. SPACER, LOWER BEARING 17. WASHER 0.656 X2.5X0.18 in 26. SHIM UPPER PIVOT (0.25) 9. SEAL LOWER, UPPER 18. BOLT M16X35 27. SHIM LOWER PIVOT (0.5) CENTER PIVOT ASSEMBLY

SHIM LOWER PIVOT (0.25) SHIM LOWER PIVOT (0.1) WASHER 17.5X30X4 mm SCREW M16X70

FITTING, LUBE 1/8-27 DRYSEAL PTF 34. ADHESIVE LOCTITE 243

5006-6 36. Remove the bottom spacer (4). 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 (3) in place and loosen and remove the bolts (7) and washers (6) that fasten the bear ing retainer (3) and shims (27-28-29) to the bottom of the rear pivot.

41. Remove the bearing retainer (3) and shims (27-28-29). 42. Remove the lower bearing spacer (8) from the top of the lower pivot. 43. Loosen and remove the bolts (14) and washers (6) that fasten the bearing retainer (12) and shims (24-25-26) to the top of the top pivot. 44. Remove the bearing retainer (12) and shims (24-25-26). 45. Use the puller to remove the seal (11) from the top of the bottom pivot. 46. Use the puller to remove the seal (11) 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 (2) 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 (1) 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. 49. Use an acceptable driver to press the seals (13-5) out of each bearing retainer (12 and 3).

20 21

22 BC06A118

35. BEARING DRIVER 36. NUT 37. SCREW

38. BEARING CUP 39. PLATE 40. 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).

19 26

22 BC06A119

41. BEARING CONE 42. SPACER

43. BEARING CONE 44. BEARING CUP

5006-7 9. Put the bearing retainer (7) in place on the upper pivot bearing assembly (9). 10. Install the bearing driver (17) and plate (21). 11. Tighten a nut (18) on the screw (19) until the bearing retainer (7) is tight against the upper pivot bearing assembly (9).

18. Use an acceptable driver to install the seal (6) in the bottom of the top pivot. 19. The bottom of the seal (6) must be even with the bottom of the top pivot.

BC06A125

20. Apply grease to the upper pivot pin (4). BC06A120

12. Measure the gap (27) between the bearing retainer (7) and the top pivot (22). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 13. Remove the bearing driver (17), plate (21), and bearing retainer (7) from the top pivot. 14. Install the shims (8) and the bearing retainer (7). 15. Install the washers (2) and M12 bolts (1). Apply one drop of 15W40 engine oil to each bolt and immediately torque the M12 bolts (1) to 124 - 132 Nm (91 - 97 pound-feet).

21. Install the upper pivot pin (4) in the top pivot. 22. Lubricate the top pivot until grease is forced out of the seal (6). 23. Rotate the upper pivot pin (4) to check the bearing assembly. The upper pivot pin (4) must rotate smoothly, but not easily. Leave the upper pivot pin (4) in place to keep dirt out of the upper pivot bearing (9). 24. Lubricate the bore for the bottom pivot with grease. Install a bearing cup in the bottom pivot. 25. Install the bearing driver (17) and plate (21).

16. Install the seal (6) in the bearing retainer (7). The top of the seal (6) must be even with the top of the bearing retainer (7).

19 18 28 29

17 BC06A123

26. Tighten a nut (18) on the screw (19) until the bearing cup (28) is seated in the bore in the bottom pivot (29). BC06A121

17. Fill the other seal (6) for the top pivot with grease.

27. Remove the bearing driver (17) and plate (21) from the bottom pivot (29).

5006-8 28. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the bottom pivot (29).

38. Apply one drop of 15W40 engine oil to each bolt and immediately torque the M12 bolts (1) to 124 132 Nm (91 - 97 pound-feet).

29. Install the bearing driver (17) and plate (21).

39. Fill the seal (6) for the bearing retainer (13) with grease.

40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13).

24 29

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). 32. Put the bearing retainer (13) in place on the lower pivot bearing (12).

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.

33. Install the bearing driver and plate.

19 29 30

BC06A121

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 M12 bolts (1).

42. Install the lower bearing spacer (11) and the bottom spacer (14). 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. 4. Apply the parking brake. 5. Apply grease to the upper pivot pin (4). 6. Install the upper pivot pin (4), spacer (3), washer (2) and M16 bolt (1). Be careful not to damage the seal (6). 7. Apply one drop of 15W40 engine oil to the bolt and immediately torque the M16 bolt (1) to 224 278 Nm (165 - 205 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. 11. Install the lower pin plate (15), three inner M12 bolts (1), and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10). 12. Apply one drop of 15W40 engine oil to the bolts and immediately torque the M12 bolts (1) to 69 Nm (51 pound-feet). 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.

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. 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. 29. Start the vacuum pump. 30. Connect the return hose. 31. Connect the supply hose. 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. 36. Connect the brake hose for the front brakes at the front bracket. 37. Stop the vacuum pump. 38. Connect the front wiring harness to the rear wiring harness. 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. Apply one drop of 15W40 engine oil to the bolts and immediately torque the six outer M12 bolts (1) to 124 to 132 Nm (91 to 97 pound-feet).

42. Disconnect the vacuum pump from the hydraulic reservoir.

18. Tighten the three inner bolts (1) to 124 to 132 Nm (91 to 97 pound-feet). 19. Remove the jacks from the rear frame. 20. Remove the blocks from the rear axle. 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).

43. Check the fluid level in the hydraulic reservoir. Add oil as required. 44. Install the fill cap in the hydraulic reservoir. 45. Bleed air from the front axle bleed screws. Refer to Section 7002 for complete brake bleeding instructions. 46. Lubricate the pivot pins for the steering cylinder rod eyes. 47. Install the covers on both sides of the machine.

5006-10

NOTES

Section 5008

5008

AUXILIARY STEERING MOTOR AND PUMP

5008-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 4 4

5008-3

SPECIFICATIONS Auxiliary steering motor Maximum amperes...............................................................................................................................30 amperes Minimum armature speed ............................................................................................................ 6950 r/min (rpm) Motor ...........................................................................................................................................................24 volts Auxiliary steering pump Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes (6.5 U.S. gpm at 1500 psi at 315 amperes)

5008-4

AUXILIARY STEERING MOTOR AND PUMP Disassembly

Assembly

NOTE: Refer to Section 5001 for removal and installation of the auxiliary steering motor and pump.

1. Lubricate all parts with clean hydraulic oil before assembly.

NOTE: The pump is the only component that is disassembled. The switch (8) and motor (1) are replaced as units and are not serviced. Refer to the illustration on page 5.

2. Lubricate and install a new seal (4) and retaining ring (3) on the plate (17). Refer to the illustration on page 5.

1. Make an alignment mark on the pump assembly and motor (1). 2. Loosen and remove the two screws (15) and lock washers (14) that hold the pump assembly to the motor (1). 3. Remove and discard the mounting gasket (13), retaining ring (3) and seal (4) from the pump assembly. 4. Loosen and remove the four bolts (2) that hold the pump assembly together. 5. Remove the end plate (21) from the body (18). 6. Remove and discard the seal (6) and backup ring (5) from the end plate (21). 7. Remove the wear plate (23), drive gear (20) and driven gear (19) from the body (18). 8. Remove the body (18) from the plate (17). 9. Remove and discard the O-rings (7) from the body (18). 10. Remove the pins (22) and wear plate (23) from the body (18). 11. Remove and discard the seal (6) and backup ring (5) from the plate (17). NOTE: The only serviceable items on the pump assembly are the seals (6), backup rings (5), O-rings (7), seal (4), retaining ring (3) and gasket (13). If any of the other items are damaged, replace the pump assembly.

Inspection 1. Inspect the wear plates (23) for grooves, scoring and pitting. If damage is found replace the pump assembly. Refer to the illustration on page 5. 2. Inspect the drive gear (20) and driven gear (19). If the shafts are worn or damaged, replace the pump assembly. 3. Clean all parts in cleaning solvent and air dry. 4. Inspect the plate (17), end plate (21) and body (18). Replace the pump assembly as necessary.

3. Lubricate and install a new backup ring (5) and a new seal (6) on the plate (17). 4. Lubricate and install new O-rings (7) on the body (18). 5. Lubricate and install the pins (22), drive gear (20), driven gear (19) and wear plates (23) on the body (18). 6. Lubricate and install a new backup ring (5) and a new seal (6) on the end plate (21). 7. Align the marks, made during disassembly, on the end plate (21), body (18) and plate (17) and install the four bolts (2). Tighten the four bolts (2). 8. Install a new gasket (13) on the pump assembly. 9. Align the marks, made during disassembly, on the pump assembly and the motor (1). 10. Install the lock washer (14) and screw (15). Torque the screw (15) to 35 to 39 Nm (312 to 348 pound-inches).

5008-5

11 16

1 13 3

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

5009 Section 5009 JOYSTICK STEERING SYSTEM (JSS) (optional)

5009-2

INDEX SAFETY RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 JOYSTICK STEERING SYSTEM (JSS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Activation logic of the software and joystick steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Preliminary check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 System efficiency check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3rd F-N-R SWITCH ON THE ARMREST (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PROCEDURES FOR TURNING ON / OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Procedure for activating the main F-N-R lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Procedure for activating the auxiliary F-N-R JSS (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turning JSS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turning JSS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turning ON auxiliary F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turning OFF auxiliary F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 KICK-DOWN BUTTON TO SELECT A LOWER GEAR (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ERROR CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STEERING VALVES PVG32 and PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 JSS HYDRAULIC PRESSURE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 STEERING SPEED CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5009-3

SAFETY RULES For all the safety measures, refer to the use and maintenance book supplied together with this manual. WARNING: this symbol is used to draw attention to the safety instructions given in the manual. When found in the text, carefully read the accompanying message and pay attention to the risk of serious or deadly accidents. M171C

WARNING: when the unit is running and the Joystick Steering control has been activated, to avoid serious or deadly accidents pay particular attention to sudden movements in the cab.

WARNING: make sure that the Joystick Steering control has been turned off during the operations of raising and lowering the unit from the trailer loading deck. The unit could fall off the ramp or off the trailer and cause serious or deadly accidents. It is absolutely forbidden to use the Joystick Steering control for these operations.

WARNING: when the Joystick Steering system is active and the operator presses the equipment locking switch, the Joystick Steering function will be active.

WARNING: the function of the Joystick steering control is forbidden when driving on roads.

WARNING: the emergency steering system always comes into operation via the main steering system.

WARNING: the main steering system is always active and is considered the normal steering system. Regular use of the Joystick Steering is allowed within 20 km/h and this limit depends on the actual conditions of the ground being worked on.

WARNING: before starting to drive on the public roads, lock the LH armrest in the vertical position with the special pin.

5009-4

JOYSTICK STEERING SYSTEM (JSS) Description of the JSS The JSS is mounted in parallel with the standard steering system, that always has priority, increasing the comfort and the functionality of the unit. The main components of the JSS are: - proportional valve PVG32 with pilot solenoid valve incorporated;

When driving on roads, the JSS must be disconnected A specific procedure avoids accidental steering and turning ON/OFF, allowing for safe turning ON and OFF (as indicated in the Use and Maintenance Manual).

- compensation valve PVFC for the pressures from the proportional valve PVG32 and from the power steering valve; - pressure switch LS connected to the line from the power steering to detect use of the standard steering: normally closed (N/C) switch, it opens at 60 bar; - pilot pressure switch connected to the proportional valve PVG32 to detect whether the pilot solenoid valve is working/defective: normally closed (N/C) switch, it opens at 8 bar; - joystick (1) controlling the proportional valve incorporated in the left armrest (2); - position switch incorporated in the left armrest with double contact: 1. up = NC (normally closed); 2. down = NO (normally open); - three-position switch (3) to control the JSS: 1. OFF – stop with mechanical lock; 2. ON – stop; 3. activation – transient position (tripping);

5 2

- relay K2 for JSS power supply; - set of diodes to combine the JSS control button and the AUX F-N-R enabling button in safety; - Can Module that incorporates the JSS activation procedure and the software for monitoring the system; - modulation controller of the electric signal between the joystick and proportional valve; - left-hand F-N-R switch (4) on the armrest (2); - Kick-Down left-hand button (5) on the armrest (2). The joystick steering gear is available only on request. The type of terrain determines the operating speed for this system.

521E-4R001

5009-5

Activation logic of the software and joystick steering

- the proportional valve suffers trouble;

To enable the joystick steering system it is necessary first of all to put the unit in a safe condition and then activate the JSS with the control button. On sending the JSS activation signal the software runs a preliminary test to verify whether the unit is in a condition of safety. Secondarily it checks the efficiency of the system.

- the JSS switch is disconnected;

Preliminary check The condition of the unit being made safe is given by: - left armrest completely lowered; - gear lever in neutral; - equipment locking switch disenabled; - pilot pressure switch on; - joystick steering switch in neutral; - unit stationary.

System efficiency check - with the JSS off, the pilot pressure must be less than or equal to 8 bar; - the software monitors the armrest position switch. When the JSS is turned on and during the whole time it stays on, the commutation of the N/O-N/C switch is checked. Any trouble is detected with an error message and the system is switched off; After all the prerequisites have been satisfied, the JSS will be powered by closing PIN 1:21 of the output AIC LSD1 that switches over the relay K2 enabling the electric supply of the JSS with consequent activation of the system under safety conditions. Once the supply is made, the system verifies that the alarm signal of the valve of the JSS is = 0 and that on the joystick supply PIN the signal is = 1. After activation the system stays in operation for the whole time in which: - 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: - the left armrest is raised; - the gearbox / main lever control is moved from neutral to forward or reverse drive; - the steering wheel is operated;

- system errors occur;

- ignition turned off. A slight audible warning and a message on the display warn that the JSS has been disconnected. To switch the JSS back on after disconnection, follow the system activation procedure. The errors related to the JSS are only displayed with the JSS switch in the ON position and they can be reset by moving the JSS switch onto OFF.

5009-6

3rd F-N-R SWITCH ON THE ARMREST (left-hand side) For the joystick steering system it is necessary to integrate a third F-N-R switch in the current operating logic of the gearbox. For this purpose the software of the control unit of the transmission (TCU) is able to turn the F-N-R switch on the armrest ON/OFF when the JSS is activated. It is therefore necessary for the TCU control unit to generate a new CAN message stating JSS F-N-R enabled/disenabled. The software in the transmission control unit (TCU) has to be compatible with systems with and without the joystick steering system. This means that all the current TCU functions will remain unchanged.

Position of the F-N-R switches in the cab 1. Main F-N-R (current) located on the gear lever of the steering column; 2. AUX F-N-R (current) incorporated on the e q u i p m e n t c o n t r o l j oy s t i ck ( o r c o n s o l e o n right-hand side); 3. AUX JSS F-N-R (new) incorporated on the armrest on the left-hand side.

PROCEDURES FOR TURNING ON / OFF Among the three F-N-R activation devices, the one on the gear lever of the steering column has priority over the other two auxiliary ones, which must be enabled, each one with a specific enabling signal and according to a specific activation procedure. If enabled, the JSS F-N-R auxiliary switch located on the left-hand side armrest has priority over the F-N-R auxiliary switch on the right. Main F-N-R lever activation procedure - The main F-N-R lever on the steering column is always active; - the main F-N-R switch has priority over all the other auxiliary F-N-R switches; - one of the auxiliary F-N-R switches can be enabled only if the main switch is in neutral. Activation procedure for auxiliary JSS F-N-R (left-hand side) The auxiliary JSS F-N-R switch is incorporated in the armrest on the left-hand side that is an integral part of the JSS: - the auxiliary 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 gearbox control unit; - this will cause activation of the auxiliary JSS switch as well as starting the JSS F-N-R enabling procedure;

- in order to enable the auxiliary JSS switch, it is necessary to check the position of the switch; - if the auxiliary JSS F-N-R switch is in neutral, enabling will take place directly; - if the auxiliary JSS F-N-R switch is not in neutral, enabling will not take place directly, but the software will check the status of the JSS F-N-R switch. Indeed, only at the moment when the JSS F-N-R switch is in the neutral position will its enabling be confirmed (without pressing the JSS activation switch again); during activation of the JSS a message is sent via CAN stating “JSS ON”; - the auxiliary JSS F-N-R switch is disenabled when the JSS is disenabled; - when turning off the JSS a message is sent via CAN stating “JSS OFF”. Turning JSS ON - Press the JSS system ON button: a. armrest on left-hand side lowered; b. equipment locking switch disenabled; c. low JSS piloting pressure; d. JSS joystick in neutral; e. no error in the JSS; f. main F-N-R gear control lever in neutral; g. vehicle stationary (speed less than or equal to 1.5 km/h). Turning JSS OFF 1. Using the steering wheel; 2. gear lever on the steering column / main F-N-R switch not in neutral; 3. armrest on left-hand side lowered; 4. JSS enabling button OFF; 5. errors in the JSS system; 6. engine OFF.

5009-7 Turning on auxiliary F-N-R The auxiliary F-N-R switch is on the console on the right-hand side. If the unit is provided with an equipment control joystick, the auxiliary F-N-R switch is incorporated on the joystick: - if the JSS is ON, JSS F-N-R is enabled and auxiliary F-N-R cannot be enabled; - if the JSS is OFF, the activation procedure remains unchanged, and that is: â&#x20AC;˘ press the auxiliary F-N-R momentary enabling switch; a. main F-N-R on the steering column in neutral; b. auxiliary F-N-R switch in neutral; c. unit stationary; d. engine ON; â&#x20AC;˘ auxiliary F-N-R provides enabling signal for 8 seconds; a. within 8 seconds: 1. press the parking brake release button; 2. engage the forward or reverse drive; 3. permanent enabling signal for auxiliary F-N-R; b. after 8 seconds: 1. auxiliary F-N-R is disenabled. Turning off auxiliary F-N-R - gear lever on the steering column / main F-N-R switch not in neutral; - parking brake engaged; - engine OFF.

KICK-DOWN BUTTON TO SELECT A LOWER GEAR (left-hand side) Besides the current button to select a lower gear on the equipment control joystick (or on the console on the right-hand side according to the option), a second button will be available to select a lower gear incorporated in the left armrest with the joystick steering system. This button will be activated together with the JSS and it will disenable the button on the right-hand side to select a lower gear.

5009-8

Summary table of the ON/OFF statuses The following table illustrates the states of activation of the JSS, JSS F-N-R and auxiliary F-N-R:

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

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



Starting status

     

Equipment locking switch disabled; Armrest on left-hand side lowered; Vehicle stationary; Main F-N-R gear lever = neutral; JSS pilot pressure less than 8 bar; JSS Joystick = neutral; No errors on JSS system.

     

Equipment locking switch disenabled; Armrest on left-hand side lowered; Vehicle stationary; Main F-N-R gear lever = neutral; JSS pilot pressure less than 8 bar; JSS Joystick = neutral; No errors on JSS system.

Resulting JSS status

JSS ON

JSS OFF

JSS ON

F-N-R conditions

 JSS ON  JSS F-N-R = neutral.

 

Vehicle stationary; Main F-N-R gear lever = neutral; AUX F-N-R = neutral.

 

AUX F-N-R Enabled within 8 seconds release parking brake and engage F or R to maintain enabling.



 JSS F-N-R Enabled Stays enabled.

JSS F-N-R Enabled Stays enabled.

Resulting F-N-R status

 

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.

 



Vehicle stationary Main F-N-R gear lever = neutral; AUX F-N-R = neutral. JSS F-N-R Enabled

5009-9

ERROR CODES The errors related to the JSS will only be displayed if the activation switch of this system is in the ON position. All the errors will be reset by turning the activation switch of the JSS into the OFF position except for the following errors: - error 1821r Power Supply Failure JSS active - error 1830y Activation Switch failure. These errors will always be shown on the display once they are present. To delete this type of error it is necessary to turn off the engine. Error codes table Error Item

Error

Message

1812y

JSS Failure Armrest Switch

1816y

JSS Activation Button Failure

1820y

JSS Power Supply Failure

1821r

JSS Power Supply Failure JSS Active

1823y

JSS Relais Grd Failure

1824y

JSS Activation Switch Short to Battery

1830y

JSS Activation Switch failure

1831y

JSS Error JSC

1832y

JSS Signal Input Error JSC

1833y

JSS Signal Output Error JSC

1835y

JSS Valve Failure Power Supply

1841y

JSS Valve Alarm

1842y

JSS Valve Alarm Open Circuit

1843y

JSS Pilot Pressure is High

1844y

JSS Pilot Pressure Switch Short to Ground

1845y

JSS Pilot Pressure is Low

1846y

JSS Failure on LS Pressure Switch

1850y

JSS Joystick Failure Neutral Switch / Power Supply

1852y

JSS Error in Ground Connection

9134y

JSS CAN communication failed

9135y

JSS CAN communication failed

Message

JSS Deactivated

Message

JSS Release Activation Button

Message

JSS Deactivated (Soft Beep)

5009-10

OPERATING PRINCIPLE The main components of the JOYSTICK STEERING SYSTEM are: - hydraulic valves ? proportional steering valve PVG32 (1) for activating the steering cylinders with an incorporated pilot solenoid valve (2); ? valve PVFC (3) that controls the LS signals from the proportional valve PVG32 (1) and from the power steering valve (4) and transmits them to the pump (5) to allow correct operation; - two-way PVRES control joystick that sends the signal to the pilot solenoid valve (2) located inside the proportional valve PVG32 (1); - modulation controller (7) of the electric signal between the joystick (10) and proportional valve (1); - F-N-R switch (12) on the armrest on the left-hand side; - Kick-Down button (13) on the left-hand armrest; - F-N-R switch (14) on console on right-hand side; - Kick-Down button (15) on equipment control Joystick on right-hand side. The JSS is controlled by a switch (8) located on the control panel, which checks, via software loaded on a component (9) installed inside the armrest, that all the necessary safety conditions for correct operation of the system are in place. These conditions must be: a. left armrest completely lowered; b. gear lever in neutral; c. equipment locking switch disenabled; d. pilot pressure sensor closed; e. JSS switch (8) in neutral; f. unit stationary. If not even one of these conditions occurs, the software will not allow activation of the system. The software will allow the operation of the joystick that activates the pilot solenoid valve (2) located inside the proportional valve PVG32 (1), via an electric signal, only after it has received all the information and has confirmed that the general situation is correct. The actuator inside the electric module (6) of the proportional valve of the steering gear (1) starts the directional shuttle, which allows the oil to flow to the line of the steering cylinder. Through the pilot pressure switch of the valve PVG32 (1), the software verifies that the oil pressure is correct for the operation of the joystick (10).

When using the JSS, if a manoeuvre is made with the steering wheel, the pressure switch LS (11), located on the LS line of the power steering valve (4) receives enough pressure to switch over and therefore to turn off the JSS. IT IS IMPORTANT to remember that, for reasons of safety, the joystick (10) must be turned off for driving on roads. Use of the joystick can be disenabled at any time by the operator with the steering wheel, which has priority over the joystick. In addition, it is absolutely prohibited to use the JSS during the operations of loading and unloading the unit on and off a truck for transport. For signalling any JSS malfunction, the control panel is provided with warning lights accompanied by audible warnings of two different lengths, depending on the trouble that has occurred.

5009-11

7 13 9 12

11 6

15 3

14 2

5 W190-4R090

5009-12

7 13 9 12

11 15

6 3

2 14

5 W190-4R098

2 210 bar

1 211.6 bar

3 210 bar

5009-13

W190-4R091

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 Illustration of the valve PVFC

T LS

5009-14

W190-4R092

Connections ports A and B. to the steering cylinder on the stem side and bottom side 350 bar, 65 l/min LS port. to port 3 of the valve PVFC port P. to the steering priority valve 350 bar, 65 l/min

port PP. port T. port T2. port TO LX.

Illustration of the valve PVG32

pilot pressure switch 8 bar outlet 25/40 bar not used not used

5009-15

W190-4R099

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

Valve PVPV Valve PVM Valve PVB Shuttle PVBS Valve PVES Shuttle PVSI

7. 8. 9. 10. 11.

Screws Seal Seal Seal Seal

Exploded view of the valve PVG32

5009-16 W190-4R093

5.7 Nm

1.7 Nm

5.7 Nm

+/Vbat Signal SW1 +/SW2

1 3

PVE E

Illustration of the Joystick Steering PVRES

5009-17

ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM Removal

STEP 3

STEP 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. Remove all dirt and grease from the steering system valves and adjacent area. IMPORTANT: MARK and LABEL all the various parts (electric connections, hydraulic connections, etc..) so as to facilitate all the various operations of INSTALLATION.

STEP 2 9 1

10 W110R358

3 2

4 5 7

6 8 W110R357

Disconnect the chassis frame cable (1) from the valve PVG32 (2), the connection (3) from the pilot pressure switch at 8 bar, the four-way “DEUTSCH” connection (4) of the electr ic actuator of the pr op or tional valve, the two-way “DEUTSCH” connection (5) of the solenoid valve. From the valve PVFC (6) disconnect the connection (7) from the 60 bar pressure switch and release the connection by removing the strap (8).

Remove nut (11) to release the chassis frame cable (1) from the stud pin (9) positioned on the rear chassis frame (10) of the unit.

5009-18

STEP 4

STEP 5

3 1

W190-4R073

W190-4R074

Open the door from the right-hand side of the unit, u n d e r t h e c a b, t o a c c e s s t h e f u s e a n d r e l ay compar tment and disconnect the ten-position “PACKARD” interface connector of the chassis frame cable (1) with the connector of the cab/joystick cable (2). Remove the chassis frame cable (1).

Disconnect the cab/joystick cable (2) from the cab wiring (3) by disconnecting the twelve-position “DEUTSCH” connector (4).

5009-19

STEP 6

STEP 8

10 4

9 5 12

2 11 W190-4R075

Disconnect the twelve-position “DEUTSCH” interface connector (1) of the cab/joystick cable (2) with the armrest cable (3) and the six-position connector (4).

STEP 7 5

7 8

W190-4R076

Disconnect the cab/joystick cable (2) from the s t ee r in g c o n tr ol dev i c e (5 ) by de t ac h i ng t he sixteen-position connector (6), the six-position “DEUTSCH” connector (7) of the transmission switch and the cab cable connector (8).

W190-4R077

Remove the steering control device (5) from the supporting plate (9) by removing the nut (10, qty. 3), and the screw (11) complete with washer (12).

5009-20

STEP 9

STEP 10 6

1 5

W190-4R078

Detach the cab/joystick cable (1) from the fixing points on the fuse and relay panel (2) by removing the two five-position connectors (3), unscrewing the nuts (4, total qty. 2), washers (5) and screws (6). Remove the cab / joystick cable (1).

W190-4R079

Disconnect the two 24-volt relays (7) and the four diodes (8) from the respective connectors of the cab / joystick cable (1).

STEP 11

W190-4R080

To remove the armrest cable (9), refer to the chapter titled “JOYSTICK STEERING ARMREST”.

5009-21

8 14 C 20

12 11 10

27 15

Detail B view from C

D 1 26

21 2

30 24

22 7

View from C

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Detail D view from E

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

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Control joystick 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

W110R359

ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM

5009-22

21 27

29 8

22 28

24 25 16 23

W190-4R097

WIRING DIAGRAM OF THE JOYSTICK STEERING SYSTEM

5009-23

Installation

STEP 13

STEP 12

3 2

4 5 7

10 W110R358

Fasten the chassis frame cable (1) to the stud pin (9) positioned on the rear chassis frame (10) of the unit by installing the nut (11).

6 8

STEP 14 W110R357

Connect the chassis frame cable (1) to the valve PVG32 (2), the connection (3) of the pilot pressure switch at 8 bar, the four-way “DEUTSCH” connection (4) of the electric actuator of the proportional valve, the two-way “DEUTSCH” connection (5) of the solenoid valve. Tie the connection (7) of the 60 bar pressure switch to the valve PVFC (6) and secure the connection by inserting the strap (8) on one of the two fixing screws of the valve.

12 14 13 16 15 W190-4R083

Open the door providing access to the fuse and relay compartment from the right-hand side of the unit, under the cab, and install the steering control device (12) on the supporting plate (13) by installing the nut (14, qty. 3), and the screw (15) complete with washer (16).

5009-24

STEP 15

STEP 17 2 12

9 10

8 1 3

1 W190-4R085 W190-4R100

Connect the two 24-volt relays (2) and the four diodes (3) to the respective connectors of the cab / joystick cable (1).

Fasten the cab/joystick cable (1) via the connectors (8) to the fixing points on the fuse and relay panel (9) by installing the nuts (10, qty. 2), washers (11) and screws (12).

STEP 18

STEP 16 4

6 13 1

W190-4R086

Connect the cab/joystick cable (1) to the cab cable (13) via the twelve-position “DEUTSCH” connector (14). W190-4R084

Connect the cab/joystick cable (1) to the steering control device (4) via the sixteen-position connector (5). Connect the six-position “DEUTSCH” connector (6) of the transmission button and the cab cable connector (7).

5009-25

STEP 19

STEP 21

2 W190-4R073

W190-4R087

Connect the ten-position “PACKARD” interface connector of the chassis frame cable (1) with the connector of the cab/joystick cable (2).

Connect the twelve-position “DEUTSCH” interface connector (4) of the cab/joystick cable (2) with the armrest cable (3) and the six-position connector (5).

STEP 20

W190-4R082

To install the armrest cable (3), refer to the chapter titled “JOYSTICK STEERING ARMREST”.

5009-26

STEERING VALVES PVG32 AND PVFC Removal

STEP 3

STEP 1

Remove all dirt and grease from the steering valves and adjacent areas.

STEP 2

2 2 3 1

4 W110R361

Disconnect the tie flexible hose (4) from the valve PVFC (2), with the solenoid valve of the emergency steering assembly and the flexible hose (5) coming from the tool distributor. Plug the flexible hoses in order to avoid oil spillage and the fittings to prevent debris from getting inside. W110R360

Detach the rigid steering pipe LS (3) from the valve PVG32 (1) and from the valve PVFC (2).

STEP 4

W110R362

Disconnect the suction flexible hose of the solenoid valve of the emergency steering assembly from the valve PVG32.

5009-27

STEP 5

STEP 7

W110R363

Disconnect the outlet flexible hose.

W110R365

Disconnect the supply flexible hose of stem side steering cylinder line.

STEP 6

STEP 8

W110R364

Disconnect the supply flexible hose of bottom side steering cylinder line.

4 3 W110R366

Remove the steering valve PVG32 (2) from the support (1) by taking out the fixing screws (3, qty. 4) complete with washers (4).

5009-28

STEP 9

STEP 12 10

1 11

9 4

W110R370

W110R367

Remove the support (1) from the side wall of the rear chassis frame by removing the screws (2) and the washers (3).

Unscrew the 60 bar pressure switch (10) with seal (11) from the â&#x20AC;&#x153;Tâ&#x20AC;? joint (9) of the steering valve PVFC (4).

STEP 10

STEP 13

12 1 12 4 W110R371 W110R368

Remove the support (1).

STEP 11 1 5

7 8 4 W110R369

Remove the steering valve PVFC (4) from the support (1) by removing the nuts (5, qty. 2) and the washers (6), which secure the screws (7) with washers (8).

Unscrew the joints (12) for connection to the hydraulic pipes from the steering valve PVFC (4).

5009-29

STEP 14

STEP 17

W190-4R014

W190-4R017

Remove the 8 bar pilot pressure switch (1) complete with seal (2) from the steering valve PVG32.

Remove the two joints (5) from the ports “A” and “B” supplying the steering cylinder line.

STEP 15

STEP 18 6

W190-4R015

W190-4R018

Remove the reduction unit (3).

Unscrew the joint (6) from the port “P”.

STEP 16

STEP 19 7

4 W190-4R016

Unscrew the joint (4) from the “LS” por t of the steering valve PVG32. W190-4R019

Remove joint (7) from port “T”.

5009-30

LEGEND OF JSS HYDRAULIC COMPONENTS 1. Steering valve support 2. Steering valve PVG32 3. Washer 4. Screw 5. Steering valve PVFC 6. Joint 7. Steering LS pipe 8. Joint 9. Joint 10. Steering cylinder line pipes 11. Steering line pipe, star side 12. Joint 13. Outlet pipe of valve PVG32 14. Steering line pipe, bottom side 15. Joint 16. Solenoid valve suction hose 17. Joint 18. LS line pipe of power steering valve 19. Washer 21. Screw 22. Washer 23. Nut 24. Screw 25. 60 bar pressure switch 26. 8 bar pressure switch 27. Seal 28. Joint 29. Joint 30. Steering LS pipe tool distributor 31. Joint 32. Joint 33. Reduction 34. Tool distributor 35. Joint 36. Intake manifold return piping 37. Pipe sheath 38. Joint 39. Rear chassis frame 40. Solenoid valve for emergency steering assembly

5009-31

16 28 30

28 11

View from “B”

14 10

27 39

23 22

25 31

17 18

40 40 B A

38 1

View from “A”

View from “C”

19 21

View from “D”

3 4

W110R372

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM

5009-32

7 22

23 22

11 C

31 5

14 10

33 18

View from B

182

25 27 17

40 13 16 39 View from A

2 38 1

View from C 3

4 6

1. Steering valve support 2. Steering valve PVG32 3. Washer 4. Screw 5. Steering valve PVFC 6. Joint 7. Steering LS pipe 8. Joint 9. Joint 10. Steering cylinder line pipes 11. Steering line pipe, star side 12. Joint 13. Outlet pipe of valve PVG32 14. Steering line pipe, bottom side 15. Joint 16. Tool distributor line pipe 17. Joint 18. LS line pipe of power steering valve 19. Washer 21. Screw 22. Washer

23. Nut 24. Screw 25. 60 bar pressure switch 26. 8 bar pressure switch 27. Seal 28. Joint 29. Joint 30. Steering LS pipe tool distributor 31. Joint 32. Joint 33. Reduction 34. Tool distributor 35. Power steering valve 36. Intake manifold return piping 37. Pipe sheath 38. Joint 39. Rear chassis frame 40. Hydraulic pump intake manifold

W110R380

HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERING SYSTEM

5009-33

Installation

STEP 21

Before reassembling the steering valves, clean all the disassembled parts thoroughly using a specific wash solvent and dry them using a jet of air. Carry out the procedure for installation following the phases described here:

1. Check each part to verify that they there are no dents, scoring or other defects. 2. Replace all damaged or deformed parts with new ones.

STEP 20 W190-4R021

Assemble the joint (2) for connection with the suction flexible hose of the steering priority valve on the port “P”. Tighten the joint to a torque of 170 Nm.

STEP 22

W190-4R020

Install the joint (1) for connection with the hydraulic outlet flexible hose on the port “T” of the steering valve PVG32. Tighten the joint to a torque of 310 Nm.

W190-4R022

Assemble the two joints (3) for connection with the steering cylinder line supply flexible hoses on the ports “A” and “B”. Tighten the joints to a torque of 100 Nm.

5009-34

STEP 23

STEP 26

6 7 8

W190-4R023

Install the joint (1) on the port “LS. Tighten the joint to a torque of 45 Nm.

W110R373

Assemble the joint (6) on the port “1” of the steering valve PVFC (5), the “T” joint (7) on the port “2” and the joint (8) on the port “3”. Tighten all the joints to a torque of 45 Nm.

STEP 24

STEP 27 10 2 11

W190-4R024

Assemble the reduction unit (2) of the pilot pressure switch on the port “Pp”. Tighten the reduction unit to a torque of 45 Nm.

STEP 25 W110R374

Install the 60 bar pressure switch (10) complete with seal (11) on the “T” joint (9).

2 W190-4R025

Install the pilot pressure switch (3) with seal (4) on the reduction unit (2).

5009-35

STEP 28

STEP 30

1 5

1 3 4 2

7 W190-4R028

Install the steering valve PVFC (2) on the support (1) by inserting the screws (3, qty. 2) complete with washers (4), the nuts (5) and washers (6).

8 W110R375

Put the valve support (1) on the side wall of the rear chassis frame by inserting the screws (7, qty. 3) complete with washers (8). Tighten the screws to a torque of 110 Nm.

STEP 29 1

STEP 31

9 W190-4R010

Position the support (1) of the steering valves on the RH side of the rear chassis frame of the unit.

11 10 W110R376

Install the steering valve PVG32 (1) on the support (9) using the lower screws (11, qty. 4) and washers (10). Tighten the screws to a torque of 30 Nm.

5009-36

STEP 32

STEP 34

W110R363 W110R365

Connect the stem side steering cylinder line supply flexible hose on the joint installed on the valve PVG32. Tighten the pipe to a torque of 60 Nm.

Connect and tighten the outlet flexible hose to a torque of 125 Nm.

STEP 35

STEP 33

W110R362

Connect the suction flexible hose of the solenoid valve of the emergency steering assembly. Tighten the pipe to a torque of 60 Nm. W110R364

Connect the bottom side steering cylinder line supply flexible hose. Tighten to a torque of 60 Nm.

5009-37

STEP 36

STEP 37 3

5 6

2 W110R377

Connect the connection flexible hose (2) with the emergency steering solenoid valve and flexible hose (3) coming from the tool distributor on the valve PVFC (1). Tighten the pipes to a torque of 14 Nm.

W110R378

Connect the rigid pipe of the device â&#x20AC;&#x153;LSâ&#x20AC;? (6) on the valve PVG32 (4) and on the valve PVFC (5). Tighten the pipe to a torque of 14 Nm.

5009-38

JOYSTICK STEERING SYSTEM ARMREST REMOVAL

STEP 3

STEP 1 3 2

6 4 W190-4R037

W190-4R036

Unscrew and remove the knob (1) and the washer (2) for longitudinal armrest adjustment.

Remove the locking screws (6, qty. 4) of the cover of the armrest (3) from the support (4). Remove the cover (3).

STEP 4

STEP 2

8 3

7 9 5

W190-4R035

Remove the cover (3) complete with support (4) from the armrest adjustment device (5).

W190-4R101

Disconnect the two-position “DEUTSCH” connector (7) of the “Kick-Down” button (8) with the armrest cable connector (9).

5009-39

STEP 5

STEP 7

8 1

9 2 W190-4R102

From the inside and bottom of the armrest cover (1) unscrew the threaded washer (2) and extract the “Kick-Down” button (3) complete with cable and connector from the top of the armrest cover.

STEP 6 5

W190-4R103

Disconnect the ten-position connector (4) of the “F-N-R” switch (5) with the ar mrest cable (6). Remove the switch (5) from the armrest cover (1).

11 W190-4R038

Remove the nuts (8, qty. 2), washers (9), screws (10) and washers (11) from the valve PVRES (7) of the Joystick. Disconnect the six-position connector (12) from the valve (7).

5009-40

STEP 8

STEP 11 5

7 12

10 2 W190-4R040

Disconnect the ten-position connector (2) from the CAN module (1) and release the armrest cable (3) from the fixing point by removing the nut (4) and the washer (5), the screw (6) and the washer (7).

STEP 9 W190-4R041

Unscrew and remove the knob (10) for height adjustment of the armrest and spacer (11). Raise and extract the armrest device (12) from the support fixed to the seat (13).

8 W190-4R039

Detach the CAN module (1) from the support (8).

STEP 10 9

W190-4R042

Disconnect the three-position â&#x20AC;&#x153;DEUTSCHâ&#x20AC;? connector (9) from the armrest positioning switch. Remove the armrest cable.

5009-41

STEP 12

STEP 13 10

1 7 3

4 2

4 W190-4R043

With the armrest lowered remove the armrest height / angle adjustment device (2) from the suppor t assembly (1) by removing the nut (3) and the washers (4), screws (5) and nylon bushings (6, qty. 2).

9 2

W190-4R104

Remove the locking bracket (7) of the pin (8) from the armrest height/angle adjustment device (2) by unscrewing the nuts (9, qty. 2), removing the screws (10) and the washers (11). Remove the pin (8) from inside the seat of the bracket (7).

5009-42

STEP 14

STEP 16 2

13 12 3

10 11

W190-4R046

Remove the support for fastening the safety belt by removing the nut (10) complete with washer (11), the screw (12) and washer (13).

STEP 17 7

6 W190-4R044

Unscrew the knob (2) from the suppor t (1) and extract the armrest height/angle adjustment pin (3). Remove the closing plate (4) from the support (1) by removing the screws (5, qty. 4) complete with washers. Remove the armrest position switch (6) from the inside of the support (1) by removing the screws (7, qty. 2) and the washers.

W190-4R047

Remove the four fixing screws (14, qty. 4) complete with washers from the seat cushion.

STEP 15

W190-4R045

Disconnect the wiring harness from the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option). Remove the screws (8, qty. 4) and washers (9) from the base of the seat. Remove the seat inside the cab by using a hoist provided with straps. Pay particular attention when carrying out this operation so as not to cause any damage to the inside or outside of the unit.

5009-43

STEP 18

STEP 20 4 1

2 W190-4R048

W190-4R050

Pressing down on the seat cushion support plate (1), slightly tilt the aluminium tongue (2) to allow release of the support (1) and allow raising/rotating the front. In this phase, take great care since the aluminium tongue (2) has greatly reduced thickness and so therefore avoid breaking it.

Unhook the metal rod (4) from the locking support (3) and remove the seat cushion support plate (1).

STEP 21 3

STEP 19 5 7

6 W190-4R051

1 W190-4R049

Raise, slowly rotating, the seat cushion support plate (1).

Turn the knob of the locking support (3) clockwise and move the plate (5) forward in such a way as to allow the sliding blocks (6, qty. 4) to slide inside the guides and get positioned in their respective seats (7). Remove the plate (5).

5009-44

STEP 22

STEP 23

1 2

W190-4R052

Remove the plate (1) of the seat by removing the retaining bolts (2, qty. 4) and washers (3). To perform this operation it is necessary to slide the plate (1) forwards to have access to the two front nuts (4) complete with washers (5) positioned inside the guides (6, qty. 2) underlying the plate (1) of the seat. Repeat the disassembly operation of the two rear screws (7) making the plate (1) slide back.

W190-4R053

Remove the armrest support plate (8).

INSTALLATION STEP 24 6

8 W190-4R054

Position the armrest support plate (8) on the seat runners (6).

5009-45

STEP 25

STEP 27

W190-4R055

W190-4R057

Position the previously removed seat plate (1) on the seat support plate (2).

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 allow locking it.

STEP 26

STEP 28 13

9 1 3

12 W190-4R058

Insert the two lugs for positioning the seat cushion support plate (11) inside the two special openings shown in the figure on the seat plate (9) and hook the metal rod (13) to the catch (12). Slowly lower the seat cushion support plate (11).

W190-4R056

Push the seat plate (1) forwards. From the top, insert the two front screws (3) complete with washers (4) and lock them at the bottom, from the seat runners (7), using the nuts (5) and the washers (6). Tighten the nuts to a torque of 32 Nm. Repeat the assembly operation of the two rear screws (8) making the seat plate (1) slide back.

5009-46

STEP 29

STEP 31 6 1

5 7

2 W190-4R048

W190-4R060

Lock the seat cushion support plate (1) by restoring the correct bend in the aluminium tongue (2). In this phase, take great care since the aluminium tongue (2) has greatly reduced thickness and so therefore avoid breaking it so as not to jeopardize seat operation.

Install the support for fastening to the safety belt by inserting the screw (5) and the washer (6), the nut (7) and the washer (8). Tighten the nut to a torque of between 47 and 68 Nm. Carefully check that the seat belt mounting hardware is tight and the seat belt is not cut or frayed.

STEP 30

STEP 32

1 9 10

W190-4R059

W190-4R061

Install the seat cushion (3) on the support plate (1) and secure it with the screws (4, qty. 4) complete with washers.

Using a hoist equipped with lifting straps, sling the seat and position it inside the cab. Connect the wiring harness to the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option). Install the seat on the base and secure it with the four screws (9) complete with washers (10). Tighten the screws to a torque of between 73 and 87 Nm. Carefully check that the tightening torque of the screws fastening the operatorâ&#x20AC;&#x2122;s seat is as prescribed and that the parts are not worn or damaged.

5009-47

STEP 33

STEP 34 11

5 9

6 13 10

3 7

2 W190-4R062

Install the armrest position switch (2) on the support (1) using the screws (3, qty. 2) complete with washers. Insert the adjuster pin (4) inside the support (1) and screw the knob (5) on it. Install the closing plate (6) on the support (1) and secure it with the screws (7, qty. 4) complete with washers.

W190-4R105

Insert the armrest locking pin (8) inside the seat of the bracket (9) and install it all on the armrest height/angle adjustment device (10) using the screws (11, qty. 2), washers (12) and nuts (13). Tighten the nuts to a torque of 7 Nm.

STEP 35

8 W190-4R106

Insert, rotate and secure the armrest locking pin (8) as shown in the figure.

5009-48

STEP 36

STEP 38 1

5 2

W190-4R065

W190-4R063

Install the armrest height / angle adjustment device (2) on the support assembly (1) by inserting the nylon bushings (3, qty. 2), screw (4) with the washers (5) and nut (6).

STEP 37

W190-4R064

Insert the armrest device (7) inside the support (8) fixed to the seat and screw on the knob (9) for armrest height adjustment complete with spacer (10).

Install the ar mrest cable connecting it to the positioning switch via the three-position â&#x20AC;&#x153;DEUTSCHâ&#x20AC;? connector (11).

5009-49

STEP 39

STEP 41

1 12 2

W190-4R066

Install the CAN module (1) inside the special seat (2) situated on the armrest device.

STEP 40 8

W190-4R068

6 1

Connect the “PHOENIX” connector (10) to the valve PVRES (9) of the Joystick and install the valve on the support (11) by inserting the screws (12, qty. 2) with the washers (13, qty. 4) and the nuts (14, qty. 2). Pay attention to the correct positioning of the valve (9) so that the letter “A” stamped on it is on the left-hand side in relation to the direction of travel of the unit.

STEP 42 16

W190-4R067

Connect the ten-position connector (3) to the CAN module (1) and secure the armrest cable (4) to the required point using the screw (5) with the washer (6), the nut (7) and washer (8).

17 W190-4R107

Insert the “Kick-Down” button (16) on the armrest cover (15) and lock it from the bottom with the threaded washer (17).

5009-50

STEP 43

STEP 44 2

4 1 7

W190-4R108

W190-4R109

Connect the two-position “DEUTSCH” connector (1) of the “Kick-Down” button (2) with the armrest cable connector (3).

Insert the “F-N-R” switch (5) in the related assembly seat of the armrest cover (4) and connect it to the ten-position connector (6) of the armrest cable (7).

STEP 45

9 8 W190-4R069

Put the armrest cover (4) on the support (8) and secure it with the screws (9, qty. 4).

5009-51

STEP 46 1 5

2 4 3

W190-4R070

Position the cover (1) complete with support (2) on the armrest adjustment device (3) and screw on the knob (4) complete with washer (5).

STEP 47 Put the battery disconnecting switch in the ON position and start the engine. Turn the steering wheel all the way to the left and then to the right several times. Switch off the engine. Check the hydraulic oil level. See the specific section for the specifications.

5009-52

JSS HYDRAULIC PRESSURE ADJUSTMENTS 1. with the engine OFF and bucket on the ground, connect a quick coupling pressure gauge to the pressure point P (1) of the tool distributor (2) and to the pressure point LS (3);

IMPORTANT: in making the following checks and pressure adjustments, the unit articulation must be locked. Great attention must be paid to following all the procedures for making the unit safe, particularly when operating on the articulation joint and near the arm of the loader.

2. with the engine at idle speed, with all the controls in neutral, JSS NOT active, the difference between the pressure P and LS must be equal to that specified (22-25 bar);

A. Main hydraulic pressure setting of the pump

3. with the engine at idle speed, with all the controls in neutral, JSS ON and joystick in neutral, the difference between the pressure P and LS must be equal to that specified (22-25 bar);

This setting is given by the difference between the pressure of the hydraulic pump and the LS signal, which must be between 22 and 25 bars:

2 2 W110R379

1. Pressure point P 2. Tool distributor 3. Pressure point LS

4. with the engine at idle speed, with all the controls in neutral, JSS ON and joystick NOT in neutral, the difference between the pressure P and LS must be equal to that specified (22-25 bar);

5. if the setting is not correct, verify that all the hydraulic connections are exact, particularly the connections on the hydraulic steering valve PVFC that manages the LS signals.

5009-53

B. Steering pressure limit setting With the engine at high reves, the pressure of the por t P of the tool distributor must be between 239 and 243 bar: - make sure that the pressure value stated in paragraph A is as specified (22-25 bar); - with the engine OFF and bucket on the ground, connect a quick coupling pressure gauge to the pressure point P of the tool distributor; - with the articulation locked, engine at high revs and JSS ON begin steering with the joystick in both directions to its limit stop. Keep this condition and read the pressure value on the pressure gauge, which must be equal to that specified above (239 and 243 bar); - if the pressure gauge records a pressure above or below the specified one, check that all the hydraulic connections have been made correctly.

C. Steering times IMPORTANT: when carrying out the following procedure check that the articulation of the unit is NOT locked. Great attention must be paid to following all the procedures for making the unit safe, particularly when operating on the articulation joint and near the arm of the loader. 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 all right to all left). The purpose of this setting is to make steering the unit equipped with the JSS similar to the standard steering system: 1. with the engine at idle speed, with all the controls in neutral and JSS ON, steer the unit completely to the left; 2. set a speed level (e.g. 1, 2 or 3);

3. move the joystick completely to the right and at the sam e time, with a chronome te r, star t measuring the time. Stop the chronometer when the unit is completely steered on the right-hand side. Take the time to compare it with the time specified in the table of speed levels. 4. move the joystick completely to the left and at the same time, with a chronometer, start measuring the time. Stop the chronometer when the unit is completely steered on the left-hand side. Take the time to compare it with the time specified in the table of speed levels. If the value is not in the range shown in the table, follow the system calibration procedure; 5. repeat what is specified in point 1, 2, 3 and 4 with the difference that the engine has to have high revs; 6. if the adjustments are not exact, verify the specifications given in paragraphs A and B.

5009-54

STEERING CALIBRATION PROCEDURE ATTENTION: The views in the following steps may be different than the machine.

STEP 4

STEP 1 Before running the machine calibration procedure, the operator must carry out the following operations: - Start the engine; - Set the machine in a straight position; - Activate the Joystick Steering System; - Slightly lift the bucket off the ground; - Release the parking brake.

STEP 2 W190-4R112

Press the confirm/send button (2) within two seconds to confirm access to the calibration procedure. If you do not press any buttons after two seconds the screen will show "Calibration", "Timeout" "Cancelled". In this case to be able to re-access the calibration procedure repeat Step 2.

STEP 5 2 W230R605

At the same time press the Joystick Steering activation switch (1) and the confirm/send button (2).

STEP 3

W190-4R113

If it is kept pressed longer than expected, the main menu screen appears.

W190-4R111

Keep pressed until the screen shows "Calibration?".

5009-55

STEP 6

STEP 8

W190-4R114

W190-4R116

If you want to run calibration, press (within two seconds) the confirm/send button (2, see figure on preceding page). The display will show a screen with the wording "Steer Straight?" that asks the operator whether the machine is positioned straight. Press the confirm / send button (2, see figure on preceding page) to confirm the operation.

After this operation the display will show a screen w i t h t h e w o r d i n g " O . K . " T h e d i s p l ay w i l l automatically show the screen with the wording "Joyst Fu ll Left" "Release when WL starts moving", the operator must then repeat Step 7 twice.

STEP 9

STEP 7

W190-4R117

W190-4R115

The display will show a screen with the wording "Joyst Full Left" "Release when WL starts moving". At this moment the operator must move the Joystick lever completely to the left. As soon as he perceives a small movement of the machine he must release the lever.

Afterwards the display will automatically show the screen with the wording "Joyst Full Right" "Release when WL starts moving". At this moment the operator must move the Joystick lever completely to the right. As soon as he perceives a small movement of the machine he must release the lever.

5009-56

STEP 10

W190-4R116

After this operation the display will show a screen w i t h t h e w o r d i n g " O . K . " . T h e d i s p l ay w i l l automatically show the screen with the wording "Joyst Full Right" "Release when WL starts moving", the operator must then repeat Step 9 twice.

STEP 11

W190-4R118

The display will show a screen with the wording "Calibration Successful" indicating the success of the calibration procedure.

SECTION INDEX

POWER TRAIN Section Title

Section Number

Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001 Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004 Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004 Drive Shafts, Center Bearing, and Universal Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006 Transmission Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007

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 8 9 14 14 16 17 20 20 22 23

6001-3

TRANSMISSION Removal

STEP 7

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

BD01D315-01

Refer to Section 8001 and remove the hydraulic pump.

Disconnect transmission wiring harness connector from control valve connector. Remove socket head bolt securing wiring harness clamp. Move wiring harness away from transmission.

STEP 5

STEP 8

STEP 4

Put a 28 liter (30 quar ts) container under transmission drain plug. Remove drain plug and drain transmission oil. Install drain plug after oil has drained. NOTE: Remove optional skid plate if equipped to gain access to transmission drain plug.

STEP 6

BD01D317-01

Just above where clamp was installed, tag and disconnect transmission wiring harness connector from temperature sensor. Move wiring harness away from transmission.

BD01D306-01

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.

6001-4

STEP 9

STEP 12

BD01D310-01

BD07N603-01

Remove two socket head bolts securing transmission wiring harness clamps.

Identify, tag, and disconnect transmission wiring harness connectors from filter maintenance switch and output speed sensor. Move transmission wiring harness away from transmission.

STEP 10

STEP 13

BD01D312-01

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.

STEP 11

BD01D316-01

Remove socket head bolt securing wiring harness clamp. Move wiring harness away from transmission.

BD03A165-01

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.

6001-5

STEP 14

STEP 16

BD03A161-01

BD01D318-01

Remove four bolts and two straps securing rear drive shaft to transmission output flange. Disconnect rear drive shaft from transmission.

Identify, tag, and disconnect cooler hose from fitting installed in LH side of transmission. Install a plug in hose. Remove and discard O-ring face seal from fitting.

STEP 15

STEP 17

BD07N608-01

Remove two bolts. Remove fill tube, with cap and oil gauge assembled, two seals, and metal strainer. Discard seals.

BD01D339-01

Remove fitting. Remove and discard O-ring from fitting. Install a plug in transmission port.

STEP 18

BD01D340-01

Repeat Steps (16) and (17) and disconnect the other cooler hose and remove fitting.

6001-6

STEP 19

STEP 21

BD01D340-01

BD03A163-01

Connect lifting equipment to transmission lifting eyes. Take up all slack in lifting equipment.

Remove bolts and washers securing RH and LH mounting brackets to rear chassis.

STEP 20

STEP 22

BD01D342-01

BD03A164-01

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.

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.

6001-7

STEP 23

STEP 24

BD01D345-01

BD01D361-01

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.

6001-8

Transmission Mounting

C B

7 8

5 2

3 9

1 7

1 6

7 10 11 10

BS08A032

1. 2. 3. 4. 5. 6. 7.

ISOLATOR WASHER ISOLATOR BOLT M22X120 (*) TOP MOUNTING BRACKET LEFT MOUNTING BRACKET RIGHT MOUNTING BRACKET WASHER

(*) Torque 890-1000 Nm (655-735 lbs-ft) (**) Torque 480-590 Nm (355-435 lbs-ft)

8. 9. 10. 11. A. B. C.

BOLT M20X50 (**) TRANSMISSION FILL TUBE BOLT M16X45 TORQUE 251-319 Nm (185-235 lbs-ft) BOLT M8X50 TORQUE 17-33 Nm (12-24 lbs-ft) REAR CHASSIS TRUNNION MOUNTING BRACKET ISOLATOR (SMALLER PIECE ON TOP)

6001-9

Installation

STEP 28

STEP 25 Check isolators for deterioration, tears, deformation, or other damage. Replace as necessary: refer to Page 8.

STEP 26

BD03A164-01

Install RH and LH mounting brackets on transmission using two washers and bolts. Do not tighten bolts.

STEP 29

BD01D361-01

If top mounting bracket was removed, put bracket on rear chassis trunnion and secure using washer and bolt. Do not tighten bolt.

STEP 27

BD03A163-01

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).

BD01D345-01

Move transmission into position above loader. Slowly lower transmission into loader.

6001-10

STEP 30

STEP 32

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.

BD01D343-01

Disconnect lifting equipment from transmission lifting eyes. BD01D342-01

STEP 33

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 34 to 41 Nm (25 to 30 pound feet).

STEP 31 BD01D34-01

Install new O-ring on fitting and install fitting in transmission. Install new O-ring face seal in fitting then connect cooler hose to fitting following tag installed during removal. Remove and discard tag.

BD03A163-01

Tighten bolts securing RH and LH mounting brackets to a torque of 890 to 1000 Nm (655 to 735 pound feet).

6001-11

STEP 34

STEP 36

BD01D318-01

BD03A161-01

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).

STEP 37

STEP 35

BD03A165-01 BD07N608-0

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 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.

6001-12

STEP 38

STEP 40

BD01D314-01

BD01D312-01

Connect transmission wiring harness connectors to output speed sensor and filter maintenance switch following tags installed during removal. Remove and discard tags.

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.

STEP 39

STEP 41

BD01D316-01

BD01D310-01

Install socket head bolt to secure wiring harness clamp.

Install two socket head bolts to secure transmission wiring harness clamps.

STEP 42

BD01D317-01

Connect transmission wiring harness connector to temperature sensor following tag installed during removal. Remove and discard tag.

6001-13

STEP 43

STEP 45

BD01D315-01

Install socket head bolt to secure wiring harness clamp. Connect transmission wir ing har ness connector to control valve connector.

BD03A177-01

Check that transmission drain plug is tight. NOTE: Install optional skid plate if equipped.

STEP 46

STEP 44

Fill transmission with 15-40W engine oil until oil level is up to the arrow in sight glass.

STEP 47 Refer to Section 8001 and install the hydraulic pump.

STEP 48 Refer to Section 9007 and install ROPS cab or ROPS canopy.

STEP 49 BD01D306-01

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.

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 LOCKED position and add oil specified in Section 1002 until oil level is up to crosshatch region. Shut down engine and put articulation lock in OPERATING position.

6001-14

FRONT AXLE Removal

STEP 4

STEP 1

BD03A167-01

BD03A040-01

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

BD03A166-01

BD03A092-01

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.

6001-15

STEP 6

STEP 8

W110R560

BD01F298-01

For machines equipped with LSD Axles (without brake damping accumulators). From front axle disconnect brake hose from elbow. Remove and discard O-ring face seal from elbow.

STEP 7

BD01D392-01

Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine.

STEP 9 W110R561

For machine equipped with Heavy Duty axles, disconnect differential lock hose. NOTE: W110C machines with Heavy Duty axles are equipped with brake damping accumulators.

Repeat Step 8 to raise other front axle tire from ground.

6001-16

STEP 10

STEP 12

BD01F297-01

Use an acceptable jack to hold front axle.

BD01F296-01

Remove eight nuts bolts, and washers securing front axle to machine.

STEP 11

STEP 13 Carefully lower front axle and remove from under machine.

BD01F295-01

Remove bolts and washers from front wheels. Remove both wheels from front axle.

6001-17

Front Axle Mounting

1 2

BS08A035

1. 2. 3. 4.

BOLT (Q.TY 8) M24X130 TORQUE 783-857 Nm (577-632 lbs-ft) WASHER (Q.TY 16) NUT (Q.TY 8) FRONT CHASSIS AXLE PADS

6001-18

W110R562

FRONT AXLE TORQUE SEQUENCE

Installation

STEP 16

STEP 14 Carefully move front axle under machine and raise against mounting pads on machine.

STEP 15

BD01F295-01

BD01F296-01

Apply one drop of engine oil to threads prior to assembly. Install washers, bolts, and nuts to secure front axle to machine. Tighten bolts to a torque of 783 to 857 Nm (577 to 632 pound feet) using torque sequence shown. B0987A88

Install both wheels on front axle and secure. Tighten bolts to a preliminary torque of 298 Nm (230 pound feet) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence.

6001-19

STEP 17

STEP 20

BD01F297-01

Remove jack from front axle.

W110R560

Install a new O-ring face seal in elbow. Connect brake hose to elbow.

STEP 18

STEP 21

BD01F298-01 BD03A166-01

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.

BD01D392-01

Using an acceptable hydraulic jack, raise axle and remove jack stand from under machine.

STEP 19 Repeat Step 18 to remove other jack stand from under machine.

6001-20

STEP 22

STEP 24 Refer to Section 7002 and bleed brakes.

STEP 25

BD03A167-01

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 23 If necessary, fill axle with gear lubricant specified in Section 1002.

BD03A092-01

Star t engine and raise bucket. Have assistant remove safety link. Lower bucket to ground and stop engine.

STEP 26 Put articulation lock in OPERATING position.

6001-21

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 BD03A169-01

Disconnect brake hose from elbow. Remove and discard O-ring face seal from elbow.

STEP 6

BD03A040-01

Put articulation lock in LOCKED position.

STEP 3 Install wood blocks between rear axle and chassis to prevent rear axle from pivoting. BD01F299-01

STEP 4

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 7

BD03A162-01

Remove four bolts and two straps. Use a pry bar to disconnect rear drive shaft from rear axle. BD01F302-01

Use an acceptable jack to hold rear axle.

6001-22

STEP 8

STEP 10 Carefully lower rear axle and remove through side of machine.

STEP 11 Remove and discard two seals from rear axle pivot point.

BD01F295-01

Remove bolts and washers from rear wheels. Remove both wheels from rear axle.

STEP 9

BD03A170-01

At front of trunnion, remove two screws 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 acceptable sleeve or rod if necessary.

6001-23

Rear Axle Mounting

4 3 2

6 5

2 3 6

8 BS08A036

1. 2. 3. 4.

TRUNNION O-RING SEAL FRONT CAP PIVOT

5. 6. 7. 8.

WASHER 22X37X4 BOLT M20X70 WASHER 24X44X4 BOLT M22X15

9. 10. 11. 12.

REAR AXLE PIVOT PIN SHIM(S) REAR CAP PIVOT

6001-24

Installation

STEP 13

NOTE: If shim(s) (11) have been lost or pivot pin (10) has been replaced, do Step 12 to determine required shim(s) otherwise go to Step 13.

STEP 12 6

1 12

BD01D482A-01

BS01E091A

Install pivot pin (10) and caps (4 and 12) in trunnion (1) without rear axle or shim(s). Install washers (5) a n d b o l t s ( 6 ) . T i g h t e n b o l t s s e c u r e l y. P u s h assembled pivot pin and caps to rear of machine as far as possible. Measure and record gap (A) between rear cap (12) 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

BD01D499-01

Clean front (A) and rear (B) pivot area of rear axle where seals (3) will be installed.

STEP 14 A 3 4 12

2 BS01E092

Lubricate two new seals (3) and new O-rings (2) using Molydisulfide Grease. Install seals, smooth side out, into front and rear of axle housing (A) until seal bottoms out in housing counterbore. Install an O-ring in each and cap (4 and 12).

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.

6001-25

STEP 16 11 6

STEP 17 4

1 BS01E091

Lubricate pivot pin (10) using Molydisulfide Grease. At rear of trunnion (1), install pivot pin into trunnion and axle (A). Install shim pack (11), rear cap (12) with O-ring installed, and two washers and bolts (6). At front of trunnion install front cap (4) with O-ring installed. Apply Loctite primer 345-62 on bolt threads and let dry for 70 seconds. Then, apply Loctite 345-199 on bolt threads and install washers and bolts (6). Tighten bolts (6) to a torque of 575 to 600 Nm (420 to 440 lbs-ft).

BD01F295-01

B0987A88

Install both wheels on front axle and secure. Tighten bolts to a preliminary torque of 298 Nm (220 pound feet) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence.

STEP 18 Remove hydraulic jack supporting rear axle and jack stands supporting loader.

6001-26

STEP 19

STEP 21 If necessary, fill axle with gear lubricant specified in Section 1002.

STEP 22 Refer to Section 7002 and bleed brakes.

STEP 23 Put articulation lock in OPERATING position.

BD03A169-01

Install a new O-ring face seal in elbow. Connect brake hose to elbow.

STEP 20

BD03A162-01

Connect rear drive shaft to rear axle. Install two straps and four bolts. Tighten bolts to a torque of 61 to 81 Nm (45 to 60 pound feet).

TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS AND TROUBLESHOOTING

6002

Section 6002

6002-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 11 12 12 12 12 12 12 13 15 16 16 16 16 16 17 17 17 17 17 17 17 17 17 17 18 19 19 19

6002-3

SPECIAL TOOLS 380001743 Transmission supplemental fitting kit. Includes: 380000509 special 90 degree adapter and 380001749 plug and cap set. 380001739 Master pressure test kit

380001740 Flowmeter kit 380001750 Flowmeter adapter 380001745 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........................................................................................................ 2.5 bar (36 psi) minimum Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi) Minimum pump output (at 2000 rpm) .....................................................................................52 L/min (14 U.S. gpm) Transmission oil operating temperature..........................................................................80 to 120 Â°C (176 to 248 Â°F) Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K4 ........................................................................................................................16 to 18 bar (232 to 261 psi)

6002-4

1 3

9 6 8

11 14 7

13 10

BS01A190

1. 2. 3. 4. 5. 6. 7.

TRANSMISSION ELECTRONIC CONTROL MODULE DOWNSHIFT BUTTON DECLUTCH ROCKER SWITCH MANUAL/AUTOMATIC ROCKER SWITCH SHIFTER SUPPLY SYSTEM CONNECTIONS B+ AND RETURN TRANSMISSION

8. 9. 10. 11. 12. 13. 14.

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 PLUG

COMPONENT LOCATIONS SYSTEMS

6002-5

12 11 1

2 10 3 9 4

14 8 13

BS03A262

1. 2. 3. 4. 5. 6. 7. 8.

CLUTCH SHAFT KR POWER TAKE OFF CLUTCH SHAFT KV CLUTCH SHAFT K2 CLUTCH SHAFT K3 OUTPUT FLANGE REAR OUTPUT FLANGE CONVERTER SIDE OUTPUT SHAFT

9. 10. 11. 12. 13. 14. 15.

TRANSMISSION PUMP INPUT FLANGE CONVERTER INDUCTIVE TRANSMITTER FOR ENGINE SPEED CLUTCH SHAFT K4 CONVERTER RELIEF VALVE CLUTCH SHAFT K1

COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6

BS01A191

1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK 2. TRANSMISSION SUSPENSION BORES

3. OUTPUT FLANGE CONVERTER SIDE 4. OIL DRAIN PLUG

COMPONENT LOCATIONS FRONT VIEW

6002-7

5 9 10 8

BS01A192

1. 2. 3. 4. 5.

CONVERTER BELL HOUSING BREATHER TRANSMISSION CASE COVER FILTER HEAD FILTER

6. 7. 8. 9. 10.

OUTPUT FLANGE REAR OIL DRAIN PLUG OUTPUT FLANGE CONVERTER SIDE TRANSMISSION CASE PARKING BRAKE

COMPONENT LOCATIONS SIDE VIEW

6002-8

BS01B048

1. 2. 3. 4.

LIFTING LUGS POWER TAKE OFF TRANSMISSION CONTROL VALVE TRANSMISSION SUSPENSION BORES

5. OUTPUT FLANGE REAR 6. FILTER 7. FILTER HEAD

COMPONENT LOCATIONS REAR VIEW

6002-9

TRANSMISSION OPERATION General

Transmission ECM Tasks

The transmission is equipped with a Transmission ECM (Electronic Control Module). This module controls modulation and shifting that were normally a s s o c i a t e d w i t h hy d r a u l i c a l l y m o d u l a t e d transmissions, providing smoother shifts and enhanced clutch life.

The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM:

The Transmission ECM relies on signals from several sensors that are incorporated into the design. These sensors measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. In a d d i t i o n , th e t ra n s m i s s i o n i n c o r p o ra t e s a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise, and all external hoses have been eliminated (all oil passages are internal).

B. Protects the engine and transmission turbine from overspeed conditions dur ing downloading. C. Receives speed information from the engine speed sensor, the turbine speed sensor, the intermediate shaft speed sensor and the transmission output shaft speed sensor. T h e s e s p e e d s e n s o r s a r e c h e ck e d t o deter mine if nor mal sensor operation is present. The data is also used to control modulation during shifting and to determine the appropriate shift patterns. D. Detects system failures and determines the appropriate alternative actions.

Transmission ECM Modulation and shifting are controlled by the Tr a n s m i s s i o n E l e c t r o n i c C o n t r o l M o d u l e (Transmission ECM). This module replaces the oil and springs that are found in hydraulically modulated transmissions. T h e Tr a n s m i s s i o n E C M c o n t r o l s t h e c l u t c h e n g a g e m e n t , p r ov i d i n g s m o o t h e r s h i f t s a n d enhanced clutch life, whether the transmission is set to the automatic or manual shift mode. The Transmission ECM also informs the Information Center, by the use of diagnostic codes, of any transmission error and the hours of operation that the error occurred.

Electrical Shift Solenoids Electrical Shift Solenoids control the modulation of the clutches, eliminating the need for a modulation valve, and providing a smooth shift while maintaining constant control over clutch engagement as follows: A. A temperature sensor relays the temperature to the Transmission ECM.

A. Determines which clutches to engage in the transmission.

oil

B. The Transmission ECM times the rate the solenoid energizes and de-energizes. C. As the transmission changes gears, there is reduced hesitation from one gear to the next.

E. Provides various diagnostic messages to the Information Center. F. Provides other information to the information center, which in turn displays engine speed, wheel speed, gear shift selection, and actual gear selection. G. Provides a method to transmission clutch control.

calibrate

the

H. Establishes clutch modulation pressure during transmission shifts.

6002-10

Transmission Sensor Data Collection The Transmission ECM collects and uses information from four sensors to accurately shift the transmission and determine if any clutches are slipping. These sensors are: Engine (Speed) Sensor - monitors engine speed to determine the load on the engine for shift points and sends the engine rpm to the Transmission ECM, which sends the information to the tachometer in the Information Center. Turbine (Speed) Sensor - assists the engine speed sensor in deter mining the load going into the transmission and helps determine shift points. Intermediate (Shaft Speed) Sensor - determines differential gear speed in the transmission to check for clutch slippage. Output (Speed) Sensor - monitors transmission output shaft speed to help determine the load on the transmission and to assist in determining shift points. Sends output shaft speed to Transmission ECM which sends the information to the speedometer in the Information Center. T h e t ra n s m i s s i o n E C M a l s o r ev i ew s vo l t a g e infor mation from the shifter and transmission solenoids to determine if there are any short circuits or open circuits in the system.

Automatic Problem Modes If the Transmission ECM detects an error condition in the transmission system, it will generate a service code in the Information Center and will enter one of three modes: A. Clutch Modulation Substitute Mode B. Limp-Home Mode C. Transmission/Transmission ECM Shutdown Mode

Clutch Modulation Substitute Mode In this mode, the transmission clutch modulation is time dependant rather than load dependant. The transmission will go into the Clutch Modulation Substitute Mode if any of the four speed sensors fail. If the output speed sensor is working and the transmission is in gear, the shift points in Automatic mode will be speed dependant but the modulation will be a predetermined amount of time. If the output speed sensor is not working and the transmission is in gear, the shift points will be load d e p e n d a n t bu t t h e m o d u l a t i o n w i l l s t i l l b e a predetermined amount of time. If the transmission is shifted from neutral into a direction in the Clutch Modulation Substitute Mode in automatic, the transmission will shift into 4th gear and shift down until it gets the correct output speed from the turbine.

Limp-Home Mode In this mode, the transmission will go into second gear, forward or reverse, no matter what gear is selected. If second gear is not obtainable, the Transmission ECM selects a series of prioritized g e a r s u n t i l a n o p e r a b l e g e a r i s fo u n d . T h e transmission will go into the Limp Home Mode if there is a fault on one clutch, a fault on one clutch valve, or a fault on more than one speed sensor.

Transmission/Transmission ECM Shutdown Mode In this mode, the Transmission ECM has detected a s e ve r e fa i l u r e t h a t d i s a b l e s c o n t r o l o f t h e transmission. The transmission will go into Shutdown Mode if there is a fault on more than one clutch, a fault on the solenoid power supply, or invalid voltage. In this mode, the Transmission ECM will shut off all solenoid valves and the power supply and the transmission shifts into and stays in neutral. If the Transmission ECM generates a code, a warning triangle will be illuminated on the Information Center.

6002-11

Transmission Clutch Calibration

Gear Selections

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.

The transmission provides 4 forward and 3 reverse gear selections. The transmission ratios were designed to give optimized speed and torque for each gear selection. The torque converter is a single stage torque converter (one locking unit in the torque converter).

Before doing the following transmission clutch calibration procedures make sure of the following:

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.

1. The machine is running and the transmission oil is warm. 2. Engine low idle speed is correct. 3. The transmission is in neutral.

Automatic/Manual Modes

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.

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.

D. Monitor will state “CALIB G/B” “CONFIRM PLEASE”, press the enter key.

As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.

E. If the conditions are not correct for clutch calibration the monitor will display the problem that needs to be corrected.

Downshifting in Automatic Mode

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.

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.

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.

6002-12

Downshifting in Manual Mode

Manual Mode

The transmission can be downshifted in the manual mode without reducing engine speed or machine speed.

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.

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.

Downshift Button 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 a three lever configuration. With the number of different ways the downshift button functions, the operator can tailor the use of the machine to the application at hand.

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. B. The shifter is moved into neutral and then into forward or reverse. C. The autoshift switch is recycled.

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 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.

Cold Start Protection System The transmission has a cold start protection system. When the transmission sump temperature is minus 10째 C (14째 F), the Transmission ECM will keep the transmission in neutral. When the transmission sump temperature warms up to minus 10째 C (14째F) (within approximately one minute), the machine will operate in all gears.

Brake Pedal Transmission Declutch 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.

6002-13

TRANSMISSION PRESSURE TEST POINTS DIAGRAM No.

IDENTIFICATION/LOCATION

CONNECTION

DESIGNATION ON VALVE BLOCK H

Measuring Points for Pressure Oil and Temperature 51

Before the Converter - Opening Pressure 8 bar (116 psi)

M10x1

Behind the Converter - Opening Pressure 2.5 bar (36 psi)

M14x1.5

Clutch Forward 16+2 bar (232 + 29 psi)

KV M10x1

Clutch Reverse 16+2 bar (232 + 29 psi)

KR M10x1

Clutch 16+2 bar (232 + 29 psi)

K1 M10x1

Clutch 16+2 bar (232 + 29 psi)

K2 M10x1

Clutch 16+2 bar (232 + 29 psi)

K3 M10x1

Clutch 16+2 bar (232 + 29 psi)

K4 M10x1

Behind the Converter Temperature 100° C, Short Time 120° C

M14x1/5

System Pressure 16+2 bar (232 + 29 psi)

M10x1

Measuring Points for Delivery Rates 15 16

Connection to the Heat Exchanger

1 5/16” - 12 UNF-2B

Connection from the Heat Exchanger

1 5/16” - 12 UNF-2B

Inductive Transmitter and Speed Sensor 21

Inductive Transmitter for Turbine Speed

M18x1.5

Output Speed Sensor

Inductive Transmitter for Central Gear Train Speed

M18x1.5

Inductive Transmitter for Engine Speed

M18x1.5

Connections 49

Plug Connection on the Hydraulic Control Unit

System Pressure

M16x1.5

Pilot Pressure

M16x1.5

NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

6002-14

MEASURING POINTS AND CONNECTIONS

BC01B047

6002-15

CHART FOR RECORDING PRESSURE READINGS Use this chart to record the pressure readings. P.I.N. Number:

Date: TEST POINTS

Shift Speed

P 65

V 53

R 55

1 56

2 57

3 58

4 60

5 51

1st F 2nd F 3rd F 4th F 1st R 2nd R 3rd R Neut P= MAIN PRESSURE

1= FIRST GEAR CLUTCH

4= FOURTH GEAR CLUTCH

V= FORWARD CLUTCH

2= SECOND GEAR CLUTCH

5= CONVERTER IN

R= REVERSE CLUTCH

3= THIRD GEAR CLUTCH

6= CONVERTER OUT

LP= LUBE PRESSURE

6 52

6002-16

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.

6002-17

CONVERTER OUT PRESSURE CHECK Test Equipment Required

2. Apply the parking brakes.

0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and 380000509 Special Adapter.

3. Install the pressure gauge.

Test Procedure

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 2.5 bar (36 psi).

1. Block the machine tires.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F).

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 380001740 Flowmeter Kit; 380001750 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 380001750 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 52 L/min (14 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).

6002-18

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.

6002-19

ERROR CODES In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with a recorded error number. See section 4005 for error code retrieval procedures and definitions.

TRANSMISSION SHIFTER LOGIC INFORMATION Function

Shifter

Shifter Wire Color

Shifter Tower Connector

Shifter Shroud Connector

Harness Wire #

Harness ped/cab #

Trans. ECM #

power

B+

black/red

19A_H

forward

yellow

25F

reverse

pink

25R

neutral

gray

25T_B

gear2(3-4)

green

25W

gear1(1-2)

blue

25Z

downshift

purple

25Y

NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is engaged.

RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES Transmission ECM Function

Transmission ECM Pin #

Transmission Valve

Clutch #

Transmission Valve Pin #

Wire #

Trans/Cab Pin #

A1P1

25K

A1P2

25L

A1P3

25M

A1P4

25N

A1P5

25P

A1P6

25J

VPSI

12,13

all Y

all K

25S

TEMP

none

36T

TEMP

none

36R

6002-20

NOTES

TRANSMISSION

6003

Section 6003

6003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 5 16

6003-3

SPECIAL TOOLS

380001577 TRANSMISSION VALVE ADJUSTMENT TOOL SET 380001560 TRANSMISSION INPUT/OUTPUT SHAFT SEAL INSTALLATION TOOL 380001559 TRANSMISSION TORQUE CONVERTER SEAL INSTALLATION TOOL

380001556 CLUTCH PACK H0LDER AND SPRING COMPRESSOR TOOLS

380001568 TRANSMISSION OUTPUT SHAFT SEAL INSTALLATION TOOL (W110C AND W130C MODELS ONLY)

380001558 ALIGNMENT DOWEL SET

380001554 NESTING PLATE

380001555 GEAR PULLER COLLET SET

380001557 CLUTCH ASSEMBLY HOLDING KNOB SET

380001567 CLUTCH SPRING COMPRESSOR (W110C AND W130C MODELS ONLY)

SPECIAL TORQUES Oil pipes Studs ............................................................................................................................... 9 Nm (80 pound inches) Socket head screw ...................................................................................................... 23 Nm (204 pound inches) Screw plug.......................................................................................................................... 51 Nm (38 pound feet) Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches) Plugs................................................................................................................................. 25 Nm (221 pound inches) Output shaft Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches) Housing cover screws (apply Loctite 574 to threads).................................................. 46 Nm (407 pound inches) Output flange screws................................................................................................... 34 Nm (301 pound inches) Oil feed housing and transmission pump Transmission pump screws ......................................................................................... 46 Nm (407 pound inches) Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches) Engine connection and converter Input shaft screws ............................................................................................................ 115 Nm (85 pound feet) Converter housing screws.................................................................................................. 68 Nm (50 pound feet) Cover............................................................................................................................ 23 Nm (204 pound inches) Converter cover ........................................................................................................... 46 Nm (407 pound inches) Input flange .................................................................................................................. 34 Nm (301 pound inches)

6003-4

SPECIAL TORQUES (CONTINUED) Duct plate Screws......................................................................................................................... 25 Nm (221 pound inches) Screw plug................................................................................................................... 30 Nm (265 pound inches) Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches) Filter Filter head screws ....................................................................................................... 25 Nm (221 pound inches) Oil distribution cover screws........................................................................................ 25 Nm (221 pound inches) Speed sensor and inductive transmitter Speed sensor screw.................................................................................................... 23 Nm (204 pound inches) Inductive transmitter .................................................................................................... 30 Nm (265 pound inches) Cover plate .................................................................................................................. 23 Nm (204 pound inches) Screw plug...................................................................................................................... 140 Nm (103 pound feet)

SPECIFICATIONS Clutch KV and KR plate clearance ......................................................................... 2.5 to 2.7 mm (0.098 to 0.106 in) Clutch K1, K2 and K3 plate clearance.................................................................... 2.1 to 2.3 mm (0.083 to 0.090 in) Clutch K4 plate clearance....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)

6003-5

DISASSEMBLY STEP 1

STEP 4

GD98M833

GD98M837

Fasten transmission on an assembly stand using CAS2801 transmission mounting brackets.

R e m ove t wo s o cke t h e a d s c r ews a n d i n s t a l l 380001577 transmission valve adjustment tool set. Remove remaining 21 socket head screws securing control valve. Loosen and remove hex rods (part of 380001577) from studs then remove control valve.

STEP 2

STEP 5

GD98M835

Remove and discard oil filter.

STEP 3

GD98M838

Remove both gaskets and the intermediate plate.

STEP 6

GD98M836

Remove hex head screws securing filter head. Remove filter head from transmission.

GD98M839

Remove socket head screws and hex nuts. Remove duct plate. Remove flat gasket.

6003-6

STEP 7

STEP 10

GD98M844

Bend lock plate away from hex head screws. Remove two hex head screws, lock plate, and washer. Remove input flange from shaft.

GD98M847

Using proper size rod, press input shaft and converter from cover.

STEP 11

STEP 8

GD98M845

Put alignment mar ks on conver ter cover and housing to aid in assembly. Remove 12 nuts and hex head screws.

GD98M848

Remove retaining ring then remove bearing.

STEP 12

STEP 9

GD98M849 GD98M846

C o n n e c t s u i t a bl e l i f t i n g e q u i p m e n t t o s h a f t . R e m o v e c o v e r, s h a f t , a n d c o n v e r t e r f r o m transmission and place in hydraulic press.

R e m o ve fo u r h ex h e a d s c r e w s a n d r e m o ve diaphragm and input shaft.

6003-7

STEP 13

STEP 16

GD98M850

GD98M853

Put input shaft and diaphragm in vise as shown. Remove 12 hex head screws to separate diaphragm and input shaft.

Remove the socket head screws for removal of the transmission pump.

STEP 17

STEP 14

GD98M854 GD98M851

Remove the inductive transmitter.

STEP 15

Apply a bearing separator on the splines shoulder of the stator shaft and pull the pump out of the housing bores, using two-leg puller. NOTE: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced.

STEP 18

GD98M852

Remove the hex head screws and remove the converter housing. GD98M855

Separate the transmission pump from stator. Separate the cam plate from pump.

6003-8

STEP 19

STEP 23 Turn the transmission 180 degrees and remove the rear output flange.

STEP 24

GD98M856

Remove the hex head screws and remove the oil feed housing. Remove the flat gasket.

STEP 20

GD98M862

Remove the speed sensor and both inductive transmitters.

STEP 25

GD98M860

Remove the hex head screws, cover, and flat gasket.

STEP 21 GD98M863

Remove the hex nuts and the two covers.

STEP 26

GD98M861

Remove the lock plate, hex head screws, and pry the converter side output flange from the shaft.

STEP 22 Pry the shaft seal out of the housing bore.

GD98M864

Install 380001558 alignment dowel set. NOTE: The following steps describe the common removal of all clutches.

6003-9

STEP 27

STEP 30 Remove 380001557 clutch assembly holding knob set and lift cover free.

STEP 31

BK00D029

Install 380001557 clutch assembly holding knob set. With knobs installed on all clutches in housing cover, install CAS2797 lifting eyebolt set and lifting device to transmission cover.

GD98M867

Remove the socket head screws and remove the output shaft and both oil baffle plates.

STEP 28

STEP 32

BK00D028

Separate the cover along with clutches from the transmission housing, using lifting device.

GD98M872

Remove clutch K2.

STEP 29

STEP 33

BK00D026

Place clutch disc carriers onto 380001554 nesting plate.

GD98M873

Remove clutch K1 while lifting clutch K4.

6003-10

STEP 34

STEP 37

GD98M877

GD98M874

Remove the bearing outer race and pull output shaft out of the housing bore.

Remove clutch K3.

STEP 35

STEP 38

GD98M875 GD98M878

Remove clutch K4 while lifting input shaft slightly.

STEP 36

Remove the rectangular ring and separate ball bearing from the shaft. NOTE: The following steps are for the disassembly of the clutch KV. The disassembly of the clutch KR is similar.

STEP 39

GD98M876

Remove clutches KV and KR together with input shaft. GD98M979

Remove the sealing ring. Pull the tapered roller bearing from the shaft. Remove the opposite tapered roller bearing.

6003-11

STEP 40

STEP 43

GD98M881

BK00D020

Separate the clutch disc carrier from the shaft.

Remove snap ring.

STEP 41

STEP 44

GD98M882

Remove the snap ring and remove the clutch disc pack.

STEP 42

BK00D019

Remove the compression spring.

STEP 45

GD98M885 BK00D018

Preload compression spring using 380001556 clutch pack holder and spring compressor tool.

Remove piston from clutch pack holder. Remove and discard the O-rings from piston.

6003-12

STEP 46

STEP 48

GD98M886

GD98M889

Remove the snap ring.

Remove the snap ring and remove the ball bearing.

STEP 47

NOTE: The following steps are for disassembly of clutch K3. Disassembly of clutches K1 and K2 is similar

STEP 49

GD98M887

GD98M890

Remove the rectangular ring. Pull the tapered roller bearing from the shaft.

STEP 50

GD98M888

Press the idler gear from the shaft using a bearing separator. Remove released needle bearing.

GD98M892

Remove the thrust washer, thrust bearing, and thrust washer.

6003-13

STEP 51

STEP 54

GD98M893

Remove the idler gear.

BK00D018

Preload compression spring using 380001556 clutch pack holder and spring compressor tool.

STEP 52

STEP 55

GD98M894

Remove the needle bearings and thrust bearing.

BKOOD020

Remove the snap ring.

STEP 53

STEP 56

GD98M895

Remove the snap ring and remove the clutch disc pack.

BK00D019

Remove the compression spring.

6003-14

STEP 57

STEP 59

BS00G001

GD98M800

Remove the sealing ring. Remove bearing using bearing puller. Tap assembly until piston drops out of the clutch pack carrier. Then, remove and discard O-rings from piston.

Remove and discard two sealing rings. Pull two bearings from shaft using bearing puller. Remove the snap ring and separate the clutch disc carrier from the shaft.

STEP 58

STEP 60

GD98M801

BK00D022

Remove the clutch disc carrier from the shaft. NOTE: The following steps are for the disassembly of the clutch K4.

Remove the snap ring and remove the clutch disc pack.

STEP 61

BK00D018

Preload compression spring using 380001556 clutch pack holder and spring compressor tool.

6003-15

STEP 62

NOTE: The following two steps are for disassembly of the input shaft. NOTE: A snap ring is used to lock turbine shaft in input shaft. Snap ring will be destroyed when turbine shaft is pressed from input shaft.

STEP 64

BK00D020

Remove the snap ring.

STEP 63

GD98M803

If turbine shaft is to be removed from input shaft, use proper size diameter sleeve or rod and press turbine shaft out of input shaft.

STEP 65 Remove bearings from input shaft using a bearing puller.

BK00D019

Remove the compression spring.

6003-16

ASSEMBLY NOTE: The following steps are for the reassembly of the oil pipes.

STEP 69

STEP 66

2 3

GD98M607

Install a new O-ring on plug. Tighten the plug to a torque of 51 Nm (38 pound feet).

STEP 70 GD98M603

Install suction tube (1), pressure pipes (2), and lubrication pressure pipe (3) in housing.

STEP 67 Secure suction tube (1) and pressure pipes (2) with socket head screw and hex nuts. Tighten to a torque of 23 Nm (204 pound inches)

STEP 68 GD98M608

Install all bearing outer races in housing bores.

STEP 71

GD98M605

Tilt the cover 180 degrees. Install the suction tubes and pressure pipes into the housing bores using a rolling tool. NOTE: Pipe end of the pressure pipes must be slightly below the housing plane face.

GD98M609

Install both oil pipes into the housing cover. Tilt the cover 180 degrees and install pipes into the housing bores using a rolling tool. NOTE: The pipe end must be slightly below the housing plane face.

6003-17

STEP 72

STEP 75

GD98M610

BK00D019

Install the studs. Tighten the studs to a torque of 9 Nm (80 pound inches). NOTE: The following steps are for the assembly of clutches KV and KR, starting with assembly of the clutch disc carrier.

STEP 73

BK00D018

Install compression spring and two spring cups in clutch disc carrier. Preload compression spring using 380001556 clutch pack holder and spring compressor tool.

STEP 76 GD98M612

Check that drain hole is clear and free of foreign matter. Install both O-rings in recesses of the piston and apply oil.

STEP 74

BK00D020

Install the snap ring. NOTE: The following steps are for the KV and KR clutch disc packs. The disc stacking of clutches KV and KR is identical. GD98M613

Install piston in clutch disc carrier.

6003-18

STEP 77

STEP 79 A

GD98M617 225B

1. 2. 3. 4. 5. 6. 7. A

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM RUNNING CLEARANCE 2.5 TO 2.7 MM (0.098 TO 0.106 IN)

Install end shim and snap ring.

STEP 80

Install clutch disc plates in KV and KR clutch disc carriers in position and sequence shown above. Install outer plates (3) with steel faced side facing piston and end shim (7). Install two inner plates (4) on the end shim side. NOTE: Snap rings of different thickness are available for adjustment of the running clearance. To ensure correct adjustment, do not apply oil to clutch discs until after adjustment is completed.

STEP 78

GD98M618

Adjust running clearance to 2.5 to 2.7 mm (0.098 to 0 . 1 0 6 i n ) . P r e ss d ow n o n t h e e n d s h i m w i th approximately 10 kg (20 lb). Measure and record dimension (A) from carrier face to end shim using depth gauge as shown. Example Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)

GD98M616

Install the clutch disc pack.

6003-19

STEP 81

STEP 84

GD98M619

GD98M621

Use tools to lift the end shim against snap ring (upward) until contact is obtained. Measure and record dimension (B) from carrier face to end shim using depth gauge as shown. Subtract this measurement from the measurement of Step 80. The difference is the running clearance.

Apply Loctite 243 to stud. Tighten stud to a torque of 17 Nm (150 pound inches).

STEP 85

Example Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in) Dimension B . . . . . . . . . . . . . . . . . 4.75 mm (0.19 in) Difference = Running. . . . . . . . . . . 2.50 mm (0.10 in) Clearance Required running clearance is 2.5 to 2.7 mm (0.098 to 0.106 in). Use snap ring(s) of different thickness as necessary to obtain correct running clearance.

STEP 82 GD98M622

Remove clutch disc pack, apply oil to discs, and install clutch disc pack, end shim, and snap ring as determined in Step 81.

Install ball bearing until contact is obtained. Secure using snap ring.

STEP 83

STEP 86

GD98M623

GD98M620

Install idler gear to align and engage all inner discs, then remove idler gear.

Install needle bearing.

6003-20

STEP 87

STEP 90

GD98M624

Support the idler gear on the bearing inner race. Press the idler gear against the shoulder.

STEP 88

BP00G020

Install gear and shaft into heated bore.

STEP 91

BK00D024 GD98M625

Secure idler gear using snap ring.

Heat bearing.

STEP 92

STEP 89

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BK00D023

Use heat gun to heat assembled clutch disc carrier inner bore. BK00D025

Install heated bear ing on shaft against shaft shoulder.

6003-21

STEP 93

STEP 96

Check operation of the clutch using compressed air. NOTE: The following steps are for assembly of clutch K1, K2, and K3.

STEP 94

GD98M632

Check that drain hole is clear and free of foreign matter. Install both O-rings in recesses of piston and apply oil. GD98M630

STEP 97

Press bearing against shoulder of shaft. Apply Loctite 243 to the stud and install the stud. Tighten the stud to a torque of 17 Nm (150 pound inches).

STEP 95

GD98M633

Install piston in clutch disc carrier.

STEP 98 GD98M631

Install the clutch disc carrier until contact is obtained.

GD98M634

Install the compression spring and spring cup.

6003-22

STEP 99

STEP 101 A

BK00D019

232A

1. 2. 3. 4. 5. 6. 7. A.

BK00D018

Install compression spring and two spring cups in clutch disc carrier. Preload compression spring using 380001556 clutch pack holder and spring compressor tool.

STEP 100

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM RUNNING CLEARANCE 2.1 TO 2.3 MM (0.083 TO 0.090 IN)

Install clutch disc plates in K1, K2, and K3 clutch disc carriers in position and sequence shown above. Install outer plate (3) with steel faced side facing piston. Install two outer and inner plates each on the end shim side. NOTE: Snap rings of different thickness are available for adjustment of the running clearance. To ensure correct adjustment, do not apply oil to clutch discs until after adjustment is completed.

STEP 102

BK00D020

Install the snap ring. NOTE: The following steps are for K1, K2 and K3 clutches. The assembly of clutches K1, K2, and K3 is identical.

GD98M636

Install the clutch disc pack.

6003-23

STEP 103

STEP 105

GD98M637

Install the end shim and snap ring.

GD98M639

Use tools to lift the end shim against snap ring (upward) until contact is obtained. Measure and record dimension (B) from carrier face to end shim u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s measurement from the measurement of Step 104. The difference is the running clearance.

STEP 104

Example Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in) Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in) Difference = Running Clearance . . .2.1 mm (0.08 in) Required running clearance is 2.1 to 2.3 mm (0.083 to 0.090 in). Use snap ring(s) of different thickness as necessary to obtain correct running clearance.

STEP 106 GD98M638

Adjust running clearance for K1, K2 and K3 to 2.1 to 2.3 mm (0.083 to 0.090 in). Press down on the end shim with approximately 10 kg (20 lb). Measure and record dimension (A) from carrier face to end shim using depth gauge as shown. Example Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)

Remove clutch disc pack, apply oil to discs, and install clutch disc pack, end shim, and snap ring as determined in Step 105.

STEP 107 3 2 1

GD98M640

Install the thrust washer (1), thrust bearing (2), and thrust washer (3). NOTE: Install the thrust washer (1) with the chamfer facing the thrust bearing.

6003-24

STEP 108

STEP 111

GD98M641

BK00D024

Install both needle bearings.

Heat bearing.

STEP 109

STEP 112 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

GD98M642

Install idler gear until all inner discs are engaged.

STEP 110 BK00D025

Place heated bearing on the shaft.

STEP 113

Check operation of the clutch using compressed air.

GD98M643

Install the thrust washer (3), thrust bearing (2), and thrust washer (1). Install the thrust washer (1) with the chamfer facing the thrust bearing. NOTE: Ensure the thrust washer (1) is overlapping with the chaff collar to accommodate all the inner discs.

6003-25 NOTE: The following steps are for assembly of clutch K4.

STEP 116

STEP 114 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

GD98M649

Apply Loctite 243 to the stud and install the stud. Tighten the stud to a torque of 17 Nm (150 pound inches).

STEP 117 GD98M647

Heat the gear to about 120Â° C (248Â° F) and install until seated in position.

STEP 115

GD98M650

Check that drain hole is clear and free of foreign matter. Install both O-rings in recesses of the piston and apply oil.

STEP 118 GD98M648

Install retaining ring to secure gear.

GD98M651

Install piston in clutch disc carrier. Be sure piston bottoms out.

6003-26

STEP 119

STEP 121 A

BK00D019

BS02C131

1. 2. 3. 4. 5. 6. 7. A.

PLATE CARRIER PISTON OUTER PLATE - ONE-SIDED COATED INNER PLATES OUTER PLATES - COATED ON BOTH SIDES SNAP RING END SHIM RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055 IN)

Install clutch disc plates in K4 clutch disc carrier in position and sequence shown above. Install outer plate (3) with steel faced side facing piston. BK00D018

Install compression spring and two spring cups in clutch disc carrier. Preload compression spring using 380001556 clutch pack holder and spring compressor tool.

NOTE: Snap rings of different thickness are available for adjustment of the running clearance. To ensure correct adjustment, do not apply oil to clutch discs until after adjustment is completed.

STEP 122

STEP 120

GD98M653

Install clutch disc pack. BK00D020

Install snap ring. NOTE: The following steps are for installing the clutch disc pack in clutch K4.

6003-27

STEP 123

STEP 125

GD98M654

Install end shim and snap ring.

GD98M656

Use tools to lift the end shim against snap ring (upward) until contact is obtained. Measure and record dimension (B) from carrier face to end shim u s i n g d e p t h g a u g e a s s h ow n . S u b t r a c t t h i s measurement from the measurement of Step 124. The difference is the running clearance.

STEP 124

Example Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in) Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in) Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in) Clearance Required running clearance is 1.2 to 1.4 mm (0.047 to 0.055 in). Use snap ring(s) of different thickness as necessary to obtain correct running clearance. GD98M655

Adjust running clearance to 1.2 to 1.4 mm (0.047 to 0 . 0 5 5 i n ) . P r e s s d ow n o n t h e e n d s h i m w i t h approximately 10 kg (20 lb). Measure and record dimension (A) from carrier face to end shim using depth gauge as shown.

STEP 126 Remove clutch disc pack, apply oil to discs, and install clutch disc pack, end shim, and snap ring as determined in Step 125.

STEP 127

Example Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)

GD98M657

Install the idler gear until all inner discs are engaged, then remove idler gear.

6003-28

STEP 128

STEP 131 1 2 3

GD98M658

Assemble two thrust washers and thrust bearing. NOTE: Upper and lower thrust washers are the same thickness.

GD98M661

Assemble thrust washer (3), thrust bearing (2), and thrust washer (1). Install the thrust washer (1) with the chamfer facing the thrust bearing.

STEP 132

STEP 129

GD98M662 GD98M659

Install the assembled clutch disc carrier until all the inner discs are engaged.

Install both needle bearings.

STEP 130

STEP 133

GD98M660 GD98M663

Install the idler gear.

Install snap ring to secure clutch disc carrier.

6003-29

STEP 134

STEP 138 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BK00D024

Heat bearing.

STEP 135 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

GD98M666

Heat gear to about 120° C (248° F) and install on input shaft until contact is obtained.

STEP 139

BK00D025

Install heated bearing on the shaft shoulder.

STEP 136 Repeat Steps 134 and 135 to install bearing on opposite end of shaft.

GD98M667

Secure gear with snap ring.

STEP 140

STEP 137 Check operation of the clutch using compressed air. NOTE: The following steps are for the reassembly of the input shaft.

GD98M668

Install snap ring into recess of turbine shaft.

6003-30

STEP 141

STEP 144

GD98M669

GD98M672

Install the turbine shaft until the snap ring snaps into the recess of the input shaft.

Install output shaft into housing bore until contact is made.

STEP 142

NOTE: The following steps are for the installation of the output shaft and clutches. All clutches have a common installation.

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

STEP 145

SM121A

K1 AB

K2 KV

GD98M673 BK00D024

Heat bearings and install on turbine shaft until bearings are against shoulder.

STEP 143

Install bearing outer races into housing cover until contact is obtained.

STEP 146

BK00F003 GD98M671

Install bearing then install rectangular ring.

Install the clutches onto 380001554 nesting plate.

6003-31

STEP 147

STEP 150

BK00D029

GD98M681

Using CAS2797 lifting eye bolt set and acceptable liftin g eq uipm en t, in stall ho using cove r o nto clutches. Install 380001557 clutch assembly holding knob set to secure clutch shafts to cover.

Install the sealing rings and insert rings in their respective grooves. Apply grease to the sealing rings and align the rings centrally.

STEP 148

STEP 151

KR KV K4

GD98M692 GD98M679

The above photo shows the position of the single clutches in the housing cover.

STEP 149 AN

KV K2

STEP 152 Tilt the housing cover 180 degrees.

KR K4 K1

Install both the O-rings into the annular groove of the oil pipes and apply grease.

GD98M866

The above shows the position of the single clutches and the input and output clutches.

6003-32

STEP 153

STEP 156

BK00D028

GD98M686

Install output gear and shaft in transmission housing. Install alignment screws. Carefully lower the cover and clutches into the gear box housing.

Install screen sheet on output shaft. Press front and rear bearings on output shaft until contact with shoulder of output shaft is made.

STEP 154

STEP 157

Remove 380001557 clutch assembly holding knob set.

STEP 155

GD98M688

Install the screening plate.

STEP 158 GD98M685

Separate the housing cover from the gearbox, using a lifting device. NOTE: The following steps are for the reassembly of the output shaft.

GD98M689

Install the output shaft.

6003-33

STEP 159

STEP 162

GD98M690

GD98M697

Apply Loctite 243 to the socket head screws and install the screws. Tighten the screws to a torque of 23 Nm (204 pound inches).

Heat the output flange to about 90Â° C (194Â° F). Apply Loctite 574 to the contact area and assemble the flange with the washers and hex head screws. Tighten the screws to a torque of 34 Nm (301 pound inches). Bend corner of lock plate over hex head screws.

STEP 160

STEP 163 Repeat Steps 161 and 162 to install shaft seal and output flange on converter side. NOTE: The following steps are for the assembly of the oil feed housing and transmission pump.

STEP 164

GD98M691

Install rectangular rings in grooves of clutch shafts. Apply grease to rings and align rings.

STEP 161

GD98M702

Install two alignment studs and install the gasket.

GD98M696

Position shaft seal with sealing lip facing oil chamber. A p p l y gr e a s e t o s ea l i n g l i p. U s e 3 8 0 0 0 1 56 8 transmission output shaft seal installation tool to install seal.

6003-34

STEP 165

STEP 168

GD98M703

Install the oil feed housing with washers and hex head screws. Screw the hex head screws in only until contact is obtained, do not tighten.

GD98M706

Install transmission pump.

STEP 169

STEP 166

GD98M707

GD98M704

Install the two alignment screws and install the stator shaft.

Apply grease to new O-rings. Install the O-rings on the socket head screws.

STEP 170

STEP 167

GD98M708

GD98M705

Apply oil and install the O-ring.

Secure the transmission pump with the socket head screws. Tighten screws to a torque of 46 Nm (407 pound inches).

6003-35

STEP 171

STEP 173

GD98M709

GD98M712

Install the oil feed housing with the hex head screws and flat washers. Tighten the screws to a torque of 25 Nm (221 pound inches).

Position converter housing. Secure with hex head screws. Tighten the screws to a torque of 68 Nm (50 pound feet).

STEP 172

STEP 174

GD98M711

GD98M713

Position the gasket and cover. Secure the cover with the hex head screws. Tighten the screws to a torque of 23 Nm (204 pound inches).

P u t in p u t s h a f t in a v i s e a s s h ow n . Po s i t io n diaphragm on input shaft and secure using 12 hex head screws. Tighten screws to a torque of 115 Nm (85 pound feet).

NOTE: The following steps are for the assembly of the engine connection and converter.

STEP 175

GD98M714

Position diaphragm and input shaft on converter. Apply Loctite 262 to threads of hex head screws. Install screws and tighten to a torque of 115 Nm (85 pound feet).

6003-36

STEP 176

STEP 178

GD98M715

GD98M718

Position converter cover on converter housing. Make sure alignment marks made during removal of cover are aligned. Install input flange, two hex head screws, lock plate, and washer. Pull cover against housing by tightening two hex head bolts evenly.

STEP 179

GD98M716

Position converter. Check and ensure that impulse disk of converter is centered on the bore for the inductive transmitter.

STEP 177 GD98M719

Secure converter cover using 12 hex head screws and nuts. Tighten screws to a torque of 46 Nm (407 pound inches).

GD98M717

Position converter cover as shown. Install bearing against shoulder in cover. Secure using retaining ring.

6003-37

STEP 180

NOTE: The following steps are for installation of transmission control valve.

STEP 183

GD98M720

Tighten input flange hex head screws to a torque of 34 Nm (301 pound inches). Lock screws by bending corners of lock plate over screws.

STEP 181

258

Install 380001577 transmission valve adjustment tool set. Be sure hex rods (par t of tool set) are not installed on studs. Mount the gasket (1), intermediate plate (2), and gasket (3).

STEP 184 Install the screw plug with new O-ring. Tighten the plug to a torque of 30 Nm (265 pound inches).

STEP 185

GD98M724

Install new sealing rings and both plugs in duct plate.

STEP 182

GD98M727

Install control valve on duct plate and 380001577 studs. Install hex rods on studs and tighten against control valve. Install 21 socket head screws. Tighten screws to a torque of 9.5 Nm (84 pound inches). Remove 380001577 transmission valve adjustment tool set. Install remaining two socket head screws. Tighten screws to a torque of 9.5 Nm (84 pound inches). GD98M725

Install the gasket and place the duct plate against shoulder. Install socket head screws and hex nuts. Tighten to a torque of 25 Nm (221 pound inches).

NOTE: The following steps are for the installation of the filter.

6003-38

STEP 186

STEP 189

GD98M729

GD98M735

Install new O-rings in recesses of oil filter head. Position filter head on transmission and secure using two socket head screws. Tighten screws to a torque of 25 Nm (221 pound inches).

Apply grease to the new O-ring and install the speed sensor with the socket head screw. Tighten the screw to a torque of 23 Nm (204 pound inches).

STEP 190

STEP 187

GD98M736

Install a new transmission filter.

With new O-rings, install the inductive transmitters. Tighten to a torque of 30 Nm (265 pound inches).

STEP 188

STEP 191

GD98M730

Install the breather.

STEP 192

GD98M733

Install new O-rings in oil distribution covers. Install the two oil distribution covers on the housing with hex nuts and flat washers. Tighten to a torque of 25 Nm (221 pound inches).

GD98M737

Install the gasket and the cover plate. Tighten to a torque of 23 Nm (204 pound inches). With a new O-ring, install the screw plug. Tighten to a torque of 140 Nm (103 pound feet).

FRONT AXLE

6004

Section 6004

6004-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACing HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly Differential Locking version DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Differential locking version DHL-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Disc Clearance of Differential Lock (100% lock for DHL-1200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Backlash and Bearing Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Pattern Check of Bevel Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage Test of DHL (100% lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal / Imput Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 6 6 7 7 13 14 25 25 25 26 26 27 30 30 35 41 43 45 47 49 52 53 54 56 56 62 67 70 72 74 75

6004-3

SPECIFICATIONS W110C Axle Options

LSD (*)

HD (**)

Multitrac Axle Tipe

MT-L3065II

MT-L3075II

MT-L3065II

Position

Front Axle

Rear Axle

Front Axle

Rear Axle

Differential Locking

Differential Open

Differential Yoke

Limited Slip Differential DS1480

DS1480

Flange to Flange (mm)

1984

Axle Ratio

21.53

Ratio Beverl Gear

3.36

Ratio Planetary Drive

6.4

DZ1200

DHL1200

D1200

Differential Locking

Differential Open

Spring pad 8x27, 788-1018.4

Above center pivot 200

12xM22x1.5; studs PCD 425

Differential version Differential type Axle Installation Dimension Output Shaft Sealing Brake Oil Volume (liters/U.S. Quarts)

Limited Slip Differential Spring pad 8x27, 788-1018.4

Above center pivot 200

12xM22x1.5; threads 12xM22x1.5; threads PCD 425 PCD 425 Lip Seal

Lip Seal

Metal Face Seal

4 x Paper Jinmyung

4 x Sinter

22 (23.2)

* Limited Slip Differential ** Heavy Duty

SPECIFICATIONS Brake Wear Measurement..................................................................................................... 4.0 mm Max (0.16 inch) Sun Gear Shaft End Play.............................................................................................................1.00 mm (0.04 inch) Drive Pinion Rolling Torque ................................................................................... 1.1 to 2.3 Nm (9.7 to 20.4 lb-inch)

SPECIAL TORQUES Bolts Securing Brake Housing to Axle Housing................................................................... 390 Nm (288 pound feet) Wheel End Retainer Bolts ................................................................................................... 500 Nm (369 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads).................................................. 700 Nm (516 pound feet) Bolts Securing Differential Housing to Axle Housing ........................................................... 390 Nm (288 pound feet) Bolts Securing Differential Cover and Ring Gear ................................................................ 410 Nm (302 pound feet) Nut for Securing Brake Tube to Axle Housing ....................................................................... 100 Nm (74 pound feet) Brake Tube to Axle Housing Fitting........................................................................................ 100 Nm (74 pound feet) Brake Tube Axle Housing Fitting.............................................................................................. 36 Nm (27 pound feet) Breather Plug........................................................................................................................... 50 Nm (37 pound feet) Oil Drain Plugs (Outputs)......................................................................................................... 50 Nm (37 pound feet) Oil Fill Plug / Dipstick ............................................................................................................... 50 Nm (37 pound feet) Brake Lining Check Plug ......................................................................................................... 50 Nm (37 pound feet) Brake Bleeder Valve ................................................................................................................. 6 Nm (4.4 pound feet) Brake Return Spring Retainer Bolts ........................................................................................ 34 Nm (25 pound feet)

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 3

4 9 W110R563

1. OIL DRAIN HOLE (AXLE HOUSING) 2. OIL DRAIN HOLE (OUTPUTS) 3. OIL FILL PLUG & DIPSTICK

4. BRAKE BLEEDER 5. CONNECTION DIFF. LOCK AND BREATHER 6. BRAKE INLET

7. PLUG 8. OIL FILLER AND OVERFLOW 9. WEAR CHECK DISC BRAKE

NOTE: Rear axle shown. Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE A

BD07N211-01

BS00M071

NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired. Wear measurement must be made on both wheel end sides. Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing the plug. Tighten plug to a torque of 50 Nm (40 pound feet).

6004-7

WHEEL END AND BRAKE Disassembly

STEP 3

NOTE: Tools and axle shown in the following photographs 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

BD06G004-01

Use lifting bracket, to hold wheel end. Loosen and remove the bolts and washers.

STEP 4 2 BD08A277-01

Fasten axle on a stand.

STEP 2

BD07N013-01

Carefully pull the wheel end from the axle housing. Remove and discard O-ring (1) from axle housing wheel end and O-ring from brake port (2).

STEP 5 W110R567

BD06G005-01

Mount the wheel end on a stand. W110R568

Remove drain plugs and drain oil from axle housing.

6004-8

STEP 6

STEP 9

BD07N113-01

Remove sun gear from the planetary gears. Do not loose the shim (s) located in the sun gear shaft.

BD07N110-01

Remove the end shim from the brake housing.

STEP 10

STEP 7

BD07N109-01 BD07N112-01

Remove plate from brake housing.

Remove snap ring on all three planetary gears.

STEP 11

STEP 8

BD07N108-01 BD07N045-01

Use an acceptable tool and remove planetary gear and bearing, repeat procedure for the other two gears.

Remove brake disk from brake housing.

6004-9

STEP 12

STEP 15

BD07N107-01

Remove brake plate from brake housing.

BD07N093-01

STEP 13

Remove the four bolts holding the wheel end to the output shaft of the carrier.

Repeat Steps 11, and 12 to remove the remaining brake plates, and friction plates.

STEP 16

STEP 14

BD07N090-01

Remove the retainer from the wheel end. BD07N097-01

STEP 17

BD07N094-01

Pry the cover off from the output shaft. Remove and discard O-ring from cover.

BD07N089-01

Attach an acceptable lifting device to the wheel end and remove the wheel end of axle from the brake housing.

6004-10

STEP 18

STEP 20

BD07N087-01

BD07N047-01

Attach an acceptable lifting device to the brake housing and remove from the carrier.

Inspect the carrier output shaft bearing. If damaged score with a die grinder and remove bearing cage. Then score bearing with die grinder and break with a hammer and chisel.

STEP 19

STEP 21

BD07N046-01

BD07N035-01

Remove the face seal ring metal ring from the wheel end shaft using a pry bar.

BD06G015-01

Inspect the stop pin (plug) for wear. If necessary drill a hole into the pin, use acceptable tool and remove the pin.

6004-11

STEP 22

STEP 25

BD07N052-01

BD06G022

Inspect bearing on wheel end shaft. If damaged score with a die grinder and remove bearing cage. Then score bearing with die grinder and break with a hammer and chisel.

Remove return spring from the brake housing.

STEP 26

STEP 23

BD07N055-01

Remove shim from the brake housing.

BD07N049-01

STEP 27

Remove six bolts from the return spring retainer.

STEP 24

BD07N056-01

Pry brake piston from the brake housing alternate sides in order to raise piston evenly. BD07N054-01

Remove return spring retainer.

6004-12

STEP 28

STEP 31

BD07N063-01

BD07N059-01

Remove brake piston from brake housing.

Remove upper seal from break housing.

STEP 29

STEP 32

BD07N065-01

BD07N067-01

Remove lower seal, located in the same groove as lower back-up ring from the brake housing.

Remove wear ring from brake housing.

STEP 30

STEP 33

BD07N064-01

Remove upper back-up ring, located in same groove as upper seal from the brake housing.

BD07N066-01

Remove lower back-up ring from the brake housing.

6004-13

Cleaning and Inspection

STEP 34

IMPORTANT: Do not use compressed air to dry bearings. Allow bearings to air dry.

STEP 37 Clean all parts except friction plates in brake disc p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FAC E PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to clear passages in planetary ring gear and brake housing.

STEP 38 BD07N079-01

Drive out the outer bearing cup on the brake housing.

STEP 35

I n s p e c t b e a r i n g r o l l e r s fo r p i t t i n g , s c o r i n g , deformation, or other damage. Check inner face and bearing cage for deformation, dents, and other da m ag e. Che ck ass ocia ted be ar ing cup s fo r scratches, grooves, or cracks. Check bearings for rough spots or binding by holding bearing and rotating. If bearing binds or action is not smooth, replace the bearing.

STEP 39 Inspect bearing cups for pitting, scoring, cracks, or other damage. Replace if any of these conditions are seen. NOTE: If a bearing or bearing cup requires replacement, the associated part must also be replaced. BD07N080-01

Flip brake housing over and pry out face seal.

STEP 36

STEP 40 Check planetary ring gear, planetary gears, and planetary carrier gear teeth for cracks, breaks, chipping, or other damage. Replace the part if any of these conditions are seen. Check planetary carrier shaft sp lines fo r br oken , cra cked, o r twiste d condition. Replace if necessary.

STEP 41 Check wheel end shaft for cracked, broken, or twisted splines. Replace if any of these conditions are seen.

BD07N081-01

Drive out inner bearing from the brake housing.

6004-14

Assembly

STEP 44

STEP 42 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A BD07N038-01

Apply Loctite 574 to the seal ring mounting surface.

STEP 45 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD07N040-01

Heat the wheel end shaft outer bearing to 120C (248F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearing on the wheel end shaft until the bearing is against the shoulder on the wheel end shaft.

STEP 43 BD07N039-01

Heat the seal ring to approximately 120° C (248° F), place the face seal ring on the wheel end shaft.

BD07N037-01

Clean mounting surface of seal ring area on wheel end.

6004-15

STEP 46

STEP 48 WARNING: Always wear gloves to prevent frostbite to your hands when handling frozen parts. SM118A

BD06G084-01

Use acceptable tool to drive seal ring into position on hub. NOTE: Be sure the sealing ring is fully seated. BD07N082-01

STEP 47 WARNING: Always wear gloves to prevent frostbite to your hands when handling frozen parts. SM118A

BD07N083-01

Place inner bearing cup in dry ice for several hours to freeze. Install the inner bearing cup into the brake housing until seated against the shoulder in the brake housing.

Place outer bearing cup in dry ice for several hours to freeze. Install the outer bearing cup into the brake housing until seated against the shoulder in the brake housing.

6004-16

STEP 49

STEP 51

BD06G032-01

A A

BD07N070-01

Install the lower back-up ring (1) into the brake housing.

A 1

STEP 52

BS00M073

1. FACE SEAL 2. BRAKE HOUSING A FILL WITH GREASE

BD07N072-01

Wet the outer diameter of the face seal with a solution of 50% water and 50% mineral spirits. Use suitable tool to install the face seal with the seal lip positioned as shown. Apply grease to seal as indicated by (A) above.

Install the lower seal (2) in the same groove as the lower back-up ring (1). Make sure seal is installed as shown in Step 56.

STEP 53

STEP 50

BD07N074-01

BD07N069-01

Clean seal grooves in brake housing with solvent.

Install the upper seal (4) into the brake housing. Make sure seal is installed as shown in Step 56.

6004-17

STEP 54

STEP 56

6 5 4 3 BD07N075-01

Install upper back-up ring (5) into the same groove as the upper seal.

STEP 55

BC08A246

WEAR RING, BACK-UP RINGS AND SEAL LOCATION 1. LOWER BACK-UP RING 2. LOWER SEAL 3. BRAKE HOUSING

4. UPPER SEAL 5. UPPER BACK-UP RING 6. WEAR RING

NOTE: Install the back-up rings and seals in the grooves of the brake housing as shown in the illustration above.

STEP 57

BD07N077-01

Clean the groove of the brake housing with cleaning solvent. Install wear ring (6) into the top groove of the brake housing. IMPORTANT: Ensure correct installation position of wear ring end points must be in the 12 oâ&#x20AC;&#x2122;clock position in the axle when installed in the machine in the area of brake oil supply and vent hole. NOTE: Make sure that the wear ring is installed correctly in the groove around the entire circumference of the brake housing. Then apply Loctite 415 at its end points.

BD07N086-01

Drive the adjustment pins flush with the surface of the brake piston. NOTE: Orientation of brake piston when driving in pins.

6004-18

STEP 58

STEP 60

BD00M283 BD07N061-01

Install return spring in the brake housing. Install with the tapered end facing upward.

STEP 61

BD07N062-01

Apply oil on the sliding surface of the brake piston, Carefully install piston in the brake housing. BD07N054-01

STEP 59

Install the return spring retainer into the brake housing.

STEP 62

BD07N057-01

Install shim into the brake housing. BD00M285

Install the six bolts into the return spring retainer and tighten to 34 Nm (25.1 pound feet).

6004-19

STEP 63

STEP 65

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD08A441-01

Coat the spline of the carrier output shaft with Loctite 767 antiseize lubricant.

STEP 66 BD07N048-01

Heat the carrier output shaft to 120C (248F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearing on the shaft until the bearing is against the carrier gear.

STEP 64

BD07N087-01

Attach an acceptable lifting device to the brake housing and inser t the brake housing on to the carrier output shaft.

STEP 67 BD06G053-01

Install a new stop pin if it was removed, damaged or worn.

BD07N089-01

Attach an acceptable lifting device to the wheel end and install the wheel end on to the brake housing. A slight rotation of the wheel end maybe necessary to align the splines on the carrier output shaft.

6004-20

STEP 68

STEP 70

BD07N090-01

BD07N095-01

Install the retainer into the wheel end on the output shaft of the carrier.

STEP 69

BD07N096-01

Install a new O-ring on the cover and use a mallet and install the cover into the wheel end.

BD07N092-01

Install the four new bolts holding the wheel end to the output shaft of the carrier. Tighten the bolts to a torque of 500 Nm (368.8 pound feet). Rotate brake housing several times in both directions and recheck torque. IMPORTANT: Do not reuse locking bolts, just one time installation is permitted.

6004-21

2 1

8 BS08A216

BRAKE DISC ASSEMBLY LAYOUT 1. END SHIM 2. PLATE (2.0 MM)

3. BRAKE PLATE (THICK) 4. SPRING RETAINER

STEP 71

5. RETURN SPRING 6. SHIM

7. BOLT (QUANTITY 6) 8. BRAKE DISC

STEP 72

BD07N107-01

Install 2.0 mm plate (2) into the brake housing.

BD07N108-01

Install brake disk (8) into the brake housing.

6004-22

STEP 73

STEP 75

BD07N109-01 BD07N110-01

Install end shim (1) on top of the 2.0 mm plate (2).

STEP 76 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD07N108-01

Install a brake plate (3) and brake disk (8) into brake housing alternately as shown on page 21 until all the brake discs (8) are installed.

STEP 74

BD08B032-01

Heat the sun gears to 120C (248F) in a bearing oven. Wearing heat resistant gloves or mittens, install the sun gears on the shaft until the bearing is against the carrier gear.

BD07N107-01

Install last 2.0 mm plate (2) into the brake housing.

6004-23

STEP 77

Sun Gear Shaft End Play Adjustment NOTE: Tools and axle shown in the following photographs 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 78 1

BD07N112-01

Install the snap rings on planetary gear shafts with snap ring pliers.

BD07N013-01

Install a new O-ring onto the axle housing (2) and a new O-ring in brake port (1) in axle housing.

STEP 79

BD08B036-01

Take a measurement from the straight edge to the face of the brake housing, the difference between this measurement and the next measurement will be dimension A. Mount the sun gear into the planet gears. Then, determine dimension A, from the inner face of the sun gear to the face of the brake housing. Example: Dimension A . . . . . . . . . . . . . 97.90 mm (3.85 inch)

STEP 80 Install the stub shaft in the spline of the axle bevel gear. Make sure the stub shaft is installed all the way into the axle bevel gear.

6004-24

STEP 81

STEP 84

BD08B033-01

BD08B035-01

Install the sun gear onto the stub shaft with out the shims.

Install the sun gear shaft into the stub shaft with the determined shim set. (size as determined in Step 83) into the sun gear shaft with grease.

STEP 82

STEP 85

BD08B034-01

BD06G072-01

Determine dimension B from the face of the sun gear to the mounting face of the axle housing.

Use lifting bracket, and install the assembled wheel end onto the axle housing.

Example: Dimension B . . . . . . . . . . . . 100.20 mm (3.95 inch)

NOTE: Turn the input flange to align splines of the stub shaft into the sun gear.

STEP 83

STEP 86

Subtract dimension A from dimension B. Then subtract 1.30 mm (0.05 inch) from the difference. The difference is the required shim size. Example: Dimension B Dimension A Difference Required end play Difference = shim size

100.20 mm (3.94 inch)  97.90 mm (3.85 inch) 2.30 mm (0.09 inch) 1.30 mm (0.05 inch) 1.00 mm (0.04 inch)

BD02D154-01

Install the washers and bolts to secure the wheel end to the axle housing. Tighten the bolts to a torque of 390 Nm (287.7 pound feet).

6004-25

STEP 87

BD07N212-01

Remove dip stick from axle housing. Refill the axle with 22 Liters (23.2 quarts) of Ambra MULTI G134 TM HYDRAULIC TRANSMISSION OIL (SAE 80W-140).

STEP 88

BD07N213-01

Insert dip stick back into the axle but do not screw in set it off on the edge fill hole, oil level should be between upper and lower level on the dip stick. Install plug into axle housing and torque plug to 50 Nm (36.9 pound feet).

6004-26

BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS. If the maximum pressure of 100 bar (1450 psi) is exceeded, the piston will move too much changing the gripping rings adjustment. If the gripping rings adjustment changes, the wheel end must be removed and disassembled and the gripping rings adjusted to the correct dimension.

STEP 89

High Pressure Test STEP 91 Operate the hand pump to increase pressure to 100 bar (1450 psi) maximum. Close connection to hand pump using the shutoff valve. During a 5 minute period, pressure shall not drop more than 3% or 3 bar (43.5 psi).

Low Pressure Test STEP 92 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period there should be no pressure drop.

BD00M305

Connect a hand pump with pressure gauge to the brake port as shown above. Fill the hand pump with hydraulic oil.

STEP 90

BD07N208-01

Build up pressure in the axle internal brake lines then bleed air from the lines. After air is bled, actuate the brakes a minimum of 5 times to a pressure of 100 bar (1450 psi) by operating the hand pump.

6004-27

REPLACING HUB SEAL Removal

STEP 95

STEP 93

BD07N094-01

Remove and discard the O-ring.

STEP 96

BD06G074-01

Remove drain plug and drain oil from the brake housing.

STEP 94

BD07N093-01

Remove the four bolts from the carrier output shaft.

STEP 97

BD07N097-01

Use pry bar and remove the end cover.

BD07N090-01

Remove the retainer from the wheel end.

6004-28

Installation

STEP 98

STEP 101

BD06G078-01

Use lifting bracket, to hold wheel end. Separate the output shaft using a puller.

STEP 99

BD06G081-01

A A

A 1 2

BD06G079-01

Use a pry bar and remove the seal from the brake housing.

STEP 100 BS00M073

1. FACE SEAL

2. BRAKE HOUSING

A. GREASE

Wet the outer diameter of the face seal with a solution of 50% water and 50% mineral spirits. Use appropriate tool to install the face seal with the seal lip positioned as shown. Apply grease to seal as indicated by (A) above.

BD07N035-01

Inspect the metal face seal ring for damage or wear marks where the seal makes contact, if required remove the bushing.

6004-29

STEP 102

STEP 105

BD06G084-01

BD07N037-01

Clean the seal ring mounting surface with solvent.

Use suitable tool and drive the metal face seal ring into position onto the hub.

STEP 103

NOTE: Be sure the sealing ring is properly seated.

STEP 106

BD06G082

Apply Loctite 574 to the seal ring mounting surface. BD06G086-01

STEP 104 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

Grease the seal lip of the shaft seal, use lifting bracket, and install the wheel end onto the brake housing.

STEP 107

SM121A

BD07N090-01

Install the retainer on the wheel end. BD07N039-01

Heat the meal face seal ring to 120Â° C (248Â° F), place the face seal ring onto the wheel end shaft.

6004-30

STEP 108

STEP 111

BD07N092-01

Install the four bolts and tighten to a torque of 500 Nm (369 pound feet). Rotate brake housing several times in both directions and recheck torque.

STEP 109

BD07N212-01

Remove the dip stick from the axle housing. Refill the axle with 22 Liters (23.2 quar ts) of the proper AMBRA MULTI G 134TM Hydraulic transmission oil (SAE 80W-140).

STEP 112

BD07N095-01

Install a new O-ring on the wheel end cover.

BD07N213-01

STEP 110

BD02D053-01

Install the wheel end cover into the wheel end.

6004-31

DIFFERENTIAL Removal and Disassembly Limited Slip Differential version DZ-1200

STEP 114

STEP 113

BD06G126-01

Fasten the axle to a stand, support the center of the axle as shown, facing the input shaft attach suitable lifting equipment to the left axle housing, remove the mounting bolts and axle half. ATTENTION: Differential can fall out of housing when axle half is removed. W110R567

W110R568

Remove drain plugs and drain oil from axle.

STEP 115

BD06G127-01

Connect lifting bracket to the differential and remove the differential from axle housing. NOTE: Make sure that the right axle stub shaft releases from the differential.

6004-32

Disassembly Limited Slip Version DZ-1200

STEP 119

STEP 116

BD07N162-01

Remove the ring gear from the differential housing. BD01F075-01

If required, remove the bearing from the housing cover using appropriate tools.

STEP 120

STEP 117

BD07N159-01

BD07N165-01

Place the differential in a press to prevent it from turning. Remove the bolts.

STEP 118

BD07N148-01

Remove the outer set of clutch plates, thrust washer, and bevel gear from the differential housing.

BD07N163-01

Remove the housing cover from the differential housing.

6004-33

STEP 121

STEP 123

BD07N145-01

Drive both roll pins out of the differential housing and remove pins.

BD07N136-01

Remove the differential shaft from the differential housing.

STEP 124

STEP 122

BD07N131-01 BD07N140-01

BD07N139-01

NOTE: Remove the two differential half shafts, bevel gears and thrust washers from the differential housing.

Remove the two bevel gears and thrust washers from the differential housing.

6004-34

STEP 125

STEP 127

BD07N129-01

BD06G131-01

Pull the bearing cups and shims from both axle housings. NOTE: Make sure to identify the shims into which axle housing they were removed.

BD07N114-01

Remove the inner set of clutch plates, thrust washer, and bevel gear from the differential housing.

STEP 126

BD07N104-01

If required, remove bearing from differential housing using a bearing puller and a press.

6004-35

3 1

9 10 11

3 14

15 8 16 2

4 9 BS08A334

LIMITED SLIP DIFFERENTIAL ASSEMBLY EXPLODED VIEW 1. 2. 3. 4.

INNER BEVEL GEAR AXLE THRUST WASHER (COPPER COLOR) REACTION PLATES FRICTION PLATES

5. 6. 7. 8.

DIFFERENTIAL ROLL PIN ROLL PIN BEARING

9. 10. 11. 12.

THRUST WASHER SPIDER GEAR HALF SHAFT SHAFT

13. 14. 15. 16.

OUTER BEVEL GEAR RING GEAR COVER DIFFERENTIAL BOLT

6004-36

Reassembly Limited Slip Differential version DZ-1200

STEP 131

STEP 128

BD07N119-01

Install one friction plate on the inner bevel gear.

STEP 132

BD07N105-01

Install bearing on differential housing using a press.

STEP 129 Check reaction plates, friction plates and thrust washers for damage or wear, replace if necessary. NOTE: Be sure to apply oil to all parts before assembly.

BD07N120-01

Install one friction plate on the inner bevel gear.

STEP 130

STEP 133

BD07N118-01

Install the thrust washer (copper color) on the inner bevel gear. NOTE: Clutch plates must be installed on the inner bevel gear in the correct order, refer to illustration on page 35.

BD07N122-01

Install two reaction plates on the inner bevel gear.

6004-37

STEP 134

STEP 137

BD07N124-01

Install two friction plates on the inner bevel gear.

BD07N127-01

Install one reaction plate on the inner bevel gear.

STEP 138

STEP 135

BD07N128-01 BD07N125-01

Install one reaction plate on the inner bevel gear.

STEP 136

BD07N126-01

Install one friction plate on the inner bevel gear.

Align all tabs of reaction plates on the inner bevel gear.

6004-38

STEP 139

STEP 141

BD07N129-01

BD07N136-01

BD07N130-01

BD07N137-01

Install the clutch pack and inner bevel gear assembly into the differential housing.

Install the full differential shaft into the housing through both thrust washers and spider gears installed in the previous step. Make sure position of hole in center of differential shaft is horizontal to the differential housing.

STEP 140 1

STEP 142 2

BD07N131-01

1. THRUST WASHER

2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the differential housing. Install another thrust washer (1) and spider gear (2) directly across from the first. Make sure to install in the correct location for the full differential shaft. NOTE: The torsional stop (tab) on the thrust washer must be positioned upwards see image above.

BD07N139-01

1. THRUST WASHER

2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the differential housing. Install another thrust washer (1) and spider gear (2) directly across.

6004-39

STEP 143

STEP 145

BD07N140-01

BD07N142-01

Install new roll pins into differential housing.

NOTE: Use new roll pins only.

STEP 146 3

BD07N138-01

Install both differential half shafts into housing through thrust washers and spider gears installed in previous step. The tapered end of half shafts (1) insert into the hole in center of differential shaft. Make sure the holes on the other end of the half shafts (2) align with the holes in the differential housing (3).

Drive the new roll pins into differential housing to secure half shafts.

STEP 144

STEP 147

BD07N138-01

Spider gear assembly installed in differential housing.

BD07N144-01

BD07N149-01

Install the thrust washer (copper color) on the outer bevel gear. NOTE: Clutch plates must be installed on the outer bevel gear in the correct order, refer to illustration on page 35.

6004-40

STEP 148

STEP 151

BD07N150-01

BD07N155-01

Install one reaction plate on the outer bevel gear.

Install two friction plates on the outer bevel gear.

STEP 149

STEP 152

BD07N151-01

Install one friction plate on the outer bevel gear.

STEP 150

BD07N153-01

Install two reaction plates on the outer bevel gear.

BD07N156-01

Install one reaction plate on the outer bevel gear.

6004-41

STEP 153

STEP 156

BD07N156-01

Install one friction plate on the outer bevel gear.

STEP 154

BD07N160-01

Clean ring gear mounting surface on differential housing.

STEP 157

BD07N158-01

Align all tabs of reaction plates on the outer bevel gear.

STEP 155

BD07N161-01

Clean mating surfaces of ring gear and differential cover. NOTE: The ring gear and the drive pinion are a matched gear set and cannot be serviced separately.

STEP 158

BD07N159-01

Install the clutch pack and outer bevel gear assembly into the differential housing. BD07N162-01

Install ring gear on differential housing. NOTE: Make sure to align bolt holes when installing ring gear and differential cover.

6004-42

Drive Pinion Removal

STEP 159

NOTE: Ring and drive pinion are matched set and can not be serviced separately.

STEP 162

BD07N163-01

NOTE: Install cover on differential housing.

STEP 160 BD07N168-01

Heat locknut securing flange with a hot air blower to loosen Loctite, approximately 120Â° C (248Â° F)

STEP 163

BD07N166-01

Place the differential in a press to prevent it from turning. Install new bolts and tighten to a torque of 410 Nm (302.4 pound feet). NOTE: Use new locking bolts do not reuse old bolts.

STEP 161 If bearing was removed from differential cover install bearing using a press.

BD07N169-01

Use suitable tool to hold input flange. Hold flange using holding tool and remove lock nut and washer. Remove holding tool from flange.

6004-43

STEP 164

STEP 167

BD07N181-01 BD07N173-01

Remove the input flange from the drive pinion and seal.

Drive inner bearing cup from the differential housing.

STEP 168

STEP 165

BD06G141-01

Remove inner bearing cup and shim from differential housing. BD07N174-01

STEP 169

Press the input pinion out of the housing.

STEP 166

BD07N175-01 BD07N183-01

Drive outer bearing cup from the differential housing.

Remove the spacer ring from the drive pinion.

6004-44

Brake Tube Removal

STEP 170

STEP 171

BD06G167

Remove inner bearing from the drive pinion using a suitable tool and a press.

BD07N030-01

Remove the plug with the breather installed from the axle housing on the differential end.

STEP 172

BD07N001-01

Remove fitting from the brake tube on the axle housing on the differential end of the axle.

6004-45

STEP 173

STEP 174

BD07N004-01

BD07N008-01

BD07N006-01

BD07N010-01

Loosen and remove the nut holding the brake tube to the axle housing on the differential end of the axle.

Loosen the brake tube at wheel end of axle housing then remove the brake tube from the axle housing.

STEP 175

BD07N015-01

Remove the fitting on the wheel end of the axle housing. NOTE: Repeat steps 171 through 174 for the other side of the axle.

6004-46

Brake Tube Installation

1 5

BS08B043

1. HEXAGON NUT 100 NM (73.8 LB.-FT.) 2. O-RING

3. BRAKE TUBE 4. AXLE HOUSING

STEP 176

5. SCREW NUT 100 NM (73.8 LB.-FT.) 6. SCREW CONNECTOR 36 NM (26.6 LB.-FT.)

STEP 177

BD07N017-01

BD07N018-01

Install a new O-rig on the fitting removed from the wheel end of the axle.

Install the connector in the axle and tighten to a torque of 36 Nm (26.6 pound feet).

6004-47

STEP 178

STEP 180

BD00M343-01

BD07N006-01

Install a new O-ring in the groove of the brake tube fitting.

STEP 179

BD07N005-01

Install the nut to secure the brake tube. Tighten the nut to a torque of 100 Nm (73.8 pound feet). BD07N010-01

STEP 181

Install the brake tube in axle housing.

BD07N009-01

Connect opposite end of brake tube to connector installed in wheel end. Tighten brake tube nut to 100 Nm (73.8 pound feet). IMPORTANT: Use the two wrench tightening method to prevent the connector in axle from turning. NOTE: Do steps 176 through 181 for the other wheel end.

6004-48

STEP 182

STEP 183 1

2 3

BD00M347-01

BREATHER VENT EXPLODED VIEW 1. O-RING

2. PLUG

3. BREATHER

Remove and discard O-ring (1) from plug (2) and install a new O-ring. Install breather (3) in plug.

BD07N003-01

Install the plug in axle housing. Tighten plug to a torque of 50 Nm (36.9 pound feet). Tighten breather valve to standard torque specification.

Drive Pinion Installation STEP 184

BD06G137-01

Find and record the housing dimension “X” located inside the differential housing where the pinion shaft is located. Dimension X (Example).......205.30 (8.08 inch)

6004-49

STEP 185

STEP 187 Calculation example A: Dimension I Dimension II Results in dimension Y

36.13 mm -------(1.422 inch) 167.95 mm -------(6.612 inch)  204.08 mm ------(8.034 inch)

Calculation example B: Dimension X

BD06G138-01

Measure the thickness of the inner bearing and record its measurement, dimension “I”.

Dimension Y Difference = shim thickness

205.30 mm -------(8.080 inch) 204.08 mm -------(8.034 inch)  1.22 mm ------(0.046 inch)

Dimension I (Example)..... 36.13 mm (1.422 inch) NOTE: Deduct the thickness of the gauge blocks being used to support the bearing from the overall measurement. IE: overall measurement 106.13 mm (4.178 inch) minus gauge block thickness 70 mm (2.756 inch) will equal dimension I.

Shims are available in 0.10 mm (0.004 inch), round up or down to the next available shim thickness, s = 1.20 (0.044 inch).

STEP 188

STEP 186

1 1

BD06G140-01

2 BD06G139-01

1. MATING NUMBER (MARKED MANUALLY) 2. PINION BASIC DIMENSION (STAMPED) 3. PINION DISTANCE DEVIATION + OR - (MARKED MANUALLY)

Distance deviation is indicated in 1/100 mm. If no distance deviation is indicated the pinion basic dimension is identical with the pinion dimension. Record this as dimension “II”. Dimension II (Example) 168 -0.05 mm = 167.95 mm .........................(6.614 inch -0.002 inch = 6.612 inch)

NOTE: Heat the bearing hole to approximately 120° C (248° F) and install the outer bearing cup until contact is made using an acceptable tool.

6004-50

STEP 189

STEP 190

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

SM121A

BD06G141-01

BD07N178-01

Heat the pinion inner bearing to 120째 C (248째 F) in a bearing oven. Wearing heat resistance gloves or mittens, install the bearing on the pinion shaft until contact. After installing bearing on pinion shaft, allow the bearing to cool to ambient temperature.

Drive Pinion Bearing Rolling Torque Adjustment STEP 191 BD06G142-01

Heat the inner bearing hole on the differential housing to approximately 120째 C (248째 F). Install the shim set determined in Step 187 in the bearing bore and press the bearing cup into to the bearing hole using a suitable tool.

BD07N175-01

Install a 9.03 mm (0.35 inch) thick spacer on the pinion shaft.

6004-51

STEP 192

STEP 194

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD06G147-01

Install the input flange on the pinion shaft.

STEP 195 BD07N186-01

Heat the pinion shaft outer bearing to 120Â° C (248Â° F) in a bearing oven. Wearing heat resistance gloves or mittens, install the bearing on the pinion shaft until contact. Prior to mounting the input flange and tightening the nut, allow the bearing to cool to ambient temperature.

STEP 193

BD07N171-01

BD06G146-01

Press the dust shield on the input flange.

BD07N170-01

Install the washer and nut on the pinion shaft.

6004-52

STEP 196

STEP 197

BD07N169-01

BD07N204-01

Use a suitable tool to hold input flange. Hold flange using holding tool and tighten nut to a torque of 700 Nm (515 pound feet). Remove holding wrench.

Check the rolling torque of the drive pinion bearing. The rolling torque should be 1.1 to 2.3 Nm (9.7 to 20.4 pound-inch). If rolling torque is too low, install a thinner spacer (Step 191); if rolling torque is too high, install a thicker spacer (Step 191).

When tightening rotate the pinion shaft in both directions several times.

STEP 198 Remove the nut and input yoke from the drive pinion shaft.

6004-53

Setting Backlash and Bearing Preload Deviation Value

-20

-10

+10

+20

Shim A

1.20 mm (0.047 inch)

1.10 mm (0.043 inch)

1.00 mm (0.039 inch)

0.90 mm (0.035 inch

0.80 (0.032 inch)

Shim B

0.80 mm (0.032 inch)

0.90 mm (0.035 inch)

1.00 mm (0.039 inch)

1.10 (0.043 inch)

1.20 (0.047 inch)

STEP 199

STEP 200 2

BD06G163-01

Record the deviation value from side of ring gear, the value will be a + or -, use the table to determine shim thicknesses needed. Example: Deviation value of +10 requires the following shims: Shim A = 0.90 mm (0.035 inch) Shim B = 1.10 mm (0.043 inch)

BC06G004

1. 2. 3. 4.

DIFFERENTIAL DRIVE HOUSING AXLE HOUSING INPUT PINION

5. AXLE HOUSING A. RING GEAR SIDE B. CARRIER SIDE

STEP 201

BD06G164-01

Insert shim A- 0.90 mm (0.354 inch) and install the bearing outer ring with a suitable tool until seated in axle housing.

6004-54

STEP 202

STEP 205

BD06G165-01

Insert shim B- 1.10 mm (0.043 inch) and install the bearing outer ring with a suitable tool until seated in axle housing.

BD07N202-01

Contact Pattern Check

Position the axle housing on the drive housing, install 4 bolts, top center, bottom center, front center, rear center, torque bolts evenly to 390 Nm (285 pound feet).

STEP 203

STEP 206

BD06G166-01

Apply marking ink on several teeth of the ring gear.

STEP 204

BD06G169-01

Roll the input pinion several times in both directions over the ring gear. Remove the differential and compare the contact pattern with examples on page 4 and page 5. If the tooth contact pattern differs, the wrong shim size was selected in Step 187. Remove differential and repeat Steps 184 though 187.

BD07N199-01

Position the differential assembly in the axle drive housing.

6004-55

Installation

STEP 209

STEP 207

BD06G171-01

Loosen and remove the nut and input flange. BD07N199-01

Position the differential assembly in the axle drive housing.

STEP 210

STEP 208

BD06G172

Install the shaft seal with the sealing lip towards oil sump using appropriate tool. BD06G170-01

Install a new O-ring on the axle housing. Position the axle housing on the drive housing.

BDO7N207-01

Install bolts and torque bolts evenly to 290 Nm (215 pound feet).

NOTE: Wet the outer diameter of the seal with a solution of 50% water and 50% mineral spirits. Fill the space between the sealing and dust lip with grease.

6004-56

STEP 211

STEP 213

BD06G173-01

BD07N213-01

Install the input flange. Using a suitable holding tool, on input flange. Apply Loctite No. 262, on the threads of the locknut. Install the washer and locknut by hand. Hold flange using holding tool and tighten nut to a torque of 700 Nm (516 pound feet).

NOTE: Rotate the input pinion several times in both directions when tightening.

STEP 212

BD07N212-01

Remove the dip stick from the axle housing. Refill the axle with 22 Liters (23.2 quarts) of AMBRA MULTI G 134TM Hydraulic transmission oil (SAE 80W-140).

6004-57

DIFFERENTIAL Removal and Disassembly Differential Locking version DHL-1200

STEP 2

STEP 1

BD06G126-01

W110R567

W110R568

Remove drain plugs and drain oil from axle.

6004-58

Disassembly

STEP 6

STEP 3

W110R474

Remove axial roller ring (could get stuck on piston). W110R471

Remove bearing outer ring and shim behind (rolling torque differential bearing) out of axle housing.

STEP 7

NOTE: Mark shim (position/bearing allocation) â&#x20AC;&#x201C; assembly aid.

STEP 4

W110R475

Lift differential assy out of axle drive housing.

STEP 8 W110R472

Remove O-ring (arrow). Pull piston out of axle housing hole.

STEP 5

W110R476

Pull both bearing inner rings off the differential.

W110R473

Remove O-rings (arrows) from piston.

6004-59

STEP 9

STEP 11

W110R477

W110R479

Hold differential by means of a press (for this purpose place pressure piece) and loosen lid screws.

Compensate spring preload of lid by means of the press and remove retaining ring. Remove releasing components (retaining ring, sliding sleeve and compression spring).

NOTE: Locking screws â&#x20AC;&#x201C; permitted for one-time use only.

STEP 12

STEP 10

W110R480 W110R478

Remove lid and loose parts. 1 = Lid 2 = Cage 3 = Lever (12x) 4 = Pressure piece 5 = Cylindrical pins (6x)

Remove disc package and disc carrier.

6004-60

STEP 13

STEP 15

W110R481

Remove crown wheel, axle bevel gear, thrust washer and constant spacer. 1 = Differential carrier 2 = Crown wheel 3 = Constant spacer 4 = Thrust washer 5 = Axle bevel gear

STEP 14

W110R482

Force slotted pin (fixing) out of both spider shaft halves (split version), then remove both spider shaft halves in arrow direction and take components (see figure no. W110R483) out of differential carrier.

W110R483

1 = Differential carrier 2 = Slotted pin (2x) 3 = Slotted pin (2x) 4 = Spider shaft (split version) 5 = Spider shaft (one-piece) 6 = Spider gear (4x) 7 = Thrust washer (4x) 8 = Axle bevel gear 9 = Constant spacer 10 = Outer disc 11 = Thrust washer

6004-61

STEP 16

STEP 17

W110R484

Pull out stub shaft, if required. NOTE: Pay attention to releasing sun gear shaft with inserted shim sun gear shaft – clearance). Mark allocation of shim versus sun gear shaft/stub shaft and output side – assembly aid.

W110R485

Pull bearing outer ring out of hole by means of striker and remove shim behind (backlash). NOTE: Mark shim (position/bearing allocation) – assembly aid.

6004-62

W110R564

DIFFERENTIAL LOCKING ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

DIFFERENTIAL, CASE DISC O. CLUTCH DIFFERENTIAL, RING WASHER THRUST GEAR, BEVEL, AXLE GEAR, BEVEL, DIFFERENTIAL WASHER THRUST AXLE DIFFERENTIAL AXLE, DIFF. SHORT PIN, SLOTTED PIN, SLOT

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

PIN DISC. CLUTCH OUTER 1.2 mm DISC. CLUTCH OUTER 1.3 mm DISC. CLUTCH OUTER 1.4 mm DISC. CLUTCH INNER DISC. CLUTCH OUTER LEVER DIFFERENTIAL, CAGE DIFFERENTIAL, COVER SCREW, HEX SOC PISTON

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

O-RING RING BEARING, ROLLER CAGE SLEEVE SPRING, COMPRESSION RING, LOCKING SLEEVE, ACTUATOR COUPLING, SPLINED SNAP RING BEARING, ROLLER BEARING, ROLLER, TAPERED

6004-63

REASSEMBLY Differential locking version DHL-1200

STEP 19

(DHL = Differential hydr. powershiftable)

W110R488

Insert steel outer disc (2) and thrust washer (3) into differential carrier (1). W110R486

A = Differential – part (standard version) B = DHL – part (Diff.-hydr.-powershiftable 100% lock)

NOTE: Pay attention to installation position of outer disc and thrust washer – see position/figure.

STEP 20

STEP 18

W110R489 W110R487

Insert constant spacer into differential carrier.

Insert axle bevel gear.

6004-64

STEP 21

STEP 23

W110R490

W110R492

Legend to figure-no. W110R490 … figure-no. W110R491:

Install split spider shaft (4) with spider gears (2) and thrust washers (3).

Differential spider - single parts:

NOTE: Insert thrust washers with tabs showing upwards - see arrow - and being located in recess.

1 = Spider shaft (one part) 2 = Spider gear (4x) 3 = Thrust washer (4x) 4 = Spider shaft (split version) 5 = Slotted pin (2x) 6 = Slotted pin (2x)

NOTE: Pay attention to installation position of spider shaft/halves - slotted pin/location holes of spider shaft towards diff. carrier.

STEP 24

STEP 22

W110R493

Fix spider shaft half (arrows) with double-slotted pins. W110R491

Insert one-part spider shaft (1) into hole/differential (without slotted pin location hole) thereby mounting two spider gears (2) with thrust washers (3). NOTE: Insert thrust washers with tabs showing upwards - see arrow - and being located in recess.

NOTE: Install double-slotted pins – always with slots in a 180° offset position to each other.

6004-65

STEP 25

STEP 27

W110R494

W110R496

Place second axle bevel gear into the differential carrier.

Install two adjusting screws (M 16) - see arrows - and press crown wheel to contact position.

STEP 26

For input version “with” bevel gear set only – see specification in the corresponding spare parts list: I f a b eve l g e a r s e t i s s p e c i f i e d , t h e p a i r i n g number/crown wheel (e.g. “7”) must be identical with pairing number/input pinion.

STEP 28

W110R495

Place thrust washer (2) and constant spacer (3) into the differential carrier (1). NOTE: Pay attention to installation position of thrust washer and constant spacer – see position/figure. W110R497

Place differential lid over the sliding sleeve with mounted compression spring (arrow).

6004-66

STEP 29

STEP 31

W110R498

W110R500

Fix lid by means of a press and snap retaining ring into groove of sliding sleeve.

Place cage (arrow) and position lever in cage with grease (assembly aid).

STEP 30

NOTE: Pay attention to installation position of levers - also see detailed sketch no. W110R499.

STEP 32

W110R499

Place lid on pressure piece (5, see arrow). NOTE: Ensure that lid is only supported on the pressure piece (5), but never on the sliding sleeve. Legend to detailed sketch:

1 = Lid 2 = Pressure piece 3 = Sliding sleeve 4 = Compression spring 5 = Pressure piece Insert pressure piece (2) - pay attention to installation position.

W110R501

Place cylindrical pins (for outer disc fixing) into the lid with grease (assembly aid).

6004-67

STEP 33

STEP 35

W110R502

W110R504

Equipment of the disc package (number and arrangement of the individual discs).

Insert disc package into the lid considering the required arrangement â&#x20AC;&#x201C; see figure-no. W110R502.

Legend to sketch no. W110R502 â&#x20AC;Ś. figure-no. W110R504:

NOTE: Pay attention to radial installation position of the outer disc - Locating grooves (arrow 1) of the outer disc to be positioned over the cylindrical pins (arrow 2).

1 = Outer disc (s = constant 4.0 mm) 2 = Outer discs (s = optional 1.2/1.3/1.4 mm) 3 = Inner discs NOTE: Possible other versions could show a deviating equipment (number and arrangement of the individual discs). The illustrations in the respective spare parts list forms the basis for the required equipment.

STEP 36

STEP 34

W110R505

Install snap ring (arrow) in the annular groove of the disc carrier and insert preassembled disc carrier so that all inner discs are mounted.

W110R503

Ensure a correct contact position of pressure piece, cage and levers. Insert outer disc (1. s = constant 4.00 mm) in the preassembled lid. NOTE: Pay attention to radial installation position of the outer disc - locating grooves (arrow 1) of the outer disc to be positioned over the cylindrical pins (arrow 2).

6004-68

Adjust disc clearance of differential lock (100% lock) for DHL-1200 (DHL = Differential hydr. powershiftable)

STEP 37

W110R506

Legend to sketch no. W110R506 â&#x20AC;Ś figure no. W110R507: 1 = Lid 2 = Pressure piece - 5870 100 072 3 = Pressure piece - 5870 100 078 4 = Load cell - 5870 700 004 5 = Disc carrier 6 = Disc package 7 = Sliding sleeve F = 50 + 30 KN X = Disc clearance (specified = 0.8 Âą 0.1 mm) ATTENTION: Ensure that lid (1) is only supported on pressure piece (2), but never on the sliding sleeve (7). ATTENTION: Ensure that pressure piece (3) is seated only on disc package (6), but not on disc carrier (5).

6004-69

STEP 38

STEP 40

W110R507

Adjust disc clearance "X" = 0.8 ± 0.1 mm: Apply “F“ = 50 + 30 KN on disc package (pos. 6 - see sketch no. 63) by means of a press and load cell (4) as well as pressure piece (3). Find dimension “X“ - from locating face lid/crown wheel to disc package (contact face of upper inner disc). Dimension “X“ e.g .........................................0.80 mm

W110R509

Tilt differential by 180° - keeping the contact position of differential carrier and lid. Find reference dimension - front face/lid to front face/crown wheel. Refer.dimension (for correctly positioned parts) = app. 39.50 mm.

STEP 41

NOTE: If the required disc clearance (0.8 ± 0.1 mm) is not achieved, use suitable outer disc(s) (s = optional) for correction.

STEP 39

W110R510

Fix differential with pressure piece (arrow) by means of a press and install lid with “new“ locking screws. NOTE: Locking screws - permitted for one-time use only. W110R508

Mount pre-assembled differential carrier until contact with lid is obtained.

Tightening torque (M16 x 1.5/12.9) ............ = 410 Nm

6004-70

STEP 42

W110R511

Place differential on the pressure piece (arrow). NOTE: Ensure that differential is supported on pressure piece /lid, but not on the sliding sleeve. Press bearing inner ring to contact position.

STEP 43

W110R512

Use suitable support (arrow) for temporarily mounted bearing inner ring, Roller bearing cage - risk of damage. Press bearing inner ring on crown wheel side to contact position.

6004-71

Setting Backlash and Bearing Preload

STEP 45

STEP 44

W110R514

Legend to sketch no. W110R514: W110R513

Read crown wheel labeling (test dimension) from crown wheel rear side. Determine required shims by means of the read value (crown wheel) and the relating specifications of the following table: Test dimension, e.g. „77“ mm is stamped on the crownwheel rear side, without + or – deviation, which corresponds to the real value/test dimension „77“ in the following table. The required shims according to this real value/test dimension are allocated in the following table.

1 = Crown-wheel 2 = Differential carrier 3 = Tapered roller bearing (differential carrier side) 4 = Tapered roller bearing (crown-wheel side) 5 = Input pinion 6 = Axle drive housing 7 = Axle housing (differential carrier side) 8 = Axle housing (crown-wheel side)

Any + or – deviation from the test dimension due to production is manually applied on the crown wheel rear side (e.g. - 20 or - 10 or 10). The required shims according to this real value/test dimension are allocated in the following table.

Table - shims for differential DHL-1200 in ZF-axle MT-L 3065 II Crown wheel labeling 77 and corrective value

-20

-10

Results in ---> real value/test dimension

76.80

76.90

77.0

77.10

Required shim thickness Shim/differential carrier side

0.80

0.90

1.00

1.10

Required shim thickness Shim/crown-wheel side

1.20

1.10

1.00

0.90

6004-72

STEP 46

STEP 49

W110R515

W110R518

Oil both O-rings (arrows) and inser t in annular grooves of piston.

Inser t determined shim (e.g. s = 1.00 mm) and bearing outer ring into hole of axle housing on differential carrier side.

STEP 47

W110R516

Oil sealing faces and insert pre-assembled piston into hole of axle housing.

STEP 48

W110R517

Inser t determined shim (e.g. s = 1.00 mm) and bearing outer ring into hole of axle housing on crown wheel side.

6004-73

Contact Pattern Check of Bevel Gear Set

STEP 53

STEP 50

W110R522

Bring axle housing to contact position by means of hex. screw and temporarily fix it. W110R519

Cover some tooth flanks of crown wheel with marking ink (contact pattern check).

STEP 51

Rotate differential several times in both directions roller setting (also see figure no W110R523). Tightening torque (M 18/10.9) .................... = 390 Nm

STEP 54

W110R520

Insert pre-assembled differential.

W110R523

Roll input pinion over crown wheel in both directions (coast - drive flank meshing - contact pattern).

STEP 52

W110R521

Position axle housing/crown wheel side (without O-ring) on axle drive housing -pay attention to radiale installation position.

6004-74

STEP 55

STEP 57

W110R524

W110R526

Disassemble differential. Compare contact pattern to examples - see chapter „0“, page 0/4 … 0/5.

Insert preassembled stub shafts into both outputs (considering allocation to the correct output side).

NOTE: If contact pattern differs considerably, use a suitable shim for correction.

STEP 58

STEP 56

W110R527

Remount differential - by mounting stub shaft into gearing of axle bevel gear (differential). W110R525

If disassembled:

STEP 59

Insert shim(s) (2) into sun gear shaft (1) and mount stub shaft (3).

W110R528

Position axial roller ring on differential and fix by means of grease (assembly aid).

6004-75

Leakage Test of DHL (100% lock)

STEP 60

STEP 62

W110R529

Oil O-ring (arrow) and mount it. Position complete axle half on the axle drive housing - by mounting the stub shaft into the gearing of the axle bevel gear (differential).

Prior to starting the test, bleed pressure chamber and then apply 100 % lock several times.

NOTE: Pay attention to radial installation position of output towards axle drive housing.

Build up test pressure p = 25 bar and close locking valve of the HP pump.

W110R531

No measurable pressure drop is permissible during a 5-minute test.

STEP 61

W110R530

Fix axle housing finally by means of hex. screws. Rotate differential several times in both directions roller setting! Tightening torque (M 18/10.9) .................... = 390 Nm

6004-76

Shaft Seal / Imput Flange

STEP 65

STEP 63

W110R534

W110R532

Remove flange.

Inser t shaft seal (1), considering the required installation position (dimension “X“) – see detailed sketches no. W110R535. Contact face (outer diameter) of shaft seal: - if rubber-coated: wet with spirit, (assembly aid) - if made of metal: apply sealing agent (Loctite no. 574). Grease the shaft seal around the sealing and dust lip. (Grease e.g."PETAMO GHY 133 N"ZF-order no. 0671 190 099).

STEP 64

NOTE: Ensure plane installation position of shaft seal - use the specified driver tool to obtain an exact installation position of the shaft seal.

W110R533

For new parts assembly only: Mount protection plate on screen sheet on input flange and bring to contact position. NOTE: Pay attention to installation position of screen sheet - also see sketch no. W110R535.

6004-77

STEP 66

W110R535

Detailed sketch “Z“: Legend to sketch no. W110R535: 1 = Shaft seal 2 = Protection plate 3 = Input flange 4 = Tapered roller bearing 5 = Input pinion 6 = Axle drive housing X = Install. dim. 16.6 ± 0.2 mm

STEP 67

W110R536

Mount flange, fix with washer and hex. nut. During tightening, rotate pinion several times in both directions (roller setting). NOTE: Install hex. nut with locking compound (Loctite-Nr. 262). Tightening torque (M36x1,5) ...................... = 700 Nm

6004-78

REAR AXLE

6004

Section 6004

6004-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Disassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Limited Slip Differential version DZ-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Differential Version D-1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Differential Version D-1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot Pin Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot Pin Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 6 6 7 7 14 14 26 26 26 27 27 28 31 31 36 42 45 48 50 52 54 56 57 59 61 62 63

6004-3

SPECIFICATIONS Brake Wear Measurement.............................................................................................................4.0 mm (0.16 inch) Sun Gear Shaft End Play.....................................................................................0.5 to 2.00 mm (0.02 to 0.079 inch) Drive Pinion Rolling Torque ......................................................................... 1.1 to 2.3 Nm (9.75 to 20 pound inches) W110C Axle Options

LSD (*)

HD (**)

Multitrac Axle Tipe

MT-L3065II

MT-L3075II

MT-L3065II

Position

Front Axle

Rear Axle

Front Axle

Rear Axle

Differential Locking

Differential Open

Differential Yoke

Limited Slip Differential DS1480

DS1480

Flange to Flange (mm)

1984

Axle Ratio

21.53

Ratio Beverl Gear

3.36

Ratio Planetary Drive

6.4

DZ1200

DHL1200

D1200

Differential Locking

Differential Open

Spring pad 8x27, 788-1018.4

Above center pivot 200

12xM22x1.5; studs PCD 425

Differential version Differential type Axle Installation Dimension Output Shaft Sealing Brake Oil Volume (liters/U.S. Quarts)

Limited Slip Differential Spring pad 8x27, 788-1018.4

Above center pivot 200

12xM22x1.5; threads 12xM22x1.5; threads PCD 425 PCD 425 Lip Seal

Lip Seal

Metal Face Seal

4 x Paper Jinmyung

4 x Sinter

22 (23.2)

* Limited Slip Differential ** Heavy Duty

SPECIAL TORQUES Bolts Securing Brake Housing to Axle Housing................................................................... 390 Nm (288 pound feet) Wheel End Retainer Bolts ................................................................................................... 500 Nm (369 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads).................................................. 700 Nm (516 pound feet) Bolts Securing Differential Housing to Axle Housing ........................................................... 390 Nm (288 pound feet) Bolts Securing Differential Cover and Ring Gear ................................................................ 410 Nm (302 pound feet) Nut for Securing Brake Tube to Axle Housing ....................................................................... 100 Nm (74 pound feet) Brake Tube to Axle Housing Fitting........................................................................................ 100 Nm (74 pound feet) Brake Tube Axle Housing Fitting.............................................................................................. 36 Nm (27 pound feet) Oil Drain Plugs (Outputs)......................................................................................................... 50 Nm (37 pound feet) Oil Fill Plug/Dipstick ................................................................................................................. 50 Nm (37 pound feet) Brake Lining Check Plug ......................................................................................................... 50 Nm (37 pound feet) Brake Bleeder ........................................................................................................................... 6 Nm (4.4 pound feet) Brake Return Spring Retainer Bolts ........................................................................................ 34 Nm (25 pound feet)

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 3

3 1

2 3

8 4

4 W110R565

1. 2. 3. 4.

OIL DRAIN HOLE (AXLE HOUSING) OIL DRAIN HOLE (OUTPUTS) OIL FILL PLUG & OIL LEVEL CHECK BRAKE BLEEDER

5. 6. 7. 8.

BREATHER BRAKE INLET PLUG OIL FILLER & OVER FLOW

9. WEAR CHECK DISK BRAKE 10. GREASE NIPPLE

NOTE: Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BD07N211-01

BS08B041

NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired. Wear measurement must be made on both wheel end sides. Remove plug, actuate brake and determine dimension (X) using a thickness gauge. If dimension (X) is less than or equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing the plug. Tighten plug to a torque of 50 Nm (37 pound feet).

6004-7

WHEEL END AND BRAKE Disassembly

STEP 3

STEP 1

BD06G004-01

Using acceptable lifting equipment to hold wheel end. Loosen and remove the bolts and washers.

STEP 4

BD06G001-01

Fasten axle on a stand.

STEP 2

BD06G072

Carefully pull the wheel end from the axle housing. NOTE: Pay attention for shim(s) that are placed between the sun gear and stub shaft. Mark location of shim(s) to aid in assembly.

STEP 5 BD06G002-01

BD07N013-01 BD06G003-01

Remove drain plugs and drain oil from axle housing.

Remove and discard the O-ring from the brake port (1) and axle housing (2).

6004-8

STEP 6

STEP 9

BD06G005-01

BD07N045-01

Mount the wheel end on a stand or suitable work bench.

Using a suitable puller remove the three planetary gears.

STEP 7

STEP 10

BD07N113-01

Remove the shim(s) from the sun gear shaft. Pull the sun gear shaft out of the planetary gears and remove. NOTE: Mark location of shim(s) to aid in assembly.

STEP 8

BD07N112-01

Using snap ring pliers remove the retaining rings from the three planetary gears.

BD07N110-01

Remove the steel end shim from brake housing.

6004-9

STEP 11

STEP 13

BD07N094-01 BD07N107-01

Remove and discard O-ring.

STEP 14

BD07N108-01

Remove the reaction and friction brake plates alternately until all brake plates have been removed.

Remove the wheel end retainer bolts.

STEP 12

STEP 15

BD07N093-01

BD07N090-01 BD07N097-01

Remover cover from wheel end.

Remove the wheel end retainer.

6004-10

STEP 16

STEP 18

BD07N089-01

BD07N046-01

Use acceptable lifting equipment and lift the wheel end from the brake housing.

STEP 17

BD06G015-01

BD00M251

Use acceptable lifting equipment and lift the brake housing from the planetary carrier.

Inspect the stop pin for wear, if necessary drill a hole into the pin, use 380001545 adapter and 380001582 striker and remove the pin.

STEP 19

BD07N047-01

Inspect wheel bearing, if bearing needs replaced cut bearing cage with a die-grinder and remove cage. Score the bearing surface with a die-grinder and break bearing from planetary carrier using a hammer and chisel.

6004-11

STEP 20

STEP 23

BD07N049-01

BD07N056-01

Loosen and remove the six bolts that secure the return spring retainer to the brake housing.

Carefully pry brake piston up, alternate sides in order to raise piston evenly.

STEP 21

STEP 24

BD07N051-01

Remove the retainer and return spring from the brake housing.

BD07N059-01

Once brake piston is free remove from housing.

STEP 25

STEP 22

BD07N067-01 BD07N055-01

Remove the shim from the brake housing.

Remove and discard the wear ring from top groove in brake housing.

6004-12

STEP 26

STEP 29

BD07N064-01

BD07N066-01

Remove and discard the upper back up ring from the brake housing.

Remove and discard the lower back up ring from the brake housing.

STEP 27

STEP 30

BD07N063-01

BD07N079-01

Remove and discard the upper piston seal from the brake housing.

Inspect outer bearing cup, if worn or damaged drive outer bearing cup from brake housing and discard.

STEP 28

STEP 31

BD07N065-01

Remove and discard the lower piston seal from the brake housing.

BD07N081-01

Inspect inner bearing cup, if worn or damaged drive inner bearing cup from brake housing and discard.

6004-13

STEP 32

STEP 34

BD07N080-01

Remove and discard the face seal from brake housing.

BD07N036-01

Remove the metal face seal ring and discard.

STEP 35

STEP 33

BD07N033-01 BD07N035-01

Inspect the metal face seal ring, if worn or damaged loosen from wheel end shaft using a pry bar.

Inspect wheel end bearing, if bearing needs replaced cut bearing cage with a die-grinder and remove cage. Score the bearing surface with a die-grinder and break bearing from wheel end shaft using a hammer and chisel.

6004-14

Cleaning and Inspection

Assembly

IMPORTANT: Do not use compressed air to dry bearings. Allow bearings to air dry.

STEP 36 Clean all parts except friction plates in brake disc p a c k u s i n g c l e a n i n g s o l v e n t . W E A R FAC E PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to clear passages in planetary ring gear and brake housing.

STEP 37

STEP 41 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

I n s p e c t b e a r i n g r o l l e r s fo r p i t t i n g , s c o r i n g , deformation, or other damage. Check inner face and bearing cage for deformation, dents, and other da ma ge. Check associat ed bear ing cups for scratches, grooves, or cracks. Check bearings for rough spots or binding by holding bearing and rotating. If bearing binds or action is not smooth, replace the bearing.

STEP 38 Inspect bearing cups for pitting, scoring, cracks, or other damage. Replace if any of these conditions are seen. NOTE: If a bearing or bearing cup requires replacement, the associated part must also be replaced.

STEP 39 Check planetary ring gear, planetary gears, and planetary carrier gear teeth for cracks, breaks, chipping, or other damage. Replace the part if any of these conditions are seen. Check planetary carrier shaft splines for bro ken, cracke d, or twisted condition. Replace if necessary.

BD07N040-01

STEP 42

STEP 40 Check wheel end shaft for cracked, broken, or twisted splines. Replace if any of these conditions are seen.

BD07N037-01

Clean the seal ring mounting surface with solvent.

6004-15

STEP 43

STEP 45

BD07N038-01

BD06G084-01

Apply Loctite 574 to the seal ring mounting surface.

Use special tool 380001566 and drive the sealing ring into position onto the hub.

STEP 44

NOTE: Only use the special tool to install the sealing ring to ensure proper seating.

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

STEP 46 WARNING: Always wear gloves to prevent frostbite to your hands when handling frozen parts. SM118A

BD07N039-01

Heat the metal face seal ring to approximately 120Â° C (248Â° F), place the face seal ring on the wheel end shaft.

BD07N083-01

Freeze new inner bearing cup in dry ice for several hours. Install bearing cup in brake housing.

6004-16

STEP 47

STEP 49

WARNING: Always wear gloves to prevent frostbite to your hands when handling frozen parts. SM118A

BD07N069-01

Clean the seal grooves of the brake housing with solvent. BD07N082-01

STEP 50

Freeze new outer bearing cup in dry ice for several hours. Install bearing cup in brake housing.

STEP 48

BD07N070-01

BD06G032-01

5 4 3

2 1 BC08A246 BS00M073

1. FACE SEAL

2. BRAKE HOUSING

GREASE

Wet the outer diameter of the face seal with a solution of 50% water and 50% mineral spirits. Use a suitable seal installer to install the face seal with the seal lip positioned as shown. Apply grease to seal as indicated by (A) above.

WEAR RING, BACK-UP RINGS AND PISTON SEAL LOCATION 1. 2. 3. 4.

LOWER BACK-UP RING LOWER PISTON SEAL BRAKE HOUSING UPPER PISTON SEAL

5. UPPER BACK-UP RING 6. WEAR RING 7. BRAKE PISTON

Install the lower back-up ring (1) in the brake housing.

6004-17

STEP 51

STEP 54

BD07N072-01

BD07N077-01

Install the lower piston seal (2) in the brake housing, make sure the groove in the seal is facing upwards.

Install the wear ring (6) in the top groove of the brake housing. End points of the wear ring must be installed in the 12 oâ&#x20AC;&#x2122;clock (top) position of the brake housing. Make sure the wear ring is installed completely in its groove in the brake housing.

STEP 52

NOTE: Apply Loctite 415 to the end points of the wear ring.

STEP 55

BD07N074-01

Install the upper piston seal (4) in the brake housing, m a k e s u r e t h e g r o o ve i n t h e s e a l i s fa c i n g downwards.

STEP 53

BD07N086-01

Set the slack adjuster pins on the brake piston by driving them in until they are flush with the pin mount.

BD07N075-01

Install the upper back up ring (5) in the brake housing.

6004-18

STEP 56

STEP 59

BD07N061-01

BD07N052-01

Apply oil on the sliding surface of the piston, back-up rings, seals and wear ring. Carefully install piston in the brake housing.

Install the brake return spring, make sure that the tapered end of the spring is facing up.

STEP 60

STEP 57

BD07N054-01 BD07N062-01

Using a plastic mallet fully seat the brake piston. Strike piston on alternate sides to seat piston evenly.

Install the brake spring retainer.

STEP 61

STEP 58

BD07N057-01

BD07N050-01

Apply oil to both sides of return spring shim and install in brake housing.

Install the six retainer bolts and tighten to a torque of 34 Nm (25 pound feet).

6004-19

STEP 62

STEP 64

BD00M251 BD06G053-01

If stop pin was removed, drive a new stop pin into the planetary carrier until contact.

Use acceptable lifting equipment and lower the brake housing onto the planetary carrier.

STEP 65

STEP 63 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

Coat the splines of the planetary carrier shaft with Loctite No. 767 antiseize lubricant.

STEP 66

SM121A

BD07N089-01 BD07N046-01

If inner wheel bearing was removed, heat the wheel bearing to 120C (248F) in a bearing oven. Wearing heat resistant gloves or mittens, install the bearing on the planetary carrier until the bearing is against the shoulder on the carrier shaft.

Using acceptable lifting equipment lower the wheel end onto the brake housing. A slight rotation of the wheel end may be necessary in order align the splines of the carrier shaft with the splines in the wheel end.

6004-20

STEP 67

STEP 69

BD07N095-01 BD07N090-01

Install a new O-ring on the wheel end cover.

Install the wheel end retainer.

STEP 70

STEP 68

BD07N096-01 BD07N092-01

Install new bolts, evenly tighten the four bolts in a cross pattern to a torque of 500 Nm (369 pound feet). While tightening bolts rotate the brake housing several time in both directions. NOTE: Use only new bolts.

Install the cover on the wheel end.

6004-21

3 2 1

4 4 BRAKE PLATE AND RETURN SPRING PARTS LOCATION 1. 2. 3. 4.

END SHIM THIN REACTION PLATE (2.0 MM) THICK REACTION PLATE FRICTION BRAKE DISC

5. 6. 7. 8.

STEP 71

BS08A216

RETURN SPRING RETAINER RETURN SPRING SHIM RETAINER BOLT (6)

STEP 72

BD07N108-01 BD07N107-01

Install a thin (2.0 MM) reaction brake plate into the brake housing. NOTE: Refer to Illustration above for correct brake plate installation.

Install a friction brake disc into the brake housing.

6004-22

STEP 73

STEP 75

BD07N107-01

BD07N110-01

Install the end shim into the brake housing.

STEP 76 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD07N108-01

Install a thick reaction brake plate and then another friction brake disc. Repeat this step until all thick reaction plates and friction brake discs have been installed.

STEP 74 BD08B032-01

Heat the three planetary gears to 120C (248F) in a bearing oven. Wearing heat resistant gloves or mittens, install the planetary gears on the planetary carrier.

BD07N107-01

Install a thin (2 mm) reaction plate.

6004-23

STEP 77

STEP 79

BD07N112-01

BD08B036-01

Install the three planetary gear retaining rings with snap ring pliers.

Take a measurement from the straight edge to the face of the brake housing, the difference between this measurement and the next measurement will be dimension A.

Sun Gear Shaft End Play Adjustment

Measure from the stop pin to the face of the brake housing.

STEP 78

Example: Dimension A . . . . . . . . . . . . . 21.25 mm (0.84 inch)

STEP 80 Install the stub shaft in the spline of the axle bevel gear. Make sure the stub shaft is installed all the way into the axle bevel gear.

STEP 81

7 BS08B042

1. 2. 3. 4.

PLANETARY CARRIER STOP PIN BRAKE HOUSING AXLE HOUSING

5. SUN GEAR SHAFT 6. SHIM(S) 7. STUB SHAFT

BD08B033-01

Install the sun gear on the stub shaft (without shim) until contact.

6004-24

STEP 82

STEP 84

BD08B034-01

BD07N113-01

Determine dimension B from the mounting face of the axle housing to the face of the sun gear. Example: Dimension B . . . . . . . . . . . . . . . . 19 mm (0.75 inch)

STEP 83 Subtract dimension A from dimension B. Then subtract 1.25 mm (0.05 inch) from the difference. The difference is the required shim size. Example: Dimension A Dimension B Difference Required end play Difference = shim size

21.25 mm (0.84 inch)  19.00 mm (0.75 inch) 2.25 mm (0.09 inch) 1.25 mm (0.05 inch) 1.00 mm (0.04 inch)

BD08B035-01

Install the sun gear shaft into the planetary gears. Install the shim set (size as determined in Step 83) into the sun gear shaft with grease.

STEP 85 1

BD07N013-01

Install a new O-ring in brake port (1), and a new O-ring on the axle housing (2).

6004-25

STEP 86

STEP 89

BD06G072-01

Using acceptable lifting equipment, install the assembled wheel end onto the axle housing. NOTE: Turn the input flange to align splines of the stub shaft into the sun gear.

BD06G003-01

Install axle drain plug in differential housing and torque to 50 Nm (37 pound feet).

STEP 90

STEP 87

BD07N212-01 BD02D154-01

Install the washers and bolts to secure the wheel end to the axle housing. Tighten the bolts to a torque of 390Nm (288 pound feet).

Remove dip stick from axle housing and wipe clean.

STEP 91

STEP 88

BD07N213-01

BD06G002-01

Install drain plug in wheel end and torque to 50 Nm (37 pound feet).

To check oil level, do not screw in dip stick, but bring it into contact with the face of the axle housing. Remove dip stick, oil level should be between upper and lower marks on dip stick. Add Ambra MULTI G 134TM Hydraulic Transmission oil (SAE 80W-140) as needed.

6004-26

BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS. If the maximum pressure of 100 bar (1450 psi) is exceeded damage to brake piston seals may occur.

STEP 92

High Pressure Test STEP 94 Operate the hand pump to increase pressure to 100 bar (1450 psi) maximum. Close connection to hand pump using the shutoff valve. During a 5 minute period, pressure shall not drop more than 3 bar (44 psi).

Low Pressure Test STEP 95 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period pressure shall not drop.

BD07N209-01

Connect a hand pump with pressure gauge to the brake port as shown above.

STEP 93

BD07N208-01

Fill the hand pump with hydraulic oil. Build up pressure in the axle internal brake lines then bleed air from the lines. After air is bled, actuate the brakes a minimum of 5 times to a pressure of 100 bar (1450 psi) by operating the hand pump. Torque brake bleeder to 6 Nm (4.4 pound feet)

6004-27

REPLACE HUB SEAL Removal

STEP 98

STEP 96

BD07N094-01

Remove and discard O-ring.

STEP 99

BD06G002-01

Remove drain plug and drain oil from the brake housing.

STEP 97

BD07N093-01

Loosen and remove the wheel end retainer bolts.

STEP 100

BD06G075-01

Use a pry bar and remove the end cover.

BD07N090-01

Remove the wheel end retainer.

6004-28

Installation STEP 103

BD06G078-01

Use acceptable lifting equipment to hold the wheel end. Separate the output shaft using a puller. BD06G081-01

STEP 101

A A

A 1 2

BD06G079-01

Use a pry bar and remove the face seal from the brake housing and discard.

STEP 102

BS00M073

1. FACE SEAL 2. BRAKE HOUSING A FILL WITH GREASE

BD07N035-01

Inspect the metal face seal ring for damage or wear, if required remove the seal ring and discard.

6004-29

STEP 104

STEP 107

BD07N037-01

BD06G084-01

Clean the seal ring mounting surface with solvent.

Use special tool 380001566 and drive the sealing ring into position onto the hub.

STEP 105

NOTE: Only use special tool to install the sealing ring to ensure proper seating.

STEP 108

BD07N038-01

Apply Loctite 574 to the seal ring mounting surface.

STEP 106

BD06G086-01

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

Use acceptable lifting equipment and install the wheel end onto the brake housing.

STEP 109

BD06G088 BD07N039-01

Heat the metal face seal ring to approximately 120Â° C (248Â° F), place the face seal ring onto the wheel end shaft.

Install the wheel end retainer.

6004-30

STEP 110

STEP 113

BD07N092-01

BD06G002-01

Install new bolts, evenly tighten the four bolts in a cross pattern to a torque of 500 Nm (369 pound feet). While tightening bolts rotate the brake housing several time in both directions.

Install drain plug on brake housing and torque to 50 Nm (37 pound feet).

STEP 114

NOTE: Use only new bolts.

STEP 111

BD07N212-01

Remove dip stick from axle housing and wipe clean. BD07N095-01

Install a new O-ring on the wheel end cover.

STEP 115

STEP 112

BD07N213-01

BD02D053-01

Install the wheel end cover into the wheel end.

6004-31

LIMITED SLIP DIFFERENTIAL VERSION DZ-1200 Removal/Disassembly

STEP 117

STEP 116

BD06G126-01

STEP 118

BD06G003-01

Remove drain plugs and drain oil from axle.

BD06G127-01

Connect suitable lifting equipment to the differential and remove the differential from axle housing. NOTE: Make sure that the right axle stub shaft releases from the differential.

STEP 119

6004-32

STEP 122

BD01F075-01

If required, remove the bearing from the housing cover using a suitable puller.

STEP 120

BD07N162-01

Remove the ring gear from the differential housing.

STEP 123

BD07N165-01

Place the differential in a press to prevent it from turning. Remove the bolts.

BD07N159-01

STEP 121

BD07N148-01

Remove the outer set of clutch plates, thrust washer, and bevel gear from the differential housing. BD07N163-01

Remove the housing cover from the differential housing.

6004-33

STEP 124

STEP 125

BD07N145-01

BD07N140-01

1 BD07N139-01

Remove the two differential half shafts, spider gears and thrust washers from the differential housing.

STEP 126 BS08B044

1. 2. 3. 4.

ROLL PIN SET DIFFERENTIAL HALF SHAFT DIFFERENTIAL SHAFT DIFFERENTIAL HOUSING

Drive both roll pin sets (1) out of the differential housing (4) to remove the diferential half shafts (2).

BD07N136-01

Remove the differential shaft from the differential housing.

6004-34

STEP 127

STEP 129

BD07N131-01

BD07N104-01

Remove the remaining two spider gears and thrust washers from the differential housing.

If required, remove bearing from differential housing using a suitable puller and a press.

STEP 128

STEP 130

BD07N129-01

BD06G131-01

Pull the bearing cups and shims from both axle housings. NOTE: Make sure to identify the shims into which axle housing they were removed.

BD07N114-01

Remove the inner set of clutch plates, thrust washer, and bevel gear from the differential housing.

6004-35

W11R556

LIMITED SLIP DIFFERENTIAL ASSEMBLY 1. 2. 3. 4.

DIFFERENTIAL, CASE DISC, OUTER CLUTCH 1.8 mm DISC, OUTER CLUTCH 1.9 mm DISC, OUTER CLUTCH 2.0 mm

5. 6. 7. 8.

DISC, INNER CLUTCH (8x) 9. WASHER THRUST (4x) WASHER THRUST (2x) 10. AXLE, DIFFERENTIAL GEAR, BEVEL, AXLE (2x) 11. AXLE, DIFF, SHORT (2x) GEAR, BEVEL, DIFF. (4x) 12. PIN, SLOTTED (2x)

13. 14. 15. 16.

PIN, SLOT (2x) COVER HOUSING BOLT (12x) BEARING, ROLLER

6004-36

Reassembly Limited Slip Differential Version DZ-1200 STEP 131

STEP 134

BD07N119-01 BD07N105-01

Install bearing on differential housing using a press.

Install one reaction plate on the inner bevel gear.

STEP 135

STEP 132 Check reaction plates, friction plates and thrust washers for damage or wear, replace if necessary. NOTE: Be sure to apply oil to all parts before assembly.

STEP 133

BD07N120-01

Install one friction plate on the inner bevel gear.

STEP 136

BD07N118-01

Install the (copper color) thrust washer on the inner bevel gear. NOTE: Clutch plates must be installed on the inner bevel gear in the correct order, refer to illustration on page 35.

BD07N122-01

Install two reaction plates on the inner bevel gear.

6004-37

STEP 137

STEP 140

BD07N124-01

BD07N127-01

Install two friction plates on the inner bevel gear.

Install one reaction plate on the inner bevel gear.

STEP 138

STEP 141

BD07N125-01

Install one reaction plate on the inner bevel gear.

STEP 139

BD07N126-01

Install one friction plate on the inner bevel gear.

BD07N128-01

Align all tabs of reaction plates on the inner bevel gear.

6004-38

STEP 142

STEP 144

BD07N129-01

BD07N136-01

BD07N130-01

BD07N137-01

Install the clutch pack and inner bevel gear assembly into the differential housing.

STEP 143 1

STEP 145 2

BD07N131-01

1. THRUST WASHER

2. SPIDER GEAR

BD07N139-01

1. THRUST WASHER

2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the differential housing. Install another thrust washer (1) and spider gear (2) directly across.

6004-39

STEP 146

STEP 148

BD07N140-01

BD07N144-01

2 2

BD07N138-01

BS08B044

1. 2. 3. 4.

STEP 147

ROLL PIN SET DIFFERENTIAL HALF SHAFT DIFFERENTIAL SHAFT DIFFERENTIAL HOUSING

Drive new roll pins (1) into the differential housing to secure half shafts. NOTE: Use new roll pins only.

BD07N138-01

Spider gear assembly installed in differential housing.

6004-40

STEP 149

STEP 152

BD07N149-01

Install the (copper color) thrust washer on the outer bevel gear. NOTE: Clutch plates must be installed on the outer bevel gear in the correct order, refer to illustration on page 35.

BD07N153-01

Install two reaction plates on the outer bevel gear.

STEP 153

STEP 150

BD07N155-01

Install two friction plates on the outer bevel gear.

STEP 154 BD07N150-01

Install one reaction plate on the outer bevel gear.

STEP 151

BD07N156-01

Install one reaction plate on the outer bevel gear.

BD07N151-01

Install one friction plate on the outer bevel gear.

6004-41

STEP 155

STEP 158

BD07N156-01

Install one friction plate on the outer bevel gear.

STEP 156

BD07N160-01

Clean ring gear mounting surface on differential housing.

STEP 159

BD07N158-01

Align all tabs of reaction plates on the outer bevel gear.

STEP 157

BD07N161-01

Clean mating surfaces of ring gear and differential cover. NOTE: The ring gear and the drive pinion are a matched gear set and cannot be serviced separately.

STEP 160

BD07N159-01

Install the clutch pack and outer bevel gear assembly into the differential housing. BD07N162-01

Install ring gear on differential housing. NOTE: Make sure to align bolt holes when installing ring gear and differential cover.

6004-42

Disassembly

STEP 161

Differential version D-1200 STEP 164

BD07N163-01

Install cover on differential housing.

STEP 162 BD06G127-01

Lift differential assy out of axle drive housing.

STEP 165

BD07N166-01

Place the differential in a press to prevent it from turning. Install new bolts and tighten to a torque of 410 Nm (302 pound feet). BD01F075-01

NOTE: Use new bolts only.

Pull both taper roller bearings off the differential carrier.

STEP 163

STEP 166

BD08B037-011

BD07N165-01

If bearing was removed from differential cover install bearing using a press.

Hold differential by means of a press. Loosen locking screws and remove lid. NOTE: Locking screws - permitted for one-time use only.

6004-43

STEP 167

STEP 169

W110R537

W110R539

Insert some locking screws, position pressure plate and press differential carrier off the crown wheel.

Force slotted pin (fixing) out of both spider shaft halves (split version), then remove both spider shaft halves in arrow direction and take components (see figure no. W110R540) out of differential carrier.

STEP 168

STEP 170

W110R538

Remove axle bevel gear, thrust washer and constant spacer. 1 = Differential carrier 2 = Crown wheel 3 = Constant spacer 4 = Thrust washer 5 = Axle bevel gear

W110R540

STD differential assembly 1 = Differential carrier 2 = Slotted pin (2x) 3 = Slotted pin (2x) 4 = Spider shaft (split version) 5 = Spider shaft (one-piece) 6 = Thrust washer (4x) 7 = Spider gear (4x) 8 = Axle bevel gear 9 = Constant spacer 10 = Outer disc 11 = Thrust washer

STEP 171 Pull bearing outer ring out of hole by means of the striker and remove shim behind (backlash). NOTE: Mark shim (position/bearing allocation) â&#x20AC;&#x201C; assembly aid.

6004-44

STEP 172

BD06G131-01

Remove O-ring (arrow). Remove bearing outer ring and shim behind (rolling torque differential bearing) from axle housing. NOTE: Mark shim (position/bearing allocation) â&#x20AC;&#x201C; assembly aid.

W110R541

1. 2. 3. 4. 5.

DIFFERENTIAL , CASE DISC O. CLUTCH DIFFERENTIAL, RING WASHER THRUST GEAR, BEVEL, AXLE

6. 7. 8. 9. 10.

GEAR, BEVEL, DIFF. WASHER THRUST AXLE, DIFFERENTIAL AXLE, DIFFERENTIAL SHORT PIN, SLOTTED SPRING 5X50

11. 12. 13. 14.

PIN SLOT. COVER HOUSING BOLT BEARING, ROLLER

6004-45

Reassembly

STEP 175

Differential version D-1200 STEP 173

W110R544

Insert steel outer disc (2) and thrust washer (3) into the differential carrier (1). W110R542

Illustration in figure no. 14 shows differential version D-1200 = standard version.

NOTE: Pay attention to installation position of outer disc and thrust washer â&#x20AC;&#x201C; see position/figure.

STEP 176

STEP 174

W110R545

Insert axle bevel gear. W110R543

Insert constant spacer into differential carrier.

6004-46

STEP 177

STEP 179

W110R546

W110R548

Legend to figure-no. W110R536 … figure-no. W110R549:

Install split spider shaft (4) with spider gears (2) and thrust washers (3).

Differential spider – single parts: 1 = Spider shaft (one part) 2 = Spider gear (4x) 3 = Thrust washer (4x) 4 = Spider shaft (split version) 5 = Slotted pin (2x) 6 = Slotted pin (2x)

NOTE: Insert thrust washers with tabs showing upwards - see arrow - and being located in recess. NOTE: Pay attention to installation position of spider shaft/halves - slotted pin/location holes of spider shaft towards diff. carrier.

STEP 180

STEP 178

W110R549 W110R547

Fix spider shaft half (arrows) with double-slotted pins. NOTE: Install double-slotted pins - always with slots in a 180° offset position to each other.

6004-47

STEP 181

STEP 183

W110R550

Insert second axle bevel gear into differential carrier.

STEP 182

W110R552

Install two adjusting screws (M 16) - see arrows - and press crown wheel to contact position. For input version “with” bevel gear set only - see specification in the corresponding spare parts list: If a bevel gear set is specified, the pairing number/crown wheel (e.g. “7”) must be identical with pairing number/input pinion.

STEP 184

W110R551

Insert thrust washer (2) and constant spacer (3) into differential carrier (1) . NOTE: Pay attention to installation position of thrust washer and constant spacer – see position/figure. W110R553

Mount housing lid.

6004-48

Drive Pinion Removal

STEP 185

NOTE: The ring gear and the drive pinion are a matched gear set and cannot be serviced separately.

STEP 187 Heat lock nut securing flange with a hot air blower to loosen Loctite, approximately 120° C (248° F).

STEP 188

W110R554

Fix differential by means of a press and fix lid with “new” locking screws. NOTE: Locking screws - permitted for one-time use only. Tightening torque (M16 x 1.5/12.9) ............ = 410 Nm

STEP 186

BD06G132-01

Install holding wrench on input flange. Hold flange and remove lock nut and washer. Remove holding tool from flange.

STEP 189

W110R555

Press both bearing inner rings to contact position. NOTE: Use suitable support (arrow) for provisionally mounted bearing ring, roller bearing cage – risk of damage. BD07N173-011

Remove the input flange from the drive pinion.

6004-49

STEP 190

STEP 193

BD06G133-01

BD07N181-01

Remove the shaft seal from the axle drive housing.

Drive inner bearing cup from the differential housing.

STEP 191

STEP 194

BD06G134-01

Press the input pinion out of the housing.

BD06G141-01

Remove inner bearing cup and shim from differential housing.

STEP 192

NOTE: Mark shim and bearing cup location to aid in assembly.

STEP 195

BD07N183-01

Drive outer bearing cup from the differential housing. BD07N175-01

Remove the spacer ring from the drive pinion.

6004-50

Brake Tube Removal

STEP 196

STEP 197

BD07N176-01

Remove inner bearing from the drive pinion using a suitable puller and a press.

BD07N030-01

Remove the plug with the breather installed from the axle housing.

STEP 198

BD07N001-01

Remove fitting from the brake tube on the axle housing.

6004-51

STEP 199

STEP 201

BD07N004-01

BD07N010-01

Remove the brake tube from the axle housing.

STEP 202

BD07N006-01

Loosen and remove the nut holding the brake tube connector to the axle housing. BD07N015-01

STEP 200

Loosen and remove brake tube fitting inside axle housing.

STEP 203

BD07N008-01

Loosen the opposite end of brake tube from fitting inside axle housing. BD07N017-01

Remove and discard O-ring from fitting. NOTE: Repeat steps 197 through 203 for the other side of the axle

6004-52

Brake Tube Installation

2 4

BRAKE TUBE PARTS LOCATION 1. BRAKE TUBE FITTING 36NM (27 POUND FEET) 2. O-RING 3. BRAKE TUBE THREADED NUT 100NM (74 POUND FEET)

STEP 204

4. AXLE HOUSING 5. BRAKE TUBE 6. HEXAGON NUT 100NM (74 POUND FEET)

STEP 205

BD07N017-01

Install a new O-ring on the brake tube fitting.

BS08B043

BD07N018-01

Install the fitting in the axle and tighten to a torque of 36 Nm (27 pound feet)

6004-53

STEP 206

STEP 208

BD00M343-01

BD07N006-01

Install a new O-ring in the groove of the brake tube.

STEP 207

BD07N005-01

Install the nut to secure the brake tube. Tighten the nut to a torque of 100 Nm (74 pound feet). BD07N010-01

Install the brake tube in axle housing.

STEP 209

BD07N009-01

Connect the opposite end of brake tube to the fitting installed in axle housing. Hold fitting with a wrench and tighten brake tube to a torque of 100 Nm (74 pound feet). NOTE: Do steps 204 through 209 for the other wheel end.

6004-54

Pivot Pin Bushing Removal

STEP 210

STEP 212

2 3

1 BD00M347-01 BD01D499-01

BREATHER VENT EXPLODED VIEW 1. O-RING

2. PLUG

3. BREATHER

Remove and discard O-ring (1) from plug (2) and install a new O-ring. Install breather (3) in plug and tighten to general bolt torque specifications.

STEP 211

1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING A. THRUST SURFACE

Inspect pivot pin bushings (1) in differential housing for cracks, breaks, deformation, or other damage. Check oil splash grooves for scoring or chipping. Check for scoring on thrust surface (A). If bushings require replacement, do Steps 213 through 221.

STEP 213

BD07N003-01

Install the breather plug in axle housing and tighten to general bolt torque specifications.

BD07N193-01

Suppor t left axle housing and wheel end with a suitable stand. Using acceptable lifting equipment to suppor t differential housing, remove bolts and remove from left axle housing.

STEP 214

BD07N194-01

Remove and discard O-ring from axle housing.

6004-55

STEP 215

STEP 217

BD08B006-01 BS08B045

Cut a slot in the pivot bushing.

STEP 216

BD08B007-01

Using a suitable length and diameter rod and spacer, press bushing out of differential housing. BD08B005-01

Put differential housing in hydraulic press. Make sure housing is properly supported.

Repeat Steps 215 and 217 to remove the other pivot bushing.

6004-56

Pivot Pin Bushing Installation

STEP 219

WARNING: Always wear gloves to prevent frostbite to your hands when handling frozen parts. SM118A

STEP 218 A 1

BD07N194-01

Install a new O-ring on the left axle housing.

STEP 220 2 BD01D495-01

2 A

BD07N193-01

Position differential housing with left axle housing and install bolts.

STEP 221 BD01D499-01

1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING 2. CENTER OF DIFFERENTIAL HOUSING A. GROOVE

Freeze new bushing in dry ice for several hours. Install bushing in differential housing with groove (A) on circumference of bushing facing center of housing Install bushing against shoulder in housing. Repeat Step 218 to install the other pivot bushing.

BD07N197-01

Torque bolts evenly to 390 Nm (288 pound feet).

6004-57

Drive Pinion Installation

STEP 224

STEP 222

3 BD06G139-01

BD06G137-01

Find and record the housing dimension “X”. Dimension X (Example). . . . . 205.30 mm (8.08 inch)

STEP 223

1. MATING NUMBER (MARKED MANUALLY) 2. PINION BASIC DIMENSION (STAMPED) 3. PINION DISTANCE DEVIATION + OR - (MARKED MANUALLY)

Distance deviation is indicated in 1/100 mm. If no distance deviation is indicated the pinion basic dimension is identical with the pinion dimension. Record this as dimension “II”. Dimension II (Example) 168 -0.05 mm = 167.95 mm . . . . . . . . . (6.614 inch -0.002 inch = 6.612 inch)

STEP 225 Calculation example A: Dimension I Dimension II Results in dimension Y BD06G138-01

Measure the thickness of the inner bearing and record its measurement, dimension “I”. Dimension I (Example) . . . . . 36.13 mm (1.422 inch) NOTE: Deduct the thickness of the gauge blocks being used to support the bearing from the overall measurement, IE: overall measurement 106.13 mm (4.178 inch) minus gauge block thickness 70 mm (2.756 inch) will equal dimension I.

36.13 mm -------(1.422 inch) 167.95 mm -------(6.612 inch)  204.08 mm ------(8.034 inch)

Calculation example B: Dimension X Dimension Y Difference = shim thickness

205.30 mm -------(8.080 inch) 204.08 mm -------(8.034 inch)  1.22 mm ------(0.046 inch)

NOTE: Shims are available in 0.10 mm (0.004 inch), round up or down to the next available shim thickness, s = 1.20 (0.044 inch)

6004-58

STEP 226

STEP 228 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD06G140-01

Heat the bearing hole to approximately 120° C (248° F) and install the outer bearing cup until contact is made using a suitable diver.

STEP 227

BD07N178-01

Heat the pinion inner bearing to 120° C (248° F) in a bearing oven. Wearing heat resistance gloves or mittens, install the bearing on the pinion shaft until contact. NOTE: After installing bearing on pinion shaft, allow the bearing to cool to ambient temperature.

BD06G141-01

BD06G142-01

Heat the inner bearing hole on the differential housing to approximately 120° C (248° F). Install the shim set determined in Step 225 in the bearing bore and pull the bearing cup into to the bearing hole using a suitable tool.

6004-59

Drive Pinion Bearing Rolling Torque Adjustment

STEP 231

STEP 229

BD06G146-01

Press the dust shield on the input flange.

BD07N175-01

STEP 232

Install a 9.03 mm (0.35 inch) thick spacer on the pinion shaft.

STEP 230 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD06G147-01

Install the input flange on the pinion shaft.

STEP 233 Put the washer and nut in place on the pinion shaft.

BD06G145-01

Heat the pinion shaft outer bearing to 120Â° C (248Â° F) in a bearing oven. Wearing heat resistance gloves or mittens, install the bearing on the pinion shaft until contact. NOTE: Prior to mounting the input flange and tightening the nut, allow the bearing to cool to ambient temperature.

6004-60

STEP 234

STEP 235

BD06G132-01

BD06G148-01

Install a holding wrench on input flange. Hold flange and tighten nut to a torque of 700 Nm (516 pound feet). Remove holding wrench.

Check the rolling torque of the drive pinion bearing. The rolling torque should be 1.1 to 2.3 Nm (9.75 to 20 lb-inch). If rolling torque is too low, install a thinner spacer (Step 229); if rolling torque is too high, install a thicker spacer (Step 229).

NOTE: When tightening rotate the pinion shaft in both directions several times.

STEP 236 Remove the nut and input yoke from the drive pinion shaft.

6004-61

Setting Backlash and Bearing Preload Deviation Value

-20

-10

+10

+20

Shim A

1.20

1.10

1.00

0.90

0.80

Shim B

0.80

0.90

1.00

1.10

1.20

STEP 237

STEP 239

BD06G164-01 BD06G163-01

Record the deviation value from side of ring gear, the value will be a + or -, use the table to determine shim thicknesses needed.

Insert shim A (0.90 mm) and install the bearing cup using a suitable driver until seated in axle housing.

STEP 240

Example: Deviation value of +10 requires the following shims: Shim A = 0.90 Shim B = 1.10

STEP 238 2

BD06G165-01

Insert shim B (1.10 mm) and install the bearing cup using a suitable driver until seated in axle housing.

3 BC06G004

1. 2. 3. 4.

DIFFERENTIAL DRIVE HOUSING AXLE HOUSING INPUT PINION

5. AXLE HOUSING A. RING GEAR SIDE B. CARRIER SIDE

6004-62

Contact Pattern Check

STEP 244

STEP 241

BD06G169-01

BD06G166-01

Apply marking ink on several teeth of the ring gear.

STEP 242

Roll the input pinion several times in both directions over the ring gear. Remove the differential and compare the contact pattern with examples on page 4 and page 5. NOTE: If the tooth contact pattern differs, the wrong shim size was used in Step 227. Remove differential and repeat Steps 222 though 227.

BD06G167-01

Position the differential assembly in the axle drive housing.

STEP 243

BD06G168-01

Position the axle housing on the drive housing, install 4 bolts, top center, bottom center, front center, rear center, torque bolts evenly to 390 Nm (288 pound feet).

6004-63

Installation

STEP 248

STEP 245

BD06G171-01

Loosen and remove the nut and input flange. BD06G167-01

Position the differential assembly in the axle drive housing.

STEP 249

STEP 246

BD06G172

Install the shaft seal with the sealing lip towards oil sump using suitable seal installer. BD06G170-01

Install a new O-ring on the axle housing.

STEP 247

BD07N207-01

Position the axle housing on the differential housing, install bolts and torque bolts evenly to 390 Nm (288 pound feet).

NOTE: Wet the outer diameter of the seal with a solution of 50% water and 50% mineral spirits. Fill the space between the sealing and dust lip with grease.

6004-64

STEP 250

STEP 252

BD06G173-01

BD06G002-01

Install the input flange. Install holding wrench on input flange. Apply Loctite No. 262, on the threads of the locknut. Install the washer and locknut by hand. Hold flange using holding tool and tighten nut to a torque of 700 Nm (516 pound feet). NOTE: Rotate the input pinion several times in both directions when tightening.

STEP 251

BD06G003-01

Install axle drain plugs and torque to 50 Nm (37 pound feet).

BD08B004-01

Check optional axle pivot stop plates for wear or damage, replace if required. Torque bolts to general bolt torque specifications.

6004-65

STEP 253

STEP 254

BD07N212-01

BD07N213-01

Remove dip stick from axle housing and fill with 22 Liters (23.2 U.S. Quarts) of Ambra MULTI G 134TM Hydraulic Transmission oil (SAE 80W-140).

To check oil level, do not screw in dip stick, but bring it into contact with the face of the axle housing. Remove dip stick, oil level should be between upper and lower marks on dip stick. Install dip stick and torque to 50 Nm (37 pound feet).

6004-66

NOTES

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 3 3 4 4 5 5 6 6 7 7 7 8 8 8 9 9 9 10 10 10

6005-3

SPECIAL TORQUES Coupler to Flywheel Bolts.................................................................................................53 to 62 Nm (39 to 46 lb-ft) Engine Drive Shaft to Coupler to Bolts .............................................................................53 to 62 Nm (39 to 46 lb-ft) Engine Drive Shaft to Transmission Bolts.........................................................................34 to 41 Nm (25 to 30 lb-ft) Center, Rear and Front Drive Shaft Bolts .........................................................................61 to 81 Nm (45 to 60 lb-ft) Carrier Bearing Bolts ......................................................................................................99 to 128 Nm (73 to 94 lb-ft) Lock Nut for Yoke on Front Drive Shaft.....................................................................339 to 375 Nm (250 to 275 lb-ft)

FRONT DRIVE SHAFT Removal

STEP 4

STEP 1

Use an acceptable puller and remove the yoke from the end of the front drive shaft.

STEP 5 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 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 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.

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.

6005-4

FRONT DRIVE SHAFT Installation

STEP 14

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.

STEP 11 BD03A183

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 lb-ft).

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. BD03A167

Install the bolts and straps that fasten the front drive shaft to the front axle. Tighten the bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).

STEP 16

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 90Â° 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 61 to 81 Nm (45 to 60 lb-ft).

6005-5

CENTER BEARING Removal

STEP 20

STEP 17

Make an alignment mark on the yoke and the front drive shaft to be sure that the yoke is installed correctly.

STEP 21 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. BD03A166

STEP 23

Loosen and remove the bolts and straps that fasten the center drive shaft to the front drive shaft.

Loosen the set screws that secure the center bearing to the front drive shaft.

STEP 18

STEP 24

BD03A183

Loosen and remove the lubrication hose from the center bearing

Loosen and remove the bolts, washers and nuts that fasten the bearing housing to the front frame.

STEP 19

STEP 25 Install two longer bolts, at least 75 mm (3 in), to hold the be ar in g housing d ur ing r emoval. Use a n acceptable puller to remove the bearing housing from the front drive shaft.

BD03A183

Loosen and remove the lock nut that fastens the yoke to the front drive shaft.

6005-6

CENTER BEARING Installation

STEP 30

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.

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 31

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.

STEP 28

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).

STEP 32

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).

STEP 29 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 61 to 81 Nm (45 to 60 pound feet).

STEP 33 Install the lubrication hose into the fitting on the bearing housing. BC05M214

Turn the set screw down to the shaft and then back it off 1/2th turn and lock it with the jam nut. Carrier bearing should slide freely on drive shaft. Repeat the procedure with the other set screw.

STEP 34 Lubr icate the center bear ing with the grease specified in Section 1002.

6005-7

CENTER DRIVE SHAFT Removal

Installation

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 61 to 81 Nm (45 to 60 lb-ft).

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 61 to 81 Nm (45 to 60 lb-ft).

6005-8

REAR DRIVE SHAFT Removal

Installation

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 61 to 81 Nm (45 to 60 lb-ft).

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 61 to 81 Nm (45 to 60 lb-ft).

6005-9

ENGINE DRIVE SHAFT Removal

Installation

STEP 47

STEP 50

BD01D342

Remove and discard the bolts and straps that fasten the engine drive shaft to the transmission.

Place the engine drive shaft into position on the transmission and install new straps and bolts. Tighten the bolts to a torque of 34 to 41 Nm (25 to 30 lb-ft).

IMPORTANT: The bolts and straps that fasten the engine drive shaft to the transmission must be replaced when removed.

STEP 51

STEP 48

BD03A172

Loosen and remove the six bolts that fasten the engine drive shaft to the engine.

STEP 49 Remove the engine drive shaft from the machine.

Apply Loctite 242 to bolt threads. Install the six bolts that fasten the engine drive shaft to the engine. Tighten the bolts to a torque of 53 to 62 Nm (39 to 46 lb-ft).

6005-10

UNIVERSAL JOINTS Installation

Removal

NOTE: The bearing race and journal that make up the universal joint are not serviced separately. If the bearing race or journal is worn or damaged, a new universal joint must be used.

STEP 52 Remove the drive shaft from the machine.

STEP 53

STEP 55 2

Clean the slots in the yoke of the drive shaft.

STEP 56 Install the universal joint and install the bearings (2) and the rings (1). Refer to the photo in Step 53.

STEP 57 Install the drive shaft.

BD01F304

1. RING

2. BEARING

Remove the ring (1) and the bearing (2) from the drive shaft. NOTE: The above photo shows the drive shaft on the machine and is for reference of the ring and bearing only.

STEP 54 Remove the universal joint from the drive shaft.

Section 6006

6006

WHEELS AND TIRES

6006-2

TABLE OF CONTENTS WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 4 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 298 Nm (220 pound-feet) in the sequence shown in Figure 1. Then a final torque of 640 to 720 Nm (475 to 530 lb-ft) in the same sequence.

A. If the machine is new. B. If a wheel has been removed and installed.

TIRE PRESSURES Tire Size

Tire Type

Front Tire pressure

Rear Tire pressure

17.5 x 25 L2 or L3

Bias Ply

3.44 bar (50 psi)

2.75 bar (40 psi)

17.5 x 25 L2 or L3

Radial

3.44 bar (50 psi)

2.75 bar (40 psi)

20.5 x 25 L2 or L3

Bias Ply

3.44 bar (50 psi)

2.75 bar (40 psi)

20.5 x 25 L2 or L3

Radial

3.44 bar (50 psi)

2.75 bar (40 psi)

6006-4

CHANGING TIRES 1. Have a qualified tire mechanic service the split rim wheels used on this machine.

WARNING: 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.

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.

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.

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.

48-44

INSTALLING A WHEEL 4. Tighten the wheel bolts to 298 Nm (220 lb-ft) in the sequence shown in Figure 1. Then tighten the wheel bolts in the same sequence to 640 to 720 Nm (475 to 530 lb-ft).

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. 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.

8 12

4 5

11 7

B0987A88

FIGURE 1. WHEEL BOLT TORQUE SEQUENCE

Section 6007

6007

TRANSMISSION CONTROL VALVE

6007-2

TABLE OF CONTENTS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 5

6007-3

CONTROL VALVE Disassembly

STEP 4

STEP 1

BD06A010

BD06A007

Mark the installation position of the wiring harness to the valve block.

Loosen and remove the cap screws, remove the cover. Remove the opposite cover.

STEP 5

STEP 2

BD06A011

Remove the wiring harness. BD06A008

Loosen and remove the cap screws that secure the distribution plate and intermediate plate to the valve body, remove the intermediate plate and distribution plate.

STEP 6

STEP 3

BD06A012

Loosen and remove the retaining plate cap screws, remove the retaining plates and solenoids.

BD06A009

Remove the wiring harness retaining clamp.

6007-4

STEP 7

STEP 9

BD06A013

Loosen and remove two cap screws, install two adjusting screws. Loosen and remove the remaining cap screws.

BD06A015

Remove the components.

STEP 10

STEP 8

BD06A016

BD06A014

Separate the housing from the valve body by equally loosening the adjusting screws.

Remove the opposite solenoids, housing, and components.

6007-5

Inspection 1. Clean all metal parts in cleaning solvent. 2. Immerse end housings, valve housing, valve plate, and distribution plate in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of housings and plates and to ensure that all bores are clear of foreign matter.

Assembly NOTE: Apply clean engine oil (15W-40) to pistons and springs, orifices, new O-rings, and filter screens before assembly.

STEP 11

3. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to ensure that orifices are clear of foreign matter. 4. Check filter screens for blockage, rips, or tears. Replace if any of these conditions are seen. 5. Inspect the plates, housings and covers for corrosion, cracks, breaks, chipping or other damage. Check bores in housings for deep scratches, gouges, and other damage. Replace a housing or cover if any of the above conditions are seen. 6. Check pressure regulators for cracks, breaks, or other damage. Check connector contacts for looseness or signs of corrosion. Replace a pressure regulator if any of these conditions are seen. Check resistance of pressure regulators using a multimeter. Replace a pressure regulator if resistance is not 17 to 21 ohms. 7. Check wiring harness connectors for signs of breaks, cracks, or other damage. Check contacts for foreign matter or corrosion. Check harness wiring for signs of broken or cracked insulation and broken or frayed wiring at connection to connectors. Replace wiring harness if any of these conditions are seen. 8. Check springs for cracks, breaks, distortion, or signs of permanent set. Replace a spring if any of these conditions are seen. 9. Inspect pistons for cracks, breaks, chipping, grooves, or other damage. Replace if any of these conditions are seen.

BD06A017

Place the valve body on the bench with the orifices up.

STEP 12

1 2 BD06A018

1. VIBRATION DAMPER 2. PISTONS

3. PRESSURE REDUCING VALVE

Install components in positions shown.

STEP 13

BD06A019

Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch).

6007-6

STEP 14

STEP 17

BD06A020

BD06A023

Install the adjusting screws, gasket, and housing cover.

Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).

STEP 15

STEP 18

BD06A021

BD06A024

Tighten the adjusting screws equally until the cover is flush on the valve body.

Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch).

STEP 16

NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.

STEP 19

BD06A022

Push the pistons down through the pressure controller wholes and remove the roll pins.

1 2

3 2 BD06A025

1. VIBRATION DAMPER 2. PISTONS

3. MAIN PRESSURE VALVE

Install components in positions shown.

6007-7

STEP 20

STEP 23

BD06A026

BD06A028

Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch). Install the adjusting screws, gasket, and housing cover.

Install the wiring harness with connector on side of valve body marking made during disassembly. Connect wiring harness to the solenoids.

STEP 24

STEP 21

BD06A029

Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).

Install the gasket, install the wiring harness plug in the cover. Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).

STEP 22

STEP 25

BD06A023

BD06A027

Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch). NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.

BD06A030

Install the wiring harness retaining clamp.

6007-8

STEP 26

STEP 28

BD06A031

BD06A033

Install the screens into the bores of the intermediate plate towards the distribution plate.

Install the distribution plate, install the cap screws and torque in a criss cross pattern to 9.5 Nm (84 pound-inch).

STEP 27

STEP 29

BD06A032

Install two adjusting screws. Place the intermediate plate with the screens facing up.

BD06A034

Install new o-rings on the plugs, install and torque plugs to 6 Nm (53 pound-inch).

SECTION INDEX

BRAKES Section Title

Section Number

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7001 Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002 Brake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003 Brake Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

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 7 7 7

7001-3

2 1 3

7 5 6

W110R569

1. BRAKE PUMP 2. COOLING FRAME 3. REAR ACCUMULATOR (FRONT AXLE)

4. FRONT ACCUMULATOR (REAR AXLE) 5. BRAKE VALVE 6. PARKING BRAKE HOSE COMPONENT LOCATION ILLUSTRATION

2 3 BS08A125

1. REAR ACCUMULATOR (FRONT AXLE) 2. FRONT ACCUMULATOR (REAR AXLE) 3. PARKING BRAKE ACCUMULATOR BRAKE ACCUMULATOR LOCATION ILLUSTRATION

7. BRAKE PUMP SUCTION HOSE 8. BRAKE PUMP PRESSURE HOSE 9. PARKING BRAKE

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 5

3 W110R570

1. 2. 3. 4. 5.

BRAKE VALVE PLATE FORWARD PLATE REAR BOLT M8X20 NUT M8

4. Connect all of the electrical connections. 5. Remove and discard tags. 6. Turn the master disconnect switch to the ON position. 7. Bleed the brake system. See Section 7002. 8. Install the cab skirts. 9. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

7001-5

2 7

10 3 W110R571

BRAKE VALVE ILLUSTRATION 1. 2. 3. 4. 5.

BRAKE VALVE REAR ACCUMULATOR LINE (FRONT AXLE) PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE TO FAN VALVE

6. 7. 8. 9. 10.

FRONT BRAKE LINE REAR BRAKE LINE FRONT ACCUMULATOR LINE (REAR AXLE) RETURN TO TANK PARKING BRAKE ACCUMULATOR

7001-6

SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS 3

13. Loosen the clamp stud on the accumulator clamps (3). 14. Remove accumulators (4) and (5) from clamps (3).

5 7

15. Disconnect hose accumulator (6).

6 BS08A125

1. 2. 3. 4. 5. 6. 7. 8.

11. Tag and disconnect the accumulator hoses (1) and (2) from brake accumulators (4) and (5). 12. Install plugs in hoses and caps on fittings.

10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump.

FRONT ACCUMULATOR HOSE REAR ACCUMULATOR HOSE MOUNTING CLAMP REAR ACCUMULATOR (FRONT AXLE) FRONT ACCUMULATOR (REAR AXLE) PARKING BRAKE ACCUMULATOR BRACKET PARKING BRAKE ACCUMULATOR HOSE

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.

(8)

from

parking

brake

16. Remove the mounting nut on the back side of bracket (7) for parking brake accumulator (6), remove the accumulator. 17. Install a plug in the hose and cap fitting.

Installation 1. Mount the accumulators (4) and (5) in clamps (3), do not tighten clamps at this time. Refer to illustration. 2. Connect hose (1) to brake accumulator (5) and tighten. 3. Connect hose (2) to brake accumulator (4) and tighten. 4. Tighten clamps (3) to 17Nm (13 pound feet).

3. Make sure the brake accumulators (4) and (5) and the parking brake accumulator (6) are completely discharged. Push down and release the brake pedal at least 30 times.

5. Install the parking brake accumulator (6) into bracket (7).

4. Turn the master disconnect switch to the OFF position.

7. Connect hose (8) accumulator (6).

5. Remove the left cab skirt located under the cab or canopy to gain access to accumulators.

8. Remove and discard tags.

6. Install the mounting nut and tighten. to

the

parking

brake

9. Stop the vacuum pump and remove.

6. To release the pressure on the parking brake accumulator (6), the line at the accumulator must be SLOWLY cracked open. A pan will be needed to catch the hydraulic oil.

10. Install the left cab skirt.

7. Connect a drain hose to the quick disconnect couplings in each brake circuit to release any pressure in the brake circuit.

12. Turn the master disconnect switch to the ON position.

8. Clean the brake accumulators (4) and (5), parking brake accumulator (6) and hoses (1), (2) and (8). Refer to illustration above.

14. Refer to Section 7008 and perform the Parking Brake Test Procedure.

9. Put identification tag on hose (8) that is connected to the parking brake accumulator (6).

11. Refer to Section 7004 and check the nitrogen charge on the accumulators.

13. Bleed the brake system. See Section 7002.

15. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

7001-7

BRAKE PUMP Removal

Installation

1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine.

NOTE: DO NOT use an impact tools on the slotted nut for mounting the pump drive gear.

2. Put blocks on both sides of each tire to prevent machine movement.

1. Install gear (4) onto the pump shaft, install slotted nut (5). Torque nut to 70 to 79 Nm (52 to 58 pound feet). Refer to the illustration on page 8.

3. Turn the master disconnect switch to the OFF position. 4. Clean the brake pump (1) and lines, refer to the illustration on page 8. 5. Put identification tags on the lines that are connected to the brake pump (1). 6. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 7. Disconnect the lines from the brake pump (1) and put plugs in each line. 8. Remove the mounting bolts (2) and washers (3) from the brake pump (1) and remove the brake pump (1). 9. Remove cotter pin (6) and slotted nut (5), remove drive gear (4).

2. Install the cotter pin (6). 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. Turn the master disconnect switch to the ON position. 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.

7001-8

5 4 2

1 6

2 8

BS08A038

BRAKE PUMP ILLUSTRATION 1. 2. 3. 4.

BRAKE PUMP MOUNTING BOLT M12X35 (TORQUE 57-65 NM/ 42-48 LB-FT) WASHER DRIVE GEAR

5. 6. 7. 8.

SLOTTED NUT (TORQUE 70-79 NM/ 52-58 LB-FT) COTTER PIN HOSE (BRAKE PUMP SUCTION) HOSE (BRAKE PUMP PRESSURE)

HYDRAULIC BRAKE TROUBLESHOOTING

7002

Section 7002

7002-2

3 3 4 5 7 7 8 9 10 11

7002-3

SPECIFICATIONS Brake pump output ...................................................................................................28 L/min at 172 bar at 2000 rpm 7.4 gpm at 2500 psi at 2000 rpm Accumulator nitrogen pre-charge pressure ..................................................................65 to 70 bar (942 to 1015 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 ......................122 to 138 bar (1769 to 2001 psi) Brake redundant pressure switch (normally closed) opening set point ... 77 to 91 bar decreasing (1116 to 1319 psi) Brake light pressure switch (normally open) closing set point ........................................... 4.1 bar increasing (60 psi) Modulation pressure front brake cylinders..................................................................76 to 84 bar (1102 to 1218 psi) Modulation pressure rear brake cylinders...................................................................74 to 82 bar (1073 to 1189 psi)

SPECIAL TOOLS

BS06M002

380001676 NITROGEN REGULATOR VALVE USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN.

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

B877168V B785789M

380001731 FLOWMETER

380001740 FLOW METER FITTING KIT

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.

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. 9. As the lowest pressure reaches 122 to 138 bar (1769 to 2001 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.

4. Make sure that the pressure gauge hoses are long enough so the gauges can be read while sitting in the operators seat.

10. After the low brake pressure light activates, press the brake pedal eight more times.

NOTE: The gauges can not be connected to the test ports if hydraulic pressure remains in the system.

11. Record the readings on the pressure gauges. The pressure gauges should read at or above 65 to 70 bar (942 to 1015 psi).

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 122 to 138 bar (1769 to 2001 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. NOTE: The brake cut-in and cut-out pressures of the brake system charge valve are factory preset and are not adjustable. NOTE: If the pressure on one of the pressure gauges is lower than specified, the problem can be a bad accumulator valve.

12. If the pressures are at or above 65 to 70 bar (942 to 1015 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. 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 65 to 70 bar (942 to 1015 psi), charge or replace the accumulator(s) (see section 7004). NOTE: Nominal temperature of 20Â° C (68Â° F), colder temperature will reduce pressure, hotter temperature will increase pressure.

7002-5

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.

2 3 1

BD07N586-01

6. Disconnect connector C (1) and connector A (2) from the EDC-7 controller (3).

BD03A092

1. SAFETY LINK

2. Raise loader arms and install the safety link (1).

IMPORTANT: Make sure that the master disconnect and ignition switch are OFF before disconnecting or connecting connectors on EDC-7 controller. NOTE: Disconnecting Connector A and C will prevent engine from starting.

BD07N588-01 BD03A040

3. Put articulation lock in LOCKED position. 4. Apply the parking brake. 5. To prime pump: Turning off ignition switch and master disconnect.

7. Lossen the pressure side fitting on the brake pump. The pressure side of the brake pump is the top hose on the brake pump. 8. Turn master disconnect ON. 9. Turn the engine over, (machine will not start), until a few drops of oil leak past the fitting. Then tighten the fitting. NOTE: The EDC-7 controller will only allow for 5 seconds of cranking then it will shut down. And then you will have to turn the ignition OFF and ON again to crank engine. 10. Turn master disconnect switch to OFF. 11. Connect connector A and connector C to the EDC-7 controller. 12. Turn master disconnect switch to ON.

7002-6 13. Start the engine and allow it to idle until both brake accumulators are fully charged. NOTE: This will be approximately 30 seconds after the low brake pressure light goes out. 14. Stop the engine. 15. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps). 16. Remove the plastic and rubber cap from each wheel end and slowly open bleed screws.

17. Attach hose to the bleed screw at each wheel end to prevent oil spillage. Submerge hoses in fluid to prevent air from re-entering the brake system. 18. Start the machine and allow it to idle. 19. Depress the brake pedal until the flow is clear (No bubbles) in each of the tubes. 20. Close all four wheel end bleed screws. 21. Replace all caps and plugs on wheel end. 22. Check the hydraulic fluid and add as necessary.

7002-7

BRAKE MODULATION PRESSURE CHECK

W110R572

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 76 to 84 bar (1102 to 1218 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 74 to 82 bar (1073 to 1189 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 in 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. Remove the locking bolt (2). 3. Turn the adjusting screw (3) to adjust the modulation pressure. NOTE: The rear brake modulation pressure cannot be adjusted separately from the front brake modulation pressure. 4. Repeat steps 5 through 10 in the Testing the Brake Modulation Pressure procedure. 5. Repeat these steps until the brake modulation pressure is within the specified range.

2 1 W270R015

1. TAMPER RESISTANT COVER 2. LOCKING BOLT 3. ADJUSTING SCREW

7002-9

SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)

W110R572

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 122 to 138 bar (1769 to 2001 psi). After the low brake pressure light activates, press the brake pedal eight more times.

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 65 to 70 bar (942 to 1015 psi). 11. If the pressures are at or above 65 to 70 bar (942 to 1015 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 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.

1. Connect the flowmeter to the brake pump as shown 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.

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.

11 9 12

NOTE

6 2

1 2

12 3

4 BS02M026

1. 2. 3. 4.

FROM HYDRAULIC RESERVOIR 5. BRAKE PUMP 9. FILTER INLET MANIFOLD ELBOW 6. FLOWMETER INLET HOSE 10. FILTER PLUG 7. 380001731 FLOWMETER 11. FILTER TO RESERVOIR HOSE TO ACCUMULATOR VALVE 8. FLOWMETER OUTLET HOSE 12. O-RING NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION BRAKE PUMP OUTPUT TEST

7002-11

F2 R1

X1 X

F1 4

8 1

8 P

B X1

R1 R2

N F

T1 T2 6

W270R014

BRAKE VALVE ASSEMBLY

7002-12 40 Nm

30 Nm 1

50 Nm

15 Nm

1 1

25 Nm

9 Nm

1 1 1 9 Nm

2 1

10 Nm

2 2.4

10 Nm

2 10 Nm

9 Nm 1

55 Nm

44-50 Nm

5.6

9-11 Nm

6 2

25 Nm 2

2.3 1.2 45 Nm 2

3 Nm

1.2 2

70 Nm 2

9 Nm

1 1

2 1

22 Nm

25 Nm

1 9 Nm 1

45 Nm 45 Nm 1

1 W270R016

BRAKE VALVE EXPLODED VIEW

7002-13

SPARE PARTS LIST 1. 2. 3. 4. 5. 6.

Seal kit Complete pedal support Dust rubber Pedal rubber cover Solenoid 24V Deutsch connector Solenoid + Cartridge valve

7002-14

NOTES

BRAKE PUMP

7003

Section 7003

7003-2

TABLE OF CONTENTS BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 4 4

7003-3

4 5

10 9

9 9

13 14

BS08B054

1. 2. 3. 4. 5. 6. 7.

OUTER SHAFT SEAL RETAINING RING SHAFT SEAL SHAFT END COVER HOUSING BACKUP RING CHANNEL SEAL THRUST PLATE

8. 9. 10. 11. 12. 13. 14.

QUAD RING DOWEL PIN GEAR HOUSING DRIVE GEAR DRIVEN GEAR PORT END COVER HOUSING BOLT

PUMP ILLUSTRATION

7003-4

BRAKE PUMP Disassembly

Assembly

1. Secure the pump by the port end cover (13) in a soft jawed vise.

1. Install shaft seal (3) into the shaft end cover housing (4).

2. Draw a line the length of the pump to assist during assemble.

2. Install the retaining ring (2) into the shaft end cover housing (4).

3. Loosen and remove bolts (14).

3. Install a new outer shaft seal (1) into the shaft end cover housing (4).

4. Tap the shaft end cover housing (4) with soft hammer to loosen it, remove the shaft end cover housing (4).

4. Place the shaft end housing (4), facing down, into a soft jawed vise.

5. Remove the backup ring (5), channel seal (6), and thrust plate (7).

5. Install new backup rings (5) and channel seals (6) into the thrust plates (7).

6. Remove the drive gear (11) from the gear housing (10).

6. Place an assembled thrust plate (7) onto the shaft end cover housing (4).

7. Remove the driven gear (12) from the gear housing (10).

IMPORTANT: Be sure to place the thrust plate (7) onto the shaft end cover housing (4) in the position shown in the illustration on page 3.

8. Tap the gear housing (10) with a soft hammer to loosen it from the port end housing cover (13) . 9. Remove the backup ring (5), channel seal (6), and thrust plate (7). 10. Remove the outer shaft seal (1) from the shaft end cover housing (4). 11. Remove the retaining ring (2) from the shaft end cover housing (4). 12. Remove the shaft seal (3) from the shaft end cover housing (4).

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.

7. Lubricate the driven gear (12) with hydraulic oil, slide the driven gear (12) through the thrust plate (7) into the shaft end cover housing (4). 8. Lubricate the drive gear (11) with hydraulic oil, slide the drive gear (11) through the thrust plate (7) into the shaft end cover housing (4). 9. Install a new quad ring (8) into the gear housing (10). Check that dowel pins (9) are in place either in the gear housing (10) or the shaft end cover housing (4). 10. Align the marks made during disassembly, carefully place the gear housing (10) onto the gears. 11. Slide the other assembled thrust plate (7) onto the shafts of the gears. IMPORTANT: Be sure to place the thrust plate (7) onto the gears in the position shown in the illustration on page 3. 12. Install a new quad ring (8) into the gear housing (10). Check that dowel pins (9) are in place either in the gear housing (10) or the port end cover housing (13). 13. Align the marks made during disassembly, place the port housing (13) onto the gear housing (10). 14. Install bolts (14) with clean and dry threads. Torque bolts to 192 Âą 5.5 Nm (141.5 Âą 4 pound feet).

BRAKE ACCUMULATORS

7004

Section 7004

7004-2

TABLE OF CONTENTS ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 6

7004-3

ACCUMULATOR SPECIAL TORQUES Gas Charging Valve..................................................................................................................20Nm (15 pound-feet)

SPECIAL TOOLS

BS06M002

380001676 NITROGEN REGULATOR VALVE

BC04A001

380001168 ACCUMULATOR VALVE ADAPTER

NOTE: Check your inventory of tools, if you have nitrogen charging kit 380001737 use it in place of the above listed tools.

BS06M003

380001390 ACCUMULATOR CHARGING HOSE

7004-4

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

G F

NITROGEN CHARGING KIT

1. Use the Nitrogen Charging accumulator pressure.

Kit

check

BS07A156

7. Connect valve A to the valve stem on the adapter (F).

2. Close valve (E).

8. Connect the accumulator to the adapter (F)

3. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise.

9. Open valve on accumulator using the adapter’s square drive (G). 10. Turn the T-handle inward on valve (A) to engage the pin in the valve stem on the adapter.

4. Turn the T-handle on valve (A) fully out. 5. Remove the valve cap from the accumulator. 6. Install adapter accumulator.

380001168

(F)

onto

the

11. Slowly open valve (E). 12. Check the charge pressure on gauge (B).

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

7004-5

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR 1. Use the Nitrogen Charging Kit to discharge the accumulator, refer to the illustration on page 4. The tool must be disconnected from the nitrogen tank.

7. Connect valve A to the valve stem on the adapter (F).

2. Close valve (E).

9. Turn the T-handle inward on valve (A) to engage the pin in the valve stem on the adapter.

3. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve (A) fully out. 380001168

(F)

onto

10. Slowly open valve (E). 11. Slowly open valve (D) and allow the nitrogen to bleed off.

5. Remove the valve cap from the accumulator. 6. Install adapter accumulator.

8. Open valve on accumulator using the adapterâ&#x20AC;&#x2122;s square drive (G).

the

7004-6

CHARGING THE ACCUMULATOR WITH DRY NITROGEN IMPORTANT: The four valves A, D, and E must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to illustration on page 4. 1. Close the shutoff valve (D) by turning it all the way to the left (counterclockwise), refer to the illustration on page 4. 2. Close the gauge valve (E) by turning it all the way to the right (clockwise). 3. Connect the charging gauges to the nitrogen supply tank, open the supply tank valve. 4. Slowly turn valve (D) clockwise while watching the pressure gauge (B). Stop turning valve (D) when the needle on the gauge (B) reaches 10 bar (145 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve (E) and check the pressure again. The charging kit is now ready to be installed on the accumulator. 5. Remove the cap from the accumulator. 6. Loosen the sealing plug with an Allen wrench. NOTE: Just loosen do not open to far so the gas leaks out 7. Install adapter 380001168 (F). 8. Back off the needle valve (A) 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. 9. Install the charging hose fitting onto the adapter. 10. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve (E) and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

11. Fill the accumulator to pressure according to Temperature/Charge Pressure chart. 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 65.2 BAR 945 PSI 66.4 BAR 963 PSI 67.6 BAR 980 PSI 68.8 BAR 998 PSI 70.0 BAR 1015 PSI 71.2 BAR 1032 PSI 72.4 BAR 1050 PSI 73.6 BAR 1067 PSI 74.8 BAR 1085 PSI

TEMPERATURE/CHARGE PRESSURE CHART

12. Close valve (E) by turning to the right (clockwise). After a few minutes open valve (E) and check the accumulator for leakage. 13. Back off the needle valve (A) 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. 14. Close the valve on the nitrogen supply tank. 15. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise. 16. Slowly remove the charging hose from the accumulator pressure valve. NOTE: A small amount of nitrogen will escape when disconnecting the hose. 17. Snug the gas charging valve on the accumulator, remove the adapter from the accumulator. 18. Torque the gas charging valve to 20 Nm (15 pound feet) 19. Install the cap on the accumulator. 20. Remove the charging gauges from the nitrogen supply tank. NOTE: A small amount of nitrogen will escape when disconnecting the hose.

Section 7008

7008

PARKING BRAKE

7008-2

TABLE OF CONTENTS PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATIC PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dynamic Parking Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Disable Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 7 7

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 1

Place wheel chocks on each wheel to prevent machine movement.

STEP 3 2 BD0CA185

Loosen the jam nut (2), turn adjusting bolt (1) 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 switch.

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.

Parking Brake Adjustment Procedure STEP 15

BD03A187

Install the two brake pads in the parking brake assembly.

STEP 12

2 BD0CA185

Turn the adjusting bolt (1) clockwise until both brake pads contact the brake disc, then turn the adjusting bolt (1) counterclockwise 1/2 turn. Tighten the jam nut (2) to secure the adjusting bolt.

STEP 16 BD03A186

Install the brake pins and retainer pins.

STEP 13 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.

Install the cover on the parking brake.

STEP 17 Perfor m the Parking Brake Test Procedure as described in this section.

STEP 18 Remove the articulation lock.

STEP 19 Place the master disconnect switch to the ON position.

7008-5

PARKING BRAKE TEST PROCEDURE STEP 20

STEP 25

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 21 Start the machine and run the engine at low idle in third gear neutral.

STEP 22 Place the Transmission-Auto switch to the manual position.

W230R430

Use up or down arrow and highlight Service, press the enter key to select the config menu.

STEP 26

STEP 23 Place the Parking Brake switch to the ON position.

STEP 24

W230R431

Press the up or down arrow and high light Calibration, press the enter key.

STEP 27 BD06F141

Press and hold the enter key for 2 to 3 seconds until the instrument cluster monitor display changes to the select screen.

W230R432

Press the up or down arrow and high light Park Brake, press the enter key.

7008-6

STEP 28

STEP 34 Shift the gear selector to third gear reverse and slowly increase the engine speed to wide open throttle.

STEP 35 Verify that the machine does not move.

STEP 36 Reduce the engine speed to low idle and return the transmission to neutral. W230R433

STEP 37

Press the up or down arrow and high light brake test, press the enter key.

STEP 29

BD06F141

Press the escape switch on the key pad to exit the test mode. W230R434

Monitor will display Test Park Brake if all conditions are met to test the brake, press the enter key. NOTE: If all conditions are not met to test the brake the monitor will display the condition that needs corrected prior to proceeding.

STEP 30 Monitor will display Test Park Brake Ready.

STEP 31 Shift the gear selector into third gear forward and slowly increase the engine speed to wide open throttle.

STEP 32 Verify that the machine does not move.

STEP 33 Reduce the engine speed to low idle and return the transmission neutral.

STEP 38 If any machine movement was detected, the parking brake must be adjusted, see procedures this section.

7008-7

Dynamic Parking Brake Test

Parking Brake Disable Procedure

STEP 39

If it becomes necessary to tow a machine, the parking brake must be disabled.

Start machine and run at low idle.

STEP 46

STEP 40

Park the machine on a hard level surface and lower the loader bucket to the ground.

STEP 47 Place wheel chocks on each wheel to prevent machine movement.

STEP 48

BD06F141

Cycle the parking brake switch to the OFF position

STEP 41 Shift the machine into 1st gear forward.

STEP 42 The parking brake light on the cluster will turn off at this time.

STEP 43

BD01F143

Install the articulation lock.

Allow machine to roll slowly forward.

STEP 49

STEP 44

Place the master disconnect switch in the OFF position.

Engage the parking brake with the parking brake switch.

STEP 50

STEP 45

Pump the brake pedal at least 30 times to discharge the accumulators.

If machine does not come to an immediate stop the parking brake must be adjusted.

7008-8

STEP 51

STEP 52

2 BD03A184

BD03A185

Loosen and remove the cover from the parking brake.

Loosen the jam nut (2), turn adjusting bolt (1) counterclockwise until the brake pads are loose. The parking brake is now disabled. NOTE: Do not replace the cover on a parking brake that has been disabled. The cover can be severely damaged if hydraulic pressure is applied to a disabled parking brake.

SECTION INDEX

HYDRAULICS Section Title

Section Number

How to Read Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8000 Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001 Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002 Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003 Loader Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006 Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007 Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013 Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

Section 8000

8000

HOW TO READ HYDRAULIC SCHEMATICS

8000-2

TABLE OF CONTENTS HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbol Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossing or Joining Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Motor Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Directional Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Composite Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIMPLE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMMON SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line and Line Fuctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 4 5 5 6 6 7 8 9 10 11 12 14 14 14 15 15 16 16 17 18

8000-3

HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC Introduction

Using Schematic Symbols

A hydraulic schematic diagram is a line drawing composed of hydraulic symbols that indicate the types of the components the hydraulic circuit contains and how they are interconnected. Accurate diagrams of hydraulic circuits are essential to the ser vice technician who must repair them. The schematic diagram is a valuable aid in diagnosing possible causes of a problem when troubleshooting machinery.

Reservoirs

The purpose of this section is to show how to read and effectively use schematic circuit diagrams.

PRESSURIZED RESERVOIR

VENTED RESERVOIR

BS07B620

A rectangle with the top removed represents a vented reservoir. A rectangle with the top in place represents a pressurized reservoir.

Circuit Diagrams 1. Cutaway Circuit Diagrams show the internal construction of the components, as well as the flow paths. By using colors, shades or various patterns in the lines and passages, they are able to show many different conditions of flow and pressure. Cutaway diagrams take considerably longer to produce because of their complexity. 2. Schematic Circuit Diagrams, the â&#x20AC;&#x153;shorthandâ&#x20AC;? system of the industry, are usually preferred for troubleshooting. A schematic diagram is made u p o f s i m p l e g e o m e t r i c s y m b o l s fo r t h e components and their controls and connections.

PRESSURIZED RESERVOIR

PRESSURIZED RESERVOIR BS07B621

The are other schematic diagrams that show a slightly different version of a pressurized reservoir, but the symbols are similar and easily recognized. An oval with a short line on top or a rectangle with c u r ve d s i d e s r e p r e s e n t s a r e s e r vo i r t h a t i s pressurized.

Symbol Systems There are several systems of symbols used when making schematic diagrams. They are as follows: I.S.O. - International Standards Organization A.N.S.I. - American National Standards Institute A.S.A. - American Standards Association

RETURN LINE ABOVE THE OIL LEVEL BS07B622

Lines connected to the reservoir usually are drawn from the top, regardless of where the actual connection is.

J.I.C. - Joint Industry Conference A combination of these symbols is shown in this section. There are differences between the symbols, bu t t h e r e i s e n o u g h s i m i l a r i t y s o t h a t i f yo u understand the symbols in this section, you will be able to interpret other symbols as well.

SUCTION LINE OR RETURN LINE BELOW THE OIL LEVEL BS07B623

If the hydraulic line terminates below the fluid level, it is drawn all the way to the bottom of the symbol

BS07B624

RESERVOIR WITH SUCTION LINE ATTACHED AT THE BOTTOM

8000-4 A hydraulic line connected to the bottom of the reservoir may be drawn from the bottom of the symbol if the bottom connection is essential to the system operation.

Lines, Tubes, and Hoses A hydraulic line, tube, hose, or any conductor that carries the fluid between components is shown as a line.

BS07B626

A working line, such as an inlet pressure or return, is shown as a solid line.

BS07B625

If the pump inlet must be charged or flooded with a positive head of oil above the inlet port, the reservoir symbol will be above the pump symbol with a suction line drawn out of the bottom of the reservoir symbol. Every vehicle or system reservoir has at least two hydraulic lines connected to it, and some may have m a ny m o r e. O f t e n t h e c o m p o n e n t s t h a t a r e connected to the reservoir are spread all over the s c h e m a t i c . R a t h e r t h a n h av i n g a nu m b e r o f confusing lines all over the schematic, it is customary to draw individual reservoir symbols close to the components. The reser voir is usually the only component symbol pictured more than once.

BS07B627

OIL FLOWS ONE WAY ONLY

BS07B628

OIL CAN FLOW EITHER WAY

Working lines with arrows show direction of flow.

BS07B629

Pilot or control lines are broken into long dashes.

BS07B630

Drain lines for leakage oil are broken into short dashes.

BS07B631

A flexible line is show as an arc between two dots and is always represented by a solid line.

BS07B632

Quite often you will see an enclosure outline that indicates that there are several symbols that make up a component assembly such as a valve or a valve stack. The enclosure outline appears like a box and is broken with dashes on all sides.

8000-5

Crossing or Joining Lines

BS07B633

LINES THAT ARE NOT CONNECTED

The shortest distance between two components that are connected is a straight line. There are lines that cross other lines, but are not connected. There are a number of ways to show crossing lines.

Variable Displacement

Variable Displacement Pressure Compensated BS07B636

A variable displacement pump is designated by drawing an arrow through the pump symbol at 45 degrees. To indicate a var iable displacement pressure compensated pump, a small box with an arrow in it will be added to the side of the pump symbol

BS07B634

LINES THAT ARE CONNECTED

Lines that are connected are shown with a dot that represents the connection or shown as a tee connection. The dot connection is the most commonly used when drawing schematic diagrams.

Pump Symbols

Lever Controlled

Pedal or Treadle Controlled BS07B637

If the pump is controlled by a lever or a pedal, it will be shown on the side of the pump.

Outlet

Inlet Fixed Displacement

Pump with Drive Shaft Fixed Displacement Reversible BS07B635

There are many basic pump designs. A simple fixed displacement pump is shown as a circle with a black triangle that is pointing outwards. The black triangle is like an arrow head and points in the direction that the oil will flow. If the pump is reversible or designed to pump in either direction, it will have two black triangles in it and they will be opposite each other.

Pump with Drive Shaft and Directional Arrow BS07B638

A drive shaft is shown as two short parallel lines extending from the side of the pump. If a curved arrow is shown on the drive shaft, it will indicate the direction of the rotation.

8000-6

Hydraulic Motor Symbols

Double Rod End Cylinder BS07B643

Nonreversible Motor

Reversible Motor BS07B639

A double rod end cylinder has a rod extending from each end of the rectangle.

Hydraulic motor symbols are circles with black triangles, but opposite a pump the triangles point inward to show the motor is a receiver of oil. One triangle is used for a non-reversible motor and two triangles are used for a reversible motor. Single Rod End Fixed Cushion Both Ends Pump

BS07B644

Motor BS07B640

A simple schematic diagram is shown with a hydraulic motor connected to a hydraulic pump.

Single Rod End Adjustable Cushion Rod End Only

Cylinder Symbols

SINGLE ROD END ADJUSTABLE CUSHION ROD END ONLY

730LBE

Some cylinders have cushions built into them. The cushion slows down the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller rectangle on the piston. If the cushion has an adjustable orifice, a slanted arrow is drawn at 45 degrees across the symbol.

Tee

Rectangle

BS07B641

A cylinder symbol is a simple rectangle representing the barrel. The piston and rod are represented by a tee that is inserted into the rectangle. The symbol can be drawn in any position. Port

Single Acting Cylinder

Double Acting Cylinder BS07B642

If the cylinder is single acting, there is only one port shown on the symbol. The port is shown on the end of the cylinder that receives pressurized fluid and the opposite end of the cylinder is left open. A double acting cylinder symbol has both ends closed and has two ports on the symbol.

8000-7

Pressure Control Symbols

Relief Valve

The basic symbol is a square (which is called an envelope) with external port connections and an arrow inside to show the oil passage and direction of flow. Usually this type of valve operates by balancing the oil pressure against a spring, so a spring is shown on one side of the symbol and a pilot pressure line on the other side.

Pump

Normally Closed Arrow Offset From Ports Inlet Spring

Arrow Aligned With Ports

Pilot Line

Outlet Normally Closed

Pressure Line

Visualize square moving toward spring BS07B646

A normally closed valve, such as a relief or sequence valve, is shown with the arrow offset from the ports and toward the pilot pressure line side of the square. The spring holds the valve closed until the pilot line oil pressure is greater than the spring pressure. Mentally visualize a build up of pressure in the pilot line and the square moving over, compressing the spring. The oil now can flow through the valve.

Relief Valve BS07B648

A relief valve is shown as a normally closed symbol connected between the pressure line and the reservoir. The flow direction arrow points away from the pressure line port and toward the reservoir. This shows very graphically how a relief valve operates. When pressure in the system overcomes the valve spring, flow is from the pressure line through the relief valve to the reservoir.

Pressure Reducing Valve High Pressure Inlet

Pilot Line

Drain Line to Reservoir

Reduced Outlet Pressure

Normally open

BS07B649

Inlet Spring

Pilot Line

Outlet Normally Open

Visualize square moving toward spring BS07B647

A normally open valve is shown with the arrow connecting the two ports. It closes when the pressure overcomes spring force. Mentally visualize a build up of pressure in the pilot line and the square moving over, compressing the spring. The oil flow through the valve is now blocked.

A pressure reducing valve is shown as a normally open symbol in a pressure line. This valve works opposite of a relief valve, since it senses outlet pressure versus inlet pressure. As the outlet pressure builds, it works against a predetermined spring force. As the spring force is overcome, flow through the valve is modulated or shut off.

8000-8

Directional Control Symbols

Sequence Valve Supply Line Relief Valve

Pump

To Primary Cylinder

Simplified Symbols One Way Valve

No Flow Sequence Valve To Secondary Cylinder BS07B650

The normally closed symbol is also used for a sequence valve. The inlet port is connected to a primary cylinder and the outlet port o the secondary cylinder line. When the piston in the primary cylinder reaches the end of its stroke, the pressure in the supply line increases. The sequence valve is also connected to the supply line and also feels the increase in pressure. As pressure increases, the square and directional flow arrow moves over, connecting the inlet and outlet ports, allowing fluid to flow to the secondary cylinder.

Free Flow BS07B676

A simple ball check valve is shown. When oil pressure is exerted on the left side of the ball, the ball is forced into the V and no oil can flow past it. When oil pressure is applied to the right side of the ball, the ball moves away from the V and oil can flow past.

By Pass Valve

Spring

BS07B677

A by pass valve is shown as a one way valve with a spring on the ball end of the symbol. This shows that a pressurized flow will be necessary to overcome the spring force and allow flow around the ball.

8000-9

Composite Symbols

Three - Position Valves

One - Way Valves Free Flow No Flow One way valve shown in the closed position

Visualize a build up of pressure on the right side of valve

BS07B680

OPEN CENTER THREE POSITION VALVE

BS07B678

A more complex one way valve is shown. This directional control symbol uses a multiple envelope (square) system that has a separate square for each position. Remember all of the port connections are made to the envelope that shows the neutral condition of the valve. Within each envelope are arrows showing the flow paths when the valve is shifted to that position.

Two - Position Valves Control Valve

Pump

Cylinder Rod End

Relief Valve Cylinder Piston End BS07B679

A simple control valve has two envelopes (representing the spool) if it is a two position valve. The envelopes show the flow conditions when they are in one position. The above schematic is showing that oil is being supplied to the rod end of the cylinder. If we visualize the directional control valve moved to the other position, it would be shown as below.

BS07B710

Pressurized oil is being supplied to the piston end of the cylinder and oil from the rod end of the cylinder is allowed to flow to the reservoir.

BS07B681

CLOSED CENTER THREE POSITION VALVE

Three position valves will have a centered (neutral) position. The centered position can be either open or closed to flow. The open center is usually used with a fixed displacement pump and the closed center is usually used with a variable displacement pump.

8000-10

Flow Control Symbols

Actuating Controls

Restrictors Lever

Pedal Non Adjustable Restrictor BS07B682

Two Position Controlled by External Pilot Pressure

Two Position Controlled By Solenoids BS07B683

BS07B686

The basic flow control symbol is a representation of a restrictor. If the restrictor is adjustable, a slanted arrow is drawn across the symbol. The restrictor could be a special fitting with a small hole in it or a small drilled passageway within a valve. If it is an adjustable restriction, it could be thought of as a water faucet that can be controlled by turning the handle to regulate the flow. Restrictors can be applied to meter out, meter in, and bleed off circuits.

Adjustable Restrictor Pressure Compensated

Three Position, Solenoid Controlled With Internal Pilot Assist Pressure BS07B684

Valve spools are controlled by levers, pedals, pilot oil, electric solenoids, etc. which are called actuating controls. These actuating controls are shown by symbols placed on the ends of the envelopes. Solenoid Control With Internal Pilot Pressure

BS07B685

THREE POSITION, SPRING CENTERED

To show that a valve is spring centered, a spring symbol is placed at each end of the envelope. The above schematic shows that an electrical solenoid and pilot pressure assist are required to overcome spring force to move the valve spool.

Adjustable Restrictor

Adjustable Restrictor Pressure and Temperature Compensated BS07B687

There are adjustable restrictors that are pressure compensated. That means that the size of the openings in the restrictor will change with increases and decreases in pressure. A perpendicular arrow indicates pressure compensation. If the restrictor has both pressure and temperature compensation, the symbol for a thermometer will also be shown.

8000-11

Accessories F i l t e r s, s t r a i n e r s, a n d h e a t ex c h a n g e r s a r e represented as squares that are turned 45 degrees and have the port connection at the corners.

An oval with details inside indicates an accumulator. T h e d e t a i l s i n s i d e w i l l t e l l yo u w h a t t y p e o f accumulator it is: spring loaded, gas charged, or other features.

Gas Charged

Filter or Strainer

BS07B691 BS07B688

A dotted line perpendicular to the flow line indicates a filter or strainer.

Cooler

The divider line indicates there is a separator between the charge and the oil. A hollow triangle indicates gas.

Spring Loaded BS07B689

A solid line perpendicular to the flow with black triangles pointing out indicates a cooler.

Heater BS07B690

The symbol for a heater is like the symbol for a cooler, except the black triangles point in.

Temperature Control Unit BS07B693

Two sets of triangles pointing in and out indicates a temperature control. As you can see, the black triangles point in the direction that the heat is dissipated. or in the case of the control unit, they show that the heat can be regulated.

BS07B692

A spring shows that the accumulator is spring loaded.

8000-12

SIMPLE SCHEMATIC The illustration below has put some of the previous symbols together to form a simple hydraulic schematic. See if you can find your way around the schematic without reading the text for each valve. The text explains the function of each valve.

Detent D

Float C

D C

BS07B596

8000-13

Valve A

Valve C

This valve is a three position valve. The spool is lever operated and spring centered. It is an open center valve. Visually place the envelopes into the center position and you will see that the valve will direct oil into one end or the other of cylinder A. when the spool in valve A is moved out of the centered position, the valves downstream will receive no oil.

This valve is also similar to valve A, but is designed to control a single acting cylinder. When you visualize placing the upper envelope in the center position you will see that oil can drain back to the reservoir from cylinder C.

Valve B

Valve D

Valve B is similar to valve A but it is a four position valve. The fourth position is a float position and is held into that position with a detent. With this valve the cylinder B can be extended, retracted, or placed in the float position. Visualize the envelope for the float position in the inlet passageway. You will see that oil can continue to flow to the next valve downstream and that the rod in cylinder B could be pushed back and forth. The oil could move from one end of the cylinder.

At the same time, oil from the pump can flow through valve C to the next valve.

Valve D is a lever operated, spring centered valve and is designed to control a hydraulic motor. If a hydraulic motor was turning a flywheel and the oil supply and return were shut off abruptly, this would cause damage to the hydraulic lines, the motor, or whatever it was powering. Therefore when the valve supplying the motor is shut off, the motor should be able to slow down gradually. The center (neutral) position of valve D will allow that to happen by letting oil from the outlet of the motor return to the inlet side. Use this information to read hydraulic schematics. The more experience you have reading schematics, the easier and more comfortable it will become to use hydraulic schematics as a troubleshooting guide.

8000-14

COMMON SYMBOLS Mechanical Devices

Line and Line Fuctions

Mechanical Connections Two Parallel Lines (Shafts, Levers, etc.)

Solid Line Main Line

Dashed Line Pilot Line

Dotted Line Exhaust or Drain Variable Component (Run arrow through symbol at 45Â°)

Enclosure Outline

Lines Crossing Spring Lines Crossing BS07B696

Lines Joining

Liquid Direction of Flow

Gaseous Direction of Flow

Flexible Line BS07B694

8000-15

Pumps and Motors

Reservoirs

Hydraulic Pump Fixed Displacement

Reservoir Open to Atmospere

Hydraulic Pump Variable Displacement

Pressure Compensated Variable Displacement Pump

Fixed Displacement Hydraulic Pump (Two Directional Flow)

Pressurized Reservoir

Line to Reservoir Below Fluid Level

Line to Rexervoir Above Fluid Level

BS07B699

Hydraulic Motor Fixed Displacement

Hydraulic Motor Variable Displacement

Hydraulic Oscillator BS07B695

8000-16

Cylinders

Valves Single Acting Check Valve

Pilot Operated Check

Double Acting Single Rod End

On-Off Manual Shut-off

Double Acting Double Rod End

Pressure Reducing Valves

Single Rod End Fixed Cushion Both Ends

Single Rod End Non-Adjustable Restrictor

Rod End Only Adjustable Cushion

Differential Cylinder BS07B706

Adjustable Restrictor

Adjustable Restrictor Pressure Compensated

Adjustable Restrictor (Temperature and Pressure Compensated) BS07B697

8000-17

Valve Actuators

Regulating or Selector Valves

Solenoid

2-Position 2-Way Valve

Detent

2-Position 3-Way Valve

Spring

2-Position 4-Way Valve

Manual

3-Position 4-Way Valve

Push Button

2-Position 4-Way Open Center Cross Over

Push-Pull Lever

Valve Capable of Infinite Positioning (Indicated by Horizontal Lines Drawn Parallel to the Envelope)

Pedal

Pressure Relief Valve

Mechanical BS07B698 BS07B700

8000-18

Accessories Pressure Compensated

Filter

Cooler

Pilot Pressure Remote Supply Heater

Temperature Controller Liquid Supply Accumulator Hydro-Pneumatic BS07B708

Reversing Motor

Station or Test Point

Pressure Indicator

Temperature Indicator

BS07B705

8000-19

Presssure Switch

Quick Disconnects (Disconnected)

Quick Disconnects (Connected) BS07B707

8000-20

NOTES

8001 Section 8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

8001-2

TABLE OF CONTENTS LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PILOT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z-bar Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS - TC LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 7 11 12 13 14 16 16 17 19 20 20 21 21 22 22 23 25 25 26 28 28 29 31 33 33 34 35 36 36 37 38 38 39 41 41 41 43 43 44 45 45 45

8001-3

LOADER CONTROL VALVE Removal

STEP 5

STEP 1

Place the master disconnect switch in the OFF position.

Park the machine on a level surface. IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

STEP 6

STEP 2

BD06F213

BD03A092

Relieve the pressure in the load travel stabilization accumulator with the manual bleeder valve located on the bottom of the load travel stabilization valve. Remove the plug and tur n the valve two tur ns counter-clockwise.

Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 7

STEP 3

Loosen the filler cap on the reservoir to release the air pressure in the reservoir.

STEP 8 Drain the hydraulic reservoir.

STEP 9

BD01F143-01

Put articulation lock in the LOCKED position.

STEP 4 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.

BD00M041-00

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

2 BS07H031

4 spool line removal and installation illustration 1. LOADER CONTROL VALVE 2. PILOT ACCUMULATOR HOSE 3. PILOT PRESSURE HOSE

4. CHECK VALVE 5. SWITCH FITTING (XT WITH LOAD TRAVEL STABILIZATION ONLY) 6. SWITCH (XT WITH LOAD TRAVEL STABILIZATION ONLY)

8001-5

Frame / I Cooling

Hoses are color coded

Cab floor

2 3

18 1

9 10 W110R576

3 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION (joystick and 1 lever version) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

GROMMET, HOSE CONNECTOR HOSE PILOT CONNECTOR VALVE CHECK TEE ELBOW ACCUMULATOR PILOT SUPPLY NUT 10 mm HOSE PILOT ACCUMULATOR

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

HOSE PILOT PRESSURE HOSE PILOT LIFT RIGHT HOSE PILOT TILT RIGHT HOSE PILOT LIFT LEFT HOSE PILOT TILT LEFT HOSE PILOT 3 SPOOL RIGHT HOSE PILOT 3 SPOOL LEFT SLEEVE 60X1200 O-RING 0.062 X 0.375 INCH CONTROL VALVE 3 SPOOL

8001-6

Red & Black 14 Red & White

17 Yellow & White

Orange & Black

See view B

Green & Black

Tee and switch on TC with ride control only

11 20

6 5

Yellow & Black

10 See view A

6 7 Insert optional

tee for coupler here 10

FITTING ARRANGEMENT (Refer only if equipped with locking hydraulics)

VIEW B

VIEW A

W110R577

3 SPOOL LINE REMOVAL AND INSTALLATION

8001-7

Frame / I Cooling

Hoses are color coded

Chassis/

Cab Floor

Front Z-Bar

3 1

8 17

Chassis / I Rear Hoses are color coded

W110R578

2 SPOOL LINE REMOVAL AND INSTALLATION (jotstick version) 1. 2. 3. 4. 5. 6. 7. 8. 9.

GROMMET ELBOW HOSE/A PILOT TANK CONNECTOR VALVE CHECK TEE ELBOW ACCUMULATOR PILOT NUT

10. 11. 12. 13. 14. 15. 16. 17. 18.

HOSE PILOT ACCUMULATOR HOSE PILOT PRESSURE HOSE PILOT LIFT RIGHT HOSE PILOT TILT RIGHT HOSE PILOT LIFT LEFT HOSE PILOT TILT LEFT SLEEVE HOSE 60X1200 O-RING CONTROL VALVE 2 SPOOL

8001-8

14 Red & Black Yellow & Black 12

13 Orange & Black View B

Green & Black 15 Tee and switch on TC with ride control only

4 11

18 6 5

10 View A

10 FITTING ARRANGEMENT (Refer only if equipped with locking hydraulics)

View B

View A

W110R579

2 SPOOL LINE REMOVAL AND INSTALLATION

8001-9

STEP 10

STEP 13

Disconnect the hoses from the remote control valve(s) at the loader control valve one at a time and fasten an identification tag to each hose. Refer to the illustrations above.

STEP 11 Install a plug in each hose and a cap on each fitting.

STEP 12

4 3

2 BD01D381

1. ROD END TILT TUBE 2. HEAD END TILT TUBE

3. HEAD END LIFT TUBE 4. ROD END LIFT TUBE

A. Tag and disconnect the rod end tilt tube (1) from the loader control valve and install a plug in the tube and a cap on the fitting.

B. Tag and disconnect the head end tilt tube (2) from the loader control valve and install a plug in the tube and a cap on the fitting.

6 BD01D376

1. 2. 3. 4. 5. 6. 7.

VALVE RETURN HOSE LOAD TRAVEL STABILIZATION TANK HOSE ACCUMULATOR DRAIN HOSE PUMP LOAD SENSING HOSE STEERING LOAD SENSING HOSE STEERING PRESSURE HOSE PUMP PRESSURE HOSE (NOT SHOWN)

A. Tag and disconnect the valve return hose (1) at the loader control valve and install a plug in the hose and a cap on the fitting. B. Tag and disconnect the pump pressure hose (7). Plug the hose and install cap on the fitting. NOTE: The pump pressure hose (7) will be connected to a elbow at the bottom of the loader control valve. C. Tag and disconnect the load travel stabilization tank hose (2) and install a plug in the hose and a cap on the fitting. D. Tag and disconnect the accumulator drain hose (3) and install a plug in the hose and a cap on the fitting. E. Tag and disconnect the pump load sensing hose (4) and install a plug in the hose and a cap on the fitting. F. Tag and disconnect the steering load sensing hose (5) and install a plug in the hose and a cap on the fitting. G. Tag and disconnect the steering pressure hose (6) and install a plug in the hose and a cap on the fitting.

C. Tag and disconnect the head end lift tube (3) from the loader control valve and install a plug in the tube and a cap on the fitting. D. Tag and disconnect the rod end lift tube (4) from the loader control valve and install a plug in the tube and a cap on the fitting. E. Tag and disconnect any auxiliary spool tubes if equipped.

8001-10

STEP 14 1

Ref. Valve mounting plate in front chassis

3 W110R580

Loosen and remove the three screw (3) and washers (2) that hold the loader control valve (1) to the valve mounting plate.

STEP 15 Use proper lifting device to lift and remove the loader control valve.

8001-11

Installation

STEP 18

STEP 16

1 3

1 5

Ref. Valve mounting plate in front chassis

3 W110R580

A. Install and align the loader control valve with the valve mounting plate. B. Install the bolts and washers that fasten the loader control valve to the valve mounting plate. Tighten the bolts. C. Before installing the fittings or connecting the tubes to the fittings, install new O-rings on the fittings.

STEP 17

6 BD01D376

1. 2. 3. 4. 5. 6. 7.

VALVE RETURN HOSE LOAD TRAVEL STABILIZATION TANK HOSE ACCUMULATOR DRAIN HOSE PUMP LOAD SENSING HOSE STEERING LOAD SENSING HOSE STEERING PRESSURE HOSE PUMP PRESSURE HOSE (NOT SHOWN)

A. Connect the steering pressure hose (6) to the loader control valve. B. Connect the steering load sensing hose (5) to the loader control valve. C. Connect the pump load sensing hose (4) to the loader control valve. D. Connect the accumulator drain hose (3) to the loader control valve. E. Connect the load travel stabilization tank hose (2) to the loader control valve/

F. Connect the pump pressure hose (7) to the bottom of the loader control valve. G. Connect the valve return hose (1) to the loader control valve.

4 3

BD01D3811

1. ROD END TILT TUBE 2. HEAD END TILT TUBE

3. HEAD END LIFT TUBE 4. ROD END LIFT TUBE

A. Connect the rod end lift tube control valve. B. Connect the head end lift loader control valve. C. Connect the head end tilt loader control valve. D. Connect the rod end tilt tube control valve.

(4) to the loader tube (3) to the tube (2) to the (1) to the loader

8001-12

REAR OF MACHINE

2 BS07H031

4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION 1. LOADER CONTROL VALVE 2. PILOT ACCUMULATOR HOSE 3. PILOT PRESSURE HOSE

4. CHECK VALVE 5. SWITCH FITTING (XT WITH LOAD TRAVEL STABILIZATION ONLY) 6. SWITCH (XT WITH LOAD TRAVEL STABILIZATION ONLY)

8001-13

Red & Black 14 Red & White

17 Yellow & White

Orange & Black

See view B

Green & Black

Tee and switch on TC with ride control only

11 20

6 5

Yellow & Black

6 7 Insert optional

tee for coupler here 10

See view A

FITTING ARRANGEMENT (Refer only if equipped with locking hydraulics)

VIEW B

VIEW A W110R577

3 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION (joystick and 1 lever version) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

GROMMET, HOSE (NOT SHOWN) CONNECTOR (NOT SHOWN) HOSE PILOT (NOT SHOWN) CONNECTOR VALVE CHECK TEE ELBOW ACCUMULATOR PILOT SUPPLY (NOT SHOWN) NUT 10 mm (NOT SHOWN) HOSE PILOT ACCUMULATOR

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

HOSE PILOT PRESSURE HOSE PILOT LIFT RIGHT HOSE PILOT TILT RIGHT HOSE PILOT LIFT LEFT HOSE PILOT TILT LEFT HOSE PILOT 3 SPOOL RIGHT HOSE PILOT 3 SPOOL LEFT SLEEVE 60X1200 (NOT SHOWN) O-RING 0.062 X 0.375 INCH (NOT SHOWN) CONTROL VALVE 3 SPOOL

8001-14

14 Red & Black Yellow & Black 12

13 Orange & Black View B

Green & Black 15 Tee and switch on TC with ride control only

4 11

18 6 5

10 View A

10 FITTING ARRANGEMENT (Refer only if equipped with locking hydraulics)

View A

View B

W110R579

2 SPOOL LINE REMOVAL AND INSTALLATION (joystick version) 1. 2. 3. 4. 5. 6. 7. 8. 9.

GROMMET (NOT SHOWN) ELBOW (NOT SHOWN) HOSE/A PILOT TANK CONNECTOR VALVE CHECK TEE ELBOW ACCUMULATOR PILOT (NOT SHOWN) NUT (NOT SHOWN)

10. HOSE PILOT ACCUMULATOR 11. HOSE PILOT PRESSURE 12. HOSE PILOT LIFT RIGHT 13. HOSE PILOT TILT RIGHT 14. HOSE PILOT LIFT LEFT 15. HOSE PILOT TILT LEFT 16. SLEEVE HOSE 60X1200 (NOT SHOWN) 17. O-RING (NOT SHOWN) 18. CONTROL VALVE, 2 SPOOL

8001-15

STEP 19

STEP 23

Connect the lines from the remote control valve to the l oader c o n t r o l va l ve. Re fe r t o t he a b ove illustration.

STEP 20

BD03A092

Raise the loader arms and remove the safety link.

STEP 24 Put the articulation lock in the OPERATING position. BD06F213

Tighten the accumulator manual bleeder valve located on the bottom of the load travel stabilization valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 25

STEP 21

Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.

Fill the hydraulic reservoir with oil. Refer to Section 1002 for the correct oil.

STEP 22 Place the master disconnect switch in the ON position.

Start the engine and run at half throttle.

STEP 26

STEP 27 Stop the engine and check for leaks.

STEP 28 Install the access cover on the front of the machine.

STEP 29 Check the level of the hydraulic oil and add hydraulic oil as required.

8001-16

HYDRAULIC PILOT CONTROL VALVE Removal

STEP 34

STEP 30 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.

BD06F209-01

Remove the front access panel.

STEP 31 Place the master disconnect switch in the OFF position.

STEP 35

STEP 32

BD06F210-01

Disconnect the electrical connectors for the remote control valve. BD06H194-01

Unlatch and open the compartment door on the right hand side.

STEP 33

STEP 36 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 37 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 38 Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.

STEP 39 Loosen and remove the screws that fasten the remote control valve to the hydraulic control tower. BD06F208-01

Open and remove the access panel.

STEP 40 Remove the remote control valve from the hydraulic control tower.

8001-17

Installation

STEP 47

STEP 41

Place the master disconnect switch in the ON position.

Install new O-rings on the adapters for the remote control valve.

STEP 48 Start the engine and run the engine at low idle.

STEP 42 Install the remote control valve and screws in the hydraulic control tower and tighten the screws.

STEP 43 Install the cover over the remote control valve and install the screws and washers.

STEP 44 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 19, 20, and 21 as necessary.

STEP 49 Check to see that the remote control valve works correctly.

STEP 50 Check for hydraulic oil leakage at the remote control valve.

STEP 51 Check the level of hydraulic oil in the reservoir and add as required.

STEP 52

STEP 45 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 46

BD06F209-01

Position the access panel on the ROPS cab or the ROPS canopy and install and tighten the screw.

BD06F210-01

Connect the electrical connectors for the remote control valve.

8001-18

STEP 53

STEP 54

BD06F208-01

Install and close the access panel.

BD06H194-01

Close the right hand compartment door.

8001-19

10 9

8 7

10 3

6 4

BS07D284

JOYSTICK AND 2 LEVER HOSE COLOR CODING 1. 2. 3. 4.

ORANGE BLACK YELLOW BLACK RED WHITE GREEN WHITE

5. ORANGE WHITE 6. YELLOW WHITE 7. PILOT PRESSURE HOSE

8. GREEN BLACK 9. RED BLACK 10. PILOT TANK HOSE

8001-20

1 2

2 3

6 7

7 1

6 8

5 5

6 2

4 8

3 7 2

BS07D283

JOYSTICK AND 1 LEVER HOSE COLOR CODING 1. 2. 3. 4. 5. 6. 7. 8.

YELLOW WHITE PILOT PRESSURE HOSE RED BLACK PILOT TANK HOSE ORANGE BLACK YELLOW BLACK GREEN BLACK RED WHITE

3 LEVER HOSE COLOR CODING 1. 2. 3. 4. 5. 6. 7. 8.

YELLOW WHITE PILOT PRESSURE HOSE RED BLACK PILOT TANK HOSE ORANGE BLACK YELLOW BLACK GREEN BLACK RED WHITE

8001-21

1 1

6 6

4 3

4 4 5

2 1

5 3

BS07D285

JOYSTICK HOSE COLOR CODING 1. 2. 3. 4. 5. 6.

PILOT PRESSURE HOSE RED BLACK PILOT TANK HOSE ORANGE BLACK YELLOW BLACK GREEN BLACK

BS08B057

2 LEVER HOSE COLOR CODING 1. 2. 3. 4. 5. 6.

PILOT TANK HOSE YELLOW BLACK PILOT PRESSURE HOSE RED BLACK GREEN BLACK ORANGE BLACK

8001-22

HYDRAULIC PUMP Removal

STEP 59

STEP 55 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 56

Place the master disconnect switch in the OFF position.

STEP 57 Drain the hydraulic reservoir then refer to Section 9007 and remove the ROPS cab or ROPS canopy.

BD01D308

1. PRESSURE HOSE 2. BOLTS (4)

STEP 58

3. HYDRAULIC PUMP 4. LOAD SENSING HOSE

A. Loosen and remove the four bolts (2) connecting the pressure hose (1) to the hydraulic pump (3).

B. Tag and disconnect the load sensing hose (4) from the hydraulic pump (3). C. Plug all lines and cap all fittings.

STEP 60 4

2 BD01D303

1. SUCTION HOSE 2. BOLTS (4)

3. HYDRAULIC PUMP 4. CASE DRAIN HOSE

A. Loosen and remove the four bolts (2) c onnect i ng the s u c t i on h os e ( 1 ) t o t he hydraulic pump (3). B. Tag and disconnect the case drain hose (4) from the top of the hydraulic pump (3). C. Plug all lines and cap all fittings.

BD01D333

Use proper lifting device to strap and support the hydraulic pump.

8001-23

Installation

STEP 61

STEP 64

BD01D307

Loosen and remove the two bolts that fasten the hydraulic pump to the transmission.

BD01D335

Remove the hydraulic pump from the machine.

Use proper lifting device to lift and suppor t the hydraulic pump. Install a new O-ring on the hydraulic pump.

STEP 63

STEP 65

STEP 62

BD01D335

Remove and discard the O-ring from the hydraulic pump.

BD01D334

Install the hydraulic pump on the transmission.

STEP 66

BD01D3077

Install the two bolts that fasten the hydraulic pump to the transmission. Tighten the two bolts to a torque of 335 to 375 Nm (245 to 275 lb ft).

8001-24

STEP 67

STEP 69 See Section 9007 for installing the ROPS cab or ROPS canopy.

STEP 70 Fill the hydraulic reservoir with hydraulic oil. See Section 1002 for correct oil type.

1 3

STEP 71 Place the master disconnect switch in the ON position.

STEP 72 BD01D308

1. PRESSURE HOSE 2. BOLTS (4)

3. HYDRAULIC PUMP 4. LOAD SENSING HOSE

Start the engine and run the engine at low idle for two minutes.

A. Install the pressure hose (1) to the hydraulic pump (3) using four bolts (2).

NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.

B. Install the load sensing hose (4) to the hydraulic pump (3).

STEP 73 Stop the engine and check for hydraulic oil leakage at the hydraulic pump.

STEP 68

STEP 74 2 1

2 BD01D303

1. SUCTION HOSE 2. BOLTS (4)

3. HYDRAULIC PUMP 4. CASE DRAIN HOSE

A. Install the suction hose (1) to the hydraulic pump (3) using four bolts (2). B. Install the case drain hose (4) to the hydraulic pump (3).

Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

8001-25

LIFT CYLINDERS Removal

STEP 79

STEP 75 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 76 Relieve the pressure in the load travel stabilization 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 80

STEP 77 Loosen the filler cap on the hydraulic reservoir to release any pressure.

STEP 78

BD01D711

Use a proper lifting device and secure a strap around the lift cylinder.

STEP 81 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.

8001-26

Installation

STEP 82

STEP 85 Apply antiseize compound to the bores in the front frame and the yoke on the piston rod.

STEP 86

BD01D710

Loosen and remove the bolt, washer and spacer that hold the pivot pin at the closed end of the lift cylinder.

STEP 83 BD01D714

Use a proper lifting device and position the lift cylinder on the machine.

STEP 87

BD01D713

Remove the pivot pin from the closed end of the lift cylinder.

STEP 84 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.

8001-27

STEP 88

STEP 91

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 92

STEP 89

BD01D709 BD01D708

Remove the caps and plugs and connect the hoses to the lift cylinder.

STEP 90 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.

Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.

STEP 93 SLOWLY extend and retract the piston rod three times to remove any air from the lift cylinders.

STEP 94 Lubricate the pivot pins with molydisulfide grease.

STEP 95 Check the level of hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-28

BUCKET CYLINDER - Z-BAR LOADER

3 7

4 1

5 2 6 1

BS08A049

Z-BAR LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION 1. 2. 3. 4. 5.

BOLT WASHER GREASE FITTING PIVOT PIN SPACER

6. 7. 8. 9. 10.

WIPER WASHER LIFT CYLINDER BUCKET CYLINDER BELLCRANK

8001-29

Removal

STEP 100

STEP 96 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 97 With the engine stopped, move the bucket control lever to release pressure in the bucket circuit.

STEP 98 BD01D695

Loosen and remove the two bolts that fasten the mounting bracket to the machine. Remove the mounting bracket.

STEP 101

BD01D694

Disconnect the proximity switch connector from the wiring harness connector.

STEP 99 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.

STEP 102

BD01D696

Loosen and remove the two bolts that fasten the target bar to the mounting bracket. Remove the target bar.

BD01D699

Disconnect the hoses from each side of the bucket cylinder. Install plugs in the hoses and caps on the fittings.

8001-30

STEP 103

STEP 106

BD01D700

BD01D704

Use acceptable equipment to hold the bucket cylinder.

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 104

STEP 107

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.

STEP 105

BD01D701

Remove the pivot pin from the rod end of the bucket cylinder.

8001-31

Installation

STEP 112

STEP 108 Apply antisieze compound to the bores in the front frame and the bores in the loader arm for the bucket cylinder.

STEP 109

BD01D699

Connect the hoses to each side of the bucket cylinder.

STEP 113

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 110

STEP 114

BD01D706

Install the pivot pin and stop the engine.

STEP 115

BD01D704

Install the pivot pin to the head end of the bucket cylinder. BD01D698

STEP 111 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.

8001-32

STEP 116

STEP 119

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 117

STEP 120 See Section 9006 for the adjustment procedure for adjusting the proximity switch.

STEP 121 Start and run the engine at low idle.

STEP 122 SLOWLY extend and retract the piston rod three times to remove any air from the bucket cylinder.

STEP 123 Lubricate the pivot pins with molydisulfide grease. BD01D695

Install the two bolts for the mounting bracket for the target bar.

STEP 118

BD01D696

Install the two bolts that fasten the target bar to the mounting bracket.

STEP 124 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-33

BUCKET CYLINDERS - TC LOADER Removal

STEP 127

STEP 125

Remove the Return-to Dig target bar (6) with the mounting bracket (3) from the yoke of the bucket cylinder (1).

Lower the bucket to the floor. With the engine stopped, move the bucket control lever to release any pressure in the bucket circuit. NOTE: The following two steps apply only to the left hand bucket cylinder.

STEP 126

STEP 128 Disconnect the hoses from the elbows at both ports of the bucket cylinders. Install a plug in the tube and a cap on the elbow.

STEP 129 Remove the roll pin (1) from the yoke (2). Remove the pivot pin (3). Refer to the illustration on page 32.

STEP 130 Loosen and remove the nuts (4) and washers (5) at the top and bottom of the cylinder bellcrank.

STEP 131

1 4

Remove the inner bellcrank (6) from the pivot pins (7).

6 BS01C084

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

BUCKET CYLINDER (LEFT HAND SIDE) PROXIMITY SWITCH MOUNTING BRACKET TARGET MOUNTING BRACKET PROXIMITY SWITCH GUARD PROXIMITY SWITCH TARGET BAR

Disconnect the Return-to-Dig proximity switch (5) and remove with the mounting bracket (2) as an assembly.

STEP 132 Remove the bolt (8) and the grease line (9) from the bucket cylinder (10).

STEP 133 Fasten acceptable lifting equipment to the bucket cylinder (10) and remove the bucket cylinder (10) from the machine.

8001-34

9 8 1

10 7

BS01C085

TC LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION 1. 2. 3. 4. 5.

ROLL PIN YOKE PIVOT PIN NUT WASHER

6. 7. 8. 9. 10.

INNER BELLCRANK PIVOT PIN BOLT GREASE LINE BUCKET CYLINDER

8001-35

Installation

STEP 140

Use acceptable lifting equipment to install the bucket cylinder (10) closed end on the pivot pins (7).

Install the Return-to Dig target bar and proximity switch assembly. Connect the proximity switch connector to the wiring harness connector. This step applies only to the left hand bucket cylinder.

STEP 135

NOTE: See Section 9006 for Return adjustment procedure.

Install the grease line (9) and the bolt (8) on the bucket cylinder (10).

STEP 141

STEP 136

Remove the plugs and caps and connect the hoses to the elbows at the cylinder ports.

STEP 134

Install the inner bellcrank (6) on the pivot pins (7).

to Dig

STEP 142

STEP 137

Start the engine and run the engine at low idle.

Install the washers (5) and nuts (4) on the retaining bolts. Tighten the nuts (4).

STEP 143

STEP 138

SLOWLY, extend and retract the piston rod three times to remove any air from the bucket cylinder (10).

Align and install the pivot pin (3) in the yoke (2).

STEP 139 Install the roll pin (1) in the yoke (2) and pivot pin (3).

STEP 144 Lubricate the pivot pins with molydisulfide grease.

STEP 145 Check the level of the hydraulic oil in the hydraulic reservoir and add as required. See Section 1002 for the correct hydraulic oil.

8001-36

OIL COOLER Removal

STEP 151

STEP 146 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

STEP 147 Place the master disconnect switch in the OFF position.

STEP 148 Raise the engine hood. BD07N611-01

STEP 149 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 150

BD07N612-01

Loosen and remove the two bolts and washers that fasten the oil cooler to the cooling frame.

STEP 152

BD07N611-01

Disconnect the top hose and install a plug in the hose and a cap on the fitting.

BD03A217

Raise oil cooler and disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting. Remove oil cooler from the machine.

8001-37

Installation

STEP 155

STEP 153

BD07N611-01

Connect the hose to the top of the oil cooler. BD03A217

Place the oil cooler in position in the cooling frame. Connect the lower hose to the oil cooler. NOTE: Make sure that the oil cooler slides into retaining bracket on frame.

STEP 154

STEP 156 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 157 Place the master disconnect switch in the ON position.

STEP 158 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 159 Install the inner plastic fender between the right rear tire and the oil cooler and tighten the two bolts holding the shield.

BD07N612-01

STEP 160 Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

BD07N611-01

Install the two bolts and washers that fasten the oil cooler to the cooling frame

8001-38

RIDE CONTROL ACCUMULATOR Removal

STEP 164

STEP 161 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 165

STEP 162

BD07N615-01

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 166

BD01F143-01

Put the articulation lock in the LOCKED position.

STEP 163

BD07N616-01

Loosen and remove the nuts and washers from the top U-bolt. Remove the U-bolt.

BD06F213

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the bottom of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

8001-39

Installation

STEP 167

STEP 168 Place the ride control accumulator in position on the front frame.

STEP 169

BD07N615-01

Loosen and remove the two bolts that fasten the accumulator lower bracket to the frame. Remove the ride control accumulator from the machine.

BD07N615-01

Install the two bolts that fasten the accumulator lower bracket to the front frame. Tighten the bolts.

STEP 170

BD07N616-01

Install the U-bolt, washers and nuts. Tighten the nuts.

8001-40

STEP 171

STEP 173

BD07N615-01

BD06F213

Remove the caps and plugs and install the hose on the elbow at the bottom of the r ide control accumulator.

Tighten the accumulator manual bleeder valve located on the bottom 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 172 Turn off and disconnect the vacuum pump from the hydraulic reservoir.

STEP 174 Refer to Section 8002 Testing the Ride Control for the proper charging of the accumulator to check for leaks.

STEP 175 Put the articulation lock in the OPERATING position.

STEP 176 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-41

RIDE CONTROL VALVE Removal

STEP 180

STEP 177 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 181 Place the master disconnect switch in the OFF position.

STEP 182 Disconnect the electrical connector from the ride control valve.

STEP 183

STEP 178

Tag and disconnect the hoses from the ride control valve. Install a plug in the hoses and caps on fittings.

STEP 184 Loosen and remove the two bolts and washers that fasten the ride control valve to the frame.

STEP 185 Remove the ride control valve from the machine.

STEP 186 Remove and discard all O-rings. BD01F143-01

Put the articulation lock in the LOCKED position.

STEP 179

BD06F213

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the bottom of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

8001-42

Installation

STEP 192

STEP 187

Connect the electrical connector to the ride control valve.

Install the ride control valve in position on the front frame.

STEP 193

STEP 188

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 194

STEP 189

Place the master disconnect switch in the ON position.

STEP 195 Start and run the engine at low idle for two minutes.

STEP 196 Stop the engine and check for hydraulic oil leakage at the ride control valve.

STEP 197 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir. BD06F213

Tighten the accumulator manual bleeder valve located on the bottom 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 198

STEP 190

Refer to Section 8002 and perform the Ride Control Test Procedure.

Lubricate and install new O-rings.

STEP 191 Connect the hoses to the ride control valve.

Put the articulation lock in the OPERATING position.

STEP 199

8001-43

FAN REVERSING VALVE Removal

STEP 204

STEP 200 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. BD07N614-01

STEP 201

BD07N604-01

Put the articulation lock in the LOCKED position.

Tag and disconnect hoses from the fan reversing valve. Install a plug in each hose and cap all fittings.

STEP 202

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.

Loosen and remove the nuts, washers and bolts.

BD01F143-01

STEP 203

STEP 206 Remove the fan reversing valve from the machine.

STEP 207 Remove and discard all O-rings from the fittings.

BD07N610-01

Disconnect the electrical connectors from the fan reversing valve.

8001-44

Installation

STEP 211

STEP 208 Place the fan reversing valve into position on the machine.

STEP 209 Lubricate and install new O-rings in the fittings.

STEP 210 Install the bolts, washers and nuts. Tighten the nuts.

BD07N610-01

Connect the electr ical connectors on the fan reversing valve.

STEP 212 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 213 Check the level of the hydraulic oil in the reservoir. BD07N604-011

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 fan reversing valve.

STEP 216 Put the articulation lock in the OPERATING position.

STEP 217 BD07N614-01

Remove caps from fittings and plugs from hoses. Connect hoses to the fan reversing valve, remove and discard tags.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

8001-45

THERMAL VALVE Removal

Installation

STEP 218

STEP 222

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 219 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 223 STEP 224 Install the bolts, washers and nuts. Tighten the nuts.

STEP 225 Connect the hoses to the thermal valve, remove and discard tags.

STEP 226 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 227

STEP 220

Check the level of the hydraulic oil in the reservoir.

STEP 228 Start the engine and run the engine at low idle for two minutes.

STEP 229 Stop the engine and check for hydraulic oil leakage at the thermal valve.

STEP 230 BD06F211

Tag and disconnect the hoses from the thermal valve. Install a plug in the hoses and a cap on the fittings.

STEP 221 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.

8001-46

NOTES

HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

8002

Section 8002

8002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem 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 Load Travel Stabilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE PILOT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE LOAD TRAVEL STABILIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 5 5 5 6 6 6 7 7 8 10 10 11 12 13 13 13 14 15 16

8002-3

SPECIFICATIONS Pump Output ..........................................................................................................150 L/min at 2200 rpm at 207 bar (40 gpm at 2200 rpm at 3000 psi) Main relief valve pressure settings .........................................................................248 to 255 bar (3596 to 3700 psi) Differential pressure........................................................................................................22 to 25 bar (320 to 360 psi) Pilot pressure..................................................................................................................29 to 40 bar (420 to 580 psi) Circuit relief valve pressure setting Auxiliary A and B port (TC and Z Bar)........................................................................................290 bar (4206 psi) Bucket A and B port (Z Bar) .......................................................................................................290 bar (4206 psi) Bucket A port (TC) .....................................................................................................................183 bar (2654 psi) Bucket B port (TC) .....................................................................................................................290 bar (4206 psi) Steering relief valve pressure setting.............................................................................................. See Section 5002 Accumulator pressure..................................................................................................................... See Section 7002

8002-4

SPECIAL TOOLS

B877168V

633L95

380001740 FLOWMETER FITTING KIT

380001741 PRESSURE FITTING KIT

B877895M

632L95

380001726 HAND PUMP

380001742 PRESSURE FITTING KIT

B877558M

B785789M

380001731 FLOWMETER

380001739 PRESSURE FITTING KIT

8002-5

TROUBLESHOOTING PROCEDURE Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts. Check the oil level in the hydraulic reservoir. Is the oil level correct?.

Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.

S e e p a g e 7 . Te s t a n d a d j u s t p u m p differential pressure then proceed to Page 7 and do the flowmeter tests of the hydraulic p u m p. S e e p a g e 12 and t e s t t h e p i l o t pressure.

Adjust the main relief valve. See page 10 in this section.

Yes Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.

Problem 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 10 and check the pressure setting of the main relief valve in the loader control valve. Is the pressure setting correct?

Problem in the Braking Circuit See Section 7002 and check the braking circuit.

8002-6

Problem in a Single Loader Circuit Star t and run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

The loader control valve is damaged. See Section 8005 and repair the loader control valve

See Section 8006 and repair the cylinder.

See Section 8005. Disassemble the loader control valve and che ck for wor n or damaged parts.

Repair the component as necessary.

Yes

Check the cylinder piston packing. Is the packing good? Yes See Page 13. 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 7. Do the Primary Pump Output Test.

Problem in the Load Travel Stabilization Lift ar ms rapidly and continuously sink towards the ground. Yes Check the manual bleed valve for the load travel stabilization accumulator to be sure that it is closed.

See the L o a d Trave l Sta b ilizatio n Te st Procedure page 14 in this section.

8002-7

TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE NOTE: The Pump Differential Pressure must be set before attempting any other tests.

Pressure Check

STEP 3

STEP 1 Make sure that the temperature of the hydraulic oil is at least 52°C to 60°C (125°F to 140°F). The following is the procedure for heating the hydraulic oil. A. Apply the parking brake. B. Start the engine. C. To measure the oil temperature with the instrument cluster: ?

Press the up or down arrow key.

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

D. Run engine at full throttle.

BD00M030

1. ARTICULATION LOCK

Install the articulation lock (1).

E. 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.

STEP 4

F. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).

STEP 2

1 BD00M041

1. COVER PLATE

Remove the cover plate to gain access to the loader control valve.

BD03A092

1. SAFETY LINK

Raise the loader arms and install the safety link (1).

8002-8

STEP 5

STEP 9 Subtract the reading of the test port (1) from the reading of the test port (3).

STEP 10 The difference between the two readings should be 22 to 25 bar (320 to 360 psi).

STEP 11 If this reading is more or less than that specified, it will be necessary to adjust the pump.

BD00N020

Adjusting the Main Hydraulic Pump STEP 12

BD00N017

1. TEST PORT (LOAD SENSE) 2. TEST PORT (PILOT PRESSURE) 3. TEST PORT (PUMP PRESSURE)

Connect two 69 bar (1000 psi) test gauges to the test ports (1) and (3) located on the loader control valve.

STEP 6 Start the engine and run at low idle.

STEP 7 Make sure all of the controls are in the neutral position and record the readings on the test gauges (1) and (3).

STEP 8 The pressure on test por t (1) should read approximately 29 bar (420 psi). The pressure on test port (3) should read approximately 51 bar (740 psi). NOTE: These readings may vary from one machine to another. The important value is the difference between the readings of gauges 1 and 3.

W110R581

The delta pressure adjusting screw is the farthest from the pump. Turn the screw clockwise to increase t h e d i f fe r e n t i a l p r e s s u r e. Tu r n i n g t h e s c r ew counterclockwise will decrease the differential pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

8002-9

NOTE

6 11 8 5 4

9 10 1

BC06C158

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

CAP 1-7/16-12 ORFS 7. FILTER INLET MANIFOLD LOADER CONTROL VALVE 8. INLINE NEEDLE VALVE FLOWMETER INLET HOSE 9. UNION LOADER CONTROL VALVE INLET HOSE 1-7/16-12 ORFS 10. “T” FITTING 380001731 FLOWMETER 11. LOAD SENSE HOSE 9/16 X 18 ORFS FLOWMETER OUTLET HOSE 12. CAP 9/16 X 18 ORFS

NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.

8002-10

TESTING AND ADJUSTING THE MAIN RELIEF VALVE NOTE: The Pump Differential Pressure must be set before attempting any other tests. Refer to page 7 of this section.

Pressure Check

STEP 3

STEP 1

1 BD00M041

BD00M030

1. ARTICULATION LOCK

Remove the cover plate to gain access to the loader control valve.

STEP 4

Install the articulation lock (1).

STEP 2

1 2 1 BD00N017

1. LOADER CONTROL VALVE 2. TEST PORT BD03A092

1. SAFETY LINK

Raise the loader arms and install the safety link (1).

Stop the engine and install a 345 bar (5000 psi) pressure gauge to the test port (2) on the front of the loader control valve (1).

8002-11

STEP 5

Adjustment

Make sure that the temperature of the hydraulic oil is at least 52°C to 60°C (125°F to 140°F). The following is the procedure for heating the hydraulic oil.

STEP 10

A. Apply the parking brake. B. Start the engine. C. To measure the oil temperature with the instrument cluster: • Press

the up or down arrow key.

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

D. Run engine at full throttle. E. 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. F. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).

STEP 6

Start the engine and remove the safety link (refer to step 2) and lower the loader arms to the ground.

STEP 7 Operate the machine at full throttle. Tilt the bucket to a full rollback position and hold while observing the pressure gauge.

STEP 8 The pressure should read between 248 and 255 bar (3596 to 3700 psi).

STEP 9 If the pressure is not within the specifications, it will be necessary to adjust the main relief valve.

BS01A046

1. LOADER CONTROL VALVE 2. RELIEF VALVE ADJUSTMENT

With the engine running and the loader on the ground, loosen the jam nut and turn the adjustment s c r e w ( 2 ) c l o c k w i s e fo r h i g h e r p r e s s u r e o r counterclockwise for lower pressure. NOTE: 1/4 turn of the adjusting screw changes the pressure setting approximately 35 bar (500 psi).

STEP 11 Repeat the Pressure Check Procedure.

STEP 12 If the pressure is not within the specifications, repeat steps 10 and 11 until pressure is within the required range.

STEP 13 Stop the engine before removing the pressure gauge.

8002-12

TESTING THE PILOT PRESSURE STEP 1

STEP 3

BD00M030 BD00N020

1. ARTICULATION LOCK

Install the articulation lock (1).

STEP 2 Make sure that the temperature of the hydraulic oil is at least 52°C to 60°C (125°F to 140°F). The following is the procedure for heating the hydraulic oil.

Stop the engine and connect a 69 bar (1000 psi) test gauge to the pilot pressure test port located on the loader control valve. NOTE: This can be accessed through the articulated joint area, use articulation joint lock before connecting gauge in this manner.

A. Apply the parking brake.

STEP 4

B. Start the engine.

Start and run the engine at low idle, roll the bucket back against the stops and hold.

C. To measure the oil temperature with the instrument cluster: • Press

the up or down arrow key.

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

STEP 5 A pressure reading of 29 to 40 bar (420 to 580 psi) should be obtained.

STEP 6 If pressure is not as specified, replace the pressure reducing valve, refer to section 8005.

STEP 7 If pressure is correct, raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position and disengage the controller lockout switch.

STEP 8 Wait for the buzzer to stop then repeatedly put the loader control lever into “FLOAT” position and back to neutral.

STEP 9 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.

8002-13

TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES Pressure Check

STEP 3

STEP 1

Connect the hand pump to the disconnected line that goes to the loader control valve.

Circuit relief valves are located as shown below.

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 4

STEP 5 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 6 Compare the reading to the specifications on Page 3.

STEP 7 If the pressure is not correct, adjust the circuit relief valve.

1 1

Adjustment STEP 1 Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure.

BS01A046

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

CIRCUIT RELIEF VALVE MAIN RELIEF VALVE BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL LOADER CONTROL VALVE

Remove the cover at the front of the machine.

STEP 2 Lower the bucket to the floor. Shut off the engine. Find an easy place to disconnect the line for the circuit to be tested.

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

8002-14

TESTING THE LOAD TRAVEL STABILIZATION 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

NOTE: This will charge the load travel stabilization 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 1

Set the load travel stabilization rocker switch to the “Always On” position. The lift arms should rise 15 to 30 cm (6 to 12 inches) with an empty bucket. BD00M030

1. ARTICULATION LOCK

Install the articulation lock (1), start the machine, activate the parking brake.

STEP 3 With the pilot controller in neutral, set the load travel stabilization 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 load travel stabilization 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 load travel stabilization.

STEP 5 Raise the lift arms to the top of their travel and dump the bucket. NOTE: Keep rocker switch in the “Off” position during steps 5, 6, 7.

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 too 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.

8002-15

HYDRAULIC COMPONENT LOCATIONS 6

20 15

14 13

3 2

9 16

4 5

12 4

18 7 8

BC00N140

1. 2. 3. 4. 5. 6. 7. 8.

LOAD TRAVEL STABILIZATION VALVE (OPTIONAL) LOAD TRAVEL STABILIZATION ACCUMULATOR ACCUMULATOR BLEEDER VALVE LIFT CYLINDERS BUCKET CYLINDER (TILT CYLINDER) STEERING CONTROL VALVE STEERING CYLINDERS AUXILIARY STEERING PUMP AND MOTOR

9. AUXILIARY STEERING PRIORITY VALVE

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

STEERING PRESSURE DIAGNOSTIC COUPLER BRAKE ACCUMULATORS BRAKE AND ACCUMULATOR CHARGING VALVE BRAKE WARNING PRESSURE SWITCH BRAKE LIGHT PRESSURE SWITCH BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER REAR BRAKE LINE FRONT BRAKE LINE PARKING BRAKE FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC COUPLERS

10. AUXILIARY STEERING PRESSURE SWITCH

NOTE: The hydraulic schematic is located in the rear pocket.

8002-16

HYDRAULIC COMPONENT LOCATIONS 39 42 23 31 22 41

40 35

25 26

25 32

BC00N140

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

FAN DRIVE MOTOR FAN REVERSING VALVE (OPTIONAL) FAN VALVE (STANDARD) BRAKE HYDRAULIC PUMP COUPLER LOCKING VALVE COUPLER LOCKING CYLINDERS IMPLEMENT HYDRAULIC PUMP HYDRAULIC OIL FILTER HYDRAULIC OIL RESERVOIR HYDRAULIC RESERVOIR BREATHER HYDRAULIC OIL COOLER

32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.

PILOT PRESSURE ACCUMULATOR PILOT PRESSURE DIAGNOSTIC COUPLER FLOAT SWITCH CONTROLLER LOADER CONTROL VALVE PUMP PRESSURE DIAGNOSTIC COUPLER LOAD SENSING DIAGNOSTIC COUPLER BRAKE PRESSURE SWITCH (2) AUXILIARY STEERING LOAD SENSE SOLENOID VALVE (OPTIONAL) PARKING BRAKE ACCUMULATOR PARKING BRAKE ACCUMULATOR DIAGNOSTIC COUPLER

NOTE: The hydraulic schematic is located in the rear pocket.

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

380001733, fitting kit.

806127

380001727, filter unit, portable.

TR98H032

380001728, vacuum pump.

8003-4

GENERAL INFORMATION Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1. When you drain the oil or disconnect any line.

1. Cylinder rod seals leak. 2. Control valve spools do not return to neutral. 3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot.

2. When you disassemble a component.

5. Pump gears, housing, and other parts wear rapidly.

3. From normal wear of the hydraulic components.

6. Relief valves or check valves held open by dirt.

4. From damaged or worn seals.

7. Quick failure of components that have been repaired.

5. From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems.

8. Cycle times are slow; machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.

TYPES OF CONTAMINATION There are two types of contamination, microscopic and visible. 1. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. 2. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e problems: A. Cylinder rod seal leak. B. Control valve NEUTRAL.

spools

not

return

C. The hydraulic system has a high operating temperature.

3. Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: A. Particles of metal or dirt in the oil. B. Air in the oil C. The oil is dark and thick. D. The oil has an odor of burned oil. E. Water in the oil. See page 7.

8003-5

CLEANING THE HYDRAULIC SYSTEM 1. Prepare the portable filter on page 3 by doing the following steps: A. Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. B. Remove the filter element from the portable filter. C. Remove all hydraulic oil from the portable filter. D. Clean the inside of the housing for the filter element. 2. You must know whether the contamination is microscopic or visible. See types of contamination on page 4. 3. If the contamination is microscopic: A. Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If needed, change the hydraulic oil. See Section 1002 for specifications. Change the hydraulic filter. B. Do steps 6 through 35. 4. If the contamination is visible:

8. Using the fitting kit shown on page 3, install the valve in the hole for the drain plug. Make sure that the valve is closed. 9. Stop the vacuum pump. 10. Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug. 11. Disconnect the vacuum pump from the hydraulic reservoir air breather hose. Remove the filler cap. 12. Install the outlet hose for the portable filter in the hydraulic reservoir filler neck. 13. Open the valve that is installed in the hole for the drain plug. 14. Move the switch for the portable filter to the ON position. Start and run the engine at 1500 rpm (r/min). 15. Run the portable filter for 10 minutes. 16. Continue to run the portable filter. Increase the engine speed to full throttle. Heat the oil to operating temperature by doing the following steps:

A. Change the hydraulic oil and hydraulic filter. See Section 1002 for specifications.

A. Hold the blade control lever in the TILT position for five seconds.

B. Do steps 5 through 35.

B. Return the blade control lever NEUTRAL position for five seconds.

5. Check the amount of contamination in the hydraulic system by doing the following steps: A. Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. B. If, in your judgment, the damage to the cylinders was caused by sever contamination and is not the result of normal wear, it is necessary to remove, clean and repair valves, pump, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Remove the breather from the reservoir and connect the vacuum pump to the opening. Start the vacuum pump. 7. Loosen and remove the drain plug from the reservoir.

the

C. Repeat steps A and B until the oil in the hydraulic system is at operating temperature. 17. Continue to run the engine at full throttle. Continue to run the portable filter. 18. Operate each hydraulic circuit to completely extend and retract the cylinders. Continue to operate each hydraulic circuit two times, one after the other for 45 minutes. 19. Decrease the engine speed to low idle. 20. Continue to run the portable filter for 10 minutes. 21. Stop the portable filter. 22. Stop the engine. 23. Remove the hose from the hydraulic reservoir.

8003-6 24. Close the valve that is installed in the hole for the drain plug. 25. Disconnect the inlet hose for the portable filter from the valve. Remove the outlet hose from the reservoir filler neck and replace filler cap.

30. Stop the vacuum pump. Disconnect the vacuum pump from the opening in the reservoir and install the breather. 31. Remove the hydraulic filter elements from the machine.

26. Connect a vacuum pump to the breather hose of the hydraulic reservoir.

32. Install new hydraulic filter elements on the machine.

27. Start the vacuum pump.

33. Start the engine. Check for oil leakage around the new hydraulic filters.

28. Remove the valve from the hole for the drain plug. 29. Install the drain plug.

34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r specifications.

8003-7

FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1. Start and run the engine at 1500 rpm (r/min). 2. Completely retract the cylinders of all attachments on the machine. Angle the blade to the right, the right cylinder will be fully retracted and the left will be fully extended. Stop the engine. WARNING: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before proceeding to the next step! 39-4

NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling. 3. Move each control lever in both directions to release pressure in the hydraulic circuits. 4. Loosen and remove the filler cap from the reservoir.

12. Be sure all control levers are in the NEUTRAL position. 13. 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. 14. 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. 15. Stop the engine. 16. Connect the system line to the CLOSED end of each cylinder. 17. Connect a suitable drain line to the OPEN end of each cylinder and place the other end in an acceptable container for contaminated oil. 18. Start the engine and run the engine at low idle. 19. 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. NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling. 20. Support any attachments that will be in the RAISED position. 21. Stop the engine.

5. Drain the hydraulic oil from the reservoir. A. The reservoir holds approximately 20 U.S. gallons (75.7 litres) of hydraulic oil. B. Have available acceptable equipment to drain the hydraulic oil. C. Remove the drain cap from the remote drain. 6. Apply brakes at least 30 times to drain oil from accumulators. 7. Remove the hydraulic filter elements from the machine. 8. Install new hydraulic filter elements on the machine. 9. Install the drain cap in the remote drain. 10. Fill the hydraulic reservoir with 20 U.S. gallons (75.7 litres) of Case TCH Fluid. 11. Disconnect the line from the OPEN end and CLOSED end of each cylinder.

22. Disconnect the drain lines and connect the system lines to the cylinders. 23. 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. 24. Install the filler cap on the reservoir. 25. Remove the hydraulic filter elements from the machine. 26. Install new hydraulic filter elements on the machine. 27. Start and run the engine at 1500 rpm (r/min), operate each hydraulic circuit to completely extend and retract the cylinders. 28. 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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6 7 8 9 9 12 12 15 15 15

8005-3

SPECIFICATIONS Special Torques End plate mounting bolts.......................................................................... 20 to 25 Nm (177 to 221 pound-inches) Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound-inches) Allen head plugs..................................................................................................................60 Nm (44 pound-feet) Steering Priority Spool Cap.................................................................................................60 Nm (44 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 ............................................................................................................60 Nm (44 pound-feet) Combination anticavitation and circuit relief ........................................................................90 Nm (66 pound-feet) Cone and plug ............................................................................................................. 10 Nm (88.5 pound-inches) Main relief valve pressure settings .........................................................................248 to 255 bar (3596 to 3700 psi) Circuit relief valve pressure setting Auxiliary A and B port (TC and Z Bar)........................................................................................290 bar (4206 psi) Bucket A and B port (Z Bar) .......................................................................................................290 bar (4206 psi) Bucket A port (TC) .....................................................................................................................183 bar (2654 psi) Bucket B port (TC) .....................................................................................................................290 bar (4206 psi)

8005-4

3 4

5 11 12

5A 1

7 13 8 9

BC06D160

1. 2. 3. 4.

HOUSING 5. LOAD CHECK VALVE 7. ANTICAVITATION AND CIRCUIT RELIEF PLATE 5A. REGENERATION CHECK VALVE 8. LS (MAIN) RELIEF VALVE BOLT 6. REGENERATION RELIEF VALVE 9. PILOT PRESSURE REDUCING VALVE WASHER 2 SPOOL VALVE HOUSING CONFIGURATION

10. 11. 12. 13.

O-RINGS LS SHUTTLE CHECK VALVE STEERING RELIEF VALVE LS BLEED ORIFICE

8005-5

24 22

19 16

23 20

17 27

28 18

10 23 16 14

15 BC06D161

14. 15. 16. 17.

CAP SCREW THROTTLE CHECK VALVE COVER SPRING

18. 19. 20. 21.

SPRING RETAINER SPRING RETAINER SPOOL JAM NUT

22. 23. 24. 25.

ADJUSTING NUT ADJUSTING ROD PLUG ORIFICE

2 SPOOL VALVE SPOOL CONFIGURATION

26. 27. 28. 29.

STEERING PRIORITY SPOOL COMPENSATION SPOOL PLUG RING

8005-6

10 10 30

17 24

31 BC06D162

2. 3. 4. 5. 10.

PLATE BOLT WASHER LOAD CHECK VALVE O-RING

17. 24. 27. 30. 31.

SPRING PLUG COMPENSATION SPOOL HOUSING ANTICAVITATION AND CIRCUIT RELIEF

3 SPOOL MOUNTING CONFIGURATION

8005-7

32 33

4 2

10 30

10 27

17 24

BC06D163

2. 3. 4. 5. 10. 17.

PLATE BOLT WASHER LOAD CHECK VALVE O-RING SPRING

24. 27. 30. 31. 32. 33.

PLUG COMPENSATION SPOOL HOUSING ANTICAVITATION AND CIRCUIT RELIEF NUT STUD

4 SPOOL MOUNTING CONFIGURATION

8005-8

10 14

16 15

18 17

10 23

BS03C037

10. 14. 15. 16. 17.

O-RING CAP SCREW THROTTLE CHECK VALVE COVER SPRING

18. 20. 21. 22. 23.

SPRING RETAINER SPOOL JAM NUT ADJUSTING NUT ADJUSTING ROD

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION

8005-9

LOADER CONTROL VALVE Disassembly

STEP 11 Remove the pilot pressure reducing valve (6).

STEP 1 Remove valve from machine, see section 8001.

STEP 12

STEP 2

Remove bolts (3) and washers (4), remove plate (2) from housing (1).

Remove bolts (14), covers (16), and springs (17).

STEP 3 Remove cap (24), spring (17), and plug (28).

NOTE: For 4 spool configuration remove nut (32) from stud (33), remove valves from housing (1).

STEP 13 2

STEP 4 Use wooden dowel or brass drift and push spools (20 and 26) from housing (1). IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.

2 1

NOTE: Repeat steps 2 and 4 for 3 and 4 spool valve configuration.

STEP 5 Remove anticavitation valves (7 and 27).

BS03C026

1. O-RINGS

2. THRUST RINGS

NOTE: Repeat step 5 for 3 and 4 spool anticavitation valves (31).

Remove and discard O-rings and thrust rings from flow limit valve (11).

STEP 6

STEP 14

Remove cone (13).

STEP 7 Remove pressure relief valve (8 and 12).

STEP 8

1 1

Remove flow limit valve (9).

STEP 9 Remove check valves (5).

STEP 10 Remove flow limiting valve (11).

BS03C025

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from pilot pressure reducing valve (9).

8005-10

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 (8 and 12).

8005-11

STEP 15

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 (7 and 31).

8005-12

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. 5. Inspect the other parts of the control valve. If any of the parts are damaged, install new parts.

Assembly STEP 1

4 A

1 See Note

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (7 and 31). Torque relief valve (A) into anticavitation valve to 140 Nm (103 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.

8005-13

STEP 2

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (8 and 12).

STEP 3

STEP 4 2

2 1

BS03C025

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on flow limiting valve (9).

BS03C026

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on flow limit valve (11).

8005-14

STEP 5

STEP 12

Install and torque regeneration check valve (14) to 100 Nm (73.7 pound-feet).

Install and torque check valves (5) to 40 Nm (29.5 pound-feet).

STEP 6

STEP 13

Install new O-rings on housing (1). Install plate (2), bolts (3) and washers (4), onto housing (1). Torque bolts to 20 to 25 Nm (177 to 221 pound-inches).

Install and torque cone and plug (13) to 10 Nm (88.5 pound-inches).

NOTE: For 4 spool configuration install new O-rings between housings (30) and housing (1), install nuts (32) on studs (33). Torque nuts to 70 Nm (51.5 pound-feet).

STEP 14 Install and torque plug (28) to 60 Nm (44 pound-feet).

STEP 15

STEP 7

Lubricate spools with hydraulic oil and push spools (20 and 26) into housing (1).

Install and torque pilot pressure reducing valve (6) to 90 Nm (66 pound-feet).

IMPORTANT: Do not force spools into housing.

STEP 8

STEP 16

Install and torque anticavitation valves (7) to 90 Nm (66 pound-feet).

Install spring retainers (18), springs (17), covers (16), and bolts (14). Torque bolts to 6 Nm (53 pound-inches).

NOTE: Repeat step for 3 and 4 spool anticavitation valves (31).

STEP 9 Install anticavitation valves (27), spring (17), and cap (24) and torque cap to 60 Nm (44 pound-feet).

STEP 10 Install and torque flow limit valve (9 and 11) to 20 to 25 Nm (177 to 221 pound-inches).

NOTE: Repeat steps 15 and 16 for 3 and 4 spool valve configuration.

STEP 17 Install spring (17) and cap (24) and torque cap to 60 Nm (44 pound-feet). NOTE: Prior to installation in the machine, circuit reliefs can be tested.

STEP 18

STEP 11

Install valve in machine, see section 8001.

Install and torque pressure relief valves (8 and 12) to 20 to 25 Nm (177 to 221 pound-inches).

STEP 19 Check loader limit pressure, see section 8002.

8005-15

CIRCUIT RELIEF Pressure Test

Adjustment

STEP 1

Connect the hand pump to the port for anticavitation and circuit relief valves (7).

Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure.

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 21Â°C (70Â°F).

STEP 3 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 4 Compare the reading to the specifications on Page 3.

STEP 5 If the pressure is not correct, adjust the circuit relief valve.

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

8005-16

NOTES

Section 8006

8006

CYLINDERS

8006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS FOR TC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Z-BAR AND TC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDERS TC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 4 4 6 7 7 7 9 10 10 10 12 13 13 13 14 14 14 15 15 15

8006-3

SPECIFICATIONS Approximate weight Lift Cylinder - TC and Z-Bar.......................................................................................................75.7 kg (167 pounds) Bucket Cylinder - Z-Bar Models.................................................................................................75.6 kg (167 pounds) Bucket Cylinder - TC Models .....................................................................................................69.8 kg (154 pounds)

SPECIAL TORQUES Screw in Gland Z-Bar Bucket Cylinder ..........................................................135 to 542 Nm (100 to 400 pound-feet) Screw in Gland TC Bucket Cylinder ..............................................................135 to 542 Nm (100 to 400 pound-feet) Screw in Gland for Lift Cylinders TC and Z-Bar Models ................................135 to 542 Nm (100 to 400 pound-feet) Piston Bolt for Lift Cylinders TC and Z-Bar Models ...............................1600 to 1830 Nm (1180 to 1350 pound-feet) Piston Bolt for Z-Bar Bucket Cylinder ....................................................2830 to 3220 Nm (2087 to 2375 pound-feet) Piston Bolt for TC Bucket Cylinder ........................................................1600 to 1830 Nm (1180 to 1350 pound-feet) Lock Screw for all Cylinders .............................................................................................. 2.3 Nm (20 pound-inches)

SPECIAL TOOLS Torque Multiplier ........................................................................................................................................380001732

8006-4

LIFT CYLINDER 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, refer to Figure 1. Do not damage the tube (1). 3. Loosen and remove the self-tapping screw (12). 4. Use a spanner wrench to loosen and remove the gland (4) out of the tube (1). 5. Pull the piston rod (13) straight out of the tube (1) to prevent damage to the tube (1). 6. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (13) near the piston (15). Put a shop cloth between the support and the piston rod (13) to prevent damage to the piston rod (13). 7. Use a torque multiplier, 380001732, to loosen and remove the bolt (14) that fastens the piston (15) to the piston rod (13). 8. Remove the piston (15) from the piston rod (13). 9. Remove the gland (4) from the piston rod (13). 10. Remove the seal (16), ring (17)and the wear ring (18) from the piston (15). 11. Remove the O-ring (10), ring (9), O-ring (11), wiper (5), seal (6), seal (7), and bushing (8) from the gland (4).

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 (13) is straight. If the piston rod is not straight, replace it with a new piston rod. 4. Illuminate the inside of the tube (1) 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 (13) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the bushings (2), (8) (in the piston rod eye or yoke and the tube. Replace as required. 7. Inspect the gland (4) for rust. Clean and remove rust as necessary. 8. Inspect the gland (4) end of the tube for sharp edges that will cut the gland O-ring (10) (and remove as necessary. 9. Inspect the piston (15) for damage and wear. If the piston is damaged or worn, replace it with a new piston.

8006-5

13 7

4 8 11 9 10 15 17 16 18 14 1 3

2 3

BS03B200

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 (NOT SHOWN) ROD BOLT PISTON

FIGURE 1. LIFT CYLINDER

16. SEAL 17. RING 18. WEAR RING

8006-6

Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland. 1. Install the bushing (8) in the gland (4), refer to Figure 1. 2. Install the seal (6) in the gland (4). The seal (6) is to be installed so that the lips of the seal (6) are toward the bushing (8). The seal (6) can be difficult to install. 3. Install the seal (7) in the gland (4). The side of the seal (7) with the groove must be toward the bushing (8). 4. Install a new wiper (5) in the gland (4). The lips of the wiper (5) must be toward the outside end of the gland (4). 5. Install a new O-ring (11) in the groove on the OD of the gland (4). 6. Install a new ring (9) in the groove on the OD of the gland (4). If both sides of the ring (9) are not flat, the side that is not flat must be toward the small end of the gland (4). 7. Install a new O-ring (10) next to the ring (9) in the groove on the outside of the gland (4). The O-ring (10) must be toward the small end of the gland.

15. Install the bolt (14) into the piston rod (13). Tighten the bolt (14) to a torque of 1600 to 1830 N m ( 1 1 8 0 t o 1 3 5 0 p o u n d - fe e t ) . A t o r q u e multiplier can be used to help torque the bolt (14). 16. Install a new wear ring (18) in the wide groove on the outside of the piston (15), refer to Figure 1. 17. Install a new ring (17) in the other groove on the outside of the piston (15). 18. Install a new seal (16) on the top of the ring (17). 19. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (1). 20. Lubricate the inside of the tube (1) and the piston (15) with clean oil. 21. Push the piston (15) straight into the tube (1). 22. When the piston (15) is in the smooth part of the tube (1), start the gland (4) into the tube (1). 23. Lubricate the O-rings (10 and 11) on the gland (4) with clean oil. 24. If the original parts are being assembled: A. Tighten the gland (4) to a torque of 135 to 542 Nm (100 to 400 pound-feet).

8. Fasten the piston rod eye or yoke in the vise.

B. Install and tighten the lock screw (12) to a torque of 2.3 Nm (20 inch-pounds).

9. Remove any marks and sharp edges on the chamfer at the end of the piston rod (13). Make sure that the piston rod (13) is clean.

C. If, after tightening the gland, the lock screw (12) holes are not aligned, a new hole for the lock screw (12) must be drilled. See Step 25B.

10. Lubricate the bore of the gland (4) and the piston rod (13) with clean oil.

25. If a new gland (4) or a new tube (1) are being assembled:

11. Push the gland (4) onto the piston rod (13). If necessary, use a soft hammer to drive the gland (4) onto the piston rod (13).

A. Tighten the gland (4) to 135 to 542 Nm (100 to 400 pound-feet).

12. Put a support below and near the end of the piston rod (13). Use a shop cloth between the suppor t and the piston rod (13) to prevent damage to the piston rod (13). 13. Start the piston (15) onto the piston rod (13). 14. Clean the threads on the end of the piston rod and the threads of the piston bolt using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to the piston rod threads 1/4 inch from the open end of the piston rod so that there is 1/2 inch of Loctite 242 on the piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads.

B. Use a No. 27 drill bit and drill a hole half in the gland (4) and half in the 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 the gland wrench. C. Install and tighten the lock screw (12) to a torque of 2.3 Nm (20 inch-pounds). 26. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate O-rings with clean oil. Install the hoses.

8006-7

BUCKET CYLINDERS Z-BAR MODELS 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, refer to Figure 2. Do not damage the tube (1). 3. Loosen and remove the locking screw (12) from the gland (4) and tube (1). 4. Use a spanner wrench to loosen and remove the gland (4) out of the tube (1). 5. Pull the piston rod (12) straight out of the tube (1) to prevent damage to the tube (1). 6. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (12) near the piston (16). Put a shop cloth between the support and the piston rod (12) to prevent damage to the piston rod (12). 7. Use a torque multiplier, 380001732 to loosen and remove the bolt (15), washer (14) that fastens the piston (16) to the piston rod (12). 8. Remove the piston (16) from the piston rod (12). 9. Remove the gland (4) from the piston rod (12). 10. Remove the seal (17), backup ring (19) and wear ring (20) from the piston (16). 11. Remove the O-ring (11), backup ring (10), wiper (5), seal (6), seal (7) and bushing (8) from the gland (4).

Inspection 1. Discard the parts that were removed from the piston (16) and the gland (4). 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 (12) is straight. If the piston rod is not straight, replace it with a new piston rod. 4. Illuminate the inside of the tube (1) 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 (12) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the bushings (2), (8) and (13) in the piston rod eye or yoke and the tube. Replace as required. 7. Inspect the gland (4) for rust and clean and remove rust as necessary. 8. Inspect the gland end of the tube (1) for sharp edges that will cut the gland O-ring (9), (11) and remove as necessary. 9. Inspect the piston (16) for damage and wear. If the piston is damaged or worn, replace it with a new piston.

8006-8

BC03G289

1. 2. 3. 4. 5.

TUBE BUSHING SCREW (NOT SHOWN) GLAND WIPER

6. 7. 8. 9. 10.

SEAL SEAL BUSHING O-RING BACKUP RING

11. 12. 13. 14. 15.

O-RING PISTON ROD BUSHING WIPER BOLT AND WASHER

FIGURE 2. BUCKET CYLINDER FOR Z-BAR MODELS

16. 17. 18. 19.

PISTON SEAL BACKUP RING WEAR RING

8006-9

Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland. 1. Install the bushing (8) in the gland (4), refer to Figure 2. 2. Install the seal (6) in the gland (4). The seal (6) is to be installed so that the lips of the seal (6) are toward the bushing (8). The wide seal (6) can be difficult to install. 3. Install the seal (7) in the gland (4). The side of the seal (7) with the groove must be toward the bushing (8). 4. Install a new wiper (5) in the gland (4). The lips of the wiper (5) must be toward the outside end of the gland (4). 5. Install a new O-ring (9) in the groove on the gland (4). 6. Install a new backup ring (10) in the groove on the OD of the gland (4). If both sides of the backup ring (10) are not flat, the side that is not flat must be toward the small end of the gland (4). 7. Install a new O-ring (11) next to the backup ring (10) in the groove on the outside of the gland (4). The O-ring (11) must be toward the small end of the gland.

15. Install the bolt (15) into the piston rod (12). Tighten the bolt (15) to a torque of 2830 to 3220 N m ( 2 0 8 7 t o 2 3 7 5 p o u n d - fe e t ) . A t o r q u e multiplier can be used to help torque the bolt (15). 16. Install a new wear ring (19) in the wide groove on the outside of the piston (16), refer to Figure 2. 17. Install a new backup ring (18) in the other groove on the outside of the piston (16). 18. Install a new seal (17) on the top of the backup ring (18). 19. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (1). 20. Lubricate the inside of the tube (1) and the piston (16) with clean oil. 21. Push the piston (16) straight into the tube (1). 22. When the piston (16) is in the smooth part of the tube (1), start the gland (4) into the tube (1). 23. Lubricate the O-rings (9 and 11) on the gland (4) with clean oil. 24. If the original parts are being assembled: A. Tighten the gland (4) to a torque of 135 to 542 Nm (100 to 400 pound-feet).

8. Fasten the piston rod eye or yoke in the vise.

B. Install and tighten the lock screw (3) to a torque of 2.3 Nm (20 inch-pounds).

9. Remove any marks and sharp edges on the chamfer at the end of the piston rod (12). Make sure that the piston rod (12) is clean.

C. If, after tightening the gland, the lock screw (3) holes are not aligned, a new hole for the lock screw (3) must be drilled. See Step 25B.

10. Lubricate the bore of the gland (4) and the piston rod (12) with clean oil.

25. If a new gland (4) or a new tube (1) are being assembled:

11. Push the gland (4) onto the piston rod (12). If necessary, use a soft hammer to drive the gland (4) onto the piston rod (12).

A. Tighten the gland (4) to a torque of 135 to 542 Nm (100 to 400 pound-feet).

12. Put a support below and near the end of the piston rod (12). Use a shop cloth between the suppor t and the piston rod (12) to prevent damage to the piston rod (12). 13. Start the piston (16) onto the piston rod (12). 14. Clean the threads on the end of the piston rod and the threads of the piston bolt using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to the piston rod threads 1/4 inch from the open end of the piston rod so that there is 1/2 inch of Loctite 242 on the piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads.

B. Use a No. 27 drill bit and drill a hole half in the gland (4) and half in the 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 the gland wrench. C. Install and tighten the lock screw (3) to a torque of 2.3 Nm (20 inch-pounds). 26. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate O-rings with clean oil. Install the hoses.

8006-10

BUCKET CYLINDERS FOR TC MODELS 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 cylinder in a vise or other holding equipment. Be careful to prevent damage to the tube (1), refer to Figure 3. 3. Loosen and remove the lock screw (3) from the gland (4) and tube (1). 4. Use a spanner wrench to loosen and remove the gland (4) from the tube (1). 5. Pull the piston rod (12) straight out of the tube (1) to prevent damage to the tube (1). 6. Fasten the rod yoke in a vise and put a support below the piston rod (12) near the piston (13). Use a shop cloth between the support and the piston rod (12) to prevent damage to the piston rod (12). 7. Use a torque multiplier, 380001732, to loosen and remove the piston bolt (17) that secures the piston (13). 8. Remove the piston (13) from the piston rod (12). 9. Remove the gland (4) from the piston rod (12). 10. Remove the backup ring (14), piston seal (15) and wear ring (16) from the piston (13). 11. Remove the wiper (5), seal (7), seal (8) and the bushing (6) from the gland (4). NOTE: Use care not to scratch the ID of gland when removing seals. 12. Remove the O-ring (10) and backup ring (11) from the OD of gland (4).

Inspection 1. Discard the parts that were removed from the piston (13) and the gland (4). 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 (12) is straight. If the piston rod is not straight, replace it with a new piston rod. 4. Illuminate the inside of the tube (1) 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 (12) or inside the tube (1) with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the bushings (2), (6) in the piston rod eye or yoke and the tube. Replace as required. 7. Inspect the gland (4) for rust and clean and remove rust as necessary. 8. Inspect the gland end of the tube (1) for sharp edges that will cut the gland O-ring (9), (10) and remove as necessary. 9. Inspect the piston (13) for damage and wear. If the piston is damaged or worn, replace it with a new piston.

8006-11

5 7 8 4 13

9 10

14 15 16 17 6

19 2

BS03B202

1. 2. 3. 4. 5.

TUBE BUSHING SCREW GLAND WIPER

6. 7. 8. 9. 10.

BUSHING ROD SEAL BUFFER SEAL O-RING O-RING

11. 12. 13. 14. 15.

BACKUP RING PISTON ROD PISTON BACKUP RING SEAL

FIGURE 3. BUCKET CYLINDER FOR TC MODELS

16. 17. 18. 19.

WEAR RING BOLT GREASE FITTING WIPER

8006-12

Assembly NOTE: If a new gland (4) is being installed, put the part number of the cylinder on the new gland (4).

15. Install the piston bolt (17). Tighten the piston bolt (17) to a torque of 1600 to 1830 Nm (1180 to 1350 pound-feet). A torque multiplier can be used to help tighten the piston bolt (17).

1. Install the bushing (6) in the gland (4), refer to Figure 3.

16. Install a new wear ring (16) in the groove on the outer end of the piston (13).

2. Install the seal (8). The seal (8) must be installed with the seal lips toward the small end of the gland (4). The seal (8) can be difficult to install.

17. Install the piston backup ring (14) into the remaining groove in the piston (13).

3. Install the seal (7). The seal (7) must be installed with the lips toward the small end of the gland (4) also. 4. Install a new wiper (5) in the gland (4). The lips of the wiper (5) must be toward the large end of the gland (4). 5. Install a new O-ring (9) in the groove of the gland (4). 6. Install a new backup ring (11) in the groove on the outside of the gland (4). If both sides of the backup ring (11) are not flat, the side that is not flat must be toward the small end of the gland (4).

18. Install a new piston seal (15) on top of the backup ring (14). 19. Fasten the tube (1) in a vise or other holding equipment. Be careful to prevent damage to the tube (1). 20. Lubricate the inside of the tube (1) and the piston (13) with clean oil. 21. Push the piston (13) straight into the tube (1). 22. When the piston (13) is in the smooth part of the tube (1), start the gland (4) into the tube (1). 23. Lubricate the O-ring (9 and 10) on the gland (4) with clean oil. 24. If the original parts are being assembled:

7. Install the O-ring (10) on the gland (4). The O-ring (10) must be toward the small end of the gland (4).

A. Tighten the gland to a torque of 135 to 542 Nm (100 to 400 pound-feet).

8. Fasten the piston rod yoke in the vise.

B. Install and tighten the lock screw (3) to a torque of 2.3 Nm (20 inch-pounds).

9. Remove any marks and sharpen edges on the chamfer at the end of the piston rod (12). 10. Lubricate the bore of the gland (4) and the piston rod (12) with clean oil. 11. Push the gland (4) onto the piston rod (12). If necessary, use a soft hammer to drive the gland (4) onto the piston rod (12). 12. Put a support below and near the end of the piston rod (12). Use a shop cloth between the suppor t and the piston rod (12) to prevent damage to the rod. 13. Put the piston (13) on the end of the piston rod (12). 14. Clean the threads on the end of the piston rod and the threads of the piston bolt using Loctite cleaning solvent. Allow to dry. Apply Loctite 242 to the piston rod threads 1/4 inch from the open end of the piston rod so that there is 1/2 inch of Loctite 242 on the piston rod threads. DO NOT apply Loctite to the first 1/4 inch of the piston rod threads.

C. If, after tightening the gland, the lock screw (3) holes are not aligned, a new hole for the lock screw (3) must be drilled. See Step 25B. 25. If a new gland (4) or a new tube (1) are being assembled: A. Tighten the 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 the gland (4) and half in the 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 the gland wrench. C. Install and tighten the lock screw (3) to a torque of 2.3 Nm (20 inch-pounds). 26. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate the O-rings with clean oil. Install the hoses.

8006-13

REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Z-BAR AND TC MODELS Disassembly 1. Put the piston tube (4) in a press, refer to Figure 4.

2. Use an acceptable driver to press the wipers (1) and bushings (2) out of the piston tube (4).

3. Clean the bore for the bushings (2) in the tube (4).

Assembly 1. Use an acceptable driver to press a new bushing (2) into the tube (4) until the bushing (2) is centered in the tube (4). 2. Use an acceptable driver to install the wipers (1) in the tube (4). The lips of the wipers (1) must be toward the outside of the bore.

2 1 2

BS01C003

1. WIPER 2. BUSHING

3. PISTON ROD YOKE 4. TUBE

FIGURE 4. BUSHING AND WIPER REMOVAL AND REPLACEMENT LIFT CYLINDERS

8006-14

REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS Disassembly 1. Put the piston rod eye (3) in a press, refer to Figure 6.

1 2

2. Use an acceptable driver to press the wipers (1) and bushing (2) out of the piston rod eye (3).

3. Put the tube (4) in a press.

4. Use an acceptable driver to press the bushings (2) out of the tube (4). 5. Clean the bore for the bushings (2) in the piston rod eye (3) and the tube (4).

Assembly 1. Use an acceptable driver to press new bushings (2) into the piston rod eye (3). Refer to Figure 6.

4 2

2. Use an acceptable driver to install the wipers (1) in the piston rod eye (3). The lips of the wipers (1) must be towards the outside of the bore.

3. Use an acceptable driver to press new bushings (2) into the tube (4).

BS01C004

1. WIPER 2. BUSHING

3. PISTON ROD EYE 4. TUBE

FIGURE 6. BUSHING AND WIPER REMOVAL AND REPLACEMENT BUCKET CYLINDER

8006-15

REPLACING BUSHINGS FOR THE BUCKET CYLINDERS TC MODELS Disassembly

Assembly

1. Put the piston tube (4) in a press, refer to Figure 5.

1. Use an acceptable driver to press new bushings (2) into the tube (4). Refer to Figure 5.

2. Use an acceptable driver to press the wipers (1) and bushing (2) out of the piston tube (4).

2. Use an acceptable driver to install the wipers (1) in the tube (4). The lips of the wipers (1) must be toward the outside of the bore.

3. Clean the bore for the bushings (2) in the tube (4).

4 2

BS01C002

1. WIPER 2. BUSHING

3. PISTON ROD YOKE 4. TUBE

FIGURE 5. BUSHING AND WIPER REMOVAL AND REPLACEMENT TC BUCKET CYLINDERS

8006-16

NOTES

Section 8007

8007

COUPLER SOLENOID LOCKING VALVE

8007-2

TABLE OF CONTENTS COUPLER SOLENOID LOCKING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 4 4

8007-3

COUPLER SOLENOID VALVE Removal 8

Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

4 3

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.

13 (C2)

SEE BRACKET MOUNT DETAIL FOR CORRECT VALVE & BRACKET ORIENTATION

11 10

W110R583

COUPLER SOLENOID VALVE PARTS ILLUSTRATION

BD01F143-01

Put the articulation lock in the LOCKED position.

1. VALVE SOLENOID 2. BRACKET COUPLER SOLENOID 3. CONNECTOR 4. WASHER 11X24X2 MM 5. NUT 6. WASHER 6.6X18X1.6 MM 7. BOLT M6X50

8. NUT M6 9. ELECTRICAL CONNECTOR 10. 11. 12. 13.

HOSE COUPLER PRESS. ELBOW 10 MM ORFSXM14 HOSE Z-BAR COUPLER HOSE COUPLER TANK

Tag and disconnect the hoses (10-12-13) from the coupler solenoid valve. Install a plug in each hose and cap all fittings. Loosen and remove the nuts, washers and bolts (6-7-8) from bracket (2). Remove the coupler so len oid valve fro m th e machine.

Remove and discard all O-rings from the fittings. W110R582

Disconnect the electrical connector (7) from the coupler solenoid valve.

Installation Place the coupler solenoid valve into position on the machine. Lubricate and install new O-rings in the fittings. Install the bolts, washers and nuts. Tighten the nuts. Connect the hoses to the coupler solenoid valve, remove and discard tags. Reconnect the electrical connector. Check the level of the hydraulic oil in the reservoir. Start the engine and run the engine at low idle for two minutes. Stop the engine and check for hydraulic oil leakage at the coupler solenoid valve. Check the level of the hydraulic oil in the reservoir and add as required.

8007-4

COUPLER SOLENOID LOCKING VALVE Disassembly

STEP 11 Install solenoid (2) on valve cartridge (3).

STEP 1 Clean exterior of valve.

STEP 12 Install nut (1) to secure solenoid (2).

STEP 2 Remove nut (1) and solenoid (2) from valve cartridge (3).

STEP 3 Remove valve cartridge (3) from valve housing (7).

STEP 4 Remove and discard all O-rings (4 and 5) and back-up rings (6).

Cleaning and Inspection STEP 5

Immerse valve cartridge (3) and valve housing (7) in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of valve cartridge and housing and to ensure that all passage ways and bores are clear.

4 6

STEP 6

Check valve cartridge for (3) for cracks, breaks, chipping, or other damage. Replace if any of these conditions are seen.

STEP 7

Check bores in valve housing (7) for deep scratches, gouges, and other damage. Replace valve if any of these conditions are seen.

STEP 8

5 6 6 5 6

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

RIDE CONTROL VALVE ACCUMULATOR

8013

Section 8013

8013-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Nitrogen Charge On Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Accumulator With Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 5 6

8013-3

SPECIFICATIONS Load Travel Stabilization Accumulator Dry Nitrogen Pressure ................................................... See chart on page 6 Load Travel Stabilization Accumulator Fluid Capacity .......................................................... 3.79 liters (231 cu. inch) Load Travel Stabilization Accumulator Maximum Operating Pressure ...........................................280 bar (4061 psi)

ACCUMULATOR SPECIAL TORQUES Accumulator Gas Charging Valve Cap ............................................................................... Hand tighten with wrench Gas Charging Valve.........................................................................................20 to 25 Nm (14.8 to 18.4 pound-feet)

SPECIAL TOOLS

BS06M002

380001676 NITROGEN REGULATOR VALVE

BC04A001

380001168 ACCUMULATOR VALVE ADAPTER

Check your inventory of tools, if you have nitrogen charging kit 380001737 use it in place of the above listed tools.

BS06M003

380001390 ACCUMULATOR CHARGING HOSE

8013-4

TESTING LOAD TRAVEL STABILIZATION STEP 1

STEP 5

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

NOTE: This will charge the load travel stabilization accumulator.

Install the ar ticulation lock, star t the machine, activate the parking brake.

STEP 6

STEP 3 Set the load travel stabilization 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 load travel stabilization.

STEP 4 Raise the lift arms to the top of their travel and dump the bucket. When the bucket reaches the fully dumped position it will generate down-force on the lift arms and cause them to sink. NOTE: Keep rocker switch in the “Off” position during this steps 4, 5, 6.

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 7 With the pilot controller in neutral, set the load travel stabilization rocker switch on the right side console to the “Always ON” position and observe the switch lamp, the lamp should illuminate.

STEP 8 With load travel stabilization ON. If it is working properly 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 5 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.

8013-5

Checking Nitrogen Charge On Accumulator

E F

NITROGEN CHARGING KIT

1. Use the Nitrogen Charging Kit to discharge the accumulator, refer to the illustration above. The tool must be disconnected from the nitrogen tank. 2. Close valve (E).

BS07A156

7. Connect valve A to the valve stem on the adapter (F). 8. Connect the accumulator to the adapter (F) 9. Open valve on accumulator using the adapter’s square drive (G).

3. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise.

10. Turn the T-handle inward on valve (A) to engage the pin in the valve stem on the adapter.

4. Turn the T-handle on valve (A) fully out.

11. Slowly open valve (E).

5. Remove the valve cap from the accumulator. 6. Install adapter accumulator.

380001168

(F)

onto

12. Check the charge pressure on gauge (B). the

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. M253A

8013-6

Charging Accumulator With Nitrogen IMPORTANT: The four valves A, D, and E must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to illustration on page 5. 1. Close the shutoff valve (D) by turning it all the way to the left (counterclockwise), refer to the illustration on page 5. 2. Close the gauge valve (E) by turning it all the way to the right (clockwise). 3. Connect the charging gauges to the nitrogen supply tank, open the supply tank valve. 4. Slowly turn valve (D) clockwise while watching the pressure gauge (B). Stop turning valve (D) when the needle on the gauge (B) reaches 10 bar (145 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve (E) and check the pressure again. The charging kit is now ready to be installed on the accumulator. 5. Remove the cap from the accumulator. 6. Loosen the sealing plug with an Allen wrench. NOTE: just loosen do not open to far so the gas leaks out 7. Install adapter 380001168 (F). 8. Back off the needle valve (A) 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. 9. Install the charging hose fitting onto the adapter. 10. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve (E) and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator. 11. Fill the accumulator to pressure according to Temperature/Charge Pressure chart.

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 16.36 BAR 237 PSI 16.55 BAR 240 PSI 16.74 BAR 243 PSI 16.87 BAR 245 PSI 17.06 BAR 248 PSI 17.26 BAR 250 PSI 17.45 BAR 253 PSI 17.58 BAR 255 PSI 17.77 BAR 258 PSI 17.96 BAR 261 PSI 18.15 BAR 263 PSI

TEMPERATURE/CHARGE PRESSURE CHART

12. Close valve (E) by turning to the right (clockwise). After a few minutes open valve (E) and check the accumulator for leakage. 13. Back off the needle valve (A) 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. 14. Close the valve on the nitrogen supply tank. 15. Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise. 16. Slowly remove the charging hose from the accumulator pressure valve. NOTE: A small amount of nitrogen will escape when disconnecting the hose. 17. Snug the gas charging valve on the accumulator, remove the adapter from the accumulator. 18. Torque the gas charging valve to 20 to 25 Nm (14.8 to 18.4 pound feet) 19. Install the cap on the accumulator. 20. Remove the charging gauges from the nitrogen supply tank. NOTE: A small amount of nitrogen will escape when disconnecting the hose.

RIDE CONTROL VALVE

8014

Section 8014

8014-2

TABLE OF CONTENTS LOAD TRAVEL STABILIZATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4

8014-3

LOAD TRAVEL STABILIZATION VALVE 9

13 12

16 17

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 ORIFICE

14. 15. 16. 17.

POPPET ORIFICE VALVE BLOCK RELIEF VALVE

STEP 8 Remove the pressure relief valve (17).

STEP 1 Remove load travel stabilization valve, refer to section 8001.

Inspection 1. Discard all O-rings.

STEP 2

2. Clean all parts in cleaning solvent.

Remove plugs (1), (8), (9), and (11).

3. Check the spools and the spool bores for damage and wear.

STEP 3 Remove the solenoid (12).

4. Check the parts of the pressure relief valve. If any of the parts are damaged, install new parts.

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).

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 5 Install and torque solenoid valve to 12 Nm (106 lb-in).

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 load travel stabilization valve in the machine, see section 8001.

STEP 11 Test the load travel stabilization system, see section 8002.

SECTION INDEX

MOUNTED EQUIPMENT Section Title

Section Number

Air Conditioning Troubleshooting and System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9002 Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003 Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004 Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006 Roll Over Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007 Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

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 (CFCâ&#x20AC;&#x2122;s) which are harmful to the earthâ&#x20AC;&#x2122;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 380001325

A22090

ELECTRONIC LEAK DETECTOR 380001327

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, 380001326

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 operatorâ&#x20AC;&#x2122;s comfort.

The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant and sends it in the form of a high pressure gas to the condenser. The air flow through the c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.

The electrical circuit of the air conditioning system consists of a fan speed control, temperature control, one (1) relay, a blower motor, blower resistor, A.C. compressor clutch, A.C. low pressure switch, A.C. high pressure switch, and A.C. warning light.

The high pressure refrigerant liquid then flows from t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e receiver-drier is a container filled with moisture removing material, which removes any moisture that may have entered the air conditioner system in order to prevent corrosion of the internal components of the air conditioner system.

3 4

208L95

1. EXPANSION VALVE 2. EVAPORATOR

3. COMPRESSOR 4. CONDENSER

5. RECEIVER-DRIER

9002-6

TROUBLESHOOTING Perform a visual inspection of the machine. Check the following and correct as necessary: 1. - Obtain service history if possible.

5. - Are there heavy accumulations of oil, or oily dust around the fittings, indicating refrigerant leakage? 6. - Are air ducts undamaged, sealed properly and in position?

2. - Is compressor drive belt in place and tensioned? 3. - Are grille screens, fan blades, condenser, air filter, and evaporator unobstructed?

7. - Condensate drain hoses and check valves present and unobstructed?

4. - Are there any sharp bends or kinks in the hoses?

Problem: No Cooling Compressor Runs

Yes Internal System Problem See Pressure Testing, Page 13

Mechanical - See Mechanical Compressor Check Page 8 Electrical - See Blower and Compressor Clutch Check Page 9

9002-7

Problem: Not Enough Cooling

Problem: Erratic Cooling

MECHANICAL HEATER

See Mechanical Compressor Check Page 8.

Make sure the heater control is OFF and that there is no coolant flow through the heater core. ELECTRICAL See Blower and Compressor Clutch Check - Blower Motor Check, Blower Switch Check and Compressor Clutch Check on Page 9. SEAL Make sure the sealing material is correctly in place. INTERNAL SYSTEM PROBLEMS See Pressure Testing, Page 13. MECHANICAL See Mechanical Compressor Check page 8. See Evaporator Heater Core Check Page 12.

Problem: System Makes Noise

ELECTRICAL See Blower and Compressor Clutch Check on Page 9.

MECHANICAL See Mechanical Compressor Check Page 8. See Blower Motor Check Page 9.

REFRIGERANT See Cab Temperature Check Page 10. ELECTRICAL See Compressor Clutch Check Page 9. INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

9002-8

SYSTEM CHECKS Mechanical Compressor Check Compressor and Fan Belts

1. Too much belt wear - replace a worn belt, because a worn belt will cause too much slippage.

Compressor Mounting Brackets

1. Loose bracket mounting bolts - tighten the bolts to the correct torque. 2. Bracket has cracks or breaks - replace the bracket.

Compressor Clutch

1. The compressor belt will slip on the compressor pulley if there is compressor seizure. Remove the compressor for service or replacement. 2. Remove the dust cover and check the air gap on the compressor clutch. The gap b e t w e e n t h e f r o n t p l a t e a n d p u l l ey assembly must be 0.41 to 0.79 mm. 3. Use a socket wrench to slowly rotate the compressor clockwise. Compressor rotation should be smooth and not require much effort.

Pulley and Belt Alignment

1. The compressor pulley and the compressor drive pulley must be aligned within 1.6 mm (1/16 inch) of each other. Use a straight edge to check pulley alignment. Adjust the compressor mounting bracket if needed.

9002-9

Blower and Compressor Clutch Check NOTE: Check supply voltage with compressor lead plugged in and engaged. Voltage drops will not be apparent without current flow. Compressor Clutch

1. If there is electrical system voltage to the clutch, check for excessive voltage drop in the ground circuit, then see Section 9004 and replace the compressor.

Low and High Pressure Switches

1. See Section 4002 and check the high and low pressure switches.

Blower Fuse (10 amp)

1. Check for damaged blower fuse.

Blower Fan Switch

1. Check switch operation. Switch must give four different blower speeds: OFF, Low, High, and Purge. 2. Check for loose connections or broken wires. Repair or replace as necessary. 3. Check resistor board.

Blower Motor

1. Check the wiring to the blower motor. Make repairs or replace items as necessary. 2. Check motor ground wire. Make sure motor ground wire is making good contact with mounting bracket.

1. With key in ON position, turn switch to maximum cold. Compressor clutch must engage.

Temperature Control Switch

NOTE: Blower must be operating, since electrical power to temperature control switch is received from blower switch. 2. Turn the blower off. Disconnect the wires from the temperature control. Using an ohmmeter, check the continuity between switch ter minals. If continuity is not present when switch is on maximum cold, replace switch.

9002-10

Cab Temperature Check Air Louvers

1. Make sure louvers and recirculation vents are fully open for most efficient air conditioning operation. Defrost louvers must be closed. 2. Check blower; blower must be running.

ATTENTION: Use caution when feeling hoses. Hoses become very hot. Check temperature by slowly reaching for hose and touching briefly several times with finger tips, increasing the duration with each touch. Air Conditioning

1. Feel the air conditioning hoses. The high pressure hoses (small line) must be warmer than the low pressure hose (large line). 2. If no temperature difference, the system is low on refrigerant, or compressor is not working correctly.

1. Put a thermometer in the air duct behind the seat and r u n t h e c o m p r e s s o r fo r f i v e m i n u t e s t o m a k e temperature stable. Refer to page 12. 2. Duct temperature must be below 25° C (72° F) if the system is operating at maximum efficiency. Duct Temperature

Temperature Sensing Probe Check

NOTE: Ambient temperature must be 27 to 43° C (80 to 110° F). 3. If temperature is above 25° C (72° F), system is low on refr igerant, there is a restr iction in the system, compressor is not working correctly, or air ducts are not sealed correctly.

1. Turn the engine OFF, key switch ON, blower switch ON and temperature control switch turned fully clockwise. 2. Remove the temperature sensing probe from the evaporator. Refer to Section 9004. 3. Put the end of the temperature sensing probe in a container with ice and water. 4. When the sensing tube has cooled to the temperature of the ice and water mixture, the temperature control switch should interrupt the current flow to the compressor. Check for current at the control switch terminals as on previous page. If current is not interrupted then replace the control switch.

9002-11

Visual and Leak Check Compressor Hoses

1. Make sure that all hose connections are tight. 2. Check hoses for bends or cracks. Replace all hoses that have damage.

1. Shut off the engine.

Leak Finding Check

WARNING: When refrigerant comes in contact with an open flame, it can form dangerous gas. Never breathe these fumes. 2. Use electronic leak detector OEM -1437 to inspect all connections. Use instructions from manufacturer of leak finding tool. NOTE: When checking compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise. NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 3. Repair all leaks and recharge the system. See Section 9003.

Condenser

1. Make sure the condenser is clean and the seals are in place. Make sure condenser fans run when temperature control switch is ON.

9002-12

Evaporator/Heater Core Check Make sure heater valve is closed

Evaporator/Heater Core

1. See Section 9004 for access to the evaporator/heater core. 2. Inspect the fins on the evaporator/heater core. All the fins that have bends or damage must be made straight. 3. Inspect the evaporator/heater core for r e s t r i c t i o n s. I f t h e c o r e i s d r y, u s e compressed air or a brush and vacuum cleaner. If the core is wet or filled with mud, flush the core with water using a hose without pressure. Make sure the water drains freely from the evaporator/heater core. DO NOT USE STEAM. WARNING: Do not steam clean any air conditioning systems parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode.

Evaporator/Heater Core Sealing

1. See Section 9004 for access to the evaporator/heater core. 2. Make sure seals are in place so blower will pull air only through the evaporator/heater core and not around the evaporator/heater core.

Filters

1. Make sure the filters are clean.

9002-13

PRESSURE TESTING Manifold Gauge Set NOTE: The gauge set is not accurate enough to optimize an existing charge of HFC-134a. The best use of the gauge set is to determine whether undercharge or overcharge exists, and then evacuate, reclaim and recharge system with the recommended quantity (charge) of HFC-134a. The manifold gauge set is the most important tool used to service the air conditioning system. The manifold gauge set is used to measure the high and low pressures of the system, as a tool to troubleshoot for correct refrigerant charge quantity, system diagnosis, and operating efficiency. The manifold gauge set can read both the high (discharge) and low (suction) sides at the same time, since pressure must be compared in order to make a diagnosis of system operation. LOW PRESSURE GAUGE - The low pressure gauge is a compound gauge. It is best used to judge eva cuat io n effe ctiven ess. A vac uum rea ding indicates a system malfunction. For this reason, it is necessar y to use a compound gauge that will indicate both pressure and vacuum.

During normal operation the low pressure gauge must always indicate from 10 to 35 psi (0.7 to 2.4 bar) after the system has run 10 to 15 minutes. HIGH PRESSURE GAUGE - The high pressure gauge is used to indicate pressures in the high side of the system. The gauge must indicate from 0 to 400 psi (0 to 27.6 bar) minimum. During normal operation, the high pressure gauge will normally indicate from 120 to 310 psi (8.3 to 21.4 bar). See pressure-temperature chart on page 14.

Pressure Test Connection C o n n e c t t h e m a n ifo l d g a u g e s e t i n t o t h e a i r conditioning system as shown. Make sure that both valves in the manifold gauge set are closed.

9002-14

PRESSURE-TEMPERATURE CHART AIR LOUVER (BEHIND SEAT) MAXIMUM TEMP. TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION 째F (째C) psi (bar) psi (bar) 째F (째C) AMBIENT

NORMAL LOW

NORMAL HIGH

80 (27)

9 to 12

145 to 165

(0.62 to 0.83)

(10 to 11.53)

11 to 15

190 to 210

(0.76 to 1.04)

(13.10 to 14.48)

16 to 18

210 to 230

(1.10 to 1.24)

(14.48 to 15.86)

17 to 19

235 to 255

(1.17 to 1.31)

(16.2 to 17.58)

20 to 21

260 to 280

(1.38 to 1.45)

(17.93 to 19.31)

22 to 24

290 to 310

(1.93 to 2.14)

(20 to 21.37)

90 (32) 95 (35) 100 (38) 105 (41) 110 (43)

The pressure-temperature chart is based on the following conditions: NOTE: High humidity will cause higher air louver temperatures and dramatic increase in suction pressure. The table shown represents readings taken in low relative humidity. Adjust the chart according to local conditions.

55 (14) 61 (18) 63 (20) 66 (22) 68 (23) 72 (25)

2. All panels and access doors installed and closed. 3. Cab filters clean and installed. 4. Heater valve at engine closed. 5. Measurements taken 15 minutes after startup.

1. Engine at 1500 RPM, no load, fan speed & temperature control at max setting, A/C switch ON, all louvers and doors open

QUICK REFERENCE TROUBLESHOOTING CHART PROBLEM

LOW PRESSURE GAUGE

HIGH PRESSURE GAUGE

SEE PAGE

NO COOLING

VERY LOW

NO COOLING

HIGH

NOT ENOUGH COOLING

NORMAL TO HIGH

NORMAL

NOT ENOUGH COOLING

LOW

NOT ENOUGH COOLING

HIGH

LOW

NOT ENOUGH COOLING

HIGH

INTERMITTENT COOLING

NORMAL

NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

9002-15

A/C RECOVERY AND CHARGING STATION CONNECTIONS STEP 1

STEP 4

Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.

Connect the hose from the high pressure gauge to the port on the discharge hose.

WARNING: Do not steam clean any air conditioning system parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode. SM104A

WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid r e f ri g er a n t i n y o u r ey e s c o u l d c a u s e blindness. SM105A

STEP 5

STEP 2

Make sure the charging station manifold gauge valves are in the closed position.

Connect the hoses from the test gauges to the service ports by turning the knurled knobs on the depressors.

STEP 6

STEP 3 Connect the hose from the low pressure gauge to the port on the suction hose.

Start the engine and run at 1500 RPM maximum speed. Operate the air conditioner system at maximum cooling setting and blower speed for 15 minutes with the cab door open. Observe the test gauges and check the chart on page 13 against the gauge readings.

9002-16

PROBLEM: NO COOLING

VERY LOW

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of No Refrigerant or Low Refrigerant Charge: 1. Leak test the system, see Page 11. It may be necessary to add refrigerant. See Section 9003. 2. Evacuate and reclaim remaining refrigerant from system. See Section 9003. 3. Repair system leaks as needed. Follow the given repair procedure. A. Discharge air from evaporator warm. B. Compressor does not run, or cycles off rapidly after start-up. (A/C warning light in cab should illuminate).

Yes

4. Check level of oil in compressor - possible for compressor to have an oil loss. 5. Remove air and moisture from the system. Replace Receiver-Drier. See Section 9004. 6. Charge system with new refrigerant. See Section 9003. 7. Continue performance possible problems.

test for other

9002-17

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of Large Quantity of Air in System: 1. Evacuate and reclaim refrigerant from system. See Section 9003. 2. Replace receiver-drier. Discharge air from evaporator warm

Yes

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine fan belt and proper condenser fan operation. 2. Check to see that condenser is clean and unobstructed and that the fins are straight. 3. Check system for too much refrigerant. Evacuate, reclaim and recharge refrigerant until gauge pressure is normal. See Section 9003. A. Liquid line (between evaporator and condenser) is very hot. B. Discharge air from evaporator warm.

4. Remove and check condenser for restrictions caused by oil or reduced heat transfer. A. Remove refrigerant from the system. See Section 9003. B. Use compressed condenser.

air

remove

oil

from

C. Replace receiver-drier. D. Remove moisture and charge the system. See section 9003. 5. Continue the performance test for other possible problems.

9002-18

Expansion Valve Malfunctioning - Indications: A. Discharge air from heater/evaporator warm. B. Much condensation on suction hose at compressor. C. Much condensation outlet.

See Section 9004 and replace the expansion valve.

evaporator

Refrigerant Contamination: 1. See table below and check stable saturation pressures at given temperature to determine if contamination exists. A. Measure pressure from gauge on reclamation unit. B. Measure temperature from refrigerant in reclamation tank. If refrigerant has been in reclamation unit for some time, use ambient temperature. The numbers in the table represent the boiling point for HFC-134a.

Refrigerant Contamination

C. Pressure readings below range given in chart indicate contaminated refrigerant. IMPORTANT: Do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance with all applicable laws and local procedure.

HFC-134a Stable Saturation Pressure/ Temperature Chart Temperature ď&#x201A;°F (ď&#x201A;° C)

Pressure PSIG (Bar)

50 (10) 55 (13) 60 (16) 65 (18) 70 (21) 75 (24) 80 (27) 85 (29) 90 (32) 95 (35) 100 (38) 102 (39) 104 (40) 106 (41) 108 (42) 110 (43) 112 (44) 114 (46) 116 (47) 118 (48) 120 (49)

45 (3.1) 51 (3.5) 57 (3.9) 64 (4.4) 71 (4.9) 78 (5.4) 88 (6.1) 95 (6.6) 104 (7.2) 114 (7.9) 124 (8.6) 129 (8.9) 133 (9.2) 138 (9.5) 142 (9.8) 147 (10.1) 152 (10.5) 157 (10.8) 162 (11.2) 167 (11.5) 172 (11.9)

9002-19

PROBLEM: NOT ENOUGH COOLING

NORMAL TO SLIGHTLY HIGH

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Air in the System - Indications: 1. Test system for leaks. See page 11. Possible leak has let air enter; check compressor seal carefully. 2. Discharge system of refrigerant. See Section 9003. A. Suction line warm to your hand.

3. Repair system leak as necessary.

B. Discharge air from heater/evaporator only a little cool.

4. Replace receiver-drier. 5. Check compressor oil level. 6. Remove air and moisture from the system. See Section 9003. 7. Charge system with new refrigerant. See Section 9003.

9002-20

LOW

LO W

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Not Enough Refrigerant - Indications: 1. Leak test system - system has a loss of refrigerant. NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7 to 29.5 grams) of refrigerant between seasons. A. If leak is found, go to Step 2. B. If no leak is found, go to Step 6. 2. Discharge refrigerant from system. See Section 9003. A. Discharge air from evaporator cool or warm - not cold.

3. Repair system leaks as needed. 4. Check oil level in compressor - It is possible for compressor to lose oil. 5. Remove air and moisture from the system. Replace Receiver-Drier. See Section 9004. 6. Charge system with new refrigerant. See Section 9003.

High Side Restriction - Indications: A. Discharge air from heater/evaporator only a little cool. B. Condensation receiver-drier.

frost

C. Liquid line to receiver-drier cool, with frost or condensation. NOTE: The frost will form downstream from or at the point of the restriction

1. Discharge refrigerant from system-restriction in receiver-drier or liquid line must be removed. 2. Remove and replace part with restriction. 3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

9002-21

Expansion Valve Not Operating - Indications: A. Discharge air from evaporator warm or cool - not cold. B. Condensation or frost on expansion valve outlet. C. Inlet end of expansion valve is warm.

1. Expansion valve outlet with condensation or frost is an indication of a restriction in the expansion valve. Replace expansion valve. See Section 9004. 2. Inlet end of expansion valve is warm (not hot), indicating expansion valve is not completely open. If the valve is stuck closed, there will be little or no flow of refrigerant through the valve. Replace expansion valve. See Section 9004.

9002-22

HIGH

LOW

SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Compressor Turning But Not Pumping Properly - Indications: 1. Discharge refrigerant from system. See Section 9003. 2. Remove the compressor from the machine. See Section 9004. 3. Remove and replace compressor because there is indication of internal leak in compressor. A. System is fully charged.

4. Replace compressor.

B. Cool discharge air from evaporator.

5. Replace receiver-drier if: A. System has been opened before. B. Receiver-drier has been used two or more years. See Section 9004 for receiver-drier replacement. 6. Charge the system with refrigerant. See Section 9003.

Expansion Valve Stuck Open Expansion Valve Stuck Open

1. Replace expansion valve. See Section 9004.

9002-23

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and proper condenser fan operation. 2. Check to see that condenser is clean and that the fins are straight. 3. Check system for too much refrigerant. A. Remove refrigerant from system until gauge pressure is below normal. See Section 9003. A. Liquid line very hot. B. Discharge air from evaporator warm.

B. Add refrigerant until gauge pressures are normal. See Section 9003. C. If there is still a problem, do step 4. 4. Remove and inspect condenser for restrictions caused by oil or reduced heat transfer. A. Discharge refrigerant from system. See Section 9003. B. Use compressed air to remove oil from condenser. C. Replace receiver-drier. See Section 9004.

Air in the System - Indications: 1. Discharge refrigerant from system. See Section 9003. 2. Replace receiver-drier. Warm discharge air from evaporator.

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

9002-24

PROBLEM: INTERMITTENT COOLING

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Moisture in the System - Indications: 1. Discharge system of refrigerant. If too much moisture enters the orifice of the expansion valve, the freezing of this moisture can stop refrigerant flow. See Section 9003.

Cooling is acceptable during cool part of day but not acceptable during hot part of day.

2. Replace receiver-drier. The moisture removing material could be full to capacity with moisture. See Section 9004. 3. Remove air and moisture from the system. See Section 9003. NOTE: The time needed to remove a large amount of moisture will be two to three hours minimum. 4. Charge system with new refrigerant. See Section 9003.

9002-25

PROBLEM: NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Too Much Refrigerant in System - Indications: A. Cool discharge air from heater/evaporator. B. Compressor makes noise.

1. Remove refrigerant from system until gauge readings are below normal. See Section 9003. 2. Add new refrigerant until gauge readings are normal. See Section 9003.

9002-26

TUBE CONNECTIONS TORQUE CHART TUBING SIZE

3/8 inch

1/2 inch

5/8 inch

THREAD SIZE

M10 -1.25

5/8-18

3/4-18 OR 3/4-16

7/8-18 OR 7/8-14

1-14

STEEL TO STEEL

31-36 Nm

40-46 Nm

45-52 Nm

ALUMINUM TO BRASS

10-14 Nm

24-30 Nm

30-37 Nm

45-52 Nm

NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used. IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these connections are easily distorted.

AIR CONDITIONER SYSTEM SERVICE

9003

Section 9003

9003-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9003-3

SPECIFICATIONS Air conditioning system refrigerant capacity ............................................................1670 to 1730 g (3.68 to 3.82 lbs) (59 to 61.1 oz.)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION 380001326

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 (CFCâ&#x20AC;&#x2122;s) which are harmful to the Earthâ&#x20AC;&#x2122;s ozone layer. Safety procedures must be followed when working with refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause ser ious injur y. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes. B. See a physician immediately. 2. A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is necessary to service the air conditioner system. Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.

9003-5

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY Recovered refr igerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it.

STEP 3

If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding.

STEP 1

A22114

Open the high and low valves.

STEP 4

BD08B201-01

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.

BD08B201-01

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.

BD08B201-01

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 BD08B201-01

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 3.75 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

BD08B201-01

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.

BD08B201-01

Install the caps on the service ports on the suction and discharge hoses.

9003-10

PRESSURE - TEMPERATURE CHART NORMAL HIGH AMBIENT NORMAL LOW TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION psi (bar) 째F (째C) psi (bar)

AIR LOUVER MAXIMUM TEMP. 째F (째C)

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 9 10 15 20 20 21

9004-3

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 380001326

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 BD07N576-01

Remove the drive belt by releasing automatic belt tensioner. NOTE: Air conditioner belt is a separate belt.

STEP 5

BD07N600-01

BD08B201-01

BD07N573-01

Loosen and remove the four bolts holding the protective shield. Remove the shield.

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.

9004-6

Installation

STEP 6

STEP 9 Place the compressor into position on the machine.

STEP 10

BD07N578-01

Disconnect the compressor clutch wire from the engine harness assembly.

STEP 7 BD07N579-01

Install the two bolts to mount the compressor.

STEP 11

2 BD07N579-01

Loosen and remove the two compressor mounting bolts (1) and remove the air conditioner belt (2).

STEP 8 Remove the compressor from the machine.

BD07N578-01

Connect the compressor clutch wire to the engine harness assembly.

9004-7

STEP 12

STEP 13 1 2

BD08B201-01

BD07N576-01

Carefully remove the protective cap, install a new O-ring, and connect the high pressure line to the discharge port on the compressor. Carefully remove the protective cap, install a new O-ring, and connect the low pressure line to the suction port on the compressor. IMPORTANT: Use caution when removing cap as new compressors have internal pressure when shipped.

BS08A051

Install the drive belt (1) first, then the air conditioner belt (2). NOTE: A/C compressor belt tension: A. Tension for a new belt is 45 Kg (100 lb). B. Tension for a belt used more than 20 hours is 41 Kg (90 lb).

9004-8

STEP 14

BD07N600-01

BD07N573-01

Install the belt cover, install the four mounting bolts for the belt cover.

STEP 15 Charge the air conditioning system according to the instructions in Section 9003.

9004-9

EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS 3

2 1 8

18 17 12

16 15

BS06G118

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

EVAPORATOR UPPER BOX PPE COVER PPE SOLENOID DRIVER UPPER BOX BOLT

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

WASHER GROMMET HEATER CORE HEATER VALVE 24V THERMOSTAT LOWER BOX

13. 14. 15. 16. 17. 18.

LOWER BOX PPE EXPANSION VALVE BLOWER RECIRCULATING VAIN RECIRCULATING MOTOR RESISTOR BLOWER MOTOR

9004-10

Removal

STEP 22

STEP 16 Park the machine on a level surface and lower the bucket to the floor.

STEP 17 If changing any air conditioning components, discharge the air conditioning system according to the instructions in Section 9003.

STEP 18 BD06G212

Open the cover on the cooler.

STEP 23

BD02N160

If changing the heater core, put a container capable of holding 22.7 liter (6 gallon) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

STEP 19 Place the master disconnect in the OFF position.

BD06G213

Remove the four screws securing the air vent, remove the vent cover.

STEP 24

STEP 20 Disconnect the wiring harness from the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option).

STEP 21

BD06G214

Remove the three screws securing the cooler to the cab, remove the cooler.

STEP 25 Fold the rubber mat over to gain access to the upper box mounting bolts. BD06G202

Remove the four bolts that fasten the operatorâ&#x20AC;&#x2122;s seat to the upper box, remove the seat from the machine.

9004-11

STEP 26

STEP 29

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 27

STEP 30

BD06G216

Remove two screws, one on each side of the upper box, securing the upper box to the lower box.

BD06G218

STEP 28

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 31

NOTE: In step 29 and 32 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.

9004-12

STEP 32

STEP 35

BD06G219

Close the vain so the upper cover can be removed.

BD06G203

Disconnect the solenoid driver.

STEP 33 Remove the upper box up and rest it against the console.

STEP 36

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 34

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.

9004-13 NOTE: If replacing the heater control valve, heater core, air conditioning expansion valve, air conditioning evaporator core do steps 37 through 46, if replacing electrical components go to step 47.

STEP 39

STEP 37

BD06G206

Remove the thermostat probe and clamp from the evaporator core.

STEP 40 BD06G204

Remove the right side cab skirt.

STEP 38 2

BD06G237

Disconnect the electrical connectors from the thermostat control.

STEP 41 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.

9004-14

STEP 42

STEP 48

Pull the heater core and evaporator core from the lower box PPE.

STEP 43 Remove the expansion valve from the evaporator core.

STEP 44 Remove and discard the O-rings from the openings in the expansion valve.

STEP 45 Remove the screws from the heater core and remove the control valve.

STEP 46 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 49

STEP 47 1

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.

9004-15

Installation

STEP 52

STEP 50 1

1 3 3 2

BD06G207

BD06G209

1. FAN SPEED SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

Replace 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 53 Install new O-rings on the heater control valve.

STEP 51

STEP 54 Install the control valve, install and tighten the screws to the heater core.

STEP 55 Install new O-rings on the openings of the expansion valve.

STEP 56 Install the heater core and evaporator core into the lower box PPE. BD06G208

STEP 57

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.

9004-16

STEP 58

STEP 60 2

BD06G237

Connect the electrical connectors to the thermostat control.

STEP 59

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 61

BD06G206

Install the thermostat probe coil and clamp to the evaporator core â&#x20AC;&#x153;coldâ&#x20AC;? tube.

BD06G204

Install the right side cab skirt.

STEP 62

BD06G238

Install the upper PPE on the heater and air conditioning cores.

9004-17

STEP 63

STEP 66

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 64

STEP 67

BD06G239

Push the wiring harness into the preformed notches in the upper PPE.

BD06G241

STEP 65

Set the upper box into position on the heater and evaporator cores.

Place the air selector on the control panel to outside air.

STEP 68

BD06G216

Install two screws, one on each side of the upper box securing the upper box to the lower box.

9004-18

STEP 69

STEP 73

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 70

STEP 74

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 71

STEP 75

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 72 Install the remainder of the floor mat.

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).

9004-19

STEP 76

STEP 78

Connect the wiring connector to the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option).

Charge the air conditioning system according to the instructions in Section 9003.

STEP 77 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.

9004-20

CONDENSER AND RECIEVER DRIER Removal

STEP 84

STEP 79 Park the machine on a level surface and lower the bucket to the ground.

STEP 80 Place the master disconnect switch in the OFF position.

STEP 81 Discharge the air conditioning system according to the instructions in Section 9003. BS03A107

STEP 82

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 85

Install plugs in the hoses and caps on the fittings.

STEP 86

BD01D142

1. COVER

2. CONDENSER

Open the cover (1) to gain access to the condenser (2).

STEP 83 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.

9004-21

Installation

STEP 87

STEP 90 2

Put the condenser in position on the bracket.

STEP 91

BD06G211

Fasten identification tags on hoses (1) and trinary switch (2). Disconnect the hoses from the receiver drier. Located above the rear axle under the machine

STEP 88 Install plugs in the hoses and caps on the fittings.

BS03A109

STEP 89

Install the bolts that fasten the condenser to the bracket, pivot the condenser down and tighten the bolts.

Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket.

STEP 92

BS03A107

Pivot the condenser to gain access to the hoses.

STEP 93 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 94 Pivot the condenser down and close the cover.

9004-22

STEP 95

STEP 97 Charge the air conditioning system according to the instructions in Section 9003.

STEP 98 Place the master disconnect switch to the ON position.

BD06G211

Mount the receiver drier and bracket, install and tighten the mounting bolt.

STEP 96

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.

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 (Z-BAR AND LR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT (TC MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT (Z-BAR, TC, AND LR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER FRAME (Z-BAR AND LR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER FRAME (TC MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 4 6 8 10 10 12 13 13 15

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 (2) for the tooth point (1) out of the tooth shank (3), refer to the illustration on this page.

2. Remove the tooth point (1). 3. Install a new tooth point (1) on the tooth shank (3). 4. Install the retaining pin (2) into the tooth point (1) 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 (2) until the retaining pin (2) is even with the outside of the tooth shank (3).

3 1

Replacement of the Bucket Teeth

1. Loosen and remove the nuts (4), hardened washers (5), and bolts (6) from the bucket teeth.

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.

TOOTH POINT PIN TOOTH SHANK NUT M20X1.5 HARDENED WASHER

6. 7. 8. 9. 10.

BOLT PLOW M20X1.5 CUTTING EDGE BOLT M27X2 NUT M27X2 CORNER TOOTH

BUCKET TEETH ILLUSTRATION

9006-4

RETURN TO DIG ADJUSTMENT (Z-BAR AND LR MODELS) 2 1

3 6

4 BS01C083

1. TARGET MOUNTING BRACKET RETURN TO DIG 2. TILT CYLINDER 3. TARGET BAR

4. PROXIMITY SWITCH MOUNTING BRACKET 5. PROXIMITY SWITCH 6. PROXIMITY SWITCH GUARD

RETURN TO DIG ADJUSTMENT ILLUSTRATION Z-BAR AND LR MODELS

WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operators compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine. CM105

IMPORTANT: Before adjusting the return-to-dig, make sure that the target bar on the bucket linkage is not damaged and all mounting bolts are tight. 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. 2. Start the engine. 3. Raise the lift arms until they are approximately horizontal and fully dump the bucket. Lower the bucket until the bucket edge is on the ground. 4. Apply the parking brake and stop the engine. 5. 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.

6. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). Align the target bar (3) parallel to the tilt cylinder (2) and tighten bolts. 7. Loosen the bolts holding the proximity switch mounting bracket (4) to the tilt cylinder (2). Adjust the proximity switch (5) face parallel to the target bar surface and tighten bolts. 8. Adjust the proximity switch (5) out towards the target bar (3), until an air gap of 3.5 to 5.0 mm (1/8 to 3/16 inch) is obtained. Torque the jam nuts 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). 9. Start the engine, position the bucket flat on the ground and stop the engine. 10. 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. 11. Align the target bar (3) parallel to the tilt cylinder (2) and tighten the bolts. 12. Turn the ignition switch to the ON position (not the accessor y position). Do NOT star t the engine. 13. Place the bucket control lever in the full ROLLBACK position. The electromagnetic detent should hold the lever in this position.

9006-5 14. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). 15. 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). NOTE: When the proximity switch face is nearly uncovered, the switch will be activated and the control lever will return to the center position. 16. Check to make sure that the 3.5 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained between the target bar (3) and the proximity switch (5). 17. Make sure the proximity switch (5) and all mounting bolts are tight 18. Start the engine.

19. Place the detent switch in the ON position and place the return to travel/float detent switch to the return to TRAVEL position. 20. Raise the lift arms to approximately the horizontal position. Put the bucket in the fully dumped position. 21. 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). 22. Lower the lift arms and verify that the bucket is flat on the ground. 23. Stop the engine.

9006-6

RETURN TO DIG ADJUSTMENT (TC MODELS) 2

4 6

5 BS01C084

1. TILT CYLINDER (LEFT HAND SIDE) 2. PROXIMITY SWITCH MOUNTING BRACKET

3. TARGET MOUNTING BRACKET 4. PROXIMITY SWITCH GUARD

5. PROXIMITY SWITCH 6. TARGET BAR

RETURN TO DIG ADJUSTMENT ILLUSTRATION TC MODELS

IMPORTANT: Before adjusting the return-to-dig, make sure that the target bar on the bucket linkage is not damaged and all mounting bolts are tight. 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. 2. Start the machine. 3. Raise the lift arms until they are approximately horizontal and roll the bucket all the way back. Lower the bucket until the bucket is on the ground. 4. Apply the parking brake and stop the engine. 5. Loosen the bolts holding the target mounting bracket (3) to the tilt cylinder clevis. Align the target mounting bracket (3) parallel to the tilt cylinder (1) and tighten the bolts. Refer to the illustration on this page. 6. Loosen the bolts holding the target bar (6) to the target mounting bracket (3). Align the target bar (6) parallel to the tilt cylinder (1) and tighten the bolts.

7. Loosen the bolts holding the proximity switch mounting bracket (2) to the tilt cylinder (1). Position the proximity switch (5) face parallel to the target bar (6) and tighten the bolts. 8. Adjust the proximity switch (5) out towards the target bar (6) until an air gap of 3.5 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 (4). 9. Start the engine, position the bucket flat on the ground and stop the engine. 10. Loosen the bolts holding the target bar (6) to the target mounting bracket (3). Slide the target bar (6) away from the proximity switch (5) until the face of the proximity switch (5) is completely uncovered. 11. Align the target bar (6) parallel to the tilt cylinder (1) and tighten the bolts. 12. Turn the ignition switch to the ON position (not the accessor y position). Do NOT star t the engine. 13. Place the bucket control lever in the full ROLLBACK position. The electromagnetic detent should hold the lever in this position. 14. Loosen the bolts holding the target bar (6) to the target mounting bracket (3).

9006-7 15. Slide the target bar (6) slowly towards the proximity switch (5), until the bucket control lever returns to the center position. Tighten the bolts holding the target bar (6). NOTE: When the proximity switch face is nearly covered by the target bar, the switch will be activated and the control lever will return to the center position.

19. Place the detent switch in the ON position and set the return to travel/float detent switch to the return to travel position. 20. Raise the lift arms to approximately the horizontal position and put the bucket in the fully dumped position.

16. Check to make sure that the 3.5 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained between the target bar (6) and the proximity switch (5).

21. 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 (6) passes in front of the proximity switch (5).

17. Make sure the proximity switch (5) and all mounting bolts are tight

22. Lower the lift arms and verify that the bucket is flat on the ground.

18. Start the engine.

23. Stop the engine.

9006-8

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT (Z-BAR, TC, AND LR MODELS)

4 6

BS01C081

1. LIFT ARM 2. RETURN TO TRAVEL TARGET

3. FRONT CHASSIS (TOP LEFT HAND SIDE) 4. PROXIMITY SWITCH

5. HEIGHT CONTROL TARGET 6. TARGET MOUNTING PLATE

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR, TC AND LR MODELS

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 (4), 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 compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine. CM105

5. Position the return to travel target (2) opposite the proximity switch (4) and tighten it to the target mounting plate (6). 6. Adjust the proximity switch (4) out towards the return to travel target (2) until an air gap of 3.5 to 5.0 mm (1/8 to 3/16 inch) is obtained. 7. Lock the proximity switch (4) in this position with the jam nut. Torque the jam nut to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).

9006-9

2 A

6 B

BS01C082

2. RETURN TO TRAVEL TARGET

5. HEIGHT CONTROL TARGET

6. TARGET MOUNTING PLATE

MACHINE

APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT

W110B Z-BAR

57 mm (2.24 inches)

358 mm (14.10 inches)

54 mm (2.13 inches)

3302 mm (130.0 inches)

W110B TC

47 mm (1.85 inches)

438 mm (17.24 inches)

48 mm (1.89 inches)

3302 mm (130.0 inches)

W110B LR

59 mm (2.32 inches)

458 mm (18.03 inches)

52 mm (2.05 inches)

3500mm (137.8 inches)

TARGET ADJUSTMENT ILLUSTRATION Z-BAR, TC AND LR MODELS

8. Refer to the table and the illustration on this page. Position the height control target (5) on the target mounting plate (6) using the table above.

14. 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 (5) is positioned in its slot in the target mounting plate (6), the lower the lift arms will stop as they are raised.

15. Raise the lift arms to approximately the horizontal position. Place the loader control lever i n t h e r a i s e p o s i t i o n a n d ve r i f y t h a t t h e electromagnet holds it in that position until the height control target (5) passes in front of the proximity switch (4). Refer to the illustration on page 8.

9. Tighten the height control target (5). 10. Position the return to travel target (2) using the table above. 11. Tighten the return to travel target (2). NOTE: The higher the return to travel target (2) is positioned in its slot in the target mounting plate (6), the lower the lift arms will stop as they are lowered. 12. Check to make sure the proximity switch (4) and all of the mounting bolts are tight. Refer to the illustration on page 8. 13. Start the engine.

16. 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 (2) passes in front of the proximity switch (4). Refer to the illustration on page 8. 17. Repeat steps 8 through 16 until the desired heights are reached. 18. Lower the bucket to the ground and stop the engine.

9006-10

LOADER FRAME (Z-BAR AND LR MODELS) Remove 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.

17. Loosen and remove bolt (1), flat washer (2) and spacer (22) that fasten the pivot pin (3) to the front frame. 18. Raise the loader frame slightly. Use an acceptable driver and drive the pivot pin (3) out of the front frame. Do not lose the washers (4) and wipers (5) between the front frame and the loader frame (9).

3. Fasten a chain hoist to the cross member (23) of the loader frame (9), refer to the illustration on page 9. 4. Loosen and remove the bolt (19), flat washer (18), and spacer (20) that fasten the pivot pin (17) to the piston rod yoke of the right lift cylinder (21). 5. Use an acceptable driver and drive the pivot pin (17) out of the piston rod yoke of the right lift cylinder (21). 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 (6 or 21). 8. Raise the lift cylinder (6 or 21) slightly and remove the driver, lower cylinder and let it rest on the frame.

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 (6 or 21). 10. Connect the chain hoist to the bucket cylinder (8). 11. Loosen and remove the bolt (14), flat washer (13), and spacer (12) that fasten the pivot pin (11) for the piston rod eye of the bucket cylinder (8) to the bell crank (10). 12. Use an acceptable driver and drive the pivot pin (11) out of the piston rod eye of the bucket cylinder (8). 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 (9). 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 (9).

BD01G010

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 pivot pin (7). 22. Raise the loader frame (9) out of the front frame. Carefully move the machine out of the loader frame (9).

9006-11

2 1

8 13

9 10

15 15

21 20 15

19 17 18 16

BS01G022

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

BOLT WASHER PIVOT PIN WASHER WIPER LIFT CYLINDER

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

PIVOT PIN BUCKET CYLINDER LOADER FRAME BELL CRANK PIVOT PIN SPACER

13. 14. 15. 16. 17. 18.

WASHER BOLT PIVOT PIN DUMP LINK PIVOT PIN WASHER

LOADER FRAME - Z-BAR MODELS ILLUSTRATION

19. 20. 21. 22. 23.

BOLT SPACER LIFT CYLINDER SPACER CROSS MEMBER

9006-12

Install 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 11. 2. Move the machine into alignment with the loader frame (9). 3. Lower the loader frame (9) into alignment with the front frame. 4. Apply antiseize compound to the pivot pins (3 and 7) that fasten the loader frame (9) to the front frame. 5. Start the pivot pins (3 and 7) into the front frame. Install the washers (4) and new wipers (5) between the loader frame (9) and the front frame. 6. Install the pivot pins (3 and 7) all the way. 7. Install the bolt (1), washer (2) and spacer (22) that fasten the pivot pins (3 and 7). Torque the bolt to 325 to 373 Nm (240 to 275 pound feet). 8. Install the proximity switch and cover. Left-hand side of the machine only. 9. Disconnect the chain hoist from the loader frame (9). 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). 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 (10). Stop the engine. WARNING: Do not use your fingers to check the alignment of the cylinder rod. Personal injury can be the result. 48-88

17. Disconnect the chain hoist from the bucket cylinder (8). 18. Fasten the chain hoist to one of the lift cylinders (6 or 21). 19. Raise the piston rod yoke of the lift cylinder (6 or 21) so the piston rod yoke is aligned with the loader frame (9). 20. Install a driver in the piston rod yoke and the loader frame (9). 21. Repeat Steps 18, 19, and 20 for the other lift cylinder (6 or 21). 22. Disconnect the chain hoist from the lift cylinder (6 or 21). 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 (23) of the loader frame (9). 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 (6 or 21) with the loader frame (9). WARNING: Do not use your fingers to check the alignment of the cylinder rod. Personal injury can be the result. 48-88

27. Remove the driver and install the pivot pin (17). 28. Install the bolt (19), washer (18), and spacer(20) that fasten the pivot pin (17). Torque the bolt to 325 to 373 Nm (240 to 275 pound feet). 29. Repeat Steps 26, 27, and 28 for the other lift cylinder (6 or 21). Stop the engine. 30. Lubricate the pivot pins with molydisulfide grease. 31. Disconnect the chain hoist from the cross member (23) of the loader frame (9). 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.

15. Install the pivot pin (11) in the bell crank (10) and the piston rod eye of the bucket cylinder (8).

34. Slowly extend and retract the clam cylinders four times to remove air from the auxiliary circuit.

16. Install the bolt (14), washer (13), and spacer (12) that fasten the pivot pin (11). Torque the bolt to 325 to 373 Nm (240 to 275 pound feet).

35. Stop the engine, check the level of the oil in the reservoir, and check for leaks. Add oil to the reservoir as required.

9006-13

LOADER FRAME (TC MODELS) Remove 1. Remove all dirt and grease from the hose and tube connections for the bucket cylinders and clam cylinder, if equipped. 2. With the engine running at low idle, roll the bucket all the way forward and lower the loader frame until the bucket is on the floor. 3. Stop the engine and apply the parking brake. 4. Loosen the filler plug in the reservoir to release the air in the reservoir. 5. Loosen and remove the bolt (9), washer (10), and spacer (8) that fasten the pivot pin (7) to the piston rod yoke of the lift cylinder (11 or 15), refer to the illustration on page 14. 6. Use an acceptable driver and drive the pivot pin (7) out of the piston rod yoke of the lift cylinder (11 or 15). Do not remove the driver. 7. Repeat Steps 5 and 6 for the other lift cylinder (11 or 15). 8. Start the engine. Roll the bucket back and lower the bucket so that the bucket is flat on the floor. Fasten the chain hoist to a lift cylinder (11 or 15). 9. Raise the lift cylinder (11 or 15) slightly and remove the driver, lower the cylinder and let it rest on the frame. 10. Repeat Steps 8 and 9 for the other lift cylinder (11 or 15). 11. Stop the engine. 12. Move the bucket control lever to the ROLLBACK position and the lift control lever to the LOWER position to relieve any pressure in the circuits.

13. Disconnect the hoses to the bucket cylinders. Disconnect the hoses from the tubes at the bucket cylinders. 14. Install a cap on each hose and a plug in each tube. 15. If equipped, disconnect the clam hydraulic connections, the auxiliary hydraulic connections, and the coupler connections as necessary. Plug and cap lines as needed. 16. Disconnect the wiring harnesses. 17. Connect the chain hoist to the loader frame (6). 18. Loosen and remove the bolt (1), washer (2), and spacer (14) that fasten the loader frame (6), pivot pin (3) and anchor link (12) pivot pin (13) to the machine frame. 19. Raise the loader frame (6) slightly. Use an acceptable driver and drive both the pivot pins (3 and 13) from the loader frame (6) and anchor link (12). 20. Do not lose the washers (4) between the front frame and the loader frame (6). 21. If equipped, remove the proximity switch cover and the proximity switch from the left-hand side of the machine. 22. Repeat Steps 18 and 19 on the opposite side of the machine. 23. Raise the loader frame from the machine. Be sure all the necessary hydraulic lines, wiring etc. are properly disconnected. 24. Carefully move the machine out of the loader frame.

9006-14

5 2

6 12 17

11 10 9 8

BS01G021

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

BOLT (325 - 373 NM (240 - 275 LB-FT)) 7. PIVOT PIN WASHER 8. SPACER PIVOT PIN 9. BOLT WASHER 10. WASHER WIPER 11. LIFT CYLINDER LOADER FRAME 12. ANCHOR LINK

13. 14. 15. 16. 17.

PIVOT PIN SPACER LIFT CYLINDER (NOT SHOWN) LOADER LINKAGE BOLT (650 - 732 NM (480 - 540 LB-FT)) GUIDE LINK NUTS (240 - 305 NM (175 - 225 LB-FT))

LOADER FRAME - TC MODELS ILLUSTRATION

9006-15

Install 1. Apply antiseize compound to the inner bores and outer bores of the front frame. 2. Move the machine into alignment with the loader frame (6), refer to the illustration on page 14. 3. Lower the loader frame (6) into alignment with the machine frame. 4. Apply antiseize compound to the pivot pins (3) and (13) that fasten the loader frame (6) to the machine frame. 5. Start the loader frame pivot pin (3), washer (4) and wiper (5). 6. Install the loader frame pivot pin (3) and anchor link pivot pin (13) on one side of the machine. 7. Repeat Steps 5 and 6 for the opposite side of the machine. 8. Install the bolt (1), washer (2) and spacer (14) that secure the pivot pins (3 and 13) to the machine on each side of the machine. Torque the bolt to 325 to 373 Nm (240 to 275 pound feet). 9. Disconnect the chain hoist from the loader frame (6). 10. If the machine is equipped with auxiliary hy d r a u l i c s , c l a m hy d r a u l i c s , o r c o u p l e r hydraulics, remove the plugs from the tube fittings and the caps from the hoses and make the necessary connections.

16. Disconnect the chain hoist from the lift cylinder (11 or 15). 17. Start the engine. Raise the loader frame (6) and roll the bucket all the way forward. Lower the bucket to the floor. Stop the engine. 18. Fasten the chain hoist to the cross member of the loader frame (6). 19. Start the engine and run the engine at low idle. 20. 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 (11 or 15) with the loader frame (6). WARNING: Do not use your fingers to check the alignment of the cylinder rod. Personal injury can be the result. 48-88

21. Remove the driver and install the pivot pin (7). 22. Install the bolt (9), washer (10), and spacer (8) that fasten the pivot pin (7). Torque the bolt to 325 to 373 Nm (240 to 275 pound feet). 23. Repeat Steps 20, 21, and 22 for the other lift cylinder (11 or 15). Stop the engine. 24. Lubricate the pivot pins with molydisulfide grease. 25. Disconnect the chain hoist from the cross member of the loader frame (6). 26. Start the engine and run the engine at low idle.

11. Connect the hoses and tubing to the bucket cylinders.

27. Slowly extend and retract the cylinders four times to remove air from the hydraulic circuit.

12. Fasten the chain hoist to one of the lift cylinders (11 or 15).

28. If equipped with auxiliary hydraulics, slowly extend and retract the clam cylinders four times to remove air from the auxiliary circuit.

13. Raise the piston rod yoke of the lift cylinder (11 or 15) so the piston rod yoke is aligned with the loader frame (6). 14. Install a driver in the piston rod yoke and the loader frame (6). 15. Repeat Steps 12, 13, and 14 for the other lift cylinder (11 or 15).

29. Stop the engine, check the level of the oil in the reservoir, and check for oil leaks. Add oil to the reservoir as required.

9006-16

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

After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site operation: • The

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. 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.

•

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 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 47-27A parts catalog.

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 47-26 serial number plate. 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 47-25 ROPS.

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.

BD06J114-01

Remove skirting under each side and front of cab.

STEP 2

STEP 6

BD01F143-01

Put articulation lock in LOCKED position.

BD06G186-01

Remove the ducts from the machine.

STEP 3 Put battery disconnect switch in OFF position.

STEP 7

STEP 4

BD06G189-01

BD01F184-01

If machine is equipped with a heater, put a 25 liter (6.6 Gallon) 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

BD06G194-01

BD06G192-01

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 1

BD06G205-01

1. AIR CONDITIONING HOSES 2. HEATER HOSES

BD06H194-01

If machine is equipped with a heater, disconnect heater hoses (2). If machine is equipped with air conditioning discharge the air conditioning system, see section 9003, and disconnect the air conditioning hoses (1), cap and plug lines and fittings.

Unlatch and open the compartment door on the right hand side.

STEP 13

STEP 10

BD06F208-01

Open and remove the access panel.

W110R585

Disconnect throttle connector and the air duct.

9007-6

STEP 14

STEP 19

BD06F209-01

Remove the front access panel.

W110R586

Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment

STEP 15

STEP 20

BD06F210-01

Disconnect the electrical connectors for the remote control valve.

BD06G188-01

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. BD06G185-01

Remove hardware securing brake valve to cab floor. Let brake valve rest on the frame.

9007-7

STEP 22

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.

STEP 25

BD06J115-01

Remove the four bolts securing the cab cover, install lifting eyes in threaded holes at top of the cab.

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.

9007-8

1 2

BC06G031-01

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

BD06G188-01

Position floor mat.

STEP 33

BD01D388-01

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

BD06G192-01

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

W110R585

Connect throttle connector and mount air duct. BD06G185-01

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 1

BD06G186-01

BD06G205-01

1. AIR CONDITIONING HOSES 2. 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 (2), if machine is equipped with air conditioning, remove plugs from hoses and caps from fittings, connect air conditioning hoses (1), 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. BD06G189-01

At RH rear, bottom of cab, connect ground strap to rear chassis.

STEP 37

BD06G194-01

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

10 9

8 7

10 3

6 4

BS07D284

1. 2. 3. 4.

ORANGE BLACK YELLOW BLACK RED WHITE GREEN WHITE

5. ORANGE WHITE 6. YELLOW WHITE 7. PILOT PRESSURE HOSE

8. GREEN BLACK 9. RED BLACK 10. PILOT TANK HOSE

JOYSTICK AND 2 LEVER HOSE COLOR CODING

9007-12

1 2

2 3

6 7

7 1

6 8

5 5

6 2

4 8

3 7 2

BS07D283

1. 2. 3. 4. 5. 6. 7. 8.

YELLOW WHITE PILOT PRESSURE HOSE RED BLACK PILOT TANK HOSE ORANGE BLACK YELLOW BLACK GREEN BLACK RED WHITE

JOYSTICK AND 1 LEVER HOSE COLOR CODING

1. 2. 3. 4. 5. 6. 7. 8.

YELLOW WHITE PILOT PRESSURE HOSE RED BLACK PILOT TANK HOSE ORANGE BLACK YELLOW BLACK GREEN BLACK RED WHITE

3 LEVER HOSE COLOR CODING

9007-13

1 1

6 6

4 3

4 4 5

2 1

5 3

BS07D285

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

PILOT PRESSURE HOSE RED BLACK PILOT TANK HOSE ORANGE BLACK YELLOW BLACK GREEN BLACK

JOYSTICK HOSE COLOR CODING

BS08B057

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

PILOT TANK HOSE YELLOW BLACK PILOT PRESSURE HOSE RED BLACK GREEN BLACK ORANGE BLACK

2 LEVER HOSE COLOR CODING

9007-14

STEP 40

STEP 43

BD06F210-01

Connect the electrical connectors for the remote control valve.

STEP 41

BD06F208-01

Install and close the access panel.

STEP 44

BD06F209-01

Place the access panel into position, install and tighten the screw.

STEP 42

BD06H194-01

Close the right hand compartment door.

STEP 45

W110R586

Connect wiring harness connectors.

BD06J114-01

Install skirting under each side and front of cab.

9007-15

STEP 46

STEP 48 Put battery disconnect switch in ON position.

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.

If machine is equipped with a heater and coolant was drained, check that coolant drain cap is tight.

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 47

STEP 50

Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 22 liters (5.8 U.S. Gallons). Install radiator cap. Fill coolant reservoir up to FULL mark on reservoir.

Put articulation lock in OPERATING position.

BD01F184-01

9007-16

NOTES

Section 9010

9010

CAB GLASS INSTALLATION

9010-2

TABLE OF CONTENTS PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3

PREPARATION FOR GLASS REPLACEMENT 1. Remove all of the damaged glass section and the silicone sealant from the window frame 2. Remove all the adhesive from the window frame. 3. The window frame recesses must be free of oil and dust. Clean the frame with rubbing alcohol with a clean rag. Do not reuse the rag.

5. Clean the new glass section. Apply a 25 mm (1 inch) wide band of glass primer (349-110) to the black ceramic painted edges of the window. 6. When replacing a front window section, a silicone forming tool is needed, refer to Figure 2. Use the template and instructions provided to make the tool.

4. Apply a 25 mm (1 inch) wide band of metal primer (349-108) to the window recesses.

GLASS INSTALLATION NOTE: Once the adhesive is applied, the glass must be installed within 5 minutes. If the glass is not installed within the 5 minute period, the adhesive must be removed and applied again. 1. Apply a 10 mm (3/8 inch) diameter bead of adhesive (345-135) to the pr imed surface approximately 12 mm (1/2 inch) from edge. 2. The adhesive may be applied either to the primed glass or to the primed metal frame. DO NOT apply the adhesive to both the glass and the frame.

3. For front glass installations install a glass spacer 12 mm (1/2 inch) from each corner on bottom edge of each glass section, refer to Figure 3. 4. Install the glass. The glass edges must not contact the metal frame at any point. 5. For front glass installations position the glass to maintain a uniform 3 mm (1/8 inch) gap between front and front side glass sections.

NOTE: When replacing two or more sections of the front glass apply extra adhesive in corners, refer to Figure 3.

SILICONE SEALANT APPLICATION - FRONT WINDOWS 1. Clean the edges of the front center and front side windows. Use glass cleaning primer. 2. Apply masking tape to the inside edge of each glass section next to the gap. 3. Apply the polyester tape on top of the masking tape across the inside side gap. Do not push the tape into the gap. 4. Apply masking tape to the outside edge of each glass section. Align the edge of the tape with edge of glass on both sections. 5. The tape must be smooth to get the best result when using the silicone forming tool.

6. Fill the joint with the clear silicone sealant (114328A1), refer to Figure 1. The silicone must completely penetrate and fill the gap between the glass sections. The sealant must extend at least 1.5 mm (1/16 inch) above the outside surface of the glass section for the length of the gap. Be sure the sealant fills against the adhesive at each end of the joint. 7. Remove the polyester tape from the inside joint. 8. Remove the extra silicone from the outside joint by carefully sliding the forming tool down the length of the joint. The tool must remain in contact with the glass sections during this process. Refer to Figure 2 for for ming tool template.

9010-4

9. Remove all the silicone from the forming tool immediately after use.

10. Remove the outside tape from the glass sections. 11. Remove the extra silicone sealant from the inside joint by carefully sliding the forming tool down the length of the joint. 12. Remove all the silicone from the forming tool immediately after use.

13. Remove the inside joint masking tape.

4 498L93

1. FRONT RH SIDE GLASS 2. FRONT CENTER GLASS

3. SILICONE BEFORE SMOOTHING 4. SILICONE AFTER SMOOTHING

FIGURE 1. SILICONE APPLICATION

NOTE: Make the forming tool from 10 mm (3/8 inch) plexiglass, or wood. Sand all radius and edges smooth.

14. If two or more glass sections are being replaced, use the procedure on the second joint. 15. Apply the gray silicone sealant above the front center, front side or rear windows for additional leak protection. 16. Apply the gray silicone sealant (345-174) down approximately 50 mm (2 inches) from the top on each front side window replaced, refer to Figure 3. 17. Apply the gray silicone sealant (345-174) down approximately 50 mm (2 inches) from the top edge of the rear glass, if replaced.

6 MM (1/2 INCH) R

120Â°

4 MM (3/16 INCH) R

FIGURE 2. SILICONE FORMING TOOL TEMPLATE

496L93

9010-5

1 3 4

6 1

497L93

1. SIDE GLASS ADHESIVE 2. CENTER GLASS ADHESIVE

4. RIGHT HAND SIDE GLASS SPACER LOCATIONS 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES) FROM TOP OF FRONT SIDE GLASS 3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF CENTER AND SIDE PANELS CENTER GLASS FIGURE 3 SILICONE APPLICATION

NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set.

9010-6

NOTES

INDEX OF FUNCTIONS

SHT

ECD

SHT

SHEET

BACKUP ALARM

5 , 14

COLOR ABBREVIATIONS 70 62

SHT

LARGE CONNECTOR LIST SHEET

INDEX / WIRE INFORMATION SHEET

SHEET

CONNECTOR LIST

SHEET

20 5 9

_ 2

158 1 10

Relay in location F5/F6

160

Relay in location F3\F4 6

17 159

CONNECTOR LIST

COLD START

4 IGNITION SWITCH POWER DISTRIBUTION ELECTRICAL SCHEMATIC SIDE 1 W230C TIER 4 WHEEL LOADER Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84485612

92 90 CONNECT FOR NA OPERATION, OPP SIDE STEADY ON. DISCONNECT FOR EUROPEAN OPERATION, OPP SIDE OFF.

162 161

Relay in location F7\F8

Relay in location F1/F2

Relay in location F9\F10

78 CAN_L3 G-0.8 CAN_H3 Y-0.8

North American models European and International models 101

101

100

Turn Signal

163

Driving Lights

Light/ Horn

Horn

169

94 164

168

103 165

167 166

102

ENGINE CONTROL

LIGHTING 1

BACKUP ALARM

172

54 173

171

57 59

56 88

87 174

86 46

47 45

61 48 58 49 85 50 84 51

170

60 82

LIGHTING 2

TRANSMISSION CONTROLS ELECTRICAL SCHEMATIC W230C TIER 4 WHEEL LOADER

8 SIDE 2

Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84485612

35 36

33 64

72 37

75 69 73

76 40

41 42 44

INSTRUMENT CLUSTER

MACHINE CONTROLS

121 113 122

155

129

154

122 126

104

128

108

130

105 114

106

125

123

124 119

115 107

117

109 156

111

116 BLUE

BROWN

DOWN LIMIT SWITCH

112 113

UP LIMIT SWITCH

Note: Telematics for future models

127 157

110 NO COM

118

R S

HOOD LIFT

HVAC

R S

AIR SEAT

RADIO POWER/CONVERTER 12 ELECTRICAL SCHEMATIC W230C TIER 4 WHEEL LOADER

SIDE 3

Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84485612

145

144 143 146 184

177 175

147

8 148

185

176

179

153 150

149

152 151

178

181

182 180

183

JOYSTICK STEERING

186

STANDARD HVAC

COMPONENT NUMBERS

W230C 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

COMPONENT STARTING RELAY RESISTOR - 75 OHM ALTERNATOR CRANK CONTROL RELAY BATTERIES CRANK REQUEST RELAY MASTER DISCONNECT SW ITCH STARTER IGNITION SW ITCH NEUTRAL START RELAY POW ER RELAY MODULE A POW ER RELAY MODULE B POW ER RELAY MODULE C GRID HEATER RELAY GRID HEATER POW ER RELAY MODULE D W ATER SEPARATOR HEATER FUEL FILTER HEATER W ATER IN FUEL SENSOR THROTTLE POTENTIOMETER ENGINE CONTROLLER RETURN TO TRAVEL FLOAT SW ITCH HEIGHT CONTROL SW ITCH ELECTROMAGNETIC DETENTS RETURN TO DIG PROXIMITY SW ITCH PILOT CONTROL RELAY ECD-K3 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW RETURN TO DIG SW ITCH PIN ENGAGE SW ITCH (OPTION) PILOT PRESSURE SOLENOID PIN ENGAGE SOLENOID (OPTION) RIDE CONTROL SW ITCH (OPTION) RIDE CONTROL RELAY (OPTION) FAN CONTROL SW ITCH (OPTION) FAN REVERSE RELAY (OPTION) PILOT CONTROL SW ITCH RIDE CONTROL SOLENOID (OPTION) ROLLBACK PRESSURE SW (XT W ITH RIDE CONTROL ONLY) ROLLBACK JUMPER FAN PW M SOLENOID FAN REVERSE SOLENOID (OPTION) OUTPUT SPEED SENSOR TRANSMISSION SOLENOID VALVE AND TEMP SENDER FILTER MAINTENANCE SW ITCH

# SHT 61 8 62 1 63 9 64 9 65 9 66 9 67 9 68 9 69 9 70 1 71 1 72 9 73 9 74 9 75 9 76 9 78 6 79 6 80 7 81 7 82 7 83 7 84 7 85 7 86 7 87 7 88 7 89 7 90 6 91 6 92 6 93 6 94 6 95 6 96 6 97 6 98 10 99 10 100 6 101 6 102 6 103 6 104 11 105 11

COMPONENT DIAGNOSTIC CONNECTOR INSTRUMENT CLUSTER CONNECTOR 1 W ARNING BUZZER PARKING BRAKE RELAY FUEL LEVEL SENDER AIR FILTER RESTRICTION SW ITCH PARKING BRAKE SOLENOID RADIATOR COOLANT TEMPERATURE SENDER BRAKE PRESSURE W ARNING SW ITCH SW ITCH PAD INSTRUMENT CLUSTER CONNECTOR 2 HYDRAULIC FILTER RESTRICTION SW ITCH HYDRAULIC OIL TEMPERATURE SENDER PARK BRAKE SW ITCH REDUNDANT BRAKE PRESSURE SW ITCH 1 REDUNDANT BRAKE PRESSURE SW ITCH 2 BACKUP ALARM RELAY BACKUP ALARM DISABLE SW ITCH W ORK LAMPS SW ITCH DOOR SW ITCH ROTATING BEACON (OPTIONAL) DOME LAMP ROTATING BEACON SW ITCH (OPTIONAL) LEFT HAND FRONT W ORK LAMP RIGHT HAND FRONT W ORK LAMP LEFT HAND REAR W ORK LAMP RIGHT HAND REAR W ORK LAMP DIODES BRAKE LAMP SW ITCH BRAKE LAMP RELAY FLASHER MODULE HAZARD SW ITCH TURN SIGNAL, HIGH-LOW BEAM, AND HORN SW ITCH DRIVING LAMPS SW ITCH LEFT HAND FRONT COMBINATION LAMPS RIGHT HAND FRONT COMBINATION LAMPS HORN RELAY HORN RELAY RIGHT HAND REAR COMBINATION LAMPS LEFT HAND REAR COMBINATION LAMPS LICENSE PLATE LAMP BACKUP ALARM FRONT W IPER HIGH SPEED RELAY W IPER 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 W IPER LOW SPEED RELAY REAR W IPER AND W ASHER SW ITCH FRONT W IPER AND W ASHER SW ITCH FRONT W IPER MOTOR REAR W IPER MOTOR

164 165 166 167 168

5 5 5 5 5

TANK HEATER CONTROL VALVE DEF LEVEL AND TANK TEMPERATURE UPSTREAM TEMPERATURE SENSOR DOW NSTREAM TEMPERATURE SENSOR DOSER METERING VALVE

8 8 8 8 8 8 8 8

TRANSMISSION ELECTRONIC CONTROL MODULE TRANSMISSION ENABLE SW ITCH FNR SW ITCH FOR JOYSTICK CONTROLS TRANSMISSION KICK DOW N SW ITCH FNR SW ITCH FOR SINGLE AXIS CONTROLS TRANSMISSION AUTO SW ITCH BRAKE DECLUTCH PRESSURE SW ITCH DECLUTCH SW ITCH

111 112 113 114 115 116 117 118

11 11 11 11 11 11 11 11

REAR W ASHER MOTOR FRONT W ASHER MOTOR DIODES SECONDARY STEERING DIODES SECONDARY STEERING SOLENOID SECONDARY STEERING MODULE SECONDARY STEERING MOTOR SECONDARY STEERING PRESSURE SW ITCH

169 170 171 172 173 174 175 176

5 7 8 8 8 8 13 13

DNOX CONTROLLER REAR VIEW CAMERA/MONITOR DIFFERENTIAL LOCK SW ITCH (MANUAL) DIFFERENTIAL LOCK SW ITCH DIFFERENTIAL LOCK SOLENOID LOCKUP SOLENOID JOYSTICK PVRES TRANSMISSION KICK DOW N SW ITCH

# 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 POW ER CONVERTER - 24 TO 12 VOLT 12 VOLT POW ER OUTLETS (OPTION) RADIO RIGHT SPEAKER LEFT SPEAKER AIR SEAT CIGAR LIGHTER AIR CONDITIONING CLUTCH RELAY AIR CONDITIONING HIGH-LOW PRESSURE SW ITCH AIR CONDITIONING COMPRESSOR CLUTCH ELECTRONIC PANEL EXTERNAL AIR TEMPERATURE SENSOR INTERNAL AIR TEMPERATURE SENSOR SUN SENSOR BLOW ER FAN RESISTOR BLOW ER MOTORS THERMOCOUPLE SENSOR MIXED AIR SENSOR COMPRESSOR RELAY RECYCLING MOTOR ELECTRONIC W ATER VALVE 24 TO 12 VOLT CONVERTER ACTUATOR DRIVER ELECTRONIC W ATER VALVE BLOW ER FAN RESISTOR BLOW ER MOTOR THERMOSTAT FAN SPEED SW ITCH AIR CONDITIONING SW ITCH CONTROL PANEL LAMPS W ATER VALVE POTENTIOMETER AIR RECIRCULATING SW ITCH HOOD UP RELAY HOOD DOW N RELAY HOOD SW ITCH HOOD MOTOR IGNITION POW ER LATCH IGNITION POW ER CONTROL START LOCKOUT NOX SENSOR HUMIDITY AND AMBIENT TEMPERATURE SENSOR NOX SENSOR (NOXS)

# 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 SW ITCH (OPTION) FNR RELAY PILOT DUMP VALVE JSS VALVE LOAD SENSE PRESSURE SENSOR PILOT PRESSURE SW ITCH JSS RELAY JOYSTICK STR SW ITCH (OPTION) JSS CONTROLLER

COMPONENT NUMBERING INFORMATION ELECTRICAL SCHEMATIC W230C TIER 4 WHEEL LOADER

16 SIDE 4

Additional copies of this schematic can be ordered through Technical Publications Distribution System. Part # RAC 84485612

LOCK

280 BAR

13 b2 a3

b1 a2

YPB

OPTIONAL OPTIONAL AUXILIARYAUXILIARY

UNLOCK

YPP

CUT IN 157-167 BAR CUT OUT 190-196 BAR

YRC

b3 a4 B

T1'

ø2.0

889868

ø0.8

ø2.0

OPTIONAL AUXILIARY

889868

ø0.8

ø2.0

889868

ø0.8

A3 B3B4

)(

...... 40 bar

......

TP7: REAR BRAKE ACCUMULATOR

)(

45 bar

TP6: FRONT BRAKE ACCUMULATOR

0.6

0.7 L/min

TP10: FRONT BRAKE TO AXLE

)(

30 bar

TP11: REAR BRAKE TO AXLE

217 bar

227 bar

14 mm^2

0.8 )(

......

1.8

TP9: PILOT PRESSURE SUPPLY

YFR

BYPASS 3.4 BAR

ø0.8

889868

ø2.0

ø0.8

LS T

ø2.0

.71

DELTA = 24 BAR CUTOFF = 280 BAR

10 MICRON MEDIA

889868

5.5 BAR

ø0.8

ø2.0

FAN REVERSE OPTION

23cc

SLS

ORB-20 Orbitrol 983 CC PER REV

PVFC

0.7

YSS

STANDARD FAN CONTROL

234 BAR

936467

234 BAR

TANK

290 bar 290 bar

936467

23cc

162 BAR

936467

290 bar

YFN

936467

290 bar

936467

TP5: MAIN PUMP PRESSURE

290 bar 936467

857047 6.7 bar

TP1: STEERING PRESSURE

889868

TP3: LOAD SENSE SIGNAL

PSS

PHF WARNING SW 2.7 BAR

0.32 LITER 60 BAR PRECHARGE

240BAR

0.31

A10VO85 90 cc/rev L

.75

11cc

PVG 32 WITH PVES

PIL_PR 8 BAR SET POINT

1.4

JSSLSR

SIGNAL FROM JOYSTICK

100 MESH .03 BAR CHECK .35 BAR RELIEF

PRESSURE REDUCER

SIGNAL TO KEYPAD C5.E

PIL_DUMP T

65 LITER VENT CHECK

0.25 BAR

1. 2. 3. 4. 5.

CIRCUIT DIAGRAM LEGEND

SHOWS CIRCUIT CROSSING NOT CONNECTED

SHOWS CIRCUIT CONNECTED

RETURN / SUCTION

PUMP SUPPLY

CIRCUIT

LOAD SENSE PILOT

COMPONENT CHECK VALVE

RESTRICTOR

FILTER OR SCREEN

OIL COOLER

LINE TYPES

Rear Axle Brakes Front axle Brakes Parking Brake Brake Valve Parking Brake Accumulator 0.16 Liter (0.17 Quart) 96 BAR (1392 PSI) Precharge 6. Rear Brake Accumulator 3.5 Liter (3.69 Quart) 70 BAR (1015 PSI) Precharge 7. Redundant Accumulator Brake Pressure Switch

8. Low Brake Pressure Warning Switch 9. Brake Declutch 10. Brake Light Pressure Switch 11. Front Brake Accumulator 3.5 Liter (3.69 Quart) 70 BAR (1015 PSI) Precharge 12. Redundant Accumulator Brake Pressure Switch 13. Coupler Solenoid Locking Valve 14. Coupler Locking Cylinders 15. Pilot Control Valve 16. Bucket Cylinder Z BAR/XR Models 17. Lift Cylinders

18. Ride Control (Option) 19. Ride Control Accumulator 3.78 Liter (4 Quart) 14.5 BAR (210 PSI) Precharge 20. Pilot Control Accumulator 0.75 Liter (0.79 Quart) 13.8 BAR (200 PSI) Precharge 21. Loader Valve 22. Steering Cylinders 23. Steering Control Valve 24. Auxiliary Steering Control Valve (Option)

25. Auxiliary Steering Pump 26. Main Hydraulic Pump Cut Off 280 BAR (4061 PSI) Delta 21 BAR (304 PSI) 27. Brake Pump 28. 100 MESH Strainers (Reservoir) 29. Reservoir 30. Reservoir Vent 31. Filter 10 Micron Media Bypass 3.4 BAR (49.3 PSI) Warning Switch 2.7 BAR (39 PSI)

32. 33. 34. 35. 36.

Oil Cooler Thermal Valve Oil Cooler Oil Cooler Fan Fan Reversing and Variable Valve Steering Back Pressure Valve 8 - 10 BAR (116 - 145 PSI) 37. Steering Control Valve PVG 32 (Option) 38. LS Joystick Steering Valve (Option)

HYDRAULIC SCHEMATIC WHEEL LOADER T4 W230C Z-BAR / XR MODELS

YPP

LOCK

280 BAR

13 b2 a3

b1 a2 T

YPB

OPTIONAL OPTIONAL AUXILIARYAUXILIARY

UNLOCK

CUT IN 157-167 BAR CUT OUT 190-196 BAR

YRC

b3 a4 B

T1'

ø2.0

889868

ø0.8

ø2.0

OPTIONAL AUXILIARY

889868

ø0.8

ø2.0

889868

ø0.8

A3 B3B4

)(

...... 40 bar

......

TP7: REAR BRAKE ACCUMULATOR

)(

45 bar

TP6: FRONT BRAKE ACCUMULATOR

0.6

0.7 L/min

TP10: FRONT BRAKE TO AXLE

)(

30 bar

TP11: REAR BRAKE TO AXLE

217 bar

227 bar

14 mm^2

0.8 )(

......

1.8

TP9: PILOT PRESSURE SUPPLY

YFR

BYPASS 3.4 BAR

ø0.8

889868

ø2.0

ø0.8

LS T

ø2.0

.71

DELTA = 24 BAR CUTOFF = 280 BAR

10 MICRON MEDIA

889868

5.5 BAR

ø0.8

ø2.0

FAN REVERSE OPTION

23cc

SLS

ORB-20 Orbitrol 983 CC PER REV

PVFC

0.7

YSS

STANDARD FAN CONTROL

234 BAR

936467

234 BAR

TANK

290 bar 290 bar

936467

23cc

162 BAR

936467

290 bar

YFN

936467

290 bar

936467

TP5: MAIN PUMP PRESSURE

290 bar 936467

857047 6.7 bar

TP1: STEERING PRESSURE

889868

TP3: LOAD SENSE SIGNAL

PSS

PHF WARNING SW 2.7 BAR

0.32 LITER 60 BAR PRECHARGE

240BAR

0.31

A10VO85 90 cc/rev L

.75

11cc

PVG 32 WITH PVES

PIL_PR 8 BAR SET POINT

1.4

JSSLSR

SIGNAL FROM JOYSTICK

100 MESH .03 BAR CHECK .35 BAR RELIEF

PRESSURE REDUCER

SIGNAL TO KEYPAD C5.E

PIL_DUMP T

65 LITER VENT CHECK

0.25 BAR

1. 2. 3. 4. 5.

CIRCUIT DIAGRAM LEGEND

SHOWS CIRCUIT CROSSING NOT CONNECTED

SHOWS CIRCUIT CONNECTED

RETURN / SUCTION

PUMP SUPPLY

CIRCUIT

LOAD SENSE PILOT

COMPONENT CHECK VALVE

RESTRICTOR

FILTER OR SCREEN

OIL COOLER

LINE TYPES

32. 33. 34. 35. 36.

HYDRAULIC SCHEMATIC WHEEL LOADER T4 W230C / TC MODELS