New Holland W230C Wheel Loader Service Repair Manual (84489509) – NH W230C Wheel Loader

W230C Wheel Loader 84489509

Use for Service Manual

W230C Wheel Loader Service Manual 84489509

Table of Contents Description General

Section No. Tab 1

Section Index - General Standard Torque Specifications

1001

Fluids and Lubricants

1002

Metric Conversion Chart

1003 Tab 2

Engines Section Index - Engines Engine and Radiator Removal and Installation

2000

Stall Tests

2002

After Cooler

2003

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

Rear view Camera and Monitor

4006

Steering

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

Joystick Steering System (JSS) (Optional)

5009

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

84489509

W230C Wheel Loader Service Manual 84489509

Table of Contents Description Power Train

Section No. 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 Removal and Installation of Hydraulic Components

8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

Cleaning the Hydraulic System

8003

Hydraulic Pump

8004

Loader Control Valve

8005

Cylinders

8006

Coupler Solenoid Locking Valve

8007

Ride Control Accumulator

8013

Ride Control Valve

8014

W230C Wheel Loader Service Manual 84489509

Table of Contents Description Mounted Equipment

Section No. Tab 9

Section Index - Mounted Equipment Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant

9002

Air Conditioner System Service

9003

Removal and Installation of Air Conditioning and Heater Components

9004

Loader

9006

Rollover 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

84489509

In Rear Pocket

SECTION INDEX

GENERAL Section Title

Section Number

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

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

84489509

1001 Section 1001 GENERAL TORQUE SPECIFICATIONS

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

84489509

1001-2

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

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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

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NOTE: Use thick nuts with Grade 8 bolts.

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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

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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.

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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

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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

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1002

Section 1002 FLUIDS AND LUBRICANTS

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

84489509

1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CAPACITIES AND LUBRICANTS W230C CAPACITIES AND SPECIFICATIONS Engine Type of oil.................................................................................................. AMBRA Mastergold HSP SAE 15W-40 Capacity ........................................................................................................................................... 13 qt. (12.3 L) Capacity (with filter change) ............................................................................................................. 14 qt. (13.2 L) Cooling System System capacity ..........................................................................................................AMBRA AgriflÃ¹ 8 gal. (30 L) Fuel System Reservoir capacity............................................................................................................................76 gal. (288 L) Hydraulic / Brake System Type of fluid............................................................................................................... AMBRA Hydrosystem 46 HV Total system capacity.......................................................................................................................53 gal. (200 L) Reservoir capacity............................................................................................................................29 gal. (110 L) Transmission Type of oil............................................................................................................AMBRA Supergold SAE 10W-30 Refill capacity - with filter change .........................................................................................................9 gal. (34 L) Axles Type of oil................................................................................................................. AMBRA TRX Transaxle Fluid Front Capacity ..................................................................................................................................... 44 qt. (42 L) Rear Capacity ..................................................................................................................................... 42 qt. (40 L) Grease fittings, as required ...................................................................................................... AMBRA GR 75 MD Tank Urea (Ad blue)................................................................................... Fluid Diesel Exhaust (SPEC ES-B5001) Capacity .............................................................................................................................................16 gal. (60 L)

ENGINE OIL RECOMMENDATIONS New Holland AMBRA Engine oil is recommended for use in your New Holland engine. New Holland AMBRA Engine Oil will lubricate your engine correctly under all operating conditions.

See the chart below for recommended viscosity at ambient air temperature ranges.

If New Holland AMBRA Multi-Viscosity Oil is not available, use only oil meeting API engine oil service category CH-4 (preferred) or CG-4.

RH99K130

84489509

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

Issued 04-11

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1002-4

HYDRAULIC OIL TEMPERATURE CHART

BC06B208

TRANSMISSION OIL TEMPERATURE CHART

BC06B209

ENGINE OIL TEMPERATURE CHART

BC06B150

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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%

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1002-6

NOTES

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1003

Section 1003 METRIC CONVERSION CHART

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

84489509

1003-2

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

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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)

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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

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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 SERVICE MANUAL 84392403

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

84489509

Section 2000

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

84489509

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

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

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2000-3

ENGINE Removal

STEP 5

IMPORTANT: Mark all the various components, electrical connections and hydraulic hoses in order to FACILITATE CONNECTION WHEN REFITTING.

STEP 1

BD02N160

Put a 37 liter (10 gallon) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap. W230R406

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

STEP 6

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

BD02N160

Put a 14.2 liter (15 U.S. quarts) container below engine oil drain. Remove cap and drain oil into container. Install cap after oil has drained. NOTE: After draining oil disconnect drain hose from frame for removal with engine.

BD06F108

The master and hood raise switch are located in the right batter box. Raise the hood with the hood lift motor. Put master disconnect switch in OFF position. Remo ve both ba ttery covers an d disco nne ct batteries from the machine. 84489509

Issued 04-11

Printed in E.C.

2000-4

STEP 7

STEP 10

1 2

W230R001

BD06F109

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

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

STEP 8

STEP 11

1 BD03A230

BD03A227

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

STEP 9

W230R422

W230R408

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

Remove the pin from the top of the lifting motor.

84489509

Issued 04-11

Printed in E.C.

2000-5

STEP 12

STEP 15

W230R002

W230R411

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

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

STEP 16

STEP 13

W230R412 W230R409

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

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

STEP 17

STEP 14

W230R413 W230R410

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

84489509

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

Issued 04-11

Printed in E.C.

2000-6

STEP 18

STEP 21

BD06F111

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

W230R417

Remove the air cleaner from the bracket.

STEP 22

STEP 19

1 W230R646 W230R415

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

Loosen the clamp on the exhaust pipe (1).

STEP 23

STEP 20

W230R420

Remove the eight mounting bolts (four on each side), remove muffler from the brackets. W230R416

Loosen the exhaust clamp from the turbocharger.

84489509

Issued 04-11

Printed in E.C.

2000-7

STEP 24

STEP 26 2

W230R425

Remove the four mounting bolts (1, two on each side), remove the support muffler (2).

BD06F115

Remove the drive belt from the engine.

STEP 27

STEP 25

BD06F116 BD06F113

Loosen clamps and remove lower cooler hose from the engine.

STEP 28 1 2

BD06F114

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

84489509

BD06F117

If loader is equipped with air conditioning, identify, tag, and disconnect the engine wiring harness connectors from air compressor clutch connector (1). Remove the three mounting bolts (2) for the compressor and set the compressor on the left battery cover.

Issued 04-11

Printed in E.C.

2000-8

STEP 29

STEP 32

1 3

BD06F118

Tag and disconnect the wiring from the alternator.

STEP 30

BD06F121

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

STEP 33

BD06F119

Remove bolt securing wiring harness clamp to engine.

STEP 31 BD06F146

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

STEP 34 3 2 1 BD06F120

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

BD06F122

Remove the radiator hose (1) from the rear of the engine, remove the heater hose from the rear of the engine (2), remove the clamp bolts and clamps (3) from the bell housing. 84489509

Issued 04-11

Printed in E.C.

2000-9

STEP 35

STEP 38

W230R426

Tag and remove the grid heater cable (optional).

STEP 36

BD06F124

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

STEP 39

BD03A142

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

BD06F125

Remove bolt and clamp.

STEP 40

STEP 37

BD06F126 BD06F123

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

84489509

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.

Issued 04-11

Printed in E.C.

2000-10

STEP 41

BD06F127

Remove the lower cover for the drive shaft.

STEP 42

BD03A172

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

84489509

Issued 04-11

Printed in E.C.

2000-11

STEP 43 Connect suitable lifting equipment to engine lifting brackets. Take up all slack in lifting equipment. Remove the engine mounting bolts (1, q.ty 4) and lift the engine enough to gain access to the drain hose, pull the drain hose with the engine.

W230R442

STEP 44 Slowly raise engine from rear chassis. Be sure all harness connections and hoses have been disconnected and are clear of the engine. Remove engine from machine.

84489509

Issued 04-11

Printed in E.C.

2000-12

Installation

1 2

2 3

4 5 6

6 7

7 8

4 5 6 7 BS03B035

1. ENGINE MOUNT BOLT 2. WASHER

3. ISOLATOR UPPER 4. ISOLATOR LOWER

STEP 45

5. WASHER 6. WASHER

7. NUT 8. REMOTE OIL DRAIN HOSE

STEP 50

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

STEP 46 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.

STEP 47 Tighten engine mounting bolts to a torque of 244 to 298 Nm (180 to 220 lb-ft).

BD03A172

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

STEP 48 Disconnect lifting equipment from engine lifting brackets.

STEP 49 Connect engine oil drain hose to frame bracket.

84489509

Issued 04-11

Printed in E.C.

2000-13

STEP 51

STEP 54

BD06F127

Install the lower cover for the drive shaft.

BD06F124

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

STEP 52

STEP 55

BD06F126

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

BD06F123

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

STEP 56

STEP 53

BD03A142

Connect wiring harness to EDC 7 controller. BD06F125

Install bolt and clamp for fuel return hose.

84489509

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

Issued 04-11

Printed in E.C.

2000-14

STEP 57

STEP 60

1 2

W230R426

BD06F121

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

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

STEP 58

STEP 61 3

1 2 2

BD06F122

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

STEP 59

BD06F120

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

STEP 62

BD06F146

Connect the engine coolant vent hose.

BD06F119

Install bolt securing wiring harness clamp to engine.

84489509

Issued 04-11

Printed in E.C.

2000-15

STEP 63

STEP 66

BD06F118

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

BD06F115

Install the drive belt.

STEP 67

STEP 64 1 2

BD06F113 BD06F117

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

STEP 65

BD06F114

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

BD06F116

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

84489509

Issued 04-11

Printed in E.C.

2000-16

STEP 68

STEP 71 1

W230R427

W230R417

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

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

STEP 69

STEP 72

W230R420

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).

W230R416

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

STEP 73

STEP 70

1 W230R646

Tighten the clamp on the exhaust pipe (1).

84489509

W230R415

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

Issued 04-11

Printed in E.C.

2000-17

STEP 74

STEP 77

BD06F111

W230R411

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

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

STEP 75

STEP 78

W230R413

W230R410

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

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

STEP 76

STEP 79

W230R412

W230R409

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

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

84489509

Issued 04-11

Printed in E.C.

2000-18

STEP 80

STEP 82

W230R408

W230R002

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

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

STEP 83

STEP 81

BD06F109 BD03A227

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

W230R422

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

84489509

Issued 04-11

Printed in E.C.

2000-19

STEP 84

STEP 85

1 BD03A221

BD02N160

NOTE: If hood strut is not adjusted properly the hood will be damaged.

Check and make sure that drain caps are tight.

When a hood is removed and replaced an initial adjustment on the strut is necessary. Adjust between the top of the lift motor adjusting jam nut (1) to the top of the threads (2) to 20 mm (X). With the motor down to its lowest point take a measurement between the left hand side hood bumper and the counter weight, record this measurement (Y). Use the following table to adjust the strut (X).

STEP 86

Y X (MM) (MM)

84489509

STEP 87 If hydraulic reservoir was drained, fill reservoir with oil, see section 1002 for specifications.

STEP 88

Hood Adjustment Table Y X (MM) (MM)

Install a new oil filter on engine. Fill engine with oil, see section 1002 for specifications.

Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 36.9 liters (9.75 gallons). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

STEP 89 Connect the batteries, install battery covers, put master disconnect switch in ON position.

STEP 90 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 and water. When the coola nt is a t ope ratin g 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.

Issued 04-11

Printed in E.C.

2000-20

STEP 91

BD06F108

Lower the hood with the hood lift motor.

STEP 92 Put articulation lock in OPERATING position.

84489509

Issued 04-11

Printed in E.C.

2000-21

RADIATOR Removal

STEP 5

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

STEP 2

BD06F128

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

STEP 6 W230R406

Put articulation lock in LOCKED position.

STEP 3 Put master disconnect switch in OFF position.

STEP 4

BD02N160

Put a 30 liter (8 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.

STEP 7 BD03A120

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

BD03A109

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

84489509

Issued 04-11

Printed in E.C.

2000-22

STEP 8

STEP 11

1 2

BD03A108

BD03A106

Loosen the upper radiator hose clamps, remove the hose.

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

STEP 9

BD06F129

Loose and remove the lower radiator hose from the radiator.

STEP 10

BD03A113

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

84489509

Issued 04-11

Printed in E.C.

2000-23

Installation

STEP 15

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

STEP 13

1 BD06F129

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

STEP 16 BD03A106

Install four lock washers and bolts (2) to secure radiator to cooling frame. Disconnect lifting equipment from lifting eyes. Remove lifting eyes and install screws (1).

STEP 14

BD03A108

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

STEP 17

BD03A113

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

BD06F130

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

84489509

Issued 04-11

Printed in E.C.

2000-24

STEP 18

STEP 21

BD06F131

Align the whole in the fender on the bolt.

BD03A120

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

STEP 19

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

STEP 22

BD06F132

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

STEP 20 BD02N160

Check that coolant drain cap is tight.

STEP 23 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liter (8 gallon). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

DSC00105.TIF

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

84489509

Issued 04-11

Printed in E.C.

2000-25

STEP 24 Put master disconnect switch in ON position.

STEP 25 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol and water. Wh en the co ola nt is at opera ting temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir.

84489509

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

STEP 26 Put articulation lock in OPERATING position.

Issued 04-11

Printed in E.C.

2000-26

NOTES

84489509

Issued 04-11

Printed in E.C.

2002

Section 2002 STALL TEST

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

84489509

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 3 3 3 5 5 5 6 7 7 7 7 7 8 8

Printed in E.C.

2002-3

SPECIFICATIONS ENGINE W/4 Speed Trans. A. Idle RPM

870-930

Alternate Low Idle

570-630

Alternate Accelerated Idle

1170-1230

B. Maximum No Load RPM

2100-2150

C. Converter Stall

1900-1940

D. Hydraulic Stall

1860-1940

E. Converter & Hydraulic Stall

1525-1605

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

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

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.

Info

Engine RPM 1623 Speed KPH Fuel Lvl %

11.9 19

W230M208

3. 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.

BD06F188

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

84489509

Issued 04-11

Printed in E.C.

2002-4

Info Coolant

2 °C

Eng Oil °C OilPressBAR

85 3.2

W230M209

W230R438

4. 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.

7. 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.

Info

Transm.

°C

Hyd.Oil Tr.Sump

°C °C

33 39

W230M210

5. 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.

Info Voltage Air Turbo DefTemp

W230R439

8. 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.

4 V 24.2 °C 42 °C 32

W230R647

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

84489509

Issued 04-11

Printed in E.C.

2002-5

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.

4. Hold the bucket control lever in the ROLLBACK position and hold the lift control lever in the FLOAT position. 5. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).

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).

84489509

Issued 04-11

Printed in E.C.

2002-6

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

W230R440

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

W230R441

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.

84489509

Issued 04-11

Printed in E.C.

2002-7

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

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

5. Turn the transmission control lever to third gear.

7. Increase the engine speed to full throttle.

6. Increase the engine speed to full throttle.

8. Check the engine speed.

7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. The stall speed must be read while the lift arms are in motion.

9. Decrease the engine speed to low idle.

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.

10. Place the transmission in neutral and apply the parking brake. 11. 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 transmission. See Section 6002 for troubleshooting information. 3. If the engine speed was less than specified, do Test No. 3.

2. If the engine speed was not as specified, do Test No. 2 and 3.

84489509

Issued 04-11

Printed in E.C.

2002-8

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. The stall speed must be read while the lift arms are in motion. 5. Check the engine speed. 6. Release the bucket control lever.

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

7. Decrease the engine speed to low idle. 8. Lower the bucket to the ground. 9. Stop the engine.

84489509

Issued 04-11

Printed in E.C.

2003

Section 2003 AFTER COOLER

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

84489509

2003-2

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

84489509

Issued 04-11

3 4 4 6 6

Printed in E.C.

2003-3

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

STEP 2 Raise hood. Install 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.

W230R429

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

STEP 6

STEP 4

BD03A119 W230R428

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

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

STEP 7

STEP 5

BD03A109 BD03A115

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

84489509

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

Issued 04-11

Printed in E.C.

2003-4

AFTERCOOLER REMOVAL Removal

STEP 4

STEP 1

W230R429

Loosen clamps and remove air cooler outlet hose. W230R428

Loosen clamps and remove turbocharger outlet components.

STEP 5

STEP 2

BD03112

BD03A115

Loosen clamps and remove air cooler inlet hose.

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

STEP 6

STEP 3

BD03A111 BD03A119

Loosen clamps and remove Intake hose.

84489509

Remove three cover mounting bolts and lift cover off.

Issued 04-11

Printed in E.C.

2003-5

STEP 7

STEP 10

BD03A109

Unlatch air conditioning condenser clamp.

BD03A113

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

STEP 8

STEP 11 Lift air cooler and frame from machine with appropriate lifting devise.

STEP 12

BD03A107

Rotate air conditioning condenser up and remove the two retaining bolts, one on each side. Move the air conditioning condenser back away from the air cooler BD03A111

STEP 9

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

BD03A117

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

84489509

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Printed in E.C.

2003-6

Leak Test

Installation STEP 1

BD03A111 BS03B028

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

leakage

detected

replace

the

after

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

STEP 2

BD03A113

Install two side mounting bolts

STEP 3

BD03A117

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

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Printed in E.C.

2003-7

STEP 4

STEP 7

BD03A107

BD03A116

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

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

STEP 8

STEP 5

BD03A115 BD03112

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

Tighten clamps at air cooler inlet.

STEP 9

STEP 6

BD03A119

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

Install three cover mounting bolts.

84489509

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2003-8

STEP 10

STEP 11 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 12 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. confirm that the pressure difference is less than 60 Bar (0.87 psi).

W230R429

Tighten clamps at air cooler outlet.

84489509

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Printed in E.C.

SECTION INDEX

FUEL SYSTEM Section Title

Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL 84392403

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

84489509

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 Rear view Camera and Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4006

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

84489509

4001 Section 4001 REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR

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

84489509

4001-2

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

84489509

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3 3 4 5 5 6 8 8 8

Printed in E.C.

4001-3

STARTER Removal

STEP 4

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

STEP 2

BD06F135

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

BD06F133

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

STEP 3

BD06F134

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

84489509

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Printed in E.C.

4001-4

Installation

STEP 7

STEP 5

1 2

BD06F134

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

STEP 8 BC05G047

1. STUDS 2. NUTS

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

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

STEP 6

1 2 BD06F135

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

84489509

Issued 04-11

Printed in E.C.

4001-5

ALTERNATOR Removal

STEP 4

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

STEP 2

BD06F137

BD06F133

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

STEP 3

BD06F138

Remove four belt cover mounting bolts, remove cover.

STEP 5

BD06F136

Disconnect wires from the alternator.

BD06F139

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

84489509

Issued 04-11

Printed in E.C.

4001-6

Installation

STEP 6

STEP 7

BD06F140

Remove mounting bolts for alternator, remove alternator.

BD06F140

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

STEP 8

BD06F139

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

84489509

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Printed in E.C.

4001-7

STEP 9

STEP 10

BD06F137

BD06F136

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

STEP 11

BD06F138

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

BD06F133

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

84489509

Issued 04-11

Printed in E.C.

4001-8

BELT INSTALLATION

BC05G045

WITH OUT AIR CONDITIONING

BC05G046

WITH AIR CONDITIONING

84489509

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4002

Section 4002 ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

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

84489509

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84489509

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7 8 44 44 44 45 46 46 46 47 47 47 47 48 48 49 50 51 51 51 52 52 52 53 53 54 55 55 56 57 58 58 59 59 60 60 60 61 61 61 62 63 63 64 64 65 65 65 66 66 66 67 68

Printed in E.C.

4002-3 Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

84489509

Issued 04-11

Printed in E.C.

4002-4 LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 84489509

Issued 04-11

Printed in E.C.

4002-5 Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOOD RAISE AND LOWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

122 122 123 124 124 124 124 125 125 125 126 126 126 126 127 128 128 128 129 136

Printed in E.C.

4002-6

NOTES

84489509

Issued 04-11

Printed in E.C.

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 Trinary Pressure Switch (Closed With Normal System Pressure) Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi) Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi) Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi) Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi) Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi) Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 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) ...................................................................xx.x 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

84489509

Issued 04-11

Printed in E.C.

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

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

BK 0.8 GXL

DIA_2, Diagnostic

GND_CAB_SPL, CAB GRND SPLICE

OD_C DIAG2 GRND 0 29

RTT/Float Ground

Bk 0.8 GXL

SFL, Return To Travel Sw

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

0 AA

Proximity Switch Grnd

Bk 1.0 SXL

PXH, Height Control RTT

SPL-A2, Ultrasonic

0 AB

Proximity Switch Grnd

Bk 1.0 SXL

SPL-A2, Ultrasonic

GND-FC, Ground A

0 AC

Proximity Switch Grnd

Bk 1.0 SXL

PXF, RTD

SPL-A2, Ultrasonic

0 AD

Ride Control Ground

Bk 1.0 SXL

YRC, Ride Control Option

SPL-A1, Ultrasonic

0 AE

Pin Engage Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

YPE, Pin Engage 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

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

84489509

Issued 04-11

Printed in E.C.

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 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

0 B15 Back Light Ground

Bk 0.8 GXL

SBE, Beacon Switch

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

84489509

Issued 04-11

Printed in E.C.

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 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_BAU EVGT_2 GND

BK 1.0 SXL

Turbo, ENG DASH_Turbo

GND_ENG2, WIF, EDC

0 BA

Pedestal Gnd Strap

84489509

Issued 04-11

Printed in E.C.

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 0 BB

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

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_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

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

0 BX

Fuel Filter Heater Ground

Bk 2.0 SXL

FFH, Fuel Filter Heater

GND_ENG1, STRT, FFH, WAT_SEP_HTR

84489509

Issued 04-11

Printed in E.C.

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 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

0 DR

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

84489509

Issued 04-11

Printed in E.C.

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 DS

Roof Splice Grounds

0 DT

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

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

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

0 ET

Power Relat GND

BK 0.8 GXL

ECB, ELECT CNTR B

SPL_SD1

84489509

Connector

Issued 04-11

Cavity

Printed in E.C.

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

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 EU

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

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

AA3

GND_Cab_SPL2, SPL Back Light GD

Telematics GRND

BK 1.0 GXL

CABE2, Cab to ENG2 BULKHD

TEL, Telematics

84489509

Issued 04-11

Printed in E.C.

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

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

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

84489509

Issued 04-11

Printed in E.C.

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 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

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

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

Ignition Switch Pwr

84489509

Issued 04-11

Printed in E.C.

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

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

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

13M

18B

18C

18D

18E

18F

18F AN

84489509

Issued 04-11

AA4

AA3 3 AA4 2 AA6 2 AA5

Printed in E.C.

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 18F BN

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

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

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

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

EDC7 Time Delay Fused Power

84489509

Issued 04-11

AA8

Printed in E.C.

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

18K D Diagnostic Fused B+

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

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

TRANS, Cab Transmission

OSS, Out Speed Sensor

18N

19A

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

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

84489509

AA10

Issued 04-11

Printed in E.C.

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 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

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

19B

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

Or 1.0 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19J F

Front Wiper Relay LS Control Fused Power

19J G Wiper Cutout Relay Fused Pwr 19K

Rear Wiper Fused Pwr

19K A Rear Wiper Sw Fused Pwr 84489509

Issued 04-11

Printed in E.C.

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

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

19L

19M

19N

Seat Compressor Fused Pwr

Or 1.0 GXL

SC, Seat Compressor Motor

ECA, Elect Center A

19P

Pin Engage/Fan Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECA, Elect Center A

19P A Pin Engage Sw Fused Pwr

Or 0.8 GXL

SPE, Pin Engage Sw

SPL-PIN, Spl Back Lgt Pwr

19P C Fan Rev Sw Fused Pwr

Or 0.8 GXL

SFC, Fan Control Switch

SPL-PIN, Spl Back Lgt Pwr

19P D Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19P E Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19R

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

SPL-2 Ultrasonic

19RR

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

ECA, Elect Center A

19R A Sec. Steering Ign Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19R C Sec. Steering Ign Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19R D Alternator Resistor Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

216F, Alternator Resistor

19R E Sec. Steering Ign Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

CAB-T, Cab Transmission

19S1

Sec. Steering Fused Pwr

Or 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

84489509

Issued 04-11

Printed in E.C.

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

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 G Door Sw Fused Power

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U H Beacon Switch Fused Power

Or 1.0 GXL

SBE, Beacon Switch

SPL-LT, Ultrasonic

19U

19W

Cigar Lighter Pwr

Or 3.0 GXL

CL, Cigar Lighter

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

84489509

Issued 04-11

Printed in E.C.

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

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

1 GA

Filter Htr Pwr

R 3.0 SXL

PRM-D1, PRM Output

SPL-HTR, Ultrasonic

1 GB

Fuel Filter Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

FFH, Fuel Filter Heater

1 GC

Water Sep Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

WSH, Water Separator Heater

1 KA

Hazard Switch Pwr

R 1.0 GXL

SHZ, Hazard Switch

SPL-FLSHR-PWR, Ultrasonic

1 NA

Battery Crossover

R 62.0 SGR

BT3, Starter Battery

BT2, Disconnect Battery

1 NB

Battery Starter

R 62.0 SGR

BT1, Battery Starter

B3, Starter Battery

1 NC

B+ Power PRMC

R 19.0 SXL

B1, Starter Power Stud

P-C1, B+ Power From 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

84489509

Issued 04-11

Printed in E.C.

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

21C B Neutral Start Relay Output

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

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

21D

21E

21F

21G

21H

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

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

84489509

Issued 04-11

Printed in E.C.

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 24B

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 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

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

24L

Low Idle Sw

24L A Low Idle Switch 24R

24S

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

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K

25L

Trans Sol Valve Y2

84489509

Issued 04-11

Printed in E.C.

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 25L 9

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 Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25L A Trans Sol Valve Y2

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25M

Trans Sol Valve Y3

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25M A Trans Sol Valve Y3

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y4

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25N A Trans Sol Valve Y4

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y5

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25P A Trans Sol Valve Y5

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

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

25N

25P

25R

25S

25T

25Z

Reverse Signal

Neutral Signal

1st And 4th Gear Signal

84489509

Issued 04-11

Printed in E.C.

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

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

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

26J

FNR Switch Jumper

LU 0.8 GXL

SFNR, FNR Switch

26K

FNR Switch Jumper

LU 0.8 GXL

SAJ, FNR Switch

26N A FNR Neutral Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26N B FNR Neutral Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26N C FNR Neutral Signal

LU 0.8 GXL

JSS 197M, FNR-Main Cab

Ntrl Diode, Diode Assy

26N D FNR Neutral Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

Ntrl Diode, Diode Assy

26N E FNR Neutral Signal

LU 0.8 GXL

Ntrl Diode, Diode Assy

Cab FNR, Main Cab FNR

26N F FNR Neutral Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR-Main Cab

26R A FNR Reverse Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26R B FNR Reverse Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26R D FNR Reverse Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

RVS Diode, Diode Assy

26R E FNR Reverse Signal

LU 0.8 GXL

Cab FNR, Main Cab FNR

RVS Diode, Diode Assy

26R F FNR Reverse Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR-Main Cab

28F

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

84489509

Issued 04-11

Printed in E.C.

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

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 C Trans Enable Indiction

Y 0.8 GXL

STE, Trans Enable Switch

SPL-D16, Ultrasonic

32J D Trans Enable Indiction

Y 0.8 TXL

SPL-D16, Ultrasonic

TECM, Trans

32J E Trans Enable Indiction

Y 0.8 GXL

197F, Main Cab FNR

SPL-D16, Ultrasonic

32J F

Trans Enable Indiction

Y 0.8 GXL

SPL JSS_21, Ultrasonic

JSS 197M, FNR Main Cab

32J G Trans Enable Indiction

Y 0.8 GXL

JSS 197F, Main Cab FNR

SPL JSS_21, Ultrasonic

32J H Trans Enable Indiction

Y 0.8 GXL

Cab FNR, Main Cab FNR

SPL JSS_21, Ultrasonic

32J J

Trans Enable Indiction

Y 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR Main Cab

33P

Brake Warning Press Low

Y 1.0 SXL

BTM_C, Cab Bottom BULKHD

PBW, Brake Warning Press Sw

33P A Brake Warning Press Low

Y 0.8 TXL

Cab B, Cab BTM 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

34D

Diff Lock SW SIG

84489509

Issued 04-11

Printed in E.C.

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

35A D Backup Alarm Relay Out

Y 0.8 GXL

209M, Backup Alarm Dis Jump

SPL 35A, Ultrasonic

35A E Backup Alarm Relay Out

Y 0.8 SXL

209F, Backup Alarm Dis Jump

SPL-D8-C1, Ultrasonic

35A F Backup Alarm Relay Out

Y 0.8 SXL

Cabe2, Cab to ENG2 BULKHD

SPL-D8-C1, Ultrasonic

35A G Backup Alarm Relay Out

Y 0.8 SXL

ENG2, ENG BULKHD 2

E-HD, Trans Hood

Backup Alarm Relay Out

Y 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

35A H Backup Alarm Relay Out

Y 1.0 SXL

HD-E, Hood Trans

BU2, Backup Alarm

35A GN

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

P 1.0 SXL

TRANS, Cab Transmission

TCOT, TCO Sender

36C

36F

36G

Torque Conv Output Temp Signal

84489509

Issued 04-11

Printed in E.C.

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

36G A Torque Conv Output Temp Signal

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

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

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

36H

Hydraulic Oil Temp Signal

36H A Hydraulic Oil Temp 36J

36T

37E

Diagnostic Signal Switched

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

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

K 1.0 GXL

D-OR, Diode OR

SPL-D, Ultrasonic

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

41J

41T

Driving Light Power

Position Lights Switched Pwr

84489509

Issued 04-11

Printed in E.C.

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

42C F Front Work Lights Fused Pwr

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

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

DU 2.0 GXL

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

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

84489509

Issued 04-11

Printed in E.C.

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

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

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

44 A

Circuit

2.0 mm 5.0 mm

Brake Light Control Power

Connector

Cavity 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

Beacon Switched Power

K 1.0 GXL

CAB-RF, Cab to Roof Conn.

SBE, Beacon Switch

46 D

Beacon Switched Power

K 1.0 GXL

ROOF, Roof to Cab Conn.

LBEPWR, Light Beacon power

49A

Back Light Power

S 0.8 GXL

HVAC1, HVAC1

SPL-BCK-LGT, Spl Back Lgt Pwr

49S

Back Light Power

S 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 A

Back Light Power

S 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

84489509

Issued 04-11

Printed in E.C.

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

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

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

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

84489509

Issued 04-11

Printed in E.C.

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

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

51K C Pilot Press SW SIG

G 1.0 GXL

JSS PIL PR, JSS Pilot Pressure

JSS FRM, JSS Frame to Cab

Joystick Signal

Y 1.0 GXL

JSS Valve, JSS HYD Valve

JSS FRM, JSS Frame to Cab

51L A Joystick Signal

Y 0.8 GXL

JSS CNT, JSS Controller

CAB FRM, Cab to JSS Frame

51NC

BK 0.8 TXL

PVRES, JSS Joystick

CAN MOD 2, JSS CAN MOD

51L

NC Neutral SW

84489509

Issued 04-11

CS0

Printed in E.C.

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

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

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

Armrest Raise

BK 0.8 TXL

Arm Pos, Arm Position

CAN MOD 2, JSS CAN MOD

51S A JSS Okay Pwr

W 0.8 GXL

JSS Cnt, JSS Controller

SPL JSS 5, Ultrasonic

51S B JSS Okay Pwr

W 0.8 GXL

Cab Arm, Cab to Armrest

SPL JSS 5, Ultrasonic

51S C JSS Okay Pwr

W 0.8 GXL

SPL JSS 15, Ultrasonic

JSS Arm, JSS Armrest to Cab

51S D JSS Okay Pwr

BK 0.8 TXL

CAN MOD_2, JSS CAN MOD

SPL JSS 15, Ultrasonic

51S E JSS Okay Pwr

W 0.8 GXL

PVRES, JSS Joystick

SPL JSS 15, Ultrasonic

51R

84489509

Issued 04-11

Printed in E.C.

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

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

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

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

W 1.0 SXL

PXM, RTD

PXT, RTD

Pilot Control Relay Out

84489509

Issued 04-11

Printed in E.C.

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

53P J Pilot Control 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

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

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

84489509

Issued 04-11

Printed in E.C.

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 59U

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

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

60D

60U

61A

61C

61R

AC Press Sw Input

C10

63C

Front Wiper Park Control

W 0.8 GXL

FWM, Front Wiper Motor

ECD, Elect Center D

63C2

Front Wiper Park Control

W 0.8 GXL

ECD, Elect Center D

63C3

Front Wiper Park Control

W 0.8 GXL

K-WCO, Wiper Cutout

87a

ECD, Elect Center D

63HC

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

SPL-HC, Ultrasonic

63HC 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

84489509

Issued 04-11

Printed in E.C.

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

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

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

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

68L

84489509

Issued 04-11

Printed in E.C.

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

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

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

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

84489509

Issued 04-11

Printed in E.C.

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

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

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 HR

CAN HI,CAN MOD3

Y 0.8 GXL TWIST

SPL CAN JS H2, Ultrasonic

JSS Cab, JSS Cab

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

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 LL

CAN2 LO, EDC

G 0.8 GXL TWIST

Cab E, Cab-Engine

SPL CAN GL, Ultrasonic

84489509

Issued 04-11

Printed in E.C.

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 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 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

ECC L1

Beacon/Dome Light L1 ECC

BUSS

L1-ECC, ECC Batt Power

cs01

ECC, Elect Cntr C

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

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

84489509

Issued 04-11

L1-1

Printed in E.C.

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

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

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

84489509

Issued 04-11

Printed in E.C.

4002-44

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 Electrical Schematic posters (rear pocket) by item number using the key at the bottom of the posters.

84489509

Issued 04-11

Printed in E.C.

4002-45

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.

84489509

Issued 04-11

Printed in E.C.

4002-46

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.

84489509

Issued 04-11

Printed in E.C.

4002-47

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 and left rear sides of the machine. NOTE: See Section 4003 and check the batteries.

6 – Crank Request Relay Located in the cab access panel for fuses and relays. 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 right side battery box cover, remove battery box cover to gain access. Check Points

Correct Reading

Possible Cause of Bad Reading

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

Continuity

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

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

Open Circuit

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

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

84489509

Issued 04-11

Printed in E.C.

4002-48

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

84489509

Continuity

Bad ignition switch.

Issued 04-11

Printed in E.C.

4002-49

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.

84489509

Issued 04-11

Printed in E.C.

4002-50

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.

84489509

Issued 04-11

Printed in E.C.

4002-51

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, 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.

84489509

Issued 04-11

Printed in E.C.

4002-52

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

84489509

Issued 04-11

Printed in E.C.

4002-53

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.

84489509

Issued 04-11

Printed in E.C.

4002-54

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.

84489509

Issued 04-11

Printed in E.C.

4002-55

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. Correct Reading

Check Points

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. Open

Bad potentiometer.

1000 ± 400 ohms at 20° C (68° F)

Bad potentiometer.

1200 ± 400 ohms at 20° C (68° F)

Bad potentiometer.

Between pin 1 and 6 at pedal NOTE: Throttle pedal in high idle position. Between pin 1 and 6 at pedal NOTE: Throttle pedal in any position. Between pin 4 and 5 at pedal

84489509

Issued 04-11

Printed in E.C.

4002-56

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.

84489509

Issued 04-11

Printed in E.C.

4002-57

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.

84489509

Issued 04-11

Printed in E.C.

4002-58

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 travel/float switch in FLOAT position. Between switch terminals 1 and 2

connector Continuity

from

the

return-to-travel/float

switch.

Put

the

return-to-

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.

84489509

24 volts

Bad height control switch.

Issued 04-11

Printed in E.C.

4002-59

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. 84489509

Issued 04-11

Printed in E.C.

4002-60

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.

84489509

24 volts

Bad return to dig switch.

Issued 04-11

Printed in E.C.

4002-61

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.

84489509

Issued 04-11

Printed in E.C.

4002-62

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.

84489509

Issued 04-11

Printed in E.C.

4002-63

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.

84489509

Issued 04-11

Printed in E.C.

4002-64

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

84489509

24 volts

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

Issued 04-11

Printed in E.C.

4002-65

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

84489509

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

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

Issued 04-11

Printed in E.C.

4002-66

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

84489509

24 volts

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

Issued 04-11

Printed in E.C.

4002-67

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.

84489509

Issued 04-11

Printed in E.C.

4002-68 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

84489509

Issued 04-11

Printed in E.C.

4002-69

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.

84489509

Issued 04-11

Printed in E.C.

4002-70

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.

84489509

Issued 04-11

Printed in E.C.

4002-71

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

84489509

33 to 240 ohms

Bad fuel level sender.

Issued 04-11

Printed in E.C.

4002-72

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

84489509

Approximately 5 volts

Check the instrument cluster (62).

Issued 04-11

Printed in E.C.

4002-73

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

84489509

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.

Issued 04-11

Printed in E.C.

4002-74

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.

84489509

Issued 04-11

Printed in E.C.

4002-75

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

84489509

Continuity

Bad wire 17P-A.

Issued 04-11

Printed in E.C.

4002-76

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

84489509

24 volts

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

Issued 04-11

Printed in E.C.

4002-77 ]

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

84489509

Approximately 5 volts

Check the instrument cluster (62).

Issued 04-11

Printed in E.C.

4002-78

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

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

24 volts

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

24 volts

Bad parking brake switch.

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

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

24 volts

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

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

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

Correct Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground circuit.

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

Approximately 11.5 volts

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

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

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

Correct Reading

Possible Cause of Bad Reading

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

Continuity

Bad ground circuit.

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

Approximately 11.5 volts

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

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

84489509

Issued 04-11

Printed in E.C.

4002-79

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.

84489509

Issued 04-11

Printed in E.C.

4002-80

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

84489509

24 volts

Bad back-up alarm disable switch.

Issued 04-11

Printed in E.C.

4002-81

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.

84489509

Issued 04-11

Printed in E.C.

4002-82

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.

84489509

Issued 04-11

Printed in E.C.

4002-83

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

84489509

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.

Issued 04-11

Printed in E.C.

4002-84

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

84489509

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.

Issued 04-11

Printed in E.C.

4002-85

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.

84489509

Issued 04-11

Printed in E.C.

4002-86

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.

84489509

Issued 04-11

Printed in E.C.

4002-87

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.

84489509

Issued 04-11

Printed in E.C.

4002-88

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

84489509

Bad turn signal switch (94). Also check wire 45A-A. Bad flasher module.

Issued 04-11

Printed in E.C.

4002-89

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.

24 volts

Bad hazard switch. If hazard switch LED is not ON with 24 volts at check point, replace hazard switch.

NOTE: Put hazard switch in ON position. Terminal for wire 45H to ground

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

24 volts

Check fuse ECC-F6 and horn relay (98). Also check wires 64C and circuit 19U.

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

84489509

Continuity

Bad ground circuit.

Issued 04-11

Printed in E.C.

4002-90

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

84489509

24 volts

Bad driving lamp switch.

Issued 04-11

Printed in E.C.

4002-91

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.

84489509

Issued 04-11

Printed in E.C.

4002-92

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.

84489509

Issued 04-11

Printed in E.C.

4002-93

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.

84489509

Issued 04-11

Printed in E.C.

4002-94

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

Check the horn relay (98). Also check wires 64 and 64-A.

NOTE: If the readings are good replace the horn.

84489509

Issued 04-11

Printed in E.C.

4002-95

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.

84489509

Issued 04-11

Printed in E.C.

4002-96

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.

84489509

Issued 04-11

Printed in E.C.

4002-97

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.

84489509

Issued 04-11

Printed in E.C.

4002-98

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.

84489509

Issued 04-11

Printed in E.C.

4002-99

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

84489509

24 volts

Check fuse ECB-F8 and five driving lamp switch (95). Also check circuit 18G.

Issued 04-11

Printed in E.C.

4002-100

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.

84489509

Issued 04-11

Printed in E.C.

4002-101

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.

84489509

Issued 04-11

Printed in E.C.

4002-102

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

84489509

Continuity 0 volts

Bad front wiper and washer switch (108). Bad wiper cut out relay.

Issued 04-11

Printed in E.C.

4002-103

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

84489509

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.

Issued 04-11

Printed in E.C.

4002-104

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

84489509

24 volts

Bad front wiper and washer switch.

Issued 04-11

Printed in E.C.

4002-105

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.

84489509

Issued 04-11

Printed in E.C.

4002-106

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.

84489509

Issued 04-11

Printed in E.C.

4002-107

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.

84489509

Issued 04-11

Printed in E.C.

4002-108

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.

84489509

Issued 04-11

Printed in E.C.

4002-109

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

84489509

24 volts

Check secondary steering module (116) and secondary steering pressure switch (118).

Issued 04-11

Printed in E.C.

4002-110

116 â&#x20AC;&#x201C; Secondary Steering Module (Option) Located in the rear frame of the machine. Correct Reading

Check Points

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

84489509

24 volts

Bad secondary steering module.

Issued 04-11

Printed in E.C.

4002-111

117 â&#x20AC;&#x201C; Secondary Steering Motor (Option) Located in the rear frame of the machine. Correct Reading

Check Points

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. 24 volts

Terminal for red wire to ground

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.

24 volts

Terminal for wire 51-B to ground

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. Correct Reading

Check Points

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.

84489509

Issued 04-11

Printed in E.C.

4002-112

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.

84489509

Issued 04-11

Printed in E.C.

4002-113

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

84489509

Possible Cause of Bad Reading Bad ground circuit. Check fuse ECC-F9, check circuit 18K.

Issued 04-11

Printed in E.C.

4002-114

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.

84489509

Issued 04-11

Printed in E.C.

4002-115

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

84489509

12 volts

Check fuse ECB-F9, also check circuit 12V. Also check the remote radio power converter (121).

Issued 04-11

Printed in E.C.

4002-116

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.

84489509

Issued 04-11

Printed in E.C.

4002-117

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR 130

126

129 127

128 W230R636 / W230R637

126.AIR SEAT 127.CIGAR LIGHTER 128.AIR CONDITIONING CLUTCH REALY

129.HIGH/LOW SWITCH 130.AIR CONDITIONING COMPRESSOR CLUTCH

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

84489509

Issued 04-11

Printed in E.C.

4002-118

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

84489509

24 volts

Check wires 61R-B and 61R.

Issued 04-11

Printed in E.C.

4002-119

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

84489509

24 volts

Check the compressor clutch relay (128), also check circuit 61C.

Issued 04-11

Printed in E.C.

4002-120

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.

84489509

Issued 04-11

Printed in E.C.

4002-121

131 – Electronic Panel Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

132 – External Air Temperature Sensor Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

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: No information at time of print.

134 – Sun Sensor Check Points NOTE: No information at time of print.

135 – Blower Motor Resistor Check Points NOTE: No information at time of print.

136 – Blower Motors Check Points NOTE: No information at time of print.

137 – Thermocouple Sensor Check Points NOTE: No information at time of print.

138 – Mixed Air Sensor Check Points NOTE: No information at time of print. 84489509

Issued 04-11

Printed in E.C.

4002-122

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: No information at time of print.

140 – Recycling Motor Check Points NOTE: No information at time of print.

141 – Electronic Water Valve Check Points NOTE: No information at time of print.

142 – 24 to 12 Volt Converter Check Points NOTE: No information at time of print.

84489509

Issued 04-11

Printed in E.C.

4002-123

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.

84489509

Issued 04-11

Printed in E.C.

4002-124

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 Check Points

Correct Reading

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.

84489509

Issued 04-11

Printed in E.C.

4002-125

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. 24 volts

Terminal for wire DNS65 to ground

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 Correct Reading

Check Points

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

84489509

24 volts

Bad blower switch.

Issued 04-11

Printed in E.C.

4002-126

150 – Air Conditioning Switch Correct Reading

Check Points

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.

84489509

Continuity with switch on.

Bad recirculating switch.

Issued 04-11

Printed in E.C.

4002-127

HOOD RAISE AND LOWER SYSTEM

157 156

154 155 W230R642 / W230R643

154.HOOD UP RELAY 155.HOOD DOWN RELAY

156.HOOD SWITCH 157.HOOD MOTOR

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

84489509

Issued 04-11

Printed in E.C.

4002-128

154 – Hood Up Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-B25 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn the master disconnect switch ON. Terminal for wire 19Y-A

24 volts

Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the raise position. Terminal for wire 59U

24 volts

Bad hood switch (156), check wire 59U.

Terminal for wire 60U

24 volts

Bad hood up relay.

155 – Hood Down Relay Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-B16 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn the master disconnect switch ON. Terminal for wire 19Y-B

24 volts

Check fuse ECC-F7, check circuit 19Y.

NOTE: Hold the hood switch (156) in the lower position. Terminal for wire 59D

24 volts

Bad hood switch (156), check wire 59D.

Terminal for wire 60D

24 volts

Bad hood down relay.

156 – Hood Switch Located in the right battery compartment with the master disconnect switch. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector HD, turn the master disconnect ON. Terminal for wire 19Y-D to ground

24 volts

Check fuse ECC-F7, check circuit 19Y.

Hold the hood switch in the raise position, between pin C and B

Continuity

Bad hood switch.

Hold the hood switch in the lower position, between pin A and B

Continuity

Bad hood switch.

84489509

Issued 04-11

Printed in E.C.

4002-129

157 â&#x20AC;&#x201C; Hood Motor Located in the left side of the engine compartment. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (156) in the raise position. Terminal for wire 60U-A

24 volts

Bad hood up relay (154), bad hood switch (156), and check fuse ECC-F7.

NOTE: Hold the hood switch (156) in the lower position. Terminal for wire 60D-A

24 volts

Bad hood down relay (155), bad hood switch (156), and check fuse ECC-F7.

NOTE: If all readings are good replace the hood motor.

84489509

Issued 04-11

Printed in E.C.

4002-130

STARTING / IGNITION SYSTEMS

158 159 160 W230R608 / W230R644

158.IGNITION POWER LATCH 159.IGNITION POWER CONTROL

160.START LOCKOUT

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

84489509

Issued 04-11

Printed in E.C.

4002-131

158 – Ignition Power Latch Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-EW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL. Terminal for wire 13K to ground

24 volts

Check circuit 13K, check Ignition switch (10).

Terminal for wire 0-EA to 0-EU on Program relay module A (13)

Continuity

Bad wire or connector

Terminal for wire 0-ET to ground

Continuity

Bad ignition power latch relay or ignition power control relay (159).

159 – Ignition Power Control Located in the cab access panel for fuses and relays. Check Points Terminal for wire 0-KA to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL. Terminal for wire 13K-A to ground

24 volts

Terminal for wire 0-EY to ground

Continuity

Check circuit 13K, check ignition switch (10). Bad ignition power control relay.

160 – Start Lockout Located in the cab access panel for fuses and relays. Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Used with Telematics on future models.

84489509

Issued 04-11

Printed in E.C.

4002-132

JOYSTICK STEERING/ MISC

176

166 168 161

173

162 164 165 171 172 174

163 167 169 175 170 177 W230R648

161.REAR VIEW CAMERA / MONITOR 162.DIFFERENTIAL LOCK SWITCH (MANUAL) 163.DIFFERENTIAL LOCK SWITCH 164.DIFFERENTIAL LOCK SOLENOID 165.LOCKUP SOLENOID 166.JOYSTICK PVRES 167.TRANSMISSION KICK DOWN SWITCH 168.ARM POS 169.FNR SWITCH (OPTION)

170.FNR RELAY 171.PILOT DUMP VALVE 172.JSS VALVE 173.LOAD SENSE PRESSURE SENSOR 174.PILOT PRESSURE SWITCH 175.JSS RELAY 176.JOYSTICK STR SWITCH (OPTION) 177.JSS 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.

84489509

Issued 04-11

Printed in E.C.

4002-133

161 – Rear View Camera / Monitor Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: See Camera manual for details.

162 – 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.

163 – Differential Lock Switch Check Points

Correct Reading

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

164 – 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.

165 – 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. 84489509

Issued 04-11

Printed in E.C.

4002-134

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

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

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

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

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

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

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

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

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

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

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

84489509

Issued 04-11

Printed in E.C.

4002-135

177 â&#x20AC;&#x201C; JSS Controller NOTE: See service manual section 5009 for Joystick steering details.

84489509

Issued 04-11

Printed in E.C.

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

84489509

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

Issued 04-11

Printed in E.C.

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

84489509

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

Issued 04-11

Printed in E.C.

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

255E

PEDAL SESNOR +5V

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

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

84489509

WIRE IDENT

CAB PW, CAB POWER WIRE IDENT 1CB-A

CIRCUIT CAB CB PROTECTED PWR

Issued 04-11

Printed in E.C.

4002-139 CABE2, CAB TO ENG2 BULKHD

CAB ARM, CAB TO ARMREST

W230R398

CAV

WIRE IDENT

CIRCUIT

225389C1

CAV

WIRE IDENT

CIRCUIT

23B-D

NOT USED

CANS-HB

CAN HI, CAN MOD2

18U-C

NOT USED

0-SJ

GRND, CAN MOD

23B-B

NOT USED

51E-A

ARMREST LOWER

18U-A

NOT USED

17P-D

B+, CAN MOD

23B-A

NOT USED

51B-H

JSS ACT SW

0-L

TELEMATICS GRND

0-SD

GRND, JOYSTICK

18T

NOT USED

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

84489509

51PW-M

JSS POWER

51C-B

JSS ACT BTN

18S-D

B+, JSS FUSED

CANS-HB

CAN HI, CAN MOD2

Issued 04-11

Printed in E.C.

4002-140 CAB B, CAB BTM BULKHEAD

CAB E, CAB-ENGINE CAV

W230R396

CAV

WIRE IDENT

CIRCUIT

22D

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

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

NOT USED

0-DW

AIC POWER GND

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+

21E-B

KEY SWITCH CRANK

19B-B

TRANS ENA SW PWR

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

84489509

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 Issued 04-11

Printed in E.C.

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

84489509

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

Issued 04-11

Printed in E.C.

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

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

3227856R1

CAV

WIRE IDENT

CIRCUIT

19W

CIGAR LIGHTER FUSED POW

0-DV

CIGAR LIGHTER GROUND

84489509

Issued 04-11

Printed in E.C.

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

CIRCUIT SEC. STEERING IGNITION FUSED PWR NOT USED

19R

SEC. STEERING IGNITION FUSED PWR

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

NOT USED

84489509

Issued 04-11

Printed in E.C.

4002-144 CONNECTOR DS - DOOR SWITCH

245482C1

CAV

WIRE IDENT

CIRCUIT

19U-F

DOOR SWITCH FUSED POWER

43S-B

DOOR OPEN SIGNAL

DTS, DOWNSTREAM TEMP SENS CAV

WIRE IDENT

CIRCUIT

38E

EXHT TEMP DWN B+

0-U

EXHT TEMP DWN GND

CONNECTOR D-OR - DIODE OR

245485C1

CAV

WIRE IDENT

CIRCUIT

42C-D

FRONT WORK LIGHTS FUSED POWER

41T-C

POSITION LIGHTS SWITCHED POWER

BACK LIGHT POWER

84489509

Issued 04-11

Printed in E.C.

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

NOT USED

CAN-HS

NOT USED

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

84489509

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

Issued 04-11

Printed in E.C.

4002-146 ENG B, CAB BOTTOM

ENG, ENGINE CAB1 CAV

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

84489509

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

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

NOT USED

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

Issued 04-11

Printed in E.C.

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

NOT USED

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

84489509

CAV

WIRE IDENT

CIRCUIT

PLTEM DTNTS PRK BRK SOL

PRK BRK SOL HRN

FAN RVSR TURN SGNL

TURN SGNL ENG SHTDWN.

J10

NOT USED

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

Issued 04-11

Printed in E.C.

4002-148 ECB, ELECT CNTR B

87312843

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-EF

BRK LTS RLY CTRL GND

63C3

FNT WPR PARK CTRL

1-DW

BRAKE LT RLY BAT PWR

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

NOT USED

23B-A

NOT USED

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

AA5

21D-A

STRTR RLY SIGNAL

FNT WPR RLY LS CTRL FSD PWR

AA6

21G

EDC7 CRANK CTRL RLY

63C2

FNT WPR PARK CTRL

AA7

23B-B

NOT USED

19C-C

PILOT CTRL RLY FSD PWR

AA8

23B-D

NOT USED

53P-C

PILOT CTRL RLY OUT

AA9

35A-A

BACKUP ALARM

58H-C

POWER

AA10

19A-P

BACKUP ALARM RELAY

58-E

RIDE CTRL SOL PWR

19J-E

FNT WPR RLY FSD PWR

61R-B

AC RELAY CONTROL

63HC-B

FNT WPR RLY HS

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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

41H-C

HIGH BEAM RH PWR

CRANK REQUEST RLY CTRL GND

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

84489509

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

Issued 04-11

Printed in E.C.

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

NOT USED

18U-D

NOT USED

23A-A

NOT USED

18U-B

NOT USED

23B-E

NOT USED

0-LA

NOT USED

0-LD

NOT USED

18T-A

NOT USED

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

84489509

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

Issued 04-11

Printed in E.C.

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

WIRE IDENT

CIRCUIT

32F

TRANS FILTER MAINT SW

36R-B

TRANS FM SWITCH RETURN

182069A1

CAV

WIRE IDENT

CIRCUIT

1-GB

FUEL FILTER HEATER PWR

0-BX

FUEL FILTER HEATER GROUND

84489509

Issued 04-11

Printed in E.C.

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

26F-D

FNR FORWARD SIGNAL

26F-E

FNR FORWARD SIGNAL

26F-C

FNR FORWARD SIGNAL

84489509

245480C1

CAV 1

WIRE IDENT 0-B8

CIRCUIT FRONT WIPER GROUND

Issued 04-11

Printed in E.C.

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

84489509

WIRE IDENT 1-E

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

0-ED

HVAC GNDS

0-EJ

POWER CONVERTER GND

0-ER

POWER CONVERTER GND

GRID HTR FUSE BAT PWR

Issued 04-11

Printed in E.C.

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

NOT USED

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

84489509

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

NOT USED

Issued 04-11

Printed in E.C.

4002-156 GND ENG3 , SPLC PK, WSHR MTR CAV

WIRE IDENT

CIRCUIT

0-BM

ENGINE SPLICE GNDS

0-BBR

GROUND

GND PDST , GROUND A 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 84489509

WIRE IDENT 0-AV

CIRCUIT

GND JSS , GROUND A

WIRE IDENT

WIRE IDENT 0-BAR

CIRCUIT WIF BODY GRND

CIRCUIT GRND Issued 04-11

Printed in E.C.

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

84489509

WIRE IDENT

CIRCUIT

36H

HYDR. OIL TEMP SIGNAL

0-HW

HYDR. OIL TEMP GROUND

Issued 04-11

Printed in E.C.

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

18N-A

BLOWER MOTOR FUSED PWR

49A

BACK LIGHT POWER

61B-A

AC SIGNAL

CAV

WIRE IDENT

CIRCUIT

25B

INT SPEED SIGNAL

0-HG

INT SPEED SENSOR GROUND

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

84489509

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

Issued 04-11

Printed in E.C.

4002-159 JSS FRAME TO CAB

JSS 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

84489509

WIRE IDENT

CIRCUIT

JSS PILOT PRESSURE

245483C1

CAV

WIRE IDENT

CIRCUIT

18S-E

B+, JSS FUSED

51K-C

PILOT PRESS SW SIG

Issued 04-11

Printed in E.C.

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 FNR FORWARD SIGNAL

51PW-P

JSS POWER

26F-C

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

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

84489509

239451A1

CIRCUIT CAV

WIRE IDENT

CIRCUIT

51L

JOYSTICK SIGNAL

51J-C

JSS ALARM

0-AT

GRND, JSS VLV

51S-J

JSS OKAY PWR

Issued 04-11

Printed in E.C.

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

245483C1

LDM3, DOME LIGHT GND CAV CAV 1

84489509

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

Issued 04-11

Printed in E.C.

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

84489509

245483C1

CAV

WIRE IDENT

CIRCUIT

42R-K

RH FRONT WORK LAMP FUSED PWR

0-MP

RH FRNT WORK LAMP GRND

Issued 04-11

Printed in E.C.

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

84489509

WIRE IDENT

CIRCUIT

65L

LEFT SPEAKER SIGNAL

0-PA

LEFT SPEAKER GROUND Issued 04-11

Printed in E.C.

4002-164 NTRL DIODE, DIODE ASSY

CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

245485C1

CAV

WIRE IDENT

CIRCUIT

26N-D

FNR NEUT SIGNAL

26N-E

FNR NEUT SIGNAL

26N-C

FNR NEUT SIGNAL

291718A1

CAV

CONNECTOR OSS - OUTPUT SPEED SENSOR

WIRE IDENT

CIRCUIT

31F

AIR FILTER RESTRICTION SWITCH SIGNAL

0-BY

AIR FILTER RESTRICTION SWITCH GRND

P A1, B+ POWER CAV 1

WIRE IDENT 1-C

CIRCUIT ECC BAT PWR

P A3, B+ POWER 291719A1

CAV

WIRE IDENT

CIRCUIT

0-HE

OUTPUT SPEED GROUND

25D

OUTPUT SPEED SIGNAL

19A

OUTPUT SPEED FUSED PWR

CAV 1

WIRE IDENT 1CB-A

CIRCUIT CAB CB PROTECTED PWR

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

245482C1

CAV

84489509

WIRE IDENT

CIRCUIT

19A-A

BRAKE DECLUTCH SW FUSED PWR

25G

BRAKE DECLUTCH SWITCH CONTROL

Issued 04-11

Printed in E.C.

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

1-AA

BRAKE LAMP SWITCH PWR

BRAKE LAMP CONTR PWR

CIRCUIT STRTR RLY BAT PWR

CAV 1

WIRE IDENT 31H

CIRCUIT HYD FLTR REST SW SGNL

CONNECTOR PO1 - POWER OUTLET

CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH

225316C1

CAV

WIRE IDENT

12176446

CIRCUIT

33P

LOW BRAKE PRESS WARNING

0-AL

BRAKE PRESS WARN SW GROUND

CAV A

WIRE IDENT 12V

B C

CIRCUIT 12V PWR TO OUTLET 1 NOT USED

0-EK

AUX POWER OUTLET 1 GND

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

84489509

WIRE IDENT 1-E

CIRCUIT GRID HTR FUSE BAT PWR

Issued 04-11

Printed in E.C.

4002-166 CONNECTOR PO2 - POWER OUTLET

CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

245483C1

CAV 12176446

CAV A

WIRE IDENT 12V-A

CIRCUIT 12V PWR TO OUTLET 2

WIRE IDENT

CIRCUIT

33R-B

RDNT BRAKE ACCUMULATOR PRESS LOW

0-HL

RED BRAKE SW GROUND

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

CIRCUIT

19S1

SEC STR FSD PWR

19L

PWR CONVERTER FSD PWR

33R-C

RDNT BRAKE ACCUMULATOR PRESS LOW

0-HM

GROUND - TRANS

84489509

CAV

CIRCUIT

Issued 04-11

Printed in E.C.

4002-167 CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

PRM A2, PRM SIGNAL CAV

WIRE IDENT

CIRCUIT

12ACC-C

PWR CONVERTER PRM CTRL PWR

0-EU

PWR CONVERTER RLY CTRL GND

CONNECTOR PRM-B1 - PRM SIGNAL 245485C1

CAV

WIRE IDENT

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 A

84489509

WIRE IDENT

CIRCUIT

54B

RTT SIGNAL

0-AA

PROXIMITY SWITCH GROUND

53P-J

PILOT CONTROL RELAY OUT Issued 04-11

Printed in E.C.

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

CIRCUIT NOT USED

NOT USED

84489509

WIRE IDENT

RAD3

12V FUSED PWR TO RADIO

NOT USED

RAD2

12V FUSED PWR TO RADIO

RAD1

RADIO GROUND

Issued 04-11

Printed in E.C.

4002-169 CONNECTOR RAD-J2 - SPEAKER

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

194788A1

CAV 292501A1

CAV

WIRE IDENT

CIRCUIT

RAD11

RIGHT SPEAKER

RAD10

RIGHT SPEAKER GROUND

RAD9

NOT USED

RAD8

NOT USED

RAD7

NOT USED

RAD6

NOT USED

RAD5

LEFT SPEAKER

RAD4

LEFT SPEAKER GROUND

CIRCUIT

36C

RADIATOR COOLANT TEMP SIGNAL

0-BAE

EDC7 SENDER GROUND

RFL, FUEL SENDER CAV 1

WIRE IDENT 36F

CIRCUIT FUEL LEVEL ANALOG

RFLG, FUEL SEND GRND CAV

CONNECTOR RAD-J3 - RADIO JUMPER

WIRE IDENT

WIRE IDENT 0-BU

CIRCUIT FUEL LEVEL SENDER GND

411311A1

CAV

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

12 13

NOT USED

84489509

Issued 04-11

Printed in E.C.

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

84489509

CIRCUIT NOT USED

68L-A

REAR WIPER SWITCH PWR

19K-D

REAR WIPER MOTR FUS PWR

68C-A

REAR WIPER PARK CONTROL

Issued 04-11

Printed in E.C.

4002-171 CONNECTOR RWMG - REAR WIPER MOTOR GROUND

CONNECTOR SBE - BEACON SWITCH

382391A1 245480C1

CAV

WIRE IDENT

0-MA

CIRCUIT REAR WIPER MOTOR GRND

CONNECTOR RWW - REAR WASHER

CAV

WIRE IDENT

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

84489509

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

NOT USED Issued 04-11

Printed in E.C.

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

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

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

84489509

Issued 04-11

Printed in E.C.

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

49-Q

BACK LIGHT POWER

NOT USED

FNR SWITCH FUSED 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

84489509

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

FRONT WASHER PUMP

49-T

BACK LIGHT POWER

63HC

FRONT WIPER HS RELAY CONTROL

NOT USED Issued 04-11

Printed in E.C.

4002-174 CONNECTOR SHC - HEIGHT CONTROL SWITCH

SJS, JOYSTICK CONTROL SW CAV

382391A1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

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

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

CIRCUIT TIME DELAY/IGN SW FSD PWR

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

84489509

0-b24 49-D

RTT/FLOAT GROUND BACK LIGHT POWER

Issued 04-11

Printed in E.C.

4002-175 CONNECTOR SPC - PILOT CONTROL SWITCH

CONNECTOR SPK - SPEAKER

382391A1

CAV

WIRE IDENT

292494A1

CIRCUIT NOT USED

CAV

65R

WIRE IDENT

RIGHT SPEAKER

CIRCUIT

0-PB

RIGHT SPEAKER GROUND

19C-F

PILOT CONTROL SW FUSED PWR

31L

PILOT CONTROL SW HIGH

NOT USED

NOT USED NOT USED

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

57-B

19P-A

CIRCUIT PIN ENGAGE SOL PWR PIN ENGAGE SW FUS PWR

NOT USED

0-B5

BACK LIGHT GROUND

49-F

BACK LIGHT POWER

84489509

Issued 04-11

Printed in E.C.

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

WIRE IDENT

CIRCUIT

87324393

CAV

WIRE IDENT

CIRCUIT

0-B31

SDA GROUND

0-B2

BACK LIGHT GND

0-B3

BACK LIGHT GND

84489509

Issued 04-11

Printed in E.C.

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

84489509

NOT USED

Issued 04-11

Printed in E.C.

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 A WIRE IDENT

BEACON LIGHT GND

0-MB

DOME LIGHT GND

0-MA

REAR WIPER MOTOR GND

BACK LIGHT POWER

0-MN

ROOF GROUNDS

0-MK

ROOF GROUNDS

CIRCUIT

49-E

49-J

BACK LIGHT POWER

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

84489509

0-MC

CIRCUIT

87324462

CAV

WIRE IDENT

Issued 04-11

Printed in E.C.

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

84489509

WIRE IDENT

CIRCUIT

21D

STARTER RELAY SIGNAL

0-GB

STARTER RELAY CONTROL GROUND

Issued 04-11

Printed in E.C.

4002-180 CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CAV 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

WIRE IDENT

CIRCUIT

68C

REAR WIPER PARK CONTROL

68L

REAR WIPER SW PWR

19K-A

REAR WIPER SW FUSED PWR

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

0-CH

SEC STR FLYBACK GND

0-CG

SEC STR FLYBACK GND

51-D

SEC STR FLYBACK

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

84489509

WIRE IDENT

Issued 04-11

Printed in E.C.

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

CONNECTOR SSM - SECONDARY STEERING MODULE

245489C1

CAV

225389C1

CAV

WIRE IDENT

CIRCUIT

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

CIRCUIT

19M-C

19R-C

SEC. STR IGNIT FUS PWR

35X-C

SEC. STR LOW PRESS SIGNAL

C D

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

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

84489509

NOT USED

Issued 04-11

Printed in E.C.

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 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

84489509

291718A1

CAV

WIRE IDENT

CIRCUIT

36G

TCO TEMPERATURE SIGNAL

36R-D

TCO TEMPERATURE RETURN

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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

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

THV, TANK HEATER CONTROL VALVE

371614A1

CAV

WIRE IDENT

CIRCUIT

38C

TANK HEAT GND

38D

TANK HEAT B+

84489509

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

Issued 04-11

Printed in E.C.

4002-185 CONNECTOR TRC - TRANSMISSION CONTROL

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

245488C1 371566A1

CAV

WIRE IDENT

CIRCUIT

CAV

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

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

84489509

CIRCUIT

19M-A

WIRE IDENT

CIRCUIT

19A-H

TRANS SHIFTER FUSED PWR

25F

FORWARD SIGNAL

25R

REVERSE SIGNAL

25T-B

NEUTRAL SIGNAL

Issued 04-11

Printed in E.C.

4002-186 CONNECTOR TS2 - TRANSMISSION SHIFTER

CONNECTOR WF - WATER IN FUEL SENSOR

8602416 245487C1

CAV

WIRE IDENT

CIRCUIT

CAV 1

WIRE IDENT 35W

CIRCUIT WATER INDICATOR

NOT USED

0-BP

WATER SENSOR GROUND

25W

3RD AND 4TH GEAR SIGNAL

18J-H

WATER SENSOR FUSED PWR

25Z

1ST AND 4TH GEAR SIGNAL

25Y

TRANSMISSION KICK DOWN SIGNAL

CONNECTOR TSS - TURBINE SPEED SENSOR

291718A1

CAV

WIRE IDENT

CIRCUIT

25C

TURBINE SPEED SIGNAL

0-HH

TURBINE SPEED SENS GRND

UTS, UPSTREAM TEMP SENSE CAV

WIRE IDENT

CIRCUIT

38F

EXHT UP SIGNAL

0E-A

EXHT TEMP UP GND

84489509

Issued 04-11

Printed in E.C.

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

CAV

WIRE IDENT

CIRCUIT

35R-B

TC LOCKUP SOL POWER

24T-B

TC LOCKUP SOL GND

YDL 2, DIFF LOCK SOLENOID CAV

WIRE IDENT

CIRCUIT

34A-E

DIFF LOCK SOL B+

34C-D

DIFF LOCK SOL GND

84489509

Issued 04-11

Printed in E.C.

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

84489509

CAV

WIRE IDENT

CIRCUIT

58-H

RIDE CONTROL SIGNAL

0-RD

RIDE CONTROL GND

Issued 04-11

Printed in E.C.

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

84489509

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

NOT USED Issued 04-11

Printed in E.C.

4002-190 CONNECTOR 197F - MAIN CAB FNR

115, GRID HTR PWR CAV

WIRE IDENT

1-BE

CIRCUIT GRID HTR PWR

CONNECTOR 140M - DIODE MODULE

225350C1

CAV 1

245488C1

CAV A

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

84489509

WIRE IDENT 1-Z

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

CIRCUIT STRTR RLY BAT PWR

Issued 04-11

Printed in E.C.

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

CAV

WIRE IDENT

CIRCUIT

0-CG

SEC STR FLYBACK GND

0-CH

SEC STR FLYBACK GND

245480C1

CAV A B

84489509

WIRE IDENT 35A-D

CIRCUIT BACKUP ALARM RELAY OUT NOT USED

Issued 04-11

Printed in E.C.

4002-192

NOTES

84489509

Issued 04-11

Printed in E.C.

4002-193

Symbols 12 Volt Radio .......................................................115

A A/C High/Low Pressure Switch ............................119 Air Filter Restriction Switch ....................................72 Air Seat Compressor and Switch .........................118 Alarm Back-up (Europe Only) ....................................100 Back-up (North America Only) ........................100 Back-up, Disable Switch ...................................80 Back-up, Relay ..................................................80 Alternator ...............................................................44

B Back-up Alarm (Europe Only) ..............................100 Back-up Alarm (North America Only) ..................100 Back-up Alarm Disable Switch ..............................80 Back-up Alarm Relay .............................................80 Batteries ................................................................47 Beacon Switch .......................................................83 Beacon, Rotating (Option) .....................................82 Brake Lamp Pressure Switch ................................87 Brake Lamps Relay ...............................................87 Brake Warning Pressure Switch ............................73 Buzzer ...................................................................71

C CAN Communication Diagnostics Connector ......113 Cigar Lighter ........................................................118 Climate Control, Automatic...................................120 24 to 12 Volt Converter ...................................122 Blower Motor Resistor .....................................121 Blower Motors .................................................121 Compressor Relay ..........................................122 Electronic Panel ..............................................121 Electronic Water Valve ....................................122 External Air Temperature Sensor ....................121 Internal Air Temperature Sensor .....................121 Mixed Air Sensor .............................................121 Recycling Motor ..............................................122 Sun Sensor .....................................................121 Thermocouple Sensor .....................................121 Climate Control, Standar ......................................123 Air Conditioning Switch ...................................126 Air Recirculation Switch ..................................126 Blower Motor ...................................................125 Blower Motor Speed Resistors with Thermal Fuse ...................................124 Blower Switch ..................................................125 Control Panel Lights ........................................126 Driver ...............................................................124 Electronic Water Valve ....................................124 Thermostat ......................................................125 Water Valve Potentiometer .............................126 Cluster, Instrument Connector 1 ............................70 Cluster, Instrument Connector 2 ............................76 84489509

Compressor Clutch ..............................................119 Compressor Clutch Relay ...................................118 Compressor, Seat ...............................................118 Connector 108F ...................................................189 Connector 115, Grid-HTR-PWR...........................190 Connector 140M ..................................................190 Connector 193, Starter Relay...............................190 Connector 194, Starter Signal ..............................190 Connector 195, Starter Relay Power....................190 Connector 197F ...................................................190 Connector 197M ..................................................190 Connector 202M ..................................................191 Connector 209F ...................................................191 Connector 209M ..................................................191 Connector 20M ....................................................189 Connector 21M, Trans-Kick-Down .......................189 Connector 215F ...................................................191 Connector 216F ...................................................191 Connector 245F, Sec-Str-Flyback ........................191 Connector 64F .....................................................189 Connector 64M ....................................................189 Connector AB+, Alternator B+..............................136 Connector ACT-Air Conditioning Compressor Clutch..................................136 Connector AD, Alternator D+................................136 Connector AIC1-ADV Instrument Cluster 1..........136 Connector AIC2-ADV Instrument Cluster 1..........137 Connector ARM FNR, FNR-MAIN CAB ...............137 Connector ARM POS, Arm position .....................137 Connector B1, Starter pwr stud ............................137 Connector B2, Starter power................................137 Connector B3, Starter battery...............................137 Connector B4, Starter power................................137 Connector BPP, Pedal position ............................137 Connector BT1, Battery starter.............................138 Connector BT2, Disconect battery .......................138 Connector BT3, Starter battery ............................138 Connector BT4, Discon-blck grnd ........................138 Connector BTM C, Cab bottom BULKHD ............138 Connector BTM E, Cab bottom ............................138 Connector BU1, Backup alarm grnd.....................138 Connector BU2, Backup alarm.............................138 Connector BUZ, AIC Buzzer ................................138 Connector CAB PW, Cab power ..........................138 Connector CABE2, Cab to ENG2 BULKHD .........139 Connector CAB ARM, Cab to armrest..................139 Connector CAB ARM FRM, Cab to arm to FRM ..139 Connector CAB B, Cab BTM BULKHEAD ...........140 Connector CAB FNR, MAIN CAB FNR ................140 Connector CAB E, Cab-engine ............................140 Connector CAB F, Cab front chas........................140 Connector CAB FRM, Cab to JSS Frame ............141 Connector CAB RF, Cab to roof connection ........141 Connector CAB T, Cab transmission ...................141 Connector CAN MOD 2, JSS CAN MOD .............142 Connector CBPW, Cab power..............................142 Connector CL - Cigar lighter.................................142 Issued 04-11

Printed in E.C.

4002-194 Connector CNV - 24V to 12V Power converter ....142 Connector DC1, Disconect battery .......................142 Connector DC2, Discon blck grnd ........................142 Connector DC3, Fuel sol disconnect ....................142 Connector DC4, Fuel sol disconnect ....................142 Connector DIA - Diagnostic ..................................143 Connector DIA 2, Diagnostic ................................143 Connector DISC - Disconnect engine...................143 Connector DM - Diode OR ...................................143 Connector DS - Door switch .................................144 Connector DTS, Downstream temp sens .............144 Connector D-OR - Diode OR................................144 Connector EDC7, Engine controller .....................145 Connector ECA L1, B+ Power ..............................145 Connector EM - Height control RTD - RTT...........145 Connector ENG B, Cab bottom ............................146 Connector ENG, Engine CAB1.............................146 Connector ECA, Elect cntr A ................................147 Connector ECB, Elect cntr B ................................148 Connector ECB, Elect cntr D ................................149 Connector ECC, Elect cntr c.................................150 Connector ENG2, ENG BULKHD 2......................151 Connector ENG-D - Disconect harness................151 Connector ENG-H - Engine to hood .....................151 Connector E-HD - Transmission hood..................152 Connector ESS - Engine speed sensor................152 Connector FFH - Fule filter heater........................152 Connector FLSHR - Flasher module ....................152 Connector FM - Filter maintenance switch ...........152 Connector FNR RLY, Relay K2 ............................153 Connector FRONT, FRNT CHAS-CAB ................153 Connector FWD Diode, diode assy ......................153 Connector FWM - Front wiper motor ....................153 Connector FWMG - Front wiper motor ground .....153 Connector FWW - Front washer...........................154 Connector GH, Grid heater...................................154 Connector GH 1, Grid heater................................154 Connector GHC - Grid heater relay ......................154 Connector GHF1, Grid heater fuse.......................154 Connector GHF3, Grid heater fuse.......................154 Connector GHF4, Grid heater ..............................154 Connector GND CAB1 , Ground A .......................154 Connector GND CAB2 , Ground A .......................154 Connector GND CAB3 , Ground C .......................154 Connector GND CAB3D , Ground A.....................154 Connector GND CAB4 , Ground C .......................154 Connector GND CAB5 , Ground C .......................155 Connector GND CAB6, STRT, FFH, WAT SEP HTR ........................................155 Connector GND-CAB-SPL - CAB ground splice ..155 Connector GND CAB SPL2, SPL BACK LGHT GD.................................................155 Connector GND ENG1 , STRT, FFH, WAT SEP HTR ........................................155 Connector GND ENG2 , WIF, EDC ......................155 Connector GND ENG3 , SPLC PK, WSHR MTR .156 Connector GND ENG4 , Rear lighting ..................156 84489509

Connector GND ENG6 , Dedicated......................156 Connector GND ENG7 , Tranny, Cool temp ........ 156 Connector GND FC , Ground A............................156 Connector GND GH1, STRT, FFH, WAT SEP HTR........................................ 156 Connector GND JSS , Ground A.......................... 156 Connector GND PDST , Ground A....................... 156 Connector GND PDST1 , Ground A.....................156 Connector GND PDST2 , Ground A.....................156 Connector GND S1 , Ground A ............................156 Connector GND S2 , Ground A ............................156 Connector GND SSCHAS, SSM Ground cable.... 156 Connector GND SSMOD, SEC STR Chasis gnd . 156 Connector GND WIF, GRND WIF RING TERM ...156 Connector GND TRANS, Ground trans................157 Connector HD - Hood switch................................157 Connector HD-E - Hood harness to transmission harness .............................. 157 Connector HD-N - Hood to engine ....................... 157 Connector HN1, Horn pwr .................................... 157 Connector HN2, Horn grnd...................................157 Connector HOT - Hydraulic oil temperature sender ..................................................... 157 Connector HTS, HMDTY And amb temp .............158 Connector HVAC1, HVAC1..................................158 Connector HVAC2 - HVAC2................................. 158 Connector ISS - INT-Speed-sensor .....................158 Connector JSS ARM, JSS Armrest to cab ........... 158 Connector JSS Cab .............................................159 Connector JSS Controller..................................... 159 Connector JSS Frame to cab ...............................159 Connector JSS Load sense..................................159 Connector JSS Pilot dump ...................................159 Connector JSS Pilot pressure .............................. 159 Connector RLY, Relay K2 .................................... 160 Connector JSS 197F, Main cab FNR ...................160 Connector JSS 197M, FNR-MAIN CAB ...............160 Connector JSS Valve, JSS HYD Valve ................160 Connector KD Diode, Diode assy.........................161 Connector L1 ECC, ECC BATT PWR ..................161 Connector LBEGRD, Light beacon grnd .............. 161 Connector LBEPWR, Light beacon pwr ...............161 Connector LDM1, Dome light B+ .........................161 Connector LDM2, Dome light auto ....................... 161 Connector LDM3, Dome light gnd ........................ 161 Connector LLF, Lights LH .................................... 161 Connector LLFW - LH Front work LAMP.............. 161 Connector LLRW- LH Rear work LAMP...............161 Connector LLR-E - LH Rear combination LAMP..162 Connector LPL - License plate LAMP ..................162 Connector LRF - RH Front combination LAMP .... 162 Connector LRFO - Front work LAMP OPT........... 162 Connector LRFR - Front work LAMP OPT ........... 163 Connector LRFS- Front work LAMP OPT ............163 Connector LRFW - RH Front work LAMP ............163 Connector LRRW- RH Rear work LAMP.............. 163 Connector LRR-E - RH Rear combination LAMP. 163 Issued 04-11

Printed in E.C.

4002-195 Connector LSPK - Left speaker............................163 Connector NTRL Diode, diode assy .....................164 Connector OSS - Output speed sensor................164 Connector PAF - Air filter restriction switch ..........164 Connector P A1, B+ Power...................................164 Connector P A3, B+ Power...................................164 Connector PBD - Brake declutch pressure switch . 164 Connector PBL - Brake lamp pressure switch......165 Connector PBW - Brake pressure warning switch165 Connector P C1, B+ PWR FRM PRMD................165 Connector P C2, B+ PWR FRM PRMD................165 Connector P C3, B+ PWR FRM PRMD................165 Connector P C4, B+ PWR FRM PRMD................165 Connector PHF, HYD OIL FILT RES SW.............165 Connector PO1 - Power outlet..............................165 Connector PO2 - Power outlet..............................166 Connector PRH, AC High press SW ....................166 Connector PRB1 - Redundant brake switch.........166 Connector PRB2 - Redundant brake switch.........166 Connector PRBF - Rollback pressure switch .......166 Connector PRM A1, PRM Output.........................166 Connector PRM A2, PRM Signal..........................167 Connector PRM-B1 - PRM Signal ........................167 Connector PRM C1, PRM Signal .........................167 Connector PRM D1, PRM Output.........................167 Connector PRM D2, PRM Signal .........................167 Connector PSS - Secondary steering pressure switch........................................167 Connector PXF - RTD .........................................167 Connector PXH - Height control RTT ...................167 Connector PXM - RTD..........................................168 Connector PXT - RTD ..........................................168 Connector RAD - Radio power .............................168 Connector RAD-J1 - Radio power ........................168 Connector RAD-J2 - Speaker...............................169 Connector RAD-J3 - Radio jumper ......................169 Connector RECT - Engine coolant temperature...169 Connector RFL, Fuel sender ................................169 Connector RFLG, Fuel send grnd ........................169 Connector ROOF, Roof to cab connection...........170 Connector RSPK - Right speaker.........................170 Connector RTHP - Throttle pedal .........................170 Connector RVS Diode, diode assy .......................170 Connector RWM - Rear wiper motor ....................170 Connector RWMG - Rear wiper motor ground .....171 Connector RWW - Rear washer ...........................171 Connector SBE - Beacon switch ..........................171 Connector SBU - Backup alarm disable switch ....171 Connector SC - Seat compressor motor ..............172 Connector SDA, Diff lock switch...........................172 Connector SDC - Declutch switch ........................172 Connector SDM, Diff lock switch ..........................172 Connector SDR - Driving lights switch..................172 Connector SFC - Fan control switch.....................173 Connector SFL - Return to travel switch...............173 Connector SFNR - FNR Switch ............................173 Connector SFWW - Front wiper and 84489509

washer switch ..........................................173 Connector SHC - Height control switch................174 Connector SHZ - Hazard switch...........................174 Connector SJS, Joystick control SW....................174 Connector S KEY, Ignition switch.........................174 Connector SPB - Parking brake switch ................174 Connector SPC - Pilot control switch ...................175 Connector SPE - PIN Engage switch ...................175 Connector SPK - Speaker ....................................175 Connector SPL-BCK-LGT - Splice back light power ...............................................176 Connector SPL-BCK-LGT2 SPLICE Back light power ........................176 Connector SPL BCK LGT, SPLICE BACK LGHT PWR .....................176 Connector SPL PED BL, SPL BACK LGT PWR 6 PCK ..................177 Connector SPL-HOOD-GND HOOD GROUND 6 PACK .......................177 Connector SPL-PED-BL-GD SPL BACK LIGHT POWER 6 PACK .......177 Connector SPL-PIN SPL BACK LIGHT POWER 6 PACK .......177 Connector SPL PK1, SPLICE 3-4 WAY ...............178 Connector SPL BCK LGT2, SPL BACK LGT PWR ................................................178 Connector SPL-PK3 - SPLICE 3 - 4 WAY............178 Connector SPL ROOF, Splice roof ground ..........178 Connector SPL-TRNS-PWR Transmission power ................................179 Connector SRC - Ride control switch...................179 Connector SRC-1 - Starter relay ..........................179 Connector SRHSTLK - RH Stalk switch...............180 Connector SRTD - Detent switch .........................180 Connector SRWP - Rear wiper switch .................180 Connector SSD, SEC STR Diode ........................180 Connector SSM - Secondary steering module .....181 Connector SSS, SS MAG Switch .........................181 Connector SS-TR - SS-MOD-TRANS ..................181 Connector STA - Transmission auto switch .........181 Connector STE - Transmission enable switch .....182 Connector SWL - Work lights switch ....................182 Connector SW-PD - Switch pad ...........................182 Connector TCOT - Torque converter output sender .....................................................182 Connector TECM, Trans ......................................183 Connector TERM CAN 2, CAN BULK HEAD .......184 Connector THV, Tank heater control valve ..........184 Connector TRANS, Transmission-cab .................184 Connector TRC - Transmission control ................185 Connector TR-SS - SEC-STR-MOD-OPT............185 Connector TS1 - Transmission shifter..................185 Connector TS2 - Transmission shifter..................186 Connector TSS - Turbine speed sensor...............186 Connector UTS, Upstream temp sense ...............186 Connector WF - Water in fuel sensor ...................186 Connector WSH - Water separator heater ...........187 Issued 04-11

Printed in E.C.

4002-196 Connector YDL, Diff lock solenoid........................187 Connector YDL 1, Diff lock solenoid.....................187 Connector YDL 2, Diff lock solenoid.....................187 Connector YFN - FNA PWM Solenoid..................187 Connector YFR - Fan reversing solenoid .............187 Connector YLS, TC Lockup valve ........................187 Connector YPB - Parking brake solenoid .............188 Connector YPE - PIN Engage OPT......................188 Connector YPE2, PIN Engage OPT .....................188 Connector YPP - Pilot pressure solenoid .............188 Connector YRC - Ride control OPT......................188 Connector YRC J, Ride cntrl jumper ....................188 Connector YRC J2, Ride control OPT ..................188 Connector YSS - Secondary steering solenoid ....189

D Declutch Brake Switch ...........................................68 Declutch Switch .....................................................68 Diagnostic Connector ............................................68 Diodes Lights .................................................................85 Secondary Steering .........................................109 Wipers .............................................................107 Dome Lamp ...........................................................83 Door Switch ...........................................................82 Driving Lamp Switch ..............................................90

E Electrical Wire Identification ....................................8 Electromagnetic Detents .......................................59 Electronic Diesel Control .......................................56 Engine Speed Sensor ............................................68

F Fan PWM Solenoid ................................................66 Fan Reverse Relay ................................................64 Fan Reversing Solenoid ........................................66 Fan Reversing Switch ............................................64 Filter Maintenance Switch .....................................68 Flasher Module ......................................................68 FNR Switch for Joystick Controls ..........................68 FNR Switch for Single Axis Controls .....................68 Front Left Hand Work Lamp .......................................83 Right Hand Work Lamp .....................................84 Front Left Hand Combination Lamp ......................92 Front Right Hand Combination Lamp ....................93 Front Washer Pump Motor ..................................106 Front Wiper and Washer Switch ..........................104 Front Wiper Cut Out Relay ..................................102 Front Wiper High Speed Relay ............................102 Front Wiper Low Speed Relay .............................103 Front Wiper Motor ................................................105 Fuel Filter Heater ...................................................53 Fuel Filter Heater Relay .........................................52 Fuel Level Sender .................................................71 84489509

G Grid Heater ............................................................52 Grid Heater Relay ..................................................52

H Hazard Switch ....................................................... 89 Heater Fuel Filter .......................................................... 53 Grid ................................................................... 52 Water Separator ................................................ 53 Height Control Switch ............................................58 Height Control/Return-To-Travel Proximity Switch 60 High-Low Beam Switch ......................................... 89 Hood Down Relay ..................................................... 128 Motor ...............................................................129 Switch .............................................................128 Up Relay .........................................................128 Horn ....................................................................... 94 Horn Relay ............................................................94 Horn Switch ...........................................................89 Hydraulic Filter Restriction Switch ......................... 77 Hydraulic Oil Temperature Sender ........................77

I Ignition Switch ....................................................... 48 Instrument Cluster Connector 1 ............................ 70 Instrument Cluster Connector 2 ............................ 76 Intermediate Speed Sensor ................................... 68

L Lamp Dome ................................................................ 83 High Beam ........................................................89 Left Hand Front Combination ............................ 92 Left Hand Front Work ........................................83 Left Hand Rear Combination (Europe Only) .....99 Left Hand Rear Combination (North America Only) ......................... 98 Left Hand Rear Work ........................................84 License Plate (Europe Only) ........................... 100 License Plate (North America Only) ..................99 Low Beam ......................................................... 89 Position ............................................................. 89 Right Hand Front Combination ......................... 93 Right Hand Front Work .....................................84 Right Hand Rear Combination (Europe Only) ... 97 Right Hand Rear Combination (North America Only) ......................... 96 Right Hand Rear Work ...................................... 84 Switch, Driving ..................................................90 Turn ................................................................... 93 Left Hand Front Combination Lamp ...................... 92 Left Hand Front Work Lamp ..................................83 Left Hand Rear Combination Lamp (Europe Only) ...........................................99 Left Hand Rear Combination Lamp Issued 04-11

Printed in E.C.

4002-197 (North America Only) ................................98 Left Hand Rear Work Lamp ...................................84 Left Speaker ........................................................116 License Plate Lamp .......................................99, 100 License Plate Lamp (Europe Only) ......................100 License Plate Lamp (North America Only) ............99 Lights Diodes .........................................................85 Locating Components on the Schematic Posters ..44

M Magnetic Detents ...................................................59 Master Disconnect Switch .....................................47 Module Flasher ..............................................................88 Secondary Steering .........................................110 Transmission Electronic Control .......................67 Motor Hood ................................................................129 Starter ...............................................................48

N Neutral Start Relay ................................................49

O Outlet, Power .......................................................115 Output Speed Sensor ............................................68

P Parking Brake Relay ..............................................71 Parking Brake Solenoid .........................................72 Parking Brake Switch ............................................78 Pilot Control Relay .................................................60 Pilot Control Switch ...............................................65 Pilot Pressure Solenoid .........................................61 Pin Engage Solenoid .............................................61 Pin Engage Switch ................................................61 Potentiometer Throttle ..............................................................55 Power Converter (24 volts to 12 volts) ................115 Power Outlet ........................................................115 Power Relay Module A Ignition Power ................................................51 B Ignition Power ................................................51 C Fuel Filter Heater ...........................................53 E Power Converter 24V to 12V .......................115 Proximity Switch Height Control/Return-To-Travel .......................60 Return-To-Dig ...................................................59

R Radiator Coolant Temperature Sender .................72 Radio 12 Volt .............................................................115 Rear Left Hand Combination Lamp (Europe Only) ....99 Left Hand Combination Lamp (North America Only) .........................99 84489509

Left Hand Work Lamp .......................................84 Right Hand Combination Lamp (Europe Only) ..97 Right Hand Combination Lamp (North America Only) .........................96 Right Hand Work Lamp .....................................84 Rear Washer Pump Motor ...................................106 Rear Wiper and Washer Switch ..........................103 Rear Wiper Motor ................................................106 Redundant Brake Pressure Switch 1 ....................78 Redundant Brake Pressure Switch 2 ....................78 Relay Backup Alarm ....................................................80 Brake Lamps .....................................................87 Compressor Clutch .........................................118 Crank Control ....................................................47 Crank Request ..................................................47 Fan Reverse ......................................................64 Front Wiper Cut Out ........................................102 Front Wiper High Speed ..................................102 Front Wiper Low Speed ..................................103 Fuel Filter Heater ..............................................53 Grid Heater ........................................................52 Hood Down .....................................................128 Hood Up ..........................................................128 Horn ..................................................................94 Neutral Start ......................................................49 Parking Brake ....................................................71 Pilot Control .......................................................60 Power Relay Module A Ignition Power ..............51 Power Relay Module B Ignition Power ..............51 Power Relay Module C Water Separator Htr ....51 Power Relay Module D Accessory Power .........52 Power Relay Module E Power Converter ........115 Ride Control ......................................................63 Starting ..............................................................46 Resistor Alternator ..........................................................46 Return to Dig Switch Switch ..................................60 Return-To-Dig Proximity Switch ............................59 Return-To-Travel/Float Switch ..............................58 Ride Control Relay ................................................63 Ride Control Solenoid ...........................................65 Ride Control Switch ...............................................63 Right Hand Front Combination Lamp ....................93 Right Hand Front Work Lamp ................................84 Right Hand Rear Combination Lamp (Europe Only) ...........................................97 Right Hand Rear Combination Lamp (North America Only) ................................96 Right Hand Rear Work Lamp ................................84 Right Speaker ......................................................116 Rollback Jumper ....................................................66 Rollback Pressure Switch ......................................65 Rotating Beacon (Option) ......................................82

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S Seat Compressor and Switch ..............................118 Secondary Steering Module ............................................................110 Motor ...............................................................111 Pressure Switch ..............................................111 Solenoid ..........................................................109 Secondary Steering Diodes .................................109 Sender Fuel Level ..........................................................71 Hydraulic Oil Temperature ................................77 Radiator Coolant Temperature ..........................72 Torque Converter Output Temperature .............68 Sensor Engine Speed ....................................................68 Intermediate Speed ...........................................68 Output Speed ....................................................68 Transmission Solenoid Valve and Temperature ..68 Turbine Speed ...................................................68 Water In Fuel .....................................................55 Shifter, Transmission .............................................68 Solenoid Fan PWM ..........................................................66 Fan Reversing ...................................................66 Parking Brake ....................................................72 Pilot Pressure ....................................................61 Pin Engage ........................................................61 Ride Control ......................................................65 Secondary Steering .........................................109 Speaker Left ..................................................................116 Right ................................................................116 Specifications ..........................................................7 Speed Resistors Blower Motor ...................................................124 Starter Motor ..........................................................48 Starting Relay ........................................................46 Steering Secondary, Module .........................................110 Secondary, Motor ............................................111 Secondary, Pressure Switch ...........................111 Secondary, Solenoid .......................................109 Switch A/C High/Low Pressure ...................................119 Air Filter Restriction ...........................................72 Back-up Alarm Disable ......................................80 Beacon ..............................................................83 Blower .............................................................125 Brake Lamp Pressure .......................................87 Brake Warning Pressure ...................................73 Declutch ............................................................68 Declutch Brake ..................................................68 Door ..................................................................82 Driving Lamp .....................................................90 Fan Reversing ...................................................64 Filter Maintenance .............................................68 FNR for Joystick Controls .................................68 84489509

FNR for Single Axis Controls ............................ 68 Front Wiper and Washer ................................. 104 Hazard ..............................................................89 Height Control ................................................... 58 High-Low Beam ................................................ 89 Hood ...............................................................128 Horn ..................................................................89 Hydraulic Filter Restriction ................................ 77 Ignition ..............................................................48 Master Disconnect ............................................47 Pad .................................................................... 75 Parking Brake ................................................... 78 Pilot Control Switch ...........................................65 Pin Engage ....................................................... 61 Proximity, Height Control/Return-To-Travel ...... 60 Proximity, Return-To-Dig ..................................59 Rear Wiper and Washer ................................. 103 Redundant Brake Pressure 1 ............................ 78 Redundant Brake Pressure 2 ............................ 78 Return to Dig .....................................................60 Return-To-Travel/Float ...................................... 58 Ride Control ...................................................... 63 Rollback Pressure ............................................. 65 Seat Compressor ............................................118 Secondary Steering Pressure .........................111 Transmission Auto ............................................68 Transmission Enable ........................................68 Transmission Kick-down ................................... 68 Turn Signal ........................................................89 Work Lamps ...................................................... 82 Switch Pad ............................................................75

T Thermal Fuse Blower Motor ...................................................125 Throttle Potentiometer ...........................................55 Torque Converter Output Temperature Sender ....68 Transmission Auto Switch .....................................68 Transmission Electronic Control Module ...............68 Transmission Enable Switch .................................68 Transmission Kick-down Switch ............................ 68 Transmission Shifter ..............................................68 Transmission Solenoid Valve and Temperature Sensors ....................................................68 Turbine Speed Sensor .......................................... 68 Turn Signal Switch ................................................ 89

U Understanding the Troubleshooting Tables .......... 44

W Warning Buzzer .....................................................71 Water In Fuel Sensor ............................................55 Water Separator Heater ...............................................................53 Heater Relay .....................................................52 Wiper Issued 04-11

Printed in E.C.

4002-199 Front Cut Out Relay ........................................102 Front Motor ......................................................105 Front Switch ....................................................104 Front Washer Pump Motor ..............................106 Front Washer Switch .......................................104 Front Wiper High Speed Relay .......................102 Front Wiper Low Speed Relay ........................103 Rear Motor ......................................................106 Rear Switch .....................................................103 Rear Washer Pump Motor ..............................106 Rear Washer Switch .......................................103 Wiper Diodes .......................................................107 Wire Identification ....................................................8 Work Lamp Switch .................................................82

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4003

Section 4003 BATTERIES

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

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 first when the battery disconnected from the battery.

ground cable cables are

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. D-47-53A

48-57B

SPECIAL TOOLS

B795328

The CAS10147 tester is used to do the Capacity (Load) Test. This tool is first used on Page 6.

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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 battery can be caused by high battery 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.

Inspect the battery at regular intervals for dirt, 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 Battery Saver and Cleaner according to the instructions on the container. New Holland Battery 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.

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 needed. Too much water can cause bad performance, a short service life, and corrosion around the battery. NOTE: Add water only. DO NOT add electrolyte.

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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.

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Capacity (Load) Test This test can be done using a variable load tester such as the Sun Electric VAT -33. Other test 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 voltage shown, the battery is in good condition. B. If the test result is less than the voltage shown, discard the battery.

B790499

1. LOAD CONTROL KNOB

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

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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.

See Specifications in Section 4001 for the reserve capacity of the battery in this machine.

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.

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

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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 permit the volume of electrolyte to increase when heated by charging the battery. 3. Install the caps on the battery.

5. Charge the battery at 30 amperes until the specific gravity is 1.250 or more an d 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.

4. Connect a battery charger to the battery.

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Section 4005

4005

INSTRUMENT CLUSTER

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

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Printed in E.C.

4005-3

INSTRUMENT CLUSTER 1

15 14

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:

84489509

Issued 04-11

Printed in E.C.

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:

84489509

Issued 04-11

Printed in E.C.

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.

7.0 H

1. In the example, above, the machine hours are displayed. Machine hours will always be 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.

N R

12 3 4

A A 11 22

W23R649

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 transmission clutches are disconnected.

blink

the

3. This zone shows the gear numerically (3th).

F 2

12 3 4

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

N R

7.0 H

A A 11 22

5 4 6

W230R650

LCD MULTI-FUNCTION DISPLAY 4 SPEED

●

A - Automatic

●

M - Manual operation.

B. If the Transmission is not operating normally the display will show ●

C - Substitute Clutch.

●

L - Limp Home.

●

S - Transmission Shutdown.

●

U - TCU Shutdown.

5. This example shows the Power Boost Status. ●

MAX - Maximum Power.

●

STD - Normal/Standard mode of Operation.

●

AUTO - Switches automatically Maximum and Standard Power.

●

ECO - Limited Power for fuel efficiency.

between

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

84489509

Issued 04-11

Printed in E.C.

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 from one screen to another, choose various 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. 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 selections are up or down from the current selection. NOTE: Display operator.

units

can

changed

BD06F188

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

Info

Engine RPM 1623 Speed KPH Fuel Lvl %

11.9 19

the

W230M208

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.

84489509

Issued 04-11

Printed in E.C.

4005-7

Info Coolant

2 °C

Eng Oil °C OilPressBAR

85 3.2

W230M209

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.

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.

Info

Transm.

°C

Hyd.Oil Tr.Sump

°C °C

33 39

W230M210

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.

Info Voltage Air Turbo DefTemp

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.

4 V 24.2 °C 42 °C 32

W230R647

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.

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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)

4. Service ●

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

●

Change Model

●

Slot 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.

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)

84489509

Issued 04-11

Printed in E.C.

84489509

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

Issued 04-11

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

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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

Figure 9

W230M149

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

Figure 7 Figure 10

W230M150

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

84489509

Figure 8

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

Issued 04-11

Printed in E.C.

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

84489509

W230M156

Figure 13

W230M157

Figure 14

W230M158

Figure 15

Figure 11

Figure 12

Issued 04-11

Printed in E.C.

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 reverts 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.

From the display screen, choose the clock designation and press the confirm key. Use the arrow keys to show field for time and date by pressing the arrow key. When the correct time and date have been entered by using the up and down arrow keys (up increases 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

Figure 19

W230M160

Figure 20

Figure 16

W230M143

Figure 17

W230M144

Figure 18

84489509

W230M159

Issued 04-11

Printed in E.C.

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:

W230M173

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

●

Not in neutral

●

Park Brake OFF

●

Machine 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 K1

●

Adjust K2

●

Adjust K3

●

Adjust K4

●

Adjust KV

●

Adjust KR

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

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

84489509

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

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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.

D BD06F186

A. Escape key B. enter key C. up key D. down key 2. Yellow Faults, buzzer will beep once every 2 seconds: A. Operator can acknowledge it by pressing the enter key. B. The message will disappear. C. Buzzer will not beep anymore. D. Yellow lamp will stay ON. E. Fault will remain in Yellow list until it is closed. 3. Red Faults, buzzer alternating sounds:

will

continuous,

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.

84489509

Issued 04-11

Printed in E.C.

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

84489509

1. Stop machine operations 2. Check charging system

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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

84489509

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 Issued 04-11

Printed in E.C.

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

84489509

Ambient pressure sensor inside ECU is defective. Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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

84489509

Broken wire or disconnection of wiring or inside injector. Check the wiring or replace injector.

Issued 04-11

Printed in E.C.

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

84489509

Defective ECU. Replace ECU if problem reoccurs

Issued 04-11

Printed in E.C.

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

84489509

Electronic disturbances, internal ECU problem. If failure remains after ECU initialization: replace ECU

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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

84489509

Buffer overrun No additional information available at time of print

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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 84489509

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. Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

4005-41

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

84489509

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

Issued 04-11

Printed in E.C.

4005-42 CODE

DEFINITION

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

4147

Logical error at engine speed sensor input

POSSIBLE STEPS FOR REPAIR 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. NOTE: This fault code is reset after power up of the TCU. It is also reset if the signal is above zero speed threshold.

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

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

4154

Short circuit to battery voltage or open circuit at output speed input

4155

Short circuit to ground at output speed input

84489509

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.

Issued 04-11

Printed in E.C.

4005-43 CODE

4156

DEFINITION

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. 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

Vehicle controller time-out (CAN)

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

4181

JSS timeout

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

4182

Engine CONF timeout

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

4183

EEC1 timeout

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

4184

EEC3 timeout

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

4185

Invalid test mode signal (CAN)

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

4193

AEB Request signal

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

4197

Engine torque signal

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

4201

Reference engine torque signal

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

4202

Actual engine torque signal

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

4203

NOM friction torque signal

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

4206

EEC2 timeout

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

84489509

Issued 04-11

Printed in E.C.

4005-44 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

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

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

84489509

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.

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.

Issued 04-11

Printed in E.C.

4005-45 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

Slippage at clutch K1

1. 2. 3. 4. 5.

Check pressure at clutch K1. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch K2

1. 2. 3. 4. 5.

Check pressure at clutch K2. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch K3

1. 2. 3. 4. 5.

Check pressure at clutch K3. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch K4

1. 2. 3. 4. 5.

Check pressure at clutch K4. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch KV

1. 2. 3. 4. 5.

Check pressure at clutch KV. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

Slippage at clutch KR

1. 2. 3. 4. 5.

Check pressure at clutch KR. Check main pressure in the system. Check signal at internal speed sensor. Check signal at output speed sensor. Replace clutch.

4279

Overtemp SUMP

1. A critical stop function warning has occurred. 2. Red stop indicator comes on and continuous buzzer sounds. 3. Stop machine and perform required service on the critical area. 4. Cool down machine. 5. Check oil level. 6. Check temperature sensor.

4281

Overspeed Engine

4273

4274

4275

4276

4277

4278

4282

84489509

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).

Issued 04-11

Printed in E.C.

4005-46 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

4306

Power supply for sensors short-circuit to ground

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

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

84489509

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. Issued 04-11

Printed in E.C.

4005-47 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

84489509

Do the transmission clutch calibration procedure.

Issued 04-11

Printed in E.C.

4005-48

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.

84489509

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.

Issued 04-11

Printed in E.C.

4005-49 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

9180

VCM controller CAN timeout

No information available at time of print.

9181

VCM controller CAN did not start

No information available at time of print.

9182

Wheel Loader Configuration Plausibility Failure - Wrong engine type

No information available at time of print.

9160

9161

84489509

Issued 04-11

Printed in E.C.

4005-50

NOTES

84489509

Issued 04-11

Printed in E.C.

Section 4006

4006

REAR VIEW CAMERA AND MONITOR

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

84489509

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

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5009

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

84489509

5001 Section 5001 REMOVAL AND INSTALLATION OF STEERING COMPONENTS

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

84489509

5001-2

TABLE OF CONTENTS STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 3 5 8 8 8 10 10 10 12 12 12 14 14 14 16 16 16

Printed in E.C.

5001-3

STEERING CONTROL VALVE Removal

STEP 7

STEP 1 Remove the cab skirts from the cab or canopy.

STEP 2 Remove all dirt and grease from steering control valve.

STEP 3 Remove hydraulic reservoir fill cap, attach a vacuum pump to the reservoir, start the pump. W230R595

STEP 4 Tag hoses connected to steering control valve.

Remove the mounting nut and washers from the steering shaft.

STEP 5

STEP 8

BD06G262

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

W230R596

Remove the steering wheel from the shaft.

STEP 9

STEP 6

W230R597 W230R594

Remove the center cap from the steering wheel.

84489509

Remove the six mounting screws from the instrument cover.

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5001-4

STEP 10

STEP 13

BD06G248

BD06G258

Remove the five mounting screws for the left and right hand trim.

Remove the two mounting screws from the lower trim.

STEP 11

STEP 14

BD06G249

BD06G259

Disconnect the ignition switch, remove the right and left hand trim pieces from the column.

Pull floor mat away from the column and remove the lower trim from the column.

STEP 12

STEP 15

BD06G257

Remove the screw from the brace.

84489509

BD06G260

Remove the two lower mounting screws from the front vent.

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Installation

STEP 16

STEP 18

BD06G261

Remove the three vents from the front trim, remove the three mounting bolts inside of the vent holes, remove the vent.

STEP 17

BD06G264

Put the rubber bushing on the spacer with the tapered end towards the steering valve.

STEP 19 Have an assistant push the valve into place while turning the steering shaft, this will engage the splines.

STEP 20

BD06G263

Remove the four mounting bolts for the steering control valve. IMPORTANT: Have an assistant support remove the valve while removing the mounting bolts.

and

BD06G263

Install and tighten the four mounting bolts for the steering control valve.

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STEP 21

STEP 24

BD06G261

Install the front trim, install and tighten the three mounting bolts inside of the vent holes, install three vents into the front trim.

BD06G257

Install the screw into the brace.

STEP 25

STEP 22

BD06G249

BD06G260

Install the two lower mounting screws that mount the front vent to the cab.

Connect the ignition switch, install the right and left hand trim pieces onto the column.

STEP 26

STEP 23

BD06G248

BD06G258

Install and tighten the five mounting screws for the left and right hand trim.

Install the lower trim onto the column, instal and tighten the two mounting screws mounting the lower trim, place the floor mat into position.

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STEP 27

STEP 30

W230R597

BD06G262

Install and tighten the six mounting screws for the instrument cover.

Start the vacuum pump, remove the caps and plugs the fittings and hoses. Connect hoses to steering control valve according to the tags installed during removal, remove and discard the tags.

STEP 28

STEP 31 Remove the vacuum pump from the reservoir, install and tighten the reservoir fill cap.

STEP 32 Start and run the machine at low idle, turn the wheel to full left and then to full right, stop the machine and check for leaks.

STEP 33 W230R595

Install the skirts onto the cab or canopy.

Install the steering wheel, install and tighten the mounting nut and washers.

STEP 34

STEP 29

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

W230R594

Install the center cap on the steering wheel.

84489509

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Printed in E.C.

5001-8

AUXILIARY STEERING PRIORITY VALVE Removal

Installation

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

1. Connect and hand tighten fitting (5) to the elbow in the steering priority valve.

2. Put master disconnect switch in OFF position.

3. Tighten pressure tube fitting (5).

3. Remove all dirt and grease from auxiliary steering priority valve and adjacent area. See illustration on page 9.

4. Tighten the nuts (6).

4. Remove hydraulic reservoir fill cap.

2. Install cap screws, washers and nuts (6).

5. Connect and tighten pressure hose (7). 6. Connect and tighten steering pressure hose (9).

5. Connect a vacuum pump to hydraulic reservoir.

7. Connect and tighten steering load sensing hose (1).

6. Start vacuum pump.

8. Connect and tighten load sensing hose (2).

7. Tag and disconnect suction hose from the suction port (4) from auxiliary steering pump and motor. Install a cap on the fitting and a plug in the hose.

9. Connect electrical connector to the pressure switch (3).

8. Tag and disconnect tank return tube (10) from the priority valve. Install a cap on the elbow and a plug in the tube. 9. Stop the vacuum pump. 10. Tag and disconnect the wiring from the steering solenoid (8). 11. Tag and disconnect the wiring from the pressure switch (3).

10. Connect electrical connector to the steering solenoid (8). 11. Start vacuum pump. 12. Connect and tighten tank return tube (10). 13. Connect and tighten hose to auxiliary steering pump port (4). 14. Stop vacuum pump. Disconnect vacuum pump from hydraulic reservoir. 15. Install fill cap on hydraulic reservoir.

12. Tag and disconnect load sensing hose (2) from auxiliary steering priority valve. Install a cap on the elbow and a plug in the hose.

16. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks.

13. Tag and disconnect load sensing hose (1) from the priority valve. Install a cap on the elbow and a plug in the hose.

17. Check to make sure priority valve operates correctly. See Section 5002.

14. Tag and disconnect steering pressure hose (9) from priority valve. Install a cap on the fitting and a plug in the hose.

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

15. Tag and disconnect pressure hose (7) from priority valve. Install a cap on the fitting and a plug in the hose. 16. Loosen fitting (5) connected to elbow installed in steering priority valve. 17. Support auxiliary steering priority valve. Remove four nuts (6), cap screws, and washers. 18. Remove auxiliary steering priority valve.

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10 1

6 9

W230R003

1. 2. 3. 4. 5.

STEERING LOAD SENSING HOSE TO PRIORITY VALVE STEERING LOAD SENSING HOSE TO STEERING VALVE PRESSURE SWITCH SUCTION PORT PUMP OUT PRESSURE TUBE FITTING

6. 7. 8. 9. 10.

CAP SCREWS AND NUTS PRESSURE HOSE STEERING SOLENOID STEERING PRESSURE HOSE TANK RETURN TUBE

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

84489509

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5001-10

STEERING PRIORITY VALVE Removal 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine, 2. Put master disconnect switch in OFF position. 3. Remove all dirt and grease from steering priority valve (7) and adjacent area. See illustration on page 11. 4. Remove hydraulic reservoir fill cap. 5. Connect a vacuum pump to hydraulic reservoir.

Installation 1. Install bolts with washers (8) through priority valve. Install new O-ring on top of priority valve (not shown). Install priority valve (7) onto low pressure pump, tighten bolts to37 to 48 Nm (27 to 35.5 pound feet). 2. Install new O-rings (6) onto high pressure pump discharge tube (5). 3. Place tube into position and intsall two split flanges (3) and eight bolts (4) with washers, tighten bolts.

6. Start vacuum pump.

4. Connect all hoses as tagged to the steering priority valve (7).

7. Tag and disconnect all hoses connected to the steering priority valve (7).

5. Stop vacuum pump.

8. Loosen and remove eight bolts (4) and two spit flanges (3). 9. Remove the high pressure pump discharge tube (5), discard O-rings (6). 10. Support the steering priority valve (7), remove mounting bolts (8). 11. Remove steering priority valve (7).

6. Disconnect reservoir.

vacuum

pump

from

hydraulic

7. Install fill cap on hydraulic reservoir. 8. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks. 9. Check to make sure steering priority valve operates correctly. See Section 5002. 10. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

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5001-11

5 6

4 3 8

W230R004

1. 2. 3. 4.

LOW PRESSURE PUMP (LOADER PUMP) HIGH PRESSURE PUMP (STEERING PUMP) SPLIT FLANGE BOLT

5. 6. 7. 8.

STEERING PUMP OUTPUT LINE O-RINGS STEERING PRIORITY VALVE BOLT

STEERING PRIORITY VALVE ILLUSTRATION

84489509

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5001-12

AUXILIARY STEERING PUMP AND MOTOR Removal 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine,

7. Connect ground cable (1) to ground stud of auxiliary steering pump and motor (7) following tag installed during removal.

2. Put master disconnect switch in OFF position.

8. Connect positive cable (2) to B+ stud of auxiliary steering pump and motor (7) following tag installed during removal.

3. Tag and disconnect two wiring harness (8) from auxiliary steering pump and motor (7) solenoid. See illustration on page 13.

9. Connect wiring harness wires (8) to auxiliary steering pump and motor (7) following tags installed during removal.

4. Tag and disconnect positive cable (2) from B+ stud of auxiliary steering pump and motor (7). 5. Tag and disconnect ground cable (1) from ground stud of auxiliary steering pump and motor (7). 6. Remove hydraulic reservoir fill cap. 7. Connect a vacuum pump to hydraulic reservoir. 8. Start vacuum pump. 9. Disconnect suction hose (4) from auxiliary steering pump and motor (7). Install a plug in suction hose and cap on fitting. 10. Stop vacuum pump. 11. Loosen fittings on pressure tube (5). 12. Support auxiliary steering pump and motor (7). Remove nuts (3), cap screws, and washers securing auxiliary steering pump and motor (7). 13. Remove pressure tube (5) and auxiliary steering pump and motor (7).

Installation 1. Position auxiliary steering pump and motor (7) on its mounting plate while connecting and hand tightening pressure tube (5) to auxiliary steering priority valve (6). See illustration on page 13.

10. Put master disconnect switch in ON position. 11. Start and run engine at low idle and raise bucket 500 mm (20 inches) above ground. Check that auxiliary steering light on information center is OFF. IMPORTANT: In following Step, do not run auxiliary steering pump and motor continuously for more than 20 seconds at a time without a two minute cool down. 12. With engine at low idle and machine steering straight ahead, turn key switch to OFF position to stop engine and then immediately back to ON position (not START position). Auxiliary steering pump and motor should start operating immediately. Check that auxiliary steering light on information center is ON and auxiliary steering pump and motor is operating. 13. Turn steering wheel all the way to left and right to make sure that auxiliary steering pump and motor operates correctly. 14. Restart engine. Check that auxiliary steering light on information center stays ON and auxiliary steering pump and motor is operating. After about three seconds motor should stop operating and auxiliary steering light should go out. 15. Let engine run and allow batteries to recharge for a minimum of 10 minutes.

2. While supporting auxiliary steering pump and motor (7) have an assistant install cap screws, washers, and nuts (3) to secure auxiliary steering pump and motor (7), tighten the nuts. 3. Tighten pressure tube (5) fittings securely. 4. Start vacuum pump. 5. Remove plug from suction hose (4) and cap from elbow. Connect suction hose to elbow installed in auxiliary steering pump and motor (7). 6. Stop and disconnect vacuum pump. Install fill cap in hydraulic reservoir. 84489509

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7 4 5 6 8

W230R005

1. GROUND CABLE 2. POSITIVE CABLE 3. NUT (4)

4. SUCTION HOSE 7. AUXILIARY STEERING PUMP AND MOTOR 5. PRESSURE TUBE 8. WIRING HARNESS 6. AUXILIARY STEERING PRIORITY VALVE AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

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STEERING CYLINDER Removal 1. Loosen the fill cap for the hydraulic reservoir to release pressure in the reservoir, then tighten the fill cap. 2. Disconnect grease hoses (1) from steering cylinders (11). See illustration on page 15. 3. Disconnect hydraulic hoses (2, 3, 9, 10, 16 and 17) from steering cylinders (11). 4. Install a plug in each hose (2, 3, 9, and 10) to prevent entry of foreign matter. 5. Remove locknut (15). 6. Remove cap screw (13). 7. Remove pin (12). 8. Remove washers (14). 9. Remove cap screw (8), washer (7), and spacer (6) securing pivot pin (5) at rear of steering cylinders (11). 10. Use a suitable driver and drive pivot pin (5) out of steering cylinder (11). 11. Remove washer(s) (4) from between steering cylinders (11) and rear frame of machine. 12. Remove steering cylinders (11).

Installation 1. Put steering cylinders (11) in position in machine. Make sure th at wa shers (4) are installed between steering cylinder (11) and rear frame. See illustration on page 15. NOTE: Install a washer (4) on top and bottom of steering cylinders (11) if possible. If only one washer (4) can be installed, place washer (4) at bottom of steering cylinders (11). 2. Make sure washers (14) are installed between steering cylinders (11) and front frame of machine. 3. Install the pivot pin (5) to secure rear of steering cylinders (11) to machine frame. Install spacer (6), washer (7), and cap screw (8) to secure pivot pin (5). 4. Tighten cap screw (8). 5. Install pin (12) in front of steering cylinders (11). Make sure that washers (14) are installed in correct position. 6. Install cap screw (13) and new locknut (15) in steering cylinders (11) rod end and pin (12). Tighten locknut (15). NOTE: Cap screw (13) should turn freely in hole after tightening. 7. Connect hose assemblies 2, 3, 9, 10, 16 and 17) to steering cylinders (11). 8. Connect grease hoses (1) 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.

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5001-15

8 7 6 5 9 4 16

10 11

3 12

1 14

1 15 11

W230R006

1. 2. 3. 4. 5.

GREASE HOSE HOSE ASSEMBLY HOSE ASSEMBLY WASHER PIVOT PIN

6. 7. 8. 9. 10.

SPACER 11. WASHER 12. CAP SCREW 13. HOSE ASSEMBLY 14. HOSE ASSEMBLY 15.

STEERING CYLINDER PIN CAP SCREW WASHER LOCKNUT

16. HOSE ASSEMBLY 17. HOSE ASSEMBLY

STEERING CYLINDER ILLUSTRATION

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5001-16

STEERING BACK PRESSURE VALVE Removal 1. Remove the fill cap for the hydraulic reservoir to release pressure in the reservoir, attach a vacuum pump to the reservoir, start the pump. 2. Disconnect hoses 2 and 6 from the pressure valve. 3. Remove the nuts, bolts and spacers from the pressure vale, remove the valve from the machine.

Installation 1. Install the valve, bolts, spacers and nuts onto the machine, tighten the bolts. 2. Install new O-rings onto the fittings of the hoses, install and tighten the hoses. 3. Stop the vacuum pump, install and tighten the reservoir filler cap. 4. Start and run the machine at low idle, turn the steering wheel from full left lock to full right lock holding the steering over relief. 5. Stop the machine and check for leaks. 6. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

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BS06G529

1. 2. 3. 4.

STEERING CONTROL VALVE RETURN HOSE PRESSURE HOSE CONNECTOR M27 ORB

5. RELIEF VALVE 6. RETURN HOSE TO FILTERS 7. RETURN MANIFOLD

STEERING BACK PRESSURE VALVE ILLUSTRATION

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NOTES

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5002

Section 5002 STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

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

84489509

5002-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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.

4. Do the main hydraulic pump test. See Section 8002. If the main pump is bad, repair or replace the main hydraulic pump.

1. Make sure the oil level in the hydraulic reservoir is correct. Visually inspect the steering system for leakage and damage.

5. Test the steering cylinders for leakage, refer to instructions on page 8. If a steering cylinder is leaking, repair or replace the steering cylinder.

2. The loader/steering pump differential pressure must be properly adjusted. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump differential Pressure.

6. If the steering system is noisy test the back pressure relief valve, refer to instructions on page 9.

3. Do the steering limit valve pressure test. Refer to page 6. If the pressure is above or below specifications, adjust the steering limit valve.

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5002-4

AUXILIARY STEERING SYSTEM PUMP TEST Equipment Required

6. Connect the ammeter clamp (1) to the cable as in illustration.

1. 380001731 Flowmeter 2. 380001740 Flowmeter fitting kit

Test Procedure 1. Install articulation lock.

BB830300

1. AMMETER CLAMP

7. Make sure that the parking brake is applied and the bucket is on the floor.

1 W230R407

1. ARTICULATION LOCK

NOTE: When performing this pressure check, always be sure the articulation lock is in place, especially when working in the articulation joint areas. 2. Loosen and remove the outlet hose to the Auxiliary Steering Pump from the Auxiliary Steering Priority Valve. 3. Install a plug into the Auxiliary Steering Priority Valve. 4. Connect the inlet of the flowmeter to the outlet line of the Auxiliary Steering Pump. 5. Install the outlet hose of the flowmeter in the hydraulic reservoir and hold in place with wire.

8. Make sure that temperature.

the

oil

operating

9. Make sure that the load valve for the flowmeter is open (zero pressure). 10. Start and run the engine. 11. Stop the engine and turn the key back to the On position. 12. Turn the steering wheel, this will activate the auxiliary steering pump. 13. Turn the load valve on the flowmeter towards CLOSED until the pressure is 104 bar (1500 psi). 14. Read the flowmeter and ammeter gauges and record the readings. 15. The flowmeter reading must not be less than 24.6 L/min, (6.5 U.S. gpm). The ammeter reading must be 315 amps. 16. Turn the key switch to the OFF position. If the flow was less than the specification, or if the amperage was more than 315 amperes, remove the auxiliary steering motor and pump. Test the auxiliary steering motor. If the motor is good, make repairs to the pump.

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AUXILIARY STEERING SYSTEM MOTOR TEST Test Equipment

5. Push the button on the remote starter switch (1) and look at the voltmeter in the tester.

1. A 24 volt battery that is fully charged. NOTE: A 24 volt battery system (two 12 volt batteries in a series) is used for this test. A 12 volt battery system will cause damage to the auxiliary steering motor.

6. Turn the load control (8) until the voltmeter (7) indicates 24 volts. Look at the ammeter (6) in the tester. Make a record of the ammeter indication.

2. A remote starter switch.

3. A tachometer to check the armature speed. 4. A Sun Electric VAT-33 Starting and Charging System Tester.

Test Procedure 1. Remove the connector that is between the terminals on the magnetic switch and the auxiliary steering motor. 2. Remove the auxiliary steering motor from the auxiliary steering pump. 3. Remove the drive coupling from the auxiliary steering motor (3). 4. Connect the auxiliary steering motor (3), remote starter switch (1) and tester (2) to the 24 volt battery system (5) as illustrated.

6. AMMETER 7. VOLTMETER 8. LOAD CONTROL

7. Hold the tachometer against the armature shaft. Look at the tachometer. Make a record of the indication. 8. Release the button on the remote starter switch (1).

Understanding The Results Of The Test 1. If the ammeter indication in step 6 was 30 amperes or less and the tachometer indication in step 7 was 6950 r/min (rpm) or more, the auxiliary steering motor is good.

B795328

2. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was higher than 30 amperes, replace the motor.

B790852

1. 2. 3. 4. 5.

84489509

REMOTE STARTER SWITCH TESTER AUXILIARY STEERING MOTOR AMMETER CLAMP 24 VOLT BATTERY SYSTEM

Issued 04-11

Printed in E.C.

5002-6

STEERING PRIORITY VALVE NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.

Pressure Setting Test

4. Make sure that the temperature of the hydraulic oil is at least 54Â° C (129Â° F).

1. Install articulation lock (1).

5. To measure the temperature of the oil using the instrument panel: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored. 6. Apply the parking brake. 7. Start and run the engine at full throttle. 8. Lower the lift arms and hold the control lever in the FLOAT position.

9. Hold the bucket control lever in the rollback position. W230R407

1. ARTICULATION LOCK

IMPORTANT: When performing the following pressure check and adjustment, the articulation lock must be installed. Use caution when working in or near the articulation area. 2. Remove the dust cap from the test port (1).

10. Continue holding until the specified temperature of the oil is reached. 11. Stop the engine. 12. Start the engine and operate the machine at full throttle. 13. With the articulation lock still in place, turn and hold the steering wheel for a hard right turn. 14. Continue holding the steering wheel, and read the pressure gauge. 15. The pressure gauge must indicate 239 to 243 bar (3465 to 3525 psi). If the pressure is not correct, adjust the steering relief valve.

2 1 BD06F148

1. G1 TEST PORT 2. G2 TEST PORT

3. Connect a 345 bar (5000 psi) pressure gauge to the test port (2). NOTE: Make sure when you connect the pressure gauge that you do so in a manner that you can read the pressure gauge while sitting in the operators seat.

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Issued 04-11

Printed in E.C.

5002-7

Pressure Setting Adjustment 1. Turn the adjusting screw clockwise to increase the pressure setting. Turn the adjusting screw counterclockwise to decrease the pressure setting. 2. Repeat pressure test procedure. 3. If necessary, adjust the limit valve again until within the specified range. 4. Stop the engine before removing the pressure gauge.

BD06F147

1. STEERING PRIORITY VALVE 2. LIMIT VALVE

84489509

Issued 04-11

Printed in E.C.

5002-8

STEERING CYLINDER LEAK TEST NOTE: Make sure all persons are clear of the area of the center pivot. Make sure the center pivot is free of any obstructions. 1. Park the machine on a level surface. 2. Turn the machine all the way to the right. 3. Stop the engine and apply the parking brake. 4. Find the tube that is connected to the rod end of the left-hand steering cylinder. Disconnect the tube from the left-hand cylinder. 5. Install a plug in the tube. 6. Start and run the engine at full throttle. 7. Turn the steering wheel to the right. Hold the steering wheel for a full right turn. Have another person check for leakage from the opening of the rod end of the left-hand steering cylinder. 8. If there is constant leakage from the rod end, the piston packing in the left-hand steering cylinder is damaged. Repairs must be made. See Section 5005.

84489509

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.

Issued 04-11

Printed in E.C.

5002-9

STEERING BACK PRESSURE VALVE 1

BS06G529

1. 2. 3. 4.

84489509

STEERING CONTROL VALVE RETURN HOSE PRESSURE HOSE CONNECTOR M27 ORB

5. RELIEF VALVE 6. RETURN HOSE TO FILTERS 7. RETURN MANIFOLD

Issued 04-11

Printed in E.C.

5002-10

Pressure Test 1. Disconnect the return hose (2) from the connector (4). 2. Install a â&#x20AC;&#x153;Tâ&#x20AC;? fitting and connect a pressure gauge capable of reading 35 bar (500 psi). 3. Start and run the machine at high idle.

84489509

4. Turn the steering wheel and observe the pressure. 5. The pressure should be 8 to 10 bar (115 to 145 psi). 6. If pressure is not as specified, replace the relief valve. NOTE: The relief valve is not adjustable.

Issued 04-11

Printed in E.C.

Section 5005

5005

STEERING CYLINDERS

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

84489509

5005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Issued 04-11

3 3 3 3 5

Printed in E.C.

5005-3

SPECIFICATIONS Torque for piston cap screw ....................................................................790 to 900 Nm (582.6 to 663.8 pound feet) Torque for gland ..................................................................................................407 Âą 68 Nm (300 Âą 50 pound feet)

STEERING CYLINDER Disassembly 1. Fasten tube (18) in a vise. Be careful not to damage the tube. See illustration on page 4. 2. Remove gland (1) from tube (18). 3. Pull piston rod (14) and piston (9) straight out of tube (18). 4. Fasten piston rod (14) yoke in vise and put a support below piston rod near piston (9). Put a shop cloth between support and piston rod to prevent damage to piston rod. 5. Loosen and remove bolt and washer (8) that hold piston (9). 6. Remove piston (9) from piston rod (14).

Inspection 1. Clean all parts in cleaning solvent. 2. Check to be sure that piston rod (14) is straight. If piston rod is bent, install a new piston rod. 3. Inspect inside of tube (18) for deep grooves and other damage. If there is any damage to tube, a new tube must be used. 4. Remove small scratches on piston rod (14) or inside tube (18) with emery cloth of medium grit. Use emery cloth with a rotary motion. 5. Inspect bushing (17). If bushing requires replacement, remove grease fitting (15) and retaining rings (16) then press bushing from tube end.

7. Remove and discard seal (13), loader ring (12), wear ring (11), and cast iron ring (10) from piston (9). 8. Remove gland (1) from piston rod (14). 9. Remove and discard O-ring (7), backup ring (6), rod wiper (2), rod seal (3), buffer seal (4), and bearing (5) from gland (1).

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Issued 04-11

Printed in E.C.

5005-4

16 17

8 9

13 12 11 10

14 2

BC05M089

1. 2. 3. 4. 5.

GLAND ROD WIPER ROD SEAL BUFFER SEAL BEARING

6. 7. 8. 9. 10.

BACKUP RING O-RING BOLT AND WASHER PISTON RING CAST IRON

11. 12. 13. 14. 15.

WEAR RING RING LOADER SEAL PISTON ROD GREASE FITTING

16. 17. 18. 19.

RETAINING RING BUSHING TUBE SCREW

STEERING CYLINDER ILLUSTRATION

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5005-5

Assembly 1. Install bearing (5) in gland (1). 2. Install buffer seal (4) in gland (1) so that lips of seal are toward small end of gland. 3. Install rod seal (3) in gland (1). Rod seal must be installed so that lips of seal are toward small end of gland. Seal can be difficult to install. Use tools that will not damage seal. See illustration on page 4. 4. Install rod wiper (2) in gland (1) with wiper lips toward large end of gland. 5. Install O-ring (7) on gland (1). 6. Install backup ring (6) on gland (1). The backup ring must be toward large end of gland. If backup ring is not flat on both sides, the side that is not flat must be toward O-ring (7). 7. Fasten piston rod (14) yoke in vise. 8. Lubricate piston rod (15) and bore in gland (1) with clean hydraulic oil. NOTE: If a new gland (1) is being installed, write part number of cylinder on gland. 9. Push gland (1) onto piston rod (14) large end first. If necessary, use a soft hammer to drive the gland onto piston rod. 10. Put a support below and near the end of piston rod (14). Put a cloth between support and piston rod to prevent damaging piston rod. 11. Install new cast iron ring (10) on piston (9). 12. Install new wear ring (11) on piston (9). 13. Install a new loader ring (12) on piston (9). 14. Install a new seal (13) over loader ring (12). 15. Clean the threads on the end of piston rod (14) and threads of bolt (8) using Loctite cleaning solvent. Allow to dry. Apply Loctite 243 to piston rod threads 6.4 mm (1/4 inch) from open end of piston rod so that there is 12.7 mm (1/2 inch) of Loctite 243 on piston rod threads. DO NOT apply Loctite to first 6.4 mm (1/4/inch) of piston rod threads.

84489509

16. Install bolt and hardened washer (8) in piston (9). 17. Install piston (9) on piston rod (14) and start bolt (8) into piston rod. 18. Tighten bolt (8) to a torque of 790 to 900 Nm (582.6 to 663.8 pound feet). 19. Fasten tube (18) in vise. Be careful not to damage tube. 20. Apply petroleum jelly to O-rings (7) and backup ring (6) on gland (1) and to sealing surface in tube (18). 21. Lubricate piston (9) and inside of tube (18) with clean hydraulic oil. 22. Push the piston (9) straight into tube (18). Be careful not to damage cast iron ring (10), wear ring (11), and seal (13) on piston (9). 23. When piston (9) is in smooth part of tube (18), start gland (1) into tube (18). 24. If the original parts are being assembled: A. Tighten gland to a torque of 407 ± 68 Nm (300 ± 50 pound-feet). B. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds). C. If, after tightening gland, the self-tapping screw (19) holes are not aligned, a new hole for self-tapping screw must be drilled. See Step 25. 25. If a new gland (1) or a new tube (18) are being assembled: A. Tighten gland (1) to a torque of 407 ± 68 Nm (300 ± 50 pound-feet). B. Use a No. 27 drill bit and drill a hole half in gland (1) and half in tube (18). Drill to a depth of 11 mm (7/16 inch). Do not drill within 13 mm (1/2 inch) of a hole for gland wrench. C. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds). 26. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.

Issued 04-11

Printed in E.C.

5005-6

NOTES

84489509

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Printed in E.C.

Section 5006

5006

CENTER PIVOT

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

84489509

5006-2

TABLE OF CONTENTS SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

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3 3 4 4 6 9

Printed in E.C.

5006-3

SPECIFICATIONS SPECIAL TORQUES M16 bolt for upper pivot pin.......................................................................224 to 278 Nm (165 to 205 pound-feet) M12 bolts for bearing retainers and lower pivot pin ..................................168 to 209 Nm (124 to 154 pound-feet) M12 bolts for lower pin plate .....................................................................224 to 278 Nm (165 to 205 pound-feet) Ferry head screws for the drive shaft ................................................................53 to 62 Nm (39 to 46 pound-feet) LUBRICANT Pivot bearings and seals ........................................................................................................ Molydisulfide grease Steering cylinder rod eyes...................................................................................................... Molydisulfide grease

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)

BC06A173

380001744 DRIVER SET

BC06A174

CAS2029 DRIVER SET

NOTE: The upper bearing can be installed using 380001744 Driver Set and the lower bearing can be installed using CAS2029 Driver Set.

84489509

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5006-4

CENTER PIVOT Disassembly 1. Remove all dirt and grease from the area of the center pivot. Park the machine on a level surface. 2. Lower the bucket until the bucket is flat on the floor. 3. Stop the engine and apply the parking brake. 4. Remove the covers from both sides of the machine. 5. Disconnect the front wiring harness from the cab floor. 6. Remove any tie straps that fasten the front wiring harness to the chassis near the center pivot. 7. Loosen and remove the nut and washer that fasten the chassis ground wire and cab ground wire to the studs. 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. 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. 12. Install a plug in the tube and a cap on the fitting. 13. Disconnect the hoses for the steering cylinder. 14. Install caps on the fittings and plugs in the hoses. 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. 17. Disconnect the return hose. 18. Install the cap on the hose and a plug in the fitting.

84489509

19. Disconnect the supply hose. 20. Install a cap on the hose and a plug in the fitting. 21. Stop the vacuum pump. 22. Loosen and remove the self-locking nut and bolt that hold the pivot pin for the steering cylinder rod eye. 23. Remove the pivot pin from the rear frame and the steering cylinder rod eye. 24. Remove the washer from the rear frame. Move the steering cylinder out of the way. 25. Repeat steps 22, 23 and 24 for the other steering cylinder. 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. 27. Place two stands below and in contact with the front frame. 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. 30. Loosen and remove the bolt (1), washer (2), and spacer (3) that fasten the upper pivot pin (4) to the rear chassis (5). 31. Use a prybar to remove the upper pivot pin (4). 32. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10). 33. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the bottom of the rear chassis (5). 34. Use the ram and hand pump to remove the lower pivot pin (10). 35. Install the puller on the bottom spacer (14), see Special Tools in this section.

Issued 04-11

Printed in E.C.

5006-5

2 3

7 5

10 6

9 5

11 6

8 13 6

8 15

BS03B152

1. 2. 3. 4.

BOLT WASHER SPACER UPPER PIVOT PIN

5. 6. 7. 8.

REAR CHASSIS SEAL BEARING RETAINER SHIM

9. 10. 11. 12.

UPPER PIVOT BEARING LOWER PIVOT PIN LOWER BEARING SPACER LOWER PIVOT BEARING

13. 14. 15. 16.

BEARING RETAINER BOTTOM SPACER LOWER PIN PLATE FRONT CHASSIS

CENTER PIVOT ASSEMBLY

84489509

Issued 04-11

Printed in E.C.

5006-6 36. Remove the bottom spacer (14). 37. Release the parking brake. 38. Use prybars to turn the left rear wheel backwards and the right rear wheel forward to move the front of the rear frame to the left for access to the bearings. Install blocks under the wheels to prevent the rear frame from moving.

Assembly 1. Pack the bearing cones with grease. Be careful not to mix the bearing cones. 2. Lubricate the bore in the top pivot with grease. 3. Install a bearing cup (20) in the top pivot (22). 4. Install the bearing driver (17) and plate (21).

39. Apply the parking brake.

17 18

40. Hold the bearing retainer (13) in place and loosen and remove the bolts (1) and washers (2) that fasten the bearing retainer (13) and shims (8) to the bottom of the rear pivot.

41. Remove the bearing retainer (13) and shims (8). 42. Remove the lower bearing spacer (11) from the top of the lower pivot. 43. Loosen and remove the bolts (1) and washers (2) that fasten the bearing retainer (7) and shims (8) to the top of the top pivot. 44. Remove the bearing retainer (7) and shims (8). 45. Use the puller to remove the seal (6) from the top of the bottom pivot. 46. Use the puller to remove the seal (6) from the bottom of the top pivot. 47. Use an acceptable driver, the hydraulic ram, and the hand pump to remove the upper pivot bearing (9) from the top pivot. See Special Tools in this section. NOTE: The spacers are matched to the bearing sets. Do not mix the spacers. Do not use the old spacers if new bearing sets are being installed. 48. Use an acceptable driver, the hydraulic ram, and the hand pump to remove the lower pivot bearing (12) from the bottom pivot. See Special Tools in this section. NOTE: The spacers are matched to the bearing sets. Do not mix the spacers. Do not use the old spacers if new bearing sets are being installed.

20 21

22 BC06A118

17. BEARING DRIVER 18. NUT 19. SREW

20. BEARING CUP 21. PLATE 22. TOP PIVOT

5. Tighten a nut (18) on the screw (19) until the bearing cup (20) is seated in the bore of the top pivot (22). Remove the bearing driver (17) and plate (21) from the top pivot (22). 6. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the top pivot (22). 7. Install the bearing driver (17) and plate (21). 8. Tighten a nut (18) on the screw (19) until the bearing cup (26) is seated against the spacer (24). Remove the bearing driver (17) and plate (21) from the top pivot (22).

19 26

49. Use an acceptable driver to press the seal (6) out of each bearing retainer (7 and 13).

22 BC06A119

23. BEARING CONE 24. SPCAER

84489509

25. BEARING CONE 26. BEARING CUP

Issued 04-11

Printed in E.C.

5006-7 9. Put the bearing retainer (7) in place on the upper pivot bearing assembly (9). 10. Install the bearing driver (17) and plate (21). 11. Tighten a nut (18) on the screw (19) until the bearing retainer (7) is tight against the upper pivot bearing assembly (9).

18. Use an acceptable driver to install the seal (6) in the bottom of the top pivot. 19. The bottom of the seal (6) must be even with the bottom of the top pivot.

BC06A125.

20. Apply grease to the upper pivot pin (4). BC06A120

12. Measure the gap (27) between the bearing retainer (7) and the top pivot (22). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 13. Remove the bearing driver (17), plate (21), and bearing retainer (7) from the top pivot. 14. Install the shims (8) and the bearing retainer (7). 15. Install the washers (2) and bolts (1). Tighten the bolts (1) to 124 Nm (91 pound-feet).

21. Install the upper pivot pin (4) in the top pivot. 22. Lubricate the top pivot until grease is forced out of the seal (6). 23. Rotate the upper pivot pin (4) to check the bearing assembly. The upper pivot pin (4) must rotate smoothly, but not easily. Leave the upper pivot pin (4) in place to keep dirt out of the upper pivot bearing (9). 24. Lubricate the bore for the bottom pivot with grease. Install a bearing cup in the bottom pivot. 25. Install the bearing driver (17) and plate (21).

16. Install the seal (6) in the bearing retainer (7). The top of the seal (6) must be even with the top of the bearing retainer (7).

18 28 29

17 BC06A123

BC06A121

17. Fill the other seal (6) for the top pivot with grease.

26. Tighten a nut (18) on the screw (19) until the bearing cup (28) is seated in the bore in the bottom pivot (29). 27. Remove the bearing driver (17) and plate (21) from the bottom pivot (29). 28. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the bottom pivot (29). 29. Install the bearing driver (17) and plate (21).

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Printed in E.C.

5006-8

40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13).

24 29

BC06A124

30. Tighten a nut (18) on the screw (19) until the bottom bearing cup (26) is seated against the spacer (24). 31. Remove the bearing driver (17) and plate (21) from the bottom pivot (29).

BC06A126

41. Install the other seal (6) in the bottom pivot. The top of the seal (6) must be even with the top of the bottom pivot.

32. Put the bearing retainer (13) in place on the lower pivot bearing (12). 33. Install the bearing driver and plate.

19 29 30

BC06A121

42. Install the lower bearing spacer (11) and the bottom spacer (14).

13 BC06A125

34. Tighten a nut (18) on the screw (19) until the bearing retainer (13) is tight against the lower pivot bearing assembly (12). 35. Measure the gap (30) between the bearing retainer (13) and the bottom pivot (29). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 36. Remove the bearing driver (17), plate (21) and bearing retainer (13) from the bottom pivot.

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).

37. Install the shims (8), the bearing retainer (13), washers (2) and bolts (1). 38. Tighten the bolts (1) to 124 Nm (91 pound-feet). 39. Fill the seal (6) for the bearing retainer (13) with grease.

84489509

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Printed in E.C.

5006-9

CONNECTING THE FRONT FRAME TO THE REAR FRAME 1. Release the parking brake. 2. Move the rear frame into alignment with the front frame. 3. Move the steering cylinders as required to move the rear frame into alignment with the front frame.

26. Align the hole in the pivot pin with the holes in the steering cylinder rod eye, and install the pivot pin. 27. Install the bolt and self-locking nut that hold the pivot pin.

4. Apply the parking brake.

28. Repeat steps 25, 26 and 27 for the other steering cylinder.

5. Apply grease to the upper pivot pin (4).

29. Start the vacuum pump.

6. Install the upper pivot pin (4), spacer (3), washer (2) and bolt (1). Be careful not to damage the seal (6).

30. Connect the return hose. 31. Connect the supply hose.

8. Apply grease to the lower pivot pin (10).

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.

9. Install the lower pivot pin (10) in the frames. Be careful not to damage the seal (6).

33. Put the bracket for the hoses in position on the front frame.

10. Use the ram and hand pump to install the bottom spacer (14). See Special Tools in this section.

34. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the front frame.

11. Install the lower pin plate (15), three inner bolts (1), and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10).

35. Connect the hoses for the steering cylinders.

12. Tighten the bolts (1) to 69 Nm (51 pound-feet).

37. Stop the vacuum pump.

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.

38. Connect the front wiring harness to the rear wiring harness.

7. Tighten the bolt (1) to 224 to 278 Nm (165 to 205 pound-feet).

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. 16. Install the shims (8). 17. Tighten the six outer bolts (1) to 224 to 278 Nm (165 to 205 pound-feet). 18. Tighten the three inner bolts (1) to 168 to 209 Nm (124 to 154 pound-feet).

36. Connect the brake hose for the front brakes at the front bracket.

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. 41. Install a tie strap to fasten the wiring harness to the tube. 42. Disconnect the vacuum pump from the hydraulic reservoir.

19. Remove the jacks from the rear frame.

43. Check the fluid level in the hydraulic reservoir. Add oil as required.

20. Remove the blocks from the rear axle.

44. Install the fill cap in the hydraulic reservoir.

21. Remove the stands from the front frame. 22. Put the drive shaft in position on the front yoke.

45. Bleed air from the front axle bleed screws. Refer to Section 7002 for complete brake bleeding instructions.

23. Install new Ferry head screws that fasten the drive shaft to the front yoke.

46. Lubricate the pivot pins for the steering cylinder rod eyes.

24. Tighten the Ferry head screws to 53 to 62 Nm (39 to 46 pound-feet).

47. Install the covers on both sides of the machine.

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. 84489509

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Printed in E.C.

5006-10

NOTES

84489509

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Printed in E.C.

Section 5008

5008

AUXILIARY STEERING MOTOR AND PUMP

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

84489509

5008-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

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3 4 4 4 4

Printed in E.C.

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)

84489509

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Printed in E.C.

5008-4

AUXILIARY STEERING MOTOR AND PUMP Assembly

Disassembly NOTE: Refer to Section 5001 for removal installation of the auxiliary steering motor and pump.

and

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).

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).

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 assembly are (7), seal (4), of the other assembly.

only serviceable items on the pump the seals (6), backup rings (5), O-rings retaining ring (3) and gasket (13). If any items are damaged, replace the pump

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. 84489509

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Printed in E.C.

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

19. 20. 21. 22. 23.

DRIVEN GEAR DRIVE GEAR END PLATE PINS WEAR PLATE

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

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5008-6

NOTES

84489509

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Printed in E.C.

5009 Section 5009 JOYSTICK STEERING SYSTEM (JSS) (optional)

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

84489509

5009-2

TABLE OF CONTENTS SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Main F-N-R lever activation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Activation procedure for auxiliary JSS F-N-R (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 JSS Related Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WORKING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 JSS HYDRAULIC PRESSURE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 STEERING CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

84489509

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Printed in E.C.

5009-3

SAFETY STANDARDS 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 machine 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 machine from the trailer loading deck. The machine 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 implement 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 highway, lock the LH arm in the vertical position with the special pin.

84489509

Issued 04-11

Printed in E.C.

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 machine. The main components of the JSS are: - proportional valve PVG32 with pilot solenoid valve incorporated;

The JSS must be disconnected for driving on roads For safely turning on and off, there is a specific procedure to avoid accidental turning on/off and steering (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. at the top N/C (normally closed); 2. at the bottom N/O (normally open); - three-position switch (3) to control the JSS: 1. Off - retained with mechanical lock; 2. On - retained; 3. activation - transitory position (clicks);

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;

521E-4R001

- 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 speed with which it is possible to work with this system depends on the type of terrain.

84489509

Issued 04-11

Printed in E.C.

5009-5

Activation logic of the software and joystick steering

Joystick steering is turned off as soon as:

To enable the joystick steering system it is necessary first of all to put the machine 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 machine is in a condition of safety. Secondarily it checks the efficiency of the system.

- the gearbox / main lever control is moved from neutral to forward or reverse drive;

Preliminary check The condition of the machine being made safe is given by: - left armrest completely lowered; - gear lever in neutral; - implement locking switch disenabled; - pilot pressure switch on;

- the left armrest is raised;

- the steering wheel is operated; - the proportional valve suffers trouble; - system errors occur; - the JSS switch is disconnected; - 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.

- joystick steering switch in neutral; - machine 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 switching of the N/O-N/C switch is checked. Any trouble is detected with an error message and the system is switched off; When all the prerequisites have been satisfied the JSS will be powered via closure of 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;

84489509

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Printed in E.C.

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. F-N-R (current) main located on the gear lever of the steering column; 2. F-N-R (current) AUX incorporated on the implement control joystick (or console on right-hand side); 3. JSS F-N-R (new) AUX 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

- 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, 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 ON button: a. armrest on left-hand side lowered; b. implement 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 raised; 4. JSS enabling button OFF; 5. errors in the JSS; 6. engine OFF.

- 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; 84489509

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Printed in E.C.

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 machine is provided with an implement 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&#x2014;? 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. machine stationary; d. engine ON; â&#x2014;? auxiliary F-N-R provides enabling signal for 8 seconds; a. within 8 seconds: 1. press the parking brake release button; 2. engage 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 implement 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.

84489509

Issued 04-11

Printed in E.C.

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: Starting status

JSS Off

JSS On

JSS / AUX F-N-R disenabled

(JSS) AUX F-N-R enabled

JSS / AUX F-N-R disenabled

JSS (AUX) F-N-R enabled

JSS activation signal

Auxiliary F-N-R enabling signal

F-N-R enabling signal or JSS enabling signal

JSS safety conditions to be respected

Implement 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 error JSS system.

Resulting JSS status

JSS On

JSS Off

JSS On

F-N-R conditions

JSS On JSS F-N-R = neutral.

Vehicle stationary; Main F-N-R gear lever = neutral; AUX F-N-R = neutral.

Vehicle stationary Main F-N-R gear lever = neutral; AUX F-N-R = neutral.

Resulting F-N-R status

JSS F-N-R Enabled Stays enabled.

AUX F-N-R Enabled within 8 seconds release parking brake and engage F or R to maintain enabling.

JSS F-N-R Enabled

F-N-R conditions not respected

If JSS F-N-R not in neutral.

If AUX F-N-R not in neutral.

Alternative F-N-R status

JSS / AUX F-N-R disenabled.

Activation signal

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Printed in E.C.

5009-9

JSS Related Error Handling All JSS related errors will be displayed only while the JSS activation switch is in ON position except for the red error “Short to power on power supply” and the failure of the activation switch which will be always displayed when present. All JSS related errors will be reset by switching the JSS activation switch to the OFF position. While ignition is ON and JSS is deactivated the software will check if the JSS Power Supply is off. Check JSS Output Control is low/open if not a red error will be displayed “Short on JSS power supply JSS active” Table of error codes Error Item

Location of Error Detection

1812y

JSC

Open Circuit, Short to Battery or Short to Ground at JSS armrest switch.

1816y

JSC

Open Circuit / JSS activation switch mechanical defect.

1820y

JSC

Check JSS Relay, JSS Valve, JSS Joystick power supply connections.

1821r

JSC

Short to ground on JSS Relay 85/AIC1.21 or short to Power on Relay 86/87a. Or Activation Switch failure.

1823y

JSC

JSS RELAY, GROUND CONNECT., BAD ELEC. CONNCT. Permanent ground at JSS Relay (87) open circuit or short to power.

1824y

JSC

Short to battery at activation button. Aactivation switch failure.

1829y

JSC

Joystiok Steering is not calibrated.

1830y

JSC

Open circuit between activation switch Pin 3 and C5.E Pin 1.

1831y

JSC

JSC CONTROLLER, WRONG OPERATION. JSC controller internal fault.

1832y

JSC

JSC CONTROLLER, JSC SIGNAL IN, OUT OF LIMITS. Input signal from JSS joystick to JSC controller out of limits. (Joystick Neutral: USignal>40%UBat + <60%Ubat; Joystick Actuated: USignal>20%UBat + <80%UBat)

1833y

JSC

Output signal from JSC controller to valve out of limits. Check connector of JSS valve and JSC controller.

1834y

JSC

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 defect.

1835y

AIC

JSS-valve/Pin4 JSC/Pin5 short to power, short to ground or open circuit.

1836y

JSC

JSS CONTROLLER, BOARD TEMPERATURE, OUT OF LIMITS Temperature on the JSC board is <-40°C or >+85°C; Check ambient temperature or short circuit at JSC power outputs.

1837y

JSC

JSS CONTROLLER, SWITCHED POWER, OUT OF LIMITS Switched power supply at JSC Pin3 is out of limit; Check elect connection for electrical transients, burst or drifts.

1838y

JSC

Neutral Sw out of range.

Message

1841y

JSC

JSS valve internal error, spool position not accurate or signal voltage out of range.

1842y

JSC

JSS valve Pin2 (alarm signal) open circuit.

1843y

JSC

Pilot pressure switch open when JSS 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.

1844y

JSC

Pilot pressure switch short to ground.

JSC

Pilot pressure switch stays closed (Input JSC8 =1) allthough 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.

1845y

84489509

Issued 04-11

Printed in E.C.

5009-10 Error Item

Location of Error Detection

1846y

JSC

Standard steering orbitro tank pressure transducer switch short to power or short to ground.

1847y

JSC

JSC Model type not available, no model type information available in JSC, probably missing information from AIC.

1850y

JSC

JSS joystick Pins2, 4 or 6 short to ground, short to battery or open circuit. Or JSS joystick internal failure.

Message

1852y

JSC

JSS joystick Pins5 open circuit. Or JSS joystick internal failure.

1860y

JSC

CAN timeout of C5.E detected by JSC.

1861y

JSC

CAN timeout of AIC detected by JSC Controller.

1863y

AIC

Internal malfunction transmission controller. TCU message JSS F-N-R dissabled or JSS F-N-R not activated.

9128y

AIC

CAN timed out during operation

9134y

AIC

CAN timed out during operation C5.E detected by AIC

9135y

AIC

CAN timed out during operation JSC detected by AIC

84489509

Issued 04-11

Printed in E.C.

5009-11

WORKING PRINCIPLE The main components of the JOYSTICK STEERING SYSTEM are: - hydraulic valves â&#x2014;? proportional steering valve PVG32 (1) for activating the steering cylinders with an incorporated pilot solenoid valve (2); â&#x2014;? 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 implement control Joystick on right-hand side.

If, when using the JSS, 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 machine on and off a truck for transport. For signalling any JSS malfunctioning, there are some warning lights on the control panel accompanied by audible warnings of two different lengths depending on the trouble that has occurred.

The JSS is controlled by a switch (8) located on the control panel, which, via software loaded on a component (9) installed inside the armrest, checks that there are all the necessary safety conditions for correct operation of the system. These conditions must be: a. left armrest completely lowered; b. gear lever in neutral; c. implement locking switch disenabled; d. pilot pressure sensor closed; e. JSS switch (8) in neutral; f. machine stationary. If not even one of these conditions occurs, the software will not allow activation of the system. Only after the software receives all the information and confirms that the general situation is correct will it allow operation of the joystick that, via an electric signal, activates the pilot solenoid valve (2) located inside the proportional valve PVG32 (1). The actuator inside the electric module (6) of the proportional valve of the steering gear (1) sets the directional shuttle in operation that 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).

84489509

Issued 04-11

Printed in E.C.

2 212 bar

1 212 bar

3 212 bar

5009-12

W230R057

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 84489509

Issued 04-11

Printed in E.C.

T LS

5009-13

Connections ports A and B. to the steering cylinder on the stem side and bottom side 350 bar, 100 l/min LS port. to port 3 of the valve PVFC port P. to the steering priority valve 350 bar, 150-230 l/min

W190-4R092

port PP. port T. port T2. port TO, LX.

pilot pressure switch 8 bar outlet 25/40 bar not used not used

Illustration of the valve PVG32 84489509

Issued 04-11

Printed in E.C.

5009-14

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

Valve PVPV Valve PVM Valve PVB Shuttle PVBS Valve PVES Valve PVSI

7. 8. 9. 10. 11.

W190-4R099

Screws Seal Seal Seal Seal

Exploded view of the valve PVG32 84489509

Issued 04-11

Printed in E.C.

5009-15

5.7 Nm

1.7 Nm

5.7 Nm

+/Vbat Signal SW1 +/SW2

1 3

PVE E

W190-4R093

Illustration of the Joystick Steering PVRES

84489509

Issued 04-11

Printed in E.C.

5009-16

ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM Removal

STEP 2

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.

1 3 2

IMPORTANT: MARK and LABEL all the various parts (electric connections, hydraulic connections, etc..) so as to facilitate all the various operations of INSTALLATION.

6 W190-4R071

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 electric actuator of the proportional 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).

84489509

Issued 04-11

Printed in E.C.

5009-17

STEP 3

STEP 4

9 10

1 W190-4R072

Release the chassis frame cable (1) from the stud pin (9) positioned on the rear chassis frame (10) of the machine by removing the nut (11).

W190-4R073

From the right-hand side of the machine, under the cab, open the door to access the fuse and relay compartment 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).

84489509

Issued 04-11

Printed in E.C.

5009-18

STEP 5

STEP 6

4 4

W190-4R075

W190-4R074

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).

Disconnect the cab/joystick cable (2) from the cab wiring (3) by disconnecting the twelve-position "DEUTSCH" connector (4).

84489509

Issued 04-11

Printed in E.C.

5009-19

STEP 7

STEP 8 5

10 9

5 12 11 W190-4R076

Disconnect the cab/joystick cable (2) from the steering contro l de vice (5) by detac hing the 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).

STEP 9 6

1 5

W190-4R078

Staccare il cavo cabina/joystick (1) dai punti di fissaggio situati sul pannello fusibili e relĂ¨ (2) mediante la rimozione dei due connettori a cinque posizioni (3), svitando i dadi (4, q.tĂ totale 2), le rondelle (5) e le viti (6). Remove the cab / joystick cable (1). 84489509

Issued 04-11

Printed in E.C.

5009-20

STEP 10

ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM 7

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

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Plate Steering control device Cab/joystick cable Chassis frame cable Washer Screw Nut Joystick Steering System switch Nylon strap Screw Washer Nut 10A fuse in position ECA-F2 Cab Stud pin on rear chassis frame Cable terminal with eyelet Metal cable clamp Armrest cable Control joystick CAN module Relay Diode Pressure switch 8 bar Pressure switch 60 bar Steering valve PVFC Steering valve PVG32 Armrest position switch F-N-R switch Kick-Down switch Solenoid Valve

W190-4R080

To remove the armrest cable (9), refer to the chapter titled "JOYSTICK STEERING ARMREST."

84489509

Issued 04-11

Printed in E.C.

5009-23

Installation

STEP 13

STEP 12 1 1 3 11

2 4

9 10 W190-4R088

Fasten the chassis frame cable (1) to the stud pin (9) positioned on the rear chassis frame (10) of the machine by installing the nut (11).

STEP 14 5

6 W190-4R071

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. Connect 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

On the right-hand side of the machine, under the cab, open the door providing access to the fuse and relay compartment and fit 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).

84489509

Issued 04-11

Printed in E.C.

5009-24

STEP 15

STEP 17 2

9 10

8 1 3

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

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). 84489509

Issued 04-11

Printed in E.C.

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.”

84489509

Issued 04-11

Printed in E.C.

5009-26

STEERING VALVES PVG32 AND PVFC Removal

STEP 3

STEP 1 Remove all dirt and grease from the steering valves and adjacent area.

STEP 2 4

3 1 2

W230R028

W230R029

Disconnect the connection hose (4) from the valve PVFC (2), with the auxiliary steering valve and the hose (5) coming from the steering priority valve. Plug the hoses in order to avoid oil spillage and the fittings to prevent debris getting inside.

STEP 4

Detach the rigid steering pipe LS (3) from the valve PVG32 (1) and from the valve PVFC (2).

W230R030

Disconnect the suction hose (6) of the steering priority valve from the valve PVG32.

84489509

Issued 04-11

Printed in E.C.

5009-27

STEP 5

STEP 7 1 3

W230R031

Disconnect the outlet hose (1).

STEP 6

W230R033

Disconnect the stem side steering cylinder line supply hose (3).

STEP 8 2 4

W230R032

Disconnect the bottom side steering cylinder line supply hose (2).

7 6

W230R034

Remove the steering valve PVG32 (4) from the support (5) by taking out the fixing screws (6, qty. 4) complete with washers (7).

84489509

Issued 04-11

Printed in E.C.

5009-28

STEP 9

STEP 12 1

11 3 2

5 4

W190-4R009

Remove the support (1) from the side wall of the rear chassis frame by removing the nuts (2, qty. 3) complete with washers (3) that lock the screws (4) and washers (5).

W230R035

Unscrew the couplings (11) for connection to the hydraulic pipes from the steering valve PVFC (6).

STEP 13

STEP 10 1

W190-4R014 W190-4R010

Remove the support (1).

Remove the 8 bar pilot pressure switch (1) complete with seal (2) from the steering valve PVG32.

STEP 11

STEP 14

1 7

9 10

6 W190-4R011

Remove the steering valve PVFC (6) from the support (1) by removing the nuts (7, qty. 2) and the washers (8) that secure the screws (9) complete with washers (10).

84489509

W190-4R015

Remove the reduction unit (3).

Issued 04-11

Printed in E.C.

5009-29

STEP 15

STEP 17

4 W190-4R016

Unscrew the coupling (4) from the “LS” port of the steering valve PVG32.

W230R037

Unscrew the coupling (6) from the port “P”.

STEP 18

STEP 16

7 5

W190-4R017

Remove the two couplings (5) from the ports “A” and “B” supplying the steering cylinder line.

W190-4R019

Remove the coupling (7) from the port “T”.

84489509

Issued 04-11

Printed in E.C.

5009-30

LEGEND OF JSS HYDRAULIC COMPONENTS WITH AUXILIARY STEERING SYSTEM 1. Steering valve support 2. Steering valve PVG32 3. Washer 4. Screw 5. Steering valve PVFC 6. Coupling 7. Rigid LS steering pipe 8. Coupling 9. Coupling 10. Steering cylinder line pipes 11. Coupling 12. Coupling 13. Outlet pipe of valve PVG32 14. Coupling 15. Coupling 16. Priority valve suction pipe 17. Coupling 18. LS auxiliary steering valve hose 19. Washer 20. Nut 21. Screw 22. Washer 23. Nut 24. Screw 25. Hose beeding line 26. Pressure switch 8 bar 27. Seal 28. Steering cylinder pipe (bottom side) 29. Steering cylinder pipe (stem side) 30. LS priority steering valve pipe 31. Coupling 32. Coupling 33. Reduction unit 34. Auxiliary steering valve 35. Hydraulic pump 36. Pressure switch 60 bar 37. Hose steering return

84489509

Issued 04-11

Printed in E.C.

5009-33

NOTES

84489509

Issued 04-11

Printed in E.C.

5009-34

LEGEND OF JSS HYDRAULIC COMPONENTS WITHOUT AUXILIARY STEERING SYSTEM 1. Steering valve support 2. Steering valve PVG32 3. Washer 4. Screw 5. Steering valve PVFC 6. Coupling 7. Rigid LS steering pipe 8. Coupling 9. Coupling 10. Steering cylinder line pipes 11. Coupling 12. Coupling 13. Outlet pipe of valve PVG32 14. Coupling 15. Coupling 16. Priority valve suction pipe 17. Coupling 18. LS auxiliary steering valve hose 19. Washer 20. Nut 21. Screw 22. Washer 23. Nut 24. Screw 25. Hose beeding line 26. Pressure switch 8 bar 27. Seal 28. Steering cylinder pipe (bottom side) 29. Steering cylinder pipe (stem side) 30. LS priority steering valve pipe 31. Coupling 32. Coupling 33. Reduction unit 34. Valve steering priority 35. Hydraulic pump 36. Pressure switch 60 bar 37. Hose steering return 38. Coupling 39. Hose valve orbitrol pressure 40. Hose LS valve orbitrol 41. Elbow 42. Coupling 43. Check valve

84489509

Issued 04-11

Printed in E.C.

5009-37

Installation

STEP 20

Before refitting 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 19 W230R041

Fit the coupling (2) for connection with the suction hose of the steering priority valve on the port “P”. Tighten the coupling to a torque of 170 Nm.

STEP 21

W190-4R020

Fit the coupling (1) for connection with the hydraulic outlet hose on the port “T” of the steering valve PVG32. Tighten the couplings to a torque of 310 Nm.

W190-4R022

Fit the two couplings (3) for connection with the steering cylinder line supply hoses on the ports “A” and “B”. Tighten the couplings to a torque of 100 Nm.

84489509

Issued 04-11

Printed in E.C.

5009-38

STEP 22

STEP 25 6 8 7 1 W190-4R023

Fit the coupling (1) on the port “LS”. Tighten the coupling to a torque of 45 Nm.

STEP 23

5 W230R042

Fit the coupling (6) on the port “1” of the steering valve PVFC (5), the “T” coupling (7) on the port “2” and the coupling (8) on the port “3”. Tighten all the couplings to a torque of 45 Nm.

W190-4R024

Fit the reduction unit (2) of the pilot pressure switch on the port “Pp”. Tighten the reduction unit to a torque of 45 Nm.

STEP 24

2 W190-4R025

Install the pilot pressure switch (3) complete with seal (4) on the reduction unit (2).

84489509

Issued 04-11

Printed in E.C.

5009-39

STEP 26

STEP 28

1 5

8 7

2 W190-4R028

W190-4R029

Fit 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).

Install the screws (7, qty. 3) and the washers (8) for assembling the support (1) complete with valve PVFC (9) and lock them with the nuts (10) and the washers (11). Tighten the nuts to a torque of 110 Nm.

STEP 27

STEP 29

W190-4R010

Position the support (1) of the steering valves on the LH side wall of the rear chassis frame of the machine.

14 13

W230R043

Fit the steering valve PVG32 (12) on the support (1) using the lower screws (13, qty. 4) and washers (14). Tighten the screws to a torque of 30 Nm.

84489509

Issued 04-11

Printed in E.C.

5009-40

STEP 30

STEP 32 3 1

W230R044

Connect the stem side steering cylinder line supply hose (1) on the coupling fitted on the valve PVG32. Tighten the pipe to a torque of 60 Nm.

W230R045

Connect and tighten the outlet hose (3) to a torque of 125 Nm.

STEP 33

STEP 31

2 4

W230R046

Connect the suction hose (4) of the steering priority valve. Tighten the pipe to a torque of 60 Nm.

W230R032

Connect the bottom side steering cylinder line supply hose (2). Tighten to a torque of 60 Nm.

84489509

Issued 04-11

Printed in E.C.

5009-41

STEP 34

STEP 35

3 5 4 1 1 W230R047

Connect the connection hose (2) on the valve PVFC (1), with the auxiliary steering valve and the hose (3) coming from the steering priority valve. Tighten the pipes to a torque of 14 Nm.

84489509

W230R048

Connect the rigid pipe of the device â&#x20AC;&#x153;LSâ&#x20AC;? (5) on the valve PVG32 (4) and on the valve PVFC (1). Tighten the pipe to a torque of 14 Nm.

Issued 04-11

Printed in E.C.

5009-42

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).

84489509

W190-4R101

Disconnect the two-position “DEUTSCH” connector (7) of the “Kick-Down” button (8) with the armrest cable connector (9).

Issued 04-11

Printed in E.C.

5009-43

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

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).

W190-4R103

Disconnect the ten-position connector (4) of the “F-N-R” switch (5) with the armrest cable (6). Remove the switch (5) from the armrest cover (1).

84489509

Issued 04-11

Printed in E.C.

5009-44

STEP 8

STEP 11 1 7

5 2

W230R049

Disconnect the ten-position connector (2) from the CAN module (1).

STEP 9

W230R052

Unscrew and remove the knob (5) for height adjustment of the armrest and spacer (6). Raise and extract the armrest device (7) from the support fixed to the seat (8).

3 W230R050

Detach the CAN module (1) from the support (3).

STEP 10 4

W230R051

Disconnect the three-position â&#x20AC;&#x153;DEUTSCHâ&#x20AC;? connector (4) from the armrest positioning switch. Remove the armrest cable.

84489509

Issued 04-11

Printed in E.C.

5009-45

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 support 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).

84489509

Issued 04-11

Printed in E.C.

5009-46

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 support (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.

STEP 15

W190-4R047

Remove the four fixing screws (14, qty. 4) complete with washers from the seat cushion.

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 machine. 84489509

Issued 04-11

Printed in E.C.

5009-47

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).

84489509

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).

Issued 04-11

Printed in E.C.

5009-48

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).

84489509

Issued 04-11

Printed in E.C.

5009-49

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.

84489509

Issued 04-11

Printed in E.C.

5009-50

STEP 29

STEP 31 6

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.

Fit 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.

84489509

Issued 04-11

Printed in E.C.

5009-51

STEP 33

STEP 34 11

5 9

6 13 10

3 7

2 W190-4R062

Fit 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 fit 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.

84489509

Issued 04-11

Printed in E.C.

5009-52

STEP 36

STEP 38 1

5 2

W190-4R065 W190-4R063

Fit 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).

Install the armrest cable connecting it to the positioning switch via the three-position â&#x20AC;&#x153;DEUTSCHâ&#x20AC;? connector (11).

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).

84489509

Issued 04-11

Printed in E.C.

5009-53

STEP 39

STEP 41

1 7 2

W190-4R066

Install the CAN module (1) inside the special seat (2) situated on the armrest device.

STEP 40

W230R054

Connect the “PHOENIX” connector (5) to the valve PVRES (4) of the Joystick and fit the valve on the support (6) by inserting the screws (7, qty. 2) with the washers (8, qty. 4) and the nuts (9, qty. 2). Pay attention to the correct positioning of the valve (4) so that the letter “A” stamped on it is on the left-hand side in relation to the direction of travel of the machine.

STEP 42

3 W230R053

Connect the ten-position connector (3) to the CAN module (1).

12 W230R055

Insert the “Kick-Down” button (11) on the armrest cover (10) and lock it from the bottom with the threaded washer (12).

84489509

Issued 04-11

Printed in E.C.

5009-54

STEP 43

STEP 44 2

4 1 7

W190-4R108

Connect the two-position “DEUTSCH” connector (1) of the “Kick-Down” button (2) with the armrest cable connector (3).

W190-4R109

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).

84489509

Issued 04-11

Printed in E.C.

5009-55

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.

84489509

Issued 04-11

Printed in E.C.

5009-56

JSS HYDRAULIC PRESSURE ADJUSTMENTS IMPORTANT: in making the following checks and pressure adjustments, the machine articulation must be locked. Great attention must be paid to following all the procedures for making the machine safe, particularly when operating on the articulation joint and near the arm of the loader.

A. Main hydraulic pressure setting of the pump This setting is given by the difference between the pressure of the hydraulic pump and the LS signal, which must be between 28 and 30 bars:

1. with the engine OFF and bucket on the ground, connect a quick coupling pressure gauge to the pressure point G1 (1) of the priority valve (2, figure 1), to the LS pressure point (3) of the hydraulic pump 1 (5, figure 2) and to the LS pressure point (4) of the hydraulic pump 2 (6, figure 2); 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 (28-30 bar); 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 (28-30 bar);

W190-4R095

Figure 1 1. Pressure point G1 2. Priority valve

84489509

Issued 04-11

Printed in E.C.

5009-57 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 (28-30 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.

7 8

W190-4R096

Figure 2 3. Pressure point LS hydraulic pump 1 4. Pressure point LS hydraulic pump 2 5. Hydraulic pump 1 6. Hydraulic pump 2 7. Pressure regulator hydraulic pump 1 8. Pressure regulator hydraulic pump 2

84489509

Issued 04-11

Printed in E.C.

5009-58

B. Steering pressure limit setting With the engine at high revs, the pressure of the port G1 must be between 239 and 244 bar: - make sure that the pressure value stated in paragraph A is as specified (28-30 bar); - with the engine OFF and bucket on the ground, connect a quick coupling pressure gauge on the pressure point G1 of the front and bottom of the priority valve (figure 1); - 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 244 bar);

4. move the joystick completely to the left and at the same time, with a chronometer, start measuring the time. Stop the ch ronometer when the machine 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.

- 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 machine is NOT locked. Great attention must be paid to following all the procedures for making the machine 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 machine from all right to all left). The purpose of this setting is to make steering the machine 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 machine 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 th e same time, with a chrono meter, start measuring the time. Stop the chronometer when the machine is completely steered on the right-hand side. Take the time to compare it with the time specified in the table of speed levels. 84489509

Issued 04-11

Printed in E.C.

5009-59

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?".

84489509

Issued 04-11

Printed in E.C.

5009-60

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 with the wording "O. K." The display will automatically show the screen with the wording "Joyst Full 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.

84489509

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 c ompletely to the right. As soon as he perceives a small movement of the machine he must release the lever.

Issued 04-11

Printed in E.C.

5009-61

STEP 10

W190-4R116

After this operation the display will show a screen with the wording "O. K.". The display will 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.

84489509

Issued 04-11

Printed in E.C.

5009-62

NOTES

84489509

Issued 04-11

Printed in E.C.

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

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

84489509

6001 Section 6001 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS

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

84489509

6001-2

TABLE OF CONTENTS TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 3 7 8 13 13 15 16 18 18 20 21

Printed in E.C.

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.

STEP 4 Refer to Section 8001 and remove the hydraulic pump.

BD01D315

Disconnect transmission wiring harness connector from control valve connector. Remove socket head bolt securing wiring harness clamp. Move wiring harness away from transmission.

STEP 8

STEP 5 Put a 25.5 liter (27 quarts) container under transmission drain plug. Remove drain plug and drain transmission oil. Install drain plug after oil has drained.

STEP 6

BD01D317

Just above where clamp was installed, tag and disconnect transmission wiring harness connector from temperature sensor. Move wiring harness away from transmission.

STEP 9 BD01D306

Identify, tag, and disconnect brake pump pressure hose and brake to hydraulic reservoir hose. Position hoses away from transmission. Remove and discard O-ring face seals from fittings. Plug hoses and cap fittings to prevent entry of foreign matter into hydraulic system.

BD01D310

Remove two socket head bolts securing transmission wiring harness clamps. 84489509

Issued 04-11

Printed in E.C.

6001-4

STEP 10

STEP 13

BD01D312

BD01F281

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.

Remove two bolts and washers securing hose retainer to front of rear chassis. Move hose retainer towards front of machine.

STEP 14

STEP 11

BD03A165

BD01D316

Remove socket head bolt securing wiring harness clamp. Move wiring harness away from transmission.

STEP 12

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.

BD01D314

Identify, tag, and disconnect transmission wiring harness connectors from filter maintenance switch and output speed sensor. Move transmission wiring harness away from transmission. 84489509

Issued 04-11

Printed in E.C.

6001-5

STEP 15

STEP 18

BD03A161

BD01D339

Remove four bolts and two straps securing rear drive shaft to transmission output flange. Disconnect rear drive shaft from transmission.

Remove fitting. Remove and discard O-ring from fitting. Install a plug in transmission port.

STEP 19

STEP 16

BD01D340 BD03A160

Remove two bolts. Remove fill tube, with cap and oil gauge assembled, two seals, and metal strainer. Discard seals.

Repeat Steps 17 and 18 and disconnect the other cooler hose and remove fitting.

STEP 20

STEP 17

BD01D343

BD01D318

Connect lifting equipment to transmission lifting eyes. Take up all slack in lifting equipment.

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.

84489509

Issued 04-11

Printed in E.C.

6001-6

STEP 21

STEP 23

BD01D342

BD03A164

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.

STEP 24

STEP 22

BD01D345 BD03A163

Remove bolts and washers securing RH and LH mounting brackets to rear chassis.

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.

STEP 25

BD01D361

If top mounting bracket requires removal, remove bolt and washer then remove bracket.

84489509

Issued 04-11

Printed in E.C.

6001-7

Transmission Mounting

4 2

1 5

2 6

1 7 5

1 5

2 C

1 B

W230R007

1. 2. 3. 4. 5.

84489509

ISOLATOR BOLT WASHER BOLT BOLT BOLT

6. 7. A. B. C.

MOUNTING BRACKET TOP MOUNTING BRACKET REAR CHASSIS TRUNNION BRACKET (6 OR 7) SMALLER PIECE ON TOP

Issued 04-11

Printed in E.C.

6001-8

Installation

STEP 29

STEP 26 Check isolators for deterioration, tears, deformation, or other damage. Replace as necessary: refer to Page 7.

STEP 27

BD03A164

Install RH and LH mounting brackets on transmission using two washers and bolts. Do not tighten bolts.

STEP 30

BD01D361

If top mounting bracket was removed, put bracket on rear chassis trunnion and secure using washer and bolt. Do not tighten bolt.

STEP 28

BD03A163

Loosely install washers and bolts to secure RH and LH mounting brackets to rear chassis. Tighten bolts securing RH and LH mounting brackets to transmission to a torque of 481 to 590 Nm (355 to 435 pound feet).

BD01D345

Move transmission into position above loader. Slowly lower transmission into loader.

84489509

Issued 04-11

Printed in E.C.

6001-9

STEP 31

STEP 33

NOTE: In this step, new straps and bolts securing the drive shaft must be installed whenever these parts are removed. Bolts have a nylon patch to maintain torque which requires new bolts.

BD01D343

Disconnect lifting equipment from transmission lifting eyes. BD01D342

STEP 34

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 75 to 81 Nm (55 to 60 pound feet).

STEP 32 BD01D340

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.

STEP 35

BD03A163

Tighten bolts securing RH and LH mounting brackets to a torque of 890 to 1000 Nm (655 to 735 pound feet).

BD01D318

84489509

Issued 04-11

Printed in E.C.

6001-10

STEP 36

STEP 39

BD03A160

BD01F281

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).

Position hose retainer on front of rear chassis and secure using two washers and bolts.

STEP 40

STEP 37

BD01D314

BD03A161

Connect rear drive shaft to transmission then install two straps and four bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).

Connect transmission wiring harness connectors to output speed sensor and filter maintenance switch following tags installed during removal. Remove and discard tags.

STEP 41

STEP 38

BD01D316 BD03A165

Connect center drive shaft to transmission and install two straps and four bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet). Connect parking brake hose to parking brake following tag installed during removal. Remove and discard tag. 84489509

Install socket head bolt to secure wiring harness clamp.

Issued 04-11

Printed in E.C.

6001-11

STEP 42

STEP 45

BD01D312

BD01D315

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.

Install socket head bolt to secure wiring harness clamp. Connect transmission wiring harness connector to control valve connector.

STEP 46

STEP 43

BD01D306 BD01D310

Install two socket head bolts to secure transmission wiring harness clamps.

At brake valve, install new O-ring face seals in fittings. Connect brake to hydraulic reservoir hose and brake pump pressure hose following tags installed during removal. Remove and discard tags.

STEP 44 STEP 47

BD01D317

Connect transmission wiring harness connector to temperature sensor following tag installed during removal. Remove and discard tag.

84489509

BD03A177

Check that transmission drain plug is tight.

Issued 04-11

Printed in E.C.

6001-12

STEP 48

STEP 50

Fill transmission with 15-40W engine oil until oil level is up to the arrow in sight glass.

Refer to Section 9007 and install ROPS cab or ROPS canopy.

STEP 49

STEP 51

Refer to Section 8001 and install the hydraulic pump.

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 engine oil, 15-40W, until oil level is up to crosshatch region. Shut down engine and put articulation lock in OPERATING position.

84489509

Issued 04-11

Printed in E.C.

6001-13

FRONT AXLE Removal

STEP 4

STEP 1

BD03A167

W230R406

Park machine on level surface. Have assistant put articulation lock in LOCKED position. IMPORTANT: If machine is equipped quick-attached components, disconnect them machine prior to proceeding.

Remove four bolts and two straps securing front drive shaft to front axle.

STEP 5

with from

STEP 2

BD03A166

BD03A092

Raise bucket and have assistant install safety link. Lower loade r arm s slowly until sa fe ty link is supporting loader arms.

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.

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.

84489509

Issued 04-11

Printed in E.C.

6001-14

STEP 6

STEP 9

BD03A168

Disconnect brake hose from elbow. Remove and discard O-ring face seal from elbow.

BD01F297

Use an acceptable jack to hold front axle.

STEP 10

STEP 7

BD01F295 BD01F298

Remove bolts and washers from front wheels. Remove both wheels from front axle.

STEP 11

BD01D392

Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine.

BD01F296

STEP 8

Remove eight nuts bolts, and washers securing front axle to machine.

Repeat Step 68 to raise other front axle tire from ground.

STEP 12 Carefully lower front axle and remove from under machine.

84489509

Issued 04-11

Printed in E.C.

6001-15

Front Axle Mounting

3 4

W230R008

1. BOLT 2. WASHER 3. WASHER

84489509

4. NUT 5. FRONT AXLE

Issued 04-11

Printed in E.C.

6001-16

Installation

STEP 15

STEP 13 Carefully move front axle under machine and raise against mounting pads on machine.

STEP 14

BD01F295

BD01F296

Apply one drop of engine oil to threads prior to assembly. Install eight washers, bolts, washers, and nuts to secure front axle to machine. Tighten bolts to a torque of 1520 to 1712 Nm (1121 to 1263 pound feet).

W230R009

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.

STEP 16

BD01F297

Remove jack from front axle.

84489509

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Printed in E.C.

6001-17

STEP 17

STEP 20

BD01F298

BD03A166

Position and support center bearing and front drive shaft and install eight washers and four bolts and nuts. Tighten bolts to a torque of 150 to 164 Nm (110 to 120 pound feet). Install two straps and four bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet). Secure lubrication hose to machine using clamp; secure opposite end of hose using nut.

STEP 21

BD01D392

Using an acceptable hydraulic jack, raise axle and remove jack stand from under machine.

STEP 18 Repeat Step 78 to remove other jack stand from under machine.

STEP 19 BD03A167

Secure drive shaft to front axle using two straps and four bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).

STEP 22 If necessary, fill axle with gear lubricant specified in Section 1002.

STEP 23 Refer to Section 7002 and bleed brakes. BD03A168

Install a new O-ring face seal in elbow. Connect brake hose to elbow.

STEP 24 Start engine and raise bucket. Have assistant remove safety link. Lower bucket to ground and stop engine.

STEP 25 Put articulation lock in OPERATING position. 84489509

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Printed in E.C.

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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 forth at least 30 times to release any pressure from hydraulic circuit.

STEP 2 BD03A169

Disconnect brake hose from elbow. Remove and discard O-ring face seal from elbow.

STEP 6

W230R406

Put articulation lock in LOCKED position.

STEP 3 Install wood blocks between rear axle and chassis to prevent rear axle from pivoting.

BD01F299

Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine. Repeat this step for other tire.

STEP 4

STEP 7

BD03A162

Remove four bolts and two straps. Use a pry bar to disconnect rear drive shaft from rear axle. BD01F302

Use an acceptable jack to hold rear axle.

84489509

Issued 04-11

Printed in E.C.

6001-19

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

Remove bolts and washers from rear wheels. Remove both wheels from rear axle.

STEP 9

BD03A170

At front of trunnion, remove two Allen head bolts and washers. Remove front cap: if necessary use two M12 by 32 mm (1.25 inches) bolts in puller holes (A); tighten bolts evenly to pull cap from axle and trunnion. Remove and discard O-ring from cap. Repeat this step at rear of trunnion except remove and retain shim(s) after removal of rear cap. Remove pivot shaft using acceptable sleeve or rod if necessary.

84489509

Issued 04-11

Printed in E.C.

6001-20

Rear Axle Mounting

W230R010

1. 2. 3. 4.

84489509

TRUNNION O-RING SEAL FRONT CAP

5. 6. 7. 8.

WASHER BOLT WASHER BOLT

9. 10. 11. 12.

REAR AXLE PIVOT PIN SHIM(S) REAR CAP

Issued 04-11

Printed in E.C.

6001-21

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

B BS01E091A

Install pivot pin (10) and caps (4 and 12) in trunnion (1) without rear axle or shim(s). Install washers (5) and bolts (6). Tighten bolts securely. Push assembled pivot pin and caps to rear of machine as far as possible. Measure and record gap (A) between rear cap (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

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 flush with housing or recessed 2.0 mm (0.079 inch). Install an O-ring in each 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. 84489509

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Printed in E.C.

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STEP 16 11 6

STEP 17 4

1 BS01E091

BD01F295

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, and two washers and bolts (6). Tighten bolts (6) to a torque of 575 to 600 Nm (420 to 440 pound feet).

W230R009

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.

84489509

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Printed in E.C.

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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

Install a new O-ring face seal in elbow. Connect brake hose to elbow.

STEP 20

BD03A162

Connect rear drive shaft to rear axle. Install two straps and four bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).

84489509

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NOTES

84489509

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6002

Section 6002 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

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

84489509

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 . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 3 8 8 8 8 8 9 9 9 9 9 10 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

Printed in E.C.

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.....................................................................................................3.5 to 6.5 bar (51 to 96 psi) Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi) Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm) Transmission oil operating temperature .........................................................................80 to 120 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)

84489509

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Printed in E.C.

6002-4

6 15

14 7

10 W230R389

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

INPUT FLANGE - DRIVE VIA PROP SHAFT CONVERTER INDUCTIVE SENSOR FOR ENGINE SPEED TRANSMISSION PUMP CLUTCH SHAFT “KR” PTO; COAXIAL, ENGINE-DEPENDENT CLUTCH SHAFT “KV” CLUTCH SHAFT “K2”

9. 10. 11. 12. 13. 14. 15.

CLUTCH SHAFT “K3” OUTPUT FLENGE - REAR SIDE OUTPUT FLANGE OUTPUT FLANGE - CONVERTER SIDE CLUTCH SIDE “K1” CONVERTER SAFETY VALVE CLUTCH SIDE “K4”

COMPONENT LOCATIONS TRANSMISSION LAYOUT 4 WG-210

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6002-5

1 1

5 4 7 2

3 6

W230R012

1. 2. 3. 4.

TRANSPORTATION EYE GEARBOX MOUNTING PADS TYPE PLATE CONNENCTION TO HEAT EXCHANGER

5. CONNECTION FROM HEAT EXCHANGER 6. OIL DRAIN PLUG 7. TEMPERATURE SWITCH FOR OIL TEMPERATURE BEHIND CONVERTER

COMPONENT LOCATIONS 4 SPEED FRONT VIEW

84489509

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Printed in E.C.

6002-6

3 9

1 12 8

7 13

W230R013

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

FULL FLOW FILTER BREATHER PTO, COAXIAL, ENGINE DEPENDENT PARKING BRAKE (DISC BRAKE) INDUCTIVE SENSOR FOR TURBINE SPEED INPUT FLANGE OUTPUT FLANGE

8. 9. 10. 11. 12. 13.

HALL-SENSOR OUTPUT SPEED CONNECTION SYSTEM PRESSURE INDUCTIVE SENSOR FOR INTERMEDIATE GEAR TRAIN SPEED INDUCTIVE SENSOR FOR ENGINE SPEED DIFFERENCE PRESSURE SWITCH FOR PRESSURE FILTER OUTPUT FLANGE REAR SIDE

COMPONENT LOCATIONS 4 SPEED SIDE VIEW

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Printed in E.C.

6002-7

6 3

W230R014

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

GEARBOX MOUNTING PADS HALL-SENSOR OUTPUT SPEED CONNECTION SYSTEM PRESSURE CONNECTION RETURN TO SUMP PLUG CONNECTION MEASURING POINT FOR PRESSURE BEFORE CONVERTER MEASURING POINT FOR PRESSURE OIL CLUTCH KV

8. 9. 10. 11. 12. 13. 14.

MEASURING POINT FOR PRESSURE OIL CLUTCH KR MEASURING POINT FOR PRESSURE OIL CLUTCH K1 MEASURING POINT FOR PRESSURE OIL CLUTCH K2 MEASURING POINT FOR PRESSURE OIL CLUTCH K3 MEASURING POINT FOR PRESSURE OIL CLUTCH K4 MEASURING POINT FOR SYSTEM PRESSURE ELECTRICAL HYDRAULIC TRANSMISSION CONTROL

COMPONENT LOCATIONS 4 SPEED REAR VIEW

84489509

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6002-8

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 associated with hydraulically modulated 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. I n ad d i t i on , t h e t ra n s m i s s i o n i n c o rp o r a t es 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).

A. Determines which clutches to engage in the transmission. B. Protects the engine and transmission turbine from overspeed conditions during 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. These speed sensors are checked to determine if normal 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 Transmission Electronic Control Module (Transmission ECM). This module replaces the oil and springs that are found in hydraulically modulated transmissions. The Transmission ECM controls the clutch engagement, providing smoother shifts and 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.

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.

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.

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.

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6002-9

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 determining 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. The t ransmi ssi on E CM also reviews volt age information 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 b u t t h e m o d u l a t i o n w i ll 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 gears until an operable gear is found. The 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 severe failure that disables control of the transmission. The transmission will go into Shutdown Mode if there is a fault on more than one clutch, a fault on the solenoid power supply, or invalid voltage. In this mode, the Transmission ECM will shut off all solenoid valves and the power supply and the transmission shifts into and stays in neutral. If the Transmission ECM generates a code, the wrench over the service manual icon will be displayed on the Information Center.

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Printed in E.C.

6002-10

Transmission Clutch Calibration The Transmission ECM has the capability to find the optimal adjustment of the clutch filling parameters for each individual transmission, providing the ability to individually adjust the optimum fill time for the individual transmission in the machine. Clutch Filling Parameter Calibration is performed on each machine at the plant and should be repeated at the first 250 hours of use and every 1000 hours thereafter. Before doing the following transmission clutch calibration procedures make sure of the following: 1. The machine is running and the transmission oil is warm. 2. Engine low idle speed is correct. 3. The transmission is in neutral.

W230M173

Highlight Calibration, and press the confirm key. Always follow the prompts on the screen. Should an error occur, use the escape key to start over again.

4. The park brake is applied. 5. If steps 1 through 4 have been accomplished, calibrate the transmission clutches as follows: With the engine running at idle, enter the service screen menu and scroll to Service screen. Press the confirm key.

7.0 H

N R

12 3 4

A A 11 22

W230M174

W230R649

W230M175

The screen will show a confirm prompt. If you doubt your ability to perform this operation, press the escape key and call your dealer.

W230M172

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Printed in E.C.

6002-11 If machine conditions are incorrect, an error message will appear. The calibration procedure will not complete. Follow the prompts to aid in correcting any machine conditions. The screen may display the following prompts to guide the user to correct machine conditions: ❷ ❷ ❷ ❷ ❷ ❷ ❷

Not in neutral Parking Brake OFF Machine moving Oil temp too low Oil temp too high Engine RPM low Engine RPM high

If conditions are correct, the user will see six calibration screens displayed. They will appear in the following order: ❷ Adjust K1 ❷ Adjust K2 ❷ Adjust K3 ❷ Adjust K4 ❷ Adjust KV ❷ Adjust KR Once the calibration process is complete, the user will be prompted to turn the engine Off and restart the machine. If the process is not completed, the screen will prompt the user to escape.

Gear Selections 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).

Automatic/Manual Modes The automatic/manual switch is located on the right control panel. The transmission is in automatic mode when the top of the automatic/manual switch is depressed. The Transmission Display Center indicates when the machine is in the automatic mode.

Upshifting in Automatic Mode Upshifting is determined by machine speed and the torque on the transmission. 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. If the machine speed is increasing, but the operator is not depressing the accelerator (such as when going down a hill), the transmission will not upshift. As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.

Downshifting in Automatic Mode Downshifting is determined directly by machine speed and transmission torque. The transmission will downshift to first or second gear as machine speed decreases and transmission torque increases. For example, if the unit begins to climb a hill in forth gear and the machine speed decreases, as the torque requirement increases, the transmission will downshift into third, then second, and down to first gear, if necessary.

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. 84489509

Issued 04-11

Printed in E.C.

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 return 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 position and the brake pedal is pushed, the Transmission ECM reduces the pressure to the transmission forward or reverse clutch. The Transmission ECM will not completely 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.

84489509

Issued 04-11

Printed in E.C.

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 11+2 bar (159.5 + 29 psi)

M10x1

Behind the Converter - Opening Pressure 4.3+3 bar (62 + 43.5 psi)

M10x1

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

Differential pressure switch for pressure filter

M14x1.5

Connections 10

Breather

Plug connection at electro-hydraulic control unit

M10x1

NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

84489509

Issued 04-11

Printed in E.C.

6002-14

21 48

10 48

15 52 63 49

54 34

W230R401

MEASURING POINTS AND CONNECTIONS

84489509

Issued 04-11

Printed in E.C.

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

6 52

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

84489509

LP= LUBE PRESSURE

Issued 04-11

Printed in E.C.

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.

84489509

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.

Issued 04-11

Printed in E.C.

6002-17

CONVERTER OUT PRESSURE CHECK Test Equipment Required

3. Install the pressure gauge.

0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and 380000509 Special Adapter.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F).

Test Procedure 1. Block the machine tires.

5. While in the cab, put the transmission in NEUTRAL. Run the engine at full throttle. Record the reading in the chart on page 16. Pressure must be a minimum of 3.5 to 6.5 bar (51 to 96 psi).

2. Apply the parking brakes.

LUBRICATION PRESSURE CHECK Test Equipment Required

3. Install the pressure gauge in the cooler return line at the transmission.

0 to 7 bar (100 psi) gauge.

4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F).

Test Procedure

5. While in the cab, run the engine at full throttle. Put the transmission in each gear and record the reading in the chart on page 16. Pressure must be 0.2 to 1.2 bar (3 to 18 psi).

1. Block the machine tires. 2. Apply the parking brakes.

FLOWMETER TEST Test Equipment Required 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 80 L/min (21 U.S. gpm) at 2000 rpm.

2. Apply the parking brakes.

CONSUMPTION TEST PROCEDURE 1. Block the machine tires. 2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F). 4. Install the flowmeter to converter outlet line (line to cooler) in series.

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).

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).

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

6002-20

NOTES

84489509

Issued 04-11

Printed in E.C.

6003

Section 6003 TRANSMISSION

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

84489509

6003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

84489509

Issued 04-11

Printed in E.C.

6003-3

SPECIAL TOOLS

Adjusting screws M6 1

380001558

Handle 2

380001557

Rolling tool 3

380001285

Assembly 380001556

Rolling tool 5

380001286

Rolling tool 6

84489509

380001287

Issued 04-11

Printed in E.C.

6003-4

Driver tool 7 380001560

Assembly fixture (Inner installer and driver) 8

84489509

380001559

Issued 04-11

Printed in E.C.

6003-5

DISASSEMBLY STEP 1

Removal of electric gear-shift control STEP 4

GD98M833

Fasten transmission on an assembly stand. W230R060

STEP 2

Remove gear-shift control (1). Loosen Torx screws (2) and separate gear-shift control housing from intermediate plate.

STEP 5 S 1

W230R058

Separate filter (1) from filter head by means of belt wrench.

STEP 3

1 W230R061

Remove gear-shift control assy. (1) and sealing plate (2). (S) Adjusting screws M6 380001558.

W230R059

Loosen Torx screws (2) and separate filter head (1) from transmission housing. NOTE: Remove O-rings. 84489509

Issued 04-11

Printed in E.C.

6003-6

STEP 6

STEP 8 2

3 1

1 4 W230R062

W230R063

Remove differential pressure switch for filter from duct plate (4).

Loosen hexagon nuts and Torx screws and separate duct plate (1) and seal (2) from housing rear part.

1 = Switch with O-ring 2 = Piston 3 = Compression spring

STEP 9

STEP 7

1 1 2 W230R064

Pull converter safety valve (1) out of housing hole. W230R065

Loosen cylindrical screw (1) and remove speed sensor (Hall sensor) (2). NOTE: Remove O-rings.

84489509

Issued 04-11

Printed in E.C.

6003-7

Removal engine connection

STEP 12

STEP 10 1

W230R068

W230R066

Loosen hexagon screws (1) and remove washer. Loosen bolted connection (2) cover/converter bell housing. NOTE: Mark radial installation position cover/converter bell housing by center punch.

Pull off output flange.

STEP 13

STEP 11

W230R069

Press input shaft and converter out of cover (ball bearing).

STEP 14 W230R067

Separate cover from converter bell housing by means of lifting device.

W230R070

Snap out retaining ring (1) and remove ball bearing (2).

84489509

Issued 04-11

Printed in E.C.

6003-8

STEP 15

Removal oil pressure pump STEP 17

W230R071

Loosen hexagon screws (1) and remove flex plate (2) from converter.

STEP 16

L oo s en bo l t ed c o nn e c t i o n (1 ) c on v er t e r b e l l housing/oil feed housing and remove converter bell housing (2).

STEP 18

1 2

W230R073

3 1

W230R072

Loosen hexagon screws (1) and remove flex plate (2) from input shaft (3).

W230R074

Loosen bolted connection (1) oil feed housing/transmission housing front part with torx screws and bolted connection (2) oil pressure pump/transmission housing front part with cylindrical screws. NOTE: Separate oil feed housing together with oil pressure pump from transmission housing front part.

84489509

Issued 04-11

Printed in E.C.

6003-9

STEP 19

STEP 21

2 3 4 W230R075

W230R077

Separate oil pressure pump (1) from oil feed housing (2).

Check oil gear pump. In case of wear marks in the pump housing, cover or on the inner and outer rotor, the complete oil pressure pump is to be replaced. 1 = cover 2 = Inner rotor 3 = Outer rotor 4 = Pump housing

STEP 20

STEP 22 2 1

W230R076

Remove O-ring (1). Loosen cylindrical screws (2).

2 W230R078

Remove shaft seal (1) from the pump housing (2).

84489509

Issued 04-11

Printed in E.C.

6003-10

Removal converter back-pressure valve

STEP 25

STEP 23

1 1 W230R081

W230R079

Preload converter safety valve (1) by means of screw driver or assembly aid and remove locking plate (2).

Remove temperature sensor (1).

STEP 26

STEP 24

2 1

W230R082

W230R080

Remove stator shaft (1). Pull pressure relief valve (2) out of the housing hole.

Remove individual parts of converter safety valve which are getting released.

Removal emergency steeri ng pump version without emergency steering pump

1 = Pressure plate 2 = Compression spring 3 = Piston

STEP 27 2

W230R083

Loosen bolted connection cover/cover (1) and cover/housing front part (2) and remove cover (3 and 4) and seal. 84489509

Issued 04-11

Printed in E.C.

6003-11

Version with emergency steering pump

STEP 30

STEP 28

W230R086

W230R084

Loosen cylindrical screws (1) and separate emergency steering pump (2) from cover. NOTE: Mark radial installation position (see arrows). Loosen bolted connection (3) cover/housing front part and remove cover (4) and seal.

Disassembly - Output and closure parts pump shaft (PTO-shaft)

Pull off output flange (1) and remove shaft seal (2). Output flange on output side with parking brake FSG-88

STEP 31 1

Output flange on converter side

STEP 29 1 W230R089

Connect pump at port (see arrow) and apply approx. 80 bar (1160 psi) pressure to the hydraulically actuated parking brake (1) until the brake disc (2) can be rotated by hand.

W230R085

Loosen hexagon screws (1), remove washer and O-ring.

84489509

Issued 04-11

Printed in E.C.

6003-12

STEP 32

STEP 35 3 2

W230R090

Loosen hexagon nut with open end wrench insert.

STEP 33

W230R093

Loosen hex. screws (1), remove washer and O ring. Pull-off output flange (2) and remove shaft seal. Remove cylindr. screw with washer (3).

2 Closure parts pump shaft (PTO-shaft)

STEP 36

W230R091

Loosen hex. screws (2) and remove parking brake (1) (see step 34).

STEP 34 W230R113

Loosen hexagon screws (1).

2 3

STEP 37 1 1 2 W230R092

Loosen hex. screws (2) of bolted brake disk/output flange connection and remove brake disk (3). W230R114

Remove cover (1) and O-ring (2).

84489509

Issued 04-11

Printed in E.C.

6003-13

Removal of input shaft, output shaft, pump shaft (PTO-shaft) and clutches

STEP 41

STEP 38

2 1

W230R118

W230R115

Force out both cylindrical pins (1). Loosen bolted connection (2) between housing front and rear part and separate housing rear part by means of lifting device.

Remove all rectangular rings (1) from the clutches and all Orings (2) from the oil tubes.

STEP 42 1

STEP 39 1

2 W230R119

Use lifting device to bring housing rear part (1) into contact position with housing front part (2) again. W230R116

Loosen bolted connection (1) of oil screen sheets.

STEP 40

STEP 43 2

2 W230R120

W230R117

Fix all clutches K1, K2, K3 and K4 by means of handle (1). Handle 380001557.

Remove output shaft (1) and lower oil screen sheet (2) from housing. 84489509

Issued 04-11

Printed in E.C.

6003-14

STEP 44

STEP 46

1 3

4 W230R121

W230R123

Separate housing rear part incl. clutches from housing front part by means of the lifting device and attaches it to the assembly truck.

The suction tube (1) and the lubrication lines (2) are rolled in and are highly difficult to remove. In case of damage, use of the appropriate special tool is imperative for fitting or replacing these components.

1 = Clutch KV 2 = Input shaft 3 = Clutch KR 4 = Pump shaft

Rolling tool 380001285.

STEP 47

STEP 45 1 1

W230R124

W230R122

Loosen cylindrical screws of oil tubes (1) in the housing front part and remove them.

Remove bearing outer rings (arrows) from the housing front part.

STEP 48

2 1 W230R125

Disengage retaining ring (1) and remove pump shafts (2). 84489509

Issued 04-11

Printed in E.C.

6003-15

STEP 49

STEP 51

W230R126

W230R128

Press ball bearing (1) off the pump shaft. Snap out rectangular ring (2).

Remove bearing outer rings (arrows) from the housing rear part.

STEP 50

STEP 52 7 6

5 4

3 W230R127

W230R129

Lift the clutches out of the housing in numerical order as described in the legend.

The lubrication lines are rolled in (1 and 2) and are highly difficult to remove. In case of damage, use of the appropriate special tool is imperative for fitting or replacing these components.

1 = K1 clutch 2 = K2 clutch 3 = K3 clutch (Version with Emerg. steering pump) 4 = K4 clutch 5 = KR clutch 6 = KV clutch 7 = input shaft

84489509

Issued 04-11

Printed in E.C.

6003-16

DISASSEMBLY - Clutches KV / KR / K1 / K2 / K3 / K4 input and output shaft

STEP 55

STEP 53 K2

K4 K1

W230R132

Pull tapered roller bearing (inner ring) off the shaft. W230R130

K1 = clutch K2 = clutch K3 = clutch K4 = clutch KR = clutch KV = clutch AN = input shaft

STEP 56 1

KV clutch

STEP 54 1

W230R133

Snap out retaining ring (1).

STEP 57

W230R131

Remove stud bolt (1) and snap out piston ring (2).

W230R134

Pull clutch (1) off the shaft.

84489509

Issued 04-11

Printed in E.C.

6003-17

STEP 58

STEP 61 1

W230R135

Fix idler gear (1) by means of cut-off device and pull it off the clutch shaft.

STEP 59

W230R138

Turn shaft (2) by 180Â° and snap out piston ring (1).

STEP 62

2 3

W230R139 W230R136

Snap retaining ring (2) out of the idler gear (1) and remove ball bearing (3).

Pull tapered roller bearing (inner ring) off the shaft.

STEP 63

STEP 60 1

W230R140

Unsnap snap ring (1). W230R137

Remove needle cage (1) from the shaft (2).

84489509

Issued 04-11

Printed in E.C.

6003-18

STEP 64

STEP 67 1 1

3 W230R141

W230R144

Remove end shim (1) and disc set (2) out the disc carrier (3).

Lift piston (1) by means of compressed air out of the cylinder bore and remove it.

STEP 65

STEP 68

1 2

W230R142

Preload compression spring (1) unsnap L-Ring. Assembly aid 380001556.

STEP 66

W230R145

Remove both O-rings (1 and 2). KR clutch

STEP 69 1

2 3

W230R143

Remove support shim (1), compression spring (2) and washer (3).

84489509

W230R146

Remove stud bolt (1) and snap out piston ring (2).

Issued 04-11

Printed in E.C.

6003-19

STEP 70

STEP 73

W230R147

Pull tapered roller bearing (inner ring) off the shaft.

STEP 71

W230R150

Fix idler gear (1) by means of cut-off device and pull it off the clutch shaft.

STEP 74 1 2 3

W230R148

Snap out retaining ring (1).

W230R151

Snap retaining ring (2) out of the idler gear (1) and remove ball bearing (3).

STEP 72

STEP 75 1

2 1

W230R134

Pull clutch (1) off the shaft. W230R152

Remove needle cage (1) from the shaft (2).

84489509

Issued 04-11

Printed in E.C.

6003-20

STEP 76

STEP 79 1

2 2 3 W230R153

Turn shaft (2) by 180Â° and snap out piston ring (1).

STEP 77

W230R156

Remove end shim (1) and disc set (2) out the disc carrier (3).

STEP 80

W230R154

Pull tapered roller bearing (inner ring) off the shaft.

W230R142

Preload compression spring (1) unsnap L-Ring. Assembly aid 380001556.

STEP 78

STEP 81 1

2 3

W230R140

Unsnap snap ring (1). W230R158

Remove support shim (1), compression spring (2) and washer (3).

84489509

Issued 04-11

Printed in E.C.

6003-21

STEP 82

STEP 85

W230R144

Lift piston (1) by means of compressed air out of the cylinder bore and remove it.

STEP 83

W230R162

Pull tapered roller bearing (inner ring) off the shaft.

STEP 86 1

1 2

W230R163 W230R145

Remove both O-rings (1 and 2).

Snap out retaining ring (1).

STEP 87

K1 clutch

STEP 84 1

W230R164

Remove axial bearing assy (1). W230R161

Remove stud bolt (1) and snap out piston ring (2).

84489509

Issued 04-11

Printed in E.C.

6003-22

STEP 88

STEP 91 1

W230R165

Take off idler gear (1), remove needle cage (2) and axial bearing assy (3).

STEP 89

W230R168

Pull tapered roller bearing (inner ring) off the shaft.

STEP 92

1 W230R140 W230R166

Pull clutch (1) off the shaft.

Unsnap snap ring (1).

STEP 93

STEP 90

1 2

3 W230R170 W230R167

Turn shaft (2) by 180Â° and snap out piston ring (1).

84489509

Remove end shim (1) and disc set (2) out the disc carrier (3).

Issued 04-11

Printed in E.C.

6003-23

STEP 94

STEP 97

1 2

W230R142

Preload cup springs unsnap L-Ring (1). Assembly aid 3881556.

W230R145

Remove both O-rings (1 and 2). K2 clutch

STEP 95

STEP 98 2

W230R172

Remove cup spring package (1).

W230R175

Remove stud bolt (1) and snap out piston ring (2).

STEP 96

STEP 99

W230R144

Lift piston (1) by means of compressed air out of the cylinder bore and remove it.

84489509

W230R176

Pull tapered roller bearing (inner ring) off the shaft.

Issued 04-11

Printed in E.C.

6003-24

STEP 100

STEP 103 1

1 W230R177

W230R180

Snap out retaining ring (1).

Pull clutch (1) off the shaft.

STEP 101

STEP 104 1

W230R178

W230R181

Remove axial bearing assy (1).

Turn shaft (2) by 180Â° and snap out piston ring (1).

STEP 102

STEP 105 1

W230R179

Take off idler gear (1), remove needle cage (2) and axial bearing assy (3).

84489509

W230R182

Pull tapered roller bearing (inner ring) off the shaft.

Issued 04-11

Printed in E.C.

6003-25

STEP 106

STEP 109

W230R140

W230R186

Unsnap snap ring (1).

Remove cup spring package (1).

STEP 107

STEP 110 1 1

3 W230R184

W230R144

Remove end shim (1) and disc set (2) out the disc carrier (3).

Lift piston (1) by means of compressed air out of the cylinder bore and remove it.

STEP 108

STEP 111

1 2

W230R142

Preload cup springs unsnap L-Ring (1). Assembly aid 3881556.

84489509

W230R145

Remove both O-rings (1 and 2).

Issued 04-11

Printed in E.C.

6003-26

STEP 115

K3 clutch

STEP 112

1 3

W230R192 W230R189

Snap out piston ring (1).

Take off idler gear (1), remove needle cage (2) and axial bearing assy (3).

STEP 116

STEP 113

1 W230R193 W230R190

Pull tapered roller bearing (inner ring) off the shaft.

Pull clutch (1) off the shaft.

STEP 117

STEP 114

W230R194 W230R191

Remove axial bearing assy (1).

84489509

Remove stud bolt (1) and snap out piston ring (2).

Issued 04-11

Printed in E.C.

6003-27

STEP 118

STEP 121

W230R195

Pull tapered roller bearing (inner ring) off the shaft.

STEP 119

W230R142

Preload cup springs unsnap L-Ring (1). Assembly aid 380001556.

STEP 122 1

W230R140

Unsnap snap ring (1).

W230R199

Remove cup spring package (1).

STEP 120

STEP 123

1 1

3 W230R197

Remove end shim (1) and disc set (2) out the disc carrier (3).

84489509

W230R144

Lift piston (1) by means of compressed air out of the cylinder bore and remove it.

Issued 04-11

Printed in E.C.

6003-28

STEP 124

STEP 127

1 2

W230R145

W230R204

Remove both O-rings (1 and 2).

Snap out (1) retaining ring.

K4 clutch

STEP 128

STEP 125 1

W230R205 W230R202

Remove stud bolt (1) and snap out piston ring (2).

Pull clutch (1) off the shaft.

STEP 129

STEP 126

W230R206 W230R203

Remove axial bearing assy (1) and idler gear (2).

Pull tapered roller bearing (inner ring) off the shaft.

84489509

Issued 04-11

Printed in E.C.

6003-29

STEP 130

STEP 133 1 2

3 W230R207

W230R140

Remove needle cage (1) and axial bearing assy (2).

Unsnap snap ring (1).

NOTE: The gear (3) cannot be removed.

STEP 134

STEP 131 1

1 2

3 W230R211 W230R208

Turn shaft (2) by 180Â° and snap out piston ring (1).

Remove end shim (1) and disc set (2) out the disc carrier (3).

STEP 135

STEP 132

W230R209

Pull tapered roller bearing (inner ring) off the shaft.

84489509

W230R142

Preload cup springs unsnap L-Ring (1). Assembly aid 380001556.

Issued 04-11

Printed in E.C.

6003-30

STEP 136

Input shaft

STEP 139 1

W230R155

Remove cup spring package (1).

W230R157

STEP 137

Snap out piston ring (1). Turbine wheel shaft and drive gear (2) are fixed by a snap ring.

STEP 140 1

W230R144

Lift piston (1) by means of compressed air out of the cylinder bore and remove it.

STEP 138

W230R171

Pull tapered roller bearing (inner ring) off the drive gear.

STEP 141

1 2

1 W230R145

Remove both O-rings (1 and 2). W230R185

Pull tapered roller bearing (inner ring) off the drive gear. It is not possible to separate input shaft and gear (1). 84489509

Issued 04-11

Printed in E.C.

6003-31 Output shaft

STEP 142

1 W230R198

Pull tapered roller bearing (inner ring) off the output shaft and remove oil screen sheet (1).

STEP 143

W230R210

Turn output shaft by 180Â° and pull off tapered roller bearing (inner ring).

84489509

Issued 04-11

Printed in E.C.

6003-32

ASSEMBLY

84489509

Issued 04-11

Printed in E.C.

6003-33 Clutches KV / KR / K1 / K2 / K3 / K4 input and output shaft

STEP 146 1

KV Clutch

STEP 144

W230R188

Mount needle cage (1) onto the shaft and oil it.

STEP 147 W230R160

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

STEP 145 2

2 1 1

W230R201

Install ball bearing (2) into the idler gear (1) until contact is obtained and fix it by means of retaining ring (3). W230R174

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2).

STEP 148

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

W230R212

Press in preassembled idler gear (1) onto the shaft until contact is obtained.

84489509

Issued 04-11

Printed in E.C.

6003-34

STEP 149

STEP 151

W230R213

W230R214

Place both O rings (1 and 2) into the piston grooves and oil them.

Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 380001556.

NOTE: Check function of the drain valve (see arrow) - There must be no jamming of the ball.

STEP 152

STEP 150

4 3 2

S W230R215 W230R144

Place piston (1) into the disk carrier. NOTE: Observe installation position, see FIGURE.

84489509

Mount inner installer (S) onto the disk carrier. Install disk (1), compression spring (2), support shim (3) and Lring (4).

Issued 04-11

Printed in E.C.

6003-35

STEP 153

STEP 155

W230R216

W230R218

Preload compression spring by means of assembly aid (S1) and pressure piece, until L-Ring has engaged into the annular groove.

Install outer and inner disks alternately into the disk carrier (4) as personated in Figure.

NOTE: It is always necessary to mount a new L-ring.

STEP 154 1

1 = Friction disk -coated on one side- (1 pcs) 2 = Outer disks (10 pcs) 3 = Inner disks (10 pcs) NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 20.

STEP 156

5 6 7 4

3 W230R217

Disk carrier with piston retraction: 1 = Washer 2 = Compression spring 3 = Support shim 4 = L-Ring 5 = Disk carrier 6 = Drain valve (piston) 7 = Piston with O-Rings

1 W230R219

Install outer and inner disks alternately into the disk carrier (4) as personated in Figure. 1 = Friction disk -coated on one side- (1 pcs) 2 = Outer disks (10 pcs) 3 = Inner disks (10 pcs) NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 16.

84489509

Issued 04-11

Printed in E.C.

6003-36

STEP 157

STEP 159 F

1 2

W230R220

W230R222

Mount end plate (1) and fix disk package by means of snap ring (2) (e .g. thicknes s = 2.65 mm / recommended value) (0.10 in).

Then press end plate against the snap ring (upwards) and read disk clearance.

STEP 158

NOTE: Disk clearance: 2.65 to 2.95 mm (0.10 to 0.11 in). NOTE: In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1 …... 4.2 mm) (0.08 …... 0.16 in).

STEP 160

W230R221

Press on end plate with F (approx. 20 lb= 10 kg) and set dial indicator to "zero“.

W230R223

Heat up clutch inner diameter (approx. 120° C) (248° F).

84489509

Issued 04-11

Printed in E.C.

6003-37

STEP 161

STEP 164

W230R224

W230R226

Install clutch until contact is obtained. Mount inner disks onto the inner disk carrier by means of short left/right rotations.

Mount bearing inner ring (1) until contact is obtained.

ATTENTION: Wear protective gloves.

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

STEP 165

STEP 162

W230R225

Fix clutch (1) by means of retaining ring (2).

STEP 163

W230R146

Mount stud bolt (1). Tightening torque ...... = 17 Nm (150.5 pound inches) Fit rectangular ring (2).

W230R160

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

84489509

Issued 04-11

Printed in E.C.

6003-38

STEP 166

KR Clutch

STEP 168

W230R227

NOTE: Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

STEP 167

W230R160

Heat up bearing inner ring (approx. 120° C) (248° F).

STEP 169 2

W230R174 W230R228

Install sealing cap -orifice- (1). NOTE: Wet contact surface with Loctite (Type No. 262).

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2). ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

STEP 170 1

W230R188

Mount needle cage (1) onto the shaft and oil it. 84489509

Issued 04-11

Printed in E.C.

6003-39

STEP 171

STEP 174

3 1

W230R201

Install ball bearing (2) into the idler gear (1) until contact is obtained and fix it by means of retaining ring (3).

W230R144

Place piston (1) into the disk carrier. NOTE: Observe installation position, see FIGURE.

STEP 175

STEP 172

W230R212

Press in preassembled idler gear (1) onto the shaft until contact is obtained.

STEP 173

W230R214

Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 380001556.

STEP 176 4 3

2 1 2

W230R213

Place both O rings (1 and 2) into the piston grooves and oil them.

84489509

W230R215

Mount inner installer (S) onto the disk carrier. Install disk (1), compression spring (2), support shim (3) and Lring (4). Issued 04-11

Printed in E.C.

6003-40

STEP 177

STEP 179

W230R216

W230R218

Preload compression spring by means of assembly aid (S1) and pressure piece, until L-Ring has engaged into the annular groove. Assembly aid 380001556.

Install outer and inner disks alternately into the disk carrier (4) as personated in Figure.

STEP 178 1

STEP 180

6 7 4

3 W230R217

Disk carrier with piston retraction: 1 = Washer 2 = Compression spring 3 = Support shim 4 = L-Ring 5 = Disk carrier 6 = Drain valve (piston) 7 = Piston with O-Rings

1 W230R219

84489509

Issued 04-11

Printed in E.C.

6003-41

STEP 181

STEP 183 F

1 2

W230R220

W230R222

Mount end plate (1) and fix disk package by means of snap ring (2) (e.g. thicknes s = 2.65 mm / recommended value) (0.10 in).

Then press end plate against the snap ring (upwards) and read disk clearance.

STEP 182

NOTE: Disk clearance: 2.65 to 2.95 mm (0.10 to 0.16 in). NOTE: In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1…... 4.2 mm) (0.08…... 0.16 in).

STEP 184

W230R221

Press on end plate with F (approx. 20 lb= 10 kg) and set dial indicator to "zero“.

W230R223

Heat up clutch inner diameter (approx. 120° C) (248° F).

84489509

Issued 04-11

Printed in E.C.

6003-42

STEP 185

STEP 188

W230R224

W230R226

Install clutch until contact is obtained. Mount inner disks onto the inner disk carrier by means of short left/right rotations.

Mount bearing inner ring (1) until contact is obtained.

ATTENTION: Wear protective gloves.

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

STEP 189

STEP 186

W230R225

Fix clutch (1) by means of retaining ring (2).

STEP 187

W230R146

Mount stud bolt (1). Tightening torque ...... = 17 Nm (150.5 pound inches) Fit rectangular ring (2).

W230R160

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

84489509

Issued 04-11

Printed in E.C.

6003-43

STEP 190

Clutch K1

STEP 192

W230R227

NOTE: Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

W230R160

Heat up bearing inner ring (approx. 120° C) (248° F).

STEP 193

STEP 191

W230R229 W230R228

Install sealing cap-orifice- (1). NOTE: Wet contact surface with Loctite (Type No. 262).

84489509

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2). ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

Issued 04-11

Printed in E.C.

6003-44

STEP 194

STEP 197 2 1

W230R213

W230R230

Place both O rings (1 and 2) into the piston grooves and oil them.

Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2).

NOTE: Check function of the drain valve (see arrow) - There must be no jamming of the ball.

STEP 198

STEP 195

W230R216

W230R144

Place piston (1) into the disk carrier. NOTE: Observe installation position, see FIGURE.

Preload cup spring package by means of assembly aid (S1) and pressure piece, until L-Ring has engaged into the annular groove. Assembly aid 380001556. NOTE: It is always necessary to mount a new L-ring.

STEP 196

W230R214

Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 380001556. 84489509

Issued 04-11

Printed in E.C.

6003-45

STEP 199

STEP 201 1

2 1

W230R231

Disk carrier with piston retraction: 1 = Cup spring package 2 = L-Ring 3 = Disk carrier 4 = Piston with O-Rings

W230R220

Mount end plate (1) and fix disk package by means of snap ring (2) (e .g. thickness = 2.65 mm / recommended value) (0.10 in).

STEP 202

STEP 200 F

1 W230R232

W230R221

Press on end plate with F (approx. 20 lb = 10 kg) and set dial indicator to "zeroâ&#x20AC;&#x153;.

Install outer and inner disks alternately into the disk carrier (4) as in Figure. 1 = Friction disk -coated on one side- (1 pcs) 2 = Outer disks (9 pcs) 3 = Inner disks (9 pcs) NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 18.

84489509

Issued 04-11

Printed in E.C.

6003-46

STEP 203

STEP 205 F

W230R222

Then press end plate against the snap ring (upwards) and read disk clearance. NOTE: Disk clearance: 2.35 to 2.65 mm (0.09 to 0.10 in).

W230R233

Mount clutch (1) until contact is obtained. ATTENTION: Wear protective gloves.

STEP 206

NOTE: In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1…... 4.2 mm) (0.08…... 0.16 in).

STEP 204

W230R234

Mount running disk (1), axial cage (2) and axial washer (3) and oil it. NOTE: Install chamfer (see arrow) of running disk (1) showing towards the axial cage. W230R223

STEP 207

Heat up clutch inner diameter (approx. 120° C) (248° F).

W230R235

Mount needle cage (1) and oil it.

84489509

Issued 04-11

Printed in E.C.

6003-47

STEP 208

STEP 211

R 1

W230R236

W230R160

Install (1) idler. Mount inner disks onto the inner disk carrier (idler) by means of short left/right rotations.

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

STEP 212

STEP 209 1

3 2 1

W230R239

Mount bearing inner ring (1) until contact is obtained. W230R237

Mount axial washer (1), axial cage (2) and running disk (3) and oil it. NOTE: Install chamfer (see arrow) of running disk (3) showing towards the axial cage.

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

STEP 213 1

STEP 210

W230R161

W230R238

Fix idler gear (1) and single parts by means of retaining ring (2). 84489509

Mount stud bolt (1). Tightening torque ...... = 17 Nm (150.5 pound inches) Fit rectangular ring (2).

Issued 04-11

Printed in E.C.

6003-48

STEP 214

STEP 216 2

W230R240

W230R241

NOTE: Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2).

Clutch K2

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

STEP 217

STEP 215

W230R160

W230R213

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

Place both O rings (1 and 2) into the piston grooves and oil them. NOTE: Check function of the drain valve (see arrow) - There must be no jamming of the ball.

84489509

Issued 04-11

Printed in E.C.

6003-49

STEP 218

STEP 221

1 S1

W230R144

Place piston (1) into the disk carrier.

W230R216

Preload cup spring package by means of assembly aid (S1) and pressure piece, until L-Ring has engaged into the annular groove. Assembly aid 380001556.

NOTE: Observe installation position, see FIGURE.

STEP 219

NOTE: It is always necessary to mount a new L-ring.

STEP 222 1

4 W230R214

Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 380001556.

W230R231

Disk carrier with piston retraction: 1 = Cup spring package 2 = L-Ring 3 = Disk carrier 4 = Piston with O-Rings

STEP 220 2 1

W230R230

Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2).

84489509

Issued 04-11

Printed in E.C.

6003-50

STEP 223

STEP 225

F 2

1 W230R242

W230R221

Install outer and inner disks alternately into the disk carrier (4) as in Figure.

Press on end plate with F (approx. 20 lb = 10 kg) and set dial indicator to "zero“.

1 = Friction disk -coated on one side- (1 pcs) 2 = Outer disks (7 pcs) 3 = Inner disks (7 pcs)

STEP 226 F

NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 14.

STEP 224 1

2 W230R222

Then press end plate against the snap ring (upwards) and read disk clearance. NOTE: Disk clearance: 1.75 to 2.05 mm (0.06 to 0.08 in). W230R220

Mount end plate (1) and fix disk package by means of snap ring (2) (e .g. thicknes s = 2.65 mm / recommended value) (0.10 in).

84489509

NOTE: In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1…... 4.2 mm) (0.08…... 0.16 in).

Issued 04-11

Printed in E.C.

6003-51

STEP 227

STEP 230 1

W230R223

W230R245

Heat up clutch inner diameter (approx. 120° C) (248° F).

Mount needle cage (1) and oil it.

STEP 228

STEP 231 R

W230R243

Mount clutch (1) until contact is obtained.

W230R246

Install (1) idler. Mount inner disks onto the inner disk carrier (idler) by means of short left/right rotations.

ATTENTION: Wear protective gloves.

STEP 229

STEP 232 2

3 2

W230R244

Mount running disk (1), axial cage (2) and axial washer (3) and oil it. NOTE: Install chamfer (see arrow) of running disk (1) showing towards the axial cage. 84489509

W230R247

Mount axial washer (1), axial cage (2) and running disk (3) and oil it. NOTE: Install chamfer (see arrow) of running disk (3) showing towards the axial cage. Issued 04-11

Printed in E.C.

6003-52

STEP 233

STEP 236 2

W230R248

W230R175

Fix idler gear (1) and single parts by means of retaining ring (2).

Mount stud bolt (1).

STEP 234

Fit rectangular ring (2).

Tightening torque ..... = 17 Nm (150.0 pound inches)

STEP 237

W230R160

Heat up bearing inner ring (approx. 120Â° C) (248Â° F). W230R250

NOTE: Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

STEP 235 1

W230R249

Mount bearing inner ring (1) until contact is obtained. ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

84489509

Issued 04-11

Printed in E.C.

6003-53

STEP 240

Clutch K3

STEP 238

W230R213

W230R160

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

STEP 239 3

Place both O rings (1 and 2) into the piston grooves and oil them. NOTE: Check function of the drain valve (see arrow) - There must be no jamming of the ball.

STEP 241

1 1

W230R251

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2). ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

W230R144

Place piston (1) into the disk carrier. NOTE: Observe installation position, see FIGURE.

Mount stud bolt (3). Tightening torque ...... = 17 Nm (150.0 pound inches)

84489509

Issued 04-11

Printed in E.C.

6003-54

STEP 242

STEP 244

W230R214

W230R216

Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 380001556.

Preload cup spring package by means of assembly aid (S1) and pressure piece, until L-Ring has engaged into the annular groove. Assembly aid 380001556.

STEP 243

NOTE: It is always necessary to mount a new L-ring.

STEP 245 1

3 S 4 W230R230

Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2).

W230R231

Disk carrier with piston retraction: 1 = Cup spring package 2 = L-Ring 3 = Disk carrier 4 = Piston with O-Rings

84489509

Issued 04-11

Printed in E.C.

6003-55

STEP 246

STEP 248

1 3

1 W230R252

W230R220

Install outer and inner disks alternately into the disk carrier (4) as personated in Figure. 1 = Friction disk -coated on one side- (1 pcs) 2 = Outer disks (7 pcs) 3 = Inner disks (7 pcs)

Mount end plate (1) and fix disk package by means of snap ring (2) (e .g. thickness = 2.65 mm / recommended value) (0.10 in).

NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 14.

STEP 247

STEP 249

2 W230R221

Press on end plate with F (approx. 20 lb = 10 kg) and set dial indicator to "zeroâ&#x20AC;&#x153;.

1 W230R253

Install outer and inner disks alternately into the disk carrier (4) as personated in Figure. 1 = Friction disk -coated on one side- (1 pcs) 2 = Outer disks (7 pcs) 3 = Inner disks (7 pcs) NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 12.

84489509

Issued 04-11

Printed in E.C.

6003-56

STEP 250

STEP 252 F

W230R222

Then press end plate against the snap ring (upwards) and read disk clearance. NOTE: Disk clearance: 1.75 to 2.05 mm (0.06 to 0.08 in).

W230R254

Mount clutch (1) until contact is obtained. ATTENTION: Wear protective gloves.

STEP 253

NOTE: In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1…... 4.2 mm) (0.08…... 0.16 in).

STEP 251

W230R255

Mount running disk (1), axial cage (2) and axial washer (3) and oil it. NOTE: Install chamfer (see arrow) of running disk (1) showing towards the axial cage. W230R223

Heat up clutch inner diameter (approx. 120° C) (248° F).

STEP 254 1

W230R256

Mount needle cage (1) and oil it. 84489509

Issued 04-11

Printed in E.C.

6003-57

STEP 255

STEP 257 1 L

W230R257

W230R259

Install (1) idler. Mount inner disks onto the inner disk carrier (idler) by means of short left/right rotations.

NOTE: Pay attention that the running disk is flush with the shaft (see arrow) collar to ensure that all inner disks are mounted on the idler gear teeth.

STEP 256

STEP 258 2

3 1

W230R258

W230R160

Mount axial washer (1), axial cage (2) and running disk (3) and oil it.

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

NOTE: Install chamfer (see arrow) of running disk (3) showing towards the axial cage.

STEP 259 2

W230R260

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2). ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down. 84489509

Issued 04-11

Printed in E.C.

6003-58

STEP 260

STEP 262 2

W230R261

W230R262

NOTE: Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring (2).

K4 Clutch

STEP 263

ATTENTION: Wear protective gloves.

STEP 261 2

W230R263

W230R160

Heat up bearing inner ring (approx. 120° C) (248° F).

Undercool shaft (1) (approx. -80°C) (-112 °F), heat up gear (2) (approx. +120°C) (248° F) and mount until contact is obtained. ATTENTION: Wear protective gloves.

STEP 264

W230R264

Secure gear by means of retaining ring (1). 84489509

Issued 04-11

Printed in E.C.

6003-59

STEP 265

STEP 268 3

2 1

W230R265

W230R268

Mount lower axial washer (1), axial needle cage (2) and upper axial washer (1) and oil it.

Mount axial washer (1), axial needle cage (2) and running disk (3) and oil it.

STEP 266

NOTE: Mount running disk (3) with the chamfer (see arrow) showing to the needle cage.

STEP 269

2 W230R266

Mount needle cage (1) and oil it. W230R213

STEP 267

Place both O rings (1 and 2) into the piston grooves and oil them. NOTE: Check function of the drain valve (see arrow) - There must be no jamming of the ball.

W230R267

Mount idler gear (1).

84489509

Issued 04-11

Printed in E.C.

6003-60

STEP 270

STEP 273

1 S1

W230R144

Place piston (1) into the disk carrier.

W230R216

Preload cup spring package by means of assembly aid (S1) and pressure piece, until L-Ring has engaged into the annular groove. Assembly aid 380001556.

NOTE: Observe installation position, see FIGURE.

STEP 271

NOTE: It is always necessary to mount a new L-ring.

STEP 274 1

4 W230R214

Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 380001556.

W230R231

Disk carrier with piston retraction: 1 = Cup spring package 2 = L-Ring 3 = Disk carrier 4 = Piston with O-Rings

STEP 272 2 1

W230R230

Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2).

84489509

Issued 04-11

Printed in E.C.

6003-61

STEP 275

STEP 277

F 2

W230R269

W230R221

Install outer and inner disks alternately into the disk carrier (4) as in Figure. 1 = Friction disk -coated on one side- (1 pcs) 2 = Inner disks (6 pcs) 3 = Outer disks (6 pcs)

Press on end plate with F (approx. 20 lb = 10 kg) and set dial indicator to "zero“.

STEP 278

NOTE: Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston. Number of friction surfaces: 12!

STEP 276

2 W230R222

Then press end plate against the snap ring (upwards) and read disk clearance. NOTE: Disk clearance: 1.35 to 1.65 mm (0.05 to 0.06 in). W230R220

Mount end plate (1) and fix disk package by means of snap ring (2) (e.g. thicknes s = 2.65 mm / recommended value) (0.10 in).

84489509

NOTE: In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1…... 4.2 mm) (0.08…... 0.16 in).

Issued 04-11

Printed in E.C.

6003-62

STEP 279

STEP 282

W230R223

W230R160

Heat up clutch inner diameter (approx. 120 째 C) (248째 F).

Heat up bearing inner ring (approx. 120째 C) (248째 F).

STEP 280

STEP 283 3

2 L

W230R270

W230R271

Mount clutch (1) until contact is obtained. Mount inner disks onto the inner disk carrier by means of short left/right rotations.

Mount bearing inner ring (1) until contact is obtained.

ATTENTION: Wear protective gloves.

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down. Fit rectangular ring (2). Mount stud bolt (3). Tightening torque ...... = 17 Nm (150.5 pound inches)

STEP 281

W230R204

Secure clutch by means of retaining ring (1).

84489509

Issued 04-11

Printed in E.C.

6003-63

STEP 284

STEP 286

W230R272

NOTE: Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.

W230R274

Secure drive gear by means of retaining ring (1).

STEP 287

Input shaft

STEP 285 2

W230R160

Heat up bearing inner ring (approx. 120° C) (248° F).

STEP 288 W230R273

Undercool input shaft (1) (approx. -80°C) (-112° F), heat up drive gear (2) (approx. +120° C) (248° F) and mount until contact is obtained.

ATTENTION: Wear protective gloves.

W230R275

Mount bearing inner ring (1) until contact is obtained. ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

84489509

Issued 04-11

Printed in E.C.

6003-64

STEP 289

STEP 292

1 2

W230R160

W230R278

Heat up bearing inner ring (approx. 120Â° C) (248Â° F).

Mount turbine shaft (1) until the snap ring engages into the input shaft groove. Snap in and interlock rectangular ring (2).

STEP 290

STEP 293

Version with lock-up clutch

3 1

W230R276

Mount bearing inner ring (1) until contact is obtained. ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

W230R279

STEP 291

Mount turbine shaft (1) until the snap ring engages into the input shaft groove. Turbine shaft is axially fixed. Snap in and interlock rectangular ring.

W230R277

Install snap ring (1) into the annular groove (2) of the turbine shaft.

84489509

Issued 04-11

Printed in E.C.

6003-65

STEP 297

Output shaft

STEP 294

W230R160

Heat up bearing inner ring (approx. 120째 C) (248째 F). W230R160

Heat up bearing inner ring (approx. 120째 C) (248째 F).

STEP 298

STEP 295 1 1

W230R282

Mount bearing inner ring (1) until contact is obtained. W230R280

Mount bearing inner ring (1) until contact is obtained. ATTENTION: Wear protective gloves.

ATTENTION: Wear protective gloves. NOTE: Adjust bearing inner ring after cooling-down.

NOTE: Adjust bearing inner ring after cooling-down.

STEP 296 1

W230R281

Mount screen sheet (1). 84489509

Issued 04-11

Printed in E.C.

6003-66

Installation of input shaft, output shaft, pump shaft (power-take off shaft) and clutches

STEP 301 3

STEP 299

1 4

4 W230R293

2 W230R291

Mount O-rings into the annular groove of the oil tubes (1 and 2) and oil them. Then insert tubes into the housing front part, oil cylindrical screws (3 and 4) and fix them.

If the suction tube (1) in the housing front part is to be replaced, it is imperative to use th special tool (rolling tool) for assembly. Then fix the tube with cylindrical screw (2).

NOTE: It is always necessary to use new cylindrical screws.

STEP 302

Tightening torque ...... = 23 Nm (203.5 pound inches)

Tightening torque....... = 23 Nm (203.5 pound inches) Rolling tool 380001285.

STEP 300

1 2 W230R294

Mount O-rings into the annular groove of the oil tubes (1 and 2) and oil them. Then insert tubes into the housing front part. W230R292

NOTE: The spare parts service supplies the lubricating oil tube (1) only as a complete package with the housing front part. NOTE: Single parts delivery upon request only. Rolling tool 380001286.

84489509

Issued 04-11

Printed in E.C.

6003-67

STEP 303

STEP 305

AN K2

W230R295

NOTE: The spare parts service supplies the lubricating oil tubes (1 and 2) only as a complete package with the housing rear part. NOTE: Single parts delivery upon request only.

W230R297

Housing rear part: Legend see STEP 304. NOTE: Place bearing outer rings into the bearing holes using assembly grease.

Rolling tool 380001287.

STEP 306

STEP 304

KR AN

KV W230R298 W230R296

Insert all bearing outer rings into the bearing holes of both housing parts. Housing front part AN = Input AB = Output KV = Forward clutch KR = Reverse clutch K1 = 1st gear clutch K2 = 2nd gear clutch K3 = 3rd gear clutch K4 = 4th gear clutch

84489509

ATTENTION: Due to the installation conditions, the installation of single clutches without using the special tool is not possible. NOTE: Housing rear part will be removed again later. Place KR clutch, AN input shaft and KV clutch into the housing rear part at the same time.

Issued 04-11

Printed in E.C.

6003-68

STEP 307

STEP 310 AN

W230R299

W230R302

Slightly lift drive gear and position K4 clutch.

Slightly lift K4 clutch and position K1 clutch.

STEP 308

STEP 311

W230R300

Mount K3 clutch.

W230R303

Press ball bearing (1) onto the pump shaft (2) until contact is obtained. Mount rectangular ring (3). Grease and centrically align rectangular ring.

STEP 309

STEP 312

W230R301

Position K2 clutch.

2 W230R304

Mount pump shaft (1) until contact is obtained. Fix pump shaft by means of retaining ring (2).

84489509

Issued 04-11

Printed in E.C.

6003-69

STEP 313

STEP 315 KV

KR K4

S W230R305

W230R307

The figure left shows the installation position of the individual clutches in the housing rear part one more time. Fix clutches K1, K2, K3 and K4 by using a handle. (S) Handle 380001557.

Use the lifting device to bring the housing rear part into contact position with the housing front part, by cautiously assembling the clutches.

ATTENTION: Clutches KV, KR and input shaft (2) are only fixed by the gear chain.

STEP 316

Then remove handles.

STEP 314

1 3 2

W230R308

Remove housing rear part again.

4 W230R306

Pivot housing rear part 180Â° by using a lifting device. 1 = Clutch KV 2 = Input shaft 3 = Clutch KR 4 = Pump shaft

STEP 317

ATTENTION: Clutch KV, KR and input shaft are only fixed by the gear chain. Attention must be paid that the non-fixed components of the gear chain do not get loose!

W230R309

Put on screen sheet (1). Install preassembled output shaft (2).

84489509

Issued 04-11

Printed in E.C.

6003-70

STEP 318 4

STEP 320 2

W230R310

W230R311

Oil cylindrical screws (1) and use them to fix screen sheet1. Tightening torque....... = 23 Nm (203.5 pound inches)

Fit both cylindrical pins (1) centrically to the mounting face.

NOTE: It is always necessary to use new cylindrical screws.

STEP 321 Checking of clearance of the gear drive train

Mount O-rings (2) into the annular groove of the oil tubes and oil them. Mount all rectangular rings (4), grease and align them centrally. Wet mounting face (3) with sealing agent Loctite (type No. 574).

STEP 319

W230R312

Position driving element and rotate KV clutch shaft.

W230R308

Carefully bring the housing front part into contact position with the housing rear part by using the lifting device. NOTE: Pay attention that both oil tubes are aligned with the holes in the housing rear part.

84489509

Issued 04-11

Printed in E.C.

6003-71

STEP 322

ASSEMBLY â&#x20AC;&#x201C; Outputs and closure parts pump shaft (PTO-shaft) 3

Closure parts pump shaft (PTO-shaft)

STEP 324 2

1 W230R313

F i x housi ng f r o nt a n d r e ar p a rt b y mea ns of cylindrical screws (1). Tightening torque.......... = 46 Nm (407 pound inches) W230R315

Mount fixing plate (2). Mount stud bolts (3).

Insert O-ring (1) into the hole of the transmission housing and grease it.

NOTE: Wet screw-in thread with Loctite (type No. 243).

Bring cover plate (2) into contact position.

Tightening torque....... = 15 Nm (132.7 pound inches)

STEP 325

STEP 323 1

W230R313

Fix cover plate with hexagon screws (1). W230R314

The screw plugs (1) must be mounted with a hydraulic pneumatic pressing tool.

Tightening torque .. = 115 Nm (1017.8 pound inches)

NOTE: In case of damage the premounted transmission housing rear part should /must be fully replaced.

84489509

Issued 04-11

Printed in E.C.

6003-72 Output flange output side with brake FSG-88

STEP 328

STEP 326 1

W230R322

W230R316

Use driver (S) to mount shaft sea, with the sealing lip showing to the oil sump. (S) Driver 380001560. NOTE: Use of the specified driver (S) ensures the exact installation position. Fill space between sealing lip and dust lip with grease.

STEP 327

Insert O-ring into the space between output flange and shaft. Fix output flange (1) by means of washer (2) and hexagon screws. Oil hexagon screws before the assembly. Tightening torque ......... = 46 Nm (407 pound inches) NOTE: It is always necessary to use new hexagon screws. Mount cylindrical screw with washer (3) for stop of the parking brake setting screw. Tightening torque ...... = 48 Nm (424.8 pound inches)

STEP 329

2 1

3 W230R321

Press screen sheet (1) onto the input flange (2). Mount output flange (2) until contact is obtained. W230R323

Fix brake disk (1) at output flange (2) by means of hexagon screws (3) and washers. Tightening torque ...... = 68 Nm (601.8 pound inches) Connect pump on port (see arrow) and apply app. 80 bar (1160 psi) pressure to parking brake (3) and bring it in contact position.

84489509

Issued 04-11

Printed in E.C.

6003-73

STEP 330

STEP 332 2 1

W230R091

W230R324

Fix parking brake (1) on transmission housing using the hex. screw - guide pin (2).

Insert setting gauge on both sides between base disk and brake disk and hold in its position.

Tightening torque.......... = 46 Nm (407 pound inches)

Clearance: 0.5 â&#x20AC;&#x201C; 1.5 mm (0.01 - 0.05 in) Nom. clearance: 1.0 mm (0.039 in)

STEP 331

STEP 333 Output flange on converter side

W230R090

Fix hex. nut on brake caliper using the open end wrench insert. Tightening torque... = 230 Nm (2035.6 pound inches)

W230R329

Use driver (S) to mount shaft sea, with the sealing lip showing to the oil sump. (S) Driver 380001560. NOTE: Use of the specified driver (S) ensures the exact installation position. NOTE: Fill space between sealing lip and dust lip with grease.

84489509

Issued 04-11

Printed in E.C.

6003-74

STEP 334

STEP 336 2 1

3 1

4 2 5 W230R330

Legend: 1 = Shaft seal 2 = Gearbox housing - rear section 3 = Roller bearing 4 = Output shaft 5 = Screen sheet

W230R332

Insert O-ring into the space between output flange and shaft. Fix output flange (1) by means of washer (2) and hexagon screws (3). Oil hexagon screws before the assembly. Tightening torque ......... = 46 Nm (407 pound inches)

STEP 335

NOTE: It is always necessary to use new hexagon screws.

2 1

W230R331

Press screen sheet (1) onto the input flange (2). Mount output flange (2) until contact is obtained.

84489509

Issued 04-11

Printed in E.C.

6003-75

REASSEMBLY â&#x20AC;&#x201C; Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor

STEP 339

Converter back-pressure valve

STEP 337 1

2 W230R360

Mount temperature sensor (1) with O-ring. Tightening torque ......... = 25 Nm (221 pound inches)

STEP 340 W230R358

Oil pressure pump

The figure shows the single parts of the converter back-pressure valve. 1 = oil feed housing 2 = piston 3 = compression spring 4 = pressure plate 5 = locking plate

2 1

STEP 338 S

1 W230R361

Insert pressure relief valve (1) into the housing hole until contact is obtained. Mount two adjusting screws (S) and place gasket (2) and oil feed housing (3). NOTE: Use assembly grease.

W230R359

Assemble single parts, preload them with assembly aid and fix them by means of locking plate (1).

84489509

Issued 04-11

Printed in E.C.

6003-76

STEP 341

STEP 344 1

1 S

2 W230R362

W230R365

Install two adjusting screws (S) and mount stator shaft (1).

Place control disk and fix it radially by means of two cylindrical screws (1). Place O-ring (2) into the annular groove and oil it.

STEP 342

STEP 345

2 W230R363

Install outer rotor.

W230R366

With the sealing lip showing downwards, carefully insert the shaft seal (1) into the pump housing (2) until contact is obtained.

STEP 343

W230R364

Install inner rotor.

84489509

Issued 04-11

Printed in E.C.

6003-77

STEP 346

STEP 348 1

W230R367

NOTE: Oil sliding bearing (see arrow) before the assembly. Mount inner installer (S) onto the stator shaft. Mount preassembled transmission pump (1).

W230R369

Fit O-rings to the cylindrical screws. NOTE: Grease O-rings. Fix transmission pump (2) by means of cylindrical screws (1). Tightening torque ......... = 46 Nm (407 pound inches)

STEP 347

STEP 349 3

W230R368

Mount preassembled pump with driver (S) until contact is obtained. (S) Assembly fixture 380001559. (Inner installer and driver).

W230R370

Fix oil feed housing (1) equally by means of Torx screws (2). Tightening torque ...... = 23 Nm (203.5 pound inches) Fasten fixing plate (3) by means of cylindrical screws (4). Tightening torque ...... = 34 Nm (300.9 pound inches)

84489509

Issued 04-11

Printed in E.C.

6003-78

STEP 350

STEP 352 2

W230R371

W230R373

Fix converter bell housing (1) by means of hexagon screws (2).

Fix flex plate (1) to converter (3) by means of hexagon screws (2).

Tightening torque.......... = 65 Nm (575 pound inches)

NOTE: Wet threads of hexagon screws with Loctite (Type No. 262).

STEP 351

Tightening torque .. = 115 Nm (1017.8 pound inches)

Engine connection

STEP 353

1 2

W230R372

Bolt input shaft (1) to flex plate (2) by means of hexagon screws (3). NOTE: Wet threads of hexagon screws with Loctite (Type No. 262).

W230R070

Install ball bearing (1) and fix it by means of V-ring (2).

Tightening torque... = 115 Nm (1017.8 pound inches)

84489509

Issued 04-11

Printed in E.C.

6003-79

STEP 354

STEP 357 1

S 1

W230R374

Put cover (1) onto the converter and press it until contact is obtained. NOTE: Support the bearing inner ring.

pressure

sleeve

(S)

the

W230R377

Mount input flange (1) until contact is obtained. ATTENTION: Wear protective gloves.

STEP 358

STEP 355

2 3

1 1 2

W230R378

W230R375

Press screen sheet (1) onto the input flange (2).

STEP 356

Fix input flange (3) by means of washer (1) and hexagon screws (2). Oil hexagon screws before the assembly. Tightening torque ...... = 34 Nm (300.9 pound inches) NOTE: It is always necessary to use new hexagon screws.

W230R376

Heat up clutch inner diameter (approx. 120° C) (248° F).

84489509

Issued 04-11

Printed in E.C.

6003-80

STEP 359

REASSEMBLY â&#x20AC;&#x201C; Emergency steering pump Version without emergency steering pump

STEP 361 1 2

W230R379

Position converter by means of lifting device until the cover (1) is in contact with the converter bell housing (2). W230R381

STEP 360

Fit adjusting screws (S) and assemble seal (1) and cover (2).

STEP 362 1

W230R380

Bolt converter bell housing (1) to cover (2) by means of cylindrical screws and hexagon nuts (3). NOTE: Pay attention to radial installation position, see markings done during disassembly (arrows).

Fix cover by means of hexagon screws (1).

Tightening torque.......... = 46 Nm (407 pound inches)

Tightening torque ...... = 23 Nm (203.5 pound inches)

84489509

W230R382

Issued 04-11

Printed in E.C.

6003-81

STEP 366

Version with emergency steering pump

STEP 363

2 4 1 3

W230R385

Fix cover (1) by means of Torx screws (2). W230R383

Press sliding bearing into the cover (1) in alignment with the plane face.

STEP 364

Tightening torque ...... = 23 Nm (203.5 pound inches) Mount emergency steering pump (3) and fix it by means of cylindrical screws (4). Tightening torque ......... = 25 Nm (221 pound inches)

1 2

W230R384

Place O-ring (1) into the annular groove of the piston pump (2) and grease it.

STEP 365 2

W230R381

Fit adjusting screws (S) and assemble seal (1) and cover (2). 84489509

Issued 04-11

Printed in E.C.

6003-82

REASSEMBLY â&#x20AC;&#x201C; Inductive sensor, Hall sensor, breather, oil filler and oil drain plug

STEP 368 4

STEP 367 2

4 2 3 1

5 W230R387

Mount oil drain plug with O-ring (1). Tightening torque ......... = 80 Nm (708 pound inches)

5 7

Bring oil level tube (2) with seal into contact position with the housing front part and fix it by means of hexagon screws (3). Tightening torque ...... = 34 Nm (300.9 pound inches) Fasten dipstick (4) in oil level tube. Fix identification plate (5) to the housing front part. NOTE: Use Loctite (type No. MS 9360).

8 9 If disassembled:

W230R386

Mount inductive sensors (1, 2 and 3) with O-rings. 1 = Inductive sensor - turbine speed 2 = Inductive sensor - speed/central gear chain 3 = Inductive sensor - engine speed Tightening torque....... = 30 Nm (265.5 pound inches) Mount breather (4). Tightening torque.......... = 12 Nm (106 pound inches) Mount speed sensor (5) with O-ring and fix it by means of cylindrical screw (6). 1 = speed sensor (Hall sensor) - output speed Tightening torque....... = 23 Nm (203.5 pound inches) Mount screw plug (7) with O-ring. Tightening torque.......... = 80 Nm (708 pound inches) Bring cover (8) with seal into contact position with the housing front part and fix it by means of hexagon screws (9). Tightening torque....... = 23 Nm (203.5 pound inches)

84489509

Issued 04-11

Printed in E.C.

6003-83

STEP 371

Reassembly of electric gear - shift control

STEP 369 4 3 1

1 W230R391

W230R064

Insert converter safety valve (1) into the housing hole until contact is obtained.

Fix duct plate (1) by means of Torx screws (2) and hexagon nuts (3). Tightening torque ...... = 23 Nm (203.5 pound inches) Mount screw plug (4) with new O-ring.

STEP 370

Tightening torque ...... = 30 Nm (265.5 pound inches)

STEP 372

W230R390

Mount stud bolts (1). NOTE: Wet screw-in thread with Loctite (type No. 243). Tightening torque....... = 15 Nm (132.7 pound inches) Place seal (2) and duct plate (3) at the housing rear part until contact is obtained. NOTE: Use assembly grease.

W230R392

Mount compression spring (4), piston (3) and switch (2) with new O-ring. 1 = Filter differential pressure valve 2 = Switch with O-ring 3 = Piston 4 = Compression spring Tightening torque ...... = 30 Nm (265.5 pound inches)

84489509

Issued 04-11

Printed in E.C.

6003-84

STEP 373

Fitting of filter

STEP 375

S 2

1 2 1 W230R393

Fit two adjusting screws. W230R059

(S) Adjusting screws 380001558. Mount sealing plate (1) and electro-hydraulic control unit (2). NOTE: It is not permitted to re-assemble the seal plate after opening the threaded joint shift unit/gearbox housing. In case of repair it is always necessary to mount a new seal plate.

Fix filter head (1) with new O-rings to the housing rear part by means of Torx screws (2). Tightening torque ...... = 34 Nm (300.9 pound inches)

STEP 376

STEP 374

2 W230R394

W230R060

Fix electro-hydraulic control unit (1) equally by means of Torx screws (2).

ATTENTION: The filter is to be installed as follows: - Slightly oil the seal - Turn in the filter until contact with the sealing surface is obtained, and then tighten it by hand with approx. 1/3 to 1/2 rotation.

Tightening torque........... = 9.5 Nm (84 pound inches)

84489509

Issued 04-11

Printed in E.C.

6003-85

NOTES

84489509

Issued 04-11

Printed in E.C.

6003-86

84489509

Issued 04-11

Printed in E.C.

6004

Section 6004 FRONT AXLE

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

84489509

6004-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 4 7 7 8 21 45 45 45

Printed in E.C.

6004-3

SPECIAL TOOLS Planetary bearing puller collet set .............................................................................................................380001757 Brake housing seal installer.......................................................................................................................380001574 Differential bearing cone puller collet set...................................................................................................380001569 Differential bearing preload wrench...........................................................................................................380001565 Brake housing inner bearing cup installer .................................................................................................380001572 Brake housing outer bearing cup installer .................................................................................................380001573 Brake housing inner bearing cup installer .................................................................................................380001556 Wear ring installer adapter ........................................................................................................................380001754 Wear ring installer adapter .......................................................................................................................380001755 Pinion depth gauge set..............................................................................................................................380001570 Pinion depth gauge block ..........................................................................................................................380001753 Puller body and screw ...............................................................................................................................380001575 Support bracket .........................................................................................................................................380001576 Slide hammer puller adapter .....................................................................................................................380001545 Slide hammer ............................................................................................................................................380001582 Replacer ....................................................................................................................................................380001552 Magnetic base with indicator .....................................................................................................................380001725 Heat gun ....................................................................................................................................................380001544 Lifting sling.................................................................................................................................................380001579 Engine stand..............................................................................................................................................380001580 Snap ring pliers..........................................................................................................................................380001584 Snap ring pliers..........................................................................................................................................380001583 Snap ring pliers..........................................................................................................................................380001585 Step plate set (includes 380001539, 380001541, and 380001542) ............................................................OEM4288 Step plate ..................................................................................................................................................380001539 Step plate ..................................................................................................................................................380001541 Step plate ..................................................................................................................................................380001542 Hexagonal wrench 4.1 in (105 mm)...........................................................................................................380003004 Lifting devise..............................................................................................................................................380002303 Clamping devise ........................................................................................................................................380001564 Assembly fixture ........................................................................................................................................380100001

84489509

Issued 04-11

Printed in E.C.

6004-4

SPECIFICATIONS Axle supplied with open differentials Overall width .............................................................................................................................. 2476 mm (97.4 inch) Track........................................................................................................................................... 2230 mm (87.7 inch) Distance flange to flange ............................................................................................................... 2314 mm (91 inch) Mounting pad center to center.................................................................................................... 1100 mm (43.3 inch) Mounting pad height .......................................................................................................................112 mm (4.4 inch) Wheel mounting bolt circle Dia. .................................................................................................... 425 mm (16.7 inch) Wheel mounting studs 20, Grade 10.9 equallt spaced Hub pilot Dia. ................................................................................................................................ 370 mm (14.5 inch) Input flange joint centerline to be.................................................................................................. 399 mm (15.7 inch) Axle filled with 20W-40 Oil Axle supplied with hydraulic avtivated locking differentials Overall width .............................................................................................................................. 2476 mm (97.4 inch) Track........................................................................................................................................... 2230 mm (87.7 inch) Distance flange to flange ............................................................................................................... 2314 mm (91 inch) Mounting pad center to center.................................................................................................... 1100 mm (43.3 inch) Mounting pad height .......................................................................................................................112 mm (4.4 inch) Wheel mounting bolt circle Dia. ......................................................................................................120 mm (4.7 inch) Wheel mounting studs 20, Grade 10.9 equallt spaced Hub pilot Dia. ................................................................................................................................ 370 mm (14.5 inch) Input flange joint centerline to be.................................................................................................. 399 mm (15.7 inch) Axle filled with 20W-40 Oil

SPECIAL TORQUES Bolts Securing Wheel End to Axle Housing...................................................................... 390 Nm (287.6 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads)................................................1200 Nm (885 pound feet) Bolts Securing Differential Ring Gear.................................................................................. 560 Nm (413 pound feet) Bolts Securing Axle Housing to Center Section .................................................................. 560 Nm (413 pound feet) Locknut Securing Planetary Carrier.................................................................................. 500 Nm (368.7 pound feet)

84489509

Issued 04-11

Printed in E.C.

6004-5

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)

84489509

Issued 04-11

Printed in E.C.

6004-6

Pinion Distance Must Be Decreased

BS01D016 BS01D010

DRIVE SIDE (CONVEX)

BS01D015

COAST SIDE (CONCAVE)

84489509

Issued 04-11

Printed in E.C.

6004-7

LUBRICATION 4

3 5 2

2 W230R550

1. OIL DRAIN HOLE (AXLE HOUSING) 2. OIL DRAIN HOLE (OUTPUTS)

3. OIL FILL HOLE 4. BRAKE BLEEDER

5. BLEEDER

WEAR MEASUREMENT ON MULTI-DISC BRAKE X

BS00M071

BD00M234

NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a changed braking behavior. A wear measurement has to be made on both wheels ends. Remove crew plug, actuate brake and determine dimension “X” using a feeler guage. If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced. Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pond-feet).

84489509

Issued 04-11

Printed in E.C.

6004-8

DISASSEMBLY Output and brake

STEP 3

STEP 1

W230R445

Remove the breather valve (see arrow). W230R551

Fix axle to assembly truck.

STEP 4

ATTENTION: Before clamping the axle fully turn in the support. Position axle first onto the two fixtures, secure with clamping brackets and then unbolt the support until contact with the axle is obtained.

STEP 2

W230R553

Secure the output with the lifting device 380002303 and loosen hexagon screws. Then separate the output assy from the axle housing.

STEP 5

W230R552

Loosen screw plugs and drain oil from the axle.

84489509

W230R447

Pull stub shaft and sun gear shaft. NOTE: Pay attention to potentially releasing shim.

Issued 04-11

Printed in E.C.

6004-9

STEP 6

STEP 9

W230R448

Fix output to assembly truck.

W230R451

Press planetary carrier with a two-armed puller out of the profile of the output shaft.

STEP 7

STEP 10

W230R449

Use a lever to remove the cover from the output shaft.

STEP 8

W230R452

Lift the planetary carrier out of the brake housing by means of the lifting device 380001578.

STEP 11

W230R450

Loosen locking screws and remove the releasing cover.

84489509

W230R453

Pull the tapered roller bearing from the planetary carrier.

Issued 04-11

Printed in E.C.

6004-10

STEP 12

STEP 15

W230R454

W230R457

Disengage retaining ring.

Lift the disk package out of the brake housing.

STEP 13

STEP 16

W230R455

Pull off planetary gear.

W230R458

Loosen hexagon screws, remove releasing cover and cup spring.

STEP 14

STEP 17

W230R456

Lift the end plate out of the brake housing.

W230R459

Mount breather valve and press piston out of the brake housing by means of compressed air.

84489509

Issued 04-11

Printed in E.C.

6004-11

STEP 18

STEP 19

W230R460

If necessary, remove guide ring, back-up rings and grooved rings out of the annular grooves of the brake housing (see arrows). NOTE: For the installation position of the single parts please also refer to the following sketch.

W230R461

Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft

STEP 20

W230R462

Lift the brake housing from the output shaft by means of the lifting device.

84489509

Issued 04-11

Printed in E.C.

6004-12

STEP 21

W230R463

Use a lever to remove the slide ring seal from the brake housing.

STEP 22

W230R464

Use a lever to remove the slide ring seal from the output shaft.

STEP 23

W230R465

Pull the tapered roller bearing from the output shaft.

84489509

Issued 04-11

Printed in E.C.

6004-13

Axle Housing

STEP 26

STEP 24

W230R468

Loosen screw neck. W230R554

Secure axle housing with the lifting device and loosen the hexagon screws. Then separate the axle housing from the axle drive housing.

STEP 27

NOTE: Pay attention to releasing differential.

STEP 25

W230R469

Pull the bearing outer ring out of the bearing hole and remove the shim behind. Then remove the O-ring (see arrow).

W230R467

Loosen the threaded connections and remove the releasing brake tube.

84489509

Issued 04-11

Printed in E.C.

6004-14

Input

STEP 30

STEP 28

W230R555

Use the lifting device to lift the differential out of the axle drive housing.

STEP 29

W230R557

Press piston (see arrow) out of the axle housing (see subsequent Figure) by means of compressed air. NOTE: This operation is only necessary for the version with DHL.

W230R556

Pull the bearing outer ring out of the housing hole and remove the shim behind.

STEP 31 Heat lock nut securing flange with a hot air blower to loosen Loctite, approximately 120Â° C (248Â° F).

STEP 32

W230R558

Install holding wrench on input flange. Hold flange using holding wrench, 380001546, and remove lock nut and washer. Remove holding tool from flange. 84489509

Issued 04-11

Printed in E.C.

6004-15

STEP 33

STEP 37

Remove the input flange from the drive pinion.

STEP 34

W230R484

If necessary, force both bearing outer rings out of the axle drive housing. W230R559

Remove the shaft seal from the axle drive housing.

STEP 35

W230R560

Press the input pinion out of the housing.

STEP 36

W230R489

Remove spacer ring and pull the tapered roller bearing from the input pinion.

84489509

Issued 04-11

Printed in E.C.

6004-16

Multi-Disk Differential Lock

STEP 41

STEP 38

W230R564

W230R561

Remove axial roller cage (arrow).

Preload the housing cover/compression spring by means of the press and disengage the retaining ring. Then remove sliding sleeve and compression spring from the housing cover.

STEP 39

STEP 42 2 1

3 4 5

W230R504

Pull both tapered roller bearings from the differential.

W230R565

Remove single parts.

STEP 40

1 = Pressure piece 2 = Cage 3 = Lever (12x) 4 = Disk carrier 5 = Disk package

W230R505

Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover.

84489509

Issued 04-11

Printed in E.C.

6004-17

STEP 43

STEP 46

W230R506

W230R519

Preload differential by means of the press, loosen locking screws and housing cover.

Force out both differential axles (short) and remove the releasing spider gears with thrust washers from the differential housing.

STEP 44

STEP 47

W230R507

Remove axle bevel gear with thrust washers from the differential housing.

STEP 45

W230R562

Pull the differential axle (long) and remove the releasing spider gears with thrust washers from the differential housing.

STEP 48

W230R508

Force out both slotted pins. W230R509

Remove the axle bevel gear and the shim behind.

84489509

Issued 04-11

Printed in E.C.

6004-18

STEP 49

W230R510

Press crown wheel from the differential carrier.

84489509

Issued 04-11

Printed in E.C.

6004-19

Differentialâ&#x20AC;?Openâ&#x20AC;?

STEP 53

STEP 50

W230R507

W230R504

Pull both tapered roller bearings from the differential.

Remove axle bevel gear with thrust washers from the differential housing.

STEP 54

STEP 51

W230R508 W230R505

Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover.

Force out both slotted pins.

STEP 55

STEP 52

W230R519

W230R506

Force out both differential axles and remove the releasing spider gears with thrust washers from the differential housing.

Preload the differential by means of the press, loosen locking screws and housing cover.

84489509

Issued 04-11

Printed in E.C.

6004-20

STEP 56

W230R509

Remove the axle bevel gear and the shim behind.

STEP 57

W230R510

Press crown wheel from the differential carrier.

84489509

Issued 04-11

Printed in E.C.

6004-21

REASSEMBLY

84489509

Issued 04-11

Printed in E.C.

6004-22

Multi-Disk Differential Lock

STEP 61

STEP 58

W230R563

W230R511

Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained.

STEP 59

Insert spider gears with thrust washers into the differential housing and fix them with the spider shaft (long). NOTE: Thrust washers must be positioned with the tabs (see arrow) being located in the recesses of the differential housing.

STEP 62 2 1

W230R512

Insert thrust washer into the differential housing.

W230R520

Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts (short).

STEP 60

NOTE: Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing. Pay attention to radial installation position of the spider shafts (fixing holes, arrow 2).

W230R513

Insert axle bevel gear.

84489509

Issued 04-11

Printed in E.C.

6004-23

STEP 63

STEP 66

W230R521

Fix spider shafts (short) with slotted pins.

W230R516

Mount two adjusting screws and insert the housing cover until contact with the differential housing is obtained.

NOTE: Flush mount slotted pins.

STEP 64

Preload the differential by means of the press and bolt with new locking screws. Tightening torque ............= 400 Nm (295 pound feet)

STEP 67

W230R507

Mount second axle bevel gear.

STEP 65 W230R566

Install compression spring onto the sliding sleeve.

W230R515

Fix the thrust washers into the housing cover by means of grease.

84489509

Issued 04-11

Printed in E.C.

6004-24

STEP 68

STEP 70

W230R564

W230R568

Insert the premounted sliding sleeve into the housing cover.

Preload disk package with an axial force of F = 50 +30 KN.

Preload the compression spring by means of the press and engage the retaining ring into the annular groove of the sliding sleeve.

Then check the setting dimension „A“ = 1.05 ± 0.1 mm (0.04 ± 0.039 inch) from the collar of the differential cover to the plane face of the outer disk (see also below sketch) .

STEP 69

NOTE: Any deviation from the specified setting dimension must be corrected with a corresponding outer disk.

STEP 71

W230R567

Setting of disk package Premount single parts according to the adjacent sketch. 1 = Housing cover 2 = Pressure piece 3 = Cage 4 = Lever (12x) 5 = Disk carrier 6 = Pressure ring 7 = Inner disks 8 = Outer disks (optional) 9 = Snap ring

84489509

W230R569

Legend to sketch: A = Setting dimension = 1.05 ±0.1 mm (0.04±0.039 in) B = Contact face To obtain a correct measuring result: The housing cover may only be supported on the contact face (B). Ensure that the assembly fixture is only supported on the disk package and not on the disk carrier (5).

Issued 04-11

Printed in E.C.

6004-25

STEP 72

STEP 74

W230R570

W230R517

Position housing cover onto pressure piece (see arrow). Insert two hexagon screws into the housing cover to radially fix the disk package.

Preload the differential by means of the press and the pressure piece.

STEP 73

Tightening torque .........= 185 Nm (136.5 pound feet)

Then finally tighten the housing cover with hexagon screws.

STEP 75

W230R571

Position the premounted differential with the lifting device onto the housing cover and preliminarily fix with hexagon screws.

W230R518

Heat both tapered roller bearings and insert until contact is obtained. NOTE: Adjust tapered roller bearing after cooling down.

84489509

Issued 04-11

Printed in E.C.

6004-26

STEP 76

W230R561

Fix axial roller cage (see arrow) to the sliding sleeve by means of grease.

84489509

Issued 04-11

Printed in E.C.

6004-27

Differential â&#x20AC;&#x153;Openâ&#x20AC;?

STEP 80

STEP 77

W230R562

W230R511

Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained.

STEP 78

STEP 81 2 1

W230R512

Insert thrust washer into the differential housing.

W230R520

Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts.

STEP 79

W230R513

Insert axle bevel gear.

84489509

Issued 04-11

Printed in E.C.

6004-28

STEP 82

STEP 85

W230R521

Fix spider shafts (short) with slotted pins.

W230R516

Mount two adjusting screws (S) and insert the housing cover until contact with the differential housing is obtained.

NOTE: Flush mount slotted pins.

STEP 83

Preload the differential by means of the press and bolt with new locking screws. Tightening torque ............= 400 Nm (295 pound feet)

STEP 86

W230R507

Mount second axle bevel gear.

STEP 84 W230R517

Attach the housing cover and preload the differential with the press. Then fix the housing cover with hexagon screws. Tightening torque .........= 185 Nm (136.5 pound feet)

W230R515

Fix the thrust washers into the housing cover by means of grease.

84489509

Issued 04-11

Printed in E.C.

6004-29

STEP 87

W230R518

Heat both tapered roller bearings and insert until contact is obtained. NOTE: Adjust tapered roller bearing after cooling down.

84489509

Issued 04-11

Printed in E.C.

6004-30

Input

STEP 90

STEP 88 1

3 2

W230R572

Find and record the housing dimension “X”. Dimension X (Example) . . . . 205.30 mm (8.08 inch)

STEP 89

1. MATING NUMBER (MARKED MANUALLY) 2. PINION BASIC DIMENSION (STAMPED) 3. PINION DISTANCE DEVIATION + OR - (MARKED MANUALLY)

BD06G139

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 91 Calculation example A: Dimension I Dimension II Results in dimension Y BD06G138

Measure the thickness of the inner bearing and record its measurement, dimension “I”. Dimension I (Example) . . . . . 36.13 mm (1.422 inch)

Calculation example B:

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.

Dimension Y

84489509

Dimension X

Difference = shim thickness

36.13 mm -------(1.422 inch) + 167.95 mm -------(6.612 inch) = 204.08 mm ------(8.034 inch) 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)

Issued 04-11

Printed in E.C.

6004-31

STEP 92

STEP 95

W230R573

Heat the bearing hole to approximately 120Â° C (248Â° F) and install the outer bearing until contact is made using the outer bearing cup installer.

STEP 93

BD06G143

Press the inner bearing on the drive pinion shaft.

Drive Pinion Bearing Rolling Torque Adjustment STEP 96

W230R574

Install the shim set determined in Step 91 in the bearing bore on the differential carrier.

STEP 94

BD06G144

Install an 8.18 mm (0.32 inch) thick spacer on the pinion shaft.

W230R575

Undercool the internal bearing outer ring and bring it into contact position in the housing hole by using 380100001 the assembly fixture. 84489509

Issued 04-11

Printed in E.C.

6004-32

STEP 97

STEP 99

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

W230R577

Install the input flange on the pinion shaft.

STEP 100 W230R576

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.

STEP 98

Put the washer in place on the pinion shaft.

STEP 101 Install holding wrench, 380001546, on input flange. Hold flange using holding tool and tighten nut to a torque of 1200 Nm (885 pound feet). Remove holding wrench. NOTE: When tightening rotate the pinion shaft in both directions several times.

STEP 102

BD06G146

Press the dust shield on the input flange.

84489509

W230R578

Check the rolling torque of the drive pinion bearing. The rolling torque should be 1.5 to 3.0 Nm (13.3 to 26.5 lb-inch). If rolling torque is too low, install a thinner spacer (Step 96); if rolling torque is too high, install a thicker spacer (Step 96).

Issued 04-11

Printed in E.C.

6004-33

Setting Backlash and Bearing Preload Deviation Value

-0.2

-0.1

0.1

Shim 2

0.8

0.9

1.0

1.1

Shim 3

1.2

1.1

1.0

0.9

STEP 103

STEP 104

2 4 W230R500

Deviation see crown wheel rear side. The test dimension „101“ is stamped into the crown wheel rear side. If no + or – deviation is indicated, this value corresponds to the actual value ”O” in the table below. According to this value, the required shims are allocated in the table below. Any + or – deviation of the test dimension caused by production is also marked on the crown wheel rear side (e.g. - 20 or - 10 or 10 or 20) . In accordance with this deviation, the required shims are allocated in the table below.

W230R501

Legend to sketch: 1 = Axle housing 2 = Shim (crown wheel side) 3 = Shim (diff. carrier side) 4 = Axle housing

STEP 105

W230R495

Insert the determined shim (e.g. s = 0.9 mm) into the hole of the axle housing and adjust the bearing outer ring (see arrow) until contact is obtained.

84489509

Issued 04-11

Printed in E.C.

6004-34

STEP 106

STEP 108

W230R579

W230R580

Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing.

Mount two locating pins (S) and bring the axle housing into contact position with the axle drive housing by means of the lifting device.

STEP 107

Then preliminarily fix the axle housing with 4 hexagon screws. Tightening torque ............= 560 Nm (413 pound feet) NOTE: Preliminarily mount the axle housing without O-ring.

STEP 109

W230R496

Insert the determined shim (e.g. s = 1.1 mm) into the hole of the axle housing and adjust the bearing outer ring until contact is obtained. W230R581

Leakage test of lock Pressurize the lock (p = 1 bar) (14.5 psi), close shut-off valve and remove air line. ATTENTION: No noticeable allowed to occur within 10 sec.

pressure

loss

NOTE: This operation is only necessary for version with DHL.

84489509

Issued 04-11

Printed in E.C.

6004-35

STEP 110

STEP 112

W230R582

Loosen and remove the nut and input flange.

W230R584

Install the input flange. Install holding wrench, 380001546, 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 1200 Nm (885 pound feet).

STEP 111

NOTE: Rotate the input pinion several times in both directions when tightening.

W230R583

Install the shaft seal with the sealing lip towards oil sump using pinion shaft seal. 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.

84489509

Issued 04-11

Printed in E.C.

6004-36

Axle Housing

STEP 115

STEP 113

W230R498

Mount fitting. W230R497

Grease O-ring (see arrow) and insert it into the axle housing.

Tightening torque .............= 36 Nm (26.5 pound feet)

STEP 116

STEP 114

W230R499 W230R585

Mount two locating pins and bring the axle housing into contact position with the axle drive housing by using the lifting device.

Grease O-ring and insert it into the annular groove of the brake tube (see arrow).

Then fix the axle housing by means of hexagon screws. Tightening torque.............= 560 Nm (413 pound feet)

84489509

Issued 04-11

Printed in E.C.

6004-37

STEP 117

W230R586

Mount brake tube with threaded connection and hexagon nut (see arrow). Tightening torque............= 100 Nm (73.7 pound feet)

STEP 118

W230R587

Provide screw plug with a new O-ring and fit it. Tightening torque..............= 50 Nm (36.8 pound feet)

84489509

Issued 04-11

Printed in E.C.

6004-38

Output and Brake

STEP 121

STEP 119

W230R524

W230R522

Pull in wheel stud into the output shaft until contact is obtained.

STEP 120

Wet O-ring of slide ring seal and locating hole with spirit. Snap new slide ring seal into the output shaft. Then mount new slide ring seal accordingly into the brake housing. NOTE: For the installation position please also refer to sketch page 39.

the

seal

STEP 122

W230R523

Heat tapered roller bearing and insert it into the output shaft until contact is obtained. W230R525

ATTENTION: The surface of the slide ring seal may not have any grooves, scratches or other types of damage. Take care that the sealing surface is parallel to the housing face. The O-rings must be mounted evenly into the locating hole and must not bulge out of the hole. Risk of injury - Metal rings have extremely sharp edges. Wear protective gloves.

84489509

Issued 04-11

Printed in E.C.

6004-39

STEP 123

STEP 125

W230R526

W230R460

Insert both bearing outer rings (see arrows) into the brake housing until contact is obtained.

Insert back-up rings and grooved rings into the annular grooves of the brake housing (see arrows).

STEP 124

NOTE: Pay attention to the installation please also refer to sketch page 39.

position;

STEP 126

W230R462

Insert the premounted brake housing by means of the lifting device over the output shaft until contact is obtained. ATTENTION: Before clamping the seal rings (slide ring seal) to installation dimension, clean the sliding surfaces and apply an oil film. We recommend to use a leather cloth soaked with oil.

W230R527

Clean the annular groove of the brake housing with spirit. Then insert the guide ring into the annular groove (see also the following sketch) and fix it with Loctite (type no.: 415) at its extremities (see arrows). NOTE: The full circumference of the guide ring must be in an exact contact position. ATTENTION: Upon installation the orifice of the guide ring must show upwards (12 oâ&#x20AC;&#x2122;clock).

84489509

Issued 04-11

Printed in E.C.

6004-40

STEP 127

STEP 129

W230R529

Insert the piston into the brake housing and carefully install with the fixing device until contact is obtained.

STEP 130

W230R461

Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft

W230R530

Insert disk and cup spring with the convex side showing upwards into the piston.

STEP 131

STEP 128

W230R531 W230R528

Flush-mount the slotted pins (6x) into the holes of the piston.

84489509

Insert cover and fix it by means of hexagon screws. Tightening torque ................= 34 Nm (25 pound feet)

Issued 04-11

Printed in E.C.

6004-41

STEP 132

STEP 134

1 2

W230R457

Mount outer and inner disks. NOTE: For the number of disks and the disk arrangement please refer to the relating spare part list.

STEP 133

W230R532

Press stop bolt into the planetary carrier until contact is obtained. Legend to sketch: 1 = Stop bolt 2 = Planetary carrier

STEP 135 1

2 3 4

W230R456

Insert end plate.

W230R533

Insert the cylindrical roller bearing into the planetary gear â&#x20AC;&#x201C; for this purpose press the cylindrical roller bearing through the packaging sleeve until the snap ring engages into the annular groove of the planetary gear. 1 = Cylindrical roller bearing 2 = Packaging sleeve 3 = Snap ring 4 = Planetary gear

84489509

Issued 04-11

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STEP 136

STEP 138

1 2

W230R454

W230R535

Heat bearing inner rings and insert the premounted planetary gears with large radius facing the planetary carrier (downwards) until contact is obtained.

Wet front face (contact face bearing inner ring, arrow 1) and profile (teeth, arrow 2) in the output shaft with anti-corrosive agent.

NOTE: Adjust down.

STEP 139

bearing

inner

rings

after

cooling

Then fix planetary gears by means of retaining rings.

STEP 137

W230R452

Align disk package centrally and radially. Then insert the planetary carrier by means of the lifting device into the teeth of the output shaft. W230R534

Heat tapered roller bearing and install it to the planetary carrier until contact is obtained.

STEP 140

W230R536

Bring planetary carrier into contact position with the cover and the old locking screws which were removed during disassembly. Then remove the locking screws again. 84489509

Issued 04-11

Printed in E.C.

6004-43

STEP 141

STEP 143

W230R537

W230R539

Pivot output 90Â°. Insert disk and fix planetary carrier with new locking screws.

Insert the cover into the output shaft until contact is obtained.

ATTENTION: Tighten locking screws successively with a tightening torque of 200 Nm (147.5 pound feet). Then retighten the locking screws successively with a tightening torque of 500 Nm (368.7 pound feet).

STEP 144

STEP 142

2 W230R540

Determine dimension I, from the mounting face of the brake housing to the front face of the stop bolt.

Dimension I ................................40.80 mm (1.6 inch) W230R538

Install O-ring (see arrow 1) to the cover (2). NOTE: Use new cover and O-ring.

84489509

Issued 04-11

Printed in E.C.

6004-44

STEP 145

STEP 147

W230R541

W230R543

Insert stub shaft into the teeth of the axle bevel gear until contact is obtained.

Measure dimension II, from the front face of the sun gear shaft to the mounting surface of the axle housing.

ATTENTION: Pay attention to the installation position; mount the stub shaft with the long teeth showing to the differential.

Dimension II ...............................38.20 mm (1.5 inch) CALCULATION EXAMPLE: Dimension I ...............................40.80 mm (1.6 inch) Dimension II .............................- 38.20 mm (1.5 inch) Difference ...................................2.60 mm (0.10 inch) Required axial play.....................- 1.00 mm (0.4 inch) Difference = shim e.g. ........... s = 1.60 mm(0.06 inch)

STEP 146

STEP 148

W230R542

Insert the sun gear shaft until contact is obtained.

W230R544

Insert sun gear shaft into the planetary carrier.

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STEP 149

STEP 152

W230R545

W230R588

Fix determined shim(s) e.g. s = 1.60 mm (0.06 inch) with grease into the sun gear shaft.

Mount two adjusting screws and use the lifting device to 380002303 bring the output into contact position with the axle housing.

STEP 150

Then fix the output by means of hexagon screws. Tightening torque .........= 390 Nm (287.6 pound feet)

STEP 153

W230R546

Fix O-ring (see arrow) with grease into the countersink of the brake housing.

STEP 151

W230R548

Mount breather (see arrow).

W230R547

Grease O-ring (see arrow) and install it to the axle housing.

84489509

Issued 04-11

Printed in E.C.

6004-46

BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS.

High Pressure Test STEP 155

STEP 154

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 2 bar (29 psi).

Low Pressure Test STEP 156 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period pressure shall not drop. W230R589

Connect a hand pump with pressure gauge to the brake port as shown above. 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.

STEP 157 Check operability of DHL

W230R590

Build up pressure p = 20 bar max. (290 psi) and close connection to HP pump via shut-off valve. Lock on: When rotating the input flange, both outputs must have the same direction of rotation. Lock off: When rotating the input flange one side has no movement or has the opposite direction of rotation.

84489509

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Printed in E.C.

6004

Section 6004 REAR AXLE

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

84489509

6004-2

84489509

Issued 04-11

3 3 3 4 6 6 7 17 35 35 35

Printed in E.C.

6004-3

SPECIAL TORQUES Bolts Securing Wheel End to Axle Housing......................................................................390 Nm (287.6 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads)................................................1200 Nm (885 pound feet) Bolts Securing Differential Ring Gear..................................................................................560 Nm (413 pound feet) Bolts Securing Axle Housing to Center Section ..................................................................560 Nm (413 pound feet) Locknut Securing Planetary Carrier..................................................................................500 Nm (368.7 pound feet)

84489509

Issued 04-11

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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)

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Pinion Distance Must Be Decreased

BS01D016 BS01D010

DRIVE SIDE (CONVEX)

BS01D015

COAST SIDE (CONCAVE)

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LUBRICATION 4 5 6

2 1 2 BC06G003

1. OIL DRAIN HOLE (AXLE HOUSING) 2. OIL DRAIN HOLE (OUTPUTS)

3. OIL FILL PLUG & DIPSTICK 4. BRAKE BLEEDER

5. BREATHER 6. BRAKE INLET

NOTE: Refer to section 1002 of this service manual for proper lubricant.

WEAR MEASUREMENT ON MULTI-DISC BRAKE A

BS00M071

BD00M234

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).

84489509

Issued 04-11

Printed in E.C.

6004-7

DISASSEMBLY Output and Brake

STEP 3

STEP 1

W230R445

Remove the breather valve (see arrow). BD06G001

Fix axle to assembly truck.

STEP 4

STEP 2

BD06G004

Secure the output with the lifting device 380002303 and loosen hexagon screws. Then separate the output assy from the axle housing.

STEP 5

W230R444

Loosen screw plugs and drain oil from the axle.

84489509

W230R447

Pull stub shaft and sun gear shaft. NOTE: Pay attention to potentially releasing shim.

Issued 04-11

Printed in E.C.

6004-8

STEP 6

STEP 9

W230R448

Fix output to assembly truck.

W230R451

Press planetary carrier with a two-armed puller out of the profile of the output shaft.

STEP 7

STEP 10

W230R449

Use a lever to remove the cover from the output shaft.

STEP 8

W230R452

Lift the planetary carrier out of the brake housing by means of the lifting device 380001578.

STEP 11

W230R450

Loosen locking screws and remove the releasing cover.

84489509

W230R453

Pull the tapered roller bearing from the planetary carrier.

Issued 04-11

Printed in E.C.

6004-9

STEP 12

STEP 15

W230R454

W230R457

Disengage retaining ring.

Lift the disk package out of the brake housing.

STEP 13

STEP 16

W230R455

Pull off planetary gear.

W230R458

Loosen hexagon screws, remove releasing cover and cup spring.

STEP 14

STEP 17

W230R456

Lift the end plate out of the brake housing.

W230R459

Mount breather valve and press piston out of the brake housing by means of compressed air.

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STEP 18

STEP 19

W230R460

W230R461

Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft

STEP 20

W230R462

Lift the brake housing from the output shaft by means of the lifting device.

84489509

Issued 04-11

Printed in E.C.

6004-11

STEP 21

W230R463

Use a lever to remove the slide ring seal from the brake housing.

STEP 22

W230R464

Use a lever to remove the slide ring seal from the output shaft.

STEP 23

W230R465

Pull the tapered roller bearing from the output shaft.

84489509

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Printed in E.C.

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Axle Housing

STEP 26

STEP 24

W230R468

Loosen screw neck. BD06G126

Secure axle housing with the lifting device and loosen the hexagon screws. Then separate the axle housing from the axle drive housing.

STEP 27

NOTE: Pay attention to releasing differential.

STEP 25

W230R469

Pull the bearing outer ring out of the bearing hole and remove the shim behind. Then remove the O-ring (see arrow).

W230R467

Loosen the threaded connections and remove the releasing brake tube.

84489509

Issued 04-11

Printed in E.C.

6004-13

Input

STEP 31

STEP 28

BD06G132

BD06G127

Use the lifting device to lift the differential out of the axle drive housing.

STEP 29

Install holding wrench on input flange. Hold flange using holding wrench, 380001546, and remove lock nut and washer. Remove holding tool from flange.

STEP 32 Remove the input flange from the drive pinion.

STEP 33

BD06G131

Pull the bearing outer ring out of the housing hole and remove the shim behind.

STEP 30 Heat lock nut securing flange with a hot air blower to loosen Loctite, approximately 120Â° C (248Â° F).

BD06G133

Remove the shaft seal from the axle drive housing.

STEP 34

BD06G134

Press the input pinion out of the housing.

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STEP 35

W230R489

Remove spacer ring and pull the tapered roller bearing from the input pinion.

STEP 36

W230R484

If necessary, force both bearing outer rings out of the axle drive housing.

84489509

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Printed in E.C.

6004-15

Differential â&#x20AC;&#x153;Openâ&#x20AC;?

STEP 40

STEP 37

W230R507

W230R504

Pull both tapered roller bearings from the differential.

Remove axle bevel gear with thrust washers from the differential housing.

STEP 41

STEP 38

W230R508 W230R505

Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover.

Force out both slotted pins.

STEP 42

STEP 39

W230R519

W230R506

Force out both differential axles and remove the releasing spider gears with thrust washers from the differential housing.

Preload the differential by means of the press, loosen locking screws and housing cover.

84489509

Issued 04-11

Printed in E.C.

6004-16

STEP 43

W230R509

Remove the axle bevel gear and the shim behind.

STEP 44

W230R510

Press crown wheel from the differential carrier.

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REASSEMBLY

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6004-18

Differential â&#x20AC;&#x153;Openâ&#x20AC;?

STEP 48

STEP 45

2 1

W230R520

W230R511

Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained.

STEP 46

Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts. NOTE: Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing. Pay attention to radial installation position of the spider shafts (fixing holes, arrow 2).

STEP 49

W230R512

Insert thrust washer into the differential housing.

STEP 47

W230R521

Fix spider shafts (short) with slotted pins. NOTE: Flush mount slotted pins.

W230R513

Insert axle bevel gear.

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STEP 50

STEP 53

W230R507

Mount second axle bevel gear.

W230R517

Attach the housing cover and preload the differential with the press.

STEP 51

Then fix the housing cover with hexagon screws. Tightening torque .........= 185 Nm (136.5 pound feet)

STEP 54

W230R515

Fix the thrust washers into the housing cover by means of grease.

STEP 52

W230R518

Heat both tapered roller bearings and insert until contact is obtained. NOTE: Adjust tapered roller bearing after cooling down.

W230R516

Mount two adjusting screws and insert the housing cover until contact with the differential housing is obtained. Preload the differential by means of the press and bolt with new locking screws. Tightening torque.............= 400 Nm (295 pound feet) 84489509

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Printed in E.C.

6004-20

Input

STEP 57

STEP 55 1

3 2

BD06G137

Find and record the housing dimension “X”. Dimension X (Example) . . . . 205.30 mm (8.08 inch)

STEP 56

1. MATING NUMBER (MARKED MANUALLY) 2. PINION BASIC DIMENSION (STAMPED) 3. PINION DISTANCE DEVIATION + OR - (MARKED MANUALLY)

BD06G139

STEP 58 Calculation example A: Dimension I Dimension II Results in dimension Y BD06G138

Measure the thickness of the inner bearing and record its measurement, dimension “I”. Dimension I (Example) . . . . . 36.13 mm (1.422 inch)

Calculation example B:

Dimension Y

84489509

Dimension X

Difference = shim thickness

36.13 mm -------(1.422 inch) + 167.95 mm -------(6.612 inch) = 204.08 mm ------(8.034 inch) 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)

Issued 04-11

Printed in E.C.

6004-21

STEP 59

STEP 62

BD06G140

Heat the bearing hole to approximately 120Â° C (248Â° F) and install the outer bearing until contact is made using the outer bearing cup installer.

STEP 60

BD06G143

Press the inner bearing on the drive pinion shaft.

Drive Pinion Bearing Rolling Torque Adjustment STEP 63

BD06G141

Install the shim set determined in Step 58 in the bearing bore on the differential carrier.

STEP 61

BD06G144

Install an 8.18 mm (0.32 inch) thick spacer on the pinion shaft.

W230R494

Undercool the internal bearing outer ring and bring it into contact position in the housing hole by using 380100001 the assembly fixture. 84489509

Issued 04-11

Printed in E.C.

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STEP 64

STEP 66

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A

BD06G147

Install the input flange on the pinion shaft.

STEP 67 BD06G145

STEP 65

Put the washer in place on the pinion shaft.

STEP 68 Install holding wrench, 380001546, on input flange. Hold flange using holding tool and tighten nut to a torque of 1200 Nm (885 pound feet). Remove holding wrench. NOTE: When tightening rotate the pinion shaft in both directions several times.

STEP 69

BD06G146

Press the dust shield on the input flange.

84489509

BD06G148

Check the rolling torque of the drive pinion bearing. The rolling torque should be 1.5 to 3.0 Nm (13.3 to 26.5 lb-inch). If rolling torque is too low, install a thinner spacer (Step 63); if rolling torque is too high, install a thicker spacer (Step 63).

Issued 04-11

Printed in E.C.

6004-23

Setting Backlash and Bearing Preload Deviation Value

-0.2

-0.1

0.1

Shim 2

0.7

0.8

0.9

1.0

Shim 3

1.3

1.2

1.1

1.0

STEP 70

STEP 71

2 4 W230R500

W230R501

Legend to sketch: 1 = Axle housing 2 = Shim (crown wheel side) 3 = Shim (diff. carrier side) 4 = Axle housing

STEP 72

W230R495

Insert the determined shim (e.g. s = 0.9 mm) (0.035 inch) into the hole of the axle housing and adjust the bearing outer ring (see arrow) until contact is obtained.

84489509

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Printed in E.C.

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STEP 73

STEP 75

BD06G167

BD06G170

Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing.

Mount two locating pins and bring the axle housing into contact position with the axle drive housing by means of the lifting device.

STEP 74

Then preliminarily fix the axle housing with 4 hexagon screws. Tightening torque ............= 560 Nm (413 pound feet) NOTE: Preliminarily mount the axle housing without O-ring.

STEP 76

W230R496

Insert the determined shim (e.g. s = 1.1 mm) (0.04 inch) into the hole of the axle housing and adjust the bearing outer ring until contact is obtained. BD06G171

Loosen and remove the nut and input flange.

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STEP 77

BD06G172

STEP 78

BD06G173

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Axle Housing

STEP 81

STEP 79

W230R498

Mount fitting. W230R497

Grease O-ring (see arrow) and insert it into the axle housing.

Tightening torque .............= 36 Nm (26.5 pound feet)

STEP 82

STEP 80

W230R499 BD06G126

Mount two locating pins and bring the axle housing into contact position with the axle drive housing by using the lifting device.

Grease O-ring and insert it into the annular groove of the brake tube (see arrow).

Then fix the axle housing by means of hexagon screws. Tightening torque.............= 560 Nm (413 pound feet)

84489509

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Printed in E.C.

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STEP 83

W230R502

Mount brake tube with threaded connection and hexagon nut (1). Tightening torque............= 100 Nm (73.7 pound feet)

STEP 84

W230R503

Provide screw plug with a new O-ring and fit it (2). Tightening torque..............= 50 Nm (36.8 pound feet)

84489509

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Printed in E.C.

6004-28

Output and Brake

STEP 87

STEP 85

W230R524

W230R522

Pull in wheel stud into the output shaft until contact is obtained.

STEP 86

the

seal

STEP 88

W230R523

Heat tapered roller bearing and insert it into the output shaft until contact is obtained. W230R525

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STEP 89

STEP 91

W230R526

W230R460

Insert both bearing outer rings (see arrows) into the brake housing until contact is obtained.

Insert back-up rings and grooved rings into the annular grooves of the brake housing (see arrows).

STEP 90

NOTE: Pay attention to the installation please also refer to sketch page 29.

position;

STEP 92

W230R462

W230R527

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STEP 93

STEP 95

W230R529

Insert the piston into the brake housing and carefully install with the fixing device until contact is obtained.

STEP 96

W230R461

Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft

W230R530

Insert disk and cup spring with the convex side showing upwards into the piston.

STEP 97

STEP 94

W230R531 W230R528

Flush-mount the slotted pins (6x) into the holes of the piston.

84489509

Insert cover and fix it by means of hexagon screws. Tightening torque ................= 34 Nm (25 pound feet)

Issued 04-11

Printed in E.C.

6004-31

STEP 98

STEP 100

1 2

W230R457

Mount outer and inner disks. NOTE: For the number of disks and the disk arrangement please refer to the relating spare part list.

STEP 99

W230R532

Press stop bolt into the planetary carrier until contact is obtained. Legend to sketch: 1 = Stop bolt 2 = Planetary carrier

STEP 101 1

2 3 4

W230R456

Insert end plate.

W230R533

84489509

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STEP 102

STEP 104

1 2

W230R454

W230R535

Heat bearing inner rings and insert the premounted planetary gears with large radius facing the planetary carrier (downwards) until contact is obtained.

Wet front face (contact face bearing inner ring, arrow 1) and profile (teeth, arrow 2) in the output shaft with anti-corrosive agent.

NOTE: Adjust down.

STEP 105

bearing

inner

rings

after

cooling

Then fix planetary gears by means of retaining rings.

STEP 103

W230R452

Align disk package centrally and radially. Then insert the planetary carrier by means of the lifting device 380001578 into the teeth of the output shaft. W230R534

Heat tapered roller bearing and install it to the planetary carrier until contact is obtained.

STEP 106

W230R536

Bring planetary carrier into contact position with the cover and the old locking screws which were removed during disassembly. Then remove the locking screws again. 84489509

Issued 04-11

Printed in E.C.

6004-33

STEP 107

STEP 109

W230R537

W230R539

Pivot output 90Â°. Insert disk and fix planetary carrier with new locking screws.

Insert the cover into the output shaft until contact is obtained.

STEP 110

STEP 108

2 W230R540

Determine dimension I, from the mounting face of the brake housing to the front face of the stop bolt.

Dimension I ..............................19.75 mm (0.77 inch) W230R538

Install O-ring (see arrow 1) to the cover (2). NOTE: Use new cover and O-ring.

84489509

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STEP 111

STEP 113

W230R541

W230R543

Insert stub shaft into the teeth of the axle bevel gear until contact is obtained.

Measure dimension II, from the front face of the sun gear shaft to the mounting surface of the axle housing.

ATTENTION: Pay attention to the installation position; mount the stub shaft with the long teeth showing to the differential.

Dimension II ............................. 17.15 mm (0.67 inch) CALCULATION EXAMPLE: Dimension I ............................. 19.75 mm (0.77 inch) Dimension II ...........................- 17.15 mm (0.67 inch) Difference ...................................2.60 mm (0.10 inch) Required axial play.....................- 1.00 mm (0.4 inch) Difference = shim e.g. ........... s = 1.60 mm(0.06 inch)

STEP 112

STEP 114

W230R542

Insert the sun gear shaft until contact is obtained.

W230R544

Insert sun gear shaft into the planetary carrier.

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STEP 115

STEP 118

W230R545

BD06G004

Fix determined shim(s) e.g. s = 1.60 mm (0.06 inch) with grease into the sun gear shaft.

Mount two adjusting screws and use the lifting device to 380002303 bring the output into contact position with the axle housing.

STEP 116

Then fix the output by means of hexagon screws. Tightening torque .........= 390 Nm (287.6 pound feet)

STEP 119

W230R546

Fix O-ring (see arrow) with grease into the countersink of the brake housing.

STEP 117

W230R548

Mount breather (see arrow).

W230R547

Grease O-ring (see arrow) and install it to the axle housing.

84489509

Issued 04-11

Printed in E.C.

6004-36

BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS.

High Pressure Test STEP 121

STEP 120

Low Pressure Test STEP 122 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period pressure shall not drop. W230R549

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NOTES

84489509

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6004-38

84489509

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DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS

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

84489509

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SPECIAL TORQUES Coupler to Flywheel Bolts......................................................................................53 to 62 Nm (39 to 46 pound feet) Engine Drive Shaft to Coupler Bolts ......................................................................53 to 62 Nm (39 to 46 pound feet) Engine Drive Shaft to Transmission Bolts .............................................................75 to 81 Nm (55 to 60 pound feet) Center, Rear and Front Drive Shaft Bolts......................................................136 to 149 Nm (100 to 110 pound feet) Carrier Bearing Bolts .....................................................................................150 to 164 Nm (110 to 120 pound feet) Lock Nut for Yoke on Front Drive Shaft.........................................................339 to 373 Nm (250 to 275 pound feet)

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

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.

Make an alignment mark on the yoke and the end of the front drive shaft to make sure that the yoke is installed correctly. 84489509

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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 373 Nm (250 to 275 pound feet).

STEP 15 Tighten the set screws that secure the center bearing to the front drive shaft alternately until they stop turning and the hex head socket wrench starts to spring. BD03A167

Install the bolts and straps that fasten the front drive shaft to the front axle. Tighten the bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).

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.

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BD03A166

Install the bolts and straps that fasten the front drive shaft to the center drive shaft. Tighten the bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).

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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 3 inches, to hold the bearing housing during removal. Use an 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. 84489509

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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 373 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 150 to 164 Nm (110 to 120 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 136 to 149 Nm (100 to 110 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 1/4th turn and lock it with the jam nut. Repeat the procedure with the other set screw.

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STEP 34 Lubricate the center bearing with the grease specified in Section 1002.

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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 136 to 149 Nm (100 to 110 pound feet).

STEP 36 Use a prybar to disengage the center drive shaft from the yoke of the front drive shaft.

STEP 40

STEP 37

BD03A166

BD03A165

Loosen and remove the bolts and straps that fasten the center drive shaft to the transmission.

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 136 to 149 Nm (100 to 110 pound feet).

STEP 38 Hold the center drive shaft and remove from the machine.

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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 136 to 149 Nm (100 to 110 pound feet).

Use a prybar to disengage the rear drive shaft from the transmission.

STEP 46

STEP 43

BD01D323

BD01F304

Loosen and remove the bolts and straps that fasten the rear drive shaft to the rear axle.

Install the bolts and straps that fasten the rear drive shaft to the transmission. Tighten the bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).

STEP 44 Hold the rear drive shaft and remove from the machine.

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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 53 to 62 Nm (39 to 46 pound feet).

IMPORTANT: The bolts and straps that fasten the engine drive shaft to the transmission must be replaced when removed.

STEP 51

STEP 48

BD03A172 BD03A172

Loosen and remove the six bolts that fasten the engine drive shaft to the engine.

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 pound feet)

STEP 49 Remove the engine drive shaft from the machine.

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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.

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Section 6006

6006

WHEELS AND TIRES

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

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6006-2

TABLE OF CONTENTS WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 pound-feet) in the same sequence.

A. If the machine is new. B. If a wheel has been removed and installed.

TIRE PRESSURES Tires 23.5X25 XLD D2.......................................................................................................................2.75 bar (40 psi) Tires 23.5X25 XRD 1A ......................................................................................................................2.75 bar (40 psi) Tires 23.5R25 XMINE-D2 YELLOW COLOR ....................................................................................2.75 bar (40 psi) Tires 23.5X25 XHA............................................................................................................................2.75 bar (40 psi) Tires 23.5R25 RL-5K.........................................................................................................................2.75 bar (40 psi) Tires 23.5R25 RT-5C L5 ...................................................................................................................2.75 bar (40 psi) Tires 23.5R25 RT-3B.........................................................................................................................2.75 bar (40 psi) Tires 23.5X25 20 PR L3 GALAXY.....................................................................................................2.75 bar (40 psi) Tires 23.5X25 16 PR L3 ALLIANCE..................................................................................................2.75 bar (40 psi) Tires 23.5R25 L2 TRIANGLE ............................................................................................................2.75 bar (40 psi) Tires 23.5R25 L3 TRIANGLE ............................................................................................................2.75 bar (40 psi) Tires 23.5R25 RM94 L3 ....................................................................................................................2.75 bar (40 psi) Tires, SHIPPING 23.5R25.................................................................................................................2.75 bar (40 psi) Tires 23.5R25 L5 TRIANGLE ............................................................................................................2.75 bar (40 psi) Tires 23.5-25 L2 BIAS TRIANGLE ....................................................................................................2.75 bar (40 psi)

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CHANGING TIRES The split rim wheels used on this machine can be dangerous. When inflating a tire on the machine, use a self-locking nozzle and stand at the front or rear of the tire. When inflating a tire off the machine, put the wheel in a tire inflation cage. The retaining ring and rim can come off with enough force to result in death to a person in front of the rim. 48-44

1. Have a qualified tire mechanic service the split rim wheels used on this machine. 2. The correct tire equipment, especially a tire inflation cage, is required. Using the wrong procedure for a split rim wheel can result in death. IMPORTANT: When installing a Michelin tire, lubricate the tire with a tire mounting lubricant and inflate the tire to 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated on the rim. Then decrease the pressure to the specified pressure.

INSTALLING A WHEEL 1. Make sure the mounting surfaces of the rim and axle flange are clean and free of dirt and grease. 2. Install the wheel, hardened washers and wheel bolts.

4. Tighten the wheel bolts to 298 Nm (220 pound-feet) in the sequence shown in Figure 1. Then tighten the wheel bolts in the same sequence to 640 to 720 Nm (475 to 530 pound-feet).

3. Use a hand wrench (not an impact) to tighten the wheel b olts to pu ll the wheel against the planetary housing. DO NOT use an impact wrench to tighten the wheel bolts.

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W230R011

WHEEL BOLT TORQUE SEQUENCE

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NOTES

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Section 6007

6007

TRANSMISSION CONTROL VALVE

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

84489509

6007-2

TABLE OF CONTENTS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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. 84489509

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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

Remove the opposite solenoids, housing, and components.

Separate the housing from the valve body by equally loosening the adjusting screws.

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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). 84489509

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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 towards valve body, install controllers connectors as shown.

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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. 84489509

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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 towards valve body, install controllers connectors as shown. 84489509

BD06A030

Install the wiring harness retaining clamp.

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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.

84489509

BD06A034

Install new o-rings on the plugs, install and torque plugs to 6 Nm (53 pound-inch).

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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

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

84489509

7001 Section 7001 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS

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

84489509

7001-2

TABLE OF CONTENTS BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 1 4

5 6

2 8 BC05M136

1. 2. 3. 4.

FRONT AXLE REAR AXLE BRAKE VALVE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

FRONT ACCUMULATOR REAR ACCUMULATOR BRAKE PUMP CONNECTOR TO FAN VALVE

COMPONENT LOCATION ILLUSTRATION

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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.

4. Connect all of the electrical connections. 5. Turn the master disconnect switch to the ON position. 6. Bleed the brake system. See Section 7002. 7. Install the cab skirts. 8. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

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).

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9 5

6 7 3

2 8 W230R016

1. 2. 3. 4. 5.

BRAKE VALVE REAR ACCUMULATOR LINE PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE

6. 7. 8. 9. 10.

FRONT BRAKE LINE REAR BRAKE LINE FRONT ACCUMULATOR RETURN TO TANK PARKING BRAKE ACCUMULATOR

BRAKE VALVE ILLUSTRATION

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SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS Installation

Removal 1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine. 2. Put blocks on both sides of each tire to prevent machine movement. 3. Make sure the service brake accumulators (1) and the parking brake accumulator (2) are completely discharged. Push down and release the brake pedal at least 30. 4. Turn the master disconnect switch to the OFF position. 5. Remove the left cab skirt located under the cab or canopy to gain access to accumulators. 6. To release the pressure on the parking brake accumulator, the line at the accumulator must be SLOWLY cracked open. A pan will be needed to catch the hydraulic oil. 7. Connect a drain hose to the quick disconnect couplings in each brake circuit to release any pressure in the brake circuit. 8. Clean the brake accumulators (1), parking brake accumulator (2) and lines. Refer to illustration on page 7. 9. Put identification tags on the line that is connected to the parking brake accumulator (2).

1. Mount the accumulators (1) in the accumulators clamps (7), do not tighten clamps at this time. Refer to illustration on page 7. 2. Connect the tubes to both brake accumulators (1) and tighten. 3. Tighten accumulator clamp studs (7) to 17Nm (13 pound feet). 4. Install the parking brake accumulator (2) into the bracket. 5. Install the nut (3) and tighten. 6. Connect the line accumulator (2).

the

parking

brake

7. Stop the vacuum pump and remove. 8. Install the left cab skirt. 9. Turn the master disconnect switch to the ON position. 10. Bleed the brake system. See Section 7002. 11. Refer to Section 7008 and perform the Parking Brake Test Procedure. 12. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 11. Disconnect the accumulators (1).

tubes

from

both

brake

12. Loosen the clamp stud (8) on the accumulator clamp (7). 13. Remove the accumulators accumulator clamps (7).

(1)

from

the

14. Install plugs in the tubes. 15. Disconnect the accumulator (2).

hose

from

parking

brake

16. Remove the nut (3), remove the parking brake accumulator (2). 17. Install a plug in the hose.

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5 6 4

8 8

7 1

1 BC05M138

1. 2. 3. 4.

BRAKE ACCUMULATORS PARKING BRAKE ACCUMULATOR MOUNTING NUT HOSE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

TUBE FRONT BRAKE ACCUMULATOR TUBE REAR BRAKE ACCUMULATOR CLAMP ACCUMULATOR CLAMP STUD

BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

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BRAKE PUMP Installation

Removal 1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine. 2. Put blocks on both sides of each tire to prevent machine movement. 3. Turn the master disconnect switch to the OFF position. 4. Clean the brake pump (1) and lines, refer to the illustration on page 9. 5. Put identification tags the lines connected to the brake pump (1).

that

are

6. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump.

1. Install gear (6) onto the pump shaft, install washer (7) and slotted nut (8), torque nut to 70 to 79 Nm (52 to 58 pound feet). Refer to the illustration on page 9. 2. Install the cotter pin (9). 3. Install the brake pump (1), mounting bolts (2) and washers (3). 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to 48 pound feet). 5. Remove the plugs or caps and connect the lines to the brake pump (1). 6. Stop the vacuum pump and remove.

7. Disconnect the lines from the brake pump (1) and put plugs in each line.

7. Turn the master disconnect switch to the ON position.

8. Remove the mounting bolts (2) and washers (3) from the brake pump (1) and remove the brake pump (1).

8. Bleed the brake system. See Section 7002.

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9. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

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9 6

BC05M139

1. BRAKE PUMP 2. MOUNTING BOLT (2) 3. WASHER (2)

4. SUCTION HOSE 5. PRESSURE HOSE 6. DRIVE GEAR

7. WASHER 8. SLOTTED NUT 9. COTTER PIN

BRAKE PUMP ILLUSTRATION

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NOTES

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7002

Section 7002 HYDRAULIC BRAKE TROUBLESHOOTING

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

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TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Valve Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SPECIFICATIONS Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar (11 to 12 gpm at 2500 psi at 2000 rpm) Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi) Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi) Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2845 psi) Brake warning pressure switch (normally closed) opening set point......................106 to 115 bar (1530 to 1670 psi) Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi) Brake light pressure switch (normally open) closing set point.............................. 5 to 6 bar increasing (75 to 85 psi) Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi) Modulation pressure rear brake cylinders ..................................................................78 to 85 bar (1130 to 1230 psi)

SPECIAL TOOLS

G 94L95

380001737 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN. BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

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TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM NOTE: The hydraulic brake schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual. 1. Check the oil level in the hydraulic reservoir; add oil as necessary. 2. Push and release the brake pedal many times with the engine stopped to remove all hydraulic pressure from the brake system until there is no pressure on the pedal. 3. Install two 207 bar (3000 psi) pressure gauges to front and rear hydraulic brake accumulator test ports, refer to page 7 for the locations of the test ports. 4. Make sure that the pressure gauge hoses are long enough so the gauges can be read while sitting in the operators seat. NOTE: The gauges can not be connected to the test ports if hydraulic pressure remains in the system. 5. Start the engine. Run the engine at low idle while reading the pressure gauges. The alarms (buzzer, master warning light and brake pressure warning light) should shut off when the accumulator with the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi), approximately 40 seconds at any engine speed. 6. After the alarms stop, run the machine at high idle to finish charging the accumulators. The pressure must increase on both gauges until 190 to 196 bar (2757 to 2843 psi) is reached. This is the accumulator valve cut-out pressure. It is normal for the pressure to drop slightly once the cut-out pressure is reached. 7. With the engine running at high idle, push and release the brake pedal rapidly while reading the drop in pressure on the gauges. The pressure drops may not be equal, but as the lowest pressure reaches 157 to 167 bar (2280 to 2420 psi), the system pressure must start to increase. This is the valve cut in pressure.

8. Stop the engine. Turn the ignition switch to the ON position. Push and release the brake several times while reading the pressure on the gauges. Each push and release of the pedal will result in a slight drop in pressure, but not necessarily equal on the two gauges. As the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi) the brake warning lamp and alarm buzzer must actuate. If the warning lamp and alarm buzzer fail to work, test the low brake pressure warning switches and electrical circuit. If the warning lamp and alarm buzzer actuate at a higher or lower pressure than specified, test the low brake pressure warning switches and replace as needed. 9. As the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi) the brake warning lamp and alarm buzzer must actuate. If the warning lamp and alarm buzzer fail to work, test the low brake pressure warning switches and electrical circuit. If the warning lamp and alarm buzzer actuate at a higher or lower pressure than specified, test the low brake pressure warning switches and replace as needed. 10. After the low brake pressure light activates, press the brake pedal eight more times. 11. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi). 12. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete. 13. If the pressures are not within the required specifications, then the brake system must be bled. 14. After bleeding the brake system, perform the brake system check again.

NOTE: The brake cut-in and cut-out pressures of the brake system charge valve are factory preset and are not adjustable.

15. Continue to slowly push and release the brake pedal several times until the gauge pressure suddenly drops to zero. The last pressure reading before the drop to zero is the nitrogen charge pressure in the accumulator. Test the pressure in both accumulators. If the pressure is below 48 to 59 bar (700 to 850 psi), charge or replace the accumulator(s) (see page 5).

NOTE: If the pressure on one of the pressure gauges is lower than specified, the problem can be a bad accumulator valve.

NOTE: Nominal temperature of 20Â° C (68Â° F), colder temperature will reduce pressure, hotter temperature will increase pressure.

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CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine. B. Push down and release the brake pedal many times to release the pressure. 2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit. 3. Close valves B and C on the nitrogen charging kit, refer to the illustration. 4. Turn the stem out of valve F until the stem stops. 5. Remove the cap screws and guard from the accumulator. 6. Remove the cap from the accumulator valve stem. 7. Connect valve F to the accumulator valve stem.

A 94L95

NITROGEN CHARGING KIT

8. Make sure that valve D is open. 9. Turn the stem into valve F and read the pressure gauge E. 10. The pressure must be 48 to 59 bar (700 to 850 psi). If the pressure is too low, charge the accumulator with dry nitrogen.

CHARGING THE ACCUMULATOR WITH DRY NITROGEN NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator. 1. Close (turn counterclockwise) valve A and open valve B. Close valves C and D. 2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the accumulator valve stem. 3. Connect the nitrogen charging kit to a dry nitrogen tank. 4. Slowly turn valve A clockwise and read gauge E until the pressure is 48 to 59 bar (700 to 850 psi). Stop turning valve A.

5. If the pressure increases above 59 bar (850 psi), quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure. 6. Connect valve F to the accumulator valve stem. Turn the stem into valve F until the stem stops moving and open valve D to charge the accumulator. 7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving. 8. Close valve B and disconnect the nitrogen charging kit from the accumulator valve stem. 9. Install the cap on the accumulator valve stem. Install the guard and cap screws on the accumulator.

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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 quick-attached components, disconnect them machine prior to proceeding.

with from

8. Start the engine and run at low idle. 9. Push the brake pedal all the way down and slowly release for one cycle. 10. Close all four wheel end bleed screws. 11. Fully depress the brake pedal three times in 5 second cycles. 12. With the brake pedal partially depressed, open the bleed screw on the left front axle. Hold the brake pedal in position until the oil is clear (no bubbles). Close the bleed screw. 13. Open the bleed screw on the right front axle. Repeat step 12.

14. Open the bleed screw on the left rear axle. Repeat step 12.

BD03A092

1. SAFETY LINK

2. Raise loader arms and install the safety link (1) for safe access to the front axle bleed screws.

15. Open the bleed screw on the right rear axle. Repeat step 12. 16. Replace all bleed screws, caps and plugs. 17. Check the hydraulic fluid and add as necessary.

3. Apply the parking brake. 4. Keep the engine speed at high idle until both brake accumulators are fully charged. NOTE: This will be approximately 30 seconds after the low brake pressure light goes out. 5. Stop the engine. 6. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps). 7. Remove the plastic and rubber caps from each wheel end and slowly open all four bleed screws. NOTE: Attach a hose to the bleed screws to prevent spilling any fluids.

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BRAKE MODULATION PRESSURE CHECK

4 BD06F145

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

Testing the Brake Modulation Pressure 1. Make sure the hydraulic accumulator cut-in and cut-out pressures are correct. Refer to page 4 of this section.

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

6. Start the engine. 7. Operate the machine at low idle and watch the pressure gauges on the brake accumulators until the gauges rise above 170 bar (2645 psi). 8. Apply and hold the brakes for 10 to 15 seconds.

2. Stop the engine. Pump the brake pedal until there is no pressure in the brake system.

9. Make a note of the pressure on the gauges for the front and rear brakes.

3. Remove the cab skirts to gain access to the brake test ports.

10. The front brake pressure should read 80 to 87 bar (1160 to 1260 psi). This is the modulation pressure for the front axle.

4. Connect two 207 bar (3000 psi) pressure gauges to the front brake test port (1) and the rear brake test port (2). 5. Connect two 207 bar (3000 psi) pressure gauges to the front brake accumulator test port (4) and the rear brake accumulator test port (3).

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11. The rear brake pressure should read 78 to 85 bar (1130 to 1230 psi). This is the modulation pressure for the rear axle 12. If the pressures are not within the specified range, it will be necessary to adjust the modulation pressures.

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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

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SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) 1

4 BD06F145

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

NOTE: Prior to doing this procedure make sure that the accumulator pressures are correct. 1. Check the level of the hydraulic fluid in the reservoir, add as needed.

6. Start the engine and let idle until both the front and rear accumulators 3 and 4 are fully charged. The accumulators are fully charged at 190 to 196 bar (2755 to 2842 psi). 7. Stop the engine. 8. Push the brake pedal down slowly, allowing for full piston actuation. NOTE: Depress the brake pedal at the rate of three strokes per minute. 9. Continue pressing the brake pedal down. The low brake pressure light should activate when the pressure reaches 106 to 115 bar (1530 to 1670 psi). After the low brake pressure light activates, press the brake pedal eight more times.

1 W230R407

10. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi).

2. Install the articulation lock (1) before doing this test.

11. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete.

3. Remove the left side cab skirt to gain access to the brake accumulator test ports.

12. If the pressures are not within the required specifications, then the brake system must be bled.

1. ARTICULATION LOCK

4. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps).

13. After bleeding the brake system, perform the brake system check again.

5. Connect two 207 bar (3000 psi) pressure gauges to the test ports 3 and 4.

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BRAKE PUMP OUTPUT TEST 1. Connect the flowmeter to the brake pump as shown, refer to the illustration below. 2. Make sure the load control of the flowmeter is open. Start the engine. Run the engine at full throttle. Make sure the oil is at operating temperature.

3. Measure the flow at 0 bar (0 psi). Record the flow reading. Slowly close the load valve on the flowmeter and read the flow at 170 bar (2500 psi). Record the flow reading. 4. Divide the flow reading at 170 bar (2500 psi) by the reading at 0 bar (0 psi). Multiply the result by 100. This is the percent efficiency of the pump. If the efficiency of the pump is less than 85%, repair or replace the pump.

5 *

4 3 2

W230R593

1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD 2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE *: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

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NOTES

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BRAKE VALVE CONNECTIONS T1-T2. F1-F2. R1-R2-R4. F. P. N. B. X. Xâ&#x20AC;&#x2122;.

Brake Brake pressure switch (F1 plugged) Accumulators Accumulators pressure switch Inlet oil Tank Other services or tank Parking brake Parking pressure switch (plugged)

BRAKE VALVE COMPONENTS 1. 2. 3. 4. 5. 6. 7. 8.

Seal kit Complete pedal support Dust rubber Pedal rubber cover Solenoid 24V Deutsch connector Solenoid + Cartridge valve Brake pressure adjustment Accumulator pressure adjustment Pedal position adjustment

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Seal kit Complete pedal support Dust rubber Pedal rubber cover Solenoid 24V Deutsch connector Solenoid + Cartridge valve

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NOTES

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7003

Section 7003 BRAKE PUMP

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

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TABLE OF CONTENTS BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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15 16

18 10 19

8 9 11

5 6

BC06F594

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

RETAINING RING SEAL RETAINER 0-RING OUTER LIP SEAL INNER LIP SEAL SHAFT END COVER HOUSING QUAD RING

8. 9. 10. 11. 12. 13.

BACKUP SEAL CHANNEL SEAL DOWEL PIN THRUST PLATE GEAR HOUSING PORT END COVER HOUSING

14. 15. 16. 17. 18. 19.

WASHER BOLT DRIVEN GEAR DRIVE GEAR DRIVE SCREW NAME PLATE

PUMP ILLUSTRATION

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BRAKE PUMP Disassembly 1. Secure the pump by the port end cover (13) in a soft jawed vise. 2. Draw a line the length of the pump to assist during assemble. 3. Loosen and remove bolts (15). 4. Tap the shaft end cover housing (6) with soft hammer to loosen it, remove the shaft end cover housing (6). 5. Remove the backup seal (8), channel seal (9), and thrust plate (11). 6. Remove the drive gear (17) from the gear housing (12). 7. Remove the driven gear (16) from the gear housing (12). 8. Tap the gear housing (12) with a soft hammer to loosen it, remove the gear housing (12). 9. Remove the backup seal (8), channel seal (9), and thrust plate (11). 10. Remove the retaining ring (1) form the shaft end cover housing (6). 11. Remove the seal retainer (2), O-ring (3), and outer lip seal (4) from the shaft end cover housing (6). 12. Remove the inner lip seal (5) from the shaft end cover housing (6).

Inspection 1. Discard all seals and quad rings. Clean all parts in cleaning solvent. Check all machined surfaces for damage or wear. 2. Hold a straightedge across each gear housing and use a feeler gauge to measure the amount of wear caused by the gear teeth in the gear pocket. If the wear in any gear pocket is more than 0.18 MM. (0.007 inch), use a new gear housing. 3. Inspect the thrust plates for scoring, pitting, or other damage. 4. Inspect the gears for wear and damage. There must be no scoring on the gear hubs or on the outside edges of the gear teeth. There must be no more than 0.05 MM. (0.002 inch) wear in the seal area of the drive shaft. If any gear must be discarded, you must use a new hydraulic pump.

Assembly 1. Install a new lip seal (3) into the seal retainer (2) so the lip of the seal will be facing away from the gears when the seal retainer (2) is installed into the shaft end cover housing (6). 2. Install a new lip seal (4) into the shaft end cover housing (6) with the lip of the seal facing towards the gears. 3. Install a new O-ring (3) onto the seal retainer (2), lubricate the O-ring with hydraulic oil. 4. Press the seal retainer (2) into the shaft end cover housing (6) and install the retaining ring (1). 5. Place the shaft end housing (6), facing down, into a soft jawed vise. 6. Install new backup seals (8) and channel seals (9) into the thrust plates (11). 7. Place a thrust plate (11) onto the shaft end cover housing (6). IMPORTANT: Be sure to place the thrust plate (11) onto the shaft end cover housing (6) in the position shown in the illustration on page 3. 8. Lubricate the driven gear (16) with hydraulic oil, slide the driven gear (16) through the thrust plate (11) into the shaft end cover housing (6). 9. Lubricate the drive gear (17) with hydraulic oil, slide the drive gear (17) through the thrust plate (11) into the shaft end cover housing (6). 10. Install a new quad ring (7) into the gear housing (12). Check that dowel pins (10) are in place either in the gear housing (12) or the shaft end cover housing (6). 11. Align the marks made during disassembly, carefully place the gear housing (12) onto the gears. 12. Slide the thrust plate (11) onto the shafts of the gears. IMPORTANT: Be sure to place the thrust plate (11) onto the gears in the position shown in the illustration on page 3. 13. Install a new quad ring (7) into the gear housing (12). Check that dowel pins (10) are in place either in the gear housing (12) or the port end cover housing (13). 14. Align the marks made during disassembly, place the port housing (12) onto the gear housing (12). 15. Install bolts (15) with clean and dry threads, washers (14). Torque bolts to 192 Âą 5.5 Nm (141.5 Âą 4 pound feet).

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7004

Section 7004 BRAKE ACCUMULATORS

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

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7004-2

TABLE OF CONTENTS SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SPECIAL TOOL E

C F

G D

A 94L95

380001737 NITROGEN CHARGING KIT

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR 1. Remove cover from accumulator charge port. Loosen the Allen screw in the charge port.

6. Connect valve F to the valve stem on the adapter.

NOTE: Do not turn the Allen screw more than 1/8 of a turn or gas will escape uncontrolled.

7. Turn the T-handle inward on valve F to engage the pin in the valve stem, open valve G.

2. Install adapter on accumulator, use the 380001737 nitrogen charging kit to discharge the accumulator, refer to illustrations above. The tool must be disconnected from the nitrogen tank.

8. Open valve D and check the charge pressure on gauge E.

3. Close valves B, C and D. 4. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise. 5. Turn the T-handle on valve F fully out.

9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem and remove adapter.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine. B. Push down and release the brake pedal 21 times to release the pressure. 2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit. 3. Close valves B and C on the nitrogen charging kit, refer to the illustration. 4. Turn the stem out of valve F until the stem stops.

5. Remove the cap from the accumulator. Loosen the Allen screw in the charge port. NOTE: Do not turn the Allen screw more than 1/8 of a turn or gas will escape uncontrolled. 6. Connect adapter to accumulator. 7. Connect valve F to the adapter valve stem. 8. Make sure that valve D and G are open. 9. Turn the stem into valve F and read the pressure gauge E. NOTE: See chart below for pressure readings. 10. If the pressure is too low, accumulator with dry nitrogen.

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6. Connect valve F to the adapter valve stem. Turn the stem into valve F until the stem stops moving and open valve G and D to charge the accumulator.

1. Close (turn counterclockwise) valve A and open valve B. Close valves C, D, and G.

7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving and close valve G.

2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the adapter valve stem. 3. Connect the nitrogen charging kit to a dry nitrogen tank. 4. Slowly turn valve A clockwise and read gauge E until the pressure is equal to charge pressure required for accumulator being charged. Stop turning valve A. 5. If the pressure increases above required pressure, quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure.

8. Close valve B and disconnect the nitrogen charging kit from the adapter valve stem, remove the adapter. 9. Torque the Allen screw to 20 Nm (15 lb-ft), install the cover on the accumulator valve stem.

TEMPERATURE 0° C 32° F 5° C 41° F 10° C 50° F 15° C 59° F 20° C 68° F 25° C 77° F 30° C 86° F 35° C 95° F 40° C 104° F

CHARGE PRESSURE 51.2 BAR 743 PSI 52.2 BAR 757 PSI 53.1 BAR 770 PSI 54.1 BAR 784 PSI 55.0 BAR 798 PSI 55.9 BAR 811 PSI 56.9 BAR 825 PSI 57.8 BAR 839 PSI 58.8 BAR 852 PSI

TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR

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Section 7008

7008

PARKING BRAKE

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

84489509

7008-2

TABLE OF CONTENTS PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PARKING BRAKE Disassembly

STEP 7

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

STEP 2 Place wheel chocks on each wheel to prevent machine movement.

STEP 3 BD03A185

Loosen the jam nut, turn adjusting bolt counterclockwise until the brake pads are loose.

STEP 8

W230R406

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. 84489509

Remove the two brake pads from the parking brake assembly.

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Inspection

STEP 14 Disengage the parking brake.

STEP 10 Clean and inspect all parts for wear and damage. Inspect the brake disc for wear and damage. Replace all parts that are worn or damaged.

NOTE: Hydraulic pressure will not be applied to the parking brake until the parking brake rocker switch is turned off, the service brakes applied and the transmission is put into gear. A. Place the parking brake rocker switch in the OFF position.

Assembly

B. Apply the service brake and put the machine into gear.

STEP 11

C. The parking brake light on the cluster will turn off at this time. Place the transmission back into neutral before proceeding.

STEP 15

BD03A187

Install the two brake pads in the parking brake assembly.

STEP 12 BD0CA185

Turn the adjusting bolt clockwise until both brake pads contact the brake disc, then turn the adjusting bolt counterclockwise one turn. Tighten the jam nut to secure the adjusting bolt.

STEP 16 Install the cover on the parking brake.

STEP 17 BD03A186

Install the brake pins and retainer pins.

STEP 13 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.

84489509

Perform 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.

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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.

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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.

STEP 38 If any machine movement was detected, the parking brake must be adjusted, see procedures this section.

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.

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SECTION INDEX

HYDRAULICS Section Title

Section Number

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001 Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002 Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004 Loader Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006 Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007 Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013 Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

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

84489509

8001 Section 8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

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

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8001-2

TABLE OF CONTENTS LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 3 4 5 7 8 8 9 11 11 12 12 13 14 14 16 16 17 19 19 21 23 23 24 25 25 26 27 27 28 29 29 30 31 31 31

Printed in E.C.

8001-3

LOADER CONTROL VALVE Removal

STEP 5

STEP 1 Park the machine on a level surface. IMPORTANT: If machine is equipped quick-attached components, disconnect them machine prior to proceeding.

with from

STEP 2

BD06H198

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

STEP 6 Loosen the filler cap on the reservoir to release the air pressure in the reservoir. BD03A092

Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 3

STEP 7 Drain the hydraulic reservoir.

STEP 8

Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

STEP 4 Place the master disconnect switch in the OFF position.

BD03A093

Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

84489509

Issued 04-11

Printed in E.C.

8001-4

W230R017

1. GREEN WHITE GREEN 2. RED WHITE GREEN 3. YELLOW BLACK GREEN

4. ORANGE BLACK GREEN 5. GREEN WHITE GREEN 6. RED WHITE GREEN

7. GREEN BLACK GREEN 8. RED BLACK GREEN

HYDRAULIC VALVE PILOT LINE CONNECTIONS

84489509

Issued 04-11

Printed in E.C.

8001-5

7 W230R018

1. DUMP LINE 2. ROLLBACK LINE 3. LOWER LINE LEFT

4. RAISE LINE RIGHT 5. LOADER VALVE

6. LOWER LINE RIGHT 7. RAISE LINE LEFT

LOADER CONTROL VALVE LINE CONNECTIONS

84489509

Issued 04-11

Printed in E.C.

8001-6

STEP 9

STEP 15

Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and 6) from the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding. Install a plug in each hose and a cap on each fitting. NOTE: Line 1, 2, 5, and 6 will need to be tagged as right or left of valve.

STEP 10 Loosen and remove tilt cylinder lines (1 and 2). Install a plug in each line and a cap on each fitting.

STEP 11 Loosen and remove lines (3 and 4). Install a plug in each line and a cap on each fitting.

STEP 12 Loosen and remove lines (6 and 7). Install a plug in each line and a cap on each fitting.

STEP 13 Loosen and remove supply and return lines. Install a plug in each line and a cap on each fitting.

STEP 14

W230R019

Loosen and remove the three bolts and spacer that hold the loader control valve to the valve mounting plate. Remove the loader control valve.

Attach proper lifting equipment to lift loader control valve.

84489509

Issued 04-11

Printed in E.C.

8001-7

Installation

STEP 23

IMPORTANT: Before installing the fittings or connecting the tubes to the fittings, install new O-rings on the fittings.

Fill the hydraulic reservoir with oil. Refer to Section 1002 for the correct oil.

STEP 24 Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 16

STEP 25 Place the master disconnect switch in the ON position.

STEP 26

W230R019

BD03A092

Install and align the loader control valve with the valve mounting plate.

Raise the loader arms and remove the safety link.

STEP 17

Run engine at half throttle.

Install the bolts and spacer that fasten the loader control valve to the valve mounting plate. Tighten the bolts.

STEP 28

STEP 18 Tighten the left lift cylinder lines (6 and 7).

STEP 19 Install and tighten the supply and return lines.

STEP 20 Install and tighten right lift cylinder lines (3 and 4).

STEP 21 Install and tighten tilt cylinder lines (1 and 2).

STEP 27

Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.

STEP 29 Stop the engine and check for leaks.

STEP 30 Install the access cover on the front of the machine.

STEP 31 Check the level of the hydraulic oil and add hydraulic oil as required.

STEP 22 Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and 6) to the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding. 84489509

Issued 04-11

Printed in E.C.

8001-8

REMOTE CONTROL VALVE Removal

STEP 37

STEP 32 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

BD06F208

Open and remove the access panel.

STEP 33 Place the master disconnect switch in the OFF position.

STEP 38

STEP 34 Unlatch and open the right hand side access door.

STEP 35 Lift the access door up and remove the access door from the pins.

STEP 36 BD06F209

Remove the front access panel.

STEP 39

BD06F207

Unlatch and open the window on the right hand side.

BD06F210

Disconnect the electrical connectors for the remote control valve.

STEP 40 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump. 84489509

Issued 04-11

Printed in E.C.

8001-9

STEP 41

Installation

Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings.

STEP 45

STEP 42 Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.

STEP 43 Loosen and remove the screws that fasten the remote control valve to the hydraulic control tower.

STEP 44 Remove the remote control valve from the hydraulic control tower.

Install new O-rings on the adapters for the remote control valve.

STEP 46 Install the remote control valve and screws in the hydraulic control tower and tighten the screws.

STEP 47 Install the cover over the remote control valve and install the screws and washers.

STEP 48 Remove the plugs from the hoses and the caps from the fittings and connect the hydraulic hoses to the fittings according to the identification tags. (Refer to illustrations on pages 11 and 12 as necessary.

STEP 49 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 50

BD06F210

Connect the electrical connectors for the remote control valve.

STEP 51 Place the master disconnect switch in the ON position.

STEP 52 Start the engine and run the engine at low idle.

STEP 53 Check to see that the remote control valve works correctly.

84489509

Issued 04-11

Printed in E.C.

8001-10

STEP 54

STEP 57

Check for hydraulic oil leakage at the remote control valve.

STEP 55 Check the level of hydraulic oil in the reservoir and add as required.

STEP 56

BD06F208

Install and close the access panel.

STEP 58

BD06F209

Position the access panel on the ROPS cab or the ROPS canopy and install and tighten the screw.

BD06F207

Close the right hand window.

84489509

Issued 04-11

Printed in E.C.

8001-11

5 6

7 6

4 2

1 2

3 5

1 6

3 4

1 6

3 4

W230R021

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

3 LEVER HOSE COLOR CODING

84489509

W230R022

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

JOYSTICK AND 1 LEVER HOSE COLOR CODING

Issued 04-11

Printed in E.C.

8001-12

1 4

5 6 5

3 4

W230R023

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

2 LEVER HOSE COLOR CODING

84489509

W230R020

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

JOYSTICK HOSE COLOR CODING

Issued 04-11

Printed in E.C.

8001-13

HYDRAULIC PUMP 10 7

17 10

7 17 8

4 5

5 6

13 15

11 12

9 W230R024

1. 2. 3. 4.

PUMP MAIN HYDRAULIC MOUNT BOLTS DRAIN HOSE BOLT

84489509

5. 6. 7. 8.

SPLIT FLANGE 9. STEERING HIGH PRESSURE TUBE 10. CLAMPS HOSE SUCTION 11. STEERING LOAD SENSE HOSE HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE

13. 14. 15. 16. 17.

BOLT SPLIT FLANGE LOADER HIGH PRESSURE STEERING PRIORITY MANIFOLD CLAMPS

Issued 04-11

Printed in E.C.

8001-14

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

STEP 59 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 60 Place the master disconnect switch in the OFF position.

STEP 61 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 62 Refer to Section 9007 and remove the ROPS cab or ROPS canopy.

STEP 63

STEP 69 Connect lifting equipment to hydraulic pump (1). Take up all slack in lifting equipment. Remove four mounting bolts (2) and washers securing pump to transmission. Pull hydraulic pump from transmission and remove from loader. Remove and discard O-ring from pump.

Installation NOTE: Install new O-rings where required.

STEP 70 Install new O-ring on hydraulic pump flange. Move pump into position and install in transmission. Install four washers and bolts (2) to secure pump (1) to transmission, tighten the bolts. Disconnect lifting equipment from pump.

STEP 71 Connect pump pressure hoses (9 and 15) to steering priority manifold (16). Install two split flanges (14). Install four bolts (13). Apply tightening and torquing according ES-S40 and LM-010 specification procedure.

Remove eight bolts (4) and washers. Remove four split flanges (5). Disconnect tubes (6) with suction hoses (7) from hydraulic pump. Remove and discard O-ring face seals from flange heads of tubes.

STEP 72

STEP 64

Connect load sense hoses (11 and 12).

Loosen clamps (10). Tag and disconnect suction hoses (7) from hydraulic reservoir and remove from machine.

STEP 74

STEP 65

STEP 75

Tag and disconnect case drain hoses (8); remove hoses (8). Remove and discard O-ring face seals from fittings.

Install suction hoses (7), tighten clamps (10) to 10 to 11 Nm (90 to 100 pound inches).

STEP 66

Connect drain hose (3).

STEP 73

Install and connect case drain hoses (8).

STEP 76

Tag and disconnect load sense hoses (11 and 12). Remove and discard O-ring face seals from fittings.

Install four split flanges (5). Install eight bolts (4) and washers, tighten bolts (4) to 73 to 90 Nm (53.8 to 66.3 pound feet).

STEP 67

STEP 77

Tag and disconnect drain hose (3). Remove and discard O-ring face seals from fittings.

Refer to Section 9007 and install the ROPS cab or ROPS canopy.

STEP 68

STEP 78

Remove four bolts (13) and washers. Remove two split flanges (14). Tag and disconnect pump pressure hoses (9 and 15) from steering priority manifold (16). Remove and discard O-ring face seals from flange heads of hoses.

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

84489509

Issued 04-11

Printed in E.C.

8001-15

STEP 79

STEP 81

Place the master disconnect switch in the ON position.

Stop the engine and check for hydraulic oil leakage at the hydraulic pump.

STEP 80

STEP 82

Start the engine and run the engine at low idle for two minutes.

Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.

84489509

Issued 04-11

Printed in E.C.

8001-16

LIFT CYLINDERS Removal

STEP 87

STEP 83 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF. BD01D709

STEP 84 Relieve the pressure in the ride control accumulator with the manual bleeder valve located at the rear of the front chassis.

Loosen and remove the bolt, washer and spacer that hold the pivot pin for the yoke.

STEP 88

STEP 85 Loosen the filler cap on the hydraulic reservoir to release any pressure.

STEP 86

BD01D711

Use a proper lifting device and secure a strap around the lift cylinder.

STEP 89 W230R479

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.

84489509

Issued 04-11

Printed in E.C.

8001-17

Installation

STEP 90

STEP 93 Apply antiseize compound to the bores in the front frame and the yoke on the piston rod.

STEP 94

BD01D710

Loosen and remove the bolt, washer and spacer that hold the pivot pin at the closed end of the lift cylinder.

STEP 91 BD01D714

Use a proper lifting device and position the lift cylinder on the machine.

STEP 95

BD01D713

Remove the pivot pin from the closed end of the lift cylinder.

STEP 92 Remove the lift cylinder from the machine BD01D713

Align the closed end of the lift cylinder with the front frame and install the pivot pin.

84489509

Issued 04-11

Printed in E.C.

8001-18

STEP 96

STEP 99

BD01D710

Align the pivot pin with the front frame and install the spacer, washer and bolt. Tighten the bolt.

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 100

STEP 97

BD01D709 W230R479

Remove the caps and plugs and connect the hoses to the lift cylinder.

STEP 98 If the yoke of the lift cylinder is not aligned with the loader frame, have another person start and run the engine at low idle and use the loader control lever to SLOWLY move the yoke into alignment with the loader frame.

Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.

STEP 101 SLOWLY extend and retract the piston rod three times to remove any air from the lift cylinders.

STEP 102 Lubricate the pivot pins with molydisulfide grease.

STEP 103 Check the level of hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

84489509

Issued 04-11

Printed in E.C.

8001-19

BUCKET CYLINDER Removal

STEP 108

STEP 104 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 105 With the engine stopped, move the bucket control lever to release pressure in the bucket circuit.

STEP 106 BD01D695

Loosen and remove the two bolts that fasten the mounting bracket to the machine. Remove the mounting bracket.

STEP 109

W230R480

Disconnect the proximity switch connector from the wiring harness connector.

STEP 107 W230R483

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.

W230R481

Loosen and remove the two bolts that fasten the target bar to the mounting bracket. Remove the target bar.

84489509

Issued 04-11

Printed in E.C.

8001-20

STEP 110

STEP 113

W230R482

BD01D701

Disconnect the hoses from each side of the bucket cylinder. Install plugs in the hoses and caps on the fittings.

Remove the pivot pin from the rod end of the bucket cylinder.

STEP 114

STEP 111

BD01D704 BD01D700

Use acceptable equipment to hold the bucket cylinder.

STEP 112

Remove the pivot pin from the head end of the bucket cylinder. NOTE: It is not necessary to remove the grease line from the pivot pin unless the pivot pin is to be replaced.

STEP 115

BD01D698

Loosen and remove the bolt, washer and spacer that fasten the pivot pin from both ends of the bucket cylinder.

84489509

BD01D706

Raise the bucket cylinder and remove the cylinder from the machine. Issued 04-11

Printed in E.C.

8001-21

Installation

STEP 120

STEP 116 Apply antisieze compound to the bores in the front frame and the bores in the loader arm for the bucket cylinder.

STEP 117

W230R482

Connect the hoses to each side of the bucket cylinder.

STEP 121

Use acceptable lifting equipment to lower the bucket cylinder into position.

If the rod end of the bucket cylinder is not aligned with the bellcrank, have another person start the engine and run the engine at low idle and use the bucket control lever to SLOWLY move the piston rod eye into alignment with the bellcrank.

STEP 118

STEP 122

BD01D706

Install the pivot pin and stop the engine.

STEP 123

BD01D704

Install the pivot pin to the head end of the bucket cylinder. BD01D698

STEP 119 Install the spacer, washer and bolt that fasten the pivot pin to the front frame. Tighten the bolt.

Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.

NOTE: If a new pivot pin is being installed, connect the grease line to the pivot pin.

84489509

Issued 04-11

Printed in E.C.

8001-22

STEP 124

STEP 127

W230R483

W230R480

Install the two bolts that fasten the mounting bracket for the switch to the bucket cylinder.

Connect the proximity switch connector to the wiring harness connector.

STEP 125

STEP 128 See Section 9006 for the adjustment procedure for adjusting the proximity switch.

STEP 129 Start and run the engine at low idle.

STEP 130 SLOWLY extend and retract the piston rod three times to remove any air from the bucket cylinder.

STEP 131 Lubricate the pivot pins with molydisulfide grease. BD01D695

Install the two bolts for the mounting bracket for the target bar.

STEP 126

STEP 132 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

W230R481

Install the two bolts that fasten the target bar to the mounting bracket.

84489509

Issued 04-11

Printed in E.C.

8001-23

OIL COOLER Removal

STEP 138

STEP 133 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

STEP 134 Place the master disconnect switch in the OFF position.

STEP 135 Raise the engine hood and remove the shield on the right side of the machine between the tire and the oil cooler.

STEP 136

BD03A154

Disconnect the top hose and install a plug in the hose and a cap on the fitting.

STEP 139

BD03A120

Have assistant hold side panel in raised position, remove two mounting screws, remove side panel.

STEP 137 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

BD03A179

Loosen and remove the bolt and washer that fasten the oil cooler to the cooling frame.

STEP 140

BD06H195

Disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting. Remove the two mounting nuts, remove the oil cooler from the machine. 84489509

Issued 04-11

Printed in E.C.

8001-24

Installation

STEP 144

STEP 141

BD03A120

BD06H195

Place the oil cooler in position in the cooling frame. Connect the lower hose to the oil cooler, install and tighten the two mounting nuts.

STEP 142

Have assistant hold side panel in raised position, install and tighten two mounting screws.

STEP 145 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 146 Place the master disconnect switch in the ON position.

STEP 147 Start the engine and run the engine at low idle for two minutes. Stop the engine and check for hydraulic oil leakage at the ports on the oil cooler.

STEP 148 Install the shield between the right rear tire and the oil cooler and tighten the two bolts holding the shield. BD03A179

Install the bolt and washer that fasten the oil cooler to the cooling frame

STEP 149 Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

STEP 143

BD03A154

Connect the hose to the top of the oil cooler.

84489509

Issued 04-11

Printed in E.C.

8001-25

RIDE CONTROL ACCUMULATOR Removal

STEP 153

STEP 150 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

STEP 151

BD06H196

Disconnect the hose from the elbow at the bottom of the ride control accumulator. Install a plug in the hose and a cap on the fitting.

STEP 154

BD06H198

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

STEP 152 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

84489509

BD06H197

Loosen and remove the nuts and washers from the U-bolt. Remove the U-bolt.

STEP 155 Loosen and remove the two bolts that fasten the accumulator bracket to the front frame. Remove the ride control accumulator from the machine.

Issued 04-11

Printed in E.C.

8001-26

Installation

STEP 159

STEP 156 Place the ride control accumulator in position on the front frame.

STEP 157 Install the two bolts that fasten the accumulator bracket to the front frame. Tighten the bolts.

STEP 158 BD06H196

Remove the caps and plugs and install the hose on the elbow at the bottom of the ride control accumulator.

STEP 160 Turn off and disconnect the vacuum pump from the hydraulic reservoir.

STEP 161 BD06H197

Install the U-bolt, washers and nuts. Tighten the nuts.

Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

STEP 162 Refer to Section 8002 Testing the Ride Control for the proper charging of the accumulator to check for leaks.

STEP 163 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

84489509

Issued 04-11

Printed in E.C.

8001-27

RIDE CONTROL VALVE Removal

STEP 166

STEP 164 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 167 Place the master disconnect switch in the OFF position.

STEP 168 Disconnect the electrical connector on top of the ride control valve.

STEP 169

STEP 165

Tag and disconnect the hoses from the ride control valve. Install a plug in the hoses and caps on fittings.

STEP 170 Loosen and remove the two bolts and washers that fasten the ride control valve to the frame.

STEP 171 Remove the ride control valve from the machine.

STEP 172 BD06H198

Remove and discard all O-rings.

Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

84489509

Issued 04-11

Printed in E.C.

8001-28

Installation

STEP 178

STEP 173

Connect the electrical connector to the ride control valve.

Install the ride control valve in position on the front frame.

STEP 179

STEP 174

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

Install the washers and bolts through the frame and into the ride control valve. Tighten the bolts.

STEP 180

STEP 175

Place the master disconnect switch in the ON position.

STEP 181 Start and run the engine at low idle for two minutes.

STEP 182 Stop the engine and check for hydraulic oil leakage at the ride control valve.

STEP 183

BD06H198

Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 7 Nm (62 lb-in).

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

STEP 184 Refer to Section 8002 and perform the Ride Control Test Procedure.

STEP 176 Lubricate and install new O-rings.

STEP 177 Connect the hoses to the ride control valve.

84489509

Issued 04-11

Printed in E.C.

8001-29

FAN REVERSING VALVE Removal

STEP 188

STEP 185 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

2 1

BD03A174

STEP 186 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

Tag and disconnect the fan forward hose (1) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan reverse hose (2) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 187

STEP 189

4 BD03A173

BD03A174

Disconnect the electrical connector for the fan reversing valve.

Tag and disconnect the fan valve return hose (3) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan valve supply hose (4) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 190 Loosen and remove the nuts, washers and bolts.

STEP 191 Remove the fan reversing valve from the machine.

STEP 192 Remove and discard all O-rings from the fittings.

84489509

Issued 04-11

Printed in E.C.

8001-30

Installation

STEP 198

STEP 193 Place the fan reversing valve into position on the machine.

STEP 194 Lubricate and install new O-rings in the fittings.

STEP 195 Install the bolts, washers and nuts. Tighten the nuts.

STEP 196

BD03A174

Connect the electrical connector for the fan reversing valve.

STEP 199 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 200

Check the level of the hydraulic oil in the reservoir.

4 BD03A173

STEP 201

Connect the fan valve supply hose (4) to the fitting on the fan reversing valve. Connect the fan valve return hose (3) to the elbow on the fan reversing valve.

Start the engine and run the engine at low idle for two minutes.

STEP 197

Stop the engine and check for hydraulic oil leakage at the fan reversing valve.

STEP 202

STEP 203 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

2 1

BD03A174

Connect the fan reverse hose (2) to the fitting on the fan reversing valve. Connect the fan forward hose (1) to the fitting on the fan reversing valve.

84489509

Issued 04-11

Printed in E.C.

8001-31

THERMAL VALVE Removal

Installation

STEP 204

STEP 208

Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

Place the thermal valve into position on the machine.

IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.

Lubricate and install new O-rings in the fittings.

STEP 205 Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 209 STEP 210 Install the bolts, washers and nuts. Tighten the nuts.

STEP 211 Connect the hoses to the thermal valve, remove and discard tags.

STEP 212 Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 213

STEP 206

Check the level of the hydraulic oil in the reservoir.

STEP 214 Start the engine and run the engine at low idle for two minutes.

STEP 215 Stop the engine and check for hydraulic oil leakage at the thermal valve.

STEP 216 BD06F211

Tag and disconnect the hoses from the thermal valve. Install a plug in the hose and a cap on the fitting.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

STEP 207 Remove the mounting bolts from the thermal valve, remove the valve from the machine.

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8001-32

NOTES

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8002

Section 8002 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

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

84489509

8002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 4 5 5 5 5 6 6 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15 16 17 17 18 20 20 20 21 22

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8002-3

SPECIFICATIONS Manufacturer ....................................................................................................................................... Bosch-Rexroth High pressure pump (closest to transmission) ..........................................................................187 L/min (49.5 gpm) Differential pressure ......................................................................................................... 26 ± 1 bar (377 ± 14.5 psi) Nominal displacement ...............................................................................................................85 cm3 (5 cubie inch) Low pressure pump (furthest from transmission) ...................................................................138.6 L/min (36.6 gpm) Differential pressure ......................................................................................................... 22 ± 1 bar (319 ± 14.5 psi) Nominal displacement ............................................................................................................63 cm3 (3.8 cubie inch) Main relief valve pressure settings .........................................................................254 to 258 bar (3684 to 3742 psi) Circuit relief valve pressure setting Auxiliary A and B port.................................................................................................................280 bar (4061 psi) Bucket A port..............................................................................................................................280 bar (4061 psi) Bucket B port..............................................................................................................................280 bar (4061 psi) Steering relief valve pressure setting ............................................................................................ See Section 5002 Accumulator pressure .................................................................................................................... See Section 7002 NOTE: Both pump sections provide flow for both the steering and loader functions.

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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

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380001739 PRESSURE FITTING KIT

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8002-5

TROUBLESHOOTING PROCEDURE Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts. Check the oil level in the hydraulic reservoir. Is the oil level correct?.

Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.

See Page 18. Do the flow meter test of the hydraulic pump.

Adjust the limit pressure. See page 11 in this section.

Yes Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.

Problems in All Circuits Replace the return line hydraulic filter. See Section 2002. Do the stall test to see if the engine is good. See Section 8003 and check for contaminated oil. Is the oil contaminated? Yes See Section 8003 and clean or replace the oil.

Problem in All Loader Circuits See Page 11 and check the pressure setting of the limit pressure in the loader control valve. Is the pressure setting correct?

Problem in the Braking Circuit See Section 7002 and check the braking circuit.

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Problem in a Single Loader Circuit Start 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 check for worn or damaged parts.

Repair the component as necessary.

See the Ride Control Test Procedure page 21 in this section.

Yes Check the cylinder piston packing. Is the packing good? Yes See Page 20. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly? Yes The problem is repaired.

Problem in the Steering Circuit See Section 5002 and check the steering circuit. Is the steering circuit good? Yes See Page 13. Do the Steering Pump Limit Pressure Test and Adjustment

Problem in the Ride Control Lift arms rapidly and continuously sink towards the ground. Yes Check the manual bleed valve for the ride control accumulator to be sure that it is closed.

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TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check

STEP 3

STEP 1

1 W230R407

1. ARTICULATION LOCK

W230R598

Install articulation lock (1).

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54째C to 57째C (129째F to 135째F). The following is the procedure for heating the hydraulic oil.

1. TEST PORT (LOAD SENSE) 2. TEST PORT (PUMP PRESSURE)

A. Start the engine and run at full throttle.

Connect two 69 bar (1000 psi) test gauges, one to the test port (2) located on the priority valve, and one on the pump load-sense pressure tap (1 closest to transmission).

B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position.

IMPORTANT: Do not steer or operate loader controls while the gauges are connected, gauges could be damaged.

C. Roll the bucket back against the stops and hold.

STEP 4

D. View the oil temperature by pressing the down arrow on the key pad to display hydraulic oil temperature.

STEP 5

After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

Start the engine and run at low idle.

Make sure all of the controls are in the neutral position and record the readings on the test gauges (1) and (2).

STEP 6 Subtract the reading of the test port (1) from the reading of the test port (2).

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STEP 7 The difference between the two readings should be 25 to 27 bar (363 to 392 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

Adjusting the High Pressure Pump Differential Pressure STEP 9 The load-sense adjusting screw is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the load-sense pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

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TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check

STEP 3

STEP 1

1 W230R407

1. ARTICULATION LOCK

W230R599

Install articulation lock (1). 1. TEST PORT (LOAD SENSE) 2. TEST PORT (PUMP PRESSURE)

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil.

●

A. Start the engine and run at full throttle.

Connect two 69 bar (1000 psi) test gauges, one to the test port (2) located on the priority valve, and one on the pump load-sense pressure tap (1 furthest from the transmission).

B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position.

IMPORTANT: Do not steer of operate loader controls while the gauges are connected, gauges could be damaged.

C. Roll the bucket back against the stops and hold.

STEP 4

To measure the instrument cluster:

oil

temperature

with

the

A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

84489509

Start the engine and run at low idle.

STEP 5 Make sure all of the controls are in the neutral position and record the readings on the test gauges (1) and (2).

STEP 6 Subtract the reading of the test port (1) from the reading of the test port (2).

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STEP 7 The difference between the two readings should be 20 to 22 bar (290 to 319 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump differential pressure.

Adjusting the Low Pressure Pump Differential Pressure STEP 9 The differential adjusting screw is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the differential pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

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TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE Pressure Check

STEP 3

STEP 1

Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the up or down arrow key. W230R407

1. ARTICULATION LOCK

B. Stop at the info screen with the temperatures that need to be monitored are on. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.

Install articulation lock (1).

STEP 2

STEP 4 Run the engine at full throttle.

STEP 5 Roll the loader bucket back against the stops.

STEP 6 Record the reading on the test gauge.

STEP 7 Reading should be 248 to 255 bar (3597 to 3700 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump limit pressure.

1 W230R600

1. TEST PORT (LOAD LIMIT)

Connect a 345 bar (5000 psi) test gauge to the test port (1), located on the priority valve.

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Adjusting the Loader Limit Pressure

STEP 9 The limit adjusting screw is located on the left side of the loader valve. Turn the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 35 bar (500 psi).

W230R601

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TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE Pressure Check

STEP 3

STEP 1

To measure the instrument cluster:

oil

temperature

with

the

A. Press the up or down arrow key. W230R407

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2

STEP 4 Start the engine and run at full throttle.

STEP 5 Steer hard in either direction over relief pressure.

STEP 6 Record the reading on the test gauge.

STEP 7 Reading should be 239 to 243 bar (3465 to 3525 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the steering limit pressure.

1 W230R600

1. TEST PORT (LOAD LIMIT)

Connect a 345 bar (5000 psi) test gauge to the test port (1), located on the priority valve.

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Adjusting the Steering Limit Pressure

STEP 9 The steering priority valve is located on the hydraulic pump, the adjusting valve is located on the transmission side of the priority valve. Turning the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure.

1 W230R602

1. STEERING LIMIT VALVE

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TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE Pressure Check

STEP 3

STEP 1

To measure the instrument cluster:

oil

temperature

with

the

A. Press the up or down arrow key. W230R407

1. ARTICULATION LOCK

Install articulation lock (1).

STEP 2

STEP 4 Start the engine and run at full throttle.

STEP 5 Roll the loader bucket back against the stops.

STEP 6 Record the reading on the test gauge.

STEP 7 Reading should be 198 to 202 bar (2870 to 2930 psi).

STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump cutoff pressure.

1 W230R603

1. TEST PORT (PUMP PRESSURE)

Connect two 345 bar (5000 psi) test gauge to the test port (1) located on the large hydraulic tube on the bottom of the pump.

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Adjusting the Loader Pump Cutoff Pressure STEP 9

W230R604

The unloading adjuster is the longer of the two adjusters on the loader pump. Turn the screw clockwise to increase the cutoff pressure. Turning the screw counterclockwise will decrease the cutoff pressure. NOTE: The adjusting screw is located just above the steering priority valve on the pump furthest from the transmission.

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TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE NOTE: This pressure is factory preset and is not adjustable.

STEP 2

Pressure Check

Raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position and disengage the controller lock-out switch.

STEP 1

STEP 3

Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil.

Wait for the buzzer to stop then repeatedly put the loader control lever into “FLOAT” position and back to neutral.

A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●

To measure the instrument cluster:

oil

temperature

with

STEP 4 The system should allow a minimum of 10 actuations into float and still cause the lift arms to come down. NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists.

the

A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.

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HIGH PRESSURE PUMP FLOW TEST NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 3 of this section.

STEP 1 Connect the flow meter (3) by disconnecting the inlet hose (6) to the valve supply tube (13), installing a cap (12) on the fitting at the valve supply tube (13). Refer to illustration on page 19.

STEP 2 Disconnect the load sense hose (7) and install a cap (12) the fitting at the loader valve (15). NOTE: This is the line that returns to the pump compensator valve.

STEP 3

STEP 6 Using the temperature gauge on the flow meter, continue to run the engine at high idle until the temperature of the hydraulic oil is at least 52°C to 60°C (125°F to 140°F).

STEP 7 Run the engine at low idle, fully open the flow meter valve.

STEP 8 Open the needle valve (8) and operate the engine at 2000 rpm. At 0 bar (0 psi) the flow should be 250 to 255 L/min (66 to 67.4 gpm).

STEP 9

Connect a “T” fitting (10) into the loader control valve inlet hose (6) and to the flow meter inlet hose (11).

Close the flow meter valve slowly and read the flow at 34.5 bar (500 psi) the flow should be 249 to 255 L/min (65.8 to 66.8 gpm).

STEP 4

STEP 10

Use a union (9) and connect an in line needle valve (8) to the open port in the “T” fitting (10), connect the load sense hose (7) to the needle valve (8).

Close the flow meter valve slowly and read the flow at 2000 psi @ 2000 rpm. The flow should read 244.5 to 247.5 L/min (64.6 to 65.4 gpm).

STEP 5

STEP 11

Make sure that the flow meter valve and the installed needle valve are in the open position. Start and run the engine at high idle, slowly close the flow meter valve until a pressure reading of 103 bar (1500 psi) is obtained.

Continue to close the flow meter valve slowly, at approximately 2900 psi the flow should drop significantly, this will be the low pressure pump destroking.

STEP 12 Continue slowly closing the flow meter valve until 3500 psi is reached. The flow should read between 120 to 122 L/min (31.6 and 32.1 gpm).

STEP 13 If any of the pump flow readings are not within specifications, the pump may be out of calibration and Technical Support Services should be contacted.

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3 5 6 11 12

7 10 9

12 8

14 15

BS06G117

1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE 2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP 3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY 4. PUMPS 9. UNION 14. ELBOW M14 ORB 5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

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TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES Pressure Check

STEP 4

STEP 1

Remove the safety strut and lower the bucket to the floor. Shut off the engine. Find an easy place to disconnect the line for the circuit to be tested.

Circuit relief valves are located as shown below.

5 1

STEP 5 Connect the hand pump to the disconnected line that goes to the loader control valve.

STEP 6 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).

STEP 7 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 8 Compare the reading to the specifications on Page 3.

STEP 9

If the pressure is not correct, adjust the circuit relief valve.

1 3

5 W230R025

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

CIRCUIT RELIEF VALVES PUMP LIMIT PRESSURE ADJUSTMENT BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL LOADER CONTROL VALVE

STEP 2 Raise the lift arms and install the safety link on the lift arm cylinder.

Adjustment STEP 1 Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

STEP 3 Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

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TESTING THE RIDE CONTROL STEP 1

STEP 6

Move the machine to a clear level surface with clearance for full lift arm and bucket movement.

Dump the bucket until it hits the dump stops. Hold the bucket in the dump position for 5 to 10 seconds.

STEP 2 Install the articulation lock, start the machine, activate the parking brake.

STEP 3 With the pilot controller in neutral, set the ride control rocker switch on the right side console to the “Always On” position and observe the switch lamp, the lamp should illuminate.

STEP 4 Set the ride control rocker switch to the “Off” position and observe the switch lamp, the lamp should go out. NOTE: This indicates that the switch is operating correctly and has power, if the switch does not illuminate see section 4002 and troubleshoot the electrical system for the ride control.

STEP 5 Raise the lift arms to the top of their travel and dump the bucket.

NOTE: This will charge the ride control accumulator.

STEP 7 Lower the lift arms and roll the bucket back to a carry position. Do not leave the lift arms or the bucket on their stops, place the pilot control lever in the neutral position.

STEP 8 Set the ride control rocker switch to the “Always On” position. The lift arms should rise 15 to 30 cm (6 to 12 inches) with an empty bucket. NOTE: Test results will be for a machine with a empty factory bucket and no attachments.

STEP 9 If there is little or no lift arm raise, the test may have been done too slowly. The elapsed time between step 6 and step 8 should not exceed six seconds. NOTE: If test was done to slowly repeat in the allotted time.

STEP 10 If test was completed in the allotted time and the lift arms still do not rise, test the nitrogen charge in the accumulator, see section 8013.

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HYDRAULIC COMPONENT LOCATIONS 5 6

7 9 4

2 3

15 14 16 19 18 17

BC00N140

1. REAR BRAKE CYLINDERS 2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER 3. BRAKE ACCUMULATORS 4. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC COUPLERS 5. BRAKE LIGHT PRESSURE SWITCH 6. BRAKE WARNING PRESSURE SWITCH 7. BRAKE AND ACCUMULATOR CHARGING VALVE 8. LIFT CYLINDERS 9. BUCKET CYLINDER (TILT CYLINDER) 10. RIDE CONTROL ACCUMULATOR

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11. FRONT BRAKE CYLINDERS 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND RIDE CONTROL VALVE (OPTIONAL) 13. PARKING BRAKE CYLINDER 14. STEERING PRESSURE DIAGNOSTIC COUPLER 15. STEERING PRIORITY VALVE 16. STEERING CYLINDERS 17. AUXILIARY STEERING PUMP AND MOTOR 18. AUXILIARY STEERING PRIORITY VALVE 19. AUXILIARY STEERING PRESSURE SWITCH

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23 24 21 22

30 31

32 33

BC00N140

20. 21. 22. 23. 24. 25. 26. 27.

FAN DRIVE MOTOR HYDRAULIC RESERVOIR BREATHER HYDRAULIC RESERVOIR PILOT PRESSURE DIAGNOSTIC COUPLER PILOT CONTROL VALVE PILOT PRESSURE ACCUMULATOR LOADER CONTROL VALVE PARKING BRAKE ACCUMULATOR

84489509

28. 29. 30. 31. 32. 33. 34.

PUMP PRESSURE DIAGNOSTIC COUPLER LOAD SENSING DIAGNOSTIC COUPLER IMPLEMENT HYDRAULIC PUMP HYDRAULIC FILTER HYDRAULIC COOLER BRAKE HYDRAULIC PUMP FAN VALVE

Issued 04-11

Printed in E.C.

8002-24

NOTES

84489509

Issued 04-11

Printed in E.C.

8003

Section 8003 CLEANING THE HYDRAULIC SYSTEM

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

84489509

8003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Revised 04-11

3 4 4 5 7

Printed in E.C.

8003-3

SPECIAL TOOLS

806128

380001733, fitting kit.

806127

380001727, filter unit, portable.

TR98H032

380001728, vacuum pump.

84489509

Revised 04-11

Printed in E.C.

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 testing in a laboratory. Examples of the problems:

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.

A. Cylinder rod seal leak. B. Control valve NEUTRAL.

spools

not

return

C. The hydraulic system has a high operating temperature.

84489509

Revised 04-11

Printed in E.C.

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.

84489509

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.

Revised 04-11

Printed in E.C.

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.

84489509

34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

Revised 04-11

Printed in E.C.

8003-7

FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1. Start and run the engine at 1500 rpm (r/min). 2. Completely retract the cylinders of all attachments on the machine. Angle the blade to the right, the right cylinder will be fully retracted and the left will be fully extended. Stop the engine. WARNING: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before proceeding to the next step! 39-4

13. Slowly move each control lever in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 14. Stop the engine. 15. Connect the system line to the CLOSED end of each cylinder. 16. Connect a suitable drain line to the OPEN end of each cylinder and place the other end in an acceptable container for contaminated oil. 17. Start the engine and run the engine at low idle.

NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.

18. Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the OPEN end of the cylinders.

3. Move each control lever in both directions to release pressure in the hydraulic circuits.

NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.

4. Loosen and remove the filler cap from the reservoir. 5. Drain the hydraulic oil from the reservoir.

19. Support any attachments that will be in the RAISED position.

A. See Section 1002 for capacity specifications.

20. Stop the engine.

B. Have available acceptable equipment to drain the hydraulic oil.

21. Disconnect the drain lines and connect the system lines to the cylinders.

C. Remove the drain plug from the bottom of the reservoir.

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

6. Remove the hydraulic filter elements from the machine.

23. Install the filler cap on the reservoir.

7. Install new hydraulic filter elements on the machine.

24. Remove the hydraulic filter elements from the machine.

8. Install the drain plug in the bottom of the reservoir.

25. Install new hydraulic filter elements on the machine.

9. Fill the hydraulic reservoir with hydraulic fluid. See Section 1002 for specifications.

26. Start and run the engine at 1500 rpm (r/min), operate each hydraulic circuit to completely extend and retract the cylinders.

10. Disconnect the line from the OPEN end and CLOSED end of each cylinder. 11. Be sure all control levers are in the NEUTRAL position.

27. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

12. Start and run the engine at low idle. IMPORTANT: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13.

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Printed in E.C.

8003-8

NOTES

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Revised 04-11

Printed in E.C.

8004

Section 8004 HYDRAULIC PUMP

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

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8004-2

TABLE OF CONTENTS PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 3 4 5 9 11

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8004-3

PUMP SPECIFICATIONS Manufacturer .................................................................................................................................................. Rexroth High pressure pump (steering pump next to transmission) .......................................................187 L/min (49.5 gpm) Nominal displacement ............................................................................................................... 85 cm3 (5 cubic inch) Low pressure pump (loader pump farthermost from transmission) ........................................138.6 L/min (36.6 gpm) Nominal displacement ............................................................................................................ 63 cm3 (3.8 cubic inch) Rotation ................................................................................................. Clockwise as seen from the end of the shaft Special torques Pump end cover bolts ..................................................................................................165 Nm (121.5 pound-feet) Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet) Control piston plug ..............................................................................................................90 Nm (66 pound-feet)

PREPARING THE EQUIPMENT PUMP FOR USE Do the following procedure any time you install a new or overhauled equipment pump: 1. Start and run the engine at half throttle for three minutes. 2. With the engine running at half throttle, move the bucket control lever into roll back position. Hold the bucket control lever in this position until the bucket stops moving.

4. Repeat Step 3 for three minutes. 5. Increase the engine speed to full throttle and repeat Steps 3 and 4. 6. Stop the engine and check for leaks. 7. Replace the hydraulic filter.

3. Hold the bucket control lever in the roll back position for five seconds. Then put the bucket control lever in the NEUTRAL position for five seconds.

84489509

Issued 04-11

Printed in E.C.

8004-4

EQUIPMENT PUMP 7

6 4

5 4

11 13

12 21

20 19

30 29 15 26

BC06F550

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

84489509

SNAP RING SEAL MAIN BODY O-RING PLUG CONTROL VALVE CAP SCREW PISTON ROD CONTROL PISTON SHAFT

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

TAPERED BEARING BEARING RACE SHIM SPRING HALF BEARING SWASH PLATE PISTONS RETAINING PLATE BALL CYLINDER

21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

PRESSURE PINS BACKUP PLATE SPRING SNAP RING PORT PLATE SHIM TAPERED BEARING BEARING RACE DOWEL PIN END COVER

Issued 04-11

Printed in E.C.

8004-5

Disassembly

STEP 3

STEP 1 Remove all dirt, oil, and grease from the exterior of the equipment pump.

STEP 2

BC06F552

Remove the control valve.

STEP 4

BC06F551

Put alignment marks on the end cover and housing.

BC06F553

Remove the four bolts.

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Printed in E.C.

8004-6

STEP 5

STEP 6

BC06F554

Remove the end cover. NOTE: Watch for the flow plate, it can be stuck to either the end cover or pump body.

84489509

BC06F555

Use a suitable bearing race puller and pull the bearing race from the end cover. NOTE: Do not damage the sealing surfaces.

Issued 04-11

Printed in E.C.

8004-7

STEP 7

STEP 9

BC06F558

Remove plug, pull control piston using a suitable tool as shown. NOTE: Do not use a magnet to pull the piston.

BC06F556

STEP 10

Remove the bearing and shim.

STEP 8

BC06F559

Remove the piston rod and swash plate. Turn the swash plate slightly to break it free from the bearings. BC06F557

Remove the rotary group from the housing in a horizontal position.

84489509

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Printed in E.C.

8004-8

STEP 11

STEP 14

BC06F560

Remove the bearing and spring.

STEP 12 BC06F563

Use a suitable bearing race puller and pull the bearing race from the housing.

STEP 15

BC06F561

Remove the shaft and bearing.

STEP 13

BC06F564

Remove the shim and plug.

BC06F562

Remove the retaining ring an seal.

84489509

Issued 04-11

Printed in E.C.

8004-9

Inspection

STEP 19

STEP 16 Clean all parts in cleaning solvent. Be careful not to remove the alignment marks made during disassembly.

STEP 17

BC06F567

Check the bearing surface.

STEP 20

BC06F565

Check for wear on the splines, seal areas for grooves, bearing areas for scaring, and key set.

STEP 18

BC06F568

Check that the retaining plate is free of grooves and that there is no sign of wear.

STEP 21

BC06F566

Check the surface that the pistons contact for grooves and scaring.

BC06F569

Check the sliding surface for scratches or metal deposits, check the tightness of the cup on the piston. NOTE: If a piston needs to be replaced, all of the pistons must be replaced.

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Printed in E.C.

8004-10

STEP 22

STEP 24

BC06F570

Check the cylinder bores and splines for damage.

STEP 23

BC06F572

Check cylinder surface for grooves, wear, embedded particles. Check flow plate for scratches or wear.

STEP 25

BC06F571

Check ball for grooves and wear.

84489509

BC06F573

Check mounting surface for the flow plate for damage.

Issued 04-11

Printed in E.C.

8004-11

Assembly

STEP 27

STEP 26

BC06F575

BC06F574

Install the plug in the housing and tighten to 127 Nm (93.5 pound-feet). Install shim and press in the bearing race.

Put the shaft and bearing in the housing.

STEP 28

BC06F576

Press in a new race into the end cover.

84489509

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Printed in E.C.

8004-12

STEP 29

STEP 31

BC06F579

Install the seal and retaining ring.

STEP 32 BC06F577

Install the end cover, 4 bolts and hand tighten.

STEP 30

BC06F578

A bearing pre load of 0.05 mm (0.002 inch) must be obtained, add remove shims from bearing as required.

BC06F580

Put new bearings in the housing. Install the reaction spring.

84489509

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Printed in E.C.

8004-13

STEP 33

STEP 34

BC06F582

Install the piston into the housing with flat surface out. Lubricate the O-ring and install the plug, tighten the plug to 90 Nm (66 pound-feet).

STEP 35

BC06F581

Install the swash plate into the housing, work the swash plate from side to side to seat it in the bearings and spring. Install the piston rod.

BC06F583

Use grease to hold the pressure pins into position, install the spacer, spring and snap ring.

84489509

Issued 04-11

Printed in E.C.

8004-14

STEP 36

STEP 39

BC06F584

Use a suitable compressor, compress the spring and install the snap ring.

STEP 37

BC06F585

BC06F587

Place the ball onto the pressure pins, install the pistons into the retaining plate.

Hold the pistons in the rotating housing using an O-ring, install the rotating group into the housing, remove the O-ring.

STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil, install the piston into the rotating housing.

84489509

Issued 04-11

Printed in E.C.

8004-15

STEP 40

STEP 41

BC06F588

Use the shim that was required for the bearing pre load in step 30. Install the shim and bearing onto the shaft.

BC06F589

Install a new O-ring on the end cover, place the flow plate onto the rotating group with aligning notch up. Place the end cover onto the housing, make sure that the aligning pin in the end cover aligns with the slot in the flow plate.

84489509

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Printed in E.C.

8004-16

STEP 42

STEP 43

BC06F591

Use new O-rings, install and tighten the control valve.

BC06F590

Instal and tighten the four bolts to 165 Nm (121.5 pound-feet).

84489509

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Section 8005

8005

LOADER CONTROL VALVE

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

84489509

8005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 4 5 6 7 8 12 12 15 15

Printed in E.C.

8005-3

SPECIFICATIONS Manufacturer .................................................................................................................................................. Rexroth Special Torques End plate mounting bolts..................................................................................................70 Nm (51.5 pound feet) Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound inches) Allen head plugs...........................................................................................................200 Nm (147.5 pound feet) Allen head locking screw................................................................................................100 Nm (73.7 pound feet) Allen head cover screws (short) ................................................................................... 20 Nm (177 pound inches) Allen head cover screws (long) ................................................................................... 10.4 Nm (92 pound inches) Anticavitation valves.......................................................................................................100 Nm (73.7 pound feet) Combination anticavitation and circuit relief .................................................................200 Nm (147.5 pound feet) Main relief valve pressure settings (Long Reach and Z-Bar) ................................ 241 to 250 bar (3495 to 3626 psi) Circuit relief valve pressure setting Auxiliary A and B port (Long Reach and Z-Bar) ........................................................................290 bar (4206 psi) Bucket A port (Long Reach and Z-Bar) .....................................................................................290 bar (4206 psi) Bucket B port (Long Reach and Z-Bar) .....................................................................................290 bar (4206 psi)

84489509

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Printed in E.C.

8005-4

1 2 4

20 8

9 10

16 6 11

15 14

W230R472

1. 2. 4. 5. 6. 7.

BOLT 8. WASHER 9. PLATE 10. REGENERATION RELIEF VALVE11. O-RINGS 12. LOAD SENSE SHUTTLE CHECK 14.

ANTICAVITATION AND CIRCUIT RELIEF LOAD SENSE BLEED DOWN ORIFICE FLOW COMPENSATOR SPOOL HOUSING PLUG PLUG

14. 15. 16. 17. 18. 19. 20.

PLUG REGENERATION CHECK VALVE LOCKING SCREW SPRING LOAD CHECK FLOW LIMIT VALVE PRESSURE RELIEFE VALVE

2 SPOOL VALVE HOUSING CONFIGURATION

84489509

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Printed in E.C.

8005-5

27 26 25 6

6 33

34 24

24 35

30 6

6 32 W230R473

6. 23. 24. 25. 26.

O-RINGS SPRING RETAINER SPRING SPRING COVER

27. 28. 29. 30. 31.

BOLT PISTON CAP NUT JAM NUT PISTON

32. 33. 34. 35.

BOLT COVER ADJUSTING ROD SPOOL

2 SPOOL VALVE SPOOL CONFIGURATION

84489509

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8005-6

36 37

W230R474

36. HOUSING

37. ANTICAVITATION AND CIRCUIT RELIEF 3 SPOOL MOUNTING CONFIGURATION

84489509

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Printed in E.C.

8005-7

27 25 24 6

26 31 6

23 33

29 30 32

6 31

34 24

23 35

W230R475

3 SPOOL VALVE SPOOL CONFIGURATION 6. 23. 24. 25. 28. 29. 30.

84489509

O-RINGS SPRING RETAINER SPRING SPRING PISTON CAP NUT JAM NUT

31. 32. 33. 34. 35.

PISTON BOLT COVER ADJUSTING ROD SPOOL

Issued 04-11

Printed in E.C.

8005-8

DISSASEMBLY STEP 1

STEP 6

Remove valve from machine, see section 8001.

Remove pressure relief valve (20).

STEP 2

STEP 7

Remove bolts (27), cover (26), springs (24 and 25), and spring retainer (23).

Remove flow limit valve (19).

STEP 8

STEP 3 Remove bolts (32), covers (33), spring (24), and spring retainer (23).

Remove locking screw (16), spring (17), and cone (18).

STEP 9

STEP 4

Remove regeneration check valve (15).

Use wooden dowel or brass drift and push spools (35) from housing (11).

STEP 10

IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.

Remove locking screw (14).

NOTE: Repeat steps 3 and 4 for a spool valve configuration.

Remove load sense shuttle check valve (7).

STEP 5

Remove locking screws (12).

Remove anticavitation valves (5, 8 and 10). NOTE: Repeat step valves (37).

for

spool anticavitation

STEP 11 STEP 12 STEP 13 Remove pilot pressure reducing valve (9).

STEP 14 Remove bolts (1) and washers (2), remove plate (4) from housing (11).

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8005-9

STEP 15

STEP 17 2 1 2

BS03C025

1. O-RINGS

BS03C027

2. THRUST RINGS

1. O-RINGS

Remove and discard O-rings and thrust rings from pilot pressure reducing valve (9).

2. THRUST RING

Remove and discard O-rings and thrust ring from locking screw (14).

STEP 16 STEP 18

1 2 1

1 1

BS03C026

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from flow limit valve (19).

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BS03C028

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Remove and discard O-rings, thrust ring, and spool seal from anticavitation valve (5).

Issued 04-11

Printed in E.C.

8005-10

STEP 19

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).

STEP 20 1 1

2 1 2

1 BS03C030

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).

84489509

Issued 04-11

Printed in E.C.

8005-11

STEP 21

1 1

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).

84489509

Issued 04-11

Printed in E.C.

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. Inspect the other parts of the control valve. If any of the parts are damaged, install new parts.

ASSEMBLY STEP 1

4 A

See Note

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8). Torque relief valve (A) into anticavitation valve to 200 Nm (147.5 pound feet). NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in direction of arrow.

84489509

Issued 04-11

Printed in E.C.

8005-13

STEP 2 1 1

2 1 2

BS03C030

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm (73.7 pound feet).

STEP 3

1 2

1 1 2 2 BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (20). 84489509

Issued 04-11

Printed in E.C.

8005-14

STEP 4

STEP 7 2

1 1

2 BS03C025

1. O-RINGS

2. THRUST RINGS

BS03C028

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Install new O-rings and thrust rings on pilot pressure reducing valve (9).

Install new O-rings, thrust ring, and spool seal on anticavitation valve (5).

STEP 5

STEP 8 Install and torque regeneration check valve (15) to 100 Nm (73.7 pound feet).

STEP 9 Install and torque locking screw (14) to 100 Nm (73.7 pound feet).

2 1

STEP 10

Install and tighten load sense shuttle check valve (7).

STEP 11 BS03C026

1. O-RINGS

2. THRUST RINGS

Install and torque locking screws (12) to 200 Nm (147.5 pound feet).

Install new O-rings and thrust rings on flow limit valve (19).

STEP 12

STEP 6

Install and torque pilot pressure reducing valve (9) to 60 Nm (44 pound feet).

STEP 13 1

Install new O-rings on housing (11). Install plate (4), bolts (1) and washers (2), onto housing (11). Torque bolts to 70 Nm (51.5 pound feet).

2 1

STEP 14 Install anticavitation valves (5 and 10) and torque to 100 Nm (73.7 pound feet). NOTE: Repeat valves (37).

step

for

spool

anticavitation

BS03C027

1. O-RINGS

2. THRUST RING

Install new O-rings and thrust ring on locking screw (14).

84489509

STEP 15 Install anticavitation valves (8) and torque to 200 Nm (147.5 pound feet).

Issued 04-11

Printed in E.C.

8005-15

STEP 16

Circuit Relief Pressure Test

Install and torque flow limit valve (19) to 20 to 25 Nm (177 to 221 pound inches).

STEP 1

STEP 17

Connect the hand pump to the port for anticavitation and circuit relief valves (21).

Install cone (18), spring (17), locking screw (16). Torque locking screw to 100 Nm (73.7 pound feet).

STEP 18 Lubricate spools with hydraulic oil and push spools (35) into housing (11).

NOTE: Repeat steps for configured with a 3 spool valve.

machines

that

are

STEP 2

IMPORTANT: Do not force spools into housing.

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 19

STEP 3

Install spring retainers (23), springs (24), covers (33), and bolts (32). Torque bolts to 10.4 Nm (92 pound inches).

Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

NOTE: Repeat configuration.

STEP 4

step

for

spool

valve

STEP 20 Install spring retainers (23), spring (24 and 25), cover (26), and bolts (27). Torque bolts to 10.4 Nm (92 pound inches).

Compare the reading to the specifications on Page 3.

STEP 5 If the pressure is not correct, adjust the circuit relief valve.

NOTE: Prior to installation in the machine, circuit reliefs can be tested.

Circuit Relief Adjustment

STEP 21

STEP 1

Install valve in machine, see section 8001.

STEP 22 Check loader limit pressure, see section 8002.

Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

84489509

Issued 04-11

Printed in E.C.

8005-16

NOTES

84489509

Issued 04-11

Printed in E.C.

Section 8006

8006

CYLINDERS

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

84489509

8006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 3 3 4 4 4 6 7 7 7 9 11 11 11 12 12 12

Printed in E.C.

8006-3

SPECIFICATIONS Approximate weight Lift Cylinder...........................................................................................................................279.2 kg (615.5 pounds) Bucket Cylinder ....................................................................................................................234.4 kg (516.7 pounds)

SPECIAL TORQUES Gland Bolts Bucket Cylinder.......................................................................420 to 500 Nm (310 to 368.8 pound-feet) Screw in Gland for Lift Cylinders ................................................................420 to 500 Nm (310 to 368.8 pound-feet)

SPECIAL TOOLS Torque Multiplier........................................................................................................................................380001732

84489509

Issued 04-11

Printed in E.C.

8006-4

LIFT CYLINDER Disassembly

Inspection

1. Clean exterior of cylinder. If hoses were removed with cylinder, remove hoses from cylinder.

1. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying.

2. Fasten tube (1) in an acceptable repair stand or other holding equipment. Do not damage tube (1).

2. Check to be sure that piston rod (13) is straight. If piston rod is not straight, replace it with a new piston rod.

3. Use a spanner wrench to loosen and remove the bolt (7, q.ty 8) of gland (4) from tube (1).

3. Shine a light inside tube (1) and check for deep grooves and other damage. If there is any damage to tube, replace with a new tube.

4. Pull piston rod (13) straight out of tube (1) to prevent damage to tube. 5. Fasten piston rod eye or yoke in a vise and put a support under piston rod (13) near piston (15). Put a shop cloth between support and piston rod to prevent damage to piston rod. 6. Remove the lock pin (14). 7. Remove piston (15) from piston rod (13). 8. Remove and discard seal (16), ring (17), and wear ring (18) and O-ring (10) from piston (15). 9. Remove and discard O-ring (11), backup ring (9), O-ring (12), wiper (5), rod seal (6), and bushing (8) from gland (4).

84489509

4. Remove any small scratches on piston rod (13) or inside tube (1) with emery cloth of medium grit. Use emery cloth with a rotary motion. 5. Inspect bushings (2) in tube eye. Replace as required. 6. Inspect gland (4) for rust. Clean and remove rust as necessary. 7. Inspect gland end of tube (4) for sharp edges that may cut gland O-ring (11) and remove as necessary. 8. Inspect piston (15) for damage and wear. If piston is damaged or worn, replace with a new piston.

Issued 04-11

Printed in E.C.

8006-5

14 5

9 8

11 16

18 17

10 15

W230R591

1. 2. 3. 4. 5.

TUBE BUSHING WIPER GLAND WIPER

6. 7. 8. 9. 10.

ROD SEAL BOLT BUSHING BACKUP RING O-RING

11. 12. 13. 14. 15.

O-RING O-RING ROD BOLT PISTON

16. 17. 18. 19.

SEAL RING WEAR RING WASHER

LIFT CYLINDER

84489509

Issued 04-11

Printed in E.C.

8006-6

Assembly NOTE: If a new gland is being used, put part number of cylinder on new gland. 1. Install bushing (8) in gland (4). 2. Install rod seal (6) in gland (4). Rod seal is to be installed so that lips of seal are toward bushing (8). Rod seal (6) can be difficult to install.

21. Turn the bolt (7, q.ty 8) on gland (4) into tube (1). Tighten gland to a torque of 420 to 500 Nm (310 to 368.8 pound-feet). 22. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.

3. Install a new wiper (5) in gland (4). Lips of wiper must be toward outside end of gland (4). 4. Install a new O-ring (12) in groove on OD of gland (4). 5. Install a new backup ring (9) in groove on OD of gland (4). If both sides of backup ring are not flat, side that is not flat must be toward small end of gland (4). 6. Install a new O-ring (11) next to backup ring (9) in groove on outside of gland (4). O-ring must be toward small end of gland. 7. Fasten piston rod (13) eye or yoke in vise. 8. Remove any marks and sharp edges on chamfer at end of piston rod (13). Make sure that piston rod is clean. 9. Lubricate bore of gland (4) and piston rod (13) with clean oil. 10. Push gland (4) onto piston rod (13). If necessary, use a soft hammer to drive gland onto piston rod. 11. Put a support below and near end of piston rod (13). Use a shop cloth between support and the piston rod to prevent damage to piston rod. 12. Start piston (15) onto piston rod (13) and install the lock pin (14) on piston (15). 13. Install a new wear ring (18) in wide groove on outside of piston (15). 14. Install a new ring (17) in the other groove on the outside of the piston (15). 15. Install a new seal (16) on top of ring (17). 16. Fasten tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to tube. 17. Lubricate inside of the tube (1) and piston (15) with clean oil. 18. Push piston (15) straight into tube (1). 19. When the piston (15) is in smooth part of tube (1), start gland (4) into tube. 20. Lubricate O-rings (11 and 12) on gland (4) with clean oil. 84489509

Issued 04-11

Printed in E.C.

8006-7

BUCKET CYLINDERS Disassembly 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Do not damage the tube (1). 3. Loosen and remove the cap screws (2) and hardened washers (18) from the gland (3) and the tube (1). 4. Pull the piston rod (4) straight out of the tube (1) to prevent damage to the tube (1). 5. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (4) near the piston (7). Put a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4). 6. Remove the retaining ring (10) that fastens the pin (11) in the piston (7) and piston rod (4). 7. Remove the pin (11) from the piston (7) and the piston rod (4). 8. Turn the piston (7) off the piston rod (4) and remove the piston (7). 9. Remove the gland (3) from the piston rod (4).

Inspection 1. Discard the parts that were removed from the piston and the gland. 2. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying. 3. Check to be sure that the piston rod is straight. If the piston rod is not straight, replace it with a new piston rod. 4. Illuminate the inside of the tube for deep grooves and other damage. If there is any damage to the tube, replace it with a new tube. 5. Remove any small scratches on the piston rod or inside the tube with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the bushings in the piston rod eye or yoke and the tube. Replace as required. 7. Inspect the gland for rust and clean and remove rust as necessary. 8. Inspect the gland end of the tube for sharp edges that will cut the gland O-ring and remove as necessary. 9. Inspect the piston for damage and wear. If the piston is damaged or worn, replace it with a new piston.

10. Remove the seal (6) from the OD of the piston (7). 11. Remove the wear ring (5) from the OD of the piston (7). 12. Remove the backup rings (8) and the O-ring (9) from the ID of the piston (7). 13. Remove the seal (16), backup ring (15), wiper (12), wide seal (13), narrow seal (14), and bushing (17) from the gland (3).

84489509

Issued 04-11

Printed in E.C.

8006-8

4 11

13 14

17 8

16 9

5 10

1 20 19

20 W230R592

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

TUBE CAP SCREW GLAND PISTON ROD WEAR RING SEAL

7. 8. 9. 10. 11.

PISTON BACKUP RING O-RING RETAINING RING PIN

12. 13. 14. 15. 16.

WIPER WIDE SEAL NARROW SEAL BACKUP RING SEAL

17. 18. 19. 20.

BUSHING HARDENED WASHER SEAL BUSHING

BUCKET CYLINDER

84489509

Issued 04-11

Printed in E.C.

8006-9

Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland.

11. Install a new backup ring (8) in the groove in the ID of the piston (7). If both sides of the backup ring (8) are not flat, the side that is not flat must be toward the O-ring (9).

1. Install the bushing (17) in the gland (3), refer to illustration on page 8.

12. Install a new O-ring (9) in the groove in the ID of the piston (7) next to the backup ring (8).

2. Install the wide seal (13) in the gland (3). The wide seal (13) is to be installed so that the lips of the wide seal (13) are toward the bushing (17). The wide seal (13) can be difficult to install.

13. Install the other new backup ring (8) in the groove in the ID of the piston (7) next to the O-ring (9). If both sides of the backup ring (8) are not flat, the side that is not flat must be toward the O-ring (9).

3. Install a new wiper (12) in the gland (3). The lips of the wiper (12) must be toward the outside end of the gland (3). 4. Install the narrow seal (14) in the gland (3). The side of the narrow seal (14) with the groove must be toward the bushing (17). 5. Install a new backup ring (15) in the groove on the outside of the gland (3). If both sides of the backup ring (15) are not flat, the side that is not flat must be toward the small end of the gland (3). 6. Install the seal (16) next to the backup ring (15) in the groove on the outside of the gland (3). The seal (16) must be toward the small end of the gland (3).

14. Lubricate the ID of the piston (7) with clean oil. 15. Start the piston (7) onto the piston rod (4). Turn the piston (7) onto the piston rod (4) until the piston (7) is seated against the shoulder of the piston rod (4). 16. If none of the holes in the piston (7) align with the holes in the piston rod (4), turn the piston (7) counterclockwise until one of the holes in the piston (7) aligns with one of holes in the piston rod (4). Do not turn the piston (7) more than 90 degrees.

7. Remove any marks and sharp edges on the chamfer at the end of the piston rod (4). Make sure that the piston rod (4) is clean.

8. Lubricate the bore of the gland (3) and the piston rod (4) with clean oil. 9. Push the gland (3) onto the piston rod (4). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (4). 10. Put a support below and near the end of the piston rod (4). Use a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4).

4 GS98J804 PISTON AND PISTON ROD HOLE ALIGNMENT

17. Install the pin (11) in the piston (7) and the piston rod (4). 18. Install the retaining ring (10) in the pin (11).

84489509

Issued 04-11

Printed in E.C.

8006-10 19. Install a new wear ring (5) in the wide groove on the OD of the piston (7).

27. Tighten the cap screws (2). Torque to 420 to 500 Nm (310 to 368.8 pound-feet).

20. Install a new seal (6) in the groove on the OD of the piston (7). 21. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (1). 22. Lubricate the inside of the tube (1) and the outside of the piston (7) with clean oil. 23. Push the piston (7) straight into the tube (1). 24. Lubricate the O-ring (16) on the gland (3) with clean oil. 25. Push the gland into the tube (1) and align the holes in the tube (1). 26. Install the cap screws (2) and hardened washers (18).

84489509

Issued 04-11

Printed in E.C.

8006-11

REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Removal 1. Put piston tube (4) in a press. 2. Use an acceptable driver to press wipers (1) and bushings (2) out of piston tube (4) eye.

3. Clean bore for bushings (2) in tube (4) eye.

Installation

1. Use an acceptable driver to press new bushings (2) into tube (4) eye. Bushings shall be recessed 8 mm (0.315 inch) in tube eye. 2. Use an acceptable driver to install wipers (1) until flush with tube (4) eye. The lips of wipers must be toward outside of bore.

2 1 2

BS01C003

1. WIPER 2. BUSHING

3. PISTON ROD YOKE 4. TUBE

BUSHING AND WIPER REMOVAL AND REPLACEMENT LIFT CYLINDERS

84489509

Issued 04-11

Printed in E.C.

8006-12

REPLACING BUSHINGS FOR THE BUCKET CYLINDER Removal

1. Put piston rod eye (3) in a press. 2. Use an acceptable driver to press wipers (1) and bushing (2) out of piston rod eye (3). 3. Put tube (4) in a press. 4. Use an acceptable driver to press bushings (2) out of tube (4) eye.

2 1

1 2

5. Clean bore for bushings (2) in piston rod eye (3) and tube (4) eye.

Installation

4 2

1. Use an acceptable driver to press new bushings (2) into piston rod eye (3) until recessed 8 mm (0.315 inch). 2. Use an acceptable driver to install wipers (1) until flush with piston rod eye (3). The lips of the wipers (1) must be towards outside of bore.

3. Use an acceptable driver to press new bushings (2) into tube (4) eye until recessed 8 mm (0.315 inch). 4. Use an acceptable driver to install wipers (1) until flush with tube (4) eye. The lips of wipers (1) must be towards outside of bore.

1 BS03B201

1. WIPER 2. BUSHING

3. PISTON ROD EYE 4. TUBE

BUSHING AND WIPER REMOVAL AND REPLACEMENT BUCKET CYLINDERS

84489509

Issued 04-11

Printed in E.C.

Section 8007

8007

COUPLER SOLENOID LOCKING VALVE

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

84489509

8007-2

TABLE OF CONTENTS coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 3 3 3

Printed in E.C.

8007-3

COUPLER SOLENOID LOCKING VALVE Disassembly

STEP 11 Install solenoid (2) on valve cartridge (3).

STEP 1 Clean exterior of valve.

STEP 12 Install nut (1) to secure solenoid (2).

STEP 2 Remove nut (1) and solenoid (2) from valve cartridge (3).

STEP 3 Remove valve cartridge (3) from valve housing (7).

STEP 4 Remove and discard all O-rings (4 and 5) and back-up rings (6).

Cleaning and Inspection STEP 5

Immerse valve cartridge (3) and valve housing (7) in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of valve cartridge and housing and to ensure that all passage ways and bores are clear.

4 6

STEP 6 Check valve cartridge for (3) for cracks, breaks, chipping, or other damage. Replace if any of these conditions are seen.

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 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.

GS98J818

1. 2. 3. 4.

NUT SOLENOID VALVE CARTRIDGE O-RING

5. O-RING 6. BACKUP RING 7. VALVE HOUSING

STEP 10 Lubricate O-rings (4 and 5) using clean oil then install valve cartridge (3) in valve housing (7). 84489509

Issued 04-11

Printed in E.C.

8007-4

NOTES

84489509

Issued 04-11

Printed in E.C.

8013

Section 8013 RIDE CONTROL ACCUMULATOR

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

84489509

8013-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SPECIFICATIONS Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 7 Ride Control Accumulator Fluid Capacity............................................................................. 3.78 liters (230 cu. inch) Ride Control Accumulator Maximum Operating Pressure..............................................................280 bar (4061 psi)

SPECIAL TOOLS

94L95

380001737 NITROGEN ACCUMULATOR CHARGING KIT

84489509

B786441M

380001738 GLAND WRENCH

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DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

C F

94L95

380001737 NITROGEN CHARGING KIT

1. Use the 380001737 Nitrogen Charging Kit to discharge the accumulator, refer to the illustration above. The tool must be disconnected from the nitrogen tank. 2. Close valves B, C and D. 3. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve F fully out. 5. Remove the guard and valve assembly cap from the accumulator.

7. Turn the T-handle inward on valve F to engage the pin in the valve stem. 8. Open valve D and check the charge pressure on gauge E. 9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem. 11. The accumulator can now be disassembled.

6. Connect valve F to the valve stem on the accumulator.

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W230R026

1. CYLINDER 2. PISTON

3. GAS VALVE 4. END CAP

5. FLUID CONNECTION

RIDE CONTROL ACCUMULATOR ILLUSTRATION

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CHARGING THE ACCUMULATOR WITH NITROGEN

GS98N801

1. VALVE C 2. TO NITROGEN TANK 3. VALVE A

4. VALVE B 5. VALVE D 6. TO ACCUMULATOR

NITROGEN CHARGING KIT 380001737

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. M253A

WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar (450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M406

WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration. IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high pressure (10 bar/150 psi and above) applications.

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8013-7 1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to the illustration on page 6. 2. Open valve B by turning it out all the way to the left (counterclockwise). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the valve cap from the pressure valve on the accumulator. 8. Back off the needle valve on the accumulator end of the charging hose by turning 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 accumulator pressure valve. 10. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

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11. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, slightly open the needle valve on the accumulator charge hose. By regulating the needle valve, fill the accumulator to pressure according to temperature chart below. Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. TEMPERATURE 10° C 50° F 13° C 55° F 16° C 60° F 18° C 65° F 21° C 70° F 24° C 75° F 27° C 80° F 29° C 85° F 32° C 90° F 35° C 95° F 38° C 100° F

CHARGE PRESSURE 1636 KPA 237 PSI 1655 KPA 240 PSI 1674 KPA 243 PSI 1687 KPA 245 PSI 1706 KPA 248 PSI 1726 KPA 250 PSI 1745 KPA 253 PSI 1758 KPA 255 PSI 1777 KPA 258 PSI 1796 KPA 261 PSI 1815 KPA 263 PSI

TEMPERATURE/CHARGE PRESSURE RIDE CONTROL ACCUMULATOR

12. Close valve B by turning to the right (clockwise). After a few minutes, check the accumulator for leakage. 13. Back off the needle valve on the accumulator end of the charging hose by turning it counterclockwise the maximum amount. This will p re ve n t n itro g e n fro m esca p ing from th e accumulator as the hose is removed. Remove the charging hose from the accumulator pressure valve. 14. Install the valve cap onto the pressure valve on the accumulator. 15. Remove the charging hose from the nitrogen supply tank.

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8013-8

NOTES

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8014

Section 8014 RIDE CONTROL VALVE

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

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8014-2

TABLE OF CONTENTS RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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RIDE CONTROL 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 ORFICE

14. 15. 16. 17.

POPPET ORFICE VALVE BLOCK RELIEF VALVE

STEP 8 Remove the pressure relief valve (17).

STEP 1 Remove ride control valve, refer to section 8001.

STEP 2

Inspection 1. Discard all O-rings.

Remove plugs (1), (8), (9), and (11).

2. Clean all parts in cleaning solvent.

STEP 3

3. Check the spools and the spool bores for damage and wear.

Remove the solenoid (12).

4. Check the parts of the pressure relief valve.

STEP 4

If any of the parts are damaged, install new parts.

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). 84489509

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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).

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STEP 8

Install plug (8) and torque to 140 Nm (103 lb-ft), plug (9) and torque to 30 Nm (22 lb-ft), and plug (11) and torque to 90 Nm (66 lb-ft).

STEP 10 Install the ride control valve in the machine, see section 8001.

STEP 11 Test the ride control system, see section 8002.

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SECTION INDEX

MOUNTED EQUIPMENT Section Title

Section Number

Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002 Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003 Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004 Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006 Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007 Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

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

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9002

Section 9002 AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A REFRIGERANT

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

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 serious injury. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes.

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 form a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.

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.

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299L7C

BELT TENSION TOOL 380001325

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, 380001326

A22090

ELECTRONIC LEAK DETECTOR 380001327

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109L7

SAFETY GOGGLES CAS-10073-3

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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 evaporator meters refrigerant 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 condenser then removes the heat from the 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 the condenser to the receiver-drier. The 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

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3. COMPRESSOR 4. CONDENSER

5. RECEIVER-DRIER

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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

Mechanical - See Mechanical Compressor Check Page 8 Electrical - See Blower and Compressor Clutch Check Page 9

Yes Internal System Problem See Pressure Testing, Page 13

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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.

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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 between the front plate and pulley 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.

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Blower and Compressor Clutch Check

Compressor Clutch

NOTE: Check supply voltage with compressor lead plugged in and engaged. Voltage drops will not be apparent without current flow. 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

84489509

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 terminals. If continuity is not present when switch is on maximum cold, replace switch.

Issued 04-11

Printed in E.C.

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 run the compressor for five minutes to make 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

84489509

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 refrigerant, there is a restriction 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.

Issued 04-11

Printed in E.C.

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 380001327 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

84489509

1. Make sure the condenser is clean and the seals are in place. Make sure condenser fans run when temperature control switch is ON.

Issued 04-11

Printed in E.C.

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 restrictions. If the core is dry, use 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.

84489509

Issued 04-11

Printed in E.C.

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.

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 Connect the manifold gauge set into the air conditioning system as shown. Make sure that both valves in the manifold gauge set are closed.

LOW PRESSURE GAUGE - The low pressure gauge is a compound gauge. It is best used to judge evacuation effectiveness. A vacuum reading indicates a system malfunction. For this reason, it is necessary to use a compound gauge that will indicate both pressure and vacuum.

84489509

Issued 04-11

Printed in E.C.

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

84489509

Issued 04-11

Printed in E.C.

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 refrigerant in your eyes could cause 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.

84489509

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.

Issued 04-11

Printed in E.C.

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 test for other possible problems.

84489509

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Printed in E.C.

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 air to condenser.

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.

84489509

Issued 04-11

Printed in E.C.

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 Â°F (Â° 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)

84489509

Issued 04-11

Printed in E.C.

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.

84489509

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Printed in E.C.

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

84489509

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.

Issued 04-11

Printed in E.C.

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.

84489509

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.

Issued 04-11

Printed in E.C.

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

84489509

1. Replace expansion valve. See Section 9004.

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

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.

84489509

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.

Issued 04-11

Printed in E.C.

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.

84489509

Issued 04-11

Printed in E.C.

9003

Section 9003 AIR CONDITIONER SYSTEM SERVICE

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

84489509

9003-2

84489509

Issued 04-11

3 3 4 5 7 10

Printed in E.C.

9003-3

SPECIFICATIONS Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION 380001326

84489509

109L7

SAFETY GOGGLES CAS-10073-3

Issued 04-11

Printed in E.C.

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 serious injury. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes.

84489509

Issued 04-11

Printed in E.C.

9003-5

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY Recovered refrigerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it.

STEP 3

If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding.

STEP 1

A22114

Open the high and low valves.

STEP 4

BD03A213

Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.

STEP 2 A22107

Make certain the refrigerant tank gas and liquid valves are open.

BD03B001

With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports. Connect the hose from the low pressure gauge to the port on the suction hose. Turn in valve depressor. Connect the hose from the high pressure gauge to the port on the discharge hose. Turn in valve depressor.

84489509

Issued 04-11

Printed in E.C.

9003-6

STEP 5

STEP 7

A22112

A22110

Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the recovery start switch.

Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely.

The compressor will shut OFF automatically when recovery is complete. Wait for 5 minutes and observe the manifold pressure gauges for a pressure rise. If pressure rises above 0 psi (0 bar), depress the hold/cont switch. Then wait for the compressor to automatically shut OFF.

STEP 8

STEP 6

A22111

Fill the A/C compressor with fresh SP-20 PAG oil equal to the amount in the reservoir.

STEP 9 A22108

Drain the oil separator of the A/C system oil. Open the air purge valve long enough to let some of the compressor discharge pressure back into the separator.

BD03A213

Remove the hoses from the service ports and install the caps.

84489509

Issued 04-11

Printed in E.C.

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 vacuum pump. A vacuum pump is the only equipment made to lower the pressure enough to change the moisture to vapor that can be removed from the system. NOTE: Refer to the vacuum pump manufacturer’s user manual for additional information.

STEP 11

D. Large system leak (broken hose, break in line). E. Too much air or moisture in system. F. Removal of compressor caused the system to be open (uncapped) longer than 5 minutes.

STEP 10 A22113

Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the vacuum key. Program a minimum of 45 minutes and press the Enter key. The display will flash once indicating the programmed data has been accepted.

STEP 12 BD03B001

With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports as follows: 1. Connect the hose from the low pressure gauge to the port on the suction hose. 2. Connect the hose from the high pressure gauge to the port on the discharge hose. 3. Turn in both thumbscrews to depress the service valves. Removal of air and moisture from the system is necessary after the refrigerant has been removed after the system has been opened for maintenance. Air enters the system when the system is opened. Air has moisture that must be removed to prevent damage to the system components.

A22115

Press the Charge key. “Program” and “Charge” will appear on the display.

NOTE: The pump on the reclamation unit will not pull a sufficient vacuum to remove air and moisture.

84489509

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Printed in E.C.

9003-8

STEP 13

STEP 16

A22113

A22123

Program 3.5 lbs and press the enter key. The display will flash once indicating the programmed data has been accepted.

Press the Vacuum key. “Automatic” will appear on the display. Vacuum will appear on the display and after a slight delay, the vacuum pump will start. The display will show the amount of time programmed and begin a countdown to zero.

STEP 14

A22114

Fully open the low and high pressure valves.

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, leak-free system will leach refrigerant from 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.

STEP 17

STEP 15

A22113 A22107

Open the red (vapor) and blue (liquid) valves on the tank.

84489509

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”.

Issued 04-11

Printed in E.C.

9003-9

STEP 18

STEP 21

A22114

BD03B001

Completely close the high and low pressure manifold valves.

Stop the engine, close any open valves and carefully remove the manifold gauge hoses.

ATTENTION: Check the OEM equipment manual before performing Step 19 to avoid damaging the recovery unit. The pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the valves accidently open or if either or both valves are opened while the A/C system is operating.

STEP 22

STEP 19 Start the engine and run at 1500 RPM. Operate the air conditioner system at maximum cooling setting and blower speed with the doors and windows open. NOTE: The compressor will not operate if the system pressure is too low or too high. The pressure indicator lamp will illuminate when the relay is actuated by a low or high pressure and the compressor clutch will disengage. To restart the compressor, the air conditioner control or blower switch must be turned to the OFF position and then to the ON position.

BD03B213

Install the caps on the service ports on the suction and discharge hoses.

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. 84489509

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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.

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.

4. Cab temperature control set to maximum cooling.

84489509

Issued 04-11

Printed in E.C.

REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS

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

84489509

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

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3 4 5 5 6 8 9 14 19 19 20

Printed in E.C.

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 form a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.

84489509

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9004-4

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION 380001326

84489509

BS03H012

SAFETY GOGGLES CAS-10073-3

Issued 04-11

Printed in E.C.

9004-5

COMPRESSOR Removal

STEP 4

STEP 1 Place the master disconnect switch in the OFF position.

STEP 2 Discharge the air conditioning system according to the instructions in Section 9003.

STEP 3 BD06F116

Remove the fan belt.

STEP 5

BD06F113

BD06F117

Disconnect the low pressure line from the suction port and the high pressure line from the discharge p o r t o n t h e c o m p r e s s o r . I m m e d i a t e ly i n s t a l l protective caps on the open ports and lines.

BD06F114

Loosen and remove the four bolts holding the protective shield. Remove the shield.

84489509

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9004-6

Installation

STEP 6

STEP 9 Place the compressor into position on the machine.

STEP 10

BD06F117

Disconnect the compressor clutch wire from the engine harness assembly.

STEP 7 BD06F117

Install the three bolts to mount the compressor.

STEP 11

BD06F117

Loosen and remove the three compressor mounting bolts.

STEP 8 Remove the compressor from the machine.

84489509

BD06F117

Connect the compressor clutch wire to the engine harness assembly.

Issued 04-11

Printed in E.C.

9004-7

STEP 12

STEP 13 Carefully remove the protective cap, install a new O-ring, and connect the low pressure line to the suction port on the compressor.

STEP 14 Install the belt.

STEP 15 Install the protective shield.

STEP 16 BD06F117

Slowly remove the protective cap, install a new O-ring, and connect the high pressure line to the discharge port on the compressor.

Charge the air conditioning system according to the instructions in Section 9003.

IMPORTANT: Use caution when removing cap as new compressors have internal pressure when shipped.

84489509

Issued 04-11

Printed in E.C.

9004-8

EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS 3

2 1 8

18 17 12

16 15

BS06G118

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

84489509

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

Issued 04-11

Printed in E.C.

9004-9

Removal

STEP 23

STEP 17 Park the machine on a level surface and lower the bucket to the floor.

STEP 18 If changing any air conditioning components, discharge the air conditioning system according to the instructions in Section 9003.

STEP 19 BD06G212

Open the cover on the cooler.

STEP 24

BD02N160

If changing the heater core, put a 37 liter (10 gallon) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

STEP 20 Place the master disconnect in the OFF position.

BD06G213

Remove the four screws securing the air vent, remove the vent cover.

STEP 25

STEP 21 Disconnect the wiring harness from the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option).

STEP 22

BD06G214

Remove the three screws securing the cooler to the cab, remove the cooler.

STEP 26 BD06G202

Fold the rubber mat over to gain access to the upper box mounting bolts.

Remove the four bolts that fasten the operatorâ&#x20AC;&#x2122;s seat to the upper box, remove the seat from the machine. 84489509

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Printed in E.C.

9004-10

STEP 27

STEP 30

BD06G215

Remove the six bolts securing the upper box.

BD06G217

G o i n g t h r o u g h t h e i n s i d e f i l t er a re a f e e l t he recirculating vain to make sure is is in the outside air, “closed”, position.

STEP 28

STEP 31

BD06G216

Remove two screws, one on each side of the upper box, securing the upper box to the lower box.

BD06G218

STEP 29

The above photo shows that the recirculating vain is not in the outside air “closed” position.

Place the air selector on the control panel to outside air.

STEP 32

NOTE: In step 30 and 33 the upper box is shown removed for clarity only, these steps must be done prior to removing the upper box.

BD06G240

Use a screw driver and disconnect the linkage.

84489509

Issued 04-11

Printed in E.C.

9004-11

STEP 33

STEP 36

BD06G219

Close the vain so the upper cover can be removed.

BD06G203

Disconnect the solenoid driver.

STEP 34 Remove the upper box up and rest it against the console.

STEP 37

NOTE: The wiring harness for the HVAC system goes through the upper cover, by resting the cover against the console the wiring harness will not need to be removed.

STEP 35

BD06G236

Remove the upper PPE from the heater and air conditioning cores. NOTE: If testing on the electrical components are required the solenoid driver can be reconnected once the upper PPE is removed.

BD06G220

Pull the wiring harness loose from the upper PPE.

84489509

Issued 04-11

Printed in E.C.

9004-12 NOTE: If replacing the heater control valve, heater core, air conditioning expansion valve, air conditioning evaporator core do steps 38 through 47, if replacing electrical components go to step 48.

STEP 40

STEP 38

BD06G206

Remove the thermostat probe and clamp from the evaporator core.

STEP 41 BD06G204

Remove the right side cab skirt.

STEP 39 2

BD06G237

Disconnect the electrical connectors from the thermostat control.

STEP 42 1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

BD06G205

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.

84489509

Issued 04-11

Printed in E.C.

9004-13

STEP 43

STEP 49

Pull the heater core and evaporator core from the lower box PPE.

STEP 44 Remove the expansion valve from the evaporator core.

STEP 45 Remove and discard the O-rings from the openings in the expansion valve.

STEP 46 Remove the screws from the heater core and remove the control valve.

STEP 47 Remove and discard the O-rings from the heater control valve.

BD06G208

Disconnect the electrical connector for the recirculating vain motor, disconnect the linkage from the vain. Remove the mounting screws and remove the motor.

STEP 50

STEP 48 1

1 3 2

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

BD06G207

Remove the fans from the lower PPE, disconnect the electrical connectors. Remove the two mounting screws for the resistor, remove the resistor.

84489509

1. FAN SPEED AND A/C SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

BD06G209

Remove the switch panel from the console. Disconnect the electrical connectors and remove switches as required.

Issued 04-11

Printed in E.C.

9004-14

Installation

STEP 53

STEP 51 1

1 3 3 2

1. FAN SPEED SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

BD06G209

Replace switches and connect the electrical connectors as required. Install the switch panel in the console.

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

BD06G207

Install the resistor, install the two mounting screws and tighten. Install the fans in the lower PPE, connect the electrical connectors.

STEP 54 Install new O-rings on the heater control valve.

STEP 52

STEP 55 Install the control valve, install and tighten the screws to the heater core.

STEP 56 Install new O-rings on the openings of the expansion valve.

STEP 57 Install the heater core and evaporator core into the lower box PPE. BD06G208

STEP 58

Install the motor and install the mounting screws and tighten. Connect the electrical connector for the recirculating vain motor, connect the linkage to the vain.

BD06G236

Connect the electrical connectors to the heater control valve.

84489509

Issued 04-11

Printed in E.C.

9004-15

STEP 59

STEP 61 3

BD06G237

Connect the electrical connectors to the thermostat control.

STEP 60

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

BD06G205

Remove the plugs from the hoses and the caps from the fittings. Install new O-rings in the evaporator fittings, connect the heater and evaporator hoses. Remove and discard identification tags that were used during disassemble.

STEP 62

BD06G206

Install the thermostat probe coil and clamp to the evaporator core â&#x20AC;&#x153;coldâ&#x20AC;? tube.

BD06G204

Install the right side cab skirt.

STEP 63

BD06G238

Install the upper PPE on the heater and air conditioning cores. 84489509

Issued 04-11

Printed in E.C.

9004-16

STEP 64

STEP 67

BD06G210. BD06G203

Connect the solenoid driver.

Make sure that the recirculating vain is in the closed position. IMPORTANT: This photo shows it in the open position and the upper box will not go back into position without damaging the recirculating vain.

STEP 65

STEP 68

BD06G239

Push the wiring harness into the preformed notches in the upper PPE.

STEP 66 Place the air selector on the control panel to outside air.

BD06G241

Set the upper box into position on the heater and evaporator cores.

STEP 69

BD06G216

Install two screws, one on each side of the upper box securing the upper box to the lower box.

84489509

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Printed in E.C.

9004-17

STEP 70

STEP 74

BD06G242

BD06G214

Install the insolation panel in the center of the upper box.

Install and tighten the three screws securing the cooler to the cab.

STEP 71

STEP 75

BD06G215

BD06G213

Install and tighten the six bolts securing the upper box.

Install the vent cover, install and tighten the four screws securing the air vent.

STEP 72

STEP 76

BD06G243

Install the right rear floor mat into the cab, if machine is equipped with air ride seat make sure to pull the wiring up above the mat for the seat.

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).

STEP 73 Install the remainder of the floor mat.

84489509

Issued 04-11

Printed in E.C.

9004-18

STEP 77

STEP 79

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 78 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

84489509

Issued 04-11

Printed in E.C.

9004-19

CONDENSER AND RECIEVER DRIER Removal

STEP 85

STEP 80 Park the machine on a level surface and lower the bucket to the ground.

STEP 81 Place the master disconnect switch in the OFF position.

STEP 82 Discharge the air conditioning system according to the instructions in Section 9003. BS03A107

Fasten identification tags on the hoses and disconnect the hoses from the condenser.

STEP 83

STEP 86

Install plugs in the hoses and caps on the fittings.

STEP 87

BD01D142

1. COVER

2. CONDENSER

Open the cover (1) to gain access to the condenser (2).

STEP 84

BS03A109

Loosen the bolts that fasten the condenser to the bracket, pivot the condenser and remove the bolts and condenser.

BD03A109

The condenser is connected to a bracket which pivots on the cooling frame. Pivot the condenser to gain access to the hoses.

84489509

Issued 04-11

Printed in E.C.

9004-20

Installation

STEP 88

STEP 91 Put the condenser in position on the bracket.

STEP 92

BD06G211

F a s t e n i d e n t i f ic a t i o n t a g s o n t h e h o s e s a n d disconnect the hoses from the receiver drier.

STEP 89 Install plugs in the hoses and caps on the fittings.

STEP 90 Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket.

BS03A109

Install the bolts that fasten the condenser to the bracket, pivot the condenser down and tighten the bolts.

STEP 93

BS03A107

Pivot the condenser to gain access to the hoses.

STEP 94 Remove the plugs from the hoses and the caps from the fittings. Install new O-rings and connect the hoses to the fittings. Remove and discard identification tags that were used during disassemble.

STEP 95 Pivot the condenser down and close the cover.

STEP 96 Mount the receiver drier and bracket, install and tighten the mounting bolt.

84489509

Issued 04-11

Printed in E.C.

9004-21

STEP 97

STEP 98 Charge the air conditioning system according to the instructions in Section 9003.

STEP 99 Place the master disconnect switch in the ON position.

BD06G211

Remove plugs from the hoses and caps from the fittings, install new O-rings and connect the hoses to the fittings, connect the trinary switch. Remove and discard identification tags that were used during disassemble.

84489509

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Printed in E.C.

9004-22

NOTES

84489509

Issued 04-11

Printed in E.C.

Section 9006

9006

LOADER

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

84489509

9006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

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3 3 3 3 3 4 5 7 9

9006-3

SPECIFICATIONS Special Torques Bolts for the Bucket Teeth .......................................................................1315 to 1480 Nm (970 to 1090 pound-feet)

BUCKET TEETH Replacement of the Tooth Points 3

1. Use a hammer and punch to drive the retaining pin (1) for the tooth point (2) out of the tooth shank (3), refer to the illustration on this page.

2. Remove the tooth point (2). 3. Install a new tooth point (2) on the tooth shank (3). 4. Install the retaining pin (1) into the tooth point (2) and tooth shank (3). Make sure the shoulder on the retaining pin is toward the cutting edge. Use a hammer to hit the retaining pin (1) until the retaining pin (1) is even with the outside of the tooth shank (3).

7 8

3 2

Replacement of the Bucket Teeth

6 10

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. 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).

B0740A88J

1. 2. 3. 4. 5.

RETAINING RING TOOTH POINT TOOTH SHANK NUT HARDENED WASHER

6. 7. 8. 9. 10.

BOLT CUTTING EDGE PLOW BOLT NUT CORNER TOOTH

BUCKET TEETH ILLUSTRATION

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). 84489509

Issued 04-11

Printed in E.C.

9006-4

RETURN TO DIG ADJUSTMENT

2 6 1

3 BS01C083

1. TARGET MOUNTING BRACKET 2. BUCKET CYLINDER

3. TARGET BAR 4. PROXIMITY SWITCH MOUNTING BRACKET

5. PROXIMITY SWITCH 6. PROXIMITY SWITCH GUARD

RETURN TO DIG ADJUSTMENT ILLUSTRATION

IMPORTANT: Before adjusting the return-to-dig, make sure that the target bar on the bucket linkage is not damaged. Slowly roll back and dump the bucket and make sure that the target bar stays the same distance from the switch. The switch mounting bracket protects the switch. Make sure the target bar cannot touch the switch when the bucket is dumped. 1. Park the machine on a level surface. Raise the lift arms until they are approximately horizontal and dump the bucket. Lower the bucket until the bucket edge is on the ground. 2. Apply the parking brake and stop the engine. 3. Loosen the bolts holding the target mounting bracket (1) to the tilt cylinder eye. Align the target mounting bracket (1) parallel to the tilt cylinder (2). Tighten the bolts, refer to the illustration on this page. 4. Loosen the bolts holding the proximity switch mounting bracket (4) to the tilt cylinder (2). Position the proximity switch (5) parallel to the target bar (3) and tighten the bolts. 5. Adjust the proximity switch (5) out towards the target bar (3), until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. Torque the jam nut to 6.7 Âą 0.6 Nm (5 Âą 0.5 pound-feet). NOTE: The proximity switch (5) must not protrude past the proximity switch guard (6). 6. Start the engine, position the bucket to the correct digging angle and stop the engine.

7. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). Slide the target bar (3) towards the proximity switch (5) until the face of the proximity switch (5) is completely covered. 8. Align the target bar (3) parallel to the tilt cylinder (2) and tighten the bolts. 9. Turn the ignition switch to the ON position. Do NOT start the engine. 10. Place the bucket control lever in the ROLLBACK position. 11. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). 12. Slide the target bar (3) slowly away from the proximity switch (5), until the control lever returns to the center position. Tighten the bolts holding the target bar (3). 13. Check to make sure that the 3.2 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained. 14. Start the engine. 15. Place the detent switch in the ON position and place the return to travel/float detent switch to the TRAVEL position. 16. Raise the lift arms approximately horizontal, and put the bucket in the fully dumped position. 17. Place the loader control lever in the ROLLBACK position, and verify that the electromagnet holds it in that position until the end of the target bar (3) passes in front of the proximity switch (5). 18. Lower the lift arms and verify that the bucket is at the correct digging angle.

84489509

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9006-5

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

3 1

BS01C081

1. TARGET MOUNTING PLATE 2. HEIGHT CONTROL TARGET

3. PROXIMITY SWITCH 4. LIFT ARM

5. RETURN TO TRAVEL TARGET 6. FRONT CHASSIS (TOP LEFT HAND SIDE)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

1. Park the machine on a level surface. 2. Start the engine and apply the parking brake. 3. Lower the lift arms and place the bucket flat on the ground. 4. Stop the engine.

6. Adjust the proximity switch (3) out towards the return to travel target (5) until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. 7. Lock the proximity switch (3) in this position with the jam nut. Torque the jam nut to 6.7 ± 0.6 Nm (5 ± 0.5 pound-feet).

NOTE: To avoid damage to the proximity switch (3), it must be adjusted back to clear everything on the lift arm as it passes. Refer to the illustration on this page. WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operators compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine. CSM105

5. Position the return to travel target (5) opposite the proximity switch (3) and tighten it to the target mounting plate (1). 84489509

Issued 04-11

Printed in E.C.

9006-6

2 A

3 B

BS01C082

1. HEIGHT CONTROL TARGET

2. RETURN TO TRAVEL TARGET

MACHINE

APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT

W230C Z-Bar

56 mm (2.2 inches)

414 mm (16.3 inches)

W230C Long Reach

70 mm (2.76 inches)

587 mm (23.11 inches)

3. TARGET MOUNTING PLATE

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT

42 mm (1.6 inches)

3302 mm (130 inches)

61 mm (2.40 inches) 4000 mm (157.48 inches)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

8. Refer to the table and the illustration on this page. Position the height control target (1) on the target mounting plate (3) using the table above. NOTE: The higher the height control target (1) is positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are raised. 9. Tighten the height control target (1). 10. Position the return to travel target (2) using the table above. NOTE: The higher the return to travel target (2) is positioned in its slot in the target mounting plate (3), the lower the lift arms will stop as they are lowered. 11. Check to make sure the proximity switch (3) and all of the mounting bolts are tight. Refer to the illustration on page 5.

14. Place the loader control lever in the raise position and verify that the electromagnet holds it in that position until the height control target (2) passes in front of the proximity switch (3). Refer to the illustration on page 5. 15. With the lift arms still raised, place the loader control lever in the lower position and verify that the electromagnet holds it in that position until the return to travel target (5) passes in front of the proximity switch (3). Refer to the illustration on page 5. 16. Repeat steps 8 through 15 until the desired heights are reached. 17. Lower the bucket to the ground and stop the engine.

12. Start the engine. 13. Place the detent switch in the ON position, and set the return to travel/float detent switch to the return to travel position. 84489509

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Printed in E.C.

9006-7

REMOVING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) 1. Park the machine on a level surface and apply the parking brake. Roll the bucket all the way forward and lower the bucket to the floor. Stop the engine. 2. Loosen the filler plug in the reservoir to release the air in the reservoir. 3. Fasten a chain hoist to the cross member (1) of the loader frame (2), refer to the illustration on page 8.

17. Loosen and remove the bolt (19), flat washer (20) and spacer (21) that fasten the pivot pin (9 or 10) to the front frame. 18. Raise the loader frame slightly. Use an acceptable driver and drive the pivot pin (9 or 10) out of the front frame. Do not lose the washers (18) and wipers (22) between the front frame and the loader frame (2).

4. Loosen and remove the bolt (12), flat washer (13), and spacer (14) that fasten the pivot pin (3) to the piston rod yoke of the right lift cylinder (4). 5. Use an acceptable driver and drive the pivot pin (3) out of the piston rod yoke of the right lift cylinder (4). Do not remove the driver. 6. Repeat Steps 4 and 5 for the left lift cylinder (8). 7. Start the engine. Roll the bucket back and lower the bucket so that the bucket is flat on the floor and fasten the chain hoist to a lift cylinder (4 or 8). 8. Raise the lift cylinder (4 or 8) slightly and remove the driver.

BD01G009

19. Remove the proximity switch cover. Left-hand side of the machine only.

9. Repeat steps 7 and 8 for the other lift cylinder (4 or 8). 10. Connect the chain hoist to the bucket cylinder (8). 11. Loosen and remove the bolt (15), flat washer (16), and spacer (17) that fasten the pivot pin (7) for the piston rod eye of the bucket cylinder (8) to the bell crank (11). 12. Use an acceptable driver and drive the pivot pin (7) 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 (2). Install caps on the hoses and plugs in the tube fittings. 15. If the machine is equipped with front lamps, loosen and remove the cap screws and lock washers that fasten the lamp brackets to the front frame. Put the lamp brackets on the fenders.

1 2

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 proxim ity switch (2) from the machine. Left-hand side of the machine only. 21. Repeat Steps 17 and 18 for the other pivot pin (9 or 10). 22. Raise the loader frame (2) out of the front frame. Carefully move the machine out of the loader frame (2).

16. Connect the chain hoist to the loader frame (2).

84489509

Issued 04-11

Printed in E.C.

9006-8

8 5

1 2

7 17

W230R027

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

CROSS MEMBER LOADER FRAME PIVOT PIN LIFT CYLINDER PIVOT PIN BUCKET CYLINDER

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

PIVOT PIN LIFT CYLINDER PIVOT PIN PIVOT PIN BELL CRANK BOLT

13. 14. 15. 16. 17. 18.

WASHER SPACER BOLT WASHER SPACER WASHER

19. 20. 21. 22. 23.

BOLT WASHER SPACER WIPER DUMP LINK

LOADER FRAME ILLUSTRATION

84489509

Issued 04-11

Printed in E.C.

9006-9

INSTALLING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) 1. Apply antiseize compound to the inner bores and outer bores for the pivot pins of the front frame, refer to the illustration on page 8. 2. Move the machine into alignment with the loader frame (2). 3. Lower the loader frame (2) into alignment with the front frame. 4. Apply antiseize compound to the pivot pins (9 and 10) that fasten the loader frame (2) to the front frame. 5. Start the pivot pins (9 and 10) into the front frame. Install the washers (18) and new wipers (22) between the loader frame (2) and the front frame. 6. Install the pivot pins (9 and 10) all the way. 7. Install the bolt (19), washer (20) and spacer (21) that fasten the pivot pins (9 and 10). Tighten the bolt. 8. Install the proximity switch and cover. Left-hand side of the machine only. 9. Disconnect the chain hoist from the loader frame (2). 10. If the machine is equipped with front lamps, hold the front lamps in place and install the cap screws and lock washers that fasten the front lamps to the front frame. Tighten the cap screws. 11. If the machine is equipped with auxiliary hydraulics, remove the plugs from the tube fittings and the caps from the hoses. Connect the hoses to the tubes. 12. Connect the chain hoist to the bucket cylinder (6) and lower the bucket cylinder (6). 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 (6) with the bell crank (11). Stop the engine. IMPORTANT: D o n o t u s e y o u r f i n g e r s t o check the alignment of the cylinder rod. Personal injury can be the result. 48-88

15. Install the pivot pin (7) in the bell crank (11) and the piston rod eye of the bucket cylinder (6). 16. Install the bolt (15), washer (16), and spacer (17) that fasten the pivot pin (7). Tighten the bolt.

84489509

17. Disconnect the chain hoist from the bucket cylinder (6). 18. Fasten the chain hoist to one of the lift cylinders (4 or 8). 19. Raise the piston rod yoke of the lift cylinder (4 or 8) so the piston rod yoke is aligned with the loader frame (2). 20. Install a driver in the piston rod yoke and the loader frame (2). 21. Repeat Steps 18, 19, and 20 for the other lift cylinder (4 or 8). 22. Disconnect the chain hoist from the lift cylinder (4 or 8). 23. Start the engine. Raise the loader frame and roll the bucket all the way forward. Lower the bucket to the floor. Stop the engine. 24. Fasten the chain hoist to the cross member (1) of the loader frame (2). 25. Start the engine and run the engine at low idle. 26. Have another person help you at this time. Move the lift control lever as required to align the piston rod yoke of one of the lift cylinders (4 or 8) with the loader frame (2). IMPORTANT: D o n o t u s e y o u r f i n g e r s t o check the alignment of the cylinder rod. Personal injury can be the result. 48-88

27. Remove the driver and install the pivot pin (3). 28. Install the bolt (12), washer (13), and spacer(14) that fasten the pivot pin (3). Tighten the bolt. 29. Repeat Steps 26, 27, and 28 for the other lift cylinder (4 or 8). Stop the engine. 30. Lubricate the pivot pins with molydisulfide grease. 31. Disconnect the chain hoist from the cross member (1) of the loader frame (2). 32. Tighten the filler plug in the reservoir. 33. If the machine is equipped with auxiliary hydraulics, start the engine and run the engine at low idle. 34. Slowly extend and retract the clam cylinders four times to remove air from the auxiliary circuit. 35. Stop the engine, check the level of the oil in the reservoir, and check for leaks. Add oil to the reservoir as required. Issued 04-11

Printed in E.C.

9006-10

NOTES

84489509

Issued 04-11

Printed in E.C.

Section 9007

9007

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF)

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

84489509

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84489509

Issued 04-11

3 3 4 4 9

Printed in E.C.

9007-3

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) Attention The Rollover Protective Structure (ROPS) or Cab Structural Frame (CSF) is a special safety component of your machine.

After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site operation: ●

The ROPS or CSF structure MUST be replaced.

●

The ROPS or CSF mounting or suspension, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

●

All damaged parts MUST be replaced.

DO NOT attach any device to the ROPS or CSF for pulling purposes. The ROPS or CSF is a certified structural support and any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS or CSF MUST be replaced so that it will provide the same protection as a new ROPS or CSF.

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS OR CAB STRUCTURAL FRAME.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY After every 500 hours of operation or every six months, whichever comes first, do the following: 1. Check the torque on the CSF cab or ROPS canopy mounting bolts; torque should be 773 to 854 Nm (570 to 630 lb-ft). If necessary, tighten the bolts to the correct torque. 2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators seat mounting bolts; torque should be 73 to 87 Nm (54 to 64 lb-ft). If necessary, tighten the bolts to the correct torque. Replace parts that are worn or damaged. WARNING: Grade 8 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those shown in the parts catalog. 47-27A

84489509

WARNING: Do not install attachments that will make the total weight of the machine more than the weight shown in the maximum gross vehicle weight section of the ROPS serial number plate. 47-26 WARNING: Do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE ROPS. 47-25

Issued 04-11

Printed in E.C.

9007-4

CSF CAB AND ROPS CANOPY Removal

STEP 5

NOTE: Procedures and photos in following steps cover in detail removal and installation of CSF structure. Removal and installation of ROPS is similar to removal and installation of CSF structure.

STEP 1 Park machine on a level surface and lower bucket to floor. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

BD06G191

Remove skirting under each side and front of cab.

STEP 2

STEP 6

W230R406

Put articulation lock in LOCKED position.

BD06G186

Remove the ducts from the machine.

STEP 3

STEP 7

Put battery disconnect switch in OFF position.

STEP 4

BD06G189

BD01F184

At RH rear, bottom of cab, disconnect ground strap from rear chassis.

If machine is equipped with a heater, put a 40 liters (10 Gallons) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.

84489509

Issued 04-11

Printed in E.C.

9007-5

STEP 8

STEP 11

BD06G194

BD06G192

If machine is equipped with windshield washers, identify, tag, and disconnect front and rear windshield washer nozzle hoses from supply hoses.

Identify, tag, and disconnect hoses from steering control valve. Plug hoses and cap steering control valve fittings to prevent entry of foreign matter into hydraulic system.

STEP 9

STEP 12 2

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

BD06G205 BD06F207

Unlatch and open the window on the right hand side.

If machine is equipped with a heater disconnect heater hoses (3), if machine is equipped with air conditioning discharge the air conditioning system, see section 9003, and disconnect the air conditioning hoses (2), cap and plug lines and fittings.

STEP 13

STEP 10

BD06F208

Open and remove the access panel.

BD06G193

Disconnect throttle connector and the air duct. 84489509

Issued 04-11

Printed in E.C.

9007-6

STEP 14

STEP 19

BD06F209

Remove the front access panel.

BD06G187

Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment

STEP 15

STEP 20

BD06F210

Disconnect the electrical connectors for the remote control valve.

STEP 16 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.

BD06G188

Raise floor mat up and away from brake pedal to gain access to mounting hardware.

STEP 21

STEP 17 Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings to prevent entry of foreign matter into hydraulic system.

STEP 18 Push the hoses out of the bottom of the cab with the rubber gromment. BD06G185

Remove hardware securing brake valve to cab floor. Let brake valve rest on the frame.

84489509

Issued 04-11

Printed in E.C.

9007-7

STEP 22

STEP 25 Slowly raise cab from rear chassis. Check that all tie straps and clamps have been removed and all hoses, tubes, and wires are disconnected and free. Check that brake valve with hoses attached are free and clear of cab. Remove the ROPS or CSF from the machine. Lower ROPS or CSF onto wooden blocks to prevent damaging cab or canopy.

BD06G184

Install lifting eyes in threaded holes at top of the cab.

STEP 23 Connect lifting equipment to cab at lifting eyes. Take up all slack in lifting equipment.

STEP 24 Remove nuts, bolts, and washers securing cab to rear chassis.

84489509

Issued 04-11

Printed in E.C.

9007-8

1 2

BC06G031

1. NUT 2. WASHER 3. RUBBER MOUNT

84489509

4. RUBBER MOUNT 5. WASHER 6. BOLT

Issued 04-11

Printed in E.C.

9007-9

Installation

STEP 32

STEP 26 Check rubber mounts (3 an 4) for deterioration, tears, deformation, or other damage; replace rubber mounts as necessary.

STEP 27

BD06G188

Position floor mat.

STEP 33

BD01D388

Position cab over rear chassis then put wood blocks under brake valve. Slowly lower cab onto rear chassis making sure that brake valve is positioned so that brake pedal enters into cab. Remove wood blocks as cab is lowered onto brake valve.

STEP 28 Install washers, bolts, and nuts to secure cab to rear chassis. Tighten bolts to a torque of 773 to 854 Nm (570 to 630 pound feet)

STEP 29 Disconnect lifting equipment from cab.

BD06G192

Remove plugs from hoses and caps from fittings. Connect hoses to steering control valve following tags installed during removal. Remove and discard tags.

STEP 34

STEP 30 Remove lifting eyes.

STEP 31

BD06G193

Connect throttle connector and mount air duct.

BD06G185

Align mounting holes in brake valve with associated holes in cab or canopy floor. Install hardware to secure brake valve to floor. 84489509

Issued 04-11

Printed in E.C.

9007-10

STEP 35

STEP 37

BD06G186

Install the ducts on the machine.

BD06G194

If machine is equipped with windshield washers, connect front and rear windshield washer nozzle hoses following tags installed during removal. Remove and discard tags.

STEP 36

STEP 38 3

1 BD06G189

At RH rear, bottom of cab, connect ground strap to rear chassis. 1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

BD06G205

If machine is equipped with a heater, remove plugs from hoses and caps from fittings, connect heater hoses (3), if machine is equipped with air conditioning, remove plugs from hoses and caps from fittings, connect air conditioning hoses (2), charge the air conditioning system, see section 9003.

STEP 39 Remove plugs from hoses and caps from fittings. Connect hoses to joystick and two-lever controller and install in hose mounting grommet halves as shown on pages 11 and 12.

84489509

Issued 04-11

Printed in E.C.

9007-11

5 6

7 6

4 2

1 2

3 5

1 6

3 4

1 6

3 4

W230R021

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

3 LEVER HOSE COLOR CODING

84489509

W230R022

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN

JOYSTICK AND 1 LEVER HOSE COLOR CODING

Issued 04-11

Printed in E.C.

9007-12

1 4

5 6 5

3 4

W230R023

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

2 LEVER HOSE COLOR CODING

84489509

W230R020

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN

JOYSTICK HOSE COLOR CODING

Issued 04-11

Printed in E.C.

9007-13

STEP 40

STEP 43

BD06F210

Connect the electrical connectors for the remote control valve.

BD06F208

Install and close the access panel.

STEP 44

STEP 41

BD06F209

Place the access panel into position, install and tighten the screw.

STEP 42

BD06F207

Close the right hand window.

STEP 45

BD06G187

Connect wiring harness connectors.

84489509

BD06G191

Install skirting under each side and front of cab.

Issued 04-11

Printed in E.C.

9007-14

STEP 46

STEP 49 Start engine and run engine at low idle. Run engine at operating temperature for approximately five minutes to completely mix Ethylene Glycol and water. When coolant is at operating temperature, stop engine. When engine has cooled, check coolant level at reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. BD01F184

If machine is equipped with a heater and coolant was drained, check that coolant drain cap is tight.

STEP 50 Put articulation lock in OPERATING position.

STEP 47 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 36.9 liters (9.75 U.S. Gallons). Install radiator cap. Fill coolant reservoir up to FULL mark on reservoir.

STEP 48 Put battery disconnect switch in ON position.

84489509

Issued 04-11

Printed in E.C.

Section 9010

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

84489509

9010

CAB GLASS INSTALLATION

9010-2

TABLE OF CONTENTS PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84489509

Issued 04-11

Printed in E.C.

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 primed 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.

84489509

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 forming tool template.

Issued 04-11

Printed in E.C.

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 496L93

FIGURE 2. SILICONE FORMING TOOL TEMPLATE 84489509

Issued 04-11

Printed in E.C.

9010-5

1 3 4

6 2

497L93

1. SIDE GLASS ADHESIVE 2. CENTER GLASS ADHESIVE

4. RIGHT HAND SIDE GLASS SPACER LOCATIONS 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES) FROM TOP OF FRONT SIDE GLASS 3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF CENTER AND SIDE PANELS CENTER GLASS FIGURE 3 SILICONE APPLICATION

NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set. 84489509

Issued 04-11

Printed in E.C.

9010-6

NOTES

84489509

Issued 04-11

Printed in E.C.