New Holland W270B Wheel Loader Service Manual (87661531) NH W270B - PDF Download by www.heydownloads.com

W270B Wheel Loader Service Manual

87661531

Table of Contents

Description General

Section No. Tab 1

Section Index - General

Description General

Section No. Tab 1

Section Index - General

Standard Torque Specifications

1001

Standard Torque Specifications

1001

Fluids and Lubricants

1002

Fluids and Lubricants

1002

Metric Conversion Chart

1003

Metric Conversion Chart

1003

Engines

Tab 2

Section Index - Engines

Engines

Tab 2

Section Index - Engines

Engine and Radiator Removal and Installation

2000

Engine and Radiator Removal and Installation

2000

Aftercooler

2003

Aftercooler

2003

Fuel System

Tab 3

Fuel System

Section Index - Fuel System

For Fuel System Repair, See the Engine Service Manual

Electrical

Tab 4

Section Index - Electrical

Electrical

Tab 3

Tab 4

Section Index - Electrical

Removal and Installation of Starter and Alternator

4001

Removal and Installation of Starter and Alternator

4001

Electrical Specifications and Troubleshooting

4002

Electrical Specifications and Troubleshooting

4002

Batteries

4003

Batteries

4003

Instrument Cluster

4005

Instrument Cluster

4005

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

W270B Wheel Loader Service Manual

87661531

Table of Contents

Description Steering

Section No. Tab 5

Section Index - Steering

Description Steering

Section No. Tab 5

Section Index - Steering

Removal and Installation of Steering Components

5001

Removal and Installation of Steering Components

5001

Steering Specifications, Pressure Checks, and Troubleshooting

5002

Steering Specifications, Pressure Checks, and Troubleshooting

5002

Steering Cylinders

5005

Steering Cylinders

5005

Center Pivot

5006

Center Pivot

5006

Auxiliary Steering Motor and Pump

5007

Auxiliary Steering Motor and Pump

5007

Power Train

Tab 6

Section Index - Power Train

Power Train

Tab 6

Section Index - Power Train

Removal and Installation of Power Train Components

6001

Removal and Installation of Power Train Components

6001

Transmission Specifications, Pressure Checks, and Troubleshooting

6002

Transmission Specifications, Pressure Checks, and Troubleshooting

6002

Transmission

6003

Transmission

6003

Front and Rear Axle

6004

Front and Rear Axle

6004

Drive Shafts, Center Bearing, and Universal Joints

6005

Drive Shafts, Center Bearing, and Universal Joints

6005

Wheels and Tires

6006

Wheels and Tires

6006

Transmission Control Valve

6007

Transmission Control Valve

6007

Brakes

Tab 7

Section Index - Brakes

Brakes

Tab 7

Section Index - Brakes

Removal and Installation of Brake Components

7001

Removal and Installation of Brake Components

7001

Hydraulic Brake Troubleshooting

7002

Hydraulic Brake Troubleshooting

7002

Brake Accumulators

7004

Brake Accumulators

7004

Parking Brake

7008

Parking Brake

7008

Hydraulics

Tab 8

Section Index - Hydraulics

Hydraulics

Tab 8

Section Index - Hydraulics

Removal and Installation of Hydraulic Components

8001

Removal and Installation of Hydraulic Components

8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

Cleaning the Hydraulic System

8003

Cleaning the Hydraulic System

8003

Hydraulic Pump

8004

Hydraulic Pump

8004

Loader Control Valve

8005

Loader Control Valve

8005

Cylinders

8006

Cylinders

8006

Pilot Pressure Accumulator and Ride Control Accumulator

8013

Pilot Pressure Accumulator and Ride Control Accumulator

8013

Ride Control Valve

8014

Ride Control Valve

8014

W270B Wheel Loader Service Manual

87661531

Table of Contents

Description Mounted Equipment

Section No. Tab 9

Section Index - Mounted Equipment

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 Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant

9002

Air Conditioner System Service

9003

Air Conditioner System Service

9003

Removal and Installation of Air Conditioning and Heater Components

9004

Removal and Installation of Air Conditioning and Heater Components

9004

Loader

9006

Loader

9006

ROPS Cab and ROPS Canpoy

9007

ROPS Cab and ROPS Canpoy

9007

Cab Glass Installation

9010

Cab Glass Installation

9010

Electrical Schematic Foldouts and Hydraulic Schematic Foldout

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

In Rear Pocket

Electrical Schematic Foldouts and Hydraulic Schematic Foldout

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

In Rear Pocket

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section Title

SECTION INDEX

GENERAL

GENERAL Section Number

Section Title

Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002

Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

1001

1001 CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section 1001

GENERAL TORQUE SPECIFICATIONS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

1001-2

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

TABLE OF CONTENTS 3 4 5 6

TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6

1001-3

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

Grade 5 Bolts, Nuts, and Studs

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

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

3/8 inch

420 to 504

48 to 57

9/16 inch

Size

PoundFeet

Newton metres

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1-1/4 inch

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

149 to 179

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

160 to 192

217 to 260

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

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

PoundFeet

Newton metres

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1085 to 1193

1-1/8 inch

800 to 880

1085 to 1193

1120 to 1240

1519 to 1681

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

1-1/2 inch

1940 to 2200

2631 to 2983

7/8 inch 1.0 inch 1-1/8 inch 1-1/4 inch 1-3/8 inch 1-1/2 inch

600 to 720 900 to 1080 1280 to 1440 1820 to 2000 2380 to 2720 3160 to 3560

814 to 976 1220 to 1465 1736 to 1953 2468 to 2712 3227 to 3688 4285 to 4827

NOTE: Use thick nuts with Grade 8 bolts.

1001-4

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

24 to 36

10.9

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.

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

3 to 4

Newton metres

Size

PoundFeet

24 to 36

54 to 64

73 to 87

8.8

PoundInches

Grade 10.9 Bolts, Nuts, and Studs

Size

Grade 8.8 Bolts, Nuts, and Studs

Size

TORQUE SPECIFICATIONS - METRIC HARDWARE

Newton metres

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

3 to 4

Size

PoundFeet

Newton metres

60 to 72

7 to 8

M10

54 to 64

73 to 87

Grade 8.8 Bolts, Nuts, and Studs 8.8

PoundInches

Newton metres

60 to 72

7 to 8

M10

96 to 108

11 to 12

M12

93 to 112

125 to 150

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

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

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

M20

450 to 540

610 to 730

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Grade 12.9 Bolts, Nuts, and Studs 12.9

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

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Grade 12.9 Bolts, Nuts, and Studs 12.9

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

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

37 Degree Flare Fitting

Thread Size

PoundInches

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Newton metres

Tube OD Hose ID

Straight Threads with O-ring

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

37 Degree Flare Fitting

Thread Size

PoundInches

Newton metres

Straight Threads with O-ring

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

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

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

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

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

5/8 inch 15.9 mm

7/8-14

300 to 696

34 to 79 Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

Thread Size

PoundInches

3/4 inch 19.0 mm

1-1/16-12

7/8 inch 22.2 mm

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

40 to 80

54 to 108

3/4 inch 19.0 mm

1-1/16-12

80 to 128

108 to 174

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

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

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

1.0 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

1-1/4 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

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

Size

PoundInches

Newton metres

5/16-18

180 to 240

20 to 27

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton metres

Size

PoundFeet

Newton metres

1/2-13

55 to 65

74 to 88

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

5/8-11

140 to 150

190 to 203

Size

1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Nom. SAE Dash Size

Tube OD

Thread Size

PoundInches

Newton metres

Thread Size

PoundInches

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Newton metres

Nom. SAE Dash Size

Tube OD

O-ring Boss End Fitting or Lock Nut

O-ring Face Seal End

Thread Size

PoundInches

Newton metres

Thread Size

PoundInches

Newton metres

O-ring Boss End Fitting or Lock Nut

O-ring Face Seal End

-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

-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

-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

-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

PoundInches

Newton metres

Thread Size

PoundInches

Newton metres

7/8-14

60 to 65

81 to 88

-10

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

Nom. SAE Dash Size

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

PoundInches

Newton metres

1-3/16-12

95 to 100

129 to 136

5/8 inch 15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread Size

PoundInches

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

-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

-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

-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

-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

-24

1-1/2 inch 38.1 mm

2-12

150 to 180

200 to 254

Section 1002

FLUIDS AND LUBRICANTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

1002

Section 1002

FLUIDS AND LUBRICANTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model W270B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model W270B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 4 4 4 5 5 5 6 6 7 7

CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model W270B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model W270B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 5 5 6 6 7 7

1002-3

CAPACITIES AND LUBRICANTS

Engine Oil Capacity with Filter Change .............................................................................................37 liters (39 U.S. quarts) Type of oil........................... AMBRA Mastergold HSP SAE 15W-40, see engine oil recommendations on page 4

Engine Cooling System Capacity...................................................................................................................56.8 liters (15.0 U.S. Gallons) Type of Coolant ...................................................................AMBRA AgriflĂš 50% water and 50% Ethylene Glycol

Fuel Tank Capacity ................................................................................................................. 393.6 liters (104 U.S. Gallons) Type of Fuel ............................................................................................................. See Diesel fuel specifications

Hydraulic System Hydraulic Reservoir Refill Capacity with Filter Change ................................................130 liters (34 U.S. Gallons) Total System Capacity ............................................................................................242 liters (63.93 U.S. Gallons) Type of Oil .................................................................................................................. AMBRA Hydrosystem 46HV

Transmission Refill Capacity with Filter Change ...............................................................................22 litres (5.81 U.S. Gallons) Type of Oil .................................................................................................. AMBRA Supergold HSP SAE 10W-30

Axles Capacity Front.................................................................................................................... 47.3 litres (12.50 U.S. Quarts) Rear ............................................................................................................................. 53 litres (14 U.S. Quarts Type of Lubricant .....................................................................................AMBRA TRX Transaxle Fluid, 80W-140

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil. Machines are shipped from the factory with break-in oil.

Brake System Type of Fluid (Same as Hydraulic System) ................................................................ AMBRA Hydrosystem 46HV

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

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.

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

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.

1002-4

HYDRAULIC OIL TEMPERATURE CHART

BC06B208

TRANSMISSION OIL TEMPERATURE CHART

BC06B208

TRANSMISSION OIL TEMPERATURE CHART

BC06B209

ENGINE OIL TEMPERATURE CHART

BC06B209

ENGINE OIL TEMPERATURE CHART

BC06B150

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.

1002-5

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

Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ............................................................................................................................................. 34 Flash point, minimum ............................................................................................................................60°C (140°F) Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F) Viscosity, at 38°C (100°F) Centistokes ......................................................................................................................................... 2.0 to 4.3 Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes) Water and sediment, by volume, maximum .................................................................................................... 0.05%

1002-6

MAINTENANCE SCHEDULE

Model W270B

Every 10 Hours

Every 50 Hours

Every 100 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

5-16

Every 6000 Hours

Engine oil level

5-16

Drain fuel filter

5-17

Checking the tension of belts

10 10

Every 10 Hours

5-16

Engine oil level

5-16

Drain fuel filter

5-17

Checking the tension of belts

10 10

Engine coolant level

5-18

Engine coolant level

Radiator and oil cooler

5-18

Radiator and oil cooler

5-19

Transmission oil level

5-19

Transmission oil level

5-19

Hydraulic oil level

5-19

Hydraulic oil level

5-20

Bucket/Attachments grease fittings

5-20

Bucket/Attachments grease fittings

5-20

Grease articulation fittings

5-20

Grease articulation fittings

5-21

Grease points

100

5-21

Grease points

100

5-23

Recirculation air filter

5-23

Recirculation air filter

5-23

Engine coolant filter

5-23

Engine coolant filter

5-24

Tire pressure

5-24

Tire pressure

250 250

Every 250 Hours

250

5-26

Replace fuel filter

5-27

Axle oil level

500

5-27

Battery electrolyte level

500

5-28

Change engine oil and filter

250

Every 500 Hours

500

5-29

Drain fuel tank condensation

5-30

Replace hydraulic oil filters

5-31

Grease articulation fittings

5-31

Change front and rear axle oil

1000

5-32

Replace cab air filters

1000

5-33

Change transmission oil and filters

1000

Check valve adjustment

Every 100 Hours

500 1000 1000

See your New Holland Dealer or refer to Service Manual

5-34

Change hydraulic oil

2000

5-35

Change coolant

2000

5-36

Replace engine air cleaner

Every 1000 Hours

Every 2000 Hours

2000

Engine Injectors

See your New Holland Dealer or refer to Service Manual

Fuel pump

See your New Holland Dealer or refer to Service Manual

Every 6000 Hours

250 250 250

5-26

Replace fuel filter

5-27

Axle oil level

500

5-27

Battery electrolyte level

500

5-28

Change engine oil and filter

250

500

5-29

Drain fuel tank condensation

5-30

Replace hydraulic oil filters

5-31

Grease articulation fittings

5-31

Change front and rear axle oil

1000

5-32

Replace cab air filters

1000

5-33

Change transmission oil and filters

1000

Every 1500 Hours

Check valve adjustment

DRAIN

LUBRICATE

5-18

Every 50 Hours

REPLACE

CHECK

CLEAN

SERVICE POINTS

INITIAL NEW MACHINE

PAGE

DRAIN

LUBRICATE

REPLACE

CHECK

INTERVALS IN HOURS SERVICE INTERVALS

5-18

Every 1500 Hours Every 2000 Hours

SERVICE POINTS

CLEAN

PAGE

INITIAL NEW MACHINE

INTERVALS IN HOURS SERVICE INTERVALS

500 1000 1000

See your New Holland Dealer or refer to Service Manual

5-34

Change hydraulic oil

2000

5-35

Change coolant

2000

5-36

Replace engine air cleaner

2000

Engine Injectors

See your New Holland Dealer or refer to Service Manual

Fuel pump

See your New Holland Dealer or refer to Service Manual

1002-7

MAINTENANCE POINTS

Model W270B

W270M115

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

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

W270M115

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

1002-8

NOTES

METRIC CONVERSION CHART

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

1003

Section 1003

1003

Section 1003

METRIC CONVERSION CHART

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

1003-2

TABLE OF CONTENTS

CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1003-3

CONVERSION FACTORS

Metric to U.S.

MULTIPLY

TO OBTAIN

MULTIPLY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

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

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

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C +32

degree F

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

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

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:

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)

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

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

1003-4

U.S. to Metric

MULTIPLY

TO OBTAIN

MULTIPLY

TO OBTAIN

Area:

square foot acre

0.092 903 0.404 686

square meter hectare

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

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

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:

pound ounce

0.453 592 28.35

kilogram gram

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Power:

horsepower

0.745 700

kilowatt

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

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

Temperature:

degree F

1.8 F - 32

degree C

Torque:

pound/inch pound/foot

0.112 985 1.355 818

newton meter newton meter

Torque:

pound/inch pound/foot

0.112 985 1.355 818

newton meter newton meter

Velocity:

miles/hr.

1.609 344 *

kilometer/hr.

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:

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.

Volume/Time:

gallon/min.

3.785 412

litre/min.

* = exact

Section Title

SECTION INDEX

ENGINES

ENGINES Section Number

Section Title

Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003

FOR THE REMOVAL, INSPECTION, OVERHAUL AND REINSTALLATION OF THE ENGINE, PLEASE REFER TO THE SPECIFIC MANUALS FOR THIS TYPE OF ENGINE AVAILABLE FROM THE SERVICE NETWORK.

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

2000

Section 2000

2000

Section 2000

2000-2

TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 4 4 14 26 26 28

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 14 26 26 28

2000-3

39 40

39 40 37 38

29 31 32

35 36 3

37 38

29 31 32

35 36

33 34

35 36

33 34

35 36

22 25 21

4 12

14 16 17

16 17

8 6

7 6

15 9

11 W270-1R003

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

RIGHT AFTERCOOLER TUBE LEFT AFTERCOOLER TUBE HOSE HOSE HOSE CLAMP WASHER MOUNT

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

PLATE BOLT WASHER BOLT NUT HOSE CLAMP

15. 16. 17. 18. 19. 20. 21.

HOSE PIPE CLAMP BOLT BUSHING PIN HOSEE

22. 23. 24. 25. 26. 27. 28.

TUBE HOSE CLAMP CLAMPA TAPE ADESIVE HOSE STRAP

29. 30. 31. 32. 33. 34. 35.

BRACKET MOUNT WASHER BOLT WASHER NUT WASHER

36. 37. 38. 39. 40. 41.

BOLT WASHER BOLT WASHER BOLT SPACER

W270-1R003

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

RIGHT AFTERCOOLER TUBE LEFT AFTERCOOLER TUBE HOSE HOSE HOSE CLAMP WASHER MOUNT

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

PLATE BOLT WASHER BOLT NUT HOSE CLAMP

15. 16. 17. 18. 19. 20. 21.

HOSE PIPE CLAMP BOLT BUSHING PIN HOSEE

22. 23. 24. 25. 26. 27. 28.

TUBE HOSE CLAMP CLAMPA TAPE ADESIVE HOSE STRAP

29. 30. 31. 32. 33. 34. 35.

BRACKET MOUNT WASHER BOLT WASHER NUT WASHER

36. 37. 38. 39. 40. 41.

BOLT WASHER BOLT WASHER BOLT SPACER

2000-4

ENGINE Removal

STEP 3

STEP 1

STEP 3

STEP 1

W270-1R008

W270-1R006

Park the machine on a flat surface and lower the bucket to the round. Place the articulation block in BLOCK position.

Open the engine hood upper side panels and remove the engine hood lower side panels, by turning the two plastic blocks indicated in the figure.

STEP 4

STEP 2

W270-1R008

W270-1R006

Park the machine on a flat surface and lower the bucket to the round. Place the articulation block in BLOCK position.

Open the engine hood upper side panels and remove the engine hood lower side panels, by turning the two plastic blocks indicated in the figure.

STEP 4

STEP 2

W270-1R007

Cut-off the engine. Actuate the brake pedal a few times to discharge the brake accumulators. Rotate the starter key into "contact" position and move the loader control levers forward and backward to bleed the pressure from the hydraulic circuit. Rotate the battery cut-off switch into position OFF, as indicated in the figure.

W270-1R009

Drain the hydraulic oil from the reservoir using a hose from the draining valve into a container of appropriate capacity (130 litres - 34 US Gal) to keep the liquid drained. To facilitate the operation, loosen the filler cap on the hydraulic tank.

W270-1R007

2000-5

STEP 5

STEP 7

2000-5

STEP 5

STEP 7

W270-1R010

W270-1R012

W270-1R010

W270-1R012

Place a container of appropriate capacity under the machine in correspondence with the radiator draining pipe. Open the valve and drain the coolant into the container. To facilitate the draining of the coolant loosen the filler cap.

Sling and hold the left rear mudguard complete with handrail and remove it from the machine by removing the securing screws (q.ty 6). Replicate the operation on the right rear mudguard.

STEP 8

STEP 6

STEP 8

STEP 6

W270-1R013 W270-1R011

Place a container of about 45 litres - 12 US Gal under the transmission oil draining and drain it by loosening the securing screws (q.ty 2) indicated in the figure holding the oil filler plug.

Also, sling and hold the cab left side ladder, then remove it from the machine removing the relevant screws (q.ty 6). Replicate the operation on the right ladder.

W270-1R013 W270-1R011

Place a container of about 45 litres - 12 US Gal under the transmission oil draining and drain it by loosening the securing screws (q.ty 2) indicated in the figure holding the oil filler plug.

Also, sling and hold the cab left side ladder, then remove it from the machine removing the relevant screws (q.ty 6). Replicate the operation on the right ladder.

2000-6

STEP 9

STEP 12

STEP 9

STEP 12

W270-1R014

W270-1R017

W270-1R014

W270-1R017

Remove the left side upper door from the relevant hinges indicated in the figure. Replicate the operation on the right side upper door.

Remove dust ejector rubber hose (1) by loosening the clamps (2).

Remove the left side upper door from the relevant hinges indicated in the figure. Replicate the operation on the right side upper door.

Remove dust ejector rubber hose (1) by loosening the clamps (2).

STEP 13

STEP 10

STEP 13

STEP 10 2

W270-1R018 W270-1R015

From the engine upper hood, loosen the clamp (1) and remove the air cleaner rain guard device (2).

STEP 11

Remove the fumes exhaust pipe from the engine upper hood by removing the securing nuts (q.ty 4) under the hood from the studs welded to the pipe support plate.

W270-1R018 W270-1R015

From the engine upper hood, loosen the clamp (1) and remove the air cleaner rain guard device (2).

STEP 11

W270-1R016

Remove pipe (1) from the turbocharger to the silencer by loosening the clamps (2).

Remove the fumes exhaust pipe from the engine upper hood by removing the securing nuts (q.ty 4) under the hood from the studs welded to the pipe support plate.

2000-7

STEP 14

STEP 16

2000-7

STEP 14

STEP 16

W270-1R019

W270-1R021

W270-1R019

W270-1R021

Remove the front upper hood by removing the securing screws (q.ty 8). Sling the hood in an appropriate manner, lift it and rest it onto the ground.

Open the radiator-after cooling rear guard grill by unscrewing side screws (1, q.ty 2) to reach the disassembly screws of the rear upper engine hood. Secure the grill using the rod located on the right side of the radiator compartment.

Remove the front upper hood by removing the securing screws (q.ty 8). Sling the hood in an appropriate manner, lift it and rest it onto the ground.

STEP 15 2

STEP 15

STEP 17

W270-1R020

Remove silencer (1) from the supports located on the beams of the engine upper hood by removing the securing nuts (q.ty 4) from rubber pad blocks (2, q.ty 4).

W270-1R020

W270-1R022

Remove securing screws (1, q.ty 3) of the engine upper rear hood.

STEP 18

Remove silencer (1) from the supports located on the beams of the engine upper hood by removing the securing nuts (q.ty 4) from rubber pad blocks (2, q.ty 4).

W270-1R022

Remove securing screws (1, q.ty 3) of the engine upper rear hood.

STEP 18

W270-1R023

Remove hood (1) from the machine.

W270-1R023

Remove hood (1) from the machine.

2000-8

STEP 19

STEP 22

STEP 19

STEP 22

W270-1R024

W270-1R027

W270-1R024

W270-1R027

Disconnect hose (1) between the coolant tank and the radiator.

Remove air-cooling steel pipe (1) from the engine to the radiator-after cooler by opening of the clamps (2, q.ty 2).

Disconnect hose (1) between the coolant tank and the radiator.

Remove air-cooling steel pipe (1) from the engine to the radiator-after cooler by opening of the clamps (2, q.ty 2).

STEP 20

STEP 23

W270-1R025

Remove the engine central upper hood by removing all the securing screws (q.ty 15).

STEP 21

W270-1R025 W270-1R028

Disconnect the air pipe (1) from the turbocharger to the radiator-aftercooler.

Remove the engine central upper hood by removing all the securing screws (q.ty 15).

STEP 21

STEP 24

Disconnect the air pipe (1) from the turbocharger to the radiator-aftercooler.

STEP 24

W270-1R026

Sling the hood in an appropriate manner, lift it and rest it onto the ground.

W270-1R028

W270-1R026 W270-1R029

Disconnect pipe (1) from the water pump to the radiator by loosening the clamps (q.ty 3).

Sling the hood in an appropriate manner, lift it and rest it onto the ground.

W270-1R029

Disconnect pipe (1) from the water pump to the radiator by loosening the clamps (q.ty 3).

2000-9

STEP 25

STEP 28

2000-9

STEP 25

STEP 28 1

2 W270-1R030

W270-1R033

W270-1R030

W270-1R033

Disconnect the engine air cleaner suction pipe (1) by loosening the clamps (2, q.ty 2).

From the right side of the central sector located between the engine and radiator-after cooler remove panel (1) by removing the securing screws (q.ty 9) to reach to the engine air cleaner removing screws.

Disconnect the engine air cleaner suction pipe (1) by loosening the clamps (2, q.ty 2).

STEP 26 3

STEP 29

2 1

1 W270-1R031

If the machine is equipped with air conditioner, recover the gas making reference to section 9003 then identify tag and disconnect de-hydration filter (1) electric connection (2) and pipe (3).

STEP 27

W270-1R031

Remove screws (1, q.ty 4) securing the engine air cleaner to the sector through the opening.

If the machine is equipped with air conditioner, recover the gas making reference to section 9003 then identify tag and disconnect de-hydration filter (1) electric connection (2) and pipe (3).

Remove screws (1, q.ty 4) securing the engine air cleaner to the sector through the opening.

STEP 30

STEP 27

STEP 30

W270-1R034

W270-1R032

Tag and disconnect hose (1) from the condenser to the cab conditioner compressor.

W270-1R035

Remove engine air cleaner (1).

W270-1R034

W270-1R032

Tag and disconnect hose (1) from the condenser to the cab conditioner compressor.

W270-1R035

Remove engine air cleaner (1).

2000-10

STEP 31

STEP 33

STEP 31

STEP 33

4 1

W270-1R036

W270-1R038

W270-1R036

W270-1R038

Use adequate cables for the weight to be lifted to sling the central sector located between the engine and the radiator-after cooler to prevent accidental falls during the disassembly phase of the machine.

Identify, tag and disconnect hoses (2,3,4,5) from the radiator liquid tank (1).

STEP 34

STEP 32

STEP 34

STEP 32 2

1 3

1 W270-1R039

W270-1R037

Free the sector from safety chain (1) of the fuel cap and engine oil dipstick (2). Remove the sector from engine compartment by removing securing screws (3, q.ty 4).

From the left side of the engine, shut valve (1) of the cab heating pipes.

W270-1R039

W270-1R037

Free the sector from safety chain (1) of the fuel cap and engine oil dipstick (2). Remove the sector from engine compartment by removing securing screws (3, q.ty 4).

STEP 35 1 2

From the left side of the engine, shut valve (1) of the cab heating pipes.

STEP 35 1 2

W270-1R040

If the machine is equipped with air conditioning, identify, tag and disconnect the refrigerant gas high-pressure the pipings (2) from compressor (1).

2000-11

STEP 36

STEP 39

2000-11

STEP 36

STEP 39

1 1

W270-1R041

W270-1R044

W270-1R041

W270-1R044

Remove the fuel feeding (1) pipe from engine controller and the piping and filter (2).

Disconnect the two electric connections (1) from the engine controller by removing the locking screw using a 4 mm Allen wrench.

Remove the fuel feeding (1) pipe from engine controller and the piping and filter (2).

Disconnect the two electric connections (1) from the engine controller by removing the locking screw using a 4 mm Allen wrench.

STEP 37

STEP 40

1 3

W270-1R042

Identify, tag and disconnect the electric connections indicated from starter motor (1). Remove relay cover (2) from the relay box by removing screw (3) to access the box securing nuts on the hydraulic oil tank.

W270-1R042 W270-1R045

Identify, tag and disconnect the electric connections indicated from the alternator.

STEP 41

STEP 38

W270-1R045

Identify, tag and disconnect the electric connections indicated from the alternator.

STEP 41

STEP 38

W270-1R043

Remove nuts (1, q.ty 2) and remove the fuses and relays box.

W270-1R046

Identify, tag and disconnect all the pipes and hoses connected to the lower side of the hydraulic oil tank.

W270-1R043

Remove nuts (1, q.ty 2) and remove the fuses and relays box.

2000-12

STEP 42

STEP 44

STEP 42

STEP 44

W270-1R047

W270-1R049

W270-1R047

W270-1R049

Install two lifting eyes on the upper side of the hydraulic oil tank then use appropriate chains to sling and hold the tank to prevent accidental falls during the disassembly phase of the machine.

Using the chains previously installed, lift the tank paying attention to any possible spill of residual oil from the tank. Rest the tank on the appropriate supporting stand.

Install two lifting eyes on the upper side of the hydraulic oil tank then use appropriate chains to sling and hold the tank to prevent accidental falls during the disassembly phase of the machine.

Using the chains previously installed, lift the tank paying attention to any possible spill of residual oil from the tank. Rest the tank on the appropriate supporting stand.

STEP 43

STEP 45

STEP 43

STEP 45

W270-1R048

W270-1R050

W270-1R048

W270-1R050

Remove the screws (q.ty 4) securing the hydraulic oil tank to the rear frame of the machine.

Remove the cab from the machine, making reference to section 9007.

Remove the screws (q.ty 4) securing the hydraulic oil tank to the rear frame of the machine.

Remove the cab from the machine, making reference to section 9007.

STEP 46

Disconnect all hydraulic lines, electric connections and propeller shafts from the transmission, following the procedure described in section 6001.

2000-13

STEP 47

STEP 50

2000-13

STEP 47

STEP 50

W270-1R051

W270-1R054

W270-1R051

W270-1R054

Remove the screws from the engine front supports (q.ty 2).

Install adjustable chains, as indicated in the figure, to the transmission-torque converter group to make the performance of the subsequent operations safe.

Remove the screws from the engine front supports (q.ty 2).

Install adjustable chains, as indicated in the figure, to the transmission-torque converter group to make the performance of the subsequent operations safe.

STEP 48

STEP 51

STEP 51 2

W270-1R052

Replicate the operation for the engine rear support.

W270-1R052 W270-1R055

From the right side of the engine-transmission group, remove panel (1) located on the torque converter cover by removing screws (2, q.ty 4) to reach the securing screws engine-converter coupling located inside.

STEP 49

Replicate the operation for the engine rear support.

W270-1R055

STEP 49

W270-1R053

Install chains with the appropriate load lifting capacity on the three designated points located on the engine and lift slowly the engine-transmission group from the frame. Make sure that all harnesses and hoses have been disconnected. Remove the group from the machine and rest it on an appropriate stand.

2000-14

STEP 52

STEP 54

STEP 52

W270-1R058

Using the adjustable chains previously installed, remove the transmission group from the engine group and rest it on an appropriate stand.

Installation

STEP 55

If the rubber pad devices of the engine (7, see figure at page 3) and transmission (30) must be replaced and install new rubber pad.

W270-1R056

Remove the inner screws (q.ty 12) turning the engine crankshaft. For this operation, remove two screws from vibration dumper, insert on the vibration dumper the tool illustrated on the page, reinstall with the two screws removed then turn slowly the engine crankshaft by means of a lever.

STEP 54

W270-1R056

STEP 56

STEP 53

STEP 56

STEP 53

W270-1R059

Grease the mounting flanges of the transmission group and the engine group for the subsequent coupling phase.

W270-1R057

Remove the outer screws (q.ty 12) securing the torque converter cover to the engine.

2000-15

STEP 57

STEP 59

2000-15

STEP 57

STEP 59

W270-1R060

W270-1R062

W270-1R060

W270-1R062

Using the adju stab le chains insta lled o n the transmission group, proceed with the coupling with the engine group. Pay special attention, during the lifting of the transmission group, to the perfect balancing and alignment with the engine group.

From the side right opening located on the transmission converter cover, insert, without tightening them, all the inner screws (q.ty 12) turning progressively the engine crankshaft. For this operation, remove two screws from the vibration dumper, insert on the vibration dumper the tool indicated on the page 25, with the two screws removed, and then turn slowly the crankshaft by means of a lever. Tighten all the screws to a torque of 40 lb-ft (55 Nm).

STEP 58

STEP 60

W270-1R061

Insert, at first, two or three outer screws, without tightening them , to try aligning perfectly the transmission group with the engine group. Then insert all the outer screws (q.ty 12) tightening them to a torque of 48 lb-ft (65 Nm).

W270-1R063

Insert the closing panel on the access opening of the inner screws applying first some sealant along the perimeter of the panel. Secure it using screws (1, q.ty 4).

W270-1R063

Insert the closing panel on the access opening of the inner screws applying first some sealant along the perimeter of the panel. Secure it using screws (1, q.ty 4).

2000-16

STEP 61

STEP 63

STEP 61

STEP 63

W270-1R053

W270-1R065

W270-1R053

W270-1R065

Install on the engine-transmission group adjustable chains of appropriate lifting capacity. These chains must be mounted on the three appropriate lifting points provided for such operation.

Align perfectly the support holes and insert, without tightening them, the securing screws complete with washers and nuts (1, q.ty 2) on the two engine rear supports to be used as a guide for the correct positioning of the engine-transmission group on the rear frame of the machine.

Install on the engine-transmission group adjustable chains of appropriate lifting capacity. These chains must be mounted on the three appropriate lifting points provided for such operation.

STEP 62

STEP 64

W270-1R064

Lift slowly the engine-transmission group and position it on the rear frame. Make sure that all harness and hose connections are not interfering, then lower the group.

W270-1R064

W270-1R066

Insert, without tightening them, securing screws (1, q.ty 2) complete with washers and nuts on the transmission supports. Make sure that the engine-transmission group is properly positioned on the frame, then tighten to a torque between 685 to 770 lb-ft (929 and 1044 Nm) the front support screws and a torque of 285 to 320 lb-ft (386 through 434 Nm) the nuts of the rear supports.

Lift slowly the engine-transmission group and position it on the rear frame. Make sure that all harness and hose connections are not interfering, then lower the group.

W270-1R066

STEP 65

Connect all the hydraulic lines and electric connections to the transmission, following the procedures described in section 6001.

2000-17

STEP 66

STEP 68

2000-17

STEP 66

STEP 68

W270-1R067

W270-1R048

W270-1R067

W270-1R048

Install lifting eyes on the hydraulic oil tank and, using chains of appropriate lifting capacity, lift it and position it on the frame of the machine for the subsequent securing phases.

Tighten the tank securing screws to a torque of 220 lb-ft (300 Nm).

Install lifting eyes on the hydraulic oil tank and, using chains of appropriate lifting capacity, lift it and position it on the frame of the machine for the subsequent securing phases.

Tighten the tank securing screws to a torque of 220 lb-ft (300 Nm).

STEP 69 4

STEP 67

5 1

STEP 69 4

STEP 67

5 1

3 3

1 W270-1R038

W270-1R068

Insert the screws securing the hydraulic oil tank (q.ty 4) to the rear frame of the machine and connect, during this phase, sleeves (1) and hoses (2) to the relevant connection properly greased. Tighten the sleeves using the metal clamps tightening device (3).

Connect hoses (2,3,4,5) to radiator liquid tank (1) tightening the relatives clamps.

W270-1R038

W270-1R068

STEP 70

Connect hoses (2,3,4,5) to radiator liquid tank (1) tightening the relatives clamps.

STEP 70

W270-1R036

Using cables, sling properly the sector, lift it and position it on the rear frame of the machine, between engine and radiator-after cooler, for the subsequent reinstallation phase.

2000-18

STEP 71

STEP 74

STEP 71

STEP 74

W270-1R035

W270-1R072

W270-1R035

W270-1R072

Prior to securing the sector, install engine air cleaner (1) otherwise, its installation could become difficult.

Secure electric connection (1) on the sector installing screws (2, q.ty 2) on the mounting brackets.

Prior to securing the sector, install engine air cleaner (1) otherwise, its installation could become difficult.

Secure electric connection (1) on the sector installing screws (2, q.ty 2) on the mounting brackets.

STEP 72

STEP 75

STEP 72

STEP 75

W270-1R034

W270-1R073

W270-1R034

W270-1R073

Insert screws (1, q.ty 4) securing the air cleaner through the right side opening of the sector.

Secure the sector on the rear frame of the machine tightening screws (1, q.ty 4) to a torque of 80 lb-ft (110 Nm).

Insert screws (1, q.ty 4) securing the air cleaner through the right side opening of the sector.

Secure the sector on the rear frame of the machine tightening screws (1, q.ty 4) to a torque of 80 lb-ft (110 Nm).

STEP 73

STEP 76

STEP 76 3

1 1

W270-1R071

Install the panel on the opening engine wall and secure it with screws (1, q.ty 9).

W270-1R071 W270-1R031

If the machine is equipped with air conditioner, connect de-hydration filter (1) electric connection (2), pipe (3) and the refrigerant gas of the pipings on the compressor.

Install the panel on the opening engine wall and secure it with screws (1, q.ty 9).

W270-1R031

If the machine is equipped with air conditioner, connect de-hydration filter (1) electric connection (2), pipe (3) and the refrigerant gas of the pipings on the compressor.

2000-19

STEP 77

STEP 80

2000-19

STEP 77

STEP 80

1 W270-1R029

W270-1R027

W270-1R029

W270-1R027

Connect engine cooling pipe (1) using by means the clamps.

Connect air-cooling pipe (1) from the engine to the radiator-aftercooler with the clamps (2).

Connect engine cooling pipe (1) using by means the clamps.

Connect air-cooling pipe (1) from the engine to the radiator-aftercooler with the clamps (2).

STEP 78

STEP 81

STEP 78

STEP 81

2 W270-1R030

W270-1R026

W270-1R030

W270-1R026

Connect engine air cleaner suction pipe (1) with the clamps (2).

Use cables to sling appropriately the central upper engine hood and position it on the machine for the subsequent reinstallation phase. Secure the hood to the machine, installing, without tightening them all the screws (q.ty 15).

Connect engine air cleaner suction pipe (1) with the clamps (2).

STEP 79 1

W270-1R028

Connect air heating pipe (1) from the engine to the radiator-aftercooler with the clamps.

2000-20

STEP 82

STEP 85

STEP 82

STEP 85

W270-1R024

W270-1R020

W270-1R024

W270-1R020

Connect hose (1) between the radiator coolant tank and the radiator and secure it in the two points arranged along the right beam of the upper central engine hood.

Install silencer (1) on the supports located on the two engine upper hood inserting the securing nuts (q.ty 4) and the relevant rubber pad (2, q.ty 4).

Connect hose (1) between the radiator coolant tank and the radiator and secure it in the two points arranged along the right beam of the upper central engine hood.

Install silencer (1) on the supports located on the two engine upper hood inserting the securing nuts (q.ty 4) and the relevant rubber pad (2, q.ty 4).

STEP 86

STEP 83

STEP 86

STEP 83 2

2 W270-1R017

W270-1R017

Position engine rear upper hood (1) on the machine.

Connect dust ejector rubber hose (1) to the silencer tightening the two clamps (2).

Position engine rear upper hood (1) on the machine.

Connect dust ejector rubber hose (1) to the silencer tightening the two clamps (2).

STEP 84

STEP 87

STEP 84

STEP 87

W270-1R023

1 2

W270-1R022

W270-1R081

W270-1R022

W270-1R081

Open the radiator-after cooler rear guard grill by loosening the side screws (q.ty 2) to access the hood securing screws (1, q.ty 3). Tigh the three srews of the upper rear hood.

Install pipe (1) from the turbocharger to the silencer tightening holders (2).

Open the radiator-after cooler rear guard grill by loosening the side screws (q.ty 2) to access the hood securing screws (1, q.ty 3). Tigh the three srews of the upper rear hood.

Install pipe (1) from the turbocharger to the silencer tightening holders (2).

2000-21

STEP 88

STEP 90

2000-21

STEP 88

STEP 90

W270-1R019

W270-1R018

W270-1R019

W270-1R018

Use lifting cables to sling the engine front upper hood and position it on the machine for the securing phase by inserting the screws (q.ty 8) without tightening them. After positioning correctly the three parts of the engine upper hood, tighten all the screws of the hood assembly.

Install the fumes exhaust pipe on the engine upper hood, inserting from the lower side of the hood itself, the securing nuts (q.ty 4) on the studs welded on the pipe supporting plate.

STEP 91

STEP 89

STEP 91

STEP 89 2

1 W270-1R050

W270-1R015

Install air cleaner rain guard device (1) on the engine upper hood tightening the clamp (2).

Reinstall the cab on the machine referring to the procedures described in section 9007.

W270-1R050

W270-1R015

Install air cleaner rain guard device (1) on the engine upper hood tightening the clamp (2).

STEP 92

Reinstall the cab on the machine referring to the procedures described in section 9007.

STEP 92

W270-1R045

Connect the electric connections indicated on the alternator.

2000-22

STEP 93

STEP 96

STEP 93

STEP 96

W270-1R044

W270-1R041

W270-1R044

W270-1R041

Connect the electric connections indicated (1) on the engine controller tightening the securing screw using a 4 mm Allen wrench.

Connect the two fuel feeding hoses on engine controller (1) and on filter (2).

Connect the electric connections indicated (1) on the engine controller tightening the securing screw using a 4 mm Allen wrench.

Connect the two fuel feeding hoses on engine controller (1) and on filter (2).

STEP 94

STEP 97 Reconnect the transmission propeller shafts following the procedure described in section 6001.

STEP 94

STEP 97 Reconnect the transmission propeller shafts following the procedure described in section 6001.

STEP 98

W270-1R043

Install the fuse and relay box on the hydraulic oil tank using screws (1, q.ty 2).

Install the fuse and relay box on the hydraulic oil tank using screws (1, q.ty 2). W270-1R084

STEP 95

Install the left upper side door on the relevant hinges by inserting screw (1, q.ty 4) and securing nut (2). Replicate the operation on the right upper side door.

W270-1R084

STEP 95

Install the left upper side door on the relevant hinges by inserting screw (1, q.ty 4) and securing nut (2). Replicate the operation on the right upper side door.

1 3

W270-1R042

Install cover (2) on the fuse box inserting screw (3) and connect the electric connections indicated on starter motor (1).

2000-23

STEP 99

STEP 101

2000-23

STEP 99

STEP 101

W270-1R013

W270-1R008

W270-1R013

W270-1R008

Using lifting cables, sling and lift the left cab climbing ladder and rest it on the machine, then reinstall it using the securing screws (q.ty 6). Replicate the operation for the climbing ladder on the right side.

Secure the engine hood lower side panels turning the plastic blocks indicated in the figure.

STEP 100

STEP 102

STEP 100

W270-1R012

Again, use lifting cables to sling, lift and rest the left rear mudguard complete with handrail on the machine and secure it with the relevant screws (q.ty 6).

STEP 102 1

W270-1R085

Fill the transmission with oil through filler neck (1) monitoring level indicator light (2), since the filling must occur in a progressive manner to prevent spilling oil from the filler neck.Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks. After two minutes stop the engine. Wait for the engine oil to drain down for an accurate read on the dipstick. Check the dipstick and add additional oil, if necessary. For the specifications, please refer to section 1002.

W270-1R012

Again, use lifting cables to sling, lift and rest the left rear mudguard complete with handrail on the machine and secure it with the relevant screws (q.ty 6).

2000-24

STEP 103

STEP 106

STEP 103

STEP 106

W270-1R086

W270-1R088

W270-1R086

W270-1R088

Fill the engine cooling system through the filler neck located on the upper hood with a 50/50 mixture of water and ethylene glycol. For the specifications, please refer to section 1002. Reinstall the radiator cap.

Move the main battery switch onto ON. Start the engine and idle it. Let the engine run for about five minutes at operating temperature to mix thoroughly the water and the anti freeze. Once the coolant reaches the operating temperature, cut-off the engine. Once the engine has cooled-off, check the level of the coolant in the tank.

STEP 104

WARNING: hot coolant could spill under pressure when removing the radiator cap. To remove the radiator cap, let the system cool-off, turn the cap very slowly, and wait for the pressure to bleed completely.

W270-1R087

Fill the hydraulic oil tank through the filler neck. Monitor level the hydraulic oil indicator light, since the filling must occur in a progressive manner to prevent spilling oil from the filler neck. Start the engine and run at 1000 rpm. Check for leakage around the filter and drain. Operate the loader controls several times to remove any air in the lines. Place the bucket/attachment on the ground and stop the engine. Check the hydraulic oil level and if it is necessary to top off with more oil.

STEP 105

When the machine is equipped with air conditioner, charge the cooling gas making reference to the procedures described in section 9003.

2000-25

9,5

Ø38 20 5

Ø97

Ø38 20

9,5

2000-25

15 97 Ø130

97 Ø130

measures in mm

measures in mm W270-1R089

Tool for rotation engine crankshaft during the assembly / disassembly phase between engine and transmission.

W270-1R089

Tool for rotation engine crankshaft during the assembly / disassembly phase between engine and transmission.

W270-1R090

2000-26

RADIATOR Removal

STEP 3

STEP 1

STEP 3

STEP 1

W270-1R010

Park the machine on a flat surface and lower the bucket to the round. Place the articulation block in BLOCK position.

STEP 2

STEP 4

STEP 2

STEP 4

W270-1R006

Remove the left and right panels from the machine and the engine upper hood assembly following the procedure described in the chapter relative to the removal of the engine.

STEP 5

W270-1R007

Cut-off the engine. Actuate the brake pedal a few times to discharge the brake accumulators. Move the starter key into "contact" position and move the loader control lever forward and backward to bleed the pressure from the hydraulic circuit. Move the battery cut-off switch into position OFF, as indicated in the figure.

2 W270-1R091

Open radiator guard grill (1) by loosening side screws (2, q.ty 2) and secure the grill using the metal rod located on the right side.

2 W270-1R091

Open radiator guard grill (1) by loosening side screws (2, q.ty 2) and secure the grill using the metal rod located on the right side.

2000-27

STEP 6

STEP 9

2000-27

STEP 6

STEP 9

1 1

W270-1R093

W270-1R095

W270-1R093

W270-1R095

Disconnect lights electric connection (1).

Remove securing screws (1, q.ty 2).

Disconnect lights electric connection (1).

Remove securing screws (1, q.ty 2).

STEP 7

STEP 10

STEP 7

STEP 10

1 W270-1R092

W270-1R096

W270-1R092

W270-1R096

Remove supports (1, q.ty 2) of rear lights (2) removing the securing screws (q.ty 3 for each support).

With the cables previously installed, lift the grill and rest it on the ground.

Remove supports (1, q.ty 2) of rear lights (2) removing the securing screws (q.ty 3 for each support).

With the cables previously installed, lift the grill and rest it on the ground.

STEP 11

STEP 8

STEP 11

STEP 8 1

2 3

2 W270-1R097

W270-1R094

Use lifting cables to sling and hold grill (1) complete with frame (2) to prevent accidental falls during the installation phase of the securing screws.

Remove securing screws (1,q.ty 4) of the radiator fan, remove the fan and disconnect pipes (2,3) from the hydraulic motor.

W270-1R097 W270-1R094

Use lifting cables to sling and hold grill (1) complete with frame (2) to prevent accidental falls during the installation phase of the securing screws.

Remove securing screws (1,q.ty 4) of the radiator fan, remove the fan and disconnect pipes (2,3) from the hydraulic motor.

2000-28

STEP 12

STEP 14

STEP 12

STEP 14

W270-1R098

W270-1R099

W270-1R098

W270-1R099

Remove the radiator fan housing by removing screws (1, q.ty 8) and free electric connection (2) attached to it.

Use adjustable chains to properly sling and hold the radiator-after cooler group to prevent accidental falls, for the subsequent removal phase from the machine.

Remove the radiator fan housing by removing screws (1, q.ty 8) and free electric connection (2) attached to it.

Use adjustable chains to properly sling and hold the radiator-after cooler group to prevent accidental falls, for the subsequent removal phase from the machine.

STEP 13

STEP 15

STEP 13

STEP 15

W270-1R101

W270-1R100

W270-1R101

W270-1R100

Disconnect all the hoses from the lower side of the radiator and the ground cable of the cooling group.

Remove from the radiator screws (1, q.ty 4) complete with rubber pad devices and the relevant washers securing it on the machine, then lift it and rest it onto the ground.

Disconnect all the hoses from the lower side of the radiator and the ground cable of the cooling group.

Remove from the radiator screws (1, q.ty 4) complete with rubber pad devices and the relevant washers securing it on the machine, then lift it and rest it onto the ground.

Installation

STEP 16

To install the radiator-after cooler group and fan guard grill, reverse the removal operation.

2000-29

STEP 17

2000-29

STEP 17

W270-1R086

Fill the engine cooling system through the filler located on the upper hood with a mixture of 50 % water and 50 % glycol ethyl anti freeze. Please refer to section 1002 for the specifications. Reinstall the cap on the radiator.

STEP 18

W270-1R088

Move the main battery switch onto ON. Start the engine and let it idle. Have the engine running for about five minutes at operating temperature to fully mix water and anti freeze. Once the coolant reaches the operating temperature, cut-off the engine. Once the engine has cooled off, check the coolant level in the tank.

2000-30

NOTES

AFTERCOOLER

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

2003

Section 2003

2003

Section 2003

AFTERCOOLER

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

2003-2

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

TABLE OF CONTENTS 3 4 4 7 7

TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 7 7

2003-3

2 1

W270-1R004

1. RADIATOR 2. WASHER

3. BOLT 4. BOLT

W270-1R004

1. RADIATOR 2. WASHER

3. BOLT 4. BOLT

2003-4

13 14

4 6

1 22

2 21

11 11

5 8

12 11

W270-1R005

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

FRAME COOLER CHARGE AIR COOLER FUEL CENTER BONDED BRACKET WASHER

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

BOLT WASHER NUT BOLT WASHER BOLT

13. COOLER, HYDRAULIC TRANSMISSION 14. BOLT 15. WASHER 16. BOLT 17. MOUNT

18. 19. 20. 21. 22. 23.

TRIM WASHER NUT NUT BRACKET REAR CHASSIS

W270-1R005

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

FRAME COOLER CHARGE AIR COOLER FUEL CENTER BONDED BRACKET WASHER

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

BOLT WASHER NUT BOLT WASHER BOLT

13. COOLER, HYDRAULIC TRANSMISSION 14. BOLT 15. WASHER 16. BOLT 17. MOUNT

18. 19. 20. 21. 22. 23.

TRIM WASHER NUT NUT BRACKET REAR CHASSIS

2003-5

TROUBLESHOOTING AFTERCOOLER STEP 1

TROUBLESHOOTING AFTERCOOLER

STEP 5

STEP 1

STEP 5

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

STEP 2

BD07B196

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

BD07B212

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

STEP 3

Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. If the pressure difference is greater than 67.6 m Bar (0.98 psi), inspect cooler components for damaged or missing parts.

STEP 4

BD07B195

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

STEP 6

STEP 4

BD07B195

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

STEP 6

Visually inspect the after cooler for damage or leaks.

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

BD07B197

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

2003-6

AFTERCOOLER REMOVAL Removal

STEP 5

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

Raise the hood and place the master disconnect switch in the OFF position.

NOTE: Radiator drain is located under the rear chassis behind the rear axle.

NOTE: Radiator drain is located under the rear chassis behind the rear axle. BD07B193

Attach suitable lifting equipment to the after cooler.

STEP 3

BD07B193

Attach suitable lifting equipment to the after cooler.

STEP 3

STEP 6

BD07B176

Drain 20 liters (5.5 gallons) of coolant from the engine cooling system.

STEP 4

BD07B179

Loosen and remove the top mounting bolts.

STEP 4

STEP 7

BD07B178

Loosen clamps and remove upper radiator hose and tube. Loosen the clamps and remove the hoses from the after cooler. Loosen clamps and disconnect radiator vent hose, disconnect cooling level sensor.

BD07B179

Loosen and remove the top mounting bolts.

STEP 7

BD07B178 BD07B194

Loosen and remove the bottom mounting bolts.

STEP 8 Remove the after cooler from the cooling frame.

Loosen clamps and remove upper radiator hose and tube. Loosen the clamps and remove the hoses from the after cooler. Loosen clamps and disconnect radiator vent hose, disconnect cooling level sensor.

BD07B194

Loosen and remove the bottom mounting bolts.

STEP 8 Remove the after cooler from the cooling frame.

2003-7

Leak Test

2003-7

Leak Test

STEP 3

BD07B178

Install two top mounting bolts. BS03B028

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

leakage

detected

replace

the

Install two top mounting bolts. BS03B028

STEP 4

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

after

NOTE: If cooler.

leakage

Installation

STEP 1

Support after cooler with appropriate lifting device. Install after cooler in its frame.

BD07B178

Install the cooler hoses and upper radiator hose and tube.

STEP 2

detected

the

after

Support after cooler with appropriate lifting device. Install after cooler in its frame.

BD07B178

Install the cooler hoses and upper radiator hose and tube.

STEP 2

STEP 5

Refill the cooling system.

BD07B194

Install two bottom mounting bolts.

replace

STEP 4

BD07B194

Install two bottom mounting bolts.

2003-8

NOTES

Section Title

SECTION INDEX

FUEL SYSTEM

FUEL SYSTEM Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL

Section Title

Section Number

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL

Section Title

SECTION INDEX

ELECTRICAL

ELECTRICAL Section Number

Section Title

Section Number

Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003

Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005

4001

4001 Section 4001

Section 4001

REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4001-2

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

TABLE OF CONTENTS 3 3 3 5 5 6 8 8 8

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 5 5 6 8 8 8

4001-3

STARTER

Removal

Installation

Removal

Installation

STEP 1

STEP 5

STEP 1

STEP 5

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

STEP 2

Open the engine compartment panel. Place the master disconnect switch in the OFF position.

STEP 3

8 7

W270-7R006

Position starter motor on machine and insert the three screws (7) and washers (8) retaining it to engine housing flange (9). Lock the three screws at 210 to 375±14 Nm torque 155 to 275±10 pound-feet).

STEP 6

STEP 6 1

W270-7R004

Place ad identification mark on the battery-starter motor cable (1), on the frame-ground cable (2), on negative start-up cable (3), on engine starter motor ground stranded wire (4) and remove starter motor cables.

5 6

STEP 4 12

STEP 4

W270-7R007

Install and lock the battery-starter motor cable (10), the frame-ground cable (11), the negative starter motor cable (12) and engine starter motor ground stranded wire (13).

STEP 7

Place the master disconnect switch in the ON position. Close the engine compartment panel.

5 6

W270-7R005

Remove setscrews (5, 3 q.ty), washers (6) and disconnect starter motor.

Place the master disconnect switch in the ON position. Close the engine compartment panel.

4001-4

24 B 1

18 11 12

11 12

3 20 13

1 23 20 13 7

3 20 13 14 22 16

10 9

3 20 13

21 13

3 20 13 5

3 20 13

21 13 3 20 13 5

3 13 20

VIEW A-A

23 20 13

14 22 16

VIEW B-B

B 8

VIEW B-B

3 13 20

VIEW A-A

W270-7R008

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

MOTOR STARTER 7. CABLE STARTER NEGATIVE SWITCH MASTER 8. CABLE STARTER NEGATIVE TO CHASSIS GND. CLAMP 9. WASHER CABLE BATTERY POSITIVE CABLE BATTERY NEGATIVE 10. BOLT 11. WASHER HARNESS 12. NUT

13. 14. 15. 16. 17. 18. 19.

NUT CABLE BATTERY TO STARTER STRAP GROUND CONDUIT BATTERY CABLES STRAP CABLE BOOT ELECTRICAL BOOT ELECTRICAL

20. 21. 22. 23. 24.

WASHER WASHER HOUSING HOOD CLAMP ENGINE BELLHOUSING

W270-7R008

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

MOTOR STARTER 7. CABLE STARTER NEGATIVE SWITCH MASTER 8. CABLE STARTER NEGATIVE TO CHASSIS GND. CLAMP 9. WASHER CABLE BATTERY POSITIVE CABLE BATTERY NEGATIVE 10. BOLT 11. WASHER HARNESS 12. NUT

13. 14. 15. 16. 17. 18. 19.

NUT CABLE BATTERY TO STARTER STRAP GROUND CONDUIT BATTERY CABLES STRAP CABLE BOOT ELECTRICAL BOOT ELECTRICAL

20. 21. 22. 23. 24.

WASHER WASHER HOUSING HOOD CLAMP ENGINE BELLHOUSING

4001-5

ALTERNATOR Removal

STEP 4

NOTE: Grill is removed for clarity only, it is not required for alternator replacement.

STEP 4

NOTE: Grill is removed for clarity only, it is not required for alternator replacement.

STEP 1

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

STEP 2

Open the left engine compartment panel. Place the master disconnect switch in the OFF position.

Open the left engine compartment panel. Place the master disconnect switch in the OFF position. W270-7R012

STEP 3

Use a wrench to move the belt tensioner (1) to loosen the tension on the belt. Remove the belt.

W270-7R012

STEP 3

Use a wrench to move the belt tensioner (1) to loosen the tension on the belt. Remove the belt.

STEP 5

W270-7R010

Disconnect wires from the alternator.

W270-7R010

Disconnect wires from the alternator.

W270-7R011

Remove alternator (2) setscrews (3, 2 q.ty) from cover (4) of belt (5) and take cover out.

4001-6

Installation

STEP 6

Installation

STEP 6

NOTE: Grill is removed for clarity only, it is not required for alternator replacement.

STEP 7

W270-7R013

Remove alternator.

1 W270-7R015

W270-7R015

Position alternator on engine, position belt cover (1) then fasten alternator and cover by means of screws (2, 2 q.ty) and lock.

STEP 8

STEP 8 3

3 4

W270-7R014

Position tensioner (3) on alternator (4) and fit belt (5).

NOTE: Belt routing instructions are on belt cover.

4001-7

STEP 9

4001-7

STEP 9

W270-7R010

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

STEP 10

Place the master disconnect switch in the ON position. Close the left engine compartment panel.

4001-8

BELT INSTALLATION

W270-7R017

WITH OUT AIR CONDITIONING

W270-7R016

WITH AIR CONDITIONING

W270-7R016

WITH AIR CONDITIONING

Section 4002

ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4002

Section 4002

ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter 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 . . . . . . . . . . . . . . . . . . . . . . . . . Ether Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 7 8 37 37 42 43 43 43 43 44 44 44 44 45 45 46 46 47 48 48 48 49 49 49 49 51 52 52 53 54 54 55 55 56 56 56 57 57 58 59 59 60 60 61 61 61 62 62

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter 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 . . . . . . . . . . . . . . . . . . . . . . . . . Ether Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Control Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 8 37 37 42 43 43 43 43 44 44 44 44 45 45 46 46 47 48 48 48 49 49 49 49 51 52 52 53 54 54 55 55 56 56 56 57 57 58 59 59 60 60 61 61 61 62 62

4002-3

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4002-4

LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Right Hand Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Left Hand Rear Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Diodes Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Electronic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 External Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Internal Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Blower Fan Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Mixed Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Compressor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Recycling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 24 to 12 Volt Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

4002-5 STANDARD CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 116 116 116 116 117 117 117 117 118

4002-6

NOTES

4002-7

SPECIFICATIONS

Electrical System ............................................................Two 12 volt batteries connected in series, negative ground System Voltage .............................................................................................................................................. 24 volts

Batteries Group Size ..........................................................................................................................................................31 Reserve Capacity ................................................................................................................................ 170 minutes Cold Cranking Capacity At -17qC (0qF) for 60 Seconds At 6.0 Volts.................................................700 amperes Load of Capacity (Load) Test .............................................................................................................400 amperes

Alternator ..................................................................................................................................... 24 volt, 95 amperes Voltage Regulator............................................................................................................. Solid State, Not Adjustable Starter................................................................................................................................ 24 volt, Solenoid Actuated Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20qC (68qF) (Nominal) ................ 68.2 ohms Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20qC (68qF) (Nominal) ............ 305 ohms Fuel Level Sender .............................................................................................................................. 33 to 240 ohms Coolant, Torque Converter, and Hydraulic Temperature Sender 20qC (68qF) ......................................... 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 20qC (68qF) (Nominal)............................................................................ 1.9 ohms Parking Brake Solenoid DC Resistance At 20qC (68qF) (Nominal) ........................................................... 40.3 ohms Pilot Pressure Solenoid (Joystick) DC Resistance At 20qC (68qF) (Nominal) ........................................... 29.9 ohms Pilot Pressure Solenoid (Single Axis) DC Resistance At 20qC (68qF) (Nominal) ...................................... 27.4 ohms Ride Control Solenoid DC Resistance At 20qC (68qF) (Nominal) .............................................................. 22.7 ohms Secondary Steering Solenoid DC Resistance At 20qC (68qF) (Nominal) .................................................. 39.3 ohms Fan Reversing Solenoid DC Resistance At 20qC (68qF) (Nominal)........................................................... 39.3 ohms Fan PWM Solenoid DC Resistance At 20qC (68qF) (Nominal) ............................................................ 26 to 32 ohms Fuel Temperature Sensor At 20qC (68qF) (Nominal) ................................................................................ 2500 ohms Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7) Analog Throttle ................................................................................. Idle Validation Switch Closes At 0.775V ± 0.1V Throttle Position Potentiometer ................................................................................................. 5V Reference ± 0.2V Low Idle Position .............................................................................................................................. 0.4V ± 0.025V High Idle Position ................................................................................................................................. 4.0V ± 0.1V

4002-8

ELECTRICAL WIRE IDENTIFICATION

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2)

0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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+

LG1_0-SXL

AD, ALTERNATOR D+

ENG, ENGINE-CAB

ALTERNATOR D+

LG1_0-SXL

AD, ALTERNATOR D+

ENG, ENGINE-CAB

WORK LIGHTS SW FSD PWR

R2_0-GXL

SPL_WL, ULTRASONIC

ECC, ELECT CNTR C

WORK LIGHTS SW FSD PWR

R2_0-GXL

SPL_WL, ULTRASONIC

ECC, ELECT CNTR C

BRK LT CTRL PWR

T1_0-SXL

FRONT, CAB-FRNT_CHAS

PBL, BRAKE_LT_PRES_SW

BRK LT CTRL PWR

T1_0-SXL

FRONT, CAB-FRNT_CHAS

PBL, BRAKE_LT_PRES_SW

BACK LIGHT POWER

DU1_0-GXL

D_OR, DIODE OR

SPL_BCK_LGT, SPLICE BACK LGHT PWR

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECB, ELECT CNTR B

BACK LIGHT POWER

DU1_0-GXL

D_OR, DIODE OR

SPL_BCK_LGT, SPLICE BACK LGHT PWR

FAN REVERSER LSD

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECB, ELECT CNTR B

FAN REVERSER LSD

FAN CONTROL PWM

W0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

FAN CONTROL PWM

W0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

PIN ENGAGE SOL PWR

W1_0-SXL

FRONT, CAB-FRNT_CHAS

YPE, PIN_ENGAGE_OPT

PIN ENGAGE SOL PWR

W1_0-SXL

FRONT, CAB-FRNT_CHAS

YPE, PIN_ENGAGE_OPT

PRBF, ROLLBACK_PRES_SW

YRC, RIDE_CONTROL_OPT

HN1, HORN_PWR

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

RIDE CTRL SOLPWR

W1_0-SXL

HORN POWER

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

BK0_8-GXL

SFL, RETURN_TO_TRAVEL_SW

0_29 RTT/FLOAT GND

YRC, RIDE_CONTROL_OPT

RIDE CTRL SOLPWR

W1_0-SXL

HN1, HORN_PWR

HORN POWER

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_29 RTT/FLOAT GND

BK0_8-GXL

SFL, RETURN_TO_TRAVEL_SW

0_AA PROX SW GND

BK1_0-SXL

PXH, HGT_CNTRL-RTT

SPL_A2, ULTRASONIC

0_AA PROX SW GND

BK1_0-SXL

PXH, HGT_CNTRL-RTT

SPL_A2, ULTRASONIC

0_AB PROX SW GND

BK1_0-SXL

SPL_A2, ULTRASONIC

GND_FC, GROUND_A

0_AB PROX SW GND

BK1_0-SXL

SPL_A2, ULTRASONIC

GND_FC, GROUND_A

0_AC PROX SW GND

BK1_0-SXL

PXF, RTD

SPL_A2, ULTRASONIC

0_AC PROX SW GND

BK1_0-SXL

PXF, RTD

SPL_A2, ULTRASONIC

0_AD RIDE CONTROL GND

BK1_0-SXL

YRC, RIDE_CONTROL_OPT

SPL_A1, ULTRASONIC

0_AD RIDE CONTROL GND

BK1_0-SXL

YRC, RIDE_CONTROL_OPT

SPL_A1, ULTRASONIC

0_AE PIN ENGAGE GND

BK1_0-SXL

SPL_A1, ULTRASONIC

YPE, PIN_ENGAGE_OPT

0_AE PIN ENGAGE GND

BK1_0-SXL

SPL_A1, ULTRASONIC

YPE, PIN_ENGAGE_OPT

0_AF HORN GND

BK1_0-SXL

HN2, HORN_GRND

SPL_A1, ULTRASONIC

0_AF HORN GND

BK1_0-SXL

HN2, HORN_GRND

SPL_A1, ULTRASONIC

0_AG FRONT CHASSIS GND

BK2_0-SXL

SPL_A1, ULTRASONIC

GND_FC, GROUND_A

0_AG FRONT CHASSIS GND

BK2_0-SXL

SPL_A1, ULTRASONIC

GND_FC, GROUND_A

0_AH RH FRONT LIGHTS GND

BK1_0-SXL

SPL_A1, ULTRASONIC

LRF, LIGHTS_RH

0_AH RH FRONT LIGHTS GND

BK1_0-SXL

SPL_A1, ULTRASONIC

LRF, LIGHTS_RH

0_AJ LH FRONT LIGHTS GND

BK1_0-SXL

SPL_A1, ULTRASONIC

LLF, LIGHTS_LH

0_AJ LH FRONT LIGHTS GND

BK1_0-SXL

SPL_A1, ULTRASONIC

LLF, LIGHTS_LH

0_AK PARK BRAKE/WARNING GND

BK1_0-SXL

SPL_A4, ULTRASONIC

GND_FC, GROUND_A

0_AK PARK BRAKE/WARNING GND

BK1_0-SXL

SPL_A4, ULTRASONIC

GND_FC, GROUND_A

1 A

0_AL BRK WARN PRES SW GND

BK1_0-SXL

PBW, BRK_WARN_PR_SW

SPL_A4, ULTRASONIC

0_AL BRK WARN PRES SW GND

BK1_0-SXL

PBW, BRK_WARN_PR_SW

SPL_A4, ULTRASONIC

0_AM RTD GND

BK1_0-SXL

PXM, RTD

PXT, RTD

0_AM RTD GND

BK1_0-SXL

PXM, RTD

PXT, RTD

0_AN PARK BRAKE SOL GND

BK1_0-SXL

YPB, PARK_BRK_SOL

SPL_A4, ULTRASONIC

0_AN PARK BRAKE SOL GND

BK1_0-SXL

YPB, PARK_BRK_SOL

SPL_A4, ULTRASONIC

BK5_0-SXL

GND_S1, GROUND_A

GND_S2, GROUND_A

0_AP

BK5_0-SXL

GND_S1, GROUND_A

GND_S2, GROUND_A

0_AQ COMFORT STR SOL GND

BK1_0-SXL

YCS, COMFORT STEER SOLEROID

SPL_A4, ULTRASONIC

0_AQ COMFORT STR SOL GND

BK1_0-SXL

YCS, COMFORT STEER SOLEROID

SPL_A4, ULTRASONIC

0_AR FRONT AX TEMP SENS GND

BK1_0-SXL

FRONT, CAB-FRNT_CHAS

HOT_FA, FRNT_AX_OIL_TEMP

0_AR FRONT AX TEMP SENS GND

BK1_0-SXL

FRONT, CAB-FRNT_CHAS

HOT_FA, FRNT_AX_OIL_TEMP

0_B

0_AP

FRONT TO REAR CHASSIS GND

BK1_0-SXL

FWW, FRONT_WASHER

SPL_ENG_GRD, GRND SPLICE 6 PCK

0_B1 BACK LIGHT GND

BK0_8-GXL

SPC, PILOT_CONTROL_SWITCH

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B2 BACK LIGHT GND

BK0_8-GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B3 BACK LIGHT GND

BK0_8-GXL

SHC, HEIGHT CONTROL SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B

FRONT WASHER GND

FRONT TO REAR CHASSIS GND

BK1_0-SXL

FWW, FRONT_WASHER

SPL_ENG_GRD, GRND SPLICE 6 PCK

0_B1 BACK LIGHT GND

BK0_8-GXL

SPC, PILOT_CONTROL_SWITCH

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B2 BACK LIGHT GND

BK0_8-GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B3 BACK LIGHT GND

BK0_8-GXL

SHC, HEIGHT CONTROL SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

FRONT WASHER GND

4002-9

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification

Cavity

Connector

Cavity

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_B4 BACK LIGHT GND

BK0_8-GXL

SRTD, DETENT_SWITCH

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B4 BACK LIGHT GND

BK0_8-GXL

SRTD, DETENT_SWITCH

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B5 BACK LIGHT GND

BK0_8-GXL

SPE, PIN_ENGAGE_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B5 BACK LIGHT GND

BK0_8-GXL

SPE, PIN_ENGAGE_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B6 CAB2 GND

BK1_0-GXL

GND_CAB2, GROUND_A

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B6 CAB2 GND

BK1_0-GXL

GND_CAB2, GROUND_A

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B7 BACK LIGHT GND

BK0_8-GXL

SFC, FAN_CONTROL_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B7 BACK LIGHT GND

BK0_8-GXL

SFC, FAN_CONTROL_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B8 FRONT WIPER MOTOR GND

BK0_8-GXL

SPL_BCK_LT_GD, SPL BACK LGHT GD

FWMG, WIPER GROUND

0_B8 FRONT WIPER MOTOR GND

BK0_8-GXL

SPL_BCK_LT_GD, SPL BACK LGHT GD

FWMG, WIPER GROUND

0_B9 BACK LIGHT GND

BK0_8-GXL

SCS, COMFORT STEER SW

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B9 BACK LIGHT GND

BK0_8-GXL

SCS, COMFORT STEER SW

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B10 HOOD GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

GND_CAB2, GROUND_A

0_B10 HOOD GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

GND_CAB2, GROUND_A

0_B11 BACK LIGHT GND

BK0_8-GXL

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B11 BACK LIGHT GND

BK0_8-GXL

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B12 HOOD DOWN RELAY GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B12 HOOD DOWN RELAY GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B13 BACK LIGHT GND

BK1_0-GXL

SPL_BCK_LT_GD, SPL BACK LGHT GD

GND_CAB2, GROUND_A

0_B13 BACK LIGHT GND

BK1_0-GXL

SPL_BCK_LT_GD, SPL BACK LGHT GD

GND_CAB2, GROUND_A

0_B14 BACK LIGHT GND

BK0_8-GXL

SWL, WORK LIGHTS SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B14 BACK LIGHT GND

BK0_8-GXL

SWL, WORK LIGHTS SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B15 BACK LIGHT GND

BK0_8-GXL

SBE, BEACON_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B15 BACK LIGHT GND

BK0_8-GXL

SBE, BEACON_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B16 HOOD DOWN CONTROL GND BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B16 HOOD DOWN CONTROL GND BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B17 BACK LIGHT GND

BK0_8-GXL

STA, TRANS_AUTO_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B17 BACK LIGHT GND

BK0_8-GXL

STA, TRANS_AUTO_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B18 BACK LIGHT GND

BK0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B18 BACK LIGHT GND

BK0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B19 BACK LIGHT GND

BK0_8-GXL

SDR, DRIVING LIGHTS SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B19 BACK LIGHT GND

BK0_8-GXL

SDR, DRIVING LIGHTS SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B20 BACK LIGHT GND

BK0_8-GXL

SRC, RIDE_CONTROL_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B20 BACK LIGHT GND

BK0_8-GXL

SRC, RIDE_CONTROL_SW

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B21 BACK LIGHT GND

BK1_0-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B21 BACK LIGHT GND

BK1_0-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B22 HOOD UP RELAY GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B22 HOOD UP RELAY GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B23 BACK LIGHT GND

BK0_8-GXL

SRWP, REAR_WIPER_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B23 BACK LIGHT GND

BK0_8-GXL

SRWP, REAR_WIPER_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_B24 BACK LIGHT GND

BK0_8-GXL

SHZ, HAZARD_SWITCH

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B24 BACK LIGHT GND

BK0_8-GXL

SHZ, HAZARD_SWITCH

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

0_B25 HOOD UP CONTROL GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B25 HOOD UP CONTROL GND

BK1_0-GXL

SPL_HOOD_GRND, HOOD GRND 6PCK

ECC, ELECT CNTR C

0_B26 BUZZER/SW PAD GND

BK0_8-GXL

SPL_BUZ, ULTRASONIC

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

0_B26 BUZZER/SW PAD GND

BK0_8-GXL

SPL_BUZ, ULTRASONIC

SPL_BCK_LT_GD2, SPL_BACK LGT GRND

4002-10

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

0_B27 BUZZER GND

BK0_8-GXL

0_B28 SW PAD GND

Connector

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

SPL_BUZ, ULTRASONIC

BK0_8-TXL

SW_PD, SWITCH PAD

0_B29 RTT/FLOAT GND

BK0_8-GXL

SPB, PARKING_BRAKE_SWITCH

0_B30 BACK LIGHT GND

BK0_8-GXL

0_BA PEDESTAL GND STRAP 0_BA EDC7 GND C

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

BUZ, AIC_BUZZER

0_B27 BUZZER GND

BK0_8-GXL

SPL_BUZ, ULTRASONIC

0_B28 SW PAD GND

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

SETHR, ETHER SWITCH

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

BK5_0-SXL

GND_PDST, GROUND_A

BK2_0-SXL

SPL_EDC1, ULTRASONIC

0_BAE EDC7 SENDER GND

BK1_0-SXL

0_BAF COOL LEVEL SNDR GND

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

SPL_BUZ, ULTRASONIC

BK0_8-TXL

SW_PD, SWITCH PAD

0_B29 RTT/FLOAT GND

BK0_8-GXL

SPB, PARKING_BRAKE_SWITCH

0_B30 BACK LIGHT GND

BK0_8-GXL

GND_PDST2, GROUND_A

0_BA PEDESTAL GND STRAP

GND_ENG2, WIF, EDC

0_BA EDC7 GND C

RECT, ENG_COOL_TEMP

GND_ENG7, TRANNY, COOL TEMP

BK1_0-SXL

CLS_, COOL_JUMP-COOL_SEND

GND_ENG7, TRANNY, COOL TEMP

0_BA HOOD GROUNDS(EURO) G

BK1_0-SXL

GND_ENG4, REAR LIGHTING

0_BA HOOD GROUNDS(NA) G_N

BK1_0-SXL

ENG_H, ENGINE TO HOOD

0_BA QSM 11 GND H

BK0_8-GXL

SPL_EDC1, ULTRASONIC

Connector

Cavity

BUZ, AIC_BUZZER

SPL_BUZ, ULTRASONIC

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

SETHR, ETHER SWITCH

SPL_PED_BL_GD, SPL BACK LGT GD 6PCK

BK5_0-SXL

GND_PDST, GROUND_A

GND_PDST2, GROUND_A

BK2_0-SXL

SPL_EDC1, ULTRASONIC

GND_ENG2, WIF, EDC

0_BAE EDC7 SENDER GND

BK1_0-SXL

RECT, ENG_COOL_TEMP

GND_ENG7, TRANNY, COOL TEMP

0_BAF COOL LEVEL SNDR GND

BK1_0-SXL

CLS_, COOL_JUMP-COOL_SEND

GND_ENG7, TRANNY, COOL TEMP

E_HD, TRANS-HOOD

0_BA HOOD GROUNDS(EURO) G

BK1_0-SXL

GND_ENG4, REAR LIGHTING

E_HD, TRANS-HOOD

GND_ENG4, REAR LIGHTING

0_BA HOOD GROUNDS(NA) G_N

BK1_0-SXL

ENG_H, ENGINE TO HOOD

GND_ENG4, REAR LIGHTING

QSM11, ENGINE CONTROLLER

0_BA QSM 11 GND H

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BAI QSM 11 GND

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BAI QSM 11 GND

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BAJ QSM 11 GND

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BAJ QSM 11 GND

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BAK QSM 11 GND

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BAK QSM 11 GND

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

0_BA ETHER RLY SGNL GND M

BK1_0-SXL

PRM_C2, PRM SIGNAL

GND_ENG2, WIF, EDC

GND_ENG3, SPLC_PK, WSHR MTR

0_BA ETHER STRT GRND N

BK1_0-SXL

ETHR, ETHER SOLENOID

GND_ENG3, SPLC_PK, WSHR MTR

QSM11, ENGINE CONTROLLER

BK0_8-GXL

SPL_EDC1, ULTRASONIC

QSM11, ENGINE CONTROLLER

GND_WIF, GRND WIF RING TERM

GND_ENG6, DEDICATED

BK1_0-SXL

GND_WIF, GRND WIF RING TERM

GND_ENG6, DEDICATED

HOT_RA, REAR_AX_OIL_TEMP

GND_ENG7, TRANNY, COOL TEMP

BK1_0-SXL

HOT_RA, REAR_AX_OIL_TEMP

GND_ENG7, TRANNY, COOL TEMP

0_BA ETHER RLY SGNL GND M

BK1_0-SXL

PRM_C2, PRM SIGNAL

GND_ENG2, WIF, EDC

0_BA ETHER STRT GRND N

BK1_0-SXL

ETHR, ETHER SOLENOID

BK0_8-GXL

SPL_EDC1, ULTRASONIC

BK1_0-SXL BK1_0-SXL

0_BAP QSM 11 GRND 0_BA WIF BODY GRND R 0_BAS REAR AX TEMP SENS GND

0_BB FAN REVERSE SOL GND

BK1_0-SXL

YFR, FAN_REV_SOL_OPT

SPL_FAN, ULTRASONIC

0_BB FAN REVERSE SOL GND

BK1_0-SXL

YFR, FAN_REV_SOL_OPT

SPL_FAN, ULTRASONIC

0_BC EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BC EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BD EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BD EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BE EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BE EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BF EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BF EDC7 GND

BK1_0-GXL

SPL_EDC1, ULTRASONIC

EDC7, ENGINE CONTROLLER

0_BG AIC POWER GND

BK0_8-GXL

ENG, ENGINE-CAB

GND_ENG6, DEDICATED

0_BG AIC POWER GND

BK0_8-GXL

ENG, ENGINE-CAB

GND_ENG6, DEDICATED

0_BH AIC POWER GND RED

BK0_8-GXL

ENG, ENGINE-CAB

GND_ENG6, DEDICATED

0_BH AIC POWER GND RED

BK0_8-GXL

ENG, ENGINE-CAB

GND_ENG6, DEDICATED

0_BJ AIC SENSOR GND

BK0_8-GXL

ENG, ENGINE-CAB

GND_ENG6, DEDICATED

0_BJ AIC SENSOR GND

BK0_8-GXL

ENG, ENGINE-CAB

GND_ENG6, DEDICATED

0_BK TRANS SPLICE GNDS

BK1_0-GXL

ENG_T, ENGINE TO TRANS

GND_ENG7, TRANNY, COOL TEMP

0_BL REAR WASHER GND

BK1_0-SXL

RWW, REAR_WASHER

SPL_ENG_GRD, GRND SPLICE 6 PCK

0_BK TRANS SPLICE GNDS

BK1_0-GXL

ENG_T, ENGINE TO TRANS

GND_ENG7, TRANNY, COOL TEMP

0_BL REAR WASHER GND

BK1_0-SXL

RWW, REAR_WASHER

SPL_ENG_GRD, GRND SPLICE 6 PCK

4002-11

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

GND_ENG3, SPLC_PK, WSHR MTR

0_BM ENGINE SPLICE GNDS

BK1_0-SXL

SPL_ENG_GRD, GRND SPLICE 6 PCK

EDC7, ENGINE CONTROLLER

0_BN FILTER HEATER CONTROL

BK0_8-GXL

PRM_C2, PRM SIGNAL

WIF, WATER_IN_FUEL_SNSR

0_BP WIF SENSOR GND

BK1_0-SXL

GND_ENG2, WIF, EDC

SPL_FAN, ULTRASONIC

0_BQ FAN SPEED PWM SOL GND

BK1_0-SXL

0_BR RH REAR LIGHT GND(EURO) 0_BR_ LH REAR LIGHT GND(NA) N

Connector

Cavity

GND_ENG3, SPLC_PK, WSHR MTR

EDC7, ENGINE CONTROLLER

WIF, WATER_IN_FUEL_SNSR

YFN, FAN_PWM_SOL

SPL_FAN, ULTRASONIC

BK1_0-SXL

LRR_E, RH_REAR_COMB_LT

GND_ENG4, REAR LIGHTING

BK1_0-SXL

LLR_N, LH_REAR_COMB_LT

SPL_J1, ULTRASONIC

0_BS FAN CONTROL GND

BK1_0-SXL

SPL_FAN, ULTRASONIC

SPL_ENG_GRD, GRND SPLICE 6 PCK

0_BT LH REAR LIGHT GND(EURO)

BK1_0-SXL

LLR_E, LH_REAR_COMB_LT

GND_ENG4, REAR LIGHTING

SPL_J1, ULTRASONIC

0_BT_ RH REAR LIGHT GND(NA) N

BK1_0-SXL

LRR_N, RH_REAR_COMB_LT

SPL_J1, ULTRASONIC

GND_ENG7, TRANNY, COOL TEMP

0_BU FUEL LEVEL SENDER GND

BK1_0-SXL

RFLG, FUEL_SEND_GRND

GND_ENG7, TRANNY, COOL TEMP

GHC, GRID_HEATER_REL

EDC7, ENGINE CONTROLLER

0_BV GRID HEATER CTRL GND

BK0_8-TXL

GHC, GRID_HEATER_REL

EDC7, ENGINE CONTROLLER

BK2_0-SXL

GND_ENG1, STRT, FFH, WAT_SEP_HTR

WSH, WATER_SEP_HTR

0_BW WATER SEP HEATER GND

BK2_0-SXL

GND_ENG1, STRT, FFH, WAT_SEP_HTR

WSH, WATER_SEP_HTR

0_BX FUEL FILTER HEATER GND

BK2_0-SXL

FFH, FUEL_FLTR_HTR

GND_ENG1, STRT, FFH, WAT_SEP_HTR

0_BX FUEL FILTER HEATER GND

BK2_0-SXL

FFH, FUEL_FLTR_HTR

GND_ENG1, STRT, FFH, WAT_SEP_HTR

0_BY AIR FILT REST SW GND

BK1_0-SXL

SPL_ENG_GRD, GRND SPLICE 6 PCK

PAF, AIR_FILT_RES_SW

0_BY AIR FILT REST SW GND

BK1_0-SXL

SPL_ENG_GRD, GRND SPLICE 6 PCK

PAF, AIR_FILT_RES_SW

0_BZ SEC STEERING SPLICE GND

BK1_0-SXL

ENG_T, ENGINE TO TRANS

GND_ENG3, SPLC_PK, WSHR MTR

0_BZ SEC STEERING SPLICE GND

BK1_0-SXL

ENG_T, ENGINE TO TRANS

GND_ENG3, SPLC_PK, WSHR MTR

0_CA SEC STEERING SIGNAL GND

BK1_0-SXL

SSM, SEC STR MOD

SPL_SEC_STR, SEC STR 6PK

0_CA SEC STEERING SIGNAL GND

BK1_0-SXL

SSM, SEC STR MOD

SPL_SEC_STR, SEC STR 6PK

0_CB SEC STEERING SIGNAL GND

BK1_0-SXL

SSM, SEC STR MOD

SPL_SEC_STR, SEC STR 6PK

0_CB SEC STEERING SIGNAL GND

BK1_0-SXL

SSM, SEC STR MOD

SPL_SEC_STR, SEC STR 6PK

SEC STEERING PRESS SW 0_CC GND

BK1_0-SXL

PSS, SEC STR PRES SWITCH

SPL_SEC_STR, SEC STR 6PK

SEC STEERING PRESS SW 0_CC GND

BK1_0-SXL

PSS, SEC STR PRES SWITCH

SPL_SEC_STR, SEC STR 6PK

0_CD SEC STEERING SPLICE GND

BK1_0-SXL

SPL_SEC_STR, SEC STR 6PK

SS_TR, SS_MOD-TRANS

0_CD SEC STEERING SPLICE GND

BK1_0-SXL

SPL_SEC_STR, SEC STR 6PK

SS_TR, SS_MOD-TRANS

SEC STEERING CHASSIS GND

BK1_0-SXL

SSM, SEC STR MOD

GND_SSMOD, SEC STR CHASIS GND

0_CE

SEC STEERING CHASSIS GND

BK1_0-SXL

SSM, SEC STR MOD

GND_SSMOD, SEC STR CHASIS GND

0_CF SEC STEERING SOL GND

BK1_0-SXL

YSS, SEC_STRG_SOL

SPL_SEC_STR, SEC STR 6PK

0_CF SEC STEERING SOL GND

BK1_0-SXL

YSS, SEC_STRG_SOL

SPL_SEC_STR, SEC STR 6PK

0_DA AIC CHASSIS GND

BK0_8-TXL

GND_PDST1, GROUND_A

AIC_2, ADV INSTR CLUSTER 2

0_DA AIC CHASSIS GND

BK0_8-TXL

GND_PDST1, GROUND_A

AIC_2, ADV INSTR CLUSTER 2

0_DA BACK LIGHT GND P

S0_8-GXL

STE, TRANS_ENABLE_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

108F, DIAGNOSTIC_CONNECTO R

GND_CAB3D, GROUND_A

0_BM ENGINE SPLICE GNDS

BK1_0-SXL

SPL_ENG_GRD, GRND SPLICE 6 PCK

0_BN FILTER HEATER CONTROL

BK0_8-GXL

PRM_C2, PRM SIGNAL

0_BP WIF SENSOR GND

BK1_0-SXL

GND_ENG2, WIF, EDC

0_BQ FAN SPEED PWM SOL GND

BK1_0-SXL

YFN, FAN_PWM_SOL

0_BR RH REAR LIGHT GND(EURO)

BK1_0-SXL

LRR_E, RH_REAR_COMB_LT

GND_ENG4, REAR LIGHTING

0_BR_ LH REAR LIGHT GND(NA) N

BK1_0-SXL

LLR_N, LH_REAR_COMB_LT

SPL_J1, ULTRASONIC

0_BS FAN CONTROL GND

BK1_0-SXL

SPL_FAN, ULTRASONIC

SPL_ENG_GRD, GRND SPLICE 6 PCK

0_BT LH REAR LIGHT GND(EURO)

BK1_0-SXL

LLR_E, LH_REAR_COMB_LT

GND_ENG4, REAR LIGHTING

0_BT_ RH REAR LIGHT GND(NA) N

BK1_0-SXL

LRR_N, RH_REAR_COMB_LT

0_BU FUEL LEVEL SENDER GND

BK1_0-SXL

RFLG, FUEL_SEND_GRND

0_BV GRID HEATER CTRL GND

BK0_8-TXL

0_BW WATER SEP HEATER GND

0_CE

0_DA BACK LIGHT GND P

S0_8-GXL

STE, TRANS_ENABLE_SW

SPL_BCK_LT_GD, SPL BACK LGHT GD

0_DAV TECM DIAGNOSTIC GND

BK0_8-GXL

108F, DIAGNOSTIC_CONNECTO R

GND_CAB3D, GROUND_A

0_DAV TECM DIAGNOSTIC GND

BK0_8-GXL

0_DB AIC POWER GND RED

BK0_8-TXL

CAB_E, CAB-ENGINE

AIC_2, ADV INSTR CLUSTER 2

0_DB AIC POWER GND RED

BK0_8-TXL

CAB_E, CAB-ENGINE

AIC_2, ADV INSTR CLUSTER 2

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

TDM, TIME_DELAY_MODULE

0_DC TIME DELAY MOD GND

TDM, TIME_DELAY_MODULE

0_DC TIME DELAY MOD GND

4002-12

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 0_DD

Circuit

Wire Size (mm2) 0.8 mm

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

VOLTMETR RELAY CONTROL BK0_8-GXL GND

Connector

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

Wire

GND_CAB_SPL2, SPL BACK LGHT GD

ECB, ELECT CNTR B

0_DD

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

VOLTMETR RELAY CONTROL BK0_8-GXL GND

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

GND_CAB_SPL2, SPL BACK LGHT GD

ECB, ELECT CNTR B

0_DE NEUT START RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

ECB, ELECT CNTR B

0_DE NEUT START RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

ECB, ELECT CNTR B

CRANK REQUEST RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

ECB, ELECT CNTR B

0_DF

CRANK REQUEST RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

ECB, ELECT CNTR B

BK1_0-GXL

GND_CAB_SPL, CAB GRND SPLICE

GND_CAB3, GROUND_C

0_DG CAB SPLICE GNDS

BK1_0-GXL

GND_CAB_SPL, CAB GRND SPLICE

GND_CAB3, GROUND_C

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

DIA, DIAGNOSTIC

0_DH

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

DIA, DIAGNOSTIC

0_DJ AC RELAY CONTROL GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

ECD, ELECT CNTR D

0_DK SEAT COMP MOTOR GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

BK0_8-TXL

0_DF

0_DG CAB SPLICE GNDS 0_DH

0_DL

DIAGNOSTIC CONNECTOR GND

PWR CONVERTER RLY CTRL GND

0_DM SPEED SENSOR GNDS 0_DN

OUTPUT SPEED SENSOR GND

DIAGNOSTIC CONNECTOR GND

B10

0_DJ AC RELAY CONTROL GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

ECD, ELECT CNTR D

SC, SEAT_COMP_MOTOR

0_DK SEAT COMP MOTOR GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

SC, SEAT_COMP_MOTOR

PRM_E2, PRM SIGNAL

0_DL

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

PRM_E2, PRM SIGNAL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

0_DM SPEED SENSOR GNDS

BK0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

BK0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

0_DN

BK0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

PWR CONVERTER RLY CTRL GND

OUTPUT SPEED SENSOR GND

B10

0_DP DIAG TECM GND

BK0_8-TXL

GND_CAB3D, GROUND_A

TECM, TRANS

0_DP DIAG TECM GND

BK0_8-TXL

GND_CAB3D, GROUND_A

TECM, TRANS

0_DQ DIAG TECM GND

BK0_8-TXL

GND_CAB3D, GROUND_A

TECM, TRANS

0_DQ DIAG TECM GND

BK0_8-TXL

GND_CAB3D, GROUND_A

TECM, TRANS

0_DR ROOF SPLICE GNDS

BK1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

GND_CAB1, GROUND_A

0_DR ROOF SPLICE GNDS

BK1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

GND_CAB1, GROUND_A

0_DS ROOF SPLICE GNDS

BK1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

GND_CAB1, GROUND_A

0_DS ROOF SPLICE GNDS

BK1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

GND_CAB1, GROUND_A

FRONT WIPER/WASHER SW GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

SFWW, FRONT WIPER/WASHER

0_DT

FRONT WIPER/WASHER SW GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

SFWW, FRONT WIPER/WASHER

0_DU PILOT PRESSURE SOL GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

YPP, PILOT_PRES_SOL

0_DU PILOT PRESSURE SOL GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

YPP, PILOT_PRES_SOL

0_DV CIGAR LIGHTER GND

BK3_0-SXL

CL, CIGAR_LIGHTER

GND_CAB3, GROUND_C

0_DV CIGAR LIGHTER GND

BK3_0-SXL

CL, CIGAR_LIGHTER

GND_CAB3, GROUND_C

0_DT

0_DW AIC POWER GND

BK0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

0_DW AIC POWER GND

BK0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

0_DX AIC SENSOR GND

BK0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

0_DX AIC SENSOR GND

BK0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

0_DY FRONT AX TEMP SENS GND

BK1_0-GXL

CAB_F, CAB-FRNT_CHAS

GND_CAB3D, GROUND_A

0_DY FRONT AX TEMP SENS GND

BK1_0-GXL

CAB_F, CAB-FRNT_CHAS

GND_CAB3D, GROUND_A

0_EA TIME DELAY RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

PRM_B2, PRM SIGNAL

0_EA TIME DELAY RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

PRM_B2, PRM SIGNAL

0_EB IGNITION RELAY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

PRM_A1, PRM SIGNAL

0_EB IGNITION RELAY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

PRM_A1, PRM SIGNAL

0_EC ACC RELAY CONTROL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

PRM_D1, PRM SIGNAL

0_EC ACC RELAY CONTROL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

PRM_D1, PRM SIGNAL

0_ED HVAC GNDS

BK3_0-SXL

HVAC2, HVAC2

GND_CAB4, GROUND_C

0_ED HVAC GNDS

BK3_0-SXL

HVAC2, HVAC2

GND_CAB4, GROUND_C

0_EE DIODE SUPRESSION GNDS

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

140M, DIODE_MODULE

0_EE DIODE SUPRESSION GNDS

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

140M, DIODE_MODULE

0_EF BRK LTS RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

ECC, ELECT CNTR C

0_EF BRK LTS RLY CTRL GND

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

ECC, ELECT CNTR C

4002-13

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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_EG FLASHER MODULE GND

BK0_8-GXL

FLSHR, FLASHER_MODULE

GND_CAB_SPL2, SPL BACK LGHT GD

0_EG FLASHER MODULE GND

BK0_8-GXL

FLSHR, FLASHER_MODULE

GND_CAB_SPL2, SPL BACK LGHT GD

0_EH FLASHER MODULE GND

BK0_8-GXL

FLSHR, FLASHER_MODULE

GND_CAB_SPL2, SPL BACK LGHT GD

0_EH FLASHER MODULE GND

BK0_8-GXL

FLSHR, FLASHER_MODULE

GND_CAB_SPL2, SPL BACK LGHT GD

0_EJ POWER CONVERTER GND

BK1_0-GXL

CNV, 24V TO 12V PWR CONVERTER

GND_CAB4, GROUND_C

0_EJ POWER CONVERTER GND

BK1_0-GXL

CNV, 24V TO 12V PWR CONVERTER

GND_CAB4, GROUND_C

0_EK AUX POWER OUTLET 1 GND

BK1_0-GXL

PO1, POWER_OUTLET

GND_CAB5, GROUND_C

0_EK AUX POWER OUTLET 1 GND

BK1_0-GXL

PO1, POWER_OUTLET

GND_CAB5, GROUND_C

0_EL AUX POWER OUTLET 2 GND

BK1_0-GXL

PO2, POWER_OUTLET

GND_CAB5, GROUND_C

0_EL AUX POWER OUTLET 2 GND

BK1_0-GXL

PO2, POWER_OUTLET

GND_CAB5, GROUND_C

0_EM RADIO GND

BK0_8-GXL

CAB_RF, CAB TO ROOF CONNECTION

GND_CAB_SPL, CAB GRND SPLICE

0_EM RADIO GND

BK0_8-GXL

CAB_RF, CAB TO ROOF CONNECTION

GND_CAB_SPL, CAB GRND SPLICE

0_EN RADIO GND

BK0_8-GXL

ROOF, ROOF TO CAB CONNECTION

RAD, RADIO_POWER

0_EN RADIO GND

BK0_8-GXL

ROOF, ROOF TO CAB CONNECTION

RAD, RADIO_POWER

0_EP HORN SW GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

SRHSTLK, RH STALK SWITCH

0_EP HORN SW GND

BK0_8-GXL

GND_CAB_SPL, CAB GRND SPLICE

SRHSTLK, RH STALK SWITCH

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

GND_CAB6, STRT, FFH, WAT_SEP_HTR

0_EQ

BK0_8-GXL

GND_CAB_SPL2, SPL BACK LGHT GD

GND_CAB6, STRT, FFH, WAT_SEP_HTR

0_ER POWER CONVERTER GND

BK1_0-GXL

CNV, 24V TO 12V PWR CONVERTER

GND_CAB4, GROUND_C

0_ER POWER CONVERTER GND

BK1_0-GXL

CNV, 24V TO 12V PWR CONVERTER

GND_CAB4, GROUND_C

0_ES GRID HTR GND

BK19_0-SXL

GH_1, GRID_HTR

GND_GH1, STRT, FFH, WAT_SEP_HTR

0_ES GRID HTR GND

BK19_0-SXL

GH_1, GRID_HTR

GND_GH1, STRT, FFH, WAT_SEP_HTR

0_GB STARTER RLY CTRL GND

BK1_0-SXL

SRC_1, RELAY

GND_ENG1, STRT, FFH, WAT_SEP_HTR

0_GB STARTER RLY CTRL GND

BK1_0-SXL

SRC_1, RELAY

GND_ENG1, STRT, FFH, WAT_SEP_HTR

0_HC TRANS SPLICE GNDS

BK1_0-SXL

SPL_TRN_GRD, SPLICE TRANS GRND

TRAN_E, TRANS TO ENG

0_HC TRANS SPLICE GNDS

BK1_0-SXL

SPL_TRN_GRD, SPLICE TRANS GRND

TRAN_E, TRANS TO ENG

0_HD SPEED SENSOR GNDS

BK1_0-SXL

TRANS, CAB-TRANSMISSION

SPL_H2, ULTRASONIC

0_HD SPEED SENSOR GNDS

BK1_0-SXL

TRANS, CAB-TRANSMISSION

SPL_H2, ULTRASONIC

BK1_0-SXL

TRANS, CAB-TRANSMISSION

OSS, OUT_SPEED_SENS

0_HE

BK1_0-SXL

TRANS, CAB-TRANSMISSION

OSS, OUT_SPEED_SENS

0_HF ENGINE SP SENSOR GND

BK0_8_GXL_ TWIST

ESS, ENG_SPEED_SENS

SPL_H2, ULTRASONIC

0_HF ENGINE SP SENSOR GND

BK0_8_GXL_ TWIST

ESS, ENG_SPEED_SENS

SPL_H2, ULTRASONIC

0_HG INT SPEED SENSOR GND

BK0_8_GXL_ TWIST

ISS, INT_SPEED_SENS

SPL_H2, ULTRASONIC

0_HG INT SPEED SENSOR GND

BK0_8_GXL_ TWIST

ISS, INT_SPEED_SENS

SPL_H2, ULTRASONIC

TURBINE SPEED SENSOR GND

BK0_8_GXL_ TWIST

TSS, TURB_SPEED_SENS

SPL_H2, ULTRASONIC

0_HH

TURBINE SPEED SENSOR GND

BK0_8_GXL_ TWIST

TSS, TURB_SPEED_SENS

SPL_H2, ULTRASONIC

0_HL RED BRAKE SW GND

BK1_0-SXL

PRB2, RED_BRAKE_SW

SPL_TRN_GRD, SPLICE TRANS GRND

0_HL RED BRAKE SW GND

BK1_0-SXL

PRB2, RED_BRAKE_SW

SPL_TRN_GRD, SPLICE TRANS GRND

0_HM RED BRAKE SW GND

BK1_0-SXL

PRB1, RED_BRAKE_SW

SPL_TRN_GRD SPLICE TRANS GRND

0_HM RED BRAKE SW GND

BK1_0-SXL

PRB1, RED_BRAKE_SW

SPL_TRN_GRD SPLICE TRANS GRND

0_HP SEC STEERING SPLICE GND

0_EQ

0_HE

0_HH

SPLICE PACK GND_CAB_SPL2 GND

OUTPUT SPEED SENSOR GND

SPLICE PACK GND_CAB_SPL2 GND

OUTPUT SPEED SENSOR GND

BK1_0-SXL

TRAN_E, TRANS TO ENG

TR_SS, SEC_STR_MOD_OPT

0_HP SEC STEERING SPLICE GND

BK1_0-SXL

TRAN_E, TRANS TO ENG

TR_SS, SEC_STR_MOD_OPT

COOLANT LEVEL SENDER 0_HV GND

BK1_0-SXL

CLS, COOL_JUMP-COOL_SEND

SPL_TRN_GRD, SPLICE TRANS GRND

COOLANT LEVEL SENDER 0_HV GND

BK1_0-SXL

CLS, COOL_JUMP-COOL_SEND

SPL_TRN_GRD, SPLICE TRANS GRND

0_HW HOT GROUND

BK1_0-SXL

HOT, HYD_OIL_TEMP_SEND

SPL_TRN_GRD, SPLICE TRANS GRND

0_HW HOT GROUND

BK1_0-SXL

HOT, HYD_OIL_TEMP_SEND

SPL_TRN_GRD, SPLICE TRANS GRND

0_JA HOOD GROUNDS(EURO)

BK1_0-SXL

HD_E, HOOD-TRANS

SPL_J1, ULTRASONIC

0_JA HOOD GROUNDS(EURO)

BK1_0-SXL

HD_E, HOOD-TRANS

SPL_J1, ULTRASONIC

4002-14

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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_JA_ HOOD GROUNDS(NA) N

BK1_0-SXL

HD_N, HOOD TO ENG

SPL_J1, ULTRASONIC

0_JA_ HOOD GROUNDS(NA) N

BK1_0-SXL

HD_N, HOOD TO ENG

SPL_J1, ULTRASONIC

0_JB BACKUP ALARM GND

BK1_0-SXL

BU1, BACKUP_ALARM_GRND

SPL_J1, ULTRASONIC

0_JB BACKUP ALARM GND

BK1_0-SXL

BU1, BACKUP_ALARM_GRND

SPL_J1, ULTRASONIC

0_JC LICENSE PLATE LIGHT GND

BK1_0-SXL

LPL, LIC_PLATE_LIGHT

SPL_J1, ULTRASONIC

0_JC LICENSE PLATE LIGHT GND

BK1_0-SXL

LPL, LIC_PLATE_LIGHT

SPL_J1, ULTRASONIC

0_LA REAR LIGHT GND

BK1_0-SXL

HD_9, HOOD TO ENG

SPL_B1, ULTRASONIC

0_LA REAR LIGHT GND

BK1_0-SXL

HD_9, HOOD TO ENG

SPL_B1, ULTRASONIC

0_LB REAR LIGHT GND

BK1_0-SXL

LLR_9, LH_REAR_COMB_LT

SPL_B1, ULTRASONIC

0_LB REAR LIGHT GND

BK1_0-SXL

LLR_9, LH_REAR_COMB_LT

SPL_B1, ULTRASONIC

0_LC REAR LIGHT GND

BK1_0-SXL

SPL_B1, ULTRASONIC

LRR_9, RH_REAR_COMB_LT

0_LC REAR LIGHT GND

BK1_0-SXL

SPL_B1, ULTRASONIC

LRR_9, RH_REAR_COMB_LT

0_LD REAR LIGHT GND

BK1_0-SXL

SPL_B1, ULTRASONIC

E_HD9, TRANS-HOOD

0_LD REAR LIGHT GND

BK1_0-SXL

SPL_B1, ULTRASONIC

E_HD9, TRANS-HOOD

0_MA REAR WIPER MOTOR GND

BK1_0-GXL

SPL_ROOF, SPLICE ROOF GROUND

RWMG, REAR_WIPER_MTR_GD

0_MA REAR WIPER MOTOR GND

BK1_0-GXL

SPL_ROOF, SPLICE ROOF GROUND

RWMG, REAR_WIPER_MTR_GD

0_MB DOME LIGHT GND

BK0_8-GXL

LDM3, DOME_LIGHT_GND

SPL_ROOF, SPLICE ROOF GROUND

0_MB DOME LIGHT GND

BK0_8-GXL

LDM3, DOME_LIGHT_GND

SPL_ROOF, SPLICE ROOF GROUND

0_MC BEACON LIGHT GND

BK1_0-GXL

LBEGRD, LIGHT BEACON GRND

SPL_ROOF, SPLICE ROOF GROUND

0_MC BEACON LIGHT GND

BK1_0-GXL

LBEGRD, LIGHT BEACON GRND

SPL_ROOF, SPLICE ROOF GROUND

0_MD BEACON LIGHT GND

BK1_0-GXL

LBEE, LIGHT BEACON EXTENSION

LBEG, LIGHT BEACON GRND

0_MD BEACON LIGHT GND

BK1_0-GXL

LBEE, LIGHT BEACON EXTENSION

LBEG, LIGHT BEACON GRND

0_ME LH REAR WORK LIGHT GND

BK1_0-GXL

LLRW, LH_REAR_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_ME LH REAR WORK LIGHT GND

BK1_0-GXL

LLRW, LH_REAR_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_MF RH REAR WORK LIGHT GND

BK1_0-GXL

LRRW, RH_REAR_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_MF RH REAR WORK LIGHT GND

BK1_0-GXL

LRRW, RH_REAR_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_MJ RH FRONT WORK LIGHT GND BK1_0-GXL

LRFW, RH_FRONT_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_MJ RH FRONT WORK LIGHT GND BK1_0-GXL

LRFW, RH_FRONT_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_MK ROOF GROUNDS

BK1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_ROOF, SPLICE ROOF GROUND

0_MK ROOF GROUNDS

BK1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_ROOF, SPLICE ROOF GROUND

0_MN ROOF GROUNDS

BK1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_ROOF, SPLICE ROOF GROUND

0_MN ROOF GROUNDS

BK1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_ROOF, SPLICE ROOF GROUND

0_MU LH FRONT WORK LIGHT GND BK1_0-GXL

LLFW, LH_FRONT_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_MU LH FRONT WORK LIGHT GND BK1_0-GXL

LLFW, LH_FRONT_WK_LT

SPL_ROOF, SPLICE ROOF GROUND

0_NB MASTER DISCONNECT GND

BK62_0-SGR

DC2, DISCON-BLCK_GRND

STTR_GRN, GRID_HTR_FUSE

0_NB MASTER DISCONNECT GND

BK62_0-SGR

DC2, DISCON-BLCK_GRND

STTR_GRN, GRID_HTR_FUSE

0_NC BATTERY DISCONNECT

BK62_0-SGR

BT4, DISCON-BLCK_GRND

DC1, DISCONECT-BATTERY

0_NC BATTERY DISCONNECT

BK62_0-SGR

BT4, DISCON-BLCK_GRND

DC1, DISCONECT-BATTERY

0_ND SSM GROUND

BK62_0-SGR

242F, CHAS_GRD-SEC_STRG_M TR

GND_SSCHAS, SSM_GROUND_CABLE

0_ND SSM GROUND

BK62_0-SGR

242F, CHAS_GRD-SEC_STRG_M TR

GND_SSCHAS, SSM_GROUND_CABLE

0_PA LEFT SPEAKER GND

BK0_8-GXL

LSPK, LEFT_SPEAKER

SPK, SPEAKER

0_PA LEFT SPEAKER GND

BK0_8-GXL

LSPK, LEFT_SPEAKER

SPK, SPEAKER

0_PB RIGHT SPEAKER GND

BK0_8-GXL

RSPK, RIGHT_SPEAKER

SPK, SPEAKER

0_PB RIGHT SPEAKER GND

BK0_8-GXL

RSPK, RIGHT_SPEAKER

SPK, SPEAKER

W0_8_GXL

S_KEY, IGNITION_SWITCH

SPL_ACC, ULTRASONIC

W0_8_GXL

SPL_ACC, ULTRASONIC

PRM_D1, PRM SIGNAL

12AC IGNITION SW ACC POWER C

W0_8_GXL

S_KEY, IGNITION_SWITCH

SPL_ACC, ULTRASONIC

12AC IGNITION SW ACC POWER C

12AC ACC PRM CONTROL POWER C_B

W0_8_GXL

SPL_ACC, ULTRASONIC

PRM_D1, PRM SIGNAL

12AC ACC PRM CONTROL POWER C_B

4002-15

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

12AC PWR CONVERTER PRM CTRL W0_8_GXL C_C PWR 12V

Wire Size (mm2) 0.8 mm 1.0 mm

2.0 mm 5.0 mm

Connector

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

SPL_ACC, ULTRASONIC

PRM_E2, PRM SIGNAL

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity A

12V PWR TO OUTLET 1

OR1_0-GXL

PO1, POWER_OUTLET

ECD, ELECT CNTR D

AA4

12V_A 12V PWR TO OUTLET 2

OR1_0-GXL

PO2, POWER_OUTLET

ECD, ELECT CNTR D

AA5

12V_B 12V FUSED PWR TO RADIO

OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

ECD, ELECT CNTR D

12V_C 12V SWITCHED POWER

OR2_0-GXL

CNV, 24V TO 12V PWR CONVERTER

SPL_12V, ULTRASONIC

12V_D PLUG 1 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

12AC PWR CONVERTER PRM CTRL W0_8_GXL C_C PWR

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

SPL_ACC, ULTRASONIC

PRM_E2, PRM SIGNAL

Cavity A

12V PWR TO OUTLET 1

OR1_0-GXL

PO1, POWER_OUTLET

ECD, ELECT CNTR D

AA4

12V_A 12V PWR TO OUTLET 2

OR1_0-GXL

PO2, POWER_OUTLET

ECD, ELECT CNTR D

AA5

12V_B 12V FUSED PWR TO RADIO

OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

ECD, ELECT CNTR D

AA6

12V_C 12V SWITCHED POWER

OR2_0-GXL

CNV, 24V TO 12V PWR CONVERTER

SPL_12V, ULTRASONIC

12V_D PLUG 1 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

AA6

12V

2.0 mm 5.0 mm

12V_E PLUG 2 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

12V_E PLUG 2 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

12V_F RADIO 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

12V_F RADIO 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

12V_G 2 WAY RADIO 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

12V_G 2 WAY RADIO 12V SW PWR

OR1_0-GXL

SPL_12V, ULTRASONIC

ECD, ELECT CNTR D

12V_H 12V FUSED PWR TO RADIO

OR0_8-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_RAD, ULTRASONIC

12V_H 12V FUSED PWR TO RADIO

OR0_8-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_RAD, ULTRASONIC

12V_H 12V FUSED PWR TO RADIO A

OR0_8-GXL

SPL_RAD, ULTRASONIC

RAD, RADIO_POWER

12V_H 12V FUSED PWR TO RADIO A

OR0_8-GXL

SPL_RAD, ULTRASONIC

RAD, RADIO_POWER

12V_H 12V FUSED PWR TO RADIO B

OR0_8-GXL

SPL_RAD, ULTRASONIC

RAD, RADIO_POWER

12V_H 12V FUSED PWR TO RADIO B

OR0_8-GXL

SPL_RAD, ULTRASONIC

RAD, RADIO_POWER

FUEL SHUTOFF FUSED PWR

OR1_0-SXL

DC3, FUEL_SOL_DISCONNECT

DISC, DISCONNECT-ENGINE

FUEL SHUTOFF FUSED PWR

OR1_0-SXL

DC3, FUEL_SOL_DISCONNECT

DISC, DISCONNECT-ENGINE

13C_A FUEL SHUTOFF FUSED PWR

OR1_0-SXL

ENG_D, DISC_HARNESS

ENG, ENGINE-CAB

13C_A FUEL SHUTOFF FUSED PWR

OR1_0-SXL

ENG_D, DISC_HARNESS

ENG, ENGINE-CAB

13C_B FUEL SHUTOFF FUSED PWR

OR1_0-SXL

CAB_E, CAB-ENGINE

ECA, ELECT CNTR A

13C_B FUEL SHUTOFF FUSED PWR

OR1_0-SXL

CAB_E, CAB-ENGINE

ECA, ELECT CNTR A

PRM_B2, PRM SIGNAL

13D

TIME DELAY RLY CTRL PWR

OR1_0-GXL

TDM, TIME_DELAY_MODULE

PRM_B2, PRM SIGNAL

13H

TIME DELAY POWER

OR3_0-GXL

SPL_DLY_RL, ULTRASONIC

PRM_B1, PRM OUTPUT

13C

13D

TIME DELAY RLY CTRL PWR

OR1_0-GXL

TDM, TIME_DELAY_MODULE

13H

TIME DELAY POWER

OR3_0-GXL

SPL_DLY_RL, ULTRASONIC

PRM_B1, PRM OUTPUT

13C

13H_B AIC TIME DELAY POWER

OR0_8-GXL

SPL_DLY_RL, ULTRASONIC

ECD, ELECT CNTR D

13H_B AIC TIME DELAY POWER

OR0_8-GXL

SPL_DLY_RL, ULTRASONIC

ECD, ELECT CNTR D

13H_C TRANS ECM TIME DLY PWR

OR0_8-GXL

SPL_DLY_RL, ULTRASONIC

ECD, ELECT CNTR D

13H_C TRANS ECM TIME DLY PWR

OR0_8-GXL

SPL_DLY_RL, ULTRASONIC

ECD, ELECT CNTR D

13H_D ENG ECM TIME DLY PWR

OR3_0-GXL

SPL_DLY_RL, ULTRASONIC

ECD, ELECT CNTR D

IGNITION SWITCH POWER

OR1_0-GXL

S_KEY, IGNITION_SWITCH

SPL_PK1, SPLICE 3-4WAY

13K_A IGNITION SWITCH POWER

OR1_0-GXL

TDM, TIME_DELAY_MODULE

SPL_PK1, SPLICE 3-4WAY

13K

OR3_0-GXL

SPL_DLY_RL, ULTRASONIC

ECD, ELECT CNTR D

IGNITION SWITCH POWER

OR1_0-GXL

S_KEY, IGNITION_SWITCH

SPL_PK1, SPLICE 3-4WAY

13K_A IGNITION SWITCH POWER

OR1_0-GXL

TDM, TIME_DELAY_MODULE

SPL_PK1, SPLICE 3-4WAY

13K

13K_B IGNITION SWITCH POWER

OR1_0-GXL

SPL_PK1, SPLICE 3-4WAY

PRM_A1, PRM SIGNAL

13K_C IGNITION SWITCH POWER

OR1_0-GXL

SPL_PK1, SPLICE 3-4WAY

ECB, ELECT CNTR B

FUEL SHUTOFF FUSED PWR

OR1_0-SXL

DC4, FUEL_SOL_DISCONNECT

DISC, DISCONNECT-ENGINE

13M

13M_ FUEL SHUTOFF FUSED PWR A

OR0_8-TXL

ENG_D, DISC_HARNESS

EDC7, ENGINE CONTROLLER

13M_ KEY SW PWR DISC SW B

OR1_0-GXL

ENG_D, DISC_HARNESS

QSM11, ENGINE CONTROLLER

13M

13K_B IGNITION SWITCH POWER

OR1_0-GXL

SPL_PK1, SPLICE 3-4WAY

PRM_A1, PRM SIGNAL

13K_C IGNITION SWITCH POWER

OR1_0-GXL

SPL_PK1, SPLICE 3-4WAY

ECB, ELECT CNTR B

FUEL SHUTOFF FUSED PWR

OR1_0-SXL

DC4, FUEL_SOL_DISCONNECT

DISC, DISCONNECT-ENGINE

13M_ FUEL SHUTOFF FUSED PWR A

OR0_8-TXL

ENG_D, DISC_HARNESS

EDC7, ENGINE CONTROLLER

13M_ KEY SW PWR DISC SW B

OR1_0-GXL

ENG_D, DISC_HARNESS

QSM11, ENGINE CONTROLLER

4002-16

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Cavity

Wire

13V

AIC_1, ADV INSTR CLUSTER 1

ECB, ELECT CNTR B

LG0_8-GXL

CAB_E, CAB-ENGINE

215F, ALTERNATOR_RESISTOR

17P_A SW PAD PWR FR0M AIC PWR OR0_8-TXL

SW_PD, SWITCH PAD

AIC_1, ADV INSTR CLUSTER 1

VOLTMETER INPUT ANALOG

14_A ALTERNATOR D+

LH HIGH BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

18B_A LH HIGH BEAM FUSED PWR

18B

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

RH HIGH BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

18C_A RH HIGH BEAM FUSED PWR

18C

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

LH LOW BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

18D_A LH LOW BEAM FUSED PWR

18D

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

RH LOW BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

18E_A RH LOW BEAM FUSED PWR

18E

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

LH POSN/TAIL FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

18F_A LH POSN/TAIL FUSED PWR

18F

OR0_8-GXL

CAB_E, CAB-ENGINE

SPL_POS_L, ULTRASONIC

18F_A LH POSN/TAIL FUSED PWR N

OR1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

18F_B LH POSN/TAIL FUSED PWR

OR1_0-SXL

ENG, ENGINE-CAB

LLR_E, LH_REAR_COMB_LT

18F_B LH POSN/TAIL FUSED PWR N

OR1_0-SXL

HD_N, HOOD TO ENG

18F_C LH POSN/TAIL FUSED PWR

OR1_0-GXL

SPL_POS_L, ULTRASONIC

18F_E LH POSN/TAIL FUSED PWR

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_POS_L, ULTRASONIC

18F_F LH POSN/TAIL FUSED PWR

OR1_0-SXL

HD_9, HOOD TO ENG

LLR_9, LH_REAR_COMB_LT

18G

LLR_N, LH_REAR_COMB_LT ECB, ELECT CNTR B

ECB, ELECT CNTR B

3 AA3 3 AA4 2 AA6 2 AA5 4

Circuit

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

OR0_8-TXL

13V

Bk = Black T = Tan LU = Light Blue

1.0 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

OR0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECB, ELECT CNTR B

LG0_8-GXL

CAB_E, CAB-ENGINE

215F, ALTERNATOR_RESISTOR

17P_A SW PAD PWR FR0M AIC PWR OR0_8-TXL

SW_PD, SWITCH PAD

AIC_1, ADV INSTR CLUSTER 1

VOLTMETER INPUT ANALOG

14_A ALTERNATOR D+

LH HIGH BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

18B_A LH HIGH BEAM FUSED PWR

18B

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

RH HIGH BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

18C_A RH HIGH BEAM FUSED PWR

18C

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

LH LOW BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

18D_A LH LOW BEAM FUSED PWR

18D

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

RH LOW BEAM FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

18E_A RH LOW BEAM FUSED PWR

18E

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECB, ELECT CNTR B

3 AA3 3 AA4 2 AA6 2 AA5

LH POSN/TAIL FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

18F_A LH POSN/TAIL FUSED PWR

OR0_8-GXL

CAB_E, CAB-ENGINE

SPL_POS_L, ULTRASONIC

18F_A LH POSN/TAIL FUSED PWR N

OR1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

18F_B LH POSN/TAIL FUSED PWR

OR1_0-SXL

ENG, ENGINE-CAB

LLR_E, LH_REAR_COMB_LT

18F_B LH POSN/TAIL FUSED PWR N

OR1_0-SXL

HD_N, HOOD TO ENG

LLR_N, LH_REAR_COMB_LT

AA7

18F_C LH POSN/TAIL FUSED PWR

OR1_0-GXL

SPL_POS_L, ULTRASONIC

18F_E LH POSN/TAIL FUSED PWR

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_POS_L, ULTRASONIC

18F_F LH POSN/TAIL FUSED PWR

OR1_0-SXL

HD_9, HOOD TO ENG

LLR_9, LH_REAR_COMB_LT

3 AA8

18F

18G

ECB, ELECT CNTR B

AA7

RH POSN/TAIL FUSED PWR

OR1_0-GXL

SPL_POS_R, ULTRASONIC

RH POSN/TAIL FUSED PWR

OR1_0-GXL

SPL_POS_R, ULTRASONIC

18G_A RH POSN/TAIL FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

18G_A RH POSN/TAIL FUSED PWR

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

AA8 4

18G_ RH POSN/TAIL FUSED PWR CN

OR1_0-SXL

SPL_POS_NA, ULTRASONIC

LRR_N, RH_REAR_COMB_LT

18G_ RH POSN/TAIL FUSED PWR CN

OR1_0-SXL

SPL_POS_NA, ULTRASONIC

LRR_N, RH_REAR_COMB_LT

18G_ LIC PLATE LT FUSED PWR D

OR1_0-SXL

SPL_POS, ULTRASONIC

E_HD, TRANS-HOOD

18G_ LIC PLATE LT FUSED PWR D

OR1_0-SXL

SPL_POS, ULTRASONIC

E_HD, TRANS-HOOD

18G_E LIC PLATE LT FUSED PWR

OR0_8-GXL

HD_E, HOOD-TRANS

LPL, LIC_PLATE_LIGHT

18G_E LIC PLATE LT FUSED PWR

OR0_8-GXL

HD_E, HOOD-TRANS

LPL, LIC_PLATE_LIGHT

18G_E LIC PLATE LT FUSED PWR N

OR1_0-SXL

LPL, LIC_PLATE_LIGHT

SPL_POS_NA, ULTRASONIC

18G_E LIC PLATE LT FUSED PWR N

OR1_0-SXL

LPL, LIC_PLATE_LIGHT

SPL_POS_NA, ULTRASONIC

18G_F RH POSN/TAIL FUSED PWR

OR0_8-GXL

CAB_E, CAB-ENGINE

SPL_POS_R, ULTRASONIC

18G_F RH POSN/TAIL FUSED PWR

OR0_8-GXL

CAB_E, CAB-ENGINE

SPL_POS_R, ULTRASONIC

18G_ RH POSN/TAIL FUSED PWR G

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_POS_R, ULTRASONIC

18G_ RH POSN/TAIL FUSED PWR G

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_POS_R, ULTRASONIC

18G_ RH POSN/TAIL FUSED PWR H

OR1_0-SXL

ENG, ENGINE-CAB

SPL_POS, ULTRASONIC

18G_ RH POSN/TAIL FUSED PWR H

OR1_0-SXL

ENG, ENGINE-CAB

SPL_POS, ULTRASONIC

18G_ RH POSN/TAIL FUSED PWR HN

OR1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

18G_ RH POSN/TAIL FUSED PWR HN

OR1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

4002-17

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

18G_J RH POSN/TAIL FUSED PWR

OR1_0-SXL

LRR_E, RH_REAR_COMB_LT

SPL_POS, ULTRASONIC

18G_J RH POSN/TAIL FUSED PWR

OR1_0-SXL

LRR_E, RH_REAR_COMB_LT

SPL_POS, ULTRASONIC

18G_J RH POSN/TAIL FUSED PWR N

OR1_0-SXL

HD_N, HOOD TO ENG

SPL_POS_NA, ULTRASONIC

18G_J RH POSN/TAIL FUSED PWR N

OR1_0-SXL

HD_N, HOOD TO ENG

SPL_POS_NA, ULTRASONIC

18G_K RH POSN/TAIL FUSED PWR

OR1_0-SXL

HD_9, HOOD TO ENG

SPL_P9, ULTRASONIC

18G_K RH POSN/TAIL FUSED PWR

OR1_0-SXL

HD_9, HOOD TO ENG

SPL_P9, ULTRASONIC

18G_L RH POSN/TAIL FUSED PWR

OR1_0-SXL

SPL_P9, ULTRASONIC

E_HD9, TRANS-HOOD

18G_L RH POSN/TAIL FUSED PWR

OR1_0-SXL

SPL_P9, ULTRASONIC

E_HD9, TRANS-HOOD

18G_ RH POSN/TAIL FUSED PWR M

OR1_0-SXL

SPL_P9, ULTRASONIC

LRR_9, RH_REAR_COMB_LT

OR2_0-GXL

CAB_E, CAB-ENGINE

SPL_D2, ULTRASONIC

18G_ RH POSN/TAIL FUSED PWR M 18J

EDC7 TIME DLY FSD PWR

OR1_0-SXL

SPL_P9, ULTRASONIC

LRR_9, RH_REAR_COMB_LT

OR2_0-GXL

CAB_E, CAB-ENGINE

SPL_D2, ULTRASONIC

18J

EDC7 TIME DLY FSD PWR

18J_A EDC7 TIME DLY FSD PWR

OR2_0-SXL

ENG, ENGINE-CAB

SPL_EDC2, ULTRASONIC

18J_A EDC7 TIME DLY FSD PWR

OR2_0-SXL

ENG, ENGINE-CAB

SPL_EDC2, ULTRASONIC

18J_B EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC2, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_B EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC2, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_C EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC2, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_C EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC2, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_D EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC4, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_D EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC4, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_E EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC4, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_E EDC7 TIME DLY FSD PWR

OR1_0-GXL

SPL_EDC4, ULTRASONIC

EDC7, ENGINE CONTROLLER

18J_F EDC7 TIME DLY FSD PWR

OR2_0-SXL

ENG, ENGINE-CAB

SPL_EDC4, ULTRASONIC

18J_F EDC7 TIME DLY FSD PWR

OR2_0-SXL

ENG, ENGINE-CAB

SPL_EDC4, ULTRASONIC

18J_G EDC7 TIME DLY FSD PWR

OR2_0-GXL

CAB_E, CAB-ENGINE

SPL_D2, ULTRASONIC

18J_G EDC7 TIME DLY FSD PWR

OR2_0-GXL

CAB_E, CAB-ENGINE

SPL_D2, ULTRASONIC

18J_H WIF SENSOR FUSED PWR

OR1_0-GXL

SPL_EDC4, ULTRASONIC

WIF, WATER_IN_FUEL_SNSR

18J_H WIF SENSOR FUSED PWR

OR1_0-GXL

SPL_EDC4, ULTRASONIC

WIF, WATER_IN_FUEL_SNSR

AA2

18J_K EDC7 TIME DLY FSD PWR

OR3_0-GXL

SPL_D2, ULTRASONIC

ECD, ELECT CNTR D

18J_L QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC4, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_K EDC7 TIME DLY FSD PWR

OR3_0-GXL

SPL_D2, ULTRASONIC

ECD, ELECT CNTR D

18J_L QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC4, ULTRASONIC

QSM11, ENGINE CONTROLLER

AA2 17

18J_M QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC2, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_M QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC2, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_N QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC2, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_N QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC2, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_P QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC4, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_P QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC4, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_Q QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC4, ULTRASONIC

QSM11, ENGINE CONTROLLER

18J_Q QSM11 TIME DELAY PWR

OR0_8-GXL

SPL_EDC4, ULTRASONIC

QSM11, ENGINE CONTROLLER

18K_A DIAGNOSTIC FUSED PWR

OR0_8-GXL

DIA, DIAGNOSTIC

ECC, ELECT CNTR C

18K_A DIAGNOSTIC FUSED PWR

OR0_8-GXL

DIA, DIAGNOSTIC

ECC, ELECT CNTR C

18L_A COMFORT STEER FSD PWR

OR0_8-GXL

SPL_CSTR, ULTRASONIC

ECA, ELECT CNTR A

18L_A COMFORT STEER FSD PWR

OR0_8-GXL

SPL_CSTR, ULTRASONIC

ECA, ELECT CNTR A

18L_B COMFORT STEER FSD PWR

OR0_8-GXL

SPL_CSTR, ULTRASONIC

ECC, ELECT CNTR C

18L_B COMFORT STEER FSD PWR

OR0_8-GXL

SPL_CSTR, ULTRASONIC

ECC, ELECT CNTR C

18L_C COMFORT STEER FSD PWR

OR0_8-GXL

SPL_CSTR, ULTRASONIC

ECC, ELECT CNTR C

18L_C COMFORT STEER FSD PWR

OR0_8-GXL

SPL_CSTR, ULTRASONIC

ECC, ELECT CNTR C

18L_D COMFORT STEER FSD PWR

OR0_8-GXL

SCS, COMFORT STEER SW

18M

AC RELAY FUSED PWR

OR0_8-GXL

ECA, ELECT CNTR A

18N

BLOWER MOTOR FUSED PWR

OR3_0-GXL

18N_A

BLOWER MOTOR FUSED PWR

18N_B

BLOWER MOTOR FUSED PWR

18R

SPL_CSTR, ULTRASONIC

OR0_8-GXL

SCS, COMFORT STEER SW

ECD, ELECT CNTR D

18M

AC RELAY FUSED PWR

OR0_8-GXL

ECA, ELECT CNTR A

SPL_BLWR, ULTRASONIC

ECA, ELECT CNTR A

18N

BLOWER MOTOR FUSED PWR

OR3_0-GXL

OR0_8-GXL

SPL_BLWR, ULTRASONIC

HVAC1, HVAC1

18N_A

BLOWER MOTOR FUSED PWR

OR3_0-GXL

SPL_BLWR, ULTRASONIC

HVAC2, HVAC2

18N_B

BLOWER MOTOR FUSED PWR

ENG, ENGINE-CAB

PRM_C1, PRM OUTPUT

18R

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

VOLTMETER RLY FUSED PWR OR2_0-SXL

18R_A VOLTMETER RLY FUSED PWR OR2_0-GXL 19A

OUTPUT SP SENSOR FSD PWR

OR1_0-SXL

TRANS, CAB-TRANSMISSION

OSS, OUT_SPEED_SENS

SPL_CSTR, ULTRASONIC

ECD, ELECT CNTR D

SPL_BLWR, ULTRASONIC

ECA, ELECT CNTR A

OR0_8-GXL

SPL_BLWR, ULTRASONIC

HVAC1, HVAC1

OR3_0-GXL

SPL_BLWR, ULTRASONIC

HVAC2, HVAC2

ENG, ENGINE-CAB

PRM_C1, PRM OUTPUT

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

TRANS, CAB-TRANSMISSION

OSS, OUT_SPEED_SENS

VOLTMETER RLY FUSED PWR OR2_0-SXL

18R_A VOLTMETER RLY FUSED PWR OR2_0-GXL 19A

OUTPUT SP SENSOR FSD PWR

OR1_0-SXL

4002-18

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 19A_A

Circuit BRAKE DECLUTCH SW FSD PWR

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

Wire

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

PBD, DEC_PRESS_SW

19A_A

19A_B FNR SW FUSED PWR

OR0_8-GXL

197M, FNR-MAIN_CAB

SPL_FNR, ULTRASONIC

19A_C FNR SW FUSED PWR

OR0_8-GXL

197F, MAIN_CAB_FNR

SPL_TRNS_PWR, TRANS_PWR

Circuit BRAKE DECLUTCH SW FSD 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

OR1_0-SXL

FRONT, CAB-FRNT_CHAS

PBD, DEC_PRESS_SW

19A_B FNR SW FUSED PWR

OR0_8-GXL

197M, FNR-MAIN_CAB

SPL_FNR, ULTRASONIC

19A_C FNR SW FUSED PWR

OR0_8-GXL

197F, MAIN_CAB_FNR

SPL_TRNS_PWR, TRANS_PWR

OR0_8-GXL

STE, TRANS_ENABLE_SW

SPL_D15, ULTRASONIC

TRANS ENABLE SW FUSED 19A_D PWR

OR0_8-GXL

STE, TRANS_ENABLE_SW

SPL_D15, ULTRASONIC

TRANS ENABLE SW FUSED 19A_D PWR

19A_E

TRANS ENABLE SW FUSED PWR

OR0_8-GXL

STE, TRANS_ENABLE_SW

SPL_D15, ULTRASONIC

19A_E

TRANS ENABLE SW FUSED PWR

OR0_8-GXL

STE, TRANS_ENABLE_SW

SPL_D15, ULTRASONIC

19A_F

TRANS ENABLE SW FUSED PWR

OR0_8-GXL

SPL_TRNS_PWR, TRANS_PWR

SPL_D15, ULTRASONIC

19A_F

TRANS ENABLE SW FUSED PWR

OR0_8-GXL

SPL_TRNS_PWR, TRANS_PWR

SPL_D15, ULTRASONIC

OR0_8-GXL

SPL_FNR, ULTRASONIC

SFNR, FNR_SWITCH

19A_G FNR SW FUSED PWR

OR0_8-GXL

SPL_FNR, ULTRASONIC

SFNR, FNR_SWITCH

SPL_TRNS_PWR, TRANS_PWR

19A_G FNR SW FUSED PWR

19A_H TRANS SHIFTER FUSED PWR OR0_8-GXL

TS1, TRANSMISSION_SHIFTER

SPL_TRNS_PWR, TRANS_PWR

19A_H TRANS SHIFTER FUSED PWR OR0_8-GXL

TS1, TRANSMISSION_SHIFTER

19A_J PLOT CTRL SW FUSED PWR

OR0_8-GXL

SPC, PILOT_CONTROL_SWITCH

SPL_PB1, ULTRASONIC

19A_J PLOT CTRL SW FUSED PWR

OR0_8-GXL

SPC, PILOT_CONTROL_SWITCH

SPL_PB1, ULTRASONIC

19A_K TECM FUSED PWR

OR0_8-TXL

SPL_TRNS_PWR, TRANS_PWR

TECM, TRANS

19A_K TECM FUSED PWR

OR0_8-TXL

SPL_TRNS_PWR, TRANS_PWR

TECM, TRANS

19A_L PARK BRK SW FUSED PWR

OR0_8-GXL

SPB, PARKING_BRAKE_SWITCH

SPL_PB1, ULTRASONIC

19A_L PARK BRK SW FUSED PWR

OR0_8-GXL

SPB, PARKING_BRAKE_SWITCH

SPL_PB1, ULTRASONIC

19A_ OUTPUT SP SNSR FUSED M PWR

OR0_8-TXL

CAB_T, CAB-TRANSMISSION

SPL_TRNS_PWR, TRANS_PWR

19A_ OUTPUT SP SNSR FUSED M PWR

OR0_8-TXL

CAB_T, CAB-TRANSMISSION

SPL_TRNS_PWR, TRANS_PWR

OR1_0-GXL

SPL_TRNS_PWR, TRANS_PWR

ECA, ELECT CNTR A

OR1_0-GXL

SPL_TRNS_PWR, TRANS_PWR

ECA, ELECT CNTR A

AA10

19A_P

BKUP ALM RLY CTRL FSD PWR

BK1_0-GXL

SPL_TRNS_PWR, TRANS_PWR

ECD, ELECT CNTR D

AA10

19A_N TRANS FUSE PWR

19A_P

BKUP ALM RLY CTRL FSD PWR

BK1_0-GXL

SPL_TRNS_PWR, TRANS_PWR

ECD, ELECT CNTR D

19A_Q

TRANS/AUTO SW FUSED PWR

OR0_8-GXL

STA, TRANS_AUTO_SW

SPL_TRNS_PWR, TRANS_PWR

19A_Q

TRANS/AUTO SW FUSED PWR

OR0_8-GXL

STA, TRANS_AUTO_SW

SPL_TRNS_PWR, TRANS_PWR

19A_R DECLUTCH SW FSD PWR

OR0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_TRNS_PWR, TRANS_PWR

19A_R DECLUTCH SW FSD PWR

OR0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_TRNS_PWR, TRANS_PWR

OR0_8-GXL

SPL_TRNS_PWR, TRANS_PWR

SPL_PB1, ULTRASONIC

19A_S TRANS FUSE PWR

OR0_8-GXL

SPL_TRNS_PWR, TRANS_PWR

SPL_PB1, ULTRASONIC

CAB_F, CAB-FRNT_CHAS

SPL_TRNS_PWR, TRANS_PWR

19A_T BRK DECLUTCH SW FSD PWR OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_TRNS_PWR, TRANS_PWR

OR0_8-GXL

SPL_FNR, ULTRASONIC

20M, TRANS_KICK-DOWN

19A_U

OR0_8-GXL

SPL_FNR, ULTRASONIC

20M, TRANS_KICK-DOWN

OR0_8-GXL

SFNR, FNR_SWITCH

SPL_FNR, ULTRASONIC

19A_V FNR SW FSD PWR

OR0_8-GXL

SFNR, FNR_SWITCH

SPL_FNR, ULTRASONIC

19A_ DIAGNOSTIC CONN FSD PWR OR0_8-GXL W

108F, DIAGNOSTIC_CONNECTO R

SPL_TRNS_PWR, TRANS_PWR

19A_ DIAGNOSTIC CONN FSD PWR OR0_8-GXL W

108F, DIAGNOSTIC_CONNECTO R

SPL_TRNS_PWR, TRANS_PWR

19B

OR0_8-GXL

SRHSTLK, RH STALK SWITCH

49a

ECA, ELECT CNTR A

19B

OR0_8-GXL

SRHSTLK, RH STALK SWITCH

49a

ECA, ELECT CNTR A

19C_A PILOT CTRL RLY FSD PWR

OR1_0-GXL

SPL_D24, ULTRASONIC

ECA, ELECT CNTR A

19C_A PILOT CTRL RLY FSD PWR

OR1_0-GXL

SPL_D24, ULTRASONIC

ECA, ELECT CNTR A

19C_B PILOT CTRL RLY FSD PWR

OR1_0-GXL

SPL_D24, ULTRASONIC

ECD, ELECT CNTR D

19C_B PILOT CTRL RLY FSD PWR

OR1_0-GXL

SPL_D24, ULTRASONIC

ECD, ELECT CNTR D

19A_S TRANS FUSE PWR

19A_T BRK DECLUTCH SW FSD PWR OR0_8-GXL 19A_U

TRANS KICK DOWN SW FSD PWR

19A_V FNR SW FSD PWR

TURN SIGNAL FSD PWR

TRANS KICK DOWN SW FSD PWR

TURN SIGNAL FSD PWR

4002-19

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Name

To Connector Cavity

Connector

19C_C PILOT CTRL RLY FSD PWR

OR0_8-GXL

SPL_D24, ULTRASONIC

ECD, ELECT CNTR D

19C_D RIDE CTRL SW FSD PWR

OR1_0-GXL

SRC, RIDE_CONTROL_SW

SPL_D24, ULTRASONIC

19D_A PARK BRK RLY FSD PWR

OR1_0-GXL

SPL_PBS, ULTRASONIC

19D_B PARK BRK RLY FSD PWR

OR0_8-GXL

SPL_PBS, ULTRASONIC

19D_C PARK BRK RLY FSD PWR

OR1_0-GXL

SPL_PBS, ULTRASONIC

OR0_8-TXL

AIC_2, ADV INSTR CLUSTER 2

19E_A AIC WAKE UP IGN

Wire Color

K = Pink U = Blue Y = Yellow

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity D5

Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

19C_C PILOT CTRL RLY FSD PWR

OR0_8-GXL

SPL_D24, ULTRASONIC

ECD, ELECT CNTR D

19C_D RIDE CTRL SW FSD PWR

OR1_0-GXL

SRC, RIDE_CONTROL_SW

SPL_D24, ULTRASONIC

ECA, ELECT CNTR A

19D_A PARK BRK RLY FSD PWR

OR1_0-GXL

SPL_PBS, ULTRASONIC

ECA, ELECT CNTR A

ECB, ELECT CNTR B

19D_B PARK BRK RLY FSD PWR

OR0_8-GXL

SPL_PBS, ULTRASONIC

ECB, ELECT CNTR B

19D_C PARK BRK RLY FSD PWR

OR1_0-GXL

SPL_PBS, ULTRASONIC

ECB, ELECT CNTR B

OR0_8-TXL

AIC_2, ADV INSTR CLUSTER 2

ECA, ELECT CNTR A

19E_A AIC WAKE UP IGN

D5 A

19H

BKUP ALM RLY FSD PWR

OR1_0-GXL

ECA, ELECT CNTR A

ECD, ELECT CNTR D

A10

19H

BKUP ALM RLY FSD PWR

OR1_0-GXL

ECA, ELECT CNTR A

ECD, ELECT CNTR D

A10

19J

FNT WPR FSD PWR

OR0_8-GXL

SPL_PK3, SPLICE 3-4WAY

ECA, ELECT CNTR A

19J

FNT WPR FSD PWR

OR0_8-GXL

SPL_PK3, SPLICE 3-4WAY

ECA, ELECT CNTR A

19J_A FNT WPR MOTOR FSD PWR

OR0_8-GXL

SPL_PK3, SPLICE 3-4WAY

FWM, FRONT-WIPER_MOTOR

19J_A FNT WPR MOTOR FSD PWR

OR0_8-GXL

SPL_PK3, SPLICE 3-4WAY

FWM, FRONT-WIPER_MOTOR

OR0_8-GXL

SFWW, FRONT WIPER/WASHER

SPL_PK3, SPLICE 3-4WAY

19J_B

OR0_8-GXL

SFWW, FRONT WIPER/WASHER

SPL_PK3, SPLICE 3-4WAY

OR0_8-GXL

SPL_PK3, SPLICE 3-4WAY

SPL_FW, ULTRASONIC

19J_C FNT WPR RLY FSD PWR

OR0_8-GXL

SPL_PK3, SPLICE 3-4WAY

SPL_FW, ULTRASONIC

OR0_8-GXL

SPL_FW, ULTRASONIC

ECD, ELECT CNTR D

19J_D

OR0_8-GXL

SPL_FW, ULTRASONIC

ECD, ELECT CNTR D

OR0_8-GXL

SPL_FW, ULTRASONIC

ECD, ELECT CNTR D

19J_E FNT WPR RLY FSD PWR

OR0_8-GXL

SPL_FW, ULTRASONIC

ECD, ELECT CNTR D

FNT WPR RLY LS CTRL FSD 19J_F PWR

OR0_8-GXL

SPL_FW, ULTRASONIC

ECD ELECT CNTR D

19J_G WPR CUT OUT RLY FSD PWR OR0_8-GXL

19J_B

FNT WPR/ WSHR SW FSD PWR

19J_C FNT WPR RLY FSD PWR 19J_D

FNT WPR RLY HS CTRL FSD PWR

19J_E FNT WPR RLY FSD PWR FNT WPR RLY LS CTRL FSD 19J_F PWR

OR0_8-GXL

19J_G WPR CUT OUT RLY FSD PWR OR0_8-GXL

SPL_FW, ULTRASONIC

ECD ELECT CNTR D

SPL_FW, ULTRASONIC

K_WCO, WIPER CUTOUT

OR1_0-GXL

SPL_RWW, ULTRASONIC

ECA, ELECT CNTR A

19K_A REAR WPR SW FSD PWR

OR1_0-GXL

SRWP, REAR_WIPER_SW

SPL_RWW, ULTRASONIC

19K_B REAR WPR SW FSD PWR

OR0_8-GXL

SRWP, REAR_WIPER_SW

SPL_RWW, ULTRASONIC

19K

REAR WPR FSD PWR

FNT WPR/ WSHR SW FSD PWR

FNT WPR RLY HS CTRL FSD PWR

SPL_FW, ULTRASONIC

K_WCO, WIPER CUTOUT

OR1_0-GXL

SPL_RWW, ULTRASONIC

ECA, ELECT CNTR A

19K_A REAR WPR SW FSD PWR

OR1_0-GXL

SRWP, REAR_WIPER_SW

SPL_RWW, ULTRASONIC

19K_B REAR WPR SW FSD PWR

OR0_8-GXL

SRWP, REAR_WIPER_SW

SPL_RWW, ULTRASONIC

19K

REAR WPR FSD PWR

19K_C REAR WPR MOTOR FSD PWR OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_RWW, ULTRASONIC

19K_C REAR WPR MOTOR FSD PWR OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

19K_D REAR WPR MOTOR FSD PWR OR1_0-SXL

ROOF, ROOF TO CAB CONNECTION

RWM, REAR_WIPER_MTR

19K_D REAR WPR MOTOR FSD PWR OR1_0-SXL

ROOF, ROOF TO CAB CONNECTION

RWM, REAR_WIPER_MTR

19L

PWR CONVERTER FSD PWR

OR2_0-GXL

PRM_E1, PRM OUTPUT

SPL_CNV, ULTRASONIC

19L_A PWR CONVERTER FSD PWR

OR2_0-GXL

CNV, 24V TO 12V PWR CONVERTER

SPL_CNV, ULTRASONIC

19L_B PWR CONVERTER FSD PWR

OR2_0-GXL

CNV, 24V TO 12V PWR CONVERTER

SPL_CNV, ULTRASONIC

SEC STR ACCESSORY FSD PWR

OR0_8-GXL

CAB_T, CAB-TRANSMISSION

ECA, ELECT CNTR A

19M_ SEC STR ACCESSORY FSD A PWR

OR1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

19M_ SEC STR ACCESSORY FSD C PWR

OR1_0-SXL

SSM, SEC STR MOD

SS_TR, SS_MOD-TRANS

19M

PWR CONVERTER FSD PWR

OR2_0-GXL

PRM_E1, PRM OUTPUT

SPL_CNV, ULTRASONIC

19L_A PWR CONVERTER FSD PWR

OR2_0-GXL

CNV, 24V TO 12V PWR CONVERTER

SPL_CNV, ULTRASONIC

19L_B PWR CONVERTER FSD PWR

OR2_0-GXL

CNV, 24V TO 12V PWR CONVERTER

SPL_CNV, ULTRASONIC

SEC STR ACCESSORY FSD PWR

OR0_8-GXL

CAB_T, CAB-TRANSMISSION

ECA, ELECT CNTR A

19M_ SEC STR ACCESSORY FSD A PWR

OR1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

19M_ SEC STR ACCESSORY FSD C PWR

OR1_0-SXL

SSM, SEC STR MOD

SS_TR, SS_MOD-TRANS

19L

19M

19N

SEAT CPRSR FSD PWR

OR1_0-GXL

SC, SEAT_COMP_MOTOR

ECA, ELECT CNTR A

19N

SEAT CPRSR FSD PWR

OR1_0-GXL

SC, SEAT_COMP_MOTOR

ECA, ELECT CNTR A

19P

PIN ENGAGE/FAN FSD PWR

OR0_8-GXL

SPL_PIN, SPL_BACK LGT PWR

ECA, ELECT CNTR A

19P

PIN ENGAGE/FAN FSD PWR

OR0_8-GXL

SPL_PIN, SPL_BACK LGT PWR

ECA, ELECT CNTR A

19P_A PIN ENGAGE SW FSD PWR

OR0_8-GXL

SPE, PIN_ENGAGE_SW

SPL_PIN, SPL_BACK LGT PWR

19P_A PIN ENGAGE SW FSD PWR

OR0_8-GXL

SPE, PIN_ENGAGE_SW

SPL_PIN, SPL_BACK LGT PWR

19P_C FAN REV SW FSD PWR

OR0_8-GXL

SFC, FAN_CONTROL_SW

SPL_PIN, SPL_BACK LGT PWR

19P_C FAN REV SW FSD PWR

OR0_8-GXL

SFC, FAN_CONTROL_SW

SPL_PIN, SPL_BACK LGT PWR

4002-20

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

19P_D FAN REV RLY FSD PWR

OR0_8-GXL

SPL_PIN, SPL_BACK LGT PWR

ECB, ELECT CNTR B

19P_D FAN REV RLY FSD PWR

OR0_8-GXL

SPL_PIN, SPL_BACK LGT PWR

ECB, ELECT CNTR B

19P_E FAN REV RLY FSD PWR

OR0_8-GXL

SPL_PIN, SPL_BACK LGT PWR

ECB, ELECT CNTR B

19P_E FAN REV RLY FSD PWR

OR0_8-GXL

SPL_PIN, SPL_BACK LGT PWR

ECB, ELECT CNTR B

SEC STR IGN FSD PWR

OR0_8-GXL

DM, DIODE OR

SPL_2, ULTRASONIC

SEC STR IGN FSD PWR

OR0_8-GXL

DM, DIODE OR

SPL_2, ULTRASONIC

19RR SEC STR IGN FSD PWR

19R

OR0_8-GXL

DM, DIODE OR

ECA, ELECT CNTR A

19RR SEC STR IGN FSD PWR

OR0_8-GXL

DM, DIODE OR

ECA, ELECT CNTR A

19R_A SEC STR IGN FSD PWR

OR1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

19R_A SEC STR IGN FSD PWR

OR1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

19R_C SEC STR IGN FSD PWR

OR1_0-SXL

SSM, SEC STR MOD

SS_TR, SS_MOD-TRANS

19R_C SEC STR IGN FSD PWR

OR1_0-SXL

SSM, SEC STR MOD

SS_TR, SS_MOD-TRANS

216F, ALTERNATOR_RESISTOR

19R_D ALTNR RESISTOR FSD PWR

OR0_8-GXL

SPL_2, ULTRASONIC

19R_E SEC STR IGN FSD PWR

19R

19R_D ALTNR RESISTOR FSD PWR

OR0_8-GXL

SPL_2, ULTRASONIC

19R_E SEC STR IGN FSD PWR

OR0_8-GXL

SPL_2, ULTRASONIC

CAB_T, CAB-TRANSMISSION

OR0_8-GXL

SPL_2, ULTRASONIC

CAB_T, CAB-TRANSMISSION

19S1 SEC STR FSD PWR

OR1_0-GXL

SS, SEC STR FUSED PWR

CAB_T, CAB-TRANSMISSION

19S1 SEC STR FSD PWR

OR1_0-GXL

SS, SEC STR FUSED PWR

CAB_T, CAB-TRANSMISSION

19S1_ SEC STR FSD PWR E

OR1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

19S1_ SEC STR FSD PWR E

OR1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

19S1_ SEC STR FSD PWR X

R1_0-SXL

SSM, SEC STR MOD

SS_TR, SS_MOD-TRANS

19S1_ SEC STR FSD PWR X

R1_0-SXL

SSM, SEC STR MOD

SS_TR, SS_MOD-TRANS

19S_B AIC DELAY FSD PWR

OR0_8-GXL

SPL_DLY3, ULTRASONIC

ECD, ELECT CNTR D

AA3

19S_B AIC DELAY FSD PWR

OR0_8-GXL

SPL_DLY3, ULTRASONIC

ECD, ELECT CNTR D

19S_C AIC DELAY FSD PWR

OR0_8-TXL

SPL_DLY3, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

19S_C AIC DELAY FSD PWR

OR0_8-TXL

SPL_DLY3, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

19S_D AIC DELAY FSD PWR

OR0_8-TXL

SPL_DLY3, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

19T_A TECM DELAY FSD PWR

OR0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

AA1

19S_D AIC DELAY FSD PWR

OR0_8-TXL

SPL_DLY3, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

19T_A TECM DELAY FSD PWR

OR0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

AA1

19U

20 14

HORN RLY FSD PWR

OR0_8-GXL

SPL_HRN, ULTRASONIC

ECC, ELECT CNTR C

HORN RLY FSD PWR

OR0_8-GXL

SPL_HRN, ULTRASONIC

ECC, ELECT CNTR C

19U_A HORN RLY FSD PWR

OR0_8-GXL

SPL_HRN, ULTRASONIC

ECC, ELECT CNTR C

19U_A HORN RLY FSD PWR

OR0_8-GXL

SPL_HRN, ULTRASONIC

ECC, ELECT CNTR C

19U_B BEACON DOME LT FSD PWR

OR1_0-GXL

SPL_LT, ULTRASONIC

ECC, ELECT CNTR C

19U_B BEACON DOME LT FSD PWR

OR1_0-GXL

SPL_LT, ULTRASONIC

ECC, ELECT CNTR C

19U_C DOME LT FSD PWR

OR0_8-GXL

ROOF, ROOF TO CAB CONNECTION

LDM1, DOME_LIGHT_B+

19U_C DOME LT FSD PWR

OR0_8-GXL

ROOF, ROOF TO CAB CONNECTION

LDM1, DOME_LIGHT_B+

19U_D DOME LT FSD PWR

OR0_8-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_LT, ULTRASONIC

19U_D DOME LT FSD PWR

OR0_8-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_LT, ULTRASONIC

19U_E HORN RLY FSD PWR

OR0_8-GXL

SPL_HRN, ULTRASONIC

ECC, ELECT CNTR C

19U_E HORN RLY FSD PWR

OR0_8-GXL

SPL_HRN, ULTRASONIC

ECC, ELECT CNTR C

19U_F DOOR SW FSD PWR

BK0_8-GXL

ROOF, ROOF TO CAB CONNECTION

DS, DOOR SWITCH

19U_F DOOR SW FSD PWR

BK0_8-GXL

ROOF, ROOF TO CAB CONNECTION

DS, DOOR SWITCH

19U_ DOOR SW FSD PWR G

OR0_8-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_LT, ULTRASONIC

19U_ DOOR SW FSD PWR G

OR0_8-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_LT, ULTRASONIC

19U_H BEACON SWITCH FSD PWR

OR1_0-GXL

SBE, BEACON_SW

SPL_LT, ULTRASONIC

19W

CIGAR LIGHTER FSD PWR

OR3_0-GXL

CL, CIGAR_LIGHTER

ECC, ELECT CNTR C

19Y

HOOD CTRL FSD PWR

OR1_0-GXL

SPL_HOOD, ULTRASONIC

ECC, ELECT CNTR C

19Y_A HOOD UP RLY FSD PWR

OR1_0-GXL

SPL_HOOD, ULTRASONIC

ECC, ELECT CNTR C

D2 D4

19U

AA3

19U_H BEACON SWITCH FSD PWR

OR1_0-GXL

SBE, BEACON_SW

SPL_LT, ULTRASONIC

19W

CIGAR LIGHTER FSD PWR

OR3_0-GXL

CL, CIGAR_LIGHTER

ECC, ELECT CNTR C

19Y

HOOD CTRL FSD PWR

OR1_0-GXL

SPL_HOOD, ULTRASONIC

ECC, ELECT CNTR C

19Y_A HOOD UP RLY FSD PWR

OR1_0-GXL

SPL_HOOD, ULTRASONIC

ECC, ELECT CNTR C

D2 D4

19Y_B HOOD DOWN RLY FSD PWR

OR1_0-GXL

SPL_HOOD, ULTRASONIC

ECC, ELECT CNTR C

19Y_B HOOD DOWN RLY FSD PWR

OR1_0-GXL

SPL_HOOD, ULTRASONIC

ECC, ELECT CNTR C

19Y_C HOOD SWITCH FSD PWR

OR1_0-GXL

CAB_E, CAB-ENGINE

SPL_HOOD, ULTRASONIC

19Y_C HOOD SWITCH FSD PWR

OR1_0-GXL

CAB_E, CAB-ENGINE

SPL_HOOD, ULTRASONIC

19Y_D HOOD SWITCH FSD PWR

OR1_0-GXL

ENG, ENGINE-CAB

HD, HOOD_SWITCH

19Y_D HOOD SWITCH FSD PWR

OR1_0-GXL

ENG, ENGINE-CAB

HD, HOOD_SWITCH

DRIVING LTS SW FSD PWR

OR1_0-GXL

SPL_PK2, SPLICE 3-4WAY

ECC, ELECT CNTR C

DRIVING LTS SW FSD PWR

OR1_0-GXL

SPL_PK2, SPLICE 3-4WAY

ECC, ELECT CNTR C

19Z_A DRIVING LTS SW FSD PWR

19Z

OR1_0-GXL

SDR, DRIVING LIGHTS SW

SPL_PK2, SPLICE 3-4WAY

19Z_A DRIVING LTS SW FSD PWR

19Z

OR1_0-GXL

SDR, DRIVING LIGHTS SW

SPL_PK2, SPLICE 3-4WAY

19Z_B DRIVING LTS SW FSD PWR

OR1_0-GXL

SDR, DRIVING LIGHTS SW

SPL_PK2, SPLICE 3-4WAY

19Z_B DRIVING LTS SW FSD PWR

OR1_0-GXL

SDR, DRIVING LIGHTS SW

SPL_PK2, SPLICE 3-4WAY

4002-21

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

Color, Size, and Material

Connector SRHSTLK, RH STALK SWITCH

IGN SW FSD PWR

R1_0-GXL

S_KEY, IGNITION_SWITCH

CAB CB PROTECTED PWR

R19_0-SXL

CB1A, CIRCUIT BRKR

1CB_ CAB CB PROTECTED PWR A

R19_0-SXL

1A 1CB

LG = Light Green G = Green P = Purple

From Connector

OR1_0-GXL

19Z_C HIGH BEAM FLASH FSD PWR

Wire Size (mm2) 0.8 mm 1.0 mm

2.0 mm 5.0 mm

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity 56d

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

From Connector Color, Size, and Material

Connector

OR1_0-GXL

SRHSTLK, RH STALK SWITCH

IGN SW FSD PWR

R1_0-GXL

S_KEY, IGNITION_SWITCH

CAB CB PROTECTED PWR

R19_0-SXL

CB1A, CIRCUIT BRKR

1CB_ CAB CB PROTECTED PWR A

R19_0-SXL

SPL_PK2, SPLICE 3-4WAY

SPL_DLY, ULTRASONIC

CBPW, CAB POWER

1CB

P_A3, B+ POWER

CAB_PW, CAB POWER

19Z_C HIGH BEAM FLASH FSD PWR

LG = Light Green G = Green P = Purple

K = Pink U = Blue Y = Yellow

To Connector Cavity 56d

Connector

Cavity

SPL_PK2, SPLICE 3-4WAY

SPL_DLY, ULTRASONIC

CBPW, CAB POWER

P_A3, B+ POWER

CAB_PW, CAB POWER

1DM

TIME DELAY/IGN SW FSD PWR

R1_0-GXL

SPL_DLY, ULTRASONIC

ECC, ELECT CNTR C

1DM

TIME DELAY/IGN SW FSD PWR

R1_0-GXL

SPL_DLY, ULTRASONIC

ECC, ELECT CNTR C

1DN

TIME DELAY FSD PWR

R1_0-GXL

TDM, TIME_DELAY_MODULE

SPL_DLY, ULTRASONIC

1DN

TIME DELAY FSD PWR

R1_0-GXL

TDM, TIME_DELAY_MODULE

SPL_DLY, ULTRASONIC

1NC

CAB CB PRM PWR

R19_0-SXL

B1, STARTER PWR STUD

CB2B, CAB B+ CB

1NC

R19_0-SXL

B1, STARTER PWR STUD

CB2B, CAB B+ CB

1_AA BRK LT SW PWR

R1_0-SXL

FRONT, CAB-FRNT_CHAS

PBL, BRAKE_LT_PRES_SW

1_AA BRK LT SW PWR

R1_0-SXL

FRONT, CAB-FRNT_CHAS

PBL, BRAKE_LT_PRES_SW

1_B9 PRM C PWR

R8_0-SXL

CB3B, CAB B+ CB

P_C5, B+ PWR FRM PRMC

1_B9 PRM C PWR

R8_0-SXL

CB3B, CAB B+ CB

P_C5, B+ PWR FRM PRMC

1_BA ALTERNATOR B+

R13_0-SXL

AB+, ALTERNATOR_B+

B2, STARTER_POWER

1_BA ALTERNATOR B+

R13_0-SXL

AB+, ALTERNATOR_B+

B2, STARTER_POWER

1_BB STRTR SOL PWR

R8_0-SXL

193, STARTER_RELAY

194, STARTER_SIGNAL

1_BB STRTR SOL PWR

R8_0-SXL

193, STARTER_RELAY

194, STARTER_SIGNAL

1_BC CAB CB PWR

R19_0-SXL

P_C3, B+ PWR FRM PRMC

CB1B, CAB B+ CB

1_BC CAB CB PWR

R19_0-SXL

P_C3, B+ PWR FRM PRMC

CB1B, CAB B+ CB

1_BE GRID HTR PWR

R19_0-SXL

115, GRID_HTR_PWR

GH, GRID_HEATER

1_BE GRID HTR PWR

R19_0-SXL

115, GRID_HTR_PWR

GH, GRID_HEATER

R8_0-GXL

P_A1, B+ POWER

L1_ECC, ECC BATT PWR

R8_0-GXL

P_A1, B+ POWER

L1_ECC, ECC BATT PWR

1_DR BRK LT SW PWR

R1_0-GXL

CAB_F, CAB-FRNT_CHAS

SPL_FLSHR_PWR, ULTRASONIC

1_C

ECC BAT PWR

cs01

1_C

ECC BAT PWR

cs01

1_DR BRK LT SW PWR

R1_0-GXL

CAB_F, CAB-FRNT_CHAS

SPL_FLSHR_PWR, ULTRASONIC

1_DU FLASHER MODULE PWR

R1_0-GXL

FLSHR, FLASHER_MODULE

SPL_FLSHR_PWR, ULTRASONIC

1_DU FLASHER MODULE PWR

R1_0-GXL

FLSHR, FLASHER_MODULE

SPL_FLSHR_PWR, ULTRASONIC

1_DV BRK LTS/FLASHER BAT PWR

R2_0-GXL

SPL_FLSHR_PWR, ULTRASONIC

ECC, ELECT CNTR C

1_DV BRK LTS/FLASHER BAT PWR

R2_0-GXL

SPL_FLSHR_PWR, ULTRASONIC

ECC, ELECT CNTR C

1_DW BRAKE LT RLY BAT PWR

R1_0-GXL

SPL_FLSHR_PWR, ULTRASONIC

ECC, ELECT CNTR C

1_DW BRAKE LT RLY BAT PWR

R1_0-GXL

SPL_FLSHR_PWR, ULTRASONIC

ECC, ELECT CNTR C

R19_0-SXL

P_C2, B+ PWR FRM PRMC

GHF1, GRID HTR FUSE

R19_0-SXL

P_C2, B+ PWR FRM PRMC

GHF1, GRID HTR FUSE

1_GA FLTR HTR PWR

1_E

GRID HTR FUSE BAT PWR

R3_0-SXL

PRM_C1, PRM OUTPUT

SPL_HTR, ULTRASONIC

1_GA FLTR HTR PWR

1_E

GRID HTR FUSE BAT PWR

R3_0-SXL

PRM_C1, PRM OUTPUT

SPL_HTR, ULTRASONIC

1_GB FUEL FLTR HTR PWR

R2_0-SXL

SPL_HTR, ULTRASONIC

FFH, FUEL_FLTR_HTR

1_GB FUEL FLTR HTR PWR

R2_0-SXL

SPL_HTR, ULTRASONIC

FFH, FUEL_FLTR_HTR

1_GC WATER SEP HTR PWR

R2_0-SXL

SPL_HTR, ULTRASONIC

WSH, WATER_SEP_HTR

1_GC WATER SEP HTR PWR

R2_0-SXL

SPL_HTR, ULTRASONIC

WSH, WATER_SEP_HTR

1_KA HAZARD SW PWR

R1_0-GXL

SHZ, HAZARD_SWITCH

SPL_FLSHR_PWR, ULTRASONIC

A 1

1_KA HAZARD SW PWR

R1_0-GXL

SHZ, HAZARD_SWITCH

SPL_FLSHR_PWR, ULTRASONIC

1_NA BATTERY CROSSOVER

R62_0-SGR

BT3, STARTER-BATTERY

BT2, DISCONECT-BATTERY

1_NA BATTERY CROSSOVER

R62_0-SGR

BT3, STARTER-BATTERY

BT2, DISCONECT-BATTERY

1_NB BATTERY STRTR

R62_0-SGR

BT1, BATTERY_STARTER

B3, STARTER-BATTERY

1_NB BATTERY STRTR

R62_0-SGR

BT1, BATTERY_STARTER

B3, STARTER-BATTERY

1_NC B+ PWR PRMC

R19_0-SXL

B1, STARTER PWR STUD

P_C1, B+ PWR FRM PRMC

1_NC B+ PWR PRMC

R19_0-SXL

B1, STARTER PWR STUD

P_C1, B+ PWR FRM PRMC

1_ND SSM PWR

R62_0-SGR

244F, STARTER-SEC_STRG_MTR

B4, STARTER_POWER

1_ND SSM PWR

R62_0-SGR

244F, STARTER-SEC_STRG_MTR

B4, STARTER_POWER

1 1

1_Y

GRID HTR FSD PWR

R19_0-SXL

GHF3, GRID_HTR_FUSE

GHF4, GRID_HTR

1_Y

GRID HTR FSD PWR

R19_0-SXL

GHF3, GRID_HTR_FUSE

GHF4, GRID_HTR

1_Z

STRTR RLY BAT PWR

R8_0-SXL

P_C4, B+ PWR FRM PRMC

195, STR_REL_PWR

1_Z

STRTR RLY BAT PWR

R8_0-SXL

P_C4, B+ PWR FRM PRMC

195, STR_REL_PWR

20G_A EDC7 ISO-K INTERFACE

W0_8-TXL

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

20G_A EDC7 ISO-K INTERFACE

W0_8-TXL

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

20G_B EDC7 ISO-K INTERFACE

W0_8_GXL

CAB_E, CAB-ENGINE

DIA, DIAGNOSTIC

NEUT START RLY OUTPUT

W0_8_GXL

SPL_CR, ULTRASONIC

ECB, ELECT CNTR B

21C_A NEUT START RLY OUTPUT

W0_8_GXL

SPL_CR, ULTRASONIC

ECB, ELECT CNTR B

21C

W0_8_GXL

CAB_E, CAB-ENGINE

DIA, DIAGNOSTIC

NEUT START RLY OUTPUT

W0_8_GXL

SPL_CR, ULTRASONIC

ECB, ELECT CNTR B

21C_A NEUT START RLY OUTPUT

W0_8_GXL

SPL_CR, ULTRASONIC

ECB, ELECT CNTR B

21C

4002-22

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

21C_B NEUT START RLY OUTPUT

Wire Size (mm2) 0.8 mm

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 W0_8_GXL

Connector

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

SPL_CR, ULTRASONIC

ECB, ELECT CNTR B

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity A10

Wire

Circuit

21C_B NEUT START RLY 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 W0_8_GXL

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

SPL_CR, ULTRASONIC

ECB, ELECT CNTR B

Cavity A10

21C_C STRTR RLY SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

SPL_CR, ULTRASONIC

21C_C STRTR RLY SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

SPL_CR, ULTRASONIC

21C_D STRTR RLY SIGNAL

W1_0-SXL

SR_9, STR_REL_signal

ENG, ENGINE-CAB

21C_D STRTR RLY SIGNAL

W1_0-SXL

SR_9, STR_REL_signal

ENG, ENGINE-CAB

W1_0-SXL

SRC_1, RELAY

ENG, ENGINE-CAB

W1_0-SXL

SRC_1, RELAY

ENG, ENGINE-CAB

W0_8_GXL

SPL_4, ULTRASONIC

ECB, ELECT CNTR B

W0_8_GXL

SPL_4, ULTRASONIC

ECB, ELECT CNTR B

21D

STRTR RLY SIGNAL

21D_A STRTR RLY SIGNAL

AA9

21D

STRTR RLY SIGNAL

21D_A STRTR RLY SIGNAL

AA9

21D_B STRTR RLY SIGNAL

W0_8_GXL

140M, DIODE_MODULE

SPL_4, ULTRASONIC

21D_B STRTR RLY SIGNAL

W0_8_GXL

140M, DIODE_MODULE

SPL_4, ULTRASONIC

21D_C STRTR RLY SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

SPL_4, ULTRASONIC

21D_C STRTR RLY SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

SPL_4, ULTRASONIC

21E

KEY SWITCH CRANK

21E_A KEY SWITCH CRANK 21F

W0_8_GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

W0_8-TXL

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

21E

KEY SWITCH CRANK

21E_A KEY SWITCH CRANK

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

32 B5

EDC7 DIGITAL GND

W0_8_GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

EDC7 DIGITAL GND

W0_8_GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

21F_A EDC7 DIGITAL GND

W0_8_GXL

ENG, ENGINE-CAB

SPL_EDC3, ULTRASONIC

21F_A EDC7 DIGITAL GND

W0_8_GXL

ENG, ENGINE-CAB

SPL_EDC3, ULTRASONIC

21F_B EDC7 DIGITAL GND

W0_8-TXL

SPL_EDC3, ULTRASONIC

EDC7, ENGINE CONTROLLER

21F_B EDC7 DIGITAL GND

W0_8-TXL

SPL_EDC3, ULTRASONIC

EDC7, ENGINE CONTROLLER

21F_C EDC7 DIGITAL GND

W0_8-TXL

RTHP, THROTTLE_PEDAL

SPL_EDC3, ULTRASONIC

21F_C EDC7 DIGITAL GND

W0_8-TXL

RTHP, THROTTLE_PEDAL

SPL_EDC3, ULTRASONIC

21G

EDC7 CRANK CTRL RLY

21GA EDC7 CRANK CTRL RLY 21H

CRANK CTRL RLY LSD

21H_A CRANK CTRL RLY LSD 21K

IGN SW START SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

W0_8-TXL

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

AA10 37

W0_8_GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

W0_8-TXL

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

21F

W0_8_GXL W0_8-TXL

21G

EDC7 CRANK CTRL RLY

21GA EDC7 CRANK CTRL RLY 21H

CRANK CTRL RLY LSD

21H_A CRANK CTRL RLY LSD

ECB, ELECT CNTR B

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

AA10 37

W0_8_GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

W0_8-TXL

ENG, ENGINE-CAB

EDC7, ENGINE CONTROLLER

W0_8_GXL

S_KEY, IGNITION_SWITCH

SPL_CRK, ULTRASONIC

W0_8_GXL

S_KEY, IGNITION_SWITCH

SPL_CRK, ULTRASONIC

W0_8-TXL

SPL_CRK, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

21K_A IGN SW START SIGNAL

W0_8-TXL

SPL_CRK, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

21K_B IGN SW START SIGNAL

W0_8_GXL

SPL_CRK, ULTRASONIC

ECB, ELECT CNTR B

THROT SIGNAL

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24B_A THROT SIGNAL

W0_8-TXL

RTHP, THROTTLE_PEDAL

QSM11, ENGINE CONTROLLER

24L

LOW IDLE SWITCH

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24R

THROT GND

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24R_A THROT GND

W0_8-TXL

RTHP, THROTTLE_PEDAL

QSM11, ENGINE CONTROLLER

THROT SUPPLY

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24S_A THROT SUPPLY

24S

W0_8-TXL

RTHP, THROTTLE_PEDAL

QSM11, ENGINE CONTROLLER

25A

ENG SP SIGNAL

25A_A ENG SP SIGNAL 25B

INT SP SIGNAL

25B_A INT SP SIGNAL 25C

TURBINE SP SIGNAL

25C_A TURBINE SP SIGNAL 25D

OUTPUT SP SIGNAL

W0_8_GXL_T TRANS, CAB-TRANSMISWIST SION

ESS, ENG_SPEED_SENS

CAB_T, CAB-TRANSMISSION

TECM, TRANS

W0_8_GXL_T TRANS, CAB-TRANSMISWIST SION

ISS, INT_SPEED_SENS

CAB_T, CAB-TRANSMISSION

TECM, TRANS

W0_8_GXL_T TRANS, CAB-TRANSMISWIST SION

TSS, TURB_SPEED_SENS

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

LU1_0-SXL

TRANS, CAB-TRANSMISSION

OSS, OUT_SPEED_SENS

LU0_8-TXL

IGN SW START SIGNAL

CAB_E, CAB-ENGINE

21K_A IGN SW START SIGNAL 24B

21K

W0_8_GXL W0_8-TXL

W0_8_GXL

SPL_CRK, ULTRASONIC

ECB, ELECT CNTR B

THROT SIGNAL

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24B_A THROT SIGNAL

24B

W0_8-TXL

RTHP, THROTTLE_PEDAL

QSM11, ENGINE CONTROLLER

24L

LOW IDLE SWITCH

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24R

THROT GND

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24R_A THROT GND

W0_8-TXL

RTHP, THROTTLE_PEDAL

QSM11, ENGINE CONTROLLER

THROT SUPPLY

W0_8-TXL

RTHP, THROTTLE_PEDAL

EDC7, ENGINE CONTROLLER

24S_A THROT SUPPLY

24S

W0_8-TXL

RTHP, THROTTLE_PEDAL

QSM11, ENGINE CONTROLLER

W0_8_GXL_T TRANS, CAB-TRANSMISWIST SION

ESS, ENG_SPEED_SENS

CAB_T, CAB-TRANSMISSION

TECM, TRANS

W0_8_GXL_T TRANS, CAB-TRANSMISWIST SION

ISS, INT_SPEED_SENS

CAB_T, CAB-TRANSMISSION

TECM, TRANS

W0_8_GXL_T TRANS, CAB-TRANSMISWIST SION

TSS, TURB_SPEED_SENS

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

LU1_0-SXL

TRANS, CAB-TRANSMISSION

OSS, OUT_SPEED_SENS

25A

ENG SP SIGNAL

25A_A ENG SP SIGNAL 25B

INT SP SIGNAL

25B_A INT SP SIGNAL 25C

TURBINE SP SIGNAL

25C_A TURBINE SP SIGNAL 25D

OUTPUT SP SIGNAL

LU0_8-TXL

4002-23

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

25D_A OUTPUT SP SIGNAL 25F

FORWARD SIGNAL

25G

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

LU0_8-TXL

TS1, TRANSMISSION_SHIFTER

TECM, TRANS

Wire

Circuit

25D_A OUTPUT SP SIGNAL 25F

FORWARD SIGNAL

25G

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

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

LU0_8-TXL

TS1, TRANSMISSION_SHIFTER

TECM, TRANS

BRK DECLUTCH SW CTRL

LU1_0-SXL

FRONT, CAB-FRNT_CHAS

PBD, DEC_PRESS_SW

BRK DECLUTCH SW CTRL

LU1_0-SXL

FRONT, CAB-FRNT_CHAS

PBD, DEC_PRESS_SW

25G_A BRK DECLUTCH SW CTRL

LU0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_DC, ULTRASONIC

25G_A BRK DECLUTCH SW CTRL

LU0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_DC, ULTRASONIC

25G_B BRK DECLUTCH SW CTRL

LU0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_DC, ULTRASONIC

25G_B BRK DECLUTCH SW CTRL

LU0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_DC, ULTRASONIC

25G_ BRK DECLUTCH SW CTRL C

LU0_8-TXL

SPL_DC, ULTRASONIC

TECM, TRANS

25G_ BRK DECLUTCH SW CTRL C

LU0_8-TXL

SPL_DC, ULTRASONIC

TECM, TRANS

25H

TRANS AUTO SIGNAL

LU0_8-TXL

STA, TRANS_AUTO_SW

TECM, TRANS

25H

TRANS AUTO SIGNAL

LU0_8-TXL

STA, TRANS_AUTO_SW

TECM, TRANS

25J

TRANS SOL VALVE Y6

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25J

TRANS SOL VALVE Y6

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25J_A TRANS SOL VALVE Y6

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25J_A TRANS SOL VALVE Y6

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

TRANS SOL VALVE Y1

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

TRANS SOL VALVE Y1

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25K_9 TRANS SOL VALVE Y2

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25K_9 TRANS SOL VALVE Y2

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25K_A TRANS SOL VALVE Y1

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25K_A TRANS SOL VALVE Y1

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

TRANS SOL VALVE Y2

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

TRANS SOL VALVE Y2

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25L_9 TRANS SOL VALVE Y1

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25L_9 TRANS SOL VALVE Y1

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25L_A TRANS SOL VALVE Y2

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25L_A TRANS SOL VALVE Y2

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

TRANS SOL VALVE Y3

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25M

TRANS SOL VALVE Y3

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25M_ TRANS SOL VALVE Y3 A

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25M_ TRANS SOL VALVE Y3 A

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

TRANS SOL VALVE Y4

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

TRANS SOL VALVE Y4

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25N_A TRANS SOL VALVE Y4

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25N_A TRANS SOL VALVE Y4

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

TRANS SOL VALVE Y5

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

TRANS SOL VALVE Y5

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25P_A TRANS SOL VALVE Y5

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25P_A TRANS SOL VALVE Y5

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

25K

25L

25M

25N

25P

25K

25L

25N

25P

25R

REVERSE SIGNAL

LU0_8-TXL

TS1, TRANSMISSION_SHIFTER

TECM, TRANS

25R

REVERSE SIGNAL

LU0_8-TXL

TS1, TRANSMISSION_SHIFTER

TECM, TRANS

25S

OUTPUT SW PWR VPS1

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25S

OUTPUT SW PWR VPS1

LU0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

25S_A OUTPUT SW PWR VPS1

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

SPL_D12, ULTRASONIC

25S_A OUTPUT SW PWR VPS1

LU0_8-TXL

CAB_T, CAB-TRANSMISSION

SPL_D12, ULTRASONIC

25S_B OUTPUT SW PWR VPS1

LU0_8-TXL

SPL_D12, ULTRASONIC

TECM, TRANS

25S_B OUTPUT SW PWR VPS1

LU0_8-TXL

SPL_D12, ULTRASONIC

TECM, TRANS

4002-24

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

25S_C OUTPUT SW PWR VPS1

Wire Size (mm2) 0.8 mm

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

Wire Name

To Connector Cavity

Connector

Cavity

Wire

TECM, TRANS

LU0_8-GXL

SPL_NEU, ULTRASONIC

ECB, ELECT CNTR B

25T_B NEUTRAL SIGNAL

LU0_8-GXL

TS1, TRANSMISSION_SHIFTER

SPL_NEU, ULTRASONIC

25T_C NEUTRAL SIGNAL

LU0_8-TXL

SPL_NEU, ULTRASONIC

TECM, TRANS

25W 25Y

NEUTRAL SIGNAL

Bk = Black T = Tan LU = Light Blue

25W

3RD AND 4TH GEAR SIGNAL

LU0_8-TXL

TS2, TRANSMISSION_SHIFTER

25Y

TRANS KICK DOWN SIGNAL

LU0_8-GXL

TS2, TRANSMISSION_SHIFTER

SPL_D11, ULTRASONIC

25Y_A TRANS KICK DOWN SIGNAL

LU0_8-TXL

SPL_D11, ULTRASONIC

TECM, TRANS

Circuit

25S_C OUTPUT SW PWR VPS1

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

SPL_D12, ULTRASONIC

25T

LU0_8-TXL

Connector

Wire Color

K = Pink U = Blue Y = Yellow

1.0 mm

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

To Connector Cavity

Connector

Cavity

SPL_D12, ULTRASONIC

TECM, TRANS

LU0_8-GXL

SPL_NEU, ULTRASONIC

ECB, ELECT CNTR B

25T_B NEUTRAL SIGNAL

LU0_8-GXL

TS1, TRANSMISSION_SHIFTER

SPL_NEU, ULTRASONIC

25T_C NEUTRAL SIGNAL

LU0_8-TXL

SPL_NEU, ULTRASONIC

TECM, TRANS

3RD AND 4TH GEAR SIGNAL

LU0_8-TXL

TS2, TRANSMISSION_SHIFTER

TECM, TRANS

TRANS KICK DOWN SIGNAL

LU0_8-GXL

TS2, TRANSMISSION_SHIFTER

SPL_D11, ULTRASONIC

25Y_A TRANS KICK DOWN SIGNAL

LU0_8-TXL

SPL_D11, ULTRASONIC

TECM, TRANS

25T

NEUTRAL SIGNAL

LU0_8-TXL

Connector

K = Pink U = Blue Y = Yellow

25Y_B TRANS KICK DOWN SIGNAL

LU0_8-GXL

197F, MAIN_CAB_FNR

SPL_D11, ULTRASONIC

25Y_B TRANS KICK DOWN SIGNAL

LU0_8-GXL

197F, MAIN_CAB_FNR

SPL_D11, ULTRASONIC

25Y_C TRANS KICK DOWN SIGNAL

LU0_8-GXL

20M, TRANS_KICK-DOWN

197M, FNR-MAIN_CAB

25Y_C TRANS KICK DOWN SIGNAL

LU0_8-GXL

20M, TRANS_KICK-DOWN

197M, FNR-MAIN_CAB

TECM, TRANS

25Z

1ST AND 4TH GEAR SIGNAL

LU0_8-TXL

TS2, TRANSMISSION_SHIFTER

26E

TRANS ENABLE SIGNAL

LU0_8-TXL

STE, TRANS_ENABLE_SW

26F_A FNR FORWARD SIGNAL

LU0_8-GXL

197M, FNR-MAIN_CAB

26F_B FNR FORWARD SIGNAL 26J

FNR SWITCH JUMPER

25Z

1ST AND 4TH GEAR SIGNAL

LU0_8-TXL

TS2, TRANSMISSION_SHIFTER

26E

TRANS ENABLE SIGNAL

LU0_8-TXL

STE, TRANS_ENABLE_SW

TECM, TRANS

26F_A FNR FORWARD SIGNAL

LU0_8-GXL

197M, FNR-MAIN_CAB

SFNR FNR_SWITCH

TECM, TRANS

SFNR FNR_SWITCH

26F_B FNR FORWARD SIGNAL

LU0_8-TXL

197F, MAIN_CAB_FNR

TECM, TRANS

LU0_8-GXL

SFNR, FNR_SWITCH

26J

FNR SWITCH JUMPER

LU0_8-TXL

197F, MAIN_CAB_FNR

TECM, TRANS

LU0_8-GXL

SFNR, FNR_SWITCH

26N_A FNR NEUT SIGNAL

LU0_8-GXL

SFNR, FNR_SWITCH

197M, FNR-MAIN_CAB

26N_A FNR NEUT SIGNAL

LU0_8-GXL

SFNR, FNR_SWITCH

197M, FNR-MAIN_CAB

26N_B FNR NEUT SIGNAL

LU0_8-TXL

197F, MAIN_CAB_FNR

TECM, TRANS

26N_B FNR NEUT SIGNAL

LU0_8-TXL

197F, MAIN_CAB_FNR

TECM, TRANS

26R_A FNR REVERSE SIGNAL

LU0_8-GXL

SFNR, FNR_SWITCH

197M, FNR-MAIN_CAB

26R_A FNR REVERSE SIGNAL

LU0_8-GXL

SFNR, FNR_SWITCH

197M, FNR-MAIN_CAB

26R_B FNR REVERSE SIGNAL

LU0_8-TXL

197F, MAIN_CAB_FNR

TECM, TRANS

26R_B FNR REVERSE SIGNAL

LU0_8-TXL

197F, MAIN_CAB_FNR

TECM, TRANS

28E

ETHER RLY SGNL

W1_0-SXL

PRM_C2, PRM SIGNAL

ENG, ENGINE-CAB

28E

ETHER RLY SGNL

W1_0-SXL

PRM_C2, PRM SIGNAL

ENG, ENGINE-CAB

28F

FUEL FLTR HTR RLY CTRL

W0_8-TXL

PRM_C2, PRM SIGNAL

EDC7, ENGINE CONTROLLER

28F

FUEL FLTR HTR RLY CTRL

W0_8-TXL

PRM_C2, PRM SIGNAL

EDC7, ENGINE CONTROLLER

28G

GRID HTR SOURCE DR

W1_0-GXL

GHC, GRID_HEATER_REL

EDC7, ENGINE CONTROLLER

28G

GRID HTR SOURCE DR

W1_0-GXL

GHC, GRID_HEATER_REL

EDC7, ENGINE CONTROLLER

28H

ETHER SW SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

SETHR, ETHER SWITCH

28H

ETHER SW SIGNAL

W0_8_GXL

CAB_E, CAB-ENGINE

SETHR, ETHER SWITCH

28J

ETHER AIC OK SIG

W0_8_GXL

SETHR, ETHER SWITCH

AIC_1, ADV INSTR CLUSTER 1

28J

ETHER AIC OK SIG

W0_8_GXL

SETHR, ETHER SWITCH

AIC_1, ADV INSTR CLUSTER 1

28P

ETHER SOL PWR

W1_0-SXL

PRM_C1, PRM OUTPUT

ETHR, ETHER SOLENOID

28P

ETHER SOL PWR

W1_0-SXL

PRM_C1, PRM OUTPUT

ETHR, ETHER SOLENOID

31D

COOLANT LEVEL SIGNAL

Y1_0-SXL

TRANS, CAB-TRANSMISSION

CLS, COOL_JUMP-COOL_SEND

31D

COOLANT LEVEL SIGNAL

Y1_0-SXL

TRANS, CAB-TRANSMISSION

CLS, COOL_JUMP-COOL_SEND

31D_A COOLANT LEVEL SIGNAL

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_2, ADV INSTR CLUSTER 2

31D_A COOLANT LEVEL SIGNAL

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_2, ADV INSTR CLUSTER 2

31D_B COOL LVL SNDR ENG TRNS

Y1_0-SXL

TRANS, CAB-TRANSMISSION

TRAN_E, TRANS TO ENG

31D_B COOL LVL SNDR ENG TRNS

Y1_0-SXL

TRANS, CAB-TRANSMISSION

TRAN_E, TRANS TO ENG

31D_C COOL LVL SNDR ENG TRNS

Y1_0-SXL

CLS_, COOL_JUMP-COOL_SEND

ENG_T, ENGINE TO TRANS

31D_C COOL LVL SNDR ENG TRNS

Y1_0-SXL

CLS_, COOL_JUMP-COOL_SEND

ENG_T, ENGINE TO TRANS

AIR FLTR REST SW SGNL

Y1_0-SXL

ENG, ENGINE-CAB

PAF, AIR_FILT_RES_SW

AIR FLTR REST SW SGNL

Y1_0-SXL

ENG, ENGINE-CAB

PAF, AIR_FILT_RES_SW

31F_A AIR FLTR REST SW SGNL

Y0_8-TXL

CAB_E, CAB-ENGINE

SW_PD, SWITCH PAD

31F_A AIR FLTR REST SW SGNL

Y0_8-TXL

CAB_E, CAB-ENGINE

SW_PD, SWITCH PAD

HYD FLTR REST SW SGNL

Y1_0-SXL

TRANS, CAB-TRANSMISSION

PHF, HYD_OIL_FILT_RES_SW

HYD FLTR REST SW SGNL

Y1_0-SXL

TRANS, CAB-TRANSMISSION

PHF, HYD_OIL_FILT_RES_SW

31H_A HYD FLTR REST SW SGNL

Y0_8-GXL

SW_PD, SWITCH PAD

CAB_T, CAB-TRANSMISSION

31H_A HYD FLTR REST SW SGNL

Y0_8-GXL

SW_PD, SWITCH PAD

CAB_T, CAB-TRANSMISSION

31F

31H

31F

31H

4002-25

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification

Connector

Cavity

Connector

Cavity

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

31L

PILOT CTRL SW HIGH

Y0_8-TXL

SPC, PILOT_CONTROL_SWITCH

AIC_2, ADV INSTR CLUSTER 2

31L

PILOT CTRL SW HIGH

Y0_8-TXL

SPC, PILOT_CONTROL_SWITCH

AIC_2, ADV INSTR CLUSTER 2

32F

TRANS FLTR MAINT SW

Y1_0-SXL

TRANS, CAB-TRANSMISSION

FM, FILT_MAINT_SW

32F

TRANS FLTR MAINT SW

Y1_0-SXL

TRANS, CAB-TRANSMISSION

FM, FILT_MAINT_SW

32F_A TRANS FLTR MAINT SW

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

32F_A TRANS FLTR MAINT SW

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

32J_A TRANS ENABLE INDICTION

Y0_8-GXL

SFNR, FNR_SWITCH

197M, FNR-MAIN_CAB

32J_A TRANS ENABLE INDICTION

Y0_8-GXL

SFNR, FNR_SWITCH

197M, FNR-MAIN_CAB

32J_C TRANS ENABLE INDICTION

Y0_8-GXL

STE, TRANS_ENABLE_SW

SPL_D16, ULTRASONIC

32J_C TRANS ENABLE INDICTION

Y0_8-GXL

STE, TRANS_ENABLE_SW

SPL_D16, ULTRASONIC

32J_D TRANS ENABLE INDICTION

Y0_8-TXL

SPL_D16, ULTRASONIC

TECM, TRANS

32J_D TRANS ENABLE INDICTION

Y0_8-TXL

SPL_D16, ULTRASONIC

TECM, TRANS

32J_E TRANS ENABLE INDICTION

32J_E TRANS ENABLE INDICTION 33P

BRK WARNING PRESS LOW

33P_A BRK WARN PRESS LOW

Y0_8-GXL

197F, MAIN_CAB_FNR

SPL_D16, ULTRASONIC

Y1_0-SXL

FRONT, CAB-FRNT_CHAS

PBW, BRK_WARN_PR_SW

AIC_2, ADV INSTR CLUSTER 2

Y0_8-TXL

CAB_F, CAB-FRNT_CHAS

33R

RDNT BRK ACCUM PRESS LOW

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_2, ADV INSTR CLUSTER 2

33R_A

RDNT BRK ACCUM PRESS LOW

Y1_0-SXL

TRANS, CAB-TRANSMISSION

SPL_RD, ULTRASONIC

33R_B

RDNT BRK ACCUM PRESS LOW

Y1_0-SXL

SPL_RD, ULTRASONIC

33R_C

RDNT BRK ACUCM PRESS LOW

Y1_0-SXL

SPL_RD, ULTRASONIC

PARK BRK SWITCH

Y0_8-TXL

35A_9 BACKUP ALARM PWR 35A_A BKUP ALM RLY OUT

33P

BRK WARNING PRESS LOW

197F, MAIN_CAB_FNR

SPL_D16, ULTRASONIC

FRONT, CAB-FRNT_CHAS

PBW, BRK_WARN_PR_SW

Y0_8-TXL

CAB_F, CAB-FRNT_CHAS

AIC_2, ADV INSTR CLUSTER 2

33R

RDNT BRK ACCUM PRESS LOW

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_2, ADV INSTR CLUSTER 2

33R_A

RDNT BRK ACCUM PRESS LOW

Y1_0-SXL

TRANS, CAB-TRANSMISSION

SPL_RD, ULTRASONIC

PRB2, RED_BRAKE_SW

33R_B

RDNT BRK ACCUM PRESS LOW

Y1_0-SXL

SPL_RD, ULTRASONIC

PRB2, RED_BRAKE_SW

PRB1, RED_BRAKE_SW

33R_C

RDNT BRK ACUCM PRESS LOW

Y1_0-SXL

SPL_RD, ULTRASONIC

PRB1, RED_BRAKE_SW

SPB, PARKING_BRAKE_SWITCH

AIC_2, ADV INSTR CLUSTER 2

33U

PARK BRK SWITCH

Y0_8-TXL

SPB, PARKING_BRAKE_SWITCH

AIC_2, ADV INSTR CLUSTER 2

Y1_0-SXL

HD_9, HOOD TO ENG

E_HD9, TRANS-HOOD

35A_9 BACKUP ALARM PWR

Y1_0-SXL

HD_9, HOOD TO ENG

E_HD9, TRANS-HOOD

Y0_8-GXL

SPL_PK1, SPLICE 3-4WAY

ECD, ELECT CNTR D

AA9

35A_A BKUP ALM RLY OUT

Y0_8-GXL

SPL_PK1, SPLICE 3-4WAY

ECD, ELECT CNTR D

AA9

35A_B BKUP ALM DISABLE SW

Y0_8-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_PK1, SPLICE 3-4WAY

35A_B BKUP ALM DISABLE SW

Y0_8-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_PK1, SPLICE 3-4WAY

35A_C BKUP ALM RLY OUT

Y0_8-GXL

CAB_E, CAB-ENGINE

SPL_PK1, SPLICE 3-4WAY

35A_C BKUP ALM RLY OUT

Y0_8-GXL

CAB_E, CAB-ENGINE

SPL_PK1, SPLICE 3-4WAY

35A_D BKUP ALM RLY OUT

Y0_8-GXL

209M, BACK-UP_ALRM_DISA_JM P

SPL_PK1, SPLICE 3-4WAY

35A_D BKUP ALM RLY OUT

Y0_8-GXL

209M, BACK-UP_ALRM_DISA_JM P

SPL_PK1, SPLICE 3-4WAY

35A_E BKUP ALM RLY OUT

Y0_8-SXL

209F, BACK-UP_ALRM_DISA_JM P

SPL_D8_C1, ULTRASONIC

35A_E BKUP ALM RLY OUT

Y0_8-SXL

209F, BACK-UP_ALRM_DISA_JM P

SPL_D8_C1, ULTRASONIC

33U

33P_A BRK WARN PRESS LOW

Y0_8-GXL Y1_0-SXL

35A_F BKUP ALM RLY OUT

Y0_8-SXL

CAB_E, CAB-ENGINE

SPL_D8_C1, ULTRASONIC

35A_F BKUP ALM RLY OUT

Y0_8-SXL

CAB_E, CAB-ENGINE

SPL_D8_C1, ULTRASONIC

35A_G BKUP ALM RLY OUT

Y1_0-SXL

ENG, ENGINE-CAB

E_HD, TRANS-HOOD

35A_G BKUP ALM RLY OUT

Y1_0-SXL

ENG, ENGINE-CAB

E_HD, TRANS-HOOD

35A_G BKUP ALM RLY OUT N

Y1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

35A_G BKUP ALM RLY OUT N

Y1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

35A_H BKUP ALM RLY OUT

Y1_0-SXL

HD_E, HOOD-TRANS

BU2, BACKUP_ALARM

35A_H BKUP ALM RLY OUT

Y1_0-SXL

HD_E, HOOD-TRANS

BU2, BACKUP_ALARM

35A_H BKUP ALM RLY OUT N

Y1_0-SXL

HD_N, HOOD TO ENG

BU2, BACKUP_ALARM

35A_H BKUP ALM RLY OUT N

Y1_0-SXL

HD_N, HOOD TO ENG

BU2, BACKUP_ALARM

35A_J REVERSE LT

K1_0-SXL

ENG, ENGINE-CAB

SPL_A1A, ULTRASONIC

35A_J REVERSE LT

K1_0-SXL

ENG, ENGINE-CAB

SPL_A1A, ULTRASONIC

4002-26

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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_K REVERSE LT

K1_0-SXL

SPL_A1A, ULTRASONIC

LRR_E, RH_REAR_COMB_LT

35A_K REVERSE LT

K1_0-SXL

SPL_A1A, ULTRASONIC

LRR_E, RH_REAR_COMB_LT

35A_L REVERSE LT

K1_0-SXL

SPL_A1A, ULTRASONIC

LLR_E, LH_REAR_COMB_LT

35A_L REVERSE LT

K1_0-SXL

SPL_A1A, ULTRASONIC

LLR_E, LH_REAR_COMB_LT

35A_ REVERSE LIGHT M

K1_0-SXL

SPL_REV, ULTRASONIC

HD_9, HOOD TO ENG

35A_ REVERSE LIGHT M

K1_0-SXL

SPL_REV, ULTRASONIC

HD_9, HOOD TO ENG

35A_N REVERSE LIGHT

K1_0-SXL

SPL_REV, ULTRASONIC

LLR_9, LH_REAR_COMB_LT

35A_N REVERSE LIGHT

K1_0-SXL

SPL_REV, ULTRASONIC

LLR_9, LH_REAR_COMB_LT

35A_P REVERSE LIGHT

K1_0-SXL

LRR_9, RH_REAR_COMB_LT

SPL_REV, ULTRASONIC

35A_P REVERSE LIGHT

K1_0-SXL

LRR_9, RH_REAR_COMB_LT

SPL_REV, ULTRASONIC

35A_R BKUP ALM RLY OUT

Y1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

Y1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

35B

AIC BUZZER HSD

W0_8-TXL

BUZ, AIC_BUZZER

AIC_1, ADV INSTR CLUSTER 1

35B

AIC BUZZER HSD

W0_8-TXL

BUZ, AIC_BUZZER

AIC_1, ADV INSTR CLUSTER 1

35C

BKUP ALM RLY CTRL

Y0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

35C

BKUP ALM RLY CTRL

Y0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

Y0_8-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_D8_C1, ULTRASONIC

Y0_8-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_D8_C1, ULTRASONIC

35R_C BKUP ALM SW

35W

WIF INDICATOR

W0_8-TXL

WIF, WATER_IN_FUEL_SNSR

EDC7, ENGINE CONTROLLER

35W

WIF INDICATOR

W0_8-TXL

WIF, WATER_IN_FUEL_SNSR

EDC7, ENGINE CONTROLLER

35X

SEC STR LOW PRESS SGNL

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_2, ADV INSTR CLUSTER 2

35X

SEC STR LOW PRESS SGNL

Y0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_2, ADV INSTR CLUSTER 2

35X_A SEC STR LOW PRESS SGNL

Y1_0-SXL

SPL_C3, ULTRASONIC

PSS, SEC STR PRES SWITCH

35X_A SEC STR LOW PRESS SGNL

Y1_0-SXL

SPL_C3, ULTRASONIC

PSS, SEC STR PRES SWITCH

35X_B SEC STR LOW PRESS SGNL

Y1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

35X_B SEC STR LOW PRESS SGNL

Y1_0-SXL

TRANS, CAB-TRANSMISSION

TR_SS, SEC_STR_MOD_OPT

35X_C SEC STR LOW PRESS SGNL

Y1_0-SXL

SPL_C3, ULTRASONIC

SS_TR, SS_MOD-TRANS

35X_C SEC STR LOW PRESS SGNL

Y1_0-SXL

SPL_C3, ULTRASONIC

SS_TR, SS_MOD-TRANS

35X_D SEC STR LOW PRESS SGNL

Y1_0-SXL

SSM, SEC STR MOD

SPL_C3, ULTRASONIC

REAR AXLE TEMP

P0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

36A_A REAR AXLE TEMP

P1_0-SXL

ENG, ENGINE-CAB

HOT_RA, REAR_AX_OIL_TEMP

FRONT AXLE TEMP

P0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

36B_A FRONT AXLE TEMP

P1_0-SXL

36A

36B

36C

RADIATOR COOL TEMP SGNL P1_0-SXL

36C_A RADITAOR COOL TEMP SGNL W0_8-TXL

CAB_F, CAB-FRNT_CHAS

FRONT, CAB-FRNT_CHAS

HOT_FA, FRNT_AX_OIL_TEMP

ENG, ENGINE-CAB

RECT, ENG_COOL_TEMP

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

AXLE FILTER RES SENSOR

P0_8-GXL

AIC_1, ADV INSTR CLUSTER 1

36D_A AXLE FILTER RES SENSOR

P1_0-SXL

SPL_FHR, ULTRASONIC

36D_B REAR AXLE FLTR SNSR

P1_0-SXL

36D_C FRONT AXLE FLTR SNSR

P1_0-SXL

36D

36F

SSM, SEC STR MOD

SPL_C3, ULTRASONIC

P0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

36A_A REAR AXLE TEMP

P1_0-SXL

ENG, ENGINE-CAB

HOT_RA, REAR_AX_OIL_TEMP

FRONT AXLE TEMP

P0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

CAB_F, CAB-FRNT_CHAS

36B_A FRONT AXLE TEMP

P1_0-SXL

FRONT, CAB-FRNT_CHAS

HOT_FA, FRNT_AX_OIL_TEMP

ENG, ENGINE-CAB

RECT, ENG_COOL_TEMP

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

CAB_F, CAB-FRNT_CHAS

36B

36C

RADIATOR COOL TEMP SGNL P1_0-SXL

36C_A RADITAOR COOL TEMP SGNL W0_8-TXL AXLE FILTER RES SENSOR

P0_8-GXL

AIC_1, ADV INSTR CLUSTER 1

36D_A AXLE FILTER RES SENSOR

P1_0-SXL

SPL_FHR, ULTRASONIC

FRONT, CAB-FRNT_CHAS

36D_B REAR AXLE FLTR SNSR

P1_0-SXL

PFA, FRONT AXLE FILTER

SPL_FHR, ULTRASONIC

36D_C FRONT AXLE FLTR SNSR

P1_0-SXL

PRA, REAR AXLE FILTER

SPL_FHR, ULTRASONIC

CAB_F, CAB-FRNT_CHAS

FRONT, CAB-FRNT_CHAS

PFA, FRONT AXLE FILTER

SPL_FHR, ULTRASONIC

PRA, REAR AXLE FILTER

SPL_FHR, ULTRASONIC

FUEL LEVEL ANALOG

P1_0-SXL

ENG, ENGINE-CAB

RFL, FUEL_SENDER

36F_A FUEL LEVEL ANALOG

P0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

TCO TEMP SIGNAL

P1_0-SXL

TRANS, CAB-TRANSMISSION

TCOT, TCO_SENDER

36G_A TCO TEMP SIGNAL

P0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

36G

Y1_0-SXL

REAR AXLE TEMP

36A

36D

FUEL LEVEL ANALOG

P1_0-SXL

ENG, ENGINE-CAB

RFL, FUEL_SENDER

36F_A FUEL LEVEL ANALOG

36F

P0_8-TXL

CAB_E, CAB-ENGINE

AIC_1, ADV INSTR CLUSTER 1

TCO TEMP SIGNAL

P1_0-SXL

TRANS, CAB-TRANSMISSION

TCOT, TCO_SENDER

36G_A TCO TEMP SIGNAL

P0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

36G

4002-27

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Cavity

Wire 36H

P1_0-SXL

TRANS, CAB-TRANSMISSION

HOT, HYD_OIL_TEMP_SEND

36H_A HYDRAULIC OIL TEMP

P0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_1, ADV INSTR CLUSTER 1

36R_A TRANS TEMPS/FLTR RETURN P1_0-SXL

TRANS, CAB-TRANSMISSION

P1_0-SXL

SPL_H1, ULTRASONIC

36R_C VALVE BODY TEMP RETURN

P0_8-TXL

36R_D TCO TEMP RETURN

P1_0-SXL

36R_B

TRANS FLTR MAINT SW RETURN

36R_E TRANS TEMPS/FLTR RETURN P0_8-TXL

From Connector Color, Size, and Material

Connector

Cavity

36H_A HYDRAULIC OIL TEMP

P0_8-TXL

CAB_T, CAB-TRANSMISSION

AIC_1, ADV INSTR CLUSTER 1

SPL_H1, ULTRASONIC

36R_A TRANS TEMPS/FLTR RETURN P1_0-SXL

TRANS, CAB-TRANSMISSION

SPL_H1, ULTRASONIC

FM, FILT_MAINT_SW

36R_B

P1_0-SXL

SPL_H1, ULTRASONIC

FM, FILT_MAINT_SW

SPL_H1, ULTRASONIC

TRC, TRANS_CONTROL

36R_C VALVE BODY TEMP RETURN

P0_8-TXL

SPL_H1, ULTRASONIC

TRC, TRANS_CONTROL

SPL_H1, ULTRASONIC

TCOT, TCO_SENDER

36R_D TCO TEMP RETURN

P1_0-SXL

SPL_H1, ULTRASONIC

TCOT, TCO_SENDER

CAB_T, CAB-TRANSMISSION

TECM, TRANS

36R_E TRANS TEMPS/FLTR RETURN P0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

36T_A VALVE BODY TEMP SGNL

P0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

37D_A DIAGNOSTIC SGNL

P0_8-TXL

108F, DIAGNOSTIC_CONNECTO R

DIAGNOSTIC SGNL SWITCHED

P0_8-TXL

108F, DIAGNOSTIC_CONNECTO R

41H_A HIGH BEAM PWR

OR1_0-GXL

SRHSTLK, RH STALK SWITCH

41H_B HIGH BEAM LH PWR

OR0_8-GXL

SPL_PK2, SPLICE 3-4WAY

41H_C HIGH BEAM RH PWR

OR0_8-GXL

41H_D HIGH BEAM PWR

OR0_8-TXL

56a

TRANS FLTR MAINT SW RETURN

VALVE BODY TEMP SGNL

P0_8-TXL

TRANS, CAB-TRANSMISSION

TRC, TRANS_CONTROL

36T_A VALVE BODY TEMP SGNL

P0_8-TXL

CAB_T, CAB-TRANSMISSION

TECM, TRANS

37D_A DIAGNOSTIC SGNL

P0_8-TXL

108F, DIAGNOSTIC_CONNECTO R

TECM, TRANS

DIAGNOSTIC SGNL SWITCHED

P0_8-TXL

108F, DIAGNOSTIC_CONNECTO R

TECM, TRANS

SPL_PK2, SPLICE 3-4WAY

41H_A HIGH BEAM PWR

OR1_0-GXL

SRHSTLK, RH STALK SWITCH

SPL_PK2, SPLICE 3-4WAY

36T

37E

ECB, ELECT CNTR B

41H_B HIGH BEAM LH PWR

OR0_8-GXL

SPL_PK2, SPLICE 3-4WAY

ECB, ELECT CNTR B

41H_C HIGH BEAM RH PWR

OR0_8-GXL

SW_PD, SWITCH PAD

SPL_PK2, SPLICE 3-4WAY

41H_D HIGH BEAM PWR

OR0_8-TXL

OR1_0-GXL

SDR, DRIVING LIGHTS SW

SRHSTLK, RH STALK SWITCH

41L_A LOW BEAM PWR

OR1_0-GXL

SRHSTLK, RH STALK SWITCH

41L_B LOW BEAM LH PWR

OR0_8-GXL

SPL_LB, ULTRASONIC

POSN LIGHTS SW PWR

Connector

41T

Cavity

HOT, HYD_OIL_TEMP_SEND

TRC, TRANS_CONTROL

41L_C LOW BEAM RH PWR

To Connector

DR LTS PWR

K = Pink U = Blue Y = Yellow

TRANS, CAB-TRANSMISSION

41J

LG = Light Green G = Green P = Purple

P1_0-SXL

P0_8-TXL

37E

Circuit

S = Gray N = Brown R = Red

HYDRAULIC OIL TEMP

VALVE BODY TEMP SGNL

36T

DU = Dark Blue W = White Or = Orange

Wire Identification

HYDRAULIC OIL TEMP

36H

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

56b

OR0_8-GXL

SPL_LB, ULTRASONIC

K1_0-GXL

SDR, DRIVING LIGHTS SW

SPL_LB, ULTRASONIC

56a K

ECB, ELECT CNTR B

SPL_PK2, SPLICE 3-4WAY

ECB, ELECT CNTR B

SW_PD, SWITCH PAD

SPL_PK2, SPLICE 3-4WAY

OR1_0-GXL

SDR, DRIVING LIGHTS SW

SRHSTLK, RH STALK SWITCH

41L_A LOW BEAM PWR

OR1_0-GXL

SRHSTLK, RH STALK SWITCH

OR0_8-GXL

SPL_LB, ULTRASONIC

41J

DR LTS PWR

ECB, ELECT CNTR B

41L_B LOW BEAM LH PWR

ECB, ELECT CNTR B

41L_C LOW BEAM RH PWR

SPL_PK2, SPLICE 3-4WAY

41T

POSN LIGHTS SW PWR

56b

OR0_8-GXL

SPL_LB, ULTRASONIC

K1_0-GXL

SDR, DRIVING LIGHTS SW

SPL_LB, ULTRASONIC ECB, ELECT CNTR B

ECB, ELECT CNTR B

SPL_PK2, SPLICE 3-4WAY

41T_A POSN LIGHTS RH SW PWR

K1_0-GXL

SPL_PK2, SPLICE 3-4WAY

ECB, ELECT CNTR B

41T_A POSN LIGHTS RH SW PWR

K1_0-GXL

SPL_PK2, SPLICE 3-4WAY

ECB, ELECT CNTR B

41T_B POSN LIGHTS LH SW PWR

K1_0-GXL

SPL_PK2, SPLICE 3-4WAY

ECB, ELECT CNTR B

41T_B POSN LIGHTS LH SW PWR

K1_0-GXL

SPL_PK2, SPLICE 3-4WAY

ECB, ELECT CNTR B

41T_C POSN LIGHTS SW PWR

K1_0-GXL

D_OR, DIODE OR

SPL_D, ULTRASONIC

41T_C POSN LIGHTS SW PWR

K1_0-GXL

D_OR, DIODE OR

SPL_D, ULTRASONIC

41T_D POSN LIGHTS SW PWR

K0_8-TXL

SW_PD, SWITCH PAD

SPL_D, ULTRASONIC

41T_D POSN LIGHTS SW PWR

K0_8-TXL

SW_PD, SWITCH PAD

SPL_D, ULTRASONIC

41T_E POSN LIGHTS SW PWR

K1_0-SXL

SPL_PK2, SPLICE 3-4WAY

SPL_D, ULTRASONIC

41T_E POSN LIGHTS SW PWR

K1_0-SXL

SPL_PK2, SPLICE 3-4WAY

SPL_D, ULTRASONIC

42C_A FNT WRK LTS FUSE PWR

DU1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_PK1, SPLICE 3-4WAY

42C_C FNT WRK LTS FUSE PWR

DU1_0-GXL

SPL_PK1, SPLICE 3-4WAY

ECB, ELECT CNTR B

42C_A FNT WRK LTS FUSE PWR

DU1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

AA1

42C_C FNT WRK LTS FUSE PWR

DU1_0-GXL

SPL_PK1, SPLICE 3-4WAY

A AA1

4002-28

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

42C_D FNT WRK LTS FUSE PWR

DU1_0-GXL

SPL_PK1, SPLICE 3-4WAY

D_OR, DIODE OR

42C_D FNT WRK LTS FUSE PWR

DU1_0-GXL

SPL_PK1, SPLICE 3-4WAY

D_OR, DIODE OR

42C_E FNT WRK LTS FUSE PWR

DU0_8-TXL

SW_PD, SWITCH PAD

SPL_PK1, SPLICE 3-4WAY

42C_E FNT WRK LTS FUSE PWR

DU0_8-TXL

SW_PD, SWITCH PAD

SPL_PK1, SPLICE 3-4WAY

42C_F FNT WRK LTS FUSE PWR

DU1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_WRKF, ULTRASONIC

42C_F FNT WRK LTS FUSE PWR

DU1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_WRKF, ULTRASONIC

42C_ RH FNT WRK LTS FUSE PWR G

DU1_0-GXL

SPL_WRKF, ULTRASONIC

LRFW, RH_FRONT_WK_LT

42C_ RH FNT WRK LTS FUSE PWR G

DU1_0-GXL

SPL_WRKF, ULTRASONIC

LRFW, RH_FRONT_WK_LT

42C_H LH FNT WRK LTS FUSE PWR

DU1_0-GXL

SPL_WRKF, ULTRASONIC

LLFW, LH_FRONT_WK_LT

42C_H LH FNT WRK LTS FUSE PWR

DU1_0-GXL

SPL_WRKF, ULTRASONIC

LLFW, LH_FRONT_WK_LT

42FS FNT WRK LTS SW PWR

DU1_0-GXL

SWL, WORK LIGHTS SW

ECB, ELECT CNTR B

42FS FNT WRK LTS SW PWR

DU1_0-GXL

SWL, WORK LIGHTS SW

ECB, ELECT CNTR B

42RS REAR WRK LTS SW PWR

DU1_0-GXL

SWL, WORK LIGHTS SW

ECB, ELECT CNTR B

42RS REAR WRK LTS SW PWR

DU1_0-GXL

SWL, WORK LIGHTS SW

ECB, ELECT CNTR B

42R_C REAR WRK LTS FUSE PWR

DU1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

ECB, ELECT CNTR B

AA2

42R_C REAR WRK LTS FUSE PWR

DU1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

ECB, ELECT CNTR B

AA2

42R_F REAR WRK LTS FUSE PWR

DU1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_WRKR, ULTRASONIC

42R_F REAR WRK LTS FUSE PWR

DU1_0-GXL

ROOF, ROOF TO CAB CONNECTION

SPL_WRKR, ULTRASONIC

42R_ RH REAR WRK LTS FUSE G PWR

DU1_0-GXL

SPL_WRKR, ULTRASONIC

LRRW, RH_REAR_WK_LT

42R_ RH REAR WRK LTS FUSE G PWR

DU1_0-GXL

SPL_WRKR, ULTRASONIC

LRRW, RH_REAR_WK_LT

42R_H LH REAR WRK LTS FUSE PWR DU1_0-GXL

SPL_WRKR, ULTRASONIC

LLRW, LH_REAR_WK_LT

42R_H LH REAR WRK LTS FUSE PWR DU1_0-GXL

SPL_WRKR, ULTRASONIC

LLRW, LH_REAR_WK_LT

42_A WRK LTS FUSED PWR

R2_0-GXL

SWL, WORK LIGHTS SW

SPL_WL, ULTRASONIC

42_A WRK LTS FUSED PWR

R2_0-GXL

SWL, WORK LIGHTS SW

SPL_WL, ULTRASONIC

42_B WRK LTS FUSED PWR

R2_0-GXL

SWL, WORK LIGHTS SW

SPL_WL, ULTRASONIC

42_B WRK LTS FUSED PWR

R2_0-GXL

SWL, WORK LIGHTS SW

SPL_WL, ULTRASONIC

43S_A DOOR OPEN SGNL

W0_8_GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_DS, ULTRASONIC

43S_A DOOR OPEN SGNL

W0_8_GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_DS, ULTRASONIC

43S_B DOOR OPEN SGNL

W0_8_GXL

ROOF, ROOF TO CAB CONNECTION

DS, DOOR SWITCH

43S_B DOOR OPEN SGNL

W0_8_GXL

ROOF, ROOF TO CAB CONNECTION

DS, DOOR SWITCH

43S_C DOOR OPEN SGNL

W0_8-TXL

SPL_DS, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

43S_C DOOR OPEN SGNL

W0_8-TXL

SPL_DS, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

W0_8-TXL

TDM, TIME_DELAY_MODULE

SPL_DS, ULTRASONIC

43S_D

W0_8-TXL

TDM, TIME_DELAY_MODULE

SPL_DS, ULTRASONIC

43_A DOME LT AUTO MODE

DU0_8-TXL

CAB_RF, CAB TO ROOF CONNECTION

AIC_1, ADV INSTR CLUSTER 1

43_A DOME LT AUTO MODE

DU0_8-TXL

CAB_RF, CAB TO ROOF CONNECTION

AIC_1, ADV INSTR CLUSTER 1

43_B DOME LT AUTO MODE

DU0_8-GXL

ROOF, ROOF TO CAB CONNECTION

LDM2, DOME_LIGHT_AUTO

43_B DOME LT AUTO MODE

DU0_8-GXL

ROOF, ROOF TO CAB CONNECTION

LDM2, DOME_LIGHT_AUTO

44A_A BRK LT RLY OUT

T0_8-GXL

SPL_BRK, ULTRASONIC

ECC, ELECT CNTR C

44A_A BRK LT RLY OUT

T0_8-GXL

SPL_BRK, ULTRASONIC

ECC, ELECT CNTR C

43S_D

TIME DELAY MOD DOOR SW RESET

44A_B BRK LT RLY OUT

T0_8-TXL

SPL_BRK, ULTRASONIC

AIC_1, ADV INSTR CLUSTER 1

44A_B BRK LT RLY OUT

T0_8-TXL

SPL_BRK, ULTRASONIC

AIC_1, ADV INSTR CLUSTER 1

44A_C BRK LT RLY OUT

T0_8-GXL

CAB_E, CAB-ENGINE

SPL_BRK, ULTRASONIC

44A_C BRK LT RLY OUT

T0_8-GXL

CAB_E, CAB-ENGINE

SPL_BRK, ULTRASONIC

44A_D BRK LT RLY OUT

T1_0-SXL

ENG, ENGINE-CAB

SPL_B8, ULTRASONIC

44A_D BRK LT RLY OUT

T1_0-SXL

ENG, ENGINE-CAB

SPL_B8, ULTRASONIC

T1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

44A_D BRK LT RLY OUT N

T1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

44A_D BRK LT RLY OUT N

44A_E BRK LT RLY OUT

T1_0-SXL

LLR_E, LH_REAR_COMB_LT

SPL_B8, ULTRASONIC

44A_E BRK LT RLY OUT

T1_0-SXL

LLR_E, LH_REAR_COMB_LT

SPL_B8, ULTRASONIC

44A_E BRK LT RLY OUT N

T1_0-SXL

HD_N, HOOD TO ENG

SPL_J2_N, ULTRASONIC

44A_E BRK LT RLY OUT N

T1_0-SXL

HD_N, HOOD TO ENG

SPL_J2_N, ULTRASONIC

44A_F BRK LT RLY OUT

T1_0-SXL

LRR_E, RH_REAR_COMB_LT

SPL_B8, ULTRASONIC

44A_F BRK LT RLY OUT

T1_0-SXL

LRR_E, RH_REAR_COMB_LT

SPL_B8, ULTRASONIC

4002-29

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

44A_F BRK LT RLY OUT N

T1_0-SXL

LLR_N, LH_REAR_COMB_LT

SPL_J2_N, ULTRASONIC

44A_F BRK LT RLY OUT N

T1_0-SXL

LLR_N, LH_REAR_COMB_LT

SPL_J2_N, ULTRASONIC

44A_G BRK LT RLY OUT N

T1_0-SXL

LRR_N, RH_REAR_COMB_LT

SPL_J2_N, ULTRASONIC

44A_G BRK LT RLY OUT N

T1_0-SXL

LRR_N, RH_REAR_COMB_LT

SPL_J2_N, ULTRASONIC

44A_J BRAKE LIGHT PWR

T1_0-SXL

SPL_L1, ULTRASONIC

HD_9, HOOD TO ENG

44A_J BRAKE LIGHT PWR

T1_0-SXL

SPL_L1, ULTRASONIC

HD_9, HOOD TO ENG

44A_K BRAKE LIGHT PWR

T1_0-SXL

SPL_L1, ULTRASONIC

LRR_9, RH_REAR_COMB_LT

44A_K BRAKE LIGHT PWR

T1_0-SXL

SPL_L1, ULTRASONIC

LRR_9, RH_REAR_COMB_LT

44A_L BRAKE LIGHT PWR

T1_0-SXL

LLR_9, LH_REAR_COMB_LT

SPL_L1, ULTRASONIC

44A_L BRAKE LIGHT PWR

T1_0-SXL

LLR_9, LH_REAR_COMB_LT

SPL_L1, ULTRASONIC

44_A BRK LT CTRL PWR

T0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECC, ELECT CNTR C

44_A BRK LT CTRL PWR

T0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECC, ELECT CNTR C

45A_A LEFT TURN SWITCH PWR

N0_8-GXL

FLSHR, FLASHER_MODULE

SRHSTLK, RH STALK SWITCH

45A_A LEFT TURN SWITCH PWR

N0_8-GXL

FLSHR, FLASHER_MODULE

SRHSTLK, RH STALK SWITCH

45B_A RIGHT TURN SWITCH PWR

N0_8-GXL

FLSHR, FLASHER_MODULE

SRHSTLK, RH STALK SWITCH

45B_A RIGHT TURN SWITCH PWR

N0_8-GXL

FLSHR, FLASHER_MODULE

SRHSTLK, RH STALK SWITCH

FLSHR, FLASHER_MODULE

SHZ, HAZARD_SWITCH

FLSHR, FLASHER_MODULE

SHZ, HAZARD_SWITCH

45H

HAZARD SWITCH PWR

N0_8-GXL

45L

45H

HAZARD SWITCH PWR

N0_8-GXL

45L

LEFT TURN SGNL

N1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

LEFT TURN SGNL

N1_0-SXL

FRONT, CAB-FRNT_CHAS

LLF, LIGHTS_LH

45L_9 LEFT TURN SGNL

N1_0-SXL

HD_9, HOOD TO ENG

LLR_9, LH_REAR_COMB_LT

45L_9 LEFT TURN SGNL

N1_0-SXL

HD_9, HOOD TO ENG

LLR_9, LH_REAR_COMB_LT

45L_A LEFT TURN SGNL

N1_0-SXL

ENG, ENGINE-CAB

LLR_E, LH_REAR_COMB_LT

45L_A LEFT TURN SGNL

N1_0-SXL

ENG, ENGINE-CAB

LLR_E, LH_REAR_COMB_LT

N1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

45L_A LEFT TURN SGNL N

N1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

45L_A LEFT TURN SGNL N

45L_B LEFT TURN SGNL

N0_8-GXL

CAB_E, CAB-ENGINE

SPL_PK3, SPLICE 3-4WAY

45L_B LEFT TURN SGNL

N0_8-GXL

CAB_E, CAB-ENGINE

SPL_PK3, SPLICE 3-4WAY

45L_B LEFT TURN SGNL N

N1_0-SXL

HD_N, HOOD TO ENG

LLR_N, LH_REAR_COMB_LT

45L_B LEFT TURN SGNL N

N1_0-SXL

HD_N, HOOD TO ENG

LLR_N, LH_REAR_COMB_LT

45L_C LEFT TURN SGNL

N0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_PK3, SPLICE 3-4WAY

45L_C LEFT TURN SGNL

N0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_PK3, SPLICE 3-4WAY

45L_D LEFT TURN SGNL

N0_8-GXL

FLSHR, FLASHER_MODULE

SPL_PK, SPLICE 3-4WAY

45L_D LEFT TURN SGNL

N0_8-GXL

FLSHR, FLASHER_MODULE

SPL_PK, SPLICE 3-4WAY

45L_E LEFT TURN SGNL

N0_8-TXL

SPL_PK3, SPLICE 3-4WAY

AIC_2, ADV INSTR CLUSTER 2

45L_E LEFT TURN SGNL

N0_8-TXL

SPL_PK3, SPLICE 3-4WAY

AIC_2, ADV INSTR CLUSTER 2

45N_A FLASHER OPP SIDE CTRL

N0_8-GXL

FLSHR, FLASHER_MODULE

64F, FLASHER_CONNECTOR

45N_A FLASHER OPP SIDE CTRL

N0_8-GXL

FLSHR, FLASHER_MODULE

64F, FLASHER_CONNECTOR

45N_B FLASHER OPP SIDE CTRL

N0_8-GXL

FLSHR, FLASHER_MODULE

64M, FLASHER_CONNECTOR

45N_B FLASHER OPP SIDE CTRL

N0_8-GXL

FLSHR, FLASHER_MODULE

64M, FLASHER_CONNECTOR

RIGHT TURN SGNL

N1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

RIGHT TURN SGNL

N1_0-SXL

FRONT, CAB-FRNT_CHAS

LRF, LIGHTS_RH

45R

45R_9 RIGHT TURN SGNL

N1_0-SXL

HD_9, HOOD TO ENG

LRR_9, RH_REAR_COMB_LT

45R_9 RIGHT TURN SGNL

N1_0-SXL

HD_9, HOOD TO ENG

LRR_9, RH_REAR_COMB_LT

45R_A RIGHT TURN SGNL

N1_0-SXL

ENG, ENGINE-CAB

LRR_E, RH_REAR_COMB_LT

45R_A RIGHT TURN SGNL

N1_0-SXL

ENG, ENGINE-CAB

LRR_E, RH_REAR_COMB_LT

45R_A RIGHT TURN SGNL N

N1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

45R_A RIGHT TURN SGNL N

N1_0-SXL

ENG, ENGINE-CAB

ENG_H, ENGINE TO HOOD

45R_B RIGHT TURN SGNL

N0_8-GXL

CAB_E, CAB-ENGINE

SPL_PK3 SPLICE 3-4WAYH

45R_B RIGHT TURN SGNL

N0_8-GXL

CAB_E, CAB-ENGINE

SPL_PK3 SPLICE 3-4WAYH

N1_0-SXL

HD_N, HOOD TO ENG

LRR_N, RH_REAR_COMB_LT

45R_B RIGHT TURN SGNL N

N1_0-SXL

HD_N, HOOD TO ENG

LRR_N, RH_REAR_COMB_LT

45R_B RIGHT TURN SGNL N

45R_C RIGHT TURN SGNL

N0_8-TXL

SPL_PK3, SPLICE 3-4WAY

AIC_2, ADV INSTR CLUSTER 2

45R_C RIGHT TURN SGNL

N0_8-TXL

SPL_PK3, SPLICE 3-4WAY

AIC_2, ADV INSTR CLUSTER 2

45R_D RIGHT TURN SGNL

N0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_PK3, SPLICE 3-4WAY

45R_D RIGHT TURN SGNL

N0_8-GXL

CAB_F, CAB-FRNT_CHAS

SPL_PK3, SPLICE 3-4WAY

4002-30

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

45R_E RIGHT TURN SGNL

N0_8-GXL

FLSHR, FLASHER_MODULE

SPL_PK3, SPLICE 3-4WAY

45R_E RIGHT TURN SGNL

N0_8-GXL

FLSHR, FLASHER_MODULE

SPL_PK3, SPLICE 3-4WAY

46_C BEACON SW PWR

K1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SBE, BEACON_SW

46_C BEACON SW PWR

K1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SBE, BEACON_SW

46_D BEACON SW PWR

K1_0-GXL

ROOF, ROOF TO CAB CONNECTION

LBEPWR, LIGHT BEACON PWR

46_D BEACON SW PWR

K1_0-GXL

ROOF, ROOF TO CAB CONNECTION

LBEPWR, LIGHT BEACON PWR

46_E BEACON LIGHT PWR

K1_0-GXL

LBEE, LIGHT BEACON EXTENSION

LBEP, LIGHT BEACON PWR

46_E BEACON LIGHT PWR

K1_0-GXL

LBEE, LIGHT BEACON EXTENSION

LBEP, LIGHT BEACON PWR

49A

BACK LIGHT POWER

S0_8-GXL

HVAC1, HVAC1

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49A

BACK LIGHT POWER

S0_8-GXL

HVAC1, HVAC1

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49S

BACK LIGHT POWER

S0_8-GXL

STA, TRANS_AUTO_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49S

BACK LIGHT POWER

S0_8-GXL

STA, TRANS_AUTO_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49U

BACK LIGHT POWER

S0_8-GXL

SETHR, ETHER SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49U

BACK LIGHT POWER

S0_8-GXL

SETHR, ETHER SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_A BACK LIGHT POWER

S0_8-GXL

SWL, WORK LIGHTS SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_A BACK LIGHT POWER

S0_8-GXL

SWL, WORK LIGHTS SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_B BACK LIGHT POWER

S0_8-GXL

SBE, BEACON_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_B BACK LIGHT POWER

S0_8-GXL

SBE, BEACON_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_C BACK LIGHT POWER

S0_8-GXL

SRWP, REAR_WIPER_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_C BACK LIGHT POWER

S0_8-GXL

SRWP, REAR_WIPER_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_D BACK LIGHT POWER

S0_8-GXL

SHZ, HAZARD_SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_D BACK LIGHT POWER

S0_8-GXL

SHZ, HAZARD_SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_E BACK LIGHT POWER

S0_8-GXL

SPL_BCK_LGT2, SPL_BACK LGT PWR

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_E BACK LIGHT POWER

S0_8-GXL

SPL_BCK_LGT2, SPL_BACK LGT PWR

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_F BACK LIGHT POWER

S0_8-GXL

SPE, PIN_ENGAGE_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_F BACK LIGHT POWER

S0_8-GXL

SPE, PIN_ENGAGE_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_G BACK LIGHT POWER

S0_8-GXL

SRC, RIDE_CONTROL_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_G BACK LIGHT POWER

S0_8-GXL

SRC, RIDE_CONTROL_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_H BACK LIGHT POWER

S0_8-GXL

STE, TRANS_ENABLE_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_H BACK LIGHT POWER

S0_8-GXL

STE, TRANS_ENABLE_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_J BACK LIGHT POWER

S0_8-GXL

SRTD, DETENT_SWITCH

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_J BACK LIGHT POWER

S0_8-GXL

SRTD, DETENT_SWITCH

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_K BACK LIGHT POWER

S0_8-GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_K BACK LIGHT POWER

S0_8-GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_L BACK LIGHT POWER

S0_8-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_L BACK LIGHT POWER

S0_8-GXL

SBU, BACK-UP_ALRM_DIS_SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_M BACK LIGHT POWER

S0_8-GXL

SHC, HEIGHT CONTROL SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_M BACK LIGHT POWER

S0_8-GXL

SHC, HEIGHT CONTROL SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_N BACK LIGHT POWER

S0_8-GXL

SPC, PILOT_CONTROL_SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_N BACK LIGHT POWER

S0_8-GXL

SPC, PILOT_CONTROL_SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_P BACK LIGHT POWER

S0_8-GXL

SDR, DRIVING LIGHTS SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_P BACK LIGHT POWER

S0_8-GXL

SDR, DRIVING LIGHTS SW

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_Q BACK LIGHT POWER

S0_8-GXL

SFC, FAN_CONTROL_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_Q BACK LIGHT POWER

S0_8-GXL

SFC, FAN_CONTROL_SW

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_R BACK LIGHT POWER

S0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_BCK_LGT, SPLICE BACK LGHT PWR

49_R BACK LIGHT POWER

S0_8-GXL

SDC, DECLUTCH_SWITCH

SPL_BCK_LGT, SPLICE BACK LGHT PWR

4002-31

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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_S BACK LIGHT POWER

S0_8-GXL

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_S BACK LIGHT POWER

S0_8-GXL

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_T BACK LIGHT POWER

S0_8-GXL

SFWW, FRONT WIPER/WASHER

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_T BACK LIGHT POWER

S0_8-GXL

SFWW, FRONT WIPER/WASHER

SPL_BCK_LGT2, SPL_BACK LGT PWR

49_U BACK LIGHT POWER

S0_8-GXL

SCS, COMFORT STEER SW

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_U BACK LIGHT POWER

S0_8-GXL

SCS, COMFORT STEER SW

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_V BACK LIGHT POWER

S0_8-GXL

SPB, PARKING_BRAKE_SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

49_V BACK LIGHT POWER

S0_8-GXL

SPB, PARKING_BRAKE_SWITCH

SPL_PED_BL, SPL BACK LGT PWR 6 PCK

W0_8_GXL

SCS, COMFORT STEER SW

SPL_CSS, ULTRASONIC

W0_8_GXL

SCS, COMFORT STEER SW

SPL_CSS, ULTRASONIC

51B_A COMFORT STR SOL PWR 51B_B COMFORT STR SOL PWR

W0_8_GXL

SPL_CSS, ULTRASONIC

ECC, ELECT CNTR C

51B_C COMFORT STR SOL PWR

W0_8_GXL

SPL_CSS, ULTRASONIC

CAB_F, CAB-FRNT_CHAS

51B_A COMFORT STR SOL PWR

D10

51B_B COMFORT STR SOL PWR

W0_8_GXL

SPL_CSS, ULTRASONIC

ECC, ELECT CNTR C

51B_C COMFORT STR SOL PWR

W0_8_GXL

SPL_CSS, ULTRASONIC

CAB_F, CAB-FRNT_CHAS

2 A

W1_0-SXL

FRONT, CAB-FRNT_CHAS

YCS, COMFORT STEER SOLEROID

COMFORT STEER CTRL

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECC, ELECT CNTR C

51CS COMFORT STR SWITCH

W0_8-TXL

SCS, COMFORT STEER SW

AIC_1, ADV INSTR CLUSTER 1

51P_A SEC STR HIGH PRESS

W1_0-SXL

SSM, SEC STR MOD

PSS, SEC STR PRES SWITCH

W0_8-TXL

SCS, COMFORT STEER SW

AIC_1, ADV INSTR CLUSTER 1

51S

W1_0-SXL

SSM, SEC STR MOD

SPL_SS, ULTRASONIC

51_A SEC STR MOTOR CTRL

51B_D COMFORT STR SOL PWR 51C

51S

STANDARD STR SIG

51_A SEC STR MOTOR CTRL

D10

W1_0-SXL

FRONT, CAB-FRNT_CHAS

YCS, COMFORT STEER SOLEROID

COMFORT STEER CTRL

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECC, ELECT CNTR C

51CS COMFORT STR SWITCH

W0_8-TXL

SCS, COMFORT STEER SW

AIC_1, ADV INSTR CLUSTER 1

51P_A SEC STR HIGH PRESS

W1_0-SXL

SSM, SEC STR MOD

PSS, SEC STR PRES SWITCH

W0_8-TXL

SCS, COMFORT STEER SW

AIC_1, ADV INSTR CLUSTER 1

W1_0-SXL

SSM, SEC STR MOD

SPL_SS, ULTRASONIC

A B10

51B_D COMFORT STR SOL PWR 51C

STANDARD STR SIG

B10 17

51_B SEC STR MOTOR CTRL

W1_0-SXL

SPL_SS, ULTRASONIC

SSS, SS MAG SWITCH

51_B SEC STR MOTOR CTRL

W1_0-SXL

SPL_SS, ULTRASONIC

SSS, SS MAG SWITCH

51_C SEC STR SOL CTRL

W1_0-SXL

SPL_SS, ULTRASONIC

YSS, SEC_STRG_SOL

51_C SEC STR SOL CTRL

W1_0-SXL

SPL_SS, ULTRASONIC

YSS, SEC_STRG_SOL

52AU FAN REVERSE AUTO

W0_8-TXL

SFC, FAN_CONTROL_SW

AIC_2, ADV INSTR CLUSTER 2

52AU FAN REVERSE AUTO

W0_8-TXL

SFC, FAN_CONTROL_SW

AIC_2, ADV INSTR CLUSTER 2

52A_A FAN REVERSE RLY OUT

W1_0-GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

52A_A FAN REVERSE RLY OUT

W1_0-GXL

CAB_E, CAB-ENGINE

ECB, ELECT CNTR B

52A_B FAN REVERSE RLY OUT

W1_0-SXL

ENG, ENGINE-CAB

YFR, FAN_REV_SOL_OPT

52A_B FAN REVERSE RLY OUT

W1_0-SXL

ENG, ENGINE-CAB

YFR, FAN_REV_SOL_OPT

ECB, ELECT CNTR B

52C

PARK BRAKE SOL LSD

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

B10

52C

PARK BRAKE SOL LSD

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

8 D8 1 B10

52J

FAN CTRL SW JUMPER

W0_8_GXL

SFC, FAN_CONTROL_SW

52J

FAN CTRL SW JUMPER

W0_8_GXL

SFC, FAN_CONTROL_SW

52M

FAN REVERSE MAN

W0_8-TXL

SFC, FAN_CONTROL_SW

AIC_2, ADV INSTR CLUSTER 2

52M

FAN REVERSE MAN

W0_8-TXL

SFC, FAN_CONTROL_SW

AIC_2, ADV INSTR CLUSTER 2

52P

PARK BRK RLY OUT

52P

PARK BRK RLY OUT

W1_0-SXL

FRONT, CAB-FRNT_CHAS

YPB, PARK_BRK_SOL

52P_A PARK BRK RLY OUT

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_PB, ULTRASONIC

W1_0-SXL

FRONT, CAB-FRNT_CHAS

YPB, PARK_BRK_SOL

52P_A PARK BRK RLY OUT

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_PB, ULTRASONIC

52P_B PARK BRK RLY OUT

W0_8_GXL

SPL_PB, ULTRASONIC

ECB, ELECT CNTR B

52P_C PARK BRK RLY OUT

W0_8-TXL

SPL_PB, ULTRASONIC

TECM, TRANS

D10

52P_B PARK BRK RLY OUT

W0_8_GXL

SPL_PB, ULTRASONIC

ECB, ELECT CNTR B

52P_C PARK BRK RLY OUT

W0_8-TXL

SPL_PB, ULTRASONIC

TECM, TRANS

D10 21

53A

RTD SW PWR

W0_8_GXL

SRTD, DETENT_SWITCH

EM, RTD_HEIGHT_CONT_RTT

53A

RTD SW PWR

W0_8_GXL

SRTD, DETENT_SWITCH

EM, RTD_HEIGHT_CONT_RTT

53B

RTD CTRL SIGNAL

W1_0-SXL

FRONT, CAB-FRNT_CHAS

PXF, RTD

53B

RTD CTRL SIGNAL

W1_0-SXL

FRONT, CAB-FRNT_CHAS

PXF, RTD

53B_A RTD CTRL SIGNAL

W1_0-SXL

PXM, RTD

PXT, RTD

53B_A RTD CTRL SIGNAL

W1_0-SXL

PXM, RTD

PXT, RTD

53B_B RTD CTRL SIGNAL

W0_8_GXL

EM, RTD_HEIGHT_CONT_RTT

CAB_F, CAB-FRNT_CHAS

53B_B RTD CTRL SIGNAL

W0_8_GXL

EM, RTD_HEIGHT_CONT_RTT

CAB_F, CAB-FRNT_CHAS

53C_A PILOT CTRL SOL LSD

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECD, ELECT CNTR D

53C_A PILOT CTRL SOL LSD

W0_8-TXL

AIC_1, ADV INSTR CLUSTER 1

ECD, ELECT CNTR D

53P_A PILOT CTRL RLY OUT

W0_8_GXL

SPL_D25, ULTRASONIC

YPP, PILOT_PRES_SOL

53P_A PILOT CTRL RLY OUT

W0_8_GXL

SPL_D25, ULTRASONIC

YPP, PILOT_PRES_SOL

53P_B PILOT CTRL RLY OUT

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_D25, ULTRASONIC

53P_C PILOT CTRL RLY OUT

W1_0-GXL

SPL_D25, ULTRASONIC

ECD, ELECT CNTR D

53P_B PILOT CTRL RLY OUT

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

53P_C PILOT CTRL RLY OUT

W1_0-GXL

SPL_D25, ULTRASONIC

4002-32

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

53P_D PILOT CTRL RLY OUT

W0_8_GXL

SHC, HEIGHT CONTROL SW

53P_E PILOT CTRL RLY OUT

W0_8_GXL

53P_F PILOT CTRL RLY OUT

W0_8_GXL

53P_G PILOT CTRL RLY OUT 53P_H PILOT CTRL RLY OUT

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

SPL_D25, ULTRASONIC

53P_D PILOT CTRL RLY OUT

W0_8_GXL

SHC, HEIGHT CONTROL SW

SRTD, DETENT_SWITCH

SPL_D25, ULTRASONIC

53P_E PILOT CTRL RLY OUT

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_D25, ULTRASONIC

53P_F PILOT CTRL RLY OUT

W0_8_GXL

W1_0-SXL

FRONT, CAB-FRNT_CHAS

SPL_A3, ULTRASONIC

53P_G PILOT CTRL RLY OUT

W1_0-SXL

SPL_A3, ULTRASONIC

PXF, RTD

53P_H PILOT CTRL RLY OUT

53P_I PILOT CTRL RLY OUT

W1_0-SXL

PXM, RTD

PXT, RTD

53P_J PILOT CTRL RLY OUT

W1_0-SXL

SPL_A3, ULTRASONIC

PXH, HGT_CNTRL-RTT

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

SPL_D25, ULTRASONIC

SRTD, DETENT_SWITCH

SPL_D25, ULTRASONIC

CAB_F, CAB-FRNT_CHAS

SPL_D25, ULTRASONIC

W1_0-SXL

FRONT, CAB-FRNT_CHAS

SPL_A3, ULTRASONIC

W1_0-SXL

SPL_A3, ULTRASONIC

PXF, RTD

53P_I PILOT CTRL RLY OUT

W1_0-SXL

PXM, RTD

PXT, RTD

53P_J PILOT CTRL RLY OUT

W1_0-SXL

SPL_A3, ULTRASONIC

PXH, HGT_CNTRL-RTT

54A

HEIGHT CTRL SW PWR

W0_8_GXL

SHC, HEIGHT CONTROL SW

EM, RTD_HEIGHT_CONT_RTT

54A

HEIGHT CTRL SW PWR

W0_8_GXL

SHC, HEIGHT CONTROL SW

EM, RTD_HEIGHT_CONT_RTT

54B

HC-RTT CTRL SGNL

W1_0-SXL

FRONT, CAB-FRNT_CHAS

PXH, HGT_CNTRL-RTT

54B

HC-RTT CTRL SGNL

W1_0-SXL

FRONT, CAB-FRNT_CHAS

PXH, HGT_CNTRL-RTT

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_D1, ULTRASONIC

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_D1, ULTRASONIC

54B_B HC-RTT CTRL SGNL

W0_8_GXL

EM, RTD_HEIGHT_CONT_RTT

SPL_D1, ULTRASONIC

54B_B HC-RTT CTRL SGNL

W0_8_GXL

EM, RTD_HEIGHT_CONT_RTT

SPL_D1, ULTRASONIC

54B_C HC-RTT CTRL SGNL

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_D1, ULTRASONIC

54B_C HC-RTT CTRL SGNL

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_D1, ULTRASONIC

55A_A RTT/FLOAT SW PWR

W0_8_GXL

EM, RTD_HEIGHT_CONT_RTT

SPL_RTT, ULTRASONIC

55A_A RTT/FLOAT SW PWR

W0_8_GXL

EM, RTD_HEIGHT_CONT_RTT

SPL_RTT, ULTRASONIC

55A_B RTT/FLOAT SW PWR

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_RTT, ULTRASONIC

55A_B RTT/FLOAT SW PWR

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_RTT, ULTRASONIC

55A_C RTT/FLOAT SW PWR

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_RTT, ULTRASONIC

55A_C RTT/FLOAT SW PWR

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

SPL_RTT, ULTRASONIC

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

EM, RTD_HEIGHT_CONT_RTT

55B

W0_8_GXL

SFL, RETURN_TO_TRAVEL_SW

EM, RTD_HEIGHT_CONT_RTT

56_A FAN CONTROL PWM

W1_0-SXL

ENG, ENGINE-CAB

YFN, FAN_PWM_SOL

56_A FAN CONTROL PWM

W1_0-SXL

ENG, ENGINE-CAB

YFN, FAN_PWM_SOL

57_A PIN ENGAGE SOL PWR

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_PINE, ULTRASONIC

57_A PIN ENGAGE SOL PWR

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_PINE, ULTRASONIC

57_B PIN ENGAGE SOL PWR

W0_8_GXL

SPE, PIN_ENGAGE_SW

SPL_PINE, ULTRASONIC

57_B PIN ENGAGE SOL PWR

W0_8_GXL

SPE, PIN_ENGAGE_SW

SPL_PINE, ULTRASONIC

57_C PIN ENGAGE SOL PWR

W0_8-TXL

SPL_PINE, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

57_C PIN ENGAGE SOL PWR

W0_8-TXL

SPL_PINE, ULTRASONIC

AIC_2, ADV INSTR CLUSTER 2

58C

W0_8_GXL

SRC, RIDE_CONTROL_SW

58C

W0_8_GXL

SRC, RIDE_CONTROL_SW

54B_A HC-RTT CTRL SGNL

55B

RTT FLOAT SW CTRL

RIDE CTRL SW JUMPER

58H_A RIDE CNTL SW PWR VPS2 58L

RIDE CTRL RLY LSD

W0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

BK0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

FRONT, CAB-FRNT_CHAS

YRC, RIDE_CONTROL_OPT

SRC, RIDE_CONTROL_SW

ECD, ELECT CNTR D

58S_E RIDE CTRL SOL TO FRNT CAB W1_0-SXL 58T

RIDE CTRL RLY SW PWR

W0_8_GXL

54B_A HC-RTT CTRL SGNL

RTT FLOAT SW CTRL

RIDE CTRL SW JUMPER

58H_A RIDE CNTL SW PWR VPS2 58L

RIDE CTRL RLY LSD

W0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

BK0_8-TXL

TECM, TRANS

ECD, ELECT CNTR D

FRONT, CAB-FRNT_CHAS

YRC, RIDE_CONTROL_OPT

SRC, RIDE_CONTROL_SW

ECD, ELECT CNTR D

B7 B

58S_E RIDE CTRL SOL TO FRNT CAB W1_0-SXL 58T

RIDE CTRL RLY SW PWR

W0_8_GXL

58_A RIDE CTRL SOL PWR

W1_0-SXL

202M, ROLLBACK_JUMPER

58_A RIDE CTRL SOL PWR

W1_0-SXL

202M, ROLLBACK_JUMPER

58_B RIDE CONTROL SOL PWR

W1_0-SXL

FRONT, CAB-FRNT_CHAS

PRBF, ROLLBACK_PRES_SW

58_B RIDE CONTROL SOL PWR

W1_0-SXL

FRONT, CAB-FRNT_CHAS

PRBF, ROLLBACK_PRES_SW

58_C RIDE CTRL SOL PWR

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_D26, ULTRASONIC

58_C RIDE CTRL SOL PWR

W0_8_GXL

CAB_F, CAB-FRNT_CHAS

SPL_D26, ULTRASONIC

58_D RIDE CTRL SOL PWR

W0_8_GXL

140M, DIODE_MODULE

SPL_D26, ULTRASONIC

58_E RIDE CTRL SOL PWR

W0_8_GXL

SPL_D26, ULTRASONIC

ECD, ELECT CNTR D

58_D RIDE CTRL SOL PWR

W0_8_GXL

140M, DIODE_MODULE

SPL_D26, ULTRASONIC

58_E RIDE CTRL SOL PWR

W0_8_GXL

SPL_D26, ULTRASONIC

ECD, ELECT CNTR D

58_F RIDE CTRL SOL PWR

W0_8_GXL

SRC, RIDE_CONTROL_SW

SPL_D26, ULTRASONIC

59D

HOOD DOWN RLY CTRL

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

59D_A HOOD DOWN RLY CTRL

W1_0-SXL

ENG, ENGINE-CAB

HD, HOOD_SWITCH

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

58_F RIDE CTRL SOL PWR

W0_8_GXL

SRC, RIDE_CONTROL_SW

SPL_D26, ULTRASONIC

59D

HOOD DOWN RLY CTRL

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

59D_A HOOD DOWN RLY CTRL

W1_0-SXL

ENG, ENGINE-CAB

HD, HOOD_SWITCH

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

59U

HOOD UP RLY CTRL

59U

HOOD UP RLY CTRL

A D8 A D3

4002-33

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

59U_A HOOD UP RLY CTRL

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Cavity

ENG, ENGINE-CAB

HD, HOOD_SWITCH

HOOD DOWN RLY OUT

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

60D_A HOOD DOWN RLY OUT

W1_0-SXL

ENG, ENGINE-CAB

HDM, HOOD_LIFT_MOTOR

HOOD UP RLY OUT

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

60U_A HOOD UP RLY OUT

W1_0-SXL

ENG, ENGINE-CAB

HDM, HOOD_LIFT_MOTOR

60U 61A

TRINARY PRESS SW INPUT

61A_B TRINARY PRESS SW INPUT 61C

ENG, ENGINE-CAB

PR, TRINARY PRESS SW

HVAC1, HVAC1

CAB_E, CAB-ENGINE

ECD, ELECT CNTR D

OR1_0-SXL

ENG, ENGINE-CAB

ACT, AC_COMP_CLUTCH

61C_B AC RELAY OUT

OR1_0-SXL

ENG, ENGINE-CAB

W1_0-SXL

ENG, ENGINE-CAB

W0_8_GXL

CAB_E, CAB-ENGINE

ECD, ELECT CNTR D

FNT WPR PARK CTRL

W0_8_GXL

FWM, FRONT-WIPER_MOTOR

63C2 FNT WPR PARK CTRL

W0_8_GXL

63C3 FNT WPR PARK CTRL

W0_8_GXL

63HC FNT WPR HS RLY CTRL

W0_8_GXL

SFWW, FRONT WIPER/WASHER

63HC_ WPR CUT OUT RLY CTRL A

W0_8_GXL

63HC_ FNT WPR HS RLY CTRL B 63H_A FNT WPR HS RLY OUT

61R_B AC RELAY CONTROL

CAB_E, CAB-ENGINE

OR0_8-GXL

AC RELAY CONTROL

W1_0-SXL

AC RELAY OUT

61R

W0_8_GXL

61C_A AC RELAY OUT

DU = Dark Blue W = White Or = Orange

Wire Identification

W1_0-SXL

60D

Bk = Black T = Tan LU = Light Blue

D10

Wire

Circuit

59U_A HOOD UP RLY CTRL

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

W1_0-SXL

ENG, ENGINE-CAB

HD, HOOD_SWITCH

HOOD DOWN RLY OUT

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

60D_A HOOD DOWN RLY OUT

W1_0-SXL

ENG, ENGINE-CAB

HDM, HOOD_LIFT_MOTOR

HOOD UP RLY OUT

W1_0-GXL

CAB_E, CAB-ENGINE

ECC, ELECT CNTR C

60U_A HOOD UP RLY OUT

W1_0-SXL

ENG, ENGINE-CAB

HDM, HOOD_LIFT_MOTOR

60D 60U 61A

TRINARY PRESS SW INPUT

61A_B TRINARY PRESS SW INPUT

W1_0-SXL

ENG, ENGINE-CAB

PR, TRINARY PRESS SW

W0_8_GXL

CAB_E, CAB-ENGINE

HVAC1, HVAC1

AC RELAY OUT

OR0_8-GXL

CAB_E, CAB-ENGINE

ECD, ELECT CNTR D

61C_A AC RELAY OUT

OR1_0-SXL

ENG, ENGINE-CAB

ACT, AC_COMP_CLUTCH

ACT_9, AC_COMP_CLUTCH

61C_B AC RELAY OUT

OR1_0-SXL

ENG, ENGINE-CAB

ACT_9, AC_COMP_CLUTCH

PR, TRINARY PRESS SW

W1_0-SXL

ENG, ENGINE-CAB

PR, TRINARY PRESS SW

W0_8_GXL

CAB_E, CAB-ENGINE

ECD, ELECT CNTR D

61C

2 B1

61R

AC RELAY CONTROL

61R_B AC RELAY CONTROL

D10 1

ECD, ELECT CNTR D

63C

FNT WPR PARK CTRL

W0_8_GXL

FWM, FRONT-WIPER_MOTOR

ECD, ELECT CNTR D

63C2 FNT WPR PARK CTRL

W0_8_GXL

ECD, ELECT CNTR D

K_WCO, WIPER CUTOUT

87A

ECD, ELECT CNTR D

63C3 FNT WPR PARK CTRL

W0_8_GXL

K_WCO, WIPER CUTOUT

87A

ECD, ELECT CNTR D

SPL_HC, ULTRASONIC

63HC FNT WPR HS RLY CTRL

W0_8_GXL

SFWW, FRONT WIPER/WASHER

SPL_HC, ULTRASONIC

K_WCO, WIPER CUTOUT

63HC_ WPR CUT OUT RLY CTRL A

W0_8_GXL

SPL_HC, ULTRASONIC

K_WCO, WIPER CUTOUT

W0_8_GXL

SPL_HC, ULTRASONIC

ECD, ELECT CNTR D

63HC_ FNT WPR HS RLY CTRL B

W0_8_GXL

SPL_HC, ULTRASONIC

ECD, ELECT CNTR D

W0_8_GXL

FWM, FRONT-WIPER_MOTOR

SPL_WHS, ULTRASONIC

63H_A FNT WPR HS RLY OUT

W0_8_GXL

FWM, FRONT-WIPER_MOTOR

SPL_WHS, ULTRASONIC

63H_B FNT WPR HS RLY OUT

W0_8_GXL

SPL_WHS, ULTRASONIC

ECD, ELECT CNTR D

63H_C FNT WPR HS RLY OUT

W0_8_GXL

140M, DIODE_MODULE

SPL_WHS, ULTRASONIC

63LC FNT WPR LS RLY CTRL

W0_8_GXL

SFWW, FRONT WIPER/WASHER

ECD, ELECT CNTR D

63L_A FNT WPR LS RLY OUT

W0_8_GXL

FWM, FRONT-WIPER_MOTOR

SPL_WLS, ULTRASONIC

63L_B FNT WPR LS RLY OUT

W0_8_GXL

K_WCO, WIPER CUTOUT

SPL_WLS, ULTRASONIC

63L_C FNT WPR LS RLY OUT

W0_8_GXL

140M, DIODE_MODULE

SPL_WLS, ULTRASONIC

W0_8_GXL

CAB_E, CAB-ENGINE

SFWW, FRONT WIPER/WASHER

63W

W1_0-SXL

ENG, ENGINE-CAB

FWW, FRONT_WASHER

63W_ FNT WASHER PUMP A

OR0_8-GXL

SRHSTLK, RH STALK SWITCH

31b

ECC, ELECT CNTR C

64C

64_A HORN POWER

63C

63W

FNT WASHER PUMP

63W_ FNT WASHER PUMP A 64C

HORN RLY CTRL

64_A HORN POWER

63H_B FNT WPR HS RLY OUT

W0_8_GXL

SPL_WHS, ULTRASONIC

ECD, ELECT CNTR D

63H_C FNT WPR HS RLY OUT

W0_8_GXL

140M, DIODE_MODULE

SPL_WHS, ULTRASONIC

63LC FNT WPR LS RLY CTRL

W0_8_GXL

SFWW, FRONT WIPER/WASHER

ECD, ELECT CNTR D

63L_A FNT WPR LS RLY OUT

W0_8_GXL

FWM, FRONT-WIPER_MOTOR

SPL_WLS, ULTRASONIC

63L_B FNT WPR LS RLY OUT

W0_8_GXL

K_WCO, WIPER CUTOUT

SPL_WLS, ULTRASONIC

63L_C FNT WPR LS RLY OUT

W0_8_GXL

140M, DIODE_MODULE

SPL_WLS, ULTRASONIC

W0_8_GXL

CAB_E, CAB-ENGINE

SFWW, FRONT WIPER/WASHER

W1_0-SXL

ENG, ENGINE-CAB

FWW, FRONT_WASHER

OR0_8-GXL

SRHSTLK, RH STALK SWITCH

31b

ECC, ELECT CNTR C

B8 D8

FNT WASHER PUMP

HORN RLY CTRL

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECC, ELECT CNTR C

OR0_8-GXL

CAB_F, CAB-FRNT_CHAS

ECC, ELECT CNTR C

65L

LEFT SPEAKER

OR0_8-GXL

LSPK, LEFT_SPEAKER

SPK, SPEAKER

65L

LEFT SPEAKER

OR0_8-GXL

LSPK, LEFT_SPEAKER

SPK, SPEAKER

65R

RIGHT SPEAKER

OR0_8-GXL

RSPK, RIGHT_SPEAKER

SPK, SPEAKER

65R

RIGHT SPEAKER

OR0_8-GXL

RSPK, RIGHT_SPEAKER

SPK, SPEAKER

OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SRWP, REAR_WIPER_SW

68C

REAR WPR PARK CTRL

SRWP, REAR_WIPER_SW

68C

REAR WPR PARK CTRL

4002-34

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

ROOF, ROOF TO CAB CONNECTION

RWM, REAR_WIPER_MTR

OR1_0-GXL

SRWP, REAR_WIPER_SW

SPL_3, ULTRASONIC

68L_A REAR WPR SW PWR

OR1_0-GXL

ROOF, ROOF TO CAB CONNECTION

RWM, REAR_WIPER_MTR

68L_B REAR WPR SW PWR

OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_3, ULTRASONIC

68L

REAR WPR SW PWR

68L_C REAR WPR SW PWR 68W

REAR WSHR PUMP

OR1_0-GXL

Cavity

Wire

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

ROOF, ROOF TO CAB CONNECTION

RWM, REAR_WIPER_MTR

OR1_0-GXL

SRWP, REAR_WIPER_SW

SPL_3, ULTRASONIC

68L_A REAR WPR SW PWR

OR1_0-GXL

ROOF, ROOF TO CAB CONNECTION

RWM, REAR_WIPER_MTR

68L_B REAR WPR SW PWR

OR1_0-GXL

CAB_RF, CAB TO ROOF CONNECTION

SPL_3, ULTRASONIC

68L_C REAR WPR SW PWR

68C_A REAR WPR PARK CTRL 68L

140M, DIODE_MODULE

SPL_3, ULTRASONIC

CAB_E, CAB-ENGINE

SRWP, REAR_WIPER_SW

68W

CAN_ CAN HIGH H

LG = Light Green G = Green P = Purple

Cavity

OR1_0-GXL

W1_0-SXL

S = Gray N = Brown R = Red

Connector

W0_8_GXL

68W_ REAR WSHR PUMP A

Circuit

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

Connector

68C_A REAR WPR PARK CTRL

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

REAR WPR SW PWR

REAR WSHR PUMP

OR1_0-GXL

Connector

Cavity

OR1_0-GXL

140M, DIODE_MODULE

SPL_3, ULTRASONIC

W0_8_GXL

CAB_E, CAB-ENGINE

SRWP, REAR_WIPER_SW

W1_0-SXL

ENG, ENGINE-CAB

RWW, REAR_WASHER

68W_ REAR WSHR PUMP A

Y0_8-TXL_TW CAN2, CAN BULK HEAD IST

EDC7, ENGINE CONTROLLER

CAN_ CAN HIGH H

Y0_8-TXL_TW CAN2, CAN BULK HEAD IST

EDC7, ENGINE CONTROLLER

CAN_ CAN HIGH HA

Y0_8-TXL_TW SPL_CAN_HVAC, ULTRAIST SONIC

CAN, CAN BULK HEAD

CAN_ CAN HIGH HA

Y0_8-TXL_TW SPL_CAN_HVAC, ULTRAIST SONIC

CAN, CAN BULK HEAD

CAN_ CAN HIGH HB

Y0_8-TXL_TW SPL_CAN_DIAG, ULTRASOIST NIC

DIA, DIAGNOSTIC

CAN_ CAN HIGH HB

Y0_8-TXL_TW SPL_CAN_DIAG, ULTRASOIST NIC

DIA, DIAGNOSTIC

CAN_ CAN HIGH HC

Y0_8-TXL_TW SPL_CAN_TRANS, ULTRAIST SONIC

SPL_CAN_DIAG, ULTRASONIC

CAN_ CAN HIGH HC

Y0_8-TXL_TW SPL_CAN_TRANS, ULTRAIST SONIC

SPL_CAN_DIAG, ULTRASONIC

CAN_ CAN HIGH HD

Y0_8-TXL_TW SPL_CAN_TRANS, ULTRAIST SONIC

TECM, TRANS

CAN_ CAN HIGH HD

Y0_8-TXL_TW SPL_CAN_TRANS, ULTRAIST SONIC

TECM, TRANS

CAN_ CAN HIGH HE

Y0_8-TXL_TW SPL_CAN, ULTRASONIC IST

SPL_CAN_TRANS, ULTRASONIC

CAN_ CAN HIGH HE

Y0_8-TXL_TW SPL_CAN, ULTRASONIC IST

SPL_CAN_TRANS, ULTRASONIC

CAN_ CAN HIGH HF

Y0_8-TXL_TW SW_PD, SWITCH PAD IST

SPL_CAN, ULTRASONIC

CAN_ CAN HIGH HF

Y0_8-TXL_TW SW_PD, SWITCH PAD IST

SPL_CAN, ULTRASONIC

CAN_ CAN HIGH HG

Y0_8-TXL_TW SPL_CAN, ULTRASONIC IST

AIC_1, ADV INSTR CLUSTER 1

CAN_ CAN HIGH HG

Y0_8-TXL_TW SPL_CAN, ULTRASONIC IST

AIC_1, ADV INSTR CLUSTER 1

CAN_ CAN HIGH FROM ENG HJ

Y0_8-TXL_TW CAN2, CAN BULK HEAD IST

QSM11, ENGINE CONTROLLER

CAN_ CAN HIGH FROM ENG HJ

Y0_8-TXL_TW CAN2, CAN BULK HEAD IST

QSM11, ENGINE CONTROLLER

CAN_ CAN HIGH HK

Y0_8-TXL_TW SPL_CAN_HVAC, ULTRAIST SONIC

HVAC_CAN1, CAN_HVAC_ATC

CAN_ CAN HIGH HK

Y0_8-TXL_TW SPL_CAN_HVAC, ULTRAIST SONIC

HVAC_CAN1, CAN_HVAC_ATC

CAN_ CAN HIGH HM

Y0_8-TXL_TW SPL_CAN_HVAC, ULTRAIST SONIC

SPL_CAN_DIAG, ULTRASONIC

CAN_ CAN HIGH HM

Y0_8-TXL_TW SPL_CAN_HVAC, ULTRAIST SONIC

SPL_CAN_DIAG, ULTRASONIC

CAN_ CAN LOW L

G0_8-TXL_T WIST

CAN2, CAN BULK HEAD

EDC7, ENGINE CONTROLLER

CAN_ CAN LOW L

G0_8-TXL_T WIST

CAN2, CAN BULK HEAD

EDC7, ENGINE CONTROLLER

CAN_ CAN LOW LA

G0_8-TXL_T WIST

SPL_CAN_HVAC_L, ULTRASONIC

CAN, CAN BULK HEAD

CAN_ CAN LOW LA

G0_8-TXL_T WIST

SPL_CAN_HVAC_L, ULTRASONIC

CAN, CAN BULK HEAD

CAN_ CAN LOW LB

G0_8-TXL_T WIST

SPL_CAN_DIAG_L, ULTRASONIC

DIA, DIAGNOSTIC

CAN_ CAN LOW LB

G0_8-TXL_T WIST

SPL_CAN_DIAG_L, ULTRASONIC

DIA, DIAGNOSTIC

CAN_ CAN LOW LC

G0_8-TXL_T WIST

SPL_CAN_TRANS_L, ULTRASONIC

SPL_CAN_DIAG_L, ULTRASONIC

CAN_ CAN LOW LC

G0_8-TXL_T WIST

SPL_CAN_TRANS_L, ULTRASONIC

SPL_CAN_DIAG_L, ULTRASONIC

CAN_ CAN LOW LD

G0_8-TXL_T WIST

SPL_D5, ULTRASONIC

SPL_CAN_TRANS_L, ULTRASONIC

CAN_ CAN LOW LD

G0_8-TXL_T WIST

SPL_D5, ULTRASONIC

SPL_CAN_TRANS_L, ULTRASONIC

CAN_ CAN LOW LE

G0_8-TXL_T WIST

SPL_CAN_L, ULTRASONIC

SPL_CAN_TRANS_L, ULTRASONIC

CAN_ CAN LOW LE

G0_8-TXL_T WIST

SPL_CAN_L, ULTRASONIC

SPL_CAN_TRANS_L, ULTRASONIC

ENG, ENGINE-CAB

4002-35

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm 1.0 mm

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm 1.0 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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_ CAN LOW LF

G0_8-TXL_T WIST

SW_PD, SWITCH PAD

SPL_CAN_L, ULTRASONIC

CAN_ CAN LOW LF

G0_8-TXL_T WIST

SW_PD, SWITCH PAD

SPL_CAN_L, ULTRASONIC

CAN_ CAN LOW LG

G0_8-TXL_T WIST

SPL_CAN_L, ULTRASONIC

AIC_1, ADV INSTR CLUSTER 1

CAN_ CAN LOW LG

G0_8-TXL_T WIST

SPL_CAN_L, ULTRASONIC

AIC_1, ADV INSTR CLUSTER 1

CAN_ CAN LOW LJ

G0_8-TXL_T WIST

SPL_D5, ULTRASONIC

TECM, TRANS

CAN_ CAN LOW LJ

G0_8-TXL_T WIST

SPL_D5, ULTRASONIC

TECM, TRANS

CAN_ CAN LOW LK

G0_8-TXL_T WIST

SPL_D5, ULTRASONIC

TECM, TRANS

CAN_ CAN LOW LK

G0_8-TXL_T WIST

SPL_D5, ULTRASONIC

TECM, TRANS

CAN_ CAN LOW LL

G0_8-TXL_T WIST

SPL_CAN_HVAC_L, ULTRASONIC

HVAC_CAN1, CAN_HVAC_ATC

CAN_ CAN LOW LL

G0_8-TXL_T WIST

SPL_CAN_HVAC_L, ULTRASONIC

HVAC_CAN1, CAN_HVAC_ATC

CAN_ CAN LOW FROM ENG LM

G0_8-TXL_T WIST

CAN2, CAN BULK HEAD

QSM11, ENGINE CONTROLLER

CAN_ CAN LOW FROM ENG LM

G0_8-TXL_T WIST

CAN2, CAN BULK HEAD

QSM11, ENGINE CONTROLLER

CAN_ CAN LOW LN

G0_8-TXL_T WIST

SPL_CAN_HVAC_L, ULTRASONIC

SPL_CAN_DIAG_L, ULTRASONIC

CAN_ CAN LOW LN

G0_8-TXL_T WIST

SPL_CAN_HVAC_L, ULTRASONIC

SPL_CAN_DIAG_L, ULTRASONIC

ECC_ BEACON/DOME LT LI ECC L1

BUSS

L1_ECC, ECC BATT PWR

cs01

ECC, ELECT CNTR C

L1_1

ECC_ BEACON/DOME LT LI ECC L1

BUSS

L1_ECC, ECC BATT PWR

cs01

ECC, ELECT CNTR C

L1_1

TRANS ECM PWR

ECA_BUSS

ECA_L1, B+ POWER

cs01

ECA, ELECT CNTR A

TRANS ECM PWR

ECA_BUSS

ECA_L1, B+ POWER

cs01

ECA, ELECT CNTR A

TRANS ECM COMFORT STEER

ECA_BUSS

ECA, ELECT CNTR A

TRANS ECM COMFORT STEER

ECA_BUSS

ECA, ELECT CNTR A

COMFORT STEER AIC PWR

ECA_BUSS

ECA, ELECT CNTR A

COMFORT STEER AIC PWR

ECA_BUSS

ECA, ELECT CNTR A

EMG STR AIC PWR

ECA_BUSS

ECA, ELECT CNTR A

EMG STR AIC PWR

ECA_BUSS

ECA, ELECT CNTR A

EMG STRG PLT EM DTNTS

ECA_BUSS

ECA, ELECT CNTR A

EMG STRG PLT EM DTNTS

ECA_BUSS

ECA, ELECT CNTR A

PLTEM DTNTS PRK BRK SOL

ECA_BUSS

ECA, ELECT CNTR A

PLTEM DTNTS PRK BRK SOL

ECA_BUSS

ECA, ELECT CNTR A

PRK BRK SOL HRN

ECA_BUSS

ECA, ELECT CNTR A

PRK BRK SOL HRN

ECA_BUSS

ECA, ELECT CNTR A

FAN RVSR TURN SGNL

ECA_BUSS

ECA, ELECT CNTR A

FAN RVSR TURN SGNL

ECA_BUSS

ECA, ELECT CNTR A

TURN SGNL ENG SHTDWN.

ECA_BUSS

ECA, ELECT CNTR A

TURN SGNL ENG SHTDWN.

ECA_BUSS

ECA, ELECT CNTR A

J11

BLWR MOTOR PWR

ECA_BUSS

ECA_L2, B+ POWER

cs01

ECA, ELECT CNTR A

J11

BLWR MOTOR PWR

ECA_BUSS

ECA_L2, B+ POWER

cs01

ECA, ELECT CNTR A

J12

BLWR MTR FRNT WIPR WASH ECA_BUSS

ECA, ELECT CNTR A

J12

BLWR MTR FRNT WIPR WASH ECA_BUSS

ECA, ELECT CNTR A

J13

FRNT WIPR RER WIPR WSH

ECA, ELECT CNTR A

J13

FRNT WIPR RER WIPR WSH

ECA, ELECT CNTR A

ECA_BUSS

J14

RER WIPR WSH BACKUP

ECA_BUSS

ECA, ELECT CNTR A

J14

RER WIPR WSH BACKUP

ECA_BUSS

ECA, ELECT CNTR A

J15

BKUP A/C

ECA_BUSS

ECA, ELECT CNTR A

J15

BKUP A/C

ECA_BUSS

ECA, ELECT CNTR A

J16

A/C SEAT COMP

ECA_BUSS

ECA, ELECT CNTR A

J16

A/C SEAT COMP

ECA_BUSS

ECA, ELECT CNTR A

J18

SEAT COMP EMG STRTR

ECA_BUSS

ECA, ELECT CNTR A

J18

SEAT COMP EMG STRTR

ECA_BUSS

ECA, ELECT CNTR A

J2_EC BEACON/DOME LT WORK LTS ECC_BUSS C

ECC, ELECT CNTR C

L1_1

ECC, ELECT CNTR C

L1_2

J2_EC BEACON/DOME LT WORK LTS ECC_BUSS C

ECC, ELECT CNTR C

L1_1

ECC, ELECT CNTR C

L1_2

J3_EC WORK LTS DRIVING LTS C

ECC_BUSS

ECC, ELECT CNTR C

L1_2

ECC, ELECT CNTR C

L1_3

J3_EC WORK LTS DRIVING LTS C

ECC_BUSS

ECC, ELECT CNTR C

L1_2

ECC, ELECT CNTR C

L1_3

J4_EC DRIVING LTS BRK LTS C

ECC_BUSS

ECC, ELECT CNTR C

L1_3

ECC, ELECT CNTR C

L1_4

J4_EC DRIVING LTS BRK LTS C

ECC_BUSS

ECC, ELECT CNTR C

L1_3

ECC, ELECT CNTR C

L1_4

J5_EC BRK LTS DLY PWR C

ECC_BUSS

ECC, ELECT CNTR C

L1_4

ECC, ELECT CNTR C

L1_5

J5_EC BRK LTS DLY PWR C

ECC_BUSS

ECC, ELECT CNTR C

L1_4

ECC, ELECT CNTR C

L1_5

4002-36

Wire Identification Codes

21C Bk - 1.0

21C Bk - 1.0 Wire Size

Wire Color Wire Name

(mm2

) 0.8 mm

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

Wire Size (mm2) 0.8 mm

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

Wire Color

K = Pink U = Blue Y = Yellow

Wire Name

To Connector Cavity

Connector

Bk = Black T = Tan LU = Light Blue

1.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Cavity

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

J6_EC DLY PWR HRN C

ECC_BUSS

ECC, ELECT CNTR C

L1_5

ECC, ELECT CNTR C

L1_6

J6_EC DLY PWR HRN C

ECC_BUSS

ECC, ELECT CNTR C

L1_5

ECC, ELECT CNTR C

L1_6

J7_EC HRN HOD CTRL C

ECC_BUSS

ECC, ELECT CNTR C

L1_6

ECC, ELECT CNTR C

L1_7

J7_EC HRN HOD CTRL C

ECC_BUSS

ECC, ELECT CNTR C

L1_6

ECC, ELECT CNTR C

L1_7

J8_EC HOD CTRL CIGAR LITR C

ECC_BUSS

ECC, ELECT CNTR C

L1_7

ECC, ELECT CNTR C

L1_8

J8_EC HOD CTRL CIGAR LITR C

ECC_BUSS

ECC, ELECT CNTR C

L1_7

ECC, ELECT CNTR C

L1_8

J9_EC DIAGNOSTIC PWR C

ECC_BUSS

ECC, ELECT CNTR C

L1_9

ECC, ELECT CNTR C

L1_8

J9_EC DIAGNOSTIC PWR C

ECC_BUSS

ECC, ELECT CNTR C

L1_9

ECC, ELECT CNTR C

L1_8

PRM_ IGN PWR FUSE SEC STRG A

BUSS

PRM_A, PWR RLY MOD A

PRM_ IGN PWR FUSE SEC STRG A

BUSS

PRM_A, PWR RLY MOD A

PRM_ TIM DLY FUSE IGN PWR FUSE BUSS, B

PRM_A, PWR RLY MOD A PRM_A, PWR RLY MOD A

PRM_ ACC PWR FUSE SPARE D

BUSS

PRM_D, PWR RLY MOD D

PRM_ ACC PWR FUSE SPARE D

BUSS

PRM_D, PWR RLY MOD D

PRM_ IGN PWR FUSE ACC PWR PWR FUSE

BUSS

PRM_A, PWR RLY MOD A

PRM_D, PWR RLY MOD D

PRM_ IGN PWR FUSE ACC PWR PWR FUSE

BUSS

PRM_A, PWR RLY MOD A

PRM_D, PWR RLY MOD D

RAD1 RADIO GND

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J1, RADIO_POWER

RAD1 RADIO GND

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J1, RADIO_POWER

RAD2 12V FSD PWR TO RADIO

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J1, RADIO_POWER

RAD2 12V FSD PWR TO RADIO

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J1, RADIO_POWER

RAD3 12V FSD PWR TO RADIO

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J1, RADIO_POWER

RAD3 12V FSD PWR TO RADIO

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J1, RADIO_POWER

RAD4 LEFT SPEAKER GND

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD4 LEFT SPEAKER GND

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD5 LEFT SPEAKER

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD5 LEFT SPEAKER

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD6 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD6 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD7 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD7 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD8 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD8 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD9 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD9 NOT USED

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD1 RIGHT SPEAKER GND 0

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD1 RIGHT SPEAKER GND 0

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2, SPEAKER

RAD11 RIGHT SPEAKER

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2 SPEAKER

RAD11 RIGHT SPEAKER

W0_8_GXL

RAD_J3, RADIO_JUMPER

RAD_J2 SPEAKER

4002-37

UNDERSTANDING THE TROUBLESHOOTING TABLES 1 – Alternator

Check Points

Correct Reading

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

Good 12 volts

Possible Cause of Bad Reading

Check Points

Correct Reading

Bad fuse.

Check the 10 ampere fuse at location 3 and 4C in the fuse block.

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

Terminal for wire 1A to ground

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

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.

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

LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.

Components can be located on the Electr ical Schematic posters (rear pocket) by item number using the key at the bottom of the posters. Use the following index to find the sheet a component is located on.

COMPONENT NUMBER

SCHEMATIC SHEET

COMPONENT NUMBER

SCHEMATIC SHEET

12 Volt Radio (Option)

123

12 Volt Radio (Option)

123

Actuator

143

Actuator

143

Air Conditioning High Pressure Switch

129

Air Conditioning High Pressure Switch

129

Air Conditioning Low Pressure Switch

129

Air Conditioning Low Pressure Switch

129

Air Filter Restriction Switch

Air Seat Compressor

126

Air Seat Compressor

126

Alternator

Back-up Alarm

103

Back-up Alarm

103

Backup Alarm Disable Switch

Back-up Alarm Relay

COMPONENT

Alternator

COMPONENT

4002-38

4002-38 COMPONENT NUMBER

SCHEMATIC SHEET

COMPONENT NUMBER

SCHEMATIC SHEET

Batteries

Beacon Switch (Option)

Blower Motor

136-147

8-9

Blower Motor

136-147

8-9

Blower Motor Speed Resistors with Thermal Fuse

135-146

8-9

Blower Motor Speed Resistors with Thermal Fuse

135-146

8-9

Brake Declutch Pressure Switch

Brake Lamp Pressure Switch

Brake Lamps Relay

Brake Warning Pressure Switch

Bucket Control Valves Electromagnetic Detents

Cigar Lighter (Option)

127

Cigar Lighter (Option)

127

Comfort Steer Fuse (Option)

Comfort Steer Relay (Option)

Comfort Steer Solenoid (Option)

Comfort Steer Switch (Option)

Compressor Clutch

130

Compressor Clutch

130

Compressor Clutch Relay

139

Compressor Clutch Relay

139

Converter (24 Volts to 12 Volts)

142

Converter (24 Volts to 12 Volts)

142

Coolant Level Sender

Crank Control Relay

Declutch Switch

61-119

4-8

61-119

4-8

Dome Lamp

Electronic Panel

131

Electronic Panel

131

Engine Controller (QSM11)

Engine Speed Sensor

Ether Solenoid

Fan PWM Solenoid

Fan Reverse Relay (Option)

Fan Reverser Switch (Option)

Fan Reversing Solenoid (Option)

COMPONENT

Diagnostic Connector

COMPONENT

Diagnostic Connector

4002-39 COMPONENT NUMBER

SCHEMATIC SHEET

Filter Maintenance Switch

Flasher Module

4002-39 COMPONENT NUMBER

SCHEMATIC SHEET

Filter Maintenance Switch

Flasher Module

55-57

FNR Switch

55-57

Front Axle Oil Temperature Sender

Front Washer Pump Motor

111

Front Washer Pump Motor

111

Front Wiper and Washer Switch

108

Front Wiper and Washer Switch

108

Front Wiper High Speed Relay

104

Front Wiper High Speed Relay

104

Front Wiper Low Speed Relay

106

Front Wiper Low Speed Relay

106

Front Wiper Motor

109

Front Wiper Motor

109

Fuel Level Sender

Hazard Switch

Height Control Switch

Height Control/Return-To-Travel Proximity Switch

Horn

Horn Relay

Hydraulic Filter Restriction Switch

Hydraulic Oil Temperature Sender

Ignition Switch

Intermediate Speed Sensor

Internal Air Temperature Sensor

133

Internal Air Temperature Sensor

133

Left Hand Front Combination Lamp

Left Hand Front Work Lamp

Left Hand Rear Combination Lamp

101

Left Hand Rear Combination Lamp

101

Left Hand Rear Work Lamp

Left Speaker

125

Left Speaker

125

License Plate Lamp

102

License Plate Lamp

102

Master Disconnect Switch

Mixed Air Sensor

138

Mixed Air Sensor

138

Neutral Start Relay

Output Speed Sensor

COMPONENT

FNR Switch

Master Disconnect Switch

COMPONENT

4002-40

4002-40 COMPONENT NUMBER

SCHEMATIC SHEET

COMPONENT NUMBER

SCHEMATIC SHEET

Parking Brake Fuse

Parking Brake Relay

Parking Brake Solenoid

Pilot Control Relay

Pilot Control Switch

Pilot Pressure Solenoid

Pin Engage Switch (Option)

Power Converter (24 Volts to 12 Volts)

121

Power Converter (24 Volts to 12 Volts)

121

Power Outlet (Option)

122

Power Outlet (Option)

122

Power Relay Module A

Power Relay Module B

Power Relay Module C

Power Relay Module D

Power Relay Module E

120

Power Relay Module E

120

Radio Fuse (Option)

Rear Axle Oil Temperature Sender

Rear Washer Pump Motor

112

Rear Washer Pump Motor

112

Rear Wiper and Washer Switch

107

Rear Wiper and Washer Switch

107

Rear Wiper Motor

110

Rear Wiper Motor

110

75-76

Redundant Brake Pressure Switches

75-76

Return-To-Dig Proximity Switch

Return-To-Travel/Float Switch

RH Front Combination Lamp

RH Front Work Lamp

RH Rear Combination Lamp

100

RH Rear Combination Lamp

100

RH Rear Work Lamp

Ride Control Relay (Option)

Ride Control Solenoid (Option)

Ride Control Switch (Option)

Right Speaker

124

Right Speaker

124

COMPONENT

Redundant Brake Pressure Switches

COMPONENT

4002-41 COMPONENT NUMBER

SCHEMATIC SHEET

Rollback Pressure Switch (Option)

Rotating Beacon (Option)

Secondary Steering Module (Option)

4002-41 COMPONENT NUMBER

SCHEMATIC SHEET

Rollback Pressure Switch (Option)

Rotating Beacon (Option)

116

Secondary Steering Module (Option)

116

Secondary Steering Motor (Option)

117

Secondary Steering Motor (Option)

117

Secondary Steering Pressure Switch (Option)

118

Secondary Steering Pressure Switch (Option)

118

Secondary Steering Solenoid (Option)

115

Secondary Steering Solenoid (Option)

115

Starter Motor

Starting Relay

Thermostat

148

Thermostat

148

Throttle Pedal

Time Delay Module

Torque Converter Output Temperature Sensor

Transmission Auto Switch

Transmission Electronic Control Module

Transmission Enable Switch

Transmission Kick-Down Switch

Transmission Shifter

Transmission Solenoid Valve and Temperature Sensor

Turbine Speed Sensor

Turn Signal, High/Low Beam, and Horn Switch

Voltmeter Fuse

Voltmeter Relay

Warning Buzzer

Work Lamps Switch

COMPONENT

4002-42

STARTING AND CHARGING SYSTEMS

2 8 1 9

7 4 11 6 12

2 8 1 9

7 4 11 6 12

W270-7R020

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

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

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

TIME DELAY MODULE MASTER DISCONNECT SWITCH STARTER IGNITION SWITCH NEUTRAL START RELAY VOLT METER 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.

W270-7R020

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

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

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

TIME DELAY MODULE MASTER DISCONNECT SWITCH STARTER IGNITION SWITCH NEUTRAL START RELAY VOLT METER RELAY

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

4002-43

1 – Starting Relay

Located in the right side of the engine compartment on starter motor, open engine compartment to gain access.

Check Points Relay housing to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

Check Points Relay housing to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position.

Terminal 87, battery hot lead (black w/white stripe), 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.

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 21C-D to ground

24 volts

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

Terminal for wire 21C-D to ground

24 volts

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

Terminal 30, lead from relay to starter solenoid, to ground

24 volts

Bad starting relay.

Terminal 30, lead from relay to starter solenoid, 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.

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.

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. Bad wire 1-BA.

NOTE: Put the ignition switch in the ON position.

Terminal for wire 14 to ground

20 volts

24 volts

Check circuit to positive post of left battery. Bad master disconnect switch. Bad wire 1-BA.

NOTE: Put the ignition switch in the ON position. Check circuit 14, 75 ohm resistor (2), and diode module. Bad fuse ECA-F4. Check power relay module A (13), and 105 ampere circuit breaker (19) in engine compartment of machine.

Terminal for wire 14 to ground

20 volts

Check circuit 14, 75 ohm resistor (2), and diode module. Bad fuse ECA-F4. Check power relay module A (13), and 105 ampere circuit breaker (19) in engine compartment of machine.

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

4 – Crank Control Relay

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

4002-44

5 – Batteries

Located on right and left rear sides of the machine.

NOTE: See Section 4003 and check the batteries.

6 – Crank Request Relay

6 – Crank Request Relay Correct Reading

Check Points

Possible Cause of Bad Reading

Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: No information at time of print.

7 – Time Delay Module

Located in the cab access panel for fuses and relays at rear of compartment.

Correct Reading

Check Points Terminal for wire 0-DC to ground

Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

Terminal for wire 1DN to ground

24 volts

Terminal for wire 0-DC to ground

Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position.

Bad 10 ampere fuse in ECC F5. Check wire 1DN to SPL-DLY and wire 1DM to fuse ECC F5.

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

Correct Reading

Check Points

24 volts

Terminal for wire 1DN to ground

Bad 10 ampere fuse in ECC F5. Check wire 1DN to SPL-DLY and wire 1DM to fuse ECC F5.

NOTE: Put the ignition switch in the ON position. Bad ignition switch (10), also check circuit 13K.

24 volts

Terminal for wire 13K-A to ground

Bad ignition switch (10), also check circuit 13K.

NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 30 seconds time delay an audible click will be heard.

Within 30 seconds of putting the ignition switch in the OFF position, check terminal for wire 13D to ground After 30 seconds of turning ignition switch to the OFF position, check terminal for wire 13D to ground

24 volts Key OFF

Bad time delay module.

Within 30 seconds of putting the ignition switch in the OFF position, check terminal for wire 13D to ground

0 volt

Bad time delay module.

After 30 seconds of turning ignition switch to the OFF position, check terminal for wire 13D to ground

24 volts Key OFF

Bad time delay module.

0 volt

Bad time delay module.

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

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.

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).

Open Circuit

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

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

4002-45

9 – Starter Motor

Located on left side of engine, open engine compartment to gain access.

Check Points Between housing of starter and ground

Correct Reading Continuity

Possible Cause of Bad Reading

Bad ground connection.

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

24 volts

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.

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

Check Points

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

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 – 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 1A to ground

24 volts

Bad 10 ampere fuse in ECC F5. Check circuit 1A.

NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.

Check Points

Correct Reading

Possible Cause of Bad Reading

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

24 volts

Bad 10 ampere fuse in ECC F5. Check circuit 1A.

NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.

Between Bat and Ign

Continuity

Bad ignition switch.

Between Bat and Ign

Continuity

Bad ignition switch.

Between Bat and Accessory

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 Starter

Continuity

Bad ignition switch.

Between Bat and Ign

Continuity

Bad ignition switch.

Between Bat and Ign

Continuity

Bad ignition switch.

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

Continuity

NOTE: Put the switch in the Accessory position. Bad ignition switch.

Between Bat and Accessory

Continuity

Bad ignition switch.

4002-46

11 – Neutral Start Relay

Located in the cab access panel for fuses and relays.

Check Points Terminal for wire 0-DE to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

24 volts

Check circuit 25T, check FNR switch (50).

NOTE: Have another person hold the ignition switch in the START position.

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 (50).

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 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.

Terminal for wire 21C to ground

24 volts

Bad neutral start relay.

12 – Voltmeter Relay

Located in the cab access panel for fuses and relays.

Check Points Terminal for wire 0-DD 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 18R-A to ground

24 volts

Check circuit 18R to power relay module C in engine compartment.

NOTE: Turn ignition switch to the ON position.

Check Points Terminal for wire 0-DD 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 18R-A to ground

24 volts

Check circuit 18R to power relay module C in engine compartment.

NOTE: Turn ignition switch to the ON position.

Terminal for wire 13K-C to ground

24 volts

Check circuit 13K or ignition switch.

Terminal for wire 13K-C to ground

24 volts

Check circuit 13K or ignition switch.

Terminal for wire 13V to ground

24 volts

Bad voltmeter relay.

Terminal for wire 13V to ground

24 volts

Bad voltmeter relay.

4002-47

POWER RELAY MODULES AND COLD STARTING SYSTEMS

16 15 19

POWER RELAY MODULES AND COLD STARTING SYSTEMS

13 14 18

15 19

13 14 18

W270-7R021

13. 14. 15. 16. 17.

POWER RLEAY MODULE A POWER RELAY MODULE B POWER RELAY MODULE C ETHER SOLENOID VOLTMETER FUSE

18. 19. 20. 21.

POWER RELAY MODULE D CIRCUIT BREAKER CAB + COMFORT STEER RELAY (OPTION) COMFORT STEER 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.

W270-7R021

13. 14. 15. 16. 17.

POWER RLEAY MODULE A POWER RELAY MODULE B POWER RELAY MODULE C ETHER SOLENOID VOLTMETER FUSE

18. 19. 20. 21.

POWER RELAY MODULE D CIRCUIT BREAKER CAB + COMFORT STEER RELAY (OPTION) COMFORT STEER SOLENOID (OPTION)

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

4002-48

13 – Power Relay Module A, Ignition Power

Located in the cab access panel for fuses and relays.

Check Points Terminal for wire 0-EB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.

Check Points Terminal for wire 0-EB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.

Terminal for wire 1CB-A to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire 1CB-A to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire 13K-B to ground

24 volts

Check circuit 13K and check ignition switch (10).

Terminal for wire 13K-B to ground

24 volts

Check circuit 13K and check ignition switch (10).

Terminal for wire J1 BUSS to ground

24 volts

Bad power relay module A.

Terminal for wire J1 BUSS to ground

24 volts

Bad power relay module A.

14 – Power Relay Module B, Ignition Power

Located in the cab access panel for fuses and relays.

Check Points Terminal for wire 0-EA to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

Check Points Terminal for wire 0-EA to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.

Terminal for wire PRM-B BUSS to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire PRM-B BUSS to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire 13D to ground

24 volts

Check circuit 13 to Time Delay Module, check TDM (7), check ignition switch (10).

Terminal for wire 13D to ground

24 volts

Check circuit 13 to Time Delay Module, check TDM (7), check ignition switch (10).

Terminal for wire 13H to ground

24 volts

Bad power relay module B.

Terminal for wire 13H to ground

24 volts

Bad power relay module B.

15 – Power Relay Module C, For Ether Solenoid

Located in the right side of the engine compartment, open engine compartment to gain access.

Check Points Terminal for wire 0-BAM to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn master disconnect switch to the ON position. Terminal for wire 1-B9 to ground

24 volts

Check Points Terminal for wire 0-BAM to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn master disconnect switch to the ON position. Check circuit 1 to starter B+.

NOTE: Remove the ether bottle from the machine. Make sure engine temperature is below -0° C (32° F). Put the ignition switch in the ON position, have an assistant press and hold the ether switch to the inject position.

Terminal for wire 1-B9 to ground

24 volts

Check circuit 1 to starter B+.

Terminal for wire 28E to ground

24 volts

Check Ether switch.

Terminal for wire 28E to ground

24 volts

Check Ether switch.

Terminal for wires 28P ground

24 volts

Bad power relay module C.

Terminal for wires 28P ground

24 volts

Bad power relay module C.

4002-49

16 – Ether Solenoid

Located in the right side of the engine compartment.

Check Points Terminal for wire 0-BAN to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect connector ETHR from ether solenoid. Between terminals A and B of solenoid.

28.8 ohm @ 20° C (68° F)

Check Points Terminal for wire 0-BAN to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect connector ETHR from ether solenoid. Between terminals A and B of solenoid.

Bad solenoid.

28.8 ohm @ 20° C (68° F)

Bad solenoid.

NOTE: If the readings are good, check circuit 28P between solenoid connector ETHR and power relay module C connector PRM-C1. Check Power Relay Module C (15).

17 – Voltmeter Fuse

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

18 – Power Relay Module D, Accessory Power

Located in the cab access panel for fuses and relays.

Check Points Terminal for wire 0-EC to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn master disconnect switch to the ON position. Terminal for wire PRM-D BUSS to ground

24 volts

Check Points Terminal for wire 0-EC to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Turn master disconnect switch to the ON position. Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

NOTE: Put the ignition switch in the ACC position.

Terminal for wire PRM-D BUSS to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

NOTE: Put the ignition switch in the ACC position.

Terminal for wire 12ACC-B to ground

24 volts

Check ignition switch (10).

Terminal for wire 12ACC-B to ground

24 volts

Check ignition switch (10).

Terminal for wire BUSS-J11 ground

24 volts

Bad power relay module D.

Terminal for wire BUSS-J11 ground

24 volts

Bad power relay module D.

19 – Circuit breaker Cab B+

Located in the right side of the engine compartment, open engine compartment to gain access.

Check Points

Correct Reading

Between terminal A and B on circuit breaker

Continuity

Possible Cause of Bad Reading

Bad circuit breaker

Check Points

Correct Reading

Between terminal A and B on circuit breaker

Continuity

Possible Cause of Bad Reading

Bad circuit breaker

4002-50

20 – Comfort Steer Relay (option) Check Points

Correct Reading

20 – Comfort Steer Relay (option) Possible Cause of Bad Reading

Check Points

Correct Reading

NOTE: No information at time of print.

21 – Comfort Steer Solenoid (option)

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

4002-51

ENGINE CONTROLLER

24 23

23 22

22 W270-7R022

22. FRONT AXLE OIL TEMPERATURE SENDER 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.

W270-7R022

22. FRONT AXLE OIL TEMPERATURE SENDER 23. THROTTLE POTENTIOMETER 24. ENGINE CONTROLLER

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

4002-52

22 – Front Axle Oil Temperature Sender Check Points

22 – Front Axle Oil Temperature Sender

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

23 – Throttle Potentiomer

Located below cab under throttle pedal.

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

NOTE: Use the Electronic Service Tool to test the throttle sensor.

24 – Engine Controller

Located on right side of engine, open engine compartment to gain access.

Check Points

Correct Reading

Possible Cause of Bad Reading

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 QSM 11.

Terminal for wire 0-BAH pin 29 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAH pin 29 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAI pin 30 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAI pin 30 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAJ pin 39 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAJ pin 39 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAK pin 40 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAK pin 40 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAP pin 50 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-BAP pin 50 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-M pin 7 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-M pin 7 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-N pin 8 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-N pin 8 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-L pin 17 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-L pin 17 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-P pin 18 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-P pin 18 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-Q pin 28 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

Terminal for wire 18J-Q pin 28 to ground

24 volts

Bad fuse ECD-F2, bad wire 18J.

NOTE: Use diagnostic service tool for additional tests on QSM 11.

4002-53

RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE 28

25 26 31

27 33

W270-7R023

25. 26. 27. 28. 29.

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

30. 31. 32. 33. 34.

HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH RETRUN TO DIG SWITCH PIN ENGAGE SWITCH (OPTION) PILOT PRESSURE SOLENOID REAR AXLE OIL TEMPERATURE SENDER

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.

W270-7R023

25. 26. 27. 28. 29.

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

30. 31. 32. 33. 34.

HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH RETRUN TO DIG SWITCH PIN ENGAGE SWITCH (OPTION) PILOT PRESSURE SOLENOID REAR AXLE OIL TEMPERATURE SENDER

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

4002-54

25 – Return-To-Travel/Float Switch

Located on right side console.

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

Possible Cause of Bad Reading

Terminal for wire 0-B2 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-B2 to ground

Continuity

Bad ground circuit.

Terminal for wire 0-29 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

24 volts

Between switch terminals 1 and 2

Bad return-to-travel/float switch.

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.

Between switch terminals 2 and 3

Terminal for wire 49-K to ground

26 – Height Control Switch

Located on right side console.

Terminals for wire 0-B3 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-D to ground.

24 volts

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

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

24 volts

Continuity

from

the

return-to-travel/float

switch.

Put

the

return-to-

Bad return-to-travel/float switch.

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.

26 – Height Control Switch

Check Points

connector

NOTE: Put the return-to-travel/float switch in the TRAVEL position.

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

NOTE: Disconnect the wiring harness travel/float switch in FLOAT position.

Check Points Terminals for wire 0-B3 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

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. Bad height control switch.

Terminal for wire 54A to ground.

24 volts

Bad height control switch.

4002-55

27 – Electromagnetic Detents

Located under right side console.

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: For joystick controller.

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 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 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 1 and 6

74 ohms @ 20° C (68° F)

Bad electromagnetic detent

NOTE: For single axis controller.

Between pins 3 and 4

328 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 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

Between pins 1 and 6

328 ohms @ 20° C (68° F)

Bad electromagnetic detent

NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (36) in OFF position and return to travel/float switch (22) in ON position.

Wiring harness connector EM, pin 1 to ground

24 volts

Bad return to travel/float switch (22). 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.

Wiring harness connector EM, pin 2 to ground

24 volts

Bad return to dig switch. Also check wires 53A.

Wiring harness connector EM, pin 3 to ground

24 volts

28 – Return-To-Dig Proximity Switch

Located on bucket cylinder.

Located on bucket cylinder. 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 (36) in the OFF position and the return to dig switch in the ON position. Terminal B for wire 0-AC to ground

Continuity

Terminal A for wire 53B to ground Terminal C for wire 53P-H to ground

Bad height control switch. Also check wires 54A.

NOTE: Place the return to dig switch in the ON position.

28 – Return-To-Dig Proximity Switch

Check Points

Bad return to travel/float switch (22). Also check wires 55A.

NOTE: Place the height control switch in the ON position.

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

24 volts

Check Points

Correct Reading

Bad return to dig switch. Also check wires 53A.

Possible Cause of Bad Reading

Bad ground circuit.

Terminal B for wire 0-AC to ground

Continuity

24 volts

Bad bucket control valve detent electromagnets (24) or return to dig switch. Also check circuit 53B.

Terminal A for wire 53B to ground

24 volts

Bad bucket control valve detent electromagnets (24) or return to dig switch. Also check circuit 53B.

24 volts

Bad pilot relay (26), also check circuit 53P.

Terminal C for wire 53P-H to ground

24 volts

Bad pilot relay (26), also check circuit 53P.

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

Bad ground circuit.

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

4002-56

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 (36) 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

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 (36) is OFF.

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

Terminal for wire 19C-C to ground

24 volts

Bad instrument cluster (57). Also check circuit 53C.

Terminal for wire 53C-A to ground

0 volt

Bad pilot control relay.

Terminal for wire 53P-A to ground

24 volts

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

Check Points

Bad fuse ECA-F5, also check circuit 19C. Bad instrument cluster (57). Also check circuit 53C. Bad pilot control relay.

NOTE: Put the pilot control switch in ON position. Bad instrument cluster (57). Also check circuit 53C.

Terminal for wire 53C-A to ground

24 volts

Bad instrument cluster (57). 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 (36) 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 Terminal C for wire 53P-J to ground

Check Points

Correct Reading

Possible Cause of Bad Reading

Bad ground circuit.

Terminal B for wire 0-AA to ground

Continuity

24 volts

Bad bucket control valve detent electromagnets (24) or return to travel switch. Also check circuit 54B.

Terminal A for wire 54B to ground

24 volts

Bad bucket control valve detent electromagnets (24) or return to travel switch. Also check circuit 54B.

24 volts

Bad pilot relay (26), also check circuit 53P.

Terminal C for wire 53P-J to ground

24 volts

Bad pilot relay (26), 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 (26), check fuse ECA-F5.

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

24 volts

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 (26), check fuse ECA-F5.

NOTE: Turn the height control switch to the ON position. Bad return to dig switch.

Terminal for wire 53A to ground.

24 volts

Bad return to dig switch.

4002-57

32 – Pin Engage Switch (option) Check Points

4002-57

32 – Pin Engage Switch (option)

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

33 – Pilot Pressure Solenoid

Located on bottom side of pilot controls.

Check Points Terminal for wire 0-DU 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 pilot control switch (36) is OFF. Terminal A for wire 53P-A to ground

24 volts

Bad pilot control relay (26), also check circuit 53P.

Check Points Terminal for wire 0-DU to ground

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Continuity

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control switch (36) is OFF. Terminal A for wire 53P-A to ground

24 volts

Bad pilot control relay (26), also check circuit 53P.

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

34 – Rear Axle Oil Temperature Sender

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

4002-58

PILOT CONTROL - RIDE CONTROL - FAN CONTROL

35 37 39

W270-7R024

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) COMFORT STEER SWITCH 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.

W270-7R024

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) COMFORT STEER SWITCH FAN PWM SOLENOID FAN REVERSE SOLENOID (OPTION)

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

4002-59

35 – Ride Control Switch (Option)

Located on right side console.

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector SRC from ride control switch.

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.

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.

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 A. Also check circuit 19C.

Terminal for wire 19C-D to ground

Bad ride control switch.

Terminal for wire 58C to ground

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

24 volts

24 volts 0 volt

Bad ride control switch.

Terminal for wire 58C 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.

Terminal for wire 49-G to ground

24 volts

36 – Ride Control Relay (Option)

Located in the cab access panel for fuses and relays.

Correct Reading

Bad ride control switch.

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

36 – Ride Control Relay (Option)

Check Points

Check fuse ECA-F5 and power relay module A. Also check circuit 19C.

NOTE: Put the ride control switch in the ON position.

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

Terminal for wire 49-G to ground

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.

Possible Cause of Bad Reading

Check Points

Correct Reading

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.

Possible Cause of Bad Reading

Terminal 85 for wire 58L to connector TECM pin 57

Continuity

Check wire 58L.

Terminal 85 for wire 58L to connector TECM pin 57

Continuity

Check wire 58L.

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

Continuity

Check wire 58H-A.

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

Continuity

Check wire 58H-A.

Terminal 87 for wire 58-E to ride control switch (32) pin 6

Continuity

Check wire 58-E

Terminal 87 for wire 58-E to ride control switch (32) 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

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

Bad ride control switch. Also check wire 58T.

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

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

Bad ride control switch. Also check wire 58T.

4002-60

37 – Fan Control Switch (Option)

Located on right side console.

Check Points Terminal for wire 0-B7 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

24 volts

Check fuse ECA-F7, power relay module A (13), also check circuit 19P.

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

24 volts

Bad fan reversing switch.

24 volts

Continuity

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

Terminal for wire 52AU to ground

24 volts

Bad fan reversing switch.

Terminal for wire 52M to ground

24 volts

Check fuse ECA-F7, power relay module A (13), also check circuit 19P.

Bad fan reversing switch.

NOTE: Put driving lamp switch in position 3. Check driving lamp switch. If LEDs in fan reversing switch are not ON with 24 volts at check point, replace fan reversing switch.

Terminal for wire 49-Q to ground

24 volts

38 – Fan Reverse Relay (Option)

Located in the cab access panel for fuses and relays.

Check Points

Possible Cause of Bad Reading

NOTE: Put fan reversing switch in momentary position, hold rocker.

NOTE: Put driving lamp switch in position 3.

Terminal for wire 49-Q to ground

Terminal for wire 0-B7 to ground

Correct Reading

NOTE: Put fan reversing switch in position 1.

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

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

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

Correct Reading

Possible Cause of Bad Reading

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

Terminal for wire 19P-D and 19P-E to ground

24 volts

Check fuse ECA-F7 and circuit 19P.

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

24 volts

Bad fan reverse solenoid, bad fan reverse switch (34), bad advanced instrument cluster (57).

24 volts

Check fuse ECA-F7 and circuit 19P.

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

24 volts

Bad fan reverse solenoid, bad fan reverse switch (34), bad advanced instrument cluster (57).

4002-61

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 19A-J to ground

24 volts

Bad fuse ECA-F1, also check circuit 19C.

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

24 volts

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 19A-J to ground

24 volts

Bad fuse ECA-F1, also check circuit 19C.

NOTE: Press pilot control switch to turn ON switch LED. Bad pilot control switch.

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

Check Points

Terminal for wire 31L to ground

24 volts

Bad pilot control switch.

NOTE: Put the driving lamp switch (95) in position 3. Check driving lamp switch (95) and fuse ECC-F3. Also check circuit 49.

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 (Option)

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 20° C (68° F)

Correct Reading

Bad ground circuit.

Connector YRC pin 2 to ground

Bad ride control solenoid.

Between terminals 1 and 2 of ride control solenoid

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

42 – Comfort Steer Switch

NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Continuity 20 to 26 ohms 20° C (68° F)

Bad ground circuit. Bad ride control solenoid.

41 – Rollback Pressure Switch (Option)

NOTE: No information at time of print.

Check Points

Correct Reading

NOTE: Disconnect connector YRC from ride control solenoid.

41 – Rollback Pressure Switch (Option) Check Points

Check Points

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

4002-62

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 1and 2 of fan PWM solenoid

26 to 32 ohms 20° C (68° F)

Pin 2 of wiring harness connector YFN to ground

Continuity

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid.

Bad fan reversing solenoid.

Between pins 1and 2 of fan PWM solenoid

26 to 32 ohms 20° C (68° F)

Bad ground circuit.

Pin 2 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 1 of wiring harness connector YFN to ground

24 volts

Bad instrument cluster. Also check wire 56.

24 volts

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 20° C (68° F) Continuity

24 volts

Between pins 1and 2 of fan reversing solenoid

Bad ground circuit.

Pin 2 of wiring harness connector YFR to ground

Bad fan reversing switch (34), reverse relay (35). Also check wire 52-A.

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector YFR from fan reversing solenoid.

Bad fan reversing solenoid.

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

Check Points

Bad instrument cluster. Also check wire 56.

36 to 42 ohms 20° C (68° F) Continuity

Bad fan reversing solenoid.

Bad ground circuit.

24 volts

Bad fan reversing switch (34), reverse relay (35). Also check wire 52-A.

4002-63

TRANSMISSION

61 55 56 57

50 45 51

53 60

55 56 57

54 58

50 45 51

53 60

54 58

W270-7R025

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.

W270-7R025

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

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

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

4002-64

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

45 – Output Speed Sensor

46 – Transmission Solenoid Valve and Temperature Sensors

47 – Filter Maintenance Switch

48 – Torque Converter Output Temperature Sender

49 – Engine Speed Sensor

50 – Intermediate Speed Sensor

51 – Turbine Speed Sensor

52 – Transmission Shifter

53 – Transmission Electronic Control Module

54 – Transmission Enable Switch

55 – FNR Switch for Joystick Controls

56 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for Single Axis Controls)

57 – FNR Switch for Single Axis Controls

58 – Transmission Auto Switch

59 – Brake Declutch Pressure Switch

60 – Declutch Switch

61 – Diagnostic Connector

4002-65

WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE

67 69

64 W270-7R026

62. 63. 64. 65.

FUSE RADIO (OPTION) 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.

W270-7R026

62. 63. 64. 65.

FUSE RADIO (OPTION) WARNING BUZZER PARKING BRAKE RELAY FUEL LEVEL SENDER

66. 67. 68. 69.

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

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

4002-66

62 – Fuse Radio (Option) Check Points

62 – Fuse Radio (Option) Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

NOTE: No information at time of print.

63 – Warning 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

Check Points

Correct Reading

Terminal for wire 0_B27 to ground

Continuity

Bad ground circuit.

NOTE: Turn the ignition switch to the ON position Bad instrument cluster

Terminal for wire 35B to ground

24 volts

NOTE: If all readings are good, replace buzzer.

64 – Parking Brake Relay

Located in the cab access panel for fuses and relays.

Correct Reading

Possible Cause of Bad Reading

NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on.

NOTE: If all readings are good, replace buzzer.

Check Points

Possible Cause of Bad Reading

Check Points

Correct Reading

Bad instrument cluster

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

Bad fuse ECA-F6, also check circuit 19D.

Terminal for wire 19D-B and 19D-C to ground

Bad instrument cluster. Also check circuit 52C.

Terminal for wire 52C to ground

Bad parking brake relay.

Terminal for wire 52P-B to ground

Terminal for wire 52C to ground Terminal for wire 52P-B to ground

24 volts 0 volt 24 volts

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

24 volts

24 volts 0 volt 24 volts

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

NOTE: Put the parking brake switch in the ON position. Bad instrument cluster. Also check wire 52C.

Terminal for wire 52C to ground

24 volts

Bad instrument cluster. Also check wire 52C.

4002-67

65 – Fuel Level Sender

Located on the fuel tank top right side.

Located on the fuel tank top right side. Correct Reading

Check Points

Continuity

Terminal for wire 0-BU to ground

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.

Correct Reading

Check Points

Continuity

Terminal for wire 0-BU to ground

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.

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

Between terminals of fuel level sender

33 to 240 ohms @ 20° C (68° F)

Bad fuel level sender.

33 to 240 ohms @ 20° C (68° F)

66 – Air Filter Restriction Switch

Located on the air filter left side.

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 and switch pad.

Bad fuel level sender.

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 and switch pad.

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. Have assistant press and hold foot brake and place FNR switch either in F or R 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.

Check Points Terminal for wire 0-AN to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

24 volts

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

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

4002-68

68 – Radiator Coolant Temperature Sender

Located on the lower radiator hose to engine on left side of engine compartment.

Check Points Terminal for wire 0-BAE to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

3521 ohms at 20° C (68° F)

Replace radiator coolant temperature sender.

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

Approximately 5 volts

Check the instrument cluster.

Check Points Terminal for wire 0-BAE to ground

Correct Reading Continuity

Between terminals of radiator coolant temperature sender

3521 ohms at 20° C (68° F)

Terminal A for wire 36C to ground

Approximately 5 volts

Located on the foot brake valve.

Located on the foot brake valve. Possible Cause of Bad Reading

Replace radiator coolant temperature sender.

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

69 – Brake Warning Pressure Switch

Correct Reading

Bad ground circuit.

NOTE: Disconnect the connector from the radiator coolant temperature sender.

69 – Brake Warning Pressure Switch

Check Points

Possible Cause of Bad Reading

Check Points

Check the instrument cluster.

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 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.

Terminal 1 for wire 33P to ground

Approximately 11.5 volts

Check circuit 33P.

NOTE: With engine not running pump brakes at least 12 times. Disconnect the wires from the brake warning pressure switch.

Between terminals 1 and 2 of the switch

Continuity

Bad brake warning pressure switch.

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

Open Circuit

Continuity

Bad brake warning pressure switch.

NOTE: Start and run the engine at idle two minutes. Bad brake warning pressure switch or brake pressure is below 110.3 bar (1600 psi). Refer to Section 7002 to check brake pressure.

Between terminals 1 and 2 of the switch

Open Circuit

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

4002-69

SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE

72 73

76 W270-7R027

70. 71. 72. 73.

FUSE COMFORT STEER FUSE PARK BRAKE HYDRAULIC FILTER RESTRICTION SWITCH HYDRAULIC OIL TEMPERATURE SENDER

74. 75. 76. 77.

PARK BRAKE SWITCH REDUNDANT BRAKE PRESSURE SWITCH 1 REDUNDANT BRAKE PRESSURE SWITCH 2 COOLANT LEVEL SENDER

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.

W270-7R027

70. 71. 72. 73.

FUSE COMFORT STEER FUSE PARK BRAKE HYDRAULIC FILTER RESTRICTION SWITCH HYDRAULIC OIL TEMPERATURE SENDER

74. 75. 76. 77.

PARK BRAKE SWITCH REDUNDANT BRAKE PRESSURE SWITCH 1 REDUNDANT BRAKE PRESSURE SWITCH 2 COOLANT LEVEL SENDER

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

4002-70

70 – Fuse Comfort Steer Check Points

70 – Fuse Comfort Steer Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

71 – Fuse Park Brake

Check Points

Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

NOTE: No information at time of print. ]

]

72 – Hydraulic Filter Restriction Switch

Located on hydraulic filter block.

Check Points

Correct Reading

Possible Cause of Bad Reading

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.

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.

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

73 – Hydraulic Oil Temperature Sender

Located on hydraulic filter block.

Check Points Terminal for wire 0-HW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

3521 ohms at 20° C (68° F)

Replace hydraulic oil temperature sender.

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

Approximately 5 volts

Check the instrument cluster.

Check Points Terminal for wire 0-HW to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

3521 ohms at 20° C (68° F)

Replace hydraulic oil temperature sender.

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

Approximately 5 volts

Check the instrument cluster.

4002-71

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-F1, also check circuit 19A.

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

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-F1, also check circuit 19A.

24 volts

Bad parking brake switch.

NOTE: Apply parking brake switch. 24 volts

Bad parking brake switch.

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

Check Points

24 volts

Terminal for wire 33U to ground

NOTE: Put the driving lamp switch (95) in position 3, 4, or 5.

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

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

Approximately 11.5 volts

Correct Reading

Possible Cause of Bad Reading

NOTE: Redundant brake switch close at 62 bar (900 psi). 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

Check Points

Bad instrument cluster, also check circuit 33R.

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, 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, also check circuit 33R.

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

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, also check circuit 33R.

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

4002-72

77 â&#x20AC;&#x201C; Coolant Level Sender

Located on radiator top tank.

Check Points Terminal for wire 0-BAF 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 A for wire 31D-C to ground

Approximately 1.6 volts AC

Check circuit 31D, also check the instrument cluster.

NOTE: If the readings are correct replace the coolant level sender.

Check Points Terminal for wire 0-BAF 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 A for wire 31D-C to ground

Approximately 1.6 volts AC

Check circuit 31D, also check the instrument cluster.

NOTE: If the readings are correct replace the coolant level sender.

4002-73

BACK UP ALARM CONTROLS

78 W270-7R028

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.

W270-7R028

78. BACK UP ALARM RELAY

79. BACK UP ALARM DISABLE SWITCH

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

4002-74

78 – Back-up Alarm Relay

Located in the cab access panel for fuses and relays.

Check Points

Correct Reading

Possible Cause of Bad Reading

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.

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 A, Ignition power (13).

Terminal for wire 19A-P to ground

24 volts

Bad fuse ECA-F1, also check wires 19A-P, power relay module A, Ignition power (13).

Terminal for wire 19H to ground

24 volts

Bad fuse ECA-F14, also check wires 19H, power relay module D, accessory power.

Terminal for wire 19H to ground

24 volts

Bad fuse ECA-F14, also check wires 19H, power relay module D, accessory power.

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.

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

79 – Back-up Alarm Disable Switch

Located on right side console.

Check Points Terminal for wire 0-B21 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF position. Depress brake pedal once. Move the transmission shift lever to REVERSE. Terminal for wire 35A-B to ground

24 volts

Bad back-up alarm relay (78), also check circuit 35A-B.

NOTE: Wires 35A-E and 35A-D are connected together, connectors 209F and 209M, and switch is removed in North American models. The connectors are disconnected and the switch is installed in TUV road approved (Germany) models. Terminal for wire 35R-C to ground

24 volts

Bad back-up alarm disable switch.

Check Points Terminal for wire 0-B21 to ground

Correct Reading Continuity

Bad back-up alarm relay.

Possible Cause of Bad Reading Bad ground circuit.

24 volts

Bad back-up alarm relay (78), also check circuit 35A-B.

24 volts

Bad back-up alarm disable switch.

4002-75

LIGHTS - 01

85 87 82

87 82

80 84

89 W270-7R029

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.

W270-7R029

80. 81. 82. 83. 84.

WORK LIGHTS SWITCH DOOR SWITCH ROTATING BEACON (OPTIONAL) DOME LIGHT ROTATING BEACON SWITCH (OPTIONAL)

85. 86. 87. 88. 89.

LEFT HAND FRONT WORK LAMP RIGHT HAND FRONT WORK LAMP LEFT HAND REAR WORK LAMP RIGHT HAND REAR WORK LAMP DIODES

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

4002-76

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.

24 volts

Terminal for wire 42-A and 42-B to ground

Bad work lamps switch.

Terminal for wire 42FS to ground

Bad work lamps switch.

Terminal for wire 42RS to ground

81 – Door Switch

Located above door in cab.

Located above door in cab. Correct Reading

24 volts

Check Points

Possible Cause of Bad Reading

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

Bad ground circuit

24 volts

Bad fuse ECC-F2.

24 volts

Bad work lamps switch.

NOTE: Put the wok lamps switch in position 3 for rear work lamps.

81 – Door Switch

Check Points

Continuity

Possible Cause of Bad Reading

NOTE: Put the work lamps switch in position 2 for front work lamps.

NOTE: Put the wok lamps switch in position 3 for rear work lamps. Terminal for wire 42RS to ground

Terminal for wire 0-B14 to ground

Correct Reading

NOTE: Put master disconnect witch in the ON position.

NOTE: Put the work lamps switch in position 2 for front work lamps. Terminal for wire 42FS to ground

Check Points

24 volts

Bad work lamps switch.

Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch in the ON position.

Bad fuse ECC-F1.

NOTE: Disconnect connector DS at door switch.

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 open

Continuity

Bad door switch.

Between pins on door switch with door closed

Open circuit

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

Check Points

Correct Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Bulb

Continuity

Bad bulb.

Terminal for wire 0-MC to ground

Continuity

Bad ground circuit.

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

NOTE: If readings are good replace the rotating beacon.

Bad circuit between the beacon and the beacon switch (84). Also check the beacon switch (84).

NOTE: Put master disconnect switch and beacon switch (84) in ON position. Terminal for wire 46-D to ground

24 volts

NOTE: If readings are good replace the rotating beacon.

Bad circuit between the beacon and the beacon switch (84). Also check the beacon switch (84).

4002-77

83 – Dome Lamp

Located in top of cab.

Located in top of cab. Correct Reading

Check Points

Possible Cause of Bad Reading

Correct Reading

Check Points

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Bulb

Continuity

Bad bulb.

Terminal for wire 0-MB to ground

Continuity

Bad ground circuit.

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

NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position.

Check fuse ECC-F1, also check circuit 19U.

Terminal for wire 19U-C to ground

Check circuit 43, also check advanced instrument cluster and time delay module (7).

Terminal for wire 43-B to ground

24 volts 24 volts 3 to 5 seconds

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

Check Points Terminal for wire 0-B15 to ground

Correct Reading Continuity

Terminal for wire 19U-H to ground

24 volts

Bad beacon switch.

Terminal for wire 46-C to ground

24 volts

Located on left front side of cab.

Located on left front side of cab. Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LLFW to LH front work lamp connector. Terminal for wire 0-MU to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 42C-H to ground

24 volts

Possible Cause of Bad Reading Bad ground circuit.

Check fuse ECC-F1, also check circuit 19U.

NOTE: Put the beacon switch in the ON position.

85 – Left Hand Front Work Lamp

Correct Reading

Check circuit 43, also check advanced instrument cluster and time delay module (7).

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3.

85 – Left Hand Front Work Lamp

Check Points

Check fuse ECC-F1, also check circuit 19U.

Check fuse ECB-F1 and driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

Check Points

Correct Reading

Bad beacon switch.

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LLFW to LH front work lamp connector. Terminal for wire 0-MU to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 42C-H to ground

24 volts

Check fuse ECB-F1 and driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

4002-78

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.

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 fuse ECB-F1 and driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

Check Points

Correct Reading

NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector. Flood lamp connector pin A to pin B

Continuity

Terminal for wire 0-MJ to ground

Continuity

Terminal for wire 42C-G to ground

24 volts

Located on left rear side of cab.

Located on left rear side of cab. 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 fuse ECB-F2 and driving lamp switch (95). Also check circuit 42R from flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.

Check Points

Correct Reading

Flood lamp connector pin A to pin B

Continuity

Terminal for wire 0-ME to ground

Continuity

Terminal for wire 42R-H to ground

24 volts

Located on right rear side of cab.

NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector. Terminal for wire 0-MF to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 42R-G to ground

24 volts

Check fuse ECB-F2 and driving lamp switch (95). Also check circuit 42R from flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.

Bad lamp bulb.

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 4 or 5.

Located on right rear side of cab. Possible Cause of Bad Reading

Possible Cause of Bad Reading

NOTE: Connect wiring harness connector LLRW to LH rear work lamp connector.

88 – Right Hand Rear Work Lamp

Correct Reading

Check fuse ECB-F1 and driving lamp switch (95). Also check circuit 42C from flood lamp to lamp switch (95) and wire 42-A to fuse ECC-F2.

NOTE: Disconnect wiring harness connector LLRW from LH rear work lamp connector.

88 – Right Hand Rear Work Lamp

Check Points

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

87 – Left Hand Rear Work Lamp

Correct Reading

Bad lamp bulb.

NOTE: Connect wiring harness connector LRFW to RH front work lamp connector.

87 – Left Hand Rear Work Lamp

Check Points

Possible Cause of Bad Reading

Check Points

Correct Reading

Check fuse ECB-F2 and driving lamp switch (95). Also check circuit 42R from flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector. Flood lamp connector pin A to pin B

Continuity

Bad lamp bulb.

NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector. Terminal for wire 0-MF to ground

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.

Terminal for wire 42R-G to ground

24 volts

Check fuse ECB-F2 and driving lamp switch (95). Also check circuit 42R from flood lamp to lamp switch (95) and wire 42-B to fuse ECC-F2.

4002-79

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.

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

None

Bad diode.

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 B to pin C

None

Bad diode.

Multimeter positive on pin C to pin A

Continuity

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 B

Continuity

Bad diode.

4002-80

LIGHTS - 02

93 94

W270-7R030

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.

W270-7R030

90. BRAKE LIGHTS SWITCH 91. BRAKE LIGHTS RELAY 92. FLASHER MODULE

93. HAZARD SWITCH 94. TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 95. DRIVING LIGHTS SWITCH

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

4002-81

90 – Brake Lamp Pressure Switch

Located on the foot brake valve.

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch in ON position. Terminal for wire 1-AA to ground Terminal for wire 44 to ground

24 volts 0 volt

24 volts

Correct Reading

Check fuse ECC-F4, also check wires 1-AA,1-DR and 1-DV.

Terminal for wire 1-AA to ground

Bad brake lamp pressure switch.

Terminal for wire 44 to ground

Bad brake lamp pressure switch.

24 volts 0 volt

Terminal for wire 44 to ground

24 volts

91 – Brake Lamps Relay

Located in the cab access panel for fuses and relays.

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, also check wires 1-AA,1-DR and 1-DV. Bad brake lamp pressure switch.

NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.

91 – Brake Lamps Relay

Check Points

Possible Cause of Bad Reading

NOTE: Put master disconnect switch in ON position.

NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal. Terminal for wire 44 to ground

Check Points

Check Points Terminal for wire 0-EF to ground

Correct Reading Continuity

Bad brake lamp pressure switch.

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch in ON position. Check fuse ECC-F4 and wires 1-DW and 1-DV.

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 to ground

0 volt

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

0 volt

Bad brake lamps relay.

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 to ground

24 volts

Bad brake lamp pressure switch (90).

Terminal for wire 44A-A to ground

24 volts

Bad brake lamps relay.

Terminal for wire 44A-A to ground

24 volts

Bad brake lamps relay.

4002-82

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.

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-EG to ground

Continuity

Bad ground circuit.

Terminal for wire 0-EH 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.

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

NOTE: Put master disconnect switch in ON position. 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

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.

Bad hazard switch (93). Also check wire 45H.

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 45L-D to ground

Intermittent 24 volts

Bad flasher module.

Terminal for wire 45R-E 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.

Terminal for wire 45B-A to ground

24 volts

Bad flasher module.

Terminal for wire 45R-E to ground

Intermittent 24 volts

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

NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position. 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. Bad turn signal switch (94) or fuse ECA-F8. Also check wire 45A-A.

Terminal for wire 45A-A to ground

24 volts

Bad flasher module.

Terminal for wire 45L-D to ground

Intermittent 24 volts

Bad turn signal switch (94) or fuse ECA-F8. Also check wire 45A-A. Bad flasher module.

4002-83

93 â&#x20AC;&#x201C; Hazard Switch

Located on steering column.

Check Points Terminal for wire 0-B24 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-KA to ground

24 volts

Check fuse ECC-F4. Also check wires 1-KA and 1-DV.

Continuity

Possible Cause of Bad Reading Bad ground circuit.

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. 24 volts

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

NOTE: Put driving lamp switch (95) in position 2 or 3.

Terminal for wire 49-D to ground

Terminal for wire 0-B24 to ground

Correct Reading

NOTE: Put master disconnect switch in ON position.

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

Check Points

24 volts

Terminal for wire 45H to ground

NOTE: Put driving lamp switch (95) in position 2 or 3. 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.

Terminal for wire 49-D to ground

24 volts

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.

4002-84

94 – Turn Signal, High-Low Beam, and Horn Switch

Located on steering column.

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

HORN SWITCH Terminal for wire 0-EP to ground

Continuity

HORN SWITCH

Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 64C to ground

24 volts

Terminal for wire 0-EP to ground

Continuity

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

Terminal for wire 64C to ground

24 volts

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

0 volts

Bad horn switch.

NOTE: Press horn switch. 0 volts

Bad horn switch.

NOTE: If readings are good, replace the switch.

Terminal for wire 64C to ground

NOTE: If readings are good, replace the switch. TURN SIGNAL

TURN SIGNAL

NOTE: Put master disconnect switch and ignition switch in ON position. Terminal for wire 19B to ground

24 volts

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

Check fuse ECA-F8 and power relay module A (13). Also check wire 19B.

NOTE: Move turn signal lever to RIGHT turn position. Terminal for wire 45B-A to ground

24 volts

Terminal for wire 19B to ground

Bad turn signal switch.

Terminal for wire 45B-A to ground

24 volts

Bad turn signal switch.

Bad 19Z-C circuit, check fuse ECC-F3.

NOTE: Pull on high beam flash lever. Terminal for wire 41H_A to ground

Terminal for wire 45A-A to ground

Terminal for wire 19Z-C to ground

24 volts

Bad high beam flash switch.

Terminal for wire 41H_A to ground

Located on right side console.

Located on right side console. Correct Reading

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch in the ON position. 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 turn signal switch.

24 volts

Bad 19Z-C circuit, check fuse ECC-F3.

24 volts

Bad high beam flash switch.

24 volts

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. Bad driving lamp switch.

NOTE: Put the driving lamp switch in position 3. Terminal for wire 41J to ground

Bad turn signal switch.

NOTE: Pull on high beam flash lever.

95 – Driving Lamp Switch

Terminal for wire 19Z-A to ground

24 volts

HIGH-LOW BEAM SWITCH

95 – Driving Lamp Switch

Check Points

Check fuse ECA-F8 and power relay module A (13). Also check wire 19B.

NOTE: Move turn signal lever to LEFT turn position.

HIGH-LOW BEAM SWITCH Terminal for wire 19Z-C to ground

24 volts

NOTE: Move turn signal lever to RIGHT turn position.

NOTE: Move turn signal lever to LEFT turn position. Terminal for wire 45A-A to ground

Bad ground circuit.

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

NOTE: Press horn switch. Terminal for wire 64C to ground

Possible Cause of Bad Reading

Terminal for wire 41T to ground

24 volts

Bad driving lamp switch.

NOTE: Put the driving lamp switch in position 3. Bad driving lamp switch.

Terminal for wire 41J to ground

24 volts

Bad driving lamp switch.

4002-85

LIGHTS - 03 AND HORN

98 W270-7R031

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.

W270-7R031

96. LEFT HAND FRONT COMBINATION LAMPS 97. RIGHT HAND FRONT COMBINATION LAMPS

98. HORN RELAY 99. HORN

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

4002-86

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

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector LLF from LH front combination lamp connector.

Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb or internal connection.

Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb or internal connection.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb or internal connection.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb or internal connection.

Combination lamp connector pin 2 to pin 1

Continuity

Bad low beam lamp bulb or internal connection.

Combination lamp connector pin 2 to pin 1

Continuity

Bad low beam lamp bulb or internal connection.

Combination lamp connector pin 5 to pin 1

Continuity

Bad turn signal lamp bulb or internal connection.

Combination lamp connector pin 5 to pin 1

Continuity

Bad turn signal lamp bulb or internal connection.

NOTE: Connect wiring harness connector LLF to LH front combination lamp connector. Put master disconnect switch in ON position and driving lamp switch (95) in position 2. Terminal for wire 0-AJ to ground

Continuity

Bad ground circuit.

Continuity

Bad ground circuit.

NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 2.

Connector LLF terminal for wire 0-AJ to ground

Bad ground circuit.

Connector LLF terminal for wire 0-AJ to ground

Check fuse ECB-F7 and driving lamp switch (95). Also check circuit 18F.

Terminal for wire 18F to ground

Continuity

24 volts

NOTE: Put driving lamp switch (95) in position 3, and high/low beam lever (94) in HIGH beam position.

Terminal for wire 18B to ground

24 volts

Check fuse ECB-F3, high/low beam relay, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18B and wire 41H.

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-A.

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.

Continuity

24 volts

Bad ground circuit. Check fuse ECB-F7 and driving lamp switch (95). Also check circuit 18F.

NOTE: Put driving lamp switch (95) in position 3, and high/low beam lever (94) in HIGH beam position.

Terminal for wire 18B to ground

24 volts

Check fuse ECB-F3, high/low beam relay, driving lamp switch (95), and high/low beam switch (94). Also check circuit 18B and wire 41H.

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-A.

NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position. Terminal for wire 45L to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45L to flasher module.

NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp.

4002-87

97 – Right Hand Front Combination Lamp

Located on the right front of the machine.

Check Points

Correct Reading

Possible Cause of Bad Reading

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 or internal connection.

Combination lamp connector pin 3 to pin 1

Continuity

Bad high beam lamp bulb or internal connection.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb or internal connection.

Combination lamp connector pin 4 to pin 1

Continuity

Bad position lamp bulb or internal connection.

Combination lamp connector pin 2 to pin 1

Continuity

Bad low beam lamp bulb or internal connection.

Combination lamp connector pin 2 to pin 1

Continuity

Bad low beam lamp bulb or internal connection.

Combination lamp connector pin 5 to pin 1

Continuity

Bad turn signal lamp bulb or internal connection.

Combination lamp connector pin 5 to pin 1

Continuity

Bad turn signal lamp bulb or internal connection.

NOTE: Connect wiring harness connector LRF to RH front combination lamp connector. Put master disconnect switch in ON position and driving lamp switch (95) in position 3. Terminal for wire 0-AH to ground Terminal for wire 18G-A to ground

Continuity 24 volts

Bad ground circuit.

Terminal for wire 0-AH to ground

Check fuse ECB-F8 and driving lamp switch (95). Also check circuit 18G and wire 41T-A.

Terminal for wire 18G-A to ground

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.

Intermittent 24 volts

24 volts

Bad ground circuit. Check fuse ECB-F8 and driving lamp switch (95). Also check circuit 18G and wire 41T-A.

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.

NOTE: Put high/low beam lever (94) in LOW beam position.

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

Continuity

NOTE: Put high/low beam lever (94) in HIGH beam position.

NOTE: Put high/low beam lever (94) in LOW beam position. Terminal for wire 18E to ground

NOTE: Connect wiring harness connector LRF to RH front combination lamp connector. Put master disconnect switch in ON position and driving lamp switch (95) in position 3.

Check the turn signal switch (94) and flasher module (92). Also check circuit 45R to flasher module.

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.

98 – Horn Relay

Located in the cab access panel for fuses and relays.

Check Points

Correct Reading

Possible Cause of Bad Reading

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 and 190U-A.

Terminal for wire 19U-A to ground

24 volts

Check fuse ECC-F6, also check wire 19U and 190U-A.

Terminal for wire 19U-E to ground

24 volts

Check wire 19U and 19U-E.

Terminal for wire 19U-E to ground

24 volts

Check wire 19U and 19U-E.

Terminal for wire 64C to ground

24 volts

Bad horn relay.

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

NOTE: Have another person push and hold the horn switch.

Bad horn switch.

Terminal for wire 64C to ground

0 volt

Bad horn relay.

Terminal for wire 64-A to ground

24 volts

Bad horn switch. Bad horn relay.

4002-88

99 â&#x20AC;&#x201C; Horn

Located on the left front of the machine with combination lamps.

Check Points Terminal for wire 0-AF to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch. Terminal for wire 64 to ground.

24 volts

NOTE: If the readings are good replace the horn.

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

Check Points Terminal for wire 0-AF to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch. Terminal for wire 64 to ground.

24 volts

NOTE: If the readings are good replace the horn.

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

4002-89

LIGHTS - 04 AND BACK UP ALARM

101

103

100

102

W270-7R032

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.

W270-7R032

100.RIGHT HAND REAR COMBINATION LAMPS 101.LEFT HAND REAR COMBINATION LAMPS

102.LICENSE PLATE LAMP 103.BACK UP ALARM

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

4002-90

100 â&#x20AC;&#x201C; Right Hand Rear Combination Lamp

Located on the right rear of the machine.

Check Points

Correct Reading

Possible Cause of Bad Reading

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 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 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 3 to pin 5

Continuity

Bad tail lamp bulb.

Combination lamp connector pin 4 to pin 5

Continuity

Bad reverse 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

Intermittent 24 volts

Check backup alarm relay (78). Also check circuit 35A to backup alarm relay (78).

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

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.

NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position. Terminal for wire 45R-A to ground

NOTE: Connect wiring harness connector LRR-E to RH rear combination lamp connector.

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. 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.

Terminal for wire 18G-A to ground

24 volts

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

NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.

4002-91

101 – Left Hand Rear Combination Lamp Check Points

Correct Reading

4002-91

101 – Left Hand Rear Combination Lamp Possible Cause of Bad Reading

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 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 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 3 to pin 5

Continuity

Bad tail lamp bulb.

Combination lamp connector pin 4 to pin 5

Continuity

Bad reverse 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

Intermittent 24 volts

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. 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

NOTE: Connect wiring harness connector LLR-E to LH rear combination lamp connector.

Check the turn signal switch (94) and flasher module (92). Also check circuit 45L to flasher module.

Terminal for wire 35A-L to ground

24 volts

Check backup alarm relay (78). Also check circuit 35A to backup alarm relay (78).

NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position. Terminal for wire 45L-A to ground

Intermittent 24 volts

Check the turn signal switch (94) and flasher module (92). Also check circuit 45L to flasher module.

102 – License Plate Lamp

Located on the right rear of the machine with combination lamp.

Check Points

Correct Reading

Check Points

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

Bulb

Continuity

Bad bulb.

Bulb

Continuity

Bad bulb.

Terminal for wire 0-JC to ground

Continuity

Bad ground circuit.

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.

NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2. Terminal for wire 18G-E to ground

24 volts

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

4002-92

103 â&#x20AC;&#x201C; Back-up Alarm

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.

Check Points Terminal for wire 0-JB to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

24 volts

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

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

4002-93

CAB WINDOW WASHER AND WIPER SYSTEM

110

109

107 108

113

111

104 106

112

105

107 108

113

111

104 106

112

105

W270-7R033

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.FRONT WASHER MOTOR 112.REAR 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.

W270-7R033

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.FRONT WASHER MOTOR 112.REAR WASHER MOTOR 113.DIODES

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

4002-94

104 – Front Wiper High Speed Relay

Located in the cab access panel for fuses and relays.

Check Points

Correct Reading

Possible Cause of Bad Reading

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 D (18).

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

24 volts

Bad front wiper and washer switch (108).

Terminals for wire 63HC-B to ground

Bad wiper high speed relay.

Terminals for wire 63HC-B to ground

Continuity 24 volts

Bad wiper high speed relay.

Terminals for wire 63C2 to ground

24 volts

105 – Front Wiper Cut Out Relay

Located in the cab access panel for fuses and relays.

Correct Reading

Bad front wiper and washer switch (108). Bad wiper high speed relay.

NOTE: Put the front wiper switch in the LOW position.

105 – Front Wiper Cut Out Relay

Check Points

Bad fuse ECA-F12, check circuit 19J, also check power relay module D (18).

NOTE: Put the front wiper switch in the HIGH position.

NOTE: Put the front wiper switch in the LOW position. Terminals for wire 63C2 to ground

24 volts

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position, front wiper switch in the low position.

Check Points

Correct Reading

Bad wiper high speed relay.

Possible Cause of Bad Reading

NOTE: Put the master disconnect switch and the ignition switch in the ON position, front wiper switch in the low position.

Terminal for wire 19J-G to ground

24 volts

Check fuse ECA-F12, check circuit 19J, also check power relay module D (18).

Terminal for wire 19J-G to ground

24 volts

Check fuse ECA-F12, check circuit 19J, also check power relay module D (18).

Terminal for wire 63L-B to ground

24 volts

Bad wiper cut out relay.

Terminal for wire 63L-B to ground

24 volts

Bad wiper cut out relay.

NOTE: Put the front wiper switch in the HIGH position. Terminals for wire 63HC-A to ground Terminals for wire 63L-B to ground

Continuity 0 volts

NOTE: Put the front wiper switch in the HIGH position. Bad front wiper and washer switch (108).

Terminals for wire 63HC-A to ground

Bad wiper cut out relay.

Terminals for wire 63L-B to ground

Continuity 0 volts

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

4002-95

106 – Front Wiper Low Speed Relay

Located in the cab access panel for fuses and relays.

Check Points

Correct Reading

Possible Cause of Bad Reading

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

24 volts

Bad fuse ECA-F12, check circuit 19J, also check power relay module D (18).

NOTE: Put the front wiper switch in the LOW position. Terminals for wire 63C to ground

Intermittent 24 volts

Terminals for wire 63LC to ground

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 D (18).

NOTE: Put the front wiper switch in the LOW position. Bad wiper low speed relay.

Terminals for wire 63C to ground

Intermittent 24 volts

0 volts

Bad front wiper and washer switch (108).

Terminals for wire 63LC to ground

0 volts

Bad front wiper and washer switch (108).

Terminal for wire 63Cw to ground

24 volts

Bad circuit 63Cw, check front wiper high speed relay (104).

Terminal for wire 63Cw to ground

24 volts

Bad circuit 63Cw, check front wiper high speed relay (104).

Terminals for wire 63C3 to ground

24 volts

Bad wiper low speed relay, also check high speed wiper relay (104).

Terminals for wire 63C3 to ground

24 volts

Bad wiper low speed relay, also check high speed wiper relay (104).

107 – Rear Wiper and Washer Switch

Located on right side console.

Check Points Terminal for wire 0-B23 to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

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

Check Points Terminal for wire 0-B23 to ground

Bad wiper low speed relay.

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 D (18). Also check circuit 19K.

Terminal for wire 19K-B to ground

24 volts

Bad fuse ECA-F13 or power relay module D (18). Also check circuit 19K.

Terminal for wire 19K-A to ground

24 volts

Bad fuse ECA-F13 or power relay module D (18). Also check circuit 19K.

Terminal for wire 19K-A to ground

24 volts

Bad fuse ECA-F13 or power relay module D (18). Also check circuit 19K.

NOTE: Put the rear wiper and washer switch in the ON position. Terminal for wire 68L to ground

24 volts

Bad rear wiper and washer switch.

NOTE: Press and hold the rear wiper and washer switch in the WASH position. Terminal for wire 68W to ground

24 volts

Bad rear wiper and washer switch.

NOTE: Put the driving lamp switch in position 3.

Terminal for wire 49-C to ground

24 volts

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. 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.

Terminal for wire 49-C to ground

24 volts

Check rotary lamp switch (95) and circuit 49. If LEDs in rear wiper and washer switch are not ON with 24 volts at check point, replace rear wiper and washer switch.

4002-96

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 D (18).

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

0 volts

Bad front wiper and washer switch also check grounding circuit.

NOTE: Put the front wiper and washer switch in the wash position. Terminal for wire 63W to ground

24 volts

Bad front wiper and washer switch.

NOTE: Put the driving lamp switch in position 2 or 3.

Terminal for wire 49-T to ground

24 volts

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 D (18).

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

0 volts

Bad front wiper and washer switch also check grounding circuit.

NOTE: Put the front wiper and washer switch in the wash position. Terminal for wire 63W to ground

24 volts

Bad front wiper and washer switch.

NOTE: Put the driving lamp switch in position 2 or 3. Check driving 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.

Terminal for wire 49-T to ground

24 volts

Check driving lamp switch (95) and circuit 49. If LEDs in rear wiper and washer switch are not ON with 24 volts at check point, replace rear wiper and washer switch.

4002-97

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.

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, disconnect connector FWM.

Between terminals B and D for wires 63H and 63L-A

Continuity

Bad front wiper motor. Confirm with ohm meter, this may be open when motor is parked.

NOTE: Connect connector FWM. 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

Bad front wiper motor. Confirm with ohm meter, this may be open when motor is parked.

NOTE: Connect connector FWM. 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.

Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), low speed relay or cut out relay.

Terminal for wire 63L-A to ground

Bad front wiper and washer switch (108)

Terminal for wire 63C to ground

NOTE: Put the front wiper and washer switch (108) in the HIGH position.

Continuity

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

24 volts

Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), high speed relay or cut out relay.

Terminal for wire 63H-A to ground

24 volts

Check fuse ECA-F12, also check circuit 19J. Bad front wiper and washer switch (108), high speed relay or cut out relay.

Terminal for wire 63C to ground

24 volts

Bad front wiper and washer switch (108).

Terminal for wire 63C to ground

24 volts

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

Intermittent 24 volts

Bad front wiper and washer switch (108).

Terminal for wire 63L-A to ground

Intermittent 24 volts

Bad front wiper and washer switch (108).

Terminal for wire 63C to ground

Intermittent 24 volts

Bad front wiper park contact.

Terminal for wire 63C to ground

Intermittent 24 volts

Bad front wiper park contact.

NOTE: If the readings are good, replace the front wiper motor.

4002-98

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.

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. Disconnect connector RWM.

Between terminals pins B and C on connector to motor for wires 19K-D and 68L-A.

Continuity

Bad rear wiper and washer switch (107).

NOTE: Connect connector RWM. Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19K-C 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.

Continuity

Bad rear wiper and washer switch (107).

NOTE: Connect connector RWM. Put the master disconnect switch and the ignition switch in the ON position. Terminal for wire 19K-C 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 68L-A to ground

24 volts

Bad rear wiper and washer switch (107).

Terminal for wire 68L-A to ground

24 volts

Bad rear wiper and washer switch (107).

Terminal for wire 68C-A to ground

Intermittent 24 volts

Bad rear wiper and washer switch (107).

Terminal for wire 68C-A to ground

Intermittent 24 volts

Bad rear wiper and washer switch (107).

NOTE: If the readings are good, replace the rear wiper motor.

111 – Front Washer Pump Motor

Located on right side under steps.

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.

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 – Rear Washer Pump Motor

Located on right side under steps.

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.

Check Points Terminal for wire 0-B to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

24 volts

Bad front wiper and washer switch (108), also check circuit 63W.

NOTE: If the readings are good, replace the front washer pump motor.

4002-99

113 â&#x20AC;&#x201C; Diode Module

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. Set multi meter to Diode check mode.

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector 140M from diode connector. Set multi meter to Diode check mode.

Multimeter positive on pin A to pin C

Open

Bad diode.

Multimeter positive on pin A to pin C

Open

Bad diode.

Multimeter positive on pin B to pin C

Open

Bad diode.

Multimeter positive on pin B to pin C

Open

Bad diode.

Multimeter positive on pin D to pin C

Open

Bad diode.

Multimeter positive on pin D to pin C

Open

Bad diode.

Multimeter positive on pin E to pin C

Open

Bad diode.

Multimeter positive on pin E to pin C

Open

Bad diode.

Multimeter positive on pin F to pin C

Open

Bad diode.

Multimeter positive on pin F to pin C

Open

Bad diode.

Multimeter positive on pin C to pin A

Continuity

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 B

Continuity

Bad diode.

Multimeter positive on pin C to pin D

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 E

Continuity

Bad diode.

Multimeter positive on pin C to pin F

Continuity

Bad diode.

Multimeter positive on pin C to pin F

Continuity

Bad diode.

NOTE: If one or more of the diodes are bad, replace the diode module.

4002-100

SECONDARY STEERING

115

SECONDARY STEERING

115

117

116 118

117

116 118

114

W270-7R034

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.

W270-7R034

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

117.SECONDARY STEERING MOTOR 118.SECONDARY STEERING PRESSUR SWITCH

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

4002-101

114 – Secondary Steering Diodes

Located in the cab access panel for fuses and relays, rear of compartment. Set multi meter to Diode check mode.

Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Disconnect wiring harness connector DM from diode connector.

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 A to pin C

Continuity

Bad diode.

Multimeter positive on pin B 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

Open

Bad diode.

Multimeter positive on pin C to pin A

Open

Bad diode.

Multimeter positive on pin C to pin B

Open

Bad diode.

Multimeter positive on pin C to pin B

Open

Bad diode.

NOTE: If one or more of the diodes are bad, replace the diode module.

115 – Secondary Steering Solenoid (Option)

Located in the rear frame of the machine.

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector YSS from secondary steering solenoid. Between pins A and B of secondary steering solenoid

36 to 42 ohms 20° c (68° f)

Between pin 2 of connector YSS and ground

Continuity

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Disconnect connector YSS from secondary steering solenoid.

Bad secondary steering solenoid.

Between pins A and B of secondary steering solenoid

36 to 42 ohms 20° c (68° f)

Bad ground circuit.

Between pin 2 of connector YSS and ground

Continuity

Bad secondary steering solenoid.

Bad ground circuit.

NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately to ON position.

Between pin 1 of connector YSS and ground

24 volts

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

24 volts

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

4002-102

116 â&#x20AC;&#x201C; Secondary Steering Module (Option)

Located in the rear frame of the machine.

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.

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 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 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 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

Bad secondary steering pressure switch (118). Also check wire 51P-A.

Pin 9 of connector SSM to ground

Open Circuit

Pin 11 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 11 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 12 of connector SSM to ground

Continuity

Bad ground circuit.

Pin 12 of connector SSM to ground

Continuity

Bad ground circuit.

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

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 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 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 A (13), ignition switch, and diode module. Also check circuit 19R.

Pin 1 of connector SSM to ground

24 volts

Check fuse ECA-F4, power relay module A (13), ignition switch, and diode module. Also check circuit 19R.

Pin 8 of connector SSM to ground

21 to 22 volts

Check circuit 35X to instrument cluster. If circuit 35X okay, problem is bad instrument cluster.

Pin 8 of connector SSM to ground

21 to 22 volts

NOTE: Start and run engine at idle speed.

Pin 9 of connector SSM to ground

Continuity

Pin 8 of connector SSM to ground

0 volts

Bad secondary steering pressure switch.

Pin 9 of connector SSM to ground

Continuity

Check circuit 35X to instrument cluster. If circuit 35X okay, problem is bad instrument cluster.

Pin 8 of connector SSM to ground

0 volts

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. Emergency steering indicator lamp should illuminate in the cluster. Terminal for wire 51-A to ground

Check circuit 35X to instrument cluster. If circuit 35X okay, problem is bad instrument cluster.

24 volts

Bad secondary steering module.

Bad secondary steering pressure switch. Check circuit 35X to instrument cluster. If circuit 35X okay, problem is bad instrument cluster.

24 volts

Bad secondary steering module.

4002-103

117 – Secondary Steering Motor (Option)

Located in the rear frame of the machine.

Located in the rear frame of the machine. Correct Reading

Check Points

Possible Cause of Bad Reading

Correct Reading

Check Points

Possible Cause of Bad Reading

Motor ground stud to ground

Continuity

Bad ground circuit.

Motor ground stud to ground

Continuity

Bad ground circuit.

Secondary steering motor relay ground terminal to ground

Continuity

Bad ground circuit.

Secondary steering motor relay ground terminal to ground

Continuity

Bad ground circuit.

Bad secondary steering motor relay coil or secondary steering solenoid (115). Also check relay coil and solenoid ground circuit.

Terminal for wire 51-B to ground.

10 to 45 ohms

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

Terminal for red wire to ground

24 volts

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. Check circuit to batteries.

NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect wire 51-B from secondary steering motor relay.

Terminal for wire 51-B to ground

10 to 45 ohms

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.

24 volts

Terminal for red wire to ground

Check circuit to batteries.

24 volts

Terminal for wire 51-B to ground

118 – Secondary Steering Pressure Switch (Option)

Located in the rear frame of the machine.

Located in the rear frame of the machine. Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Engine must be off. Disconnect wiring harness connector PSS from secondary steering pressure switch.

Correct Reading

Check Points

Possible Cause of Bad Reading

NOTE: Engine must be off. 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 C

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin A

Open Circuit

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.

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 A

Continuity

Bad secondary steering pressure switch.

Pressure switch pin B to pin C

Open Circuit

Bad secondary steering pressure switch.

Pressure switch pin B to pin C

Open Circuit

Bad secondary steering pressure switch.

NOTE: If continuity is not correct, check pressure at PSS port to confirm pressure drops below 2.5 bar (35 psi) with engine off before replacing pressure switch.

4002-104

CAN COMMUNICATION

119

W270-7R035

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.

W270-7R035

119.DIAGNOSTIC CONNECTOR

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

4002-105

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-A to ground

24 volts

Check Points

Correct Reading

Bad ground circuit.

Terminal A for wire 0-DH to ground

Continuity

Check fuse ECC-F9, check circuit 18K.

Terminal B for wire 18K-A to ground

24 volts

Possible Cause of Bad Reading

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

4002-106

RADIO AND POWER CONVERTER

RADIO AND POWER CONVERTER 125

125

124

124 122 123

122 123

120 121

120 121 W270-7R036

120.POWER RELAY MODULE E 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.

W270-7R036

120.POWER RELAY MODULE E 121.POWER CONVERTER 24 TO 12 VOLT 122.12 VOLT POWER OUTLETS (OPTION)

123.RADIO 124.RIGHT SPEAKER 125.LEFT SPEAKER

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

4002-107

120 – Power Relay Module E

Located in the cab access panel for fuses and relays.

Check Points Terminal for wire 0-DL to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

Check Points Terminal for wire 0-DL to ground

Correct Reading Continuity

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON position.

Terminal for wire PRM-E BUSS to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire PRM-E BUSS to ground

24 volts

Check circuit 1CB to 105 Amp circuit breaker in engine compartment, check circuit breaker.

Terminal for wire 19L to ground

24 volts

Bad power relay module E, bad fuse F1.

Terminal for wire 19L to ground

24 volts

Bad power relay module E, bad fuse F1.

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.

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 E, also check circuit 19L.

Terminal for wire 19L-B and 19L-A to ground

24 volts

Bad fuse F1 in power relay module E, also check circuit 19L.

Terminal for wire 12V-C to ground

12 volts

Bad power converter.

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

NOTE: If the readings are good replace the power outlet.

Possible Cause of Bad Reading

Check Points

Correct Reading

Bad ground circuit.

Terminal for wire 0-EK or 0-EL to ground

Continuity

Bad power converter (121), check fuse ECD-F4 and F5, also check wire 12V-A.

Terminal for wire 12V or 12V-A to ground

12 volts

NOTE: If the readings are good replace the power outlet.

Possible Cause of Bad Reading

Bad ground circuit. Bad power converter (121), check fuse ECD-F4 and F5, also check wire 12V-A.

4002-108

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.

Check Points

Correct Reading

Terminal in radio connector for wire 0-EN to ground

Continuity

Possible Cause of Bad Reading

Bad ground circuit.

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

Terminal in radio connector for wire 12V-HA to ground

12 volts

Check fuse ECD-F6, also check circuit 12V. Also check the remote radio power converter (121).

124 – Right Speaker (Option)

Located in the cab.

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

12 volts

Correct Reading

Check fuse ECD-F6, also check circuit 12V. Also check the remote radio power converter (121).

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

Bad circuit between the right speaker and the radio or a bad radio (123).

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 (123).

Pin 2 in wiring harness connector RSPK to ground

Continuity

NOTE: If the readings are good, replace the right speaker.

125 – Left Speaker (Option)

Located in the cab.

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

Bad circuit between the right speaker and the radio or a bad radio (123). Bad circuit between the right speaker and the radio (123).

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

Bad circuit between the left speaker and the radio or a bad radio (123).

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 (123).

Pin 2 in wiring harness connector LSPK to ground

Continuity

NOTE: If the readings are good, replace the left speaker.

Bad circuit between the left speaker and the radio or a bad radio (123). Bad circuit between the left speaker and the radio (123).

4002-109

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR

4002-109

AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR

126

130

130 127

129

127

129

128

128 W270-7R037

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.

W270-7R037

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.

4002-110

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 A (13). Also check wire 19N.

NOTE: Put the seat compressor switch in the ON position. Terminal for wire from seat switch at compressor

24 volts

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 A (13). Also check wire 19N.

NOTE: Put the seat compressor switch in the ON position. Bad seat switch, also check circuit from seat switch to compressor.

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 Points

Correct Reading

Check fuse ECC-F8, also check circuit 19W.

Terminal for wire 19W to ground

24 volts

Bad ground circuit.

Terminal for wire 0-DV to ground

Continuity

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 in position 1, 2, 3 or 4 and push AC switch to ON.

Check Points Terminal for wire 0-DJ to ground

Correct Reading Continuity

Possible Cause of Bad Reading Check fuse ECC-F8, also check circuit 19W. Bad ground circuit.

Possible Cause of Bad Reading Bad ground circuit.

NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch in position 1, 2, 3 or 4 and push AC switch to ON.

Terminal for wire 61R-B to ground

24 volts

Check thermostat switch, AC trinary switch, AC switch, and check wire 61R-B.

Terminal for wire 61R-B to ground

24 volts

Check thermostat switch, AC trinary switch, AC switch, and check wire 61R-B.

Terminal for wire 18M to ground

24 volts

Check fuse ECA-F15, also check wire 18M.

Terminal for wire 18M to ground

24 volts

Check fuse ECA-F15, also check wire 18M.

Terminal for wire 61C to ground

24 volts

Bad compressor clutch relay.

Terminal for wire 61C to ground

24 volts

Bad compressor clutch relay.

4002-111

129 – A/C High/Low Pressure Switch

Located on the top of the engine air filter bracket.

Check Points

Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (137) in position 1, 2, 3 or 4 and push AC switch to ON. Terminal B for wire 61A to ground

24 volts

Check the thermostat switch, AC switch, and 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).

Check Points

Terminal B for wire 61A to ground

Between terminals of trinary pressure switch

Located on the left side of the engine.

Located on the left side of the engine. Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (137) in position 1, 2, 3 or 4 and push AC switch to ON. Terminals for wire 61C-B to ground

24 volts

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

24 volts

Check the thermostat switch, AC switch, and check circuit 61A.

NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch.

130 – Compressor Clutch Correct Reading

Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (137) in position 1, 2, 3 or 4 and push AC switch to ON.

130 – Compressor Clutch

Check Points

Correct Reading

Check Points

Continuity

Correct Reading

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).

Possible Cause of Bad Reading

NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (137) in position 1, 2, 3 or 4 and push AC switch to ON. Terminals for wire 61C-B to ground

24 volts

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

4002-112

CLIMATE CONTROL - AUTOMATIC TEMPERATURE CONTROL

138 134 133

138 134 135 136 137

133

140 141 137

131 139

142

140 141 137

131 139

142

132

W270-7R038

131.ELECTRONIC PANEL 132.EXTERNAL AIR TEMPERATURE SENSOR 133.INTERNAL AIR TEMPERATURE SENSOR 134.SUN SENSOR 135.BLOWER FAN RESISTOR 136.BLOWER MOTORS

135 136 137

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.

W270-7R038

131.ELECTRONIC PANEL 132.EXTERNAL AIR TEMPERATURE SENSOR 133.INTERNAL AIR TEMPERATURE SENSOR 134.SUN SENSOR 135.BLOWER FAN RESISTOR 136.BLOWER MOTORS

137.THERMOCOUPLE SENSOR 138.MIXED AIR SENSOR 139.COMPRESSOR RELAY 140.RECYCLING MOTOR 141.ELETRONIC WATER VALVE 142.24 TO 12 VOLT CONVERTER

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

4002-113

131 – Electronic Panel Check Points

4002-113

131 – Electronic Panel Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

NOTE: No information at time of print.

132 – External Air Temperature Sensor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

NOTE: No information at time of print.

133 – Internal Air Temperature Sensor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

134 – Sun Sensor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

135 – Blower Fan Resistor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

136 – Blower Motors

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

137 – Thermocouple Sensor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

138 – Mixed Air Sensor

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

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

Correct Reading

Possible Cause of Bad Reading

4002-114

139 – Compressor Relay Check Points

139 – Compressor Relay Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

140 – Recycling Motor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

141 – Electronic Water Valve

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

142 – 24 to 12 Volt Converter

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

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

4002-115

STANDARD CLIMATE CONTROL

144 145

146 147 148

149 150 151

152 153

W270-7R039

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.

W270-7R039

143.ACTUATOR 144.DRIVER 145.ELETRONIC WATER VALVE 146.BLOWER FAN RESISTOR 147.BLOWER MOTOR 148.THERMOSTAT 149.FAN SPEED SWITCH 150.AIR CONDITIONING SWITCH

151.CONTROL PANEL LIGHTS 152.WATER VALVE POTENTIOMETER 153.AIR RECIRCULATING SWITCH

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

4002-116

143 – Actuator Check Points

143 – Actuator 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

Check Points

Correct Reading

Possible Cause of Bad Reading

Terminals for wire DNS66 to ground

Continuity

Check Points

NOTE: No information at time of print.

144 – Driver

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

145 – Electronic Water Valve

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

146 – Blower Fan Resistor

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

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 to position 4. Terminal for wire DNS65 to ground

24 volts

Check the blower switch.

Bad ground circuit.

NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch to position 4. Terminal for wire DNS65 to ground

24 volts

Check the blower switch.

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

148 – Thermostat

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

149 – Fan Speed Switch

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

4002-117

150 – Air Conditioning Switch Check Points

4002-117

150 – Air Conditioning Switch Correct Reading

Possible Cause of Bad Reading

Check Points

NOTE: No information at time of print.

151 – Control Panel Lights

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

Possible Cause of Bad Reading

Correct Reading

Possible Cause of Bad Reading

NOTE: No information at time of print.

152 – Water Valve Potentiometer

Check Points

Correct Reading

Possible Cause of Bad Reading

Check Points

Correct Reading

NOTE: No information at time of print.

153 – Air Recirculating Switch

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

Check Points NOTE: No information at time of print.

Correct Reading

Possible Cause of Bad Reading

4002-118

CONNECTORS CONNECTOR 108F - DIAGNOSTIC CONNECTOR

CONNECTORS

CONNECTOR 197F - MAIN CAB FNR

291663A1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR 108F - DIAGNOSTIC CONNECTOR

225350C1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR 197F - MAIN CAB FNR

291663A1

CAV

WIRE IDENT

CIRCUIT

225350C1

CAV

WIRE IDENT

CIRCUIT

19A-W

Diagnostic Conn. Fused Power

19A-C

FNR Switch Fused Power

19A-W

Diagnostic Conn. Fused Power

19A-C

FNR Switch Fused Power

37D-A

Diagnostic Signal

26F-B

FNR Forward Signal

37D-A

Diagnostic Signal

26F-B

FNR Forward Signal

0-DAV

Diagnostic TECM Ground

26N-B

FNR Neutral Signal

0-DAV

Diagnostic TECM Ground

26N-B

FNR Neutral Signal

37E

Diagnostic Signal Switched

26R-B

FNR Reverse Signal

Diagnostic Signal Switched

26R-B

FNR Reverse Signal

Not Used

32J-E

Trans Enable Indication Lamp

Not Used

32J-E

Trans Enable Indication Lamp

Not Used

25Y-B

Trans Kick Down Signal

Not Used

25Y-B

Trans Kick Down Signal

CONNECTOR 140M - DIODE MODULE

CONNECTOR 197M - FNR MAIN CAB

CONNECTOR 140M - DIODE MODULE

CONNECTOR 197M - FNR MAIN CAB

225351C1 245488C1

CAV A

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

225351C1

CIRCUIT

245488C1

19A-B

FNR Switched Fused Power

CAV

63H-C

Front Wiper High Speed

26F-A

FNR Forward Signal

63L-C

Front Wiper Low Speed

26N-A

FNR Neutral Signal

0-EE

Diode Suppression Grounds

26R-A

FNR Reverse Signal

58-D

Ride Control Solenoid Power

32J-A

21D-B

Starter Relay Signal

25Y-C

68L-C

Rear Wiper Switch Power

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

19A-B

FNR Switched Fused Power

63H-C

Front Wiper High Speed

26F-A

FNR Forward Signal

63L-C

Front Wiper Low Speed

26N-A

FNR Neutral Signal

0-EE

Diode Suppression Grounds

26R-A

FNR Reverse Signal

Trans Enable Indication Lamp

58-D

Ride Control Solenoid Power

32J-A

Trans Enable Indication Lamp

Trans Kick Down Signal

21D-B

Starter Relay Signal

25Y-C

Trans Kick Down Signal

68L-C

Rear Wiper Switch Power

4002-119 CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

CONNECTOR 215F - ALTERNATOR RESISTOR

4002-119 CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

CONNECTOR 215F - ALTERNATOR RESISTOR

199436A1 245481C1

CAV A

WIRE IDENT 35A-E

CAV 1

CIRCUIT

WIRE IDENT 14-A

199436A1

CIRCUIT

245481C1

Alternator D+

CAV

Backup Alarm Relay Out

WIRE IDENT 35A-E

CIRCUIT

WIRE IDENT 14-A

CIRCUIT Alternator D+

Backup Alarm Relay Out

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

CAV

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

199436A1

CAV 245480C1

CAV A

WIRE IDENT 35A-D

WIRE IDENT 19R-D

199436A1

CIRCUIT

CAV

Alternator Resistor Fused Pwr

CIRCUIT

245480C1

CAV

CONNECTOR 242F-CHAS GRD SEC STRG MTR

Backup Alarm Relay Out Not Used

WIRE IDENT 35A-D

B CAV

CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

WIRE IDENT 0-ND

CIRCUIT

CONNECTOR 242F-CHAS GRD SEC STRG MTR

Backup Alarm Relay Out Not Used

CAV

CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

WIRE IDENT 0-ND

CIRCUIT SSM Ground

CONNECTOR 244F-STARTER SEC STRG MTR

CAV

WIRE IDENT 1-ND

CIRCUIT SSM PWR

225316C1

WIRE IDENT

Alternator Resistor Fused Pwr

CONNECTOR 244F-STARTER SEC STRG MTR

CAV

19R-D

CIRCUIT

CIRCUIT SSM Ground

WIRE IDENT

225316C1

CAV

WIRE IDENT

CIRCUIT

19A-U

Trans Kick Down Switched Pwr

19A-U

Trans Kick Down Switched Pwr

25Y-C

Trans Kick Down Signal

25Y-C

Trans Kick Down Signal

WIRE IDENT 1-ND

CIRCUIT SSM PWR

4002-120

CONNECTOR 64F - FLASHER CONNECTOR

CONNECTOR AD-ALTERNATOR-D+ CAV 1

WIRE IDENT 14

CIRCUIT

CONNECTOR AD-ALTERNATOR-D+ CAV

Alternator D+

CONNECTOR AIC1 - ADV INSTRUMENT CLUSTER 1

WIRE IDENT 45N-A

CIRCUIT Alternator D+

CONNECTOR AIC1 - ADV INSTRUMENT CLUSTER 1

245481C1

CAV

WIRE IDENT

245481C1

CIRCUIT

CAV

Flasher Optional Side Control

CONNECTOR 64M - FLASHER CONNECTOR

WIRE IDENT 45N-A

CIRCUIT Flasher Optional Side Control

CONNECTOR 64M - FLASHER CONNECTOR

87419488

CAV

WIRE IDENT

87419488

CIRCUIT

CAV

WIRE IDENT 45N-B

CIRCUIT Flasher Optional Side Control

CONNECTOR AB-ALTERNATOR-B+

Voltmeter Input ANALOG

13V

Voltmeter Input ANALOG

36F-A

Fuel Level ANALOG

36F-A

Fuel Level ANALOG

CAN-HG

CAN High

CAN-HG

CAN High

CAN-LG

CAN Low

CAN-LG

CAN Low

36A

Rear Axle Temperature

36A

Rear Axle Temperature

0-DX

AIC Sensor Ground

0-DX

AIC Sensor Ground

43-A

Dome Light Auto Mode

245480C1

43-A

WIRE IDENT 1-BA

CIRCUIT Alternator B+

CONNECTOR ACT 9 - AIR CONDITIONING COMPRESSOR CLUTCH

Dome Light Auto Mode

36B

Front Axle Temperature

36H-A

Hydraulic Oil Temperature

10 CAV

CAV 1

WIRE IDENT 45N-B

CIRCUIT Flasher Optional Side Control

CONNECTOR AB-ALTERNATOR-B+

Not Used 36C-A

Radiator Coolant Temp Signal

CAV

0-DW

AIC Power Ground

35B

AIC Buzzer HSD

52C

Park Brake Solenoid LSD

44A-B

Brake Light Relay Out

WIRE IDENT 1-BA

CIRCUIT Alternator B+

CONNECTOR ACT 9 - AIR CONDITIONING COMPRESSOR CLUTCH

36C-A

Radiator Coolant Temp Signal

0-DW

AIC Power Ground

35B

AIC Buzzer HSD

52C

Park Brake Solenoid LSD

44A-B

Brake Light Relay Out

Standard Steering Signal

51S

Standard Steering Signal

Comfort Steering Switch

51CS

Comfort Steering Switch

Not Used

Ether AIC OK Signal

28J

Not Used

28J

53C-A

Pilot Control Solenoid LSD

53C-A

Pilot Control Solenoid LSD

51C

Comfort Steering Control

51C

Comfort Steering Control

Not Used

Fan Reverser LSD

Not Used

Ether AIC OK Signal

Not Used 52

Fan Reverser LSD Not Used

245480C1

25 AC relay out

Not Used

51S

61C-B

Hydraulic Oil Temperature

51CS

245480C1

Front Axle Temperature

36H-A

CIRCUIT

36B

WIRE IDENT

CAV

CIRCUIT

13V

245480C1

CAV

WIRE IDENT

17P-A 56

Switch Pad Pwr From AIC Pwr Fan Control PWM

CAV 1

WIRE IDENT 61C-B

CIRCUIT AC relay out

17P-A

Switch Pad Pwr From AIC Pwr

Fan Control PWM

4002-121 CONNECTOR AIC2 - ADV INSTRUMENT CLUSTER 2

CONNECTOR B1-STARTER PWR STUD CAV

WIRE IDENT

CIRCUIT

CONNECTOR B1-STARTER PWR STUD CAV

1-NC

B+ PWR PRMC

1-NC

B+ PWR PRMC

1-NC

CAB CB PRM PWR

1-NC

CAB CB PRM PWR

CAV 1

WIRE IDENT 1-BA

CONNECTOR B2-STARTER-POWER

CIRCUIT

CAV

Alternator B+

87410948

WIRE IDENT

1 2 3

CIRCUIT

CAV

WIRE IDENT

Door Open Signal

CAV

Not Used

WIRE IDENT 1-NB

CIRCUIT Battery STRTR

Not Used 43S-C

Door Open Signal

CAV

Not Used

33R

Redundant Brk Accm Press Low

33R

Redundant Brk Accm Press Low

33P-A

Brake Low Pressure Warning

33P-A

Brake Low Pressure Warning

33U

Park Brake Switch

33U

Park Brake Switch

52M

Fan Reverse Manual

52M

Fan Reverse Manual

52AU

Fan Reverse Auto

52AU

Fan Reverse Auto

45L-E

Left Turn Signal

45L-E

Left Turn Signal

45R-C

Right Turn Signal

45R-C

Right Turn Signal

35X

Sec. Steering Low Press Signal

35X

Sec. Steering Low Press Signal

CONNECTOR B4-STARTER-POWER CAV 1

Not Used Not Used

CAV 1

0-DB

AIC Power Ground Red

57-C

Pin Engage Solenoid Power

21K-A

Ignition Switch Start Signal

31L

Pilot Control Switch High

Not Used

19S-C

AIC Delay Fused Power

19E-A

AIC Wake Up Ignition

0-DA

AIC Chassis Ground

Not Used

31D-A

CIRCUIT SSM PWR

CONNECTOR BT1-BATTERY-STARTER

AIC Delay Fused Power

WIRE IDENT 1-ND

19S-D

CIRCUIT Alternator B+

WIRE IDENT 1-NB

CIRCUIT Battery STRTR

CONNECTOR BT2-DISCONNECT-BATTERY CAV 1

WIRE IDENT 1-NA

CIRCUIT Battery Crossover

CONNECTOR BT3-STARTER-BATTERY CAV 1

WIRE IDENT 1-NA

CIRCUIT Battery Crossover

Coolant Level Signal

CONNECTOR B3-STARTER-BATTERY

CIRCUIT

WIRE IDENT 1-BA

87410948

CONNECTOR B3-STARTER-BATTERY

Not Used 43S-C

CIRCUIT

CONNECTOR B2-STARTER-POWER

CAV

WIRE IDENT

CAV 1

Not Used

CAV 1

0-DB

AIC Power Ground Red

57-C

Pin Engage Solenoid Power

21K-A

Ignition Switch Start Signal

31L

Pilot Control Switch High

Not Used

19S-C

AIC Delay Fused Power

19E-A

AIC Wake Up Ignition

0-DA

AIC Chassis Ground

CAV 1

WIRE IDENT 0-NC

CIRCUIT Battery Disconnect

CIRCUIT Battery STRTR

WIRE IDENT 1-NA

CIRCUIT Battery Crossover

CONNECTOR BT3-STARTER-BATTERY

Not Used

CAV

Not Used

WIRE IDENT 1-NA

CIRCUIT Battery Crossover

Coolant Level Signal

CONNECTOR BT4-DISCON-BLCK-GRND CAV

SSM PWR

CONNECTOR BT2-DISCONNECT-BATTERY

Not Used

31D-A

WIRE IDENT 1-NB

CIRCUIT

CONNECTOR BT1-BATTERY-STARTER

Not Used

AIC Delay Fused Power

WIRE IDENT 1-ND

13 19S-D

CIRCUIT Battery STRTR

CONNECTOR B4-STARTER-POWER

WIRE IDENT 1-NB

CONNECTOR BT4-DISCON-BLCK-GRND CAV 1

WIRE IDENT 0-NC

CIRCUIT Battery Disconnect

4002-122

CONNECTOR BU1-BACKUP-ALARM-GRND CAV 1

WIRE IDENT 0-JB

CIRCUIT Backup Alarm GND

CONNECTOR BU2-BACKUP-ALARM CAV

WIRE IDENT

CIRCUIT

35A-H

BKUP ALM RLY OUT

35A-HN

BKUP ALM RLY OUT

CONNECTOR BUZ - AIC BUZZER

222136A1

CAV

WIRE IDENT

CIRCUIT

35B

AIC Buzzer HSD

0-B27

Buzzer Ground

CONNECTOR CAB-E - CAB TO ENGINE

CAV

WIRE IDENT

CONNECTOR BU1-BACKUP-ALARM-GRND

CIRCUIT

18G-F

RH Position/Tail Fused Power

45L-B

Left Turn Signal

CAV

21F

EDC7 Digital Ground

45R-B

Right Turn Signal

18R-A

Voltmeter Relay Fused Power

18J-G

EDC7 Time Delay Fused Power

21D-C

Starter Relay Signal

28H

Ether Switch Signal

0-DX

AIC Sensor Ground

18J

EDC7 Time Delay Fused Power

0-DW

AIC Power Ground

0-DB

AIC Power Ground Red

13C-B

Fuel Shutoff Fused Power

52A-A

Fan Reverse Relay Out

24 25

WIRE IDENT

CIRCUIT

18G-F

RH Position/Tail Fused Power

45L-B

Left Turn Signal

21F

EDC7 Digital Ground

45R-B

Right Turn Signal

18R-A

Voltmeter Relay Fused Power

18J-G

EDC7 Time Delay Fused Power

21D-C

Starter Relay Signal

28H

Ether Switch Signal

0-DX

AIC Sensor Ground

18J

EDC7 Time Delay Fused Power

0-DW

AIC Power Ground

0-DB

AIC Power Ground Red

13C-B

Fuel Shutoff Fused Power

52A-A

Fan Reverse Relay Out

Fan Control PWM

68W

Rear Washer Pump

68W

Rear Washer Pump

63W

Front Washer Pump

63W

Front Washer Pump

14-A

Alternator D+

14-A

Alternator D+

21E

Key Switch Crank

21E

Key Switch Crank

0-JB

CIRCUIT Backup Alarm GND

CONNECTOR BU2-BACKUP-ALARM CAV

WIRE IDENT

CIRCUIT

35A-H

BKUP ALM RLY OUT

35A-HN

BKUP ALM RLY OUT

CONNECTOR BUZ - AIC BUZZER

31F-A

Air Filter Restriction Sw Signal

31F-A

Air Filter Restriction Sw Signal

61R-B

AC Relay Control

61R-B

AC Relay Control

61A-B

Trinary Pressure Switch Input

61A-B

Trinary Pressure Switch Input

20G-B

EDC7 ISO-K Interface

20G-B

222136A1

EDC7 ISO-K Interface

36A

Rear Axle Temperature

36F-A

Fuel Level ANALOG

36C-A

Radiator Coolant Temp Signal

19Y-C

Hood Switch Fused Power

CAV

WIRE IDENT

CIRCUIT

35B

AIC Buzzer HSD

0-B27

Buzzer Ground

CONNECTOR CAB-E - CAB TO ENGINE

36A

Rear Axle Temperature

36F-A

Fuel Level ANALOG

36C-A

Radiator Coolant Temp Signal

19Y-C

Hood Switch Fused Power

60D

Hood Down Relay Out

60D

Hood Down Relay Out

59D

Hood Down Relay Control

59D

Hood Down Relay Control

60U

Hood Up Relay Out

60U

Hood Up Relay Out

59U

Hood Up Relay Control

59U

Hood Up Relay Control

35A-F

Backup Alarm Relay Out

35A-F

Backup Alarm Relay Out

225415C1

CAV

WIRE IDENT

CIRCUIT

21C-C

Starter Relay Signal

21C-C

Starter Relay Signal

61C

AC Relay Out

61C

AC Relay Out

21G

EDC7 Crank Control Relay

21G

EDC7 Crank Control Relay

21H

Crank Control Relay LSD

21H

Crank Control Relay LSD

18F-A

LH Position/Tail Fused Power

18F-A

LH Position/Tail Fused Power

Not Used

WIRE IDENT

9 WIRE IDENT

225415C1

CAV

Not Used

35A-C

Backup Alarm Relay Out

35A-C

Backup Alarm Relay Out

44A-C

Brake Light Relay Out

44A-C

Brake Light Relay Out

4002-123 CONNECTOR CAB-F - CAB FRONT CHASSIS

CONNECTOR CAB-PW-CAB-POWER CAV 1

WIRE IDENT 1CB-A

CIRCUIT

CONNECTOR CAB-PW-CAB-POWER CAV

CAB CB Protected PWR

CONNECTOR CAB-RF - CAB TO ROOF CONNECTION

WIRE IDENT

1CB-A

CIRCUIT CAB CB Protected PWR

CONNECTOR CAB-RF - CAB TO ROOF CONNECTION

291661A1

CAV

WIRE IDENT

291661A1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

45L-C

Left Turn Signal

45L-C

Left Turn Signal

51B-C

Comfort Steering Solenoid Pwr

51B-C

Comfort Steering Solenoid Pwr

45R-D

Right Turn Signal

388710A1

45R-D

Right Turn Signal Not Used

18G-G

Position RH Fused Power

18F-E

Position LH Fused Power

18B-A

High Beam LH Fused Power

36B

Front Axle Temperature

O-DY

Front Axle Temperature Ground

Not Used

54B-A

Height-RTT Signal

53B-B

RTD Signal

64A

Horn Power

18D-A

Low Beam LH Fused Power

18E-A

Low Beam RH Fused Power

18C-A

High Beam RH Fused Power

Not Used

CAV

WIRE IDENT

CIRCUIT

43-A

Dome Light Auto Mode

42R-C

Rear Work Light Fused Power

42C-A

Front Work Lights Fused Power

19U-D

Dome Light Fused Power

46-C

Beacon Switch Power

0-DR

Roof Splice Grounds

0-DS

Roof Splice Grounds

19K-C

Rear Wiper Motor Fused Power

68C

Rear Wiper Park Control

68L-B

Rear Wiper Switch Power

0-EM

Radio Ground

12V-B

12V Fused Power to Radio

43S-A

Door Open Signal

388710A1

Not Used

18G-G

Position RH Fused Power

18F-E

Position LH Fused Power

18B-A

High Beam LH Fused Power

36B

Front Axle Temperature

O-DY

Front Axle Temperature Ground

Not Used

54B-A

Height-RTT Signal

53B-B

RTD Signal

64A

Horn Power

18D-A

Low Beam LH Fused Power

18E-A

Low Beam RH Fused Power

18C-A

High Beam RH Fused Power

Not Used

53P-F

Pilot Control Relay Out

57-A

Pin Engage Sol Pwr

58-C

Ride Control Sol Pwr

1-DR

23 24

19U-G

Door Switch Fused Power

53P-F

Pilot Control Relay Out

57-A

Pin Engage Sol Pwr

58-C

Ride Control Sol Pwr

Brake Lamp Switch Power

1-DR

Brake Lamp Switch Power

44-A

Brake Lamp Control Power

44-A

Brake Lamp Control Power

52P-A

Park Brake Relay Out

52P-A

Park Brake Relay Out

Not Used

33P-A

Low Brake Pressure Warning

33P-A

Low Brake Pressure Warning

19A-T

Brake Declutch Switch Fused Power

19A-T

Brake Declutch Switch Fused Power

25G-A

Brake Declutch Switch Control

25G-A

Brake Declutch Switch Control

Not Used

CAV

WIRE IDENT

CIRCUIT

43-A

Dome Light Auto Mode

42R-C

Rear Work Light Fused Power

42C-A

Front Work Lights Fused Power

19U-D

Dome Light Fused Power

46-C

Beacon Switch Power

0-DR

Roof Splice Grounds

0-DS

Roof Splice Grounds

19K-C

Rear Wiper Motor Fused Power

68C

Rear Wiper Park Control

68L-B

Rear Wiper Switch Power

0-EM

Radio Ground

12V-B

12V Fused Power to Radio

43S-A

Door Open Signal

19U-G

Door Switch Fused Power

4002-124

CONNECTOR CAB-T - CAB TO TRANMISSION

CONNECTOR CAN - CAN BULK HEAD

CONNECTOR CAB-T - CAB TO TRANMISSION

380839A1

CAV

WIRE IDENT

CONNECTOR CAN - CAN BULK HEAD

380839A1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

33R

Front Brake Accumulator Pressure Low

33R

Front Brake Accumulator Pressure Low

31D-A

Coolant Level Signal

31D-A

Coolant Level Signal

19M

Secondary Steering Accessory Fused Power

19M

Secondary Steering Accessory Fused Power

19R-E

Sec. Steering Ignition Fused Power

CAN-HA

CAN High

19R-E

Sec. Steering Ignition Fused Power

CAN-HA

CAN High

36T-A

Valve Body Temp Signal

CAN-LA

CAN Low

36T-A

Valve Body Temp Signal

CAN-LA

CAN Low

35X

Secondary Steer Low Press Signal

35X

Secondary Steer Low Press Signal

25A-A

Engine Speed Signal

25A-A

Engine Speed Signal

25C-A

Turbine Speed Signal

25C-A

Turbine Speed Signal

87315266

CAV

WIRE IDENT

CIRCUIT

CONNECTOR CAN2 - CAN BULK HEAD

25B-A

Intermediate Speed Signal

25B-A

Intermediate Speed Signal

25D-A

Output Speed Signal

25D-A

Output Speed Signal

0-DM

Speed Sensor Ground

0-DM

Speed Sensor Ground

36R-E

Trans Temp/Filter Return

36R-E

Trans Temp/Filter Return

36G-A

TCO Temp Signal

Not Used

Trans Solenoid Valve Y1

25K-A

25L-A

Trans Solenoid Valve Y2

25L-A

Trans Solenoid Valve Y2

25M-A

Trans Solenoid Valve Y3

25M-A

Trans Solenoid Valve Y3

25N-A

Trans Solenoid Valve Y4

25N-A

Trans Solenoid Valve Y4

25P-A

Trans Solenoid Valve Y5

25P-A

Trans Solenoid Valve Y5

25J-A

Trans Solenoid Valve Y6

25J-A

Trans Solenoid Valve Y6

25S-A

Output Sw Power VPS1

25S-A

Output Sw Power VPS1

31H-A

Hyd Filter Restriction Switch Sig

31H-A

Hyd Filter Restriction Switch Sig

Not Used

19S1

CAV A

WIRE IDENT CAN-H

CIRCUIT CAN High

CAN-HJ

CAN High From Engine

CAN-L

CAN Low

CAN-LM

CAN Low From Engine

CONNECTOR CB1A-CIRCUIT BRKR

Sec. Steering Fused Power Not Used

Not Used

19S1

0-DN

Output Speed Sensor Ground

CAV

19A-M

Output Speed Sen. Fused Pwr

36H-A

Hydraulic Oil Temp

32F-A

Trans Filter Maint Switch

WIRE IDENT 1CB

CIRCUIT CAB CB Protected PWR

CONNECTOR CB2B-CAB+ CB CAV 1

WIRE IDENT 1NC

CIRCUIT CAB CB PRM PWR

CAV

WIRE IDENT

CIRCUIT

CONNECTOR CAN2 - CAN BULK HEAD

Trans Solenoid Valve Y1

87315267

87315266

87315267

CAV

WIRE IDENT

CIRCUIT

CAN-H

CAN High

CAN-HJ

CAN High From Engine

CAN-L

CAN Low

CAN-LM

CAN Low From Engine

CONNECTOR CB1A-CIRCUIT BRKR

Sec. Steering Fused Power Not Used

0-DN

Output Speed Sensor Ground

CAV

19A-M

Output Speed Sen. Fused Pwr

36H-A

Hydraulic Oil Temp

32F-A

Trans Filter Maint Switch

WIRE IDENT 1CB

CIRCUIT CAB CB Protected PWR

CONNECTOR CB2B-CAB+ CB CAV 1

WIRE IDENT 1NC

CIRCUIT CAB CB PRM PWR

4002-125 CONNECTOR CB3B-CAB+ CB CAV 1

WIRE IDENT 1B9

4002-125 CONNECTOR CB3B-CAB+ CB

CONNECTOR CNV - 24V TO 12V POWER CONVERTER

CIRCUIT

CAV

PRM C PWR

CONNECTOR CBPW-CAB-POWER CAV 1

WIRE IDENT 1CB

WIRE IDENT 1B9

CONNECTOR CNV - 24V TO 12V POWER CONVERTER

CIRCUIT PRM C PWR

CONNECTOR CBPW-CAB-POWER

CIRCUIT

CAV

CAB CB Protected PWR

WIRE IDENT 1CB

CIRCUIT CAB CB Protected PWR

225351C1

CAV

CONNECTOR CL - CIGAR LIGHTER

WIRE IDENT

CIRCUIT

CAV

19L-A

Power Converter Fused Power

19L-B

0-EJ

225351C1

CONNECTOR CL - CIGAR LIGHTER

Power Converter Fused Power

19L-B

Power Converter Fused Power

Power Converter Ground

0-EJ

Power Converter Ground

Not Used

12V-C

12V Switched Power

12V-C

12V Switched Power

0-ER

Power Converter Ground

0-ER

Power Converter Ground

Not Used

CONNECTOR D-OR - DIODE OR

3227856R1

WIRE IDENT

CIRCUIT

19L-A

CONNECTOR D-OR - DIODE OR

CAV

WIRE IDENT

3227856R1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

19W

Cigar Lighter Fused Power

19W

Cigar Lighter Fused Power

0-DV

Cigar Lighter Ground

0-DV

Cigar Lighter Ground

CONNECTOR CLS - COOL JUMP - COOL SEND

CONNECTOR CLS - COOL JUMP - COOL SEND 245485C1

CAV A

WIRE IDENT

42C-D

CIRCUIT

CAV

Front Work Lights Fused Power

WIRE IDENT 42C-D

CIRCUIT Front Work Lights Fused Power

41T-C

Position Lights Switched Power

41T-C

Position Lights Switched Power

Back Light Power

CONNECTOR DC1-DISCONNECT-BATTERY

194788A1

CAV

WIRE IDENT

245485C1

CIRCUIT

CAV

31D_C

Coolant Level Signal

CAV

0_BAF

Coolant Level Sender Ground

WIRE IDENT 0-NC

CIRCUIT Battery Disconnect

CONNECTOR DC1-DISCONNECT-BATTERY

194788A1

WIRE IDENT

CIRCUIT

31D_C

Coolant Level Signal

CAV

0_BAF

Coolant Level Sender Ground

CONNECTOR DC2-DISCON-BLCK-GRND CAV 1

WIRE IDENT 0-NB

CIRCUIT Master Disconnect GND

WIRE IDENT 0-NC

CIRCUIT Battery Disconnect

CONNECTOR DC2-DISCON-BLCK-GRND CAV 1

WIRE IDENT 0-NB

CIRCUIT Master Disconnect GND

4002-126

CONNECTOR DC3-FUEL-SOL-DISCONNECT CAV 1

WIRE IDENT 13C

CONNECTOR DC3-FUEL-SOL-DISCONNECT

CONNECTOR DM - DIODE OR

CIRCUIT

CAV

Fuel Shutoff Fused PWR

CONNECTOR DC4-FUEL-SOL-DISCONNECT CAV

WIRE IDENT

WIRE IDENT 13C

CONNECTOR DM - DIODE OR

CIRCUIT Fuel Shutoff Fused PWR

CONNECTOR DC4-FUEL-SOL-DISCONNECT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

245485C1

13M

Fuel Shutoff Fused PWR

CAV A

WIRE IDENT 19RR

Sec. Steering Ignition Fused Pwr

19R

Sec. Steering Ignition Fused Pwr

CONNECTOR DIA - DIAGNOSTIC

CIRCUIT

245485C1

13M

CAV A

Not Used

Fuel Shutoff Fused PWR

WIRE IDENT

CAV

WIRE IDENT

18K-A

Diagnostics Fused Power

CAN-HB

Controller Area Network High

CAN-LB

Controller Area Network Low

20G-B

EDC7 ISO-K Interface

CONNECTOR DNS-AC-SWITCH

CIRCUIT

CAV

DNS72

DNS68

DNS71

5 6

CIRCUIT

13C

Fuel Shutoff Fused Power

13M

Fuel Shutoff Fused Power

CAV

WIRE IDENT

CIRCUIT

CONNECTOR DNS-ACTUATOR

0-DH

Ground

18K-A

Diagnostics Fused Power

CAV

DNS48

CAN-HB

Controller Area Network High

DNS48

DNS49

CAN-LB

Controller Area Network Low

DNS49

20G-B

EDC7 ISO-K Interface

WIRE IDENT

CIRCUIT

CONNECTOR DNS-BLUE - ATC CONTROL PANEL CAV

WIRE IDENT

CIRCUIT

310057A1

CONNECTOR DISC - DISCONNECT ENGINE

CAV

WIRE IDENT

CAV

245482C1

Sec. Steering Ignition Fused Pwr

DNS72

CONNECTOR DNS-ACTUATOR

Ground

19R

CIRCUIT

0-DH

Sec. Steering Ignition Fused Pwr Not Used

310057A1

CIRCUIT

19RR

CONNECTOR DIA - DIAGNOSTIC

CONNECTOR DNS-AC-SWITCH CAV

WIRE IDENT

CAV

WIRE IDENT

DNS8

DNS10

DNS11

DNS2

DNS4

DNS3

DNS6

DNS9

DNS31

DNS13

245482C1

DNS6

DNS9

DNS31

CAV

WIRE IDENT

CIRCUIT

13C

Fuel Shutoff Fused Power

13M

Fuel Shutoff Fused Power

CIRCUIT

CONNECTOR DNS-BLUE - ATC CONTROL PANEL

CONNECTOR DISC - DISCONNECT ENGINE

CIRCUIT

WIRE IDENT

DNS13

DNS18

DNS7

DNS12

DNS19

CIRCUIT

4002-127 CONNECTOR DNS-COMPRESSOR-RELAY CAV

WIRE IDENT

4002-127 CONNECTOR DNS-COMPRESSOR-RELAY

CONNECTOR DNS-HVAC2

CIRCUIT

CAV

WIRE IDENT

DNS19

DNS20

DNS16

DNS14

CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS

225315C1

CAV CAV

WIRE IDENT

DNS2

DNS1

CIRCUIT

WIRE IDENT

DNS36

DNS35

CONNECTOR DNS-HVAC2

CIRCUIT

CONNECTOR DNS-EXTERNAL-AIR-TEMP-SNS

CIRCUIT

225315C1

CAV CAV

WIRE IDENT

DNS2

DNS1

CIRCUIT

CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS

DNS36

DNS35

CONNECTOR DNS-HVAC-CAN1 CAV 1

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

DNS4

DNS3

DNS17

DNS5

CONNECTOR DNS-NOT-USED

CIRCUIT

CONNECTOR DNS-NOT-USED

225294C1

WIRE IDENT

CIRCUIT

CONNECTOR DNS-INTERNAL-AIR-TEMP-SNS

CONNECTOR DNS-HVAC-CAN1

CAV

WIRE IDENT

225294C1

CIRCUIT

CAV

WIRE IDENT

DNS9

DNS8

CONNECTOR DNS-HVAC1

CIRCUIT

CONNECTOR DNS-HVAC1 225326C1

CAV

WIRE IDENT

225326C1

CIRCUIT

CAV

DNS12

DNS11

DNS10

225294C1

CAV A

WIRE IDENT

CIRCUIT

WIRE IDENT

225294C1

CAV

WIRE IDENT

DNS14

DNS15

DNS13

CIRCUIT

4002-128

4002-128 CONNECTOR DNS-BLOWER

CONNECTOR DNS-YELLOW - ATC CONTROL PANEL CAV CAV

WIRE IDENT

DNS25

DNS24

DNS47

DNS43

DNS44

DNS21

DNS23

DNS28

DNS26

DNS30

DNS27

DNS29

DNS22

DNS45

DNS46

CIRCUIT

WIRE IDENT

CIRCUIT

CAV

DNS41

CAV

DNS42

DNS25

DNS24

DNS47

DNS43

DNS44

DNS21

DNS23

DNS28

DNS26

DNS30

DNS27

DNS29

DNS22

DNS45

DNS46

CONNECTOR DNS-THERMOCOUPLE-SENSO CAV 1

WIRE IDENT

CIRCUIT

DNS46

DNS40

CONNECTOR DNS-MIXED-AIR-SENSOR CAV

WIRE IDENT

DNS39

DNS45

CIRCUIT

CONNECTOR DNS-BLOWER

CONNECTOR DNS-YELLOW - ATC CONTROL PANEL WIRE IDENT

CIRCUIT

DNS41

DNS42

CAV

WIRE IDENT

CAV 1

DNS46

DNS40

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

DNS39

DNS45

CONNECTOR DNS-PWM-BLOWER-PIN4

CIRCUIT

CAV

WIRE IDENT

DNS34

DNS33

DNS32

DNS31

CIRCUIT

CAV

DNS30

DNS29

DNS28

CAV

HIRSCHMANN 772717-001

WIRE IDENT

CIRCUIT

WIRE IDENT

DNS30

DNS29

DNS28

DNS38

DNS27

DNS38

DNS27

DNS47

DNS26

DNS47

DNS26

DNS37

CONNECTOR DNS-RECYCLING-MOTOR CONNECTOR DNS-PWM-BLOWER-PIN2 CAV CIRCUIT

CIRCUIT

CONNECTOR DNS-RECYCLING-MOTOR

CONNECTOR DNS-PWM-BLOWER-PIN2 WIRE IDENT

CIRCUIT

CONNECTOR DNS-ELECT-WATER-VALVE

CAV

CIRCUIT

CONNECTOR DNS-VOLTAGE-CONVERTER

DNS34

WIRE IDENT

CIRCUIT

CONNECTOR DNS-MIXED-AIR-SENSOR

CONNECTOR DNS-ELECT-WATER-VALVE

HIRSCHMANN 772717-001

WIRE IDENT

CAV

CIRCUIT

CONNECTOR DNS-THERMOCOUPLE-SENSO

CONNECTOR DNS-VOLTAGE-CONVERTER CONNECTOR DNS-PWM-BLOWER-PIN4

WIRE IDENT

CIRCUIT

CAV

DNS21

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

DNS21

DNS41

DNS22

DNS41

DNS22

DNS42

DNS23

DNS42

DNS23

DNS24

DNS25

CIRCUIT

4002-129 CONNECTOR DNS-RESISTOR

CONNECTOR DNS-SPEED-SELECTOR CAV

WIRE IDENT

CIRCUIT

4002-129

CAV

WIRE IDENT

CONNECTOR DNS-RESISTOR

CONNECTOR DNS-SPEED-SELECTOR

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

DNS74

DNS61

DNS74

DNS61

DNS62

DNS61

DNS62

DNS63

DNS62

DNS63

DNS64

DNS63

DNS64

DNS73

CONNECTOR DNS-ELECT-WATER-VALVE-S

CONNECTOR DNS-CTRL-PANEL-LIGHT

CONNECTOR DNS-CTRL-PANEL-LIGHT CAV

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

CAV

DNS60

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

DNS60

DNS69

DNS56

DNS69

DNS56

DNS70

DNS57

DNS70

DNS57

DNS58

DNS59

CONNECTOR DNS-WATER-VALVE-POT CAV

WIRE IDENT

CONNECTOR DNS-DRIVER

CIRCUIT

CAV

WIRE IDENT

DNS55

DNS54

CONNECTOR DNS-RECIRCULATING-SWITCH WIRE IDENT

411311A1

DNS51

CAV

DNS53

DNS50

DNS52

DNS49

DNS48

DNS55

DNS57

8 9

CAV 1

WIRE IDENT

CIRCUIT

DNS67

CONNECTOR DNS-THERMOSTAT-2 CAV 1

WIRE IDENT

CIRCUIT

DNS68

WIRE IDENT

CIRCUIT

411311A1

CIRCUIT

DNS51

CAV

DNS53

DNS50

DNS52

DNS49

DNS48

DNS55

DNS57

DNS58

DNS59

DNS51

DNS53

DNS54

DNS56

DNS51

DNS53

DNS54

WIRE IDENT

DNS56

CIRCUIT

CAV

CONNECTOR DNS-THERMOSTAT-1 CAV 1

WIRE IDENT

CIRCUIT

DNS67

CONNECTOR DNS-THERMOSTAT-2 CAV 1

CONNECTOR DNS-ELECTRIC-FAN CAV

CONNECTOR DNS-DRIVER

CIRCUIT

CONNECTOR DNS-RECIRCULATING-SWITCH

CIRCUIT

CONNECTOR DNS-THERMOSTAT-1

CIRCUIT

CONNECTOR DNS-WATER-VALVE-POT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

DNS68

CONNECTOR DNS-ELECTRIC-FAN CAV

WIRE IDENT

DNS65

DNS66

CIRCUIT

WIRE IDENT

CIRCUIT

4002-130

4002-130 CONNECTOR DNS-HVAC1-S

245482C1

225294C1

CAV

WIRE IDENT

CONNECTOR DNS-HVAC1-S

CONNECTOR DS - DOOR SWITCH

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

CONNECTOR DS - DOOR SWITCH

245482C1

225294C1

CAV

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

DNS67

19U-F

Door Switch Fused Power

DNS67

19U-F

Door Switch Fused Power

DNS76

43S-B

Door Open Signal

DNS76

43S-B

Door Open Signal

DNS69

CONNECTOR E-HD9-TRANS-HOOD

CONNECTOR DNS-HVAC2-S

245482C1 225315C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

245482C1

CIRCUIT

225315C1

18G-L

RH POSN/TAIL Fused PWR

35A-9

Backup Alarm PWR

0-LD

Rear Light GND

DNS74

DNS75

CAV

WIRE IDENT

CIRCUIT

18G-L

RH POSN/TAIL Fused PWR

DNS74

35A-9

Backup Alarm PWR

DNS75

0-LD

Rear Light GND

WIRE IDENT

CIRCUIT

4002-131 CONNECTOR ECA - ELECTRICAL CENTER A

87315248

CAV C4

WIRE IDENT 19H

CIRCUIT BKUP ALM RLY FSD PWR

18M

AC RELAY FUSED PWR

FAN RVSR TURN SGNL

PLTEM DTNTS PRK BRK SOL

PRK BRK SOL HRN

TRANS ECM COMFORT STEER

TURN SGNL ENG SHTDWN

J16

A/C SEAT COMP

J15

BKUP A/C

CAV

WIRE IDENT

CIRCUIT

19J

FNT WPR FSD PWR

19K

REAR WPR FSD PWR

19N

SEAT CPRSR FSD PWR

19M

SEC STR ACCESSORY FSD PWR

COMFORT STEER AIC PWR

EMG STR AIC PWR

EMG STRG PLT EM DTNTS

TRANS ECM PWR

J11

BLWR MOTOR PWR

87315248

CAV

WIRE IDENT

CIRCUIT

19H

BKUP ALM RLY FSD PWR

18M

AC RELAY FUSED PWR

FAN RVSR TURN SGNL

PLTEM DTNTS PRK BRK SOL

PRK BRK SOL HRN

TRANS ECM COMFORT STEER

TURN SGNL ENG SHTDWN

J16

A/C SEAT COMP

J15

BKUP A/C

J12

BLWR MTR FRNT WIPR WASH

J12

BLWR MTR FRNT WIPR WASH

J13

FRNT WIPR RER WIPR WSH

J13

FRNT WIPR RER WIPR WSH

J14

RER WIPR WSH BACKUP

J14

RER WIPR WSH BACKUP

J18

SEAT COMP EMG STRTR

J18

SEAT COMP EMG STRTR

19A_N

TRANS FUSE PWR

19A_N

TRANS FUSE PWR

18L_A

COMFORT STEER FSD PWR

18L_A

COMFORT STEER FSD PWR

19E_A

AIC WAKE UP IGN

19E_A

AIC WAKE UP IGN

19RR

SEC STR IGN FSD PWR

19RR

SEC STR IGN FSD PWR

19C_A

PILOT CTRL RLY FSD PWR

19C_A

PILOT CTRL RLY FSD PWR

19D_A

PARK BRK RLY FSD PWR

19D_A

PARK BRK RLY FSD PWR

19P

PIN ENGAGE/FAN FSD PWR

19P

PIN ENGAGE/FAN FSD PWR

19B

TURN SIGNAL FSD PWR

19B

TURN SIGNAL FSD PWR

13C_B

FUEL SHUTOFF FUSED PWR

13C_B

FUEL SHUTOFF FUSED PWR

18N

BLOWER MOTOR FUSED PWR

18N

BLOWER MOTOR FUSED PWR

CAV

WIRE IDENT

CIRCUIT

19J

FNT WPR FSD PWR

19K

REAR WPR FSD PWR

19N

SEAT CPRSR FSD PWR

19M

SEC STR ACCESSORY FSD PWR

COMFORT STEER AIC PWR

EMG STR AIC PWR

EMG STRG PLT EM DTNTS

TRANS ECM PWR

J11

BLWR MOTOR PWR

4002-132

CONNECTOR ECB - ELECTRICAL CENTER B

87312843

CAV

WIRE IDENT

CIRCUIT

42FS

Front Work Lights Power

42RS

Rear Work Lights Power

41H-B

High Beam LH Power

41H-C

High Beam RH Power

41L-C

Low Beam LH Power

41L-B

Low Beam RH Power

41T-B

Position Lights LH Sw Power

41T-A

Position Lights RH Sw Power

21H

Crank Control Relay LSD

A10

21C-B

Neutral Start Relay Output

AA1

42C-C

Front Work Lights Fused Power

AA2

42R-C

Rear Work Lights Fused Power

AA3

18B-A

High Beam LH Fused Power

AA4

18C-A

High Beam RH Fused Power

AA5

18E-A

Low Beam RH Fused Power

CAV

WIRE IDENT

CIRCUIT

21K-B

Ignition Switch Start Signal

0-DE

Neutral Start Relay Control Gnd

21F

EDC7 Digital Ground

0-DF

Crank Request Relay Ctrl Gnd

19P-E

Fan Reverse Relay Fused Pwr

Fan Reverser LSD

19D-C

Park Brake relay Fused Pwr

B10

52C

Park Brake Solenoid LSD

13K-C

Ignition Switch Power

13V

Voltmeter Input ANALOG

25T

Neutral Signal

21C

Neutral Start Relay Output

21C-A

Neutral Start Relay Output

21E

Key Switch Crank

19P-D

Fan Reverse Relay Fused Pwr

52A-A

Fan Reverse Relay Out

19D-B

Park Brake Relay Fused Pwr

D10

52P-B

Park Brake Relay Out

87312843

CAV

WIRE IDENT

CIRCUIT

42FS

Front Work Lights Power

42RS

Rear Work Lights Power

41H-B

High Beam LH Power

41H-C

High Beam RH Power

41L-C

Low Beam LH Power

41L-B

Low Beam RH Power

41T-B

Position Lights LH Sw Power

41T-A

Position Lights RH Sw Power

21H

Crank Control Relay LSD

A10

21C-B

Neutral Start Relay Output

AA1

42C-C

Front Work Lights Fused Power

AA2

42R-C

Rear Work Lights Fused Power

AA3

18B-A

High Beam LH Fused Power

AA4

18C-A

High Beam RH Fused Power

AA5

18E-A

Low Beam RH Fused Power

AA6

18D-A

Low Beam LH Fused Power

AA7

18F-C

Pos Tail Lights LH Fused Power

AA8

18G

Pos Tail Lights RH Fused Power

AA6

18D-A

Low Beam LH Fused Power

AA7

18F-C

Pos Tail Lights LH Fused Power

AA8

18G

Pos Tail Lights RH Fused Power

AA9

21D-A

Starter Relay Signal

AA9

21D-A

Starter Relay Signal

AA10

21G

EDC7 Crank Control Relay

AA10

21G

EDC7 Crank Control Relay

18R-A

Voltmeter Relay Fused Power

18R-A

Voltmeter Relay Fused Power

0-DD

Voltmeter Relay control Ground

0-DD

Voltmeter Relay control Ground

CAV

WIRE IDENT

CIRCUIT

21K-B

Ignition Switch Start Signal

0-DE

Neutral Start Relay Control Gnd

21F

EDC7 Digital Ground

0-DF

Crank Request Relay Ctrl Gnd

19P-E

Fan Reverse Relay Fused Pwr

Fan Reverser LSD

19D-C

Park Brake relay Fused Pwr

B10

52C

Park Brake Solenoid LSD

13K-C

Ignition Switch Power

13V

Voltmeter Input ANALOG

25T

Neutral Signal

21C

Neutral Start Relay Output

21C-A

Neutral Start Relay Output

21E

Key Switch Crank

19P-D

Fan Reverse Relay Fused Pwr

52A-A

Fan Reverse Relay Out

19D-B

Park Brake Relay Fused Pwr

D10

52P-B

Park Brake Relay Out

4002-133 CONNECTOR ECC - ELECTRICAL CENTER C

87315249

CAV A1

WIRE IDENT 19U-B

CIRCUIT Beacon/Dome Lt Fused Pwr

Work Lights Sw Fused Pwr

19Z

Driving Lights Sw Fused Pwr

1-DV

Brake Lts/Flasher Bat Pwr

1DM

Time Delay/Ign Sw Fused Pwr

19U

Horn Relay Fused Power

19Y

Hood Control Fused Power

19W

Cigar Lighter Fused Power

18K-A

Diagnostic Fused Power

60U

Hood Up Relay Out

0-B25

Hood Up Control Ground

60D

Hood Down Relay Out

0-B16

Hood Down Control Ground

1-DW

Brake Light Relay Bat Power

0-EF

Brake Light Relay Control Gnd

19U-A

Horn Relay Fused Power

64C

Horn Relay Control

18L-C

Comfort Steering Fused Pwr

B10

51C

Comfort Steering Control

0-B22

Hood Up Relay Ground

0-B12

Hood Down Relay Ground

59U

Hood Up Relay Control

19Y-A

Hood Up Relay Fused Power

59D

Hood Down Relay Control

CAV

WIRE IDENT

CIRCUIT

19Y-B

Hood Down Relay Fused Power

44-A

Brake Light Control Power

44A-A

Brake Light Relay Out

19U-E

Horn relay Fused Power

64-A

Horn Power

18L-B

Comfort Steering Fused Power

D10

51B-B

Comfort Steering Solenoid Pwr

L1-1

ECC-L1

Beacon/Dome Lights LI ECC

L1-1

J2-ECC

Beacon/Dome Lt Work Lights

L1-2

J2-ECC

Beacon/Dome Lt Work Lights

L1-2

J3-ECC

Work Lights Driving Lights

L1-3

J3-ECC

Work Lights Driving Lights

L1-3

J4-ECC

Driving Lights Brake Lights

L1-4

J4-ECC

Driving Lights Brake Lights

L1-4

J5-ECC

Brake Lights Delay Power

L1-5

J5-ECC

Brake Lights Delay Power

L1-5

J6-ECC

Delay Power Horn

L1-6

J6-ECC

Delay Power horn

L1-6

J7-ECC

Horn HOD Control

L1-7

J7-ECC

Horn HOD Control

L1-7

J8-ECC

HOD Control Cigar Lighter

L1-8

J8-ECC

HOD Control Cigar Lighter

L1-8

J9-ECC

Diagnostic Power

L1-9

J9-ECC

Diagnostic Power

87315249

CAV

WIRE IDENT

CIRCUIT

19U-B

Beacon/Dome Lt Fused Pwr

Work Lights Sw Fused Pwr

19Z

Driving Lights Sw Fused Pwr

1-DV

Brake Lts/Flasher Bat Pwr

1DM

Time Delay/Ign Sw Fused Pwr

19U

Horn Relay Fused Power

19Y

Hood Control Fused Power

19W

Cigar Lighter Fused Power

18K-A

Diagnostic Fused Power

60U

Hood Up Relay Out

0-B25

Hood Up Control Ground

60D

Hood Down Relay Out

0-B16

Hood Down Control Ground

1-DW

Brake Light Relay Bat Power

0-EF

Brake Light Relay Control Gnd

19U-A

Horn Relay Fused Power

64C

Horn Relay Control

18L-C

Comfort Steering Fused Pwr

B10

51C

Comfort Steering Control

0-B22

Hood Up Relay Ground

0-B12

Hood Down Relay Ground

59U

Hood Up Relay Control

19Y-A

Hood Up Relay Fused Power

59D

Hood Down Relay Control

CAV

WIRE IDENT

CIRCUIT

19Y-B

Hood Down Relay Fused Power

44-A

Brake Light Control Power

44A-A

Brake Light Relay Out

19U-E

Horn relay Fused Power

64-A

Horn Power

18L-B

Comfort Steering Fused Power

D10

51B-B

Comfort Steering Solenoid Pwr

L1-1

ECC-L1

Beacon/Dome Lights LI ECC

L1-1

J2-ECC

Beacon/Dome Lt Work Lights

L1-2

J2-ECC

Beacon/Dome Lt Work Lights

L1-2

J3-ECC

Work Lights Driving Lights

L1-3

J3-ECC

Work Lights Driving Lights

L1-3

J4-ECC

Driving Lights Brake Lights

L1-4

J4-ECC

Driving Lights Brake Lights

L1-4

J5-ECC

Brake Lights Delay Power

L1-5

J5-ECC

Brake Lights Delay Power

L1-5

J6-ECC

Delay Power Horn

L1-6

J6-ECC

Delay Power horn

L1-6

J7-ECC

Horn HOD Control

L1-7

J7-ECC

Horn HOD Control

L1-7

J8-ECC

HOD Control Cigar Lighter

L1-8

J8-ECC

HOD Control Cigar Lighter

L1-8

J9-ECC

Diagnostic Power

L1-9

J9-ECC

Diagnostic Power

4002-134

CONNECTOR ECD - ELECTRICAL CENTER D

87312843

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

53C-A

Pilot Control Solenoid LSD

Engine ECM Time Delay Pwr

58T

13H-B

AIC Time Delay Power

58L

12V-D

Plug 1 12V Switched Power

Plug 2 12V Switched Power

B10

13H-C

Trans ECM Time Delay Pwr

13H-D

A3 A4 A5

CAV

12V-E

87312843

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

53C-A

Pilot Control Solenoid LSD

Engine ECM Time Delay Pwr

58T

Ride Control Relay Switch Pwr

13H-B

AIC Time Delay Power

58L

Ride Control Relay LSD

12V-D

Plug 1 12V Switched Power

18M

AC Relay Fused Power

12V-E

Plug 2 12V Switched Power

B10

0-DJ

AC Relay Control Ground

12V-F

Radio 12V Switched Power

63C2

Front Wiper Park Control

13H-C

Trans ECM Time Delay Pwr

Ride Control Relay Switch Pwr

13H-D

Ride Control Relay LSD

18M

AC Relay Fused Power

0-DJ

AC Relay Control Ground

63C2

Front Wiper Park Control

12V-F

Radio 12V Switched Power

12V-G

2 Way Radio 12V Sw Power

63C

Front Wiper Park Control

12V-G

2 Way Radio 12V Sw Power

63C

Front Wiper Park Control

35C

Backup Alarm Relay Control

19J-D

Front Wiper Relay HS Ctrl Fused Pwr

35C

Backup Alarm Relay Control

19J-D

Front Wiper Relay HS Ctrl Fused Pwr

A10

19H

Backup Alarm Relay Fused Pwr

63H-B

Front Wiper HS Relay Out

A10

19H

Backup Alarm Relay Fused Pwr

63H-B

Front Wiper HS Relay Out

AA1

19T-A

TECM Delay Fused Power

19T-A

TECM Delay Fused Power

AA2

18J-K

EDC7 Time Delay Fused Power

19J-F

Front Wiper Relay LS Ctrl Fused Pwr

AA1 AA2

18J-K

EDC7 Time Delay Fused Power

19J-F

Front Wiper Relay LS Ctrl Fused Pwr

63C2

Front Wiper Park Control

AA3

19S-B

AIC Delay Fused Power

63C2

Front Wiper Park Control

12V

12V Power to Outlet 1

AA3

19S-B

AIC Delay Fused Power

AA4

12V

12V Power to Outlet 1

19C-C

Pilot control Relay Fused Pwr

AA4

19C-C

Pilot control Relay Fused Pwr

AA5

12V-A

12V Power to Outlet 2

53P-C

Pilot Control Relay Out

AA5

12V-A

12V Power to Outlet 2

53P-C

Pilot Control Relay Out

AA6

12V-B

12V Fused Power to Radio

58H-A

Ride Ctrl Switched Pwr VPS2

AA6

12V-B

12V Fused Power to Radio

58H-A

Ride Ctrl Switched Pwr VPS2

AA9

35A-A

Backup Alarm Relay Out

58-E

Ride Control Solenoid Power

AA9

35A-A

Backup Alarm Relay Out

58-E

Ride Control Solenoid Power

19A-P

Backup Alarm Relay Ctrl Fused Pwr

19A-P

Backup Alarm Relay Ctrl Fused Pwr

61R-B

AC Relay Control

D10

61C

AC Relay Out

AA10

61R-B

AC Relay Control

D10

61C

AC Relay Out

AA10

19J-E

Front Wiper Relay Fused Power

19J-E

Front Wiper Relay Fused Power

63HC-B

Front Wiper HS Relay Control

63HC-B

Front Wiper HS Relay Control

63C3

Front Wiper Park Control

63C3

Front Wiper Park Control

63LC

Front Wiper LS Relay Control

63LC

Front Wiper LS Relay Control

19C-B

Pilot Control Relay Fused Pwr

19C-B

Pilot Control Relay Fused Pwr

4002-135 CONNECTOR EM - HEIGHT CONTROL RTD - RTT

CAV

WIRE IDENT

4002-135 CONNECTOR EM - HEIGHT CONTROL RTD - RTT

CIRCUIT

WIRE IDENT

CIRCUIT

55A-A

RTT/Float Switched Power

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

CONNECTOR ENG - ENGINE TO CAB

225414C1

CAV

WIRE IDENT

CIRCUIT

21C-D

Starter Relay signal

61C-A

AC Relay Out

61C-B

AC Relay Out

21GA

EDC7 Crank Control Relay

21H-A

Crank Control Relay LSD

18F-AN

LH Position/Tail Fuse Power

18F-B

WIRE IDENT

CIRCUIT

45R-AN

Right Turn Signal

45R-AN

Right Turn Signal

18R

Voltmeter Relay Fused Power

18R

Voltmeter Relay Fused Power

18J-F

EDC7 Time Delay Fused Power

18J-F

EDC7 Time Delay Fused Power

21D

Starter Relay Signal

21D

Starter Relay Signal

28E

Ether Relay Signal

28E

Ether Relay Signal

0-BJ

AIC Sensor Ground

0-BJ

AIC Sensor Ground

18J-A

EDC7 Time Delay Fused Power

18J-A

EDC7 Time Delay Fused Power

0-BG

AIC Power Ground

0-BG

AIC Power Ground

0-BH

AIC Power Ground Red

13C-A

Fuel Shutoff Fused Power

52A-B

Fan Reverse Relay Out

56-A

Fan Control PWM

225351C1

CAV

225351C1

0-BH

AIC Power Ground Red

13C-A

Fuel Shutoff Fused Power

52A-B

Fan Reverse Relay Out

56-A

CAV

Fan Control PWM

68W-A

Rear Washer Pump

63W-A

Front Washer Pump

Alternator D+

21E-A

Key Switch Crank

31F

Air Filter Restriction Sw Signal

61R

AC Relay Control

61A

31 32

WIRE IDENT

CIRCUIT

55A-A

RTT/Float Switched Power

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

68W-A

Rear Washer Pump

63W-A

Front Washer Pump

Alternator D+

21E-A

Key Switch Crank

31F

Air Filter Restriction Sw Signal

61R

AC Relay Control

Trinary Pressure Switch Input

61A

Trinary Pressure Switch Input

20G-A

EDC7 ISO-K Interface

20G-A

EDC7 ISO-K Interface

36A-A

Rear Axle Temperature

36A-A

Rear Axle Temperature

36F

Fuel Level ANALOG

36F

Fuel Level ANALOG

36C

Radiator Coolant Temp Signal

36C

Radiator Coolant Temp Signal

CONNECTOR ENG - ENGINE TO CAB

19Y-D

Hood Switch Fused Power

19Y-D

Hood Switch Fused Power

60D-A

Hood Down Relay Out

60D-A

Hood Down Relay Out

59D-A

Hood Down Relay Control

59D-A

Hood Down Relay Control

60U-A

Hood Up Relay Out

60U-A

Hood Up Relay Out

59U-A

Hood Up Relay Control

59U-A

Hood Up Relay Control

35A-G

Backup Alarm Relay Out

35A-G

Backup Alarm Relay Out

35A-GN

Backup Alarm Relay Out

35A-GN

Backup Alarm Relay Out

225414C1

CAV

CONNECTOR ENG-D - DISCONECT HARNESS

WIRE IDENT

CIRCUIT

21C-D

Starter Relay signal

61C-A

AC Relay Out

61C-B

AC Relay Out

21GA

EDC7 Crank Control Relay

21H-A

Crank Control Relay LSD

18F-AN

LH Position/Tail Fuse Power

18F-B

LH Position/Tail Fuse Power

Not Used

Backup Alarm Relay Out

35A-R

LH Position/Tail Fuse Power Not Used

35A-R

35A-J

Reverse Light

35A-J

Reverse Light

44A-D

Brake Light Relay Out

44A-D

Brake Light Relay Out

44A-DN

Brake Light Relay Out

44A-DN

Brake Light Relay Out

18G-H

RH Position/Tail Fuse Power

18G-H

RH Position/Tail Fuse Power

18G-HN

RH Position/Tail Fuse Power

45L-A

Left Turn Signal

45L-AN

Left Turn Signal

21F-A

EDC7 Digital Ground

45R-A

Right Turn Signal

Backup Alarm Relay Out

18G-HN

RH Position/Tail Fuse Power

45L-A

Left Turn Signal

CAV

Fuel Shutoff Fused Power

45L-AN

Left Turn Signal

13C-A

Fuel Shutoff Fused Power

13M-A

Fuel Shutoff Fused Power

21F-A

EDC7 Digital Ground

13M-A

Fuel Shutoff Fused Power

13M-B

Key Switch Power Disc Switch

45R-A

Right Turn Signal

13M-B

Key Switch Power Disc Switch

245483C1

CAV

CONNECTOR ENG-D - DISCONECT HARNESS

WIRE IDENT 13C-A

CIRCUIT

245483C1

WIRE IDENT

CIRCUIT

4002-136

CONNECTOR ENG-H - ENGINE TO HOOD

CONNECTOR ESS - ENGINE SPEED SENSOR

291718A1

CAV 225320C1

CAV

WIRE IDENT

CIRCUIT

0-BAG-N

Hood Ground (NA)

44A-DN

Brake Light Relay Out

WIRE IDENT

291718A1

CIRCUIT

CAV 225320C1

25A

Engine Speed Signal

0-HF

Engine Speed Sensor Ground

CONNECTOR ETHR-ETHER-SOLENOID

CAV

WIRE IDENT

CIRCUIT

0-BAG-N

Hood Ground (NA)

44A-DN

Brake Light Relay Out

45L-AN

Left Turn Signal

CIRCUIT

25A

Engine Speed Signal

0-HF

Engine Speed Sensor Ground

CONNECTOR ETHR-ETHER-SOLENOID

45L-AN

Left Turn Signal

45R-AN

Right Turn Signal

45R-AN

Right Turn Signal

18G-HN

RH Position/Tail Fused Pwr

18G-HN

RH Position/Tail Fused Pwr

18F-AN

LH Position/Tail Fused Pwr

18F-AN

LH Position/Tail Fused Pwr

35A-GN

Backup Alarm Relay Out

35A-GN

Backup Alarm Relay Out

35A-R

Backup Alarm Relay Out

35A-R

Backup Alarm Relay Out

CONNECTOR ENG-T - ENGINE TO TRANSMISSION

WIRE IDENT

CONNECTOR ENG-T - ENGINE TO TRANSMISSION 245485C1

CAV

WIRE IDENT

245485C1

CIRCUIT

CAV

ETHER SOL PWR

28P

ETHER SOL PWR

0-BAN

ETHER STRT GRND

0-BAN

ETHER STRT GRND

Not Used

225326C1

WIRE IDENT

0-BZ

2 3 4

CIRCUIT

28P

CAV

WIRE IDENT

225326C1

CAV

WIRE IDENT

CIRCUIT

Sec. Steering Splice Ground

0-BZ

Sec. Steering Splice Ground

0-BK

Transmission Splice Grounds

0-BK

Transmission Splice Grounds

31D-C

Coolant Level Sender Eng Transmission

31D-C

Coolant Level Sender Eng Transmission

Not Used

4002-137 CONNECTOR FLSHR - FLASHER MODULE

CONNECTOR FRONT - CAB FRONT CHASSIS

225389C1

CAV

WIRE IDENT

CONNECTOR FRONT - CAB FRONT CHASSIS

225389C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

373358A1

1-DU

Flasher Module Power

45N-A

Flasher Optional Side Control

0-EH

Flasher Module Ground

0-EG

Flasher Module Ground

Not Used

CAV

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 Optional Side Control

CONNECTOR FM - FILTER MAINTENANCE SWITCH

45L

Left Turn Signal

51B-D

Comfort Steering Sol Power

45R

Right Turn Signal

WIRE IDENT

CIRCUIT

32F

Trans Filter Maint Sw

36R-B

Trans FM Switch Return

Not Used

18G-A

RH Position/Tail Fused Power

18F

LH Position/Tail Fused Power

18B

LH High Beam Fused Power

36B-A

Front Axle Temperature

0-AR

Front Axle Temp Sensor GND

36D-A

54B

53B

RTD Control Signal

Horn Power

18D

LH Low Beam Fused Power

18E

18C

1-DU

Flasher Module Power

45N-A

Flasher Optional Side Control

0-EH

Flasher Module Ground

0-EG

Flasher Module Ground

Not Used

CAV

WIRE IDENT

CIRCUIT

45L

Left Turn Signal

51B-D

Comfort Steering Sol Power

45R

Right Turn Signal

Not Used

18G-A

RH Position/Tail Fused Power

18F

LH Position/Tail Fused Power

18B

LH High Beam Fused Power

36B-A

Front Axle Temperature

0-AR

Front Axle Temp Sensor GND

36D-A

54B

53B

RTD Control Signal

Horn Power

18D

LH Low Beam Fused Power

RH Low Beam Fused Power

18E

RH Low Beam Fused Power

18C

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 Optional Side Control

Height-RTT Control Signal

CONNECTOR FM - FILTER MAINTENANCE SWITCH

Height-RTT Control Signal

RH High Beam Fused Power

Not Used

53P-G

Pilot Control Relay Out

Pin Engage Sol Pwr

58-B

Ride Control Sol Pwr

58S-E

Ride Control Solenoid to Front Cab

1-AA

Brake Lamp Switch Power

Brake Lamp Control Power

52P

Park Brake Relay Out

33P

Low Brake Pressure Warning

19A-A

25G

371614A1

CIRCUIT

CAV

WIRE IDENT

373358A1

RH High Beam Fused Power

53P-G

Pilot Control Relay Out

Pin Engage Sol Pwr

58-B

Ride Control Sol Pwr

58S-E

Ride Control Solenoid to Front Cab

1-AA

Brake Lamp Switch Power

Brake Lamp Control Power

52P

Park Brake Relay Out

33P

Low Brake Pressure Warning

Brake Declutch Sw Fused Pwr

19A-A

Brake Declutch Sw Fused Pwr

Brake Declutch Switch Control

25G

Brake Declutch Switch Control

Not Used

371614A1

CAV

WIRE IDENT

CIRCUIT

32F

Trans Filter Maint Sw

36R-B

Trans FM Switch Return

Not Used

4002-138

CONNECTOR FWM - FRONT WIPER MOTOR

245715C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

63H-A

Front Wiper High Speed Rly Out

63W-A

63L-A

Front Wiper Low Speed Rly Out

0-B

19J-A

Front Wiper Motor Fused Power

63C

Front Wiper Park Control

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

3227856R1

CAV

Front Washer Pump

Front Wiper High Speed Rly Out

63W-A

Front Washer Pump

Front Washer Ground

63L-A

Front Wiper Low Speed Rly Out

0-B

Front Washer Ground

19J-A

Front Wiper Motor Fused Power

63C

Front Wiper Park Control

WIRE IDENT

CIRCUIT

0-DR

Roof Splice GNDS

0-DS

Roof Splice GNDS

CONNECTOR GND-CAB1-GROUD-A

CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

CAV

WIRE IDENT

0-B8

CIRCUIT

0-DR

Roof Splice GNDS

0-DS

Roof Splice GNDS

CONNECTOR GND-CAB2-GROUD-A

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-B6

CAB2 GND

0-B6

CAB2 GND

0-B13

Back Light GND

0-B13

Back Light GND

0-B10

Hood GND

0-B10

Hood GND

245480C1

WIRE IDENT

CONNECTOR GND-CAB2-GROUD-A

CAV

CIRCUIT

63H-A

CAV

WIRE IDENT

CONNECTOR GND-CAB1-GROUD-A CAV

CONNECTOR FWW - FRONT WASHER

245715C1

3227856R1

CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

CONNECTOR FWM - FRONT WIPER MOTOR

CONNECTOR FWW - FRONT WASHER

245480C1

CIRCUIT

CAV

CONNECTOR GND-CAB3-GROUD-C

Front Wiper Ground

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT 0-B8

CIRCUIT

CONNECTOR GND-CAB3-GROUD-C

Front Wiper Ground

CAV

WIRE IDENT

CIRCUIT

0-DG

CAB Splice GNDS

0-DG

CAB Splice GNDS

0-DV

Cigar Lighter GND

0-DV

Cigar Lighter GND

CONNECTOR GND-CAB4-GROUD-C CAV

WIRE IDENT

CIRCUIT

CONNECTOR GND-CAB4-GROUD-C CAV

WIRE IDENT

CIRCUIT

0-ED

HVAC GNDS

0-ED

HVAC GNDS

0-EJ

Power Converter GND

0-EJ

Power Converter GND

0-ER

Power Converter GND

0-ER

Power Converter GND

4002-139 CONNECTOR GND-CAB5-GROUD-C CAV

WIRE IDENT

CAV

CIRCUIT

0-EK

AUX Power Outlet 1 GND

0-EL

AUX Power Outlet 2 GND

WIRE IDENT 0-EQ

CONNECTOR GND-CAB5-GROUD-C

CIRCUIT

0-DJ

AC Relay Control Ground

0-DU

Pilot Pressure Solenoid Gnd

CAV

0-DH

Diagnostic Connector Ground

0-EK

AUX Power Outlet 1 GND

0-EL

AUX Power Outlet 2 GND

CONNECTOR GND-CAB-SPL2 - SPLICE BACK LIGHT GROUND

CONNECTOR GND-CAB6-STRT-FFH-WAT-SEPHTR CAV

WIRE IDENT

4002-139

CIRCUIT

CONNECTOR GND-CAB3D-GROUD-A CAV

WIRE IDENT

CIRCUIT

WIRE IDENT 0-EQ

WIRE IDENT

CIRCUIT

0-DJ

AC Relay Control Ground

0-DU

Pilot Pressure Solenoid Gnd

0-DH

Diagnostic Connector Ground

CONNECTOR GND-CAB-SPL2 - SPLICE BACK LIGHT GROUND

CONNECTOR GND-CAB6-STRT-FFH-WAT-SEPHTR CAV

Splice Pack GND-CAB-SPL2 GND

WIRE IDENT

CAV

CIRCUIT Splice Pack GND-CAB-SPL2 GND

CONNECTOR GND-CAB3D-GROUD-A

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-DP

DIAG TECM GND

0-DP

DIAG TECM GND

0-DQ

DIAG TECM GND

0-DQ

DIAG TECM GND

0-DY

Front AX TEMP SENS GND

0-DY

Front AX TEMP SENS GND

CAV

0-DAV

TECM Diagnostic GND

0-DAV

TECM Diagnostic GND

0-DC

Time Delay Module Ground

0-EA

Time Delay Relay Control Gnd

0-EB

Ignition Relay Control Ground

0-EC

ACC Relay Control Ground

0-DD

Voltmeter Relay Control Gnd

87324393

CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE

CAV

WIRE IDENT

CIRCUIT

0-DC

Time Delay Module Ground

0-EA

Time Delay Relay Control Gnd

0-EB

Ignition Relay Control Ground

0-EC

ACC Relay Control Ground

0-DD

Voltmeter Relay Control Gnd

0-DF

Crank Request Relay Control Gnd

0-DF

Crank Request Relay Control Gnd

0-DE

Neutral Start Relay Control Gnd

0-DE

Neutral Start Relay Control Gnd

0-EQ

Splice Pack Gnd Cab SPL2 GND

0-EQ

Splice Pack Gnd Cab SPL2 GND

CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE

Not Used

0-EH

Flasher Module Ground

0-EH

Flasher Module Ground

0-EG

Flasher Module Ground

0-EG

Flasher Module Ground

0-EF

Brake Lights Relay Control Gnd

0-EF

Brake Lights Relay Control Gnd

CONNECTOR GND-ENG2-WIF-EDC

87324393

WIRE IDENT

CAV

CIRCUIT

87324393

CIRCUIT

0-EE

Diode Suppression Grounds

CAV

0-EM

Radio Ground

0-BP

0-EP

Horn Switch Ground

Not Used

CONNECTOR GND-ENG2-WIF-EDC

87324393

CAV

WIRE IDENT

Not Used

CIRCUIT

0-EE

Diode Suppression Grounds

CAV

WIF Sensor GND

0-EM

Radio Ground

0-BP

WIF Sensor GND

0-BAC

EDC7 GND

0-EP

Horn Switch Ground

0-BAC

EDC7 GND

0-BAM

Ether RLY SGNL GND

Not Used

0-BAM

Ether RLY SGNL GND

Not Used

WIRE IDENT

CIRCUIT

0-DG

Cab Splice Grounds

0-DG

Cab Splice Grounds

0-DT

Front Wiper/Washer Sw Gnd

0-DT

Front Wiper/Washer Sw Gnd

0-DL

Power Converter Relay Ctrl Gnd

0-DL

Power Converter Relay Ctrl Gnd

0-DK

Seat Compressor Motor Ground

0-DK

Seat Compressor Motor Ground

WIRE IDENT

CIRCUIT

4002-140

4002-140 CONNECTOR GND-PDST2-GROUND-A

CONNECTOR GND-ENG3-SPLC-PK-WSHR-MTR CAV

WIRE IDENT

CIRCUIT

0-BM

Engine Splice GNDS

0-BAM

Ether STRT GRND

0-BZ

SEC Steering Splice GND

CONNECTOR GND-ENG6-DEDICATED

CAV 1

WIRE IDENT 0-BG

AIC Power GND

0-BH

AIC Power GND RED

0-BJ

AIC Sensor GND

0-BAR

WIF Body GRND

CAV

WIRE IDENT 0-AP

CAV

WIRE IDENT 0-AP

Cool Level SNDR GND

CIRCUIT

0-BAE

EDC7 Sender GND

0-BM

Engine Splice GNDS

0-BAM

Ether STRT GRND

0-BZ

SEC Steering Splice GND

CONNECTOR GND-ENG6-DEDICATED

0-ND

CIRCUIT SSM Ground

0-BG

AIC Power GND

0-BH

AIC Power GND RED

0-BJ

AIC Sensor GND

0-BAR

WIF Body GRND

0-BAF

Cool Level SNDR GND

0-BAE

EDC7 Sender GND

0-BU

Fuel Level Sender GND

0-BU

Fuel Level Sender GND

0-BAS

Rear AX TEMP SENS GND

0-BAS

Rear AX TEMP SENS GND

0-BK

TRANS Splice GNDS

0-BK

TRANS Splice GNDS

CAV 1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT 0-CE

CONNECTOR GND-FC-GROUND-A

CIRCUIT SEC Steering Chassis GND

WIRE IDENT

CIRCUIT

0-AG

Front Chassis GND

0-AG

Front Chassis GND

0-AK

Park Brake /Warning GND

0-AK

Park Brake /Warning GND

0-AB

PROX SW GND

0-AB

PROX SW GND

CONNECTOR GND-PDST-GROUND-A CAV 1

WIRE IDENT 0-BA

CIRCUIT Pedestal GND STRAP

CONNECTOR GND-PDST-GROUND-A CAV 1

CONNECTOR GND-PDST1-GROUND-A CAV 1

WIRE IDENT 0-DA

CIRCUIT AIC Chassis GND

WIRE IDENT 0-BA

CIRCUIT Pedestal GND STRAP

CONNECTOR GND-PDST1-GROUND-A CAV 1

WIRE IDENT 0-DA

WIRE IDENT 0-AP

CIRCUIT Front to Rear Chassis GND

CONNECTOR GND-S2-GROUND-A CAV

WIRE IDENT 0-AP

CIRCUIT Front to Rear Chassis GND

CONNECTOR GND-SSCHAS-SSM-GROUND-CABLE CAV 1

CIRCUIT AIC Chassis GND

WIRE IDENT 0-ND

CIRCUIT SSM Ground

CONNECTOR GND-SSMOD-SEC-STR-CHASSIS-GND CAV 1

CAV

Pedestal GND STRAP

CIRCUIT

CONNECTOR GND-FC-GROUND-A

CAV

CONNECTOR GND-ENG7-TRANNY-COOL-TEMP WIRE IDENT

0-BA

CIRCUIT

CONNECTOR GND-S1-GROUND-A

CONNECTOR GND-SSMOD-SEC-STR-CHASSIS-GND

WIRE IDENT

CIRCUIT

CAV WIRE IDENT

CAV

1 WIRE IDENT

Front to Rear Chassis GND

CONNECTOR GND-SSCHAS-SSM-GROUND-CABLE CAV

CIRCUIT

Front to Rear Chassis GND

CIRCUIT

0-BAF

WIRE IDENT

CIRCUIT

CONNECTOR GND-S2-GROUND-A

CONNECTOR GND-ENG7-TRANNY-COOL-TEMP

CAV

WIRE IDENT

Pedestal GND STRAP

CIRCUIT

CAV

0-BA

CIRCUIT

CONNECTOR GND-S1-GROUND-A

1 CAV

WIRE IDENT

CONNECTOR GND-PDST2-GROUND-A

CONNECTOR GND-ENG3-SPLC-PK-WSHR-MTR

WIRE IDENT 0-CE

CIRCUIT SEC Steering Chassis GND

4002-141 CONNECTOR HD-9-HOOD TO ENG

CONNECTOR HD-HOOD SWITCH

245485C1

CAV

WIRE IDENT

245485C1

CIRCUIT

59D-A

Hood Down RLY CTRL

19Y-D

Hood Switch FSD PWR

CAV

225319C1

CAV

WIRE IDENT

0-LA

Rear Light GND

SPL-L1

Brake Light PWR

CIRCUIT

59D-A

Hood Down RLY CTRL

19Y-D

Hood Switch FSD PWR

59U-A

Hood UP RLY CTRL

225319C1

CIRCUIT

WIRE IDENT

59U-A

Hood UP RLY CTRL

CAV

CONNECTOR HD-N - HOOD TO ENGINE

WIRE IDENT

CIRCUIT

0-LA

Rear Light GND

SPL-L1

Brake Light PWR

CONNECTOR HD-N - HOOD TO ENGINE

45L-9

Left Turn SGNL

45L-9

Left Turn SGNL

45R-9

Right Turn SGNL

45R-9

Right Turn SGNL

18G-K

RH POSN/TAIL Fused PWR

18G-K

RH POSN/TAIL Fused PWR

18F-F

LH POSN/TAIL Fused PWR

18F-F

LH POSN/TAIL Fused PWR

35A-9

Backup Alarm PWR

35A-9

Backup Alarm PWR

35A-M

Reverse Light

35A-M

Reverse Light

CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS

225319C1

CAV

245484C1

CAV

WIRE IDENT

CIRCUIT

18G-E

License Plate Light Fused Pwr

35A-H

0-JA

WIRE IDENT

225319C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-JA-N

Hood Grounds (NA)

0-JA-N

Hood Grounds (NA)

44A-EN

Brake Light relay Out

44A-EN

Brake Light relay Out

45L-BN

Left Turn Signal

45L-BN

Left Turn Signal

45R-BN

Right Turn Signal

45R-BN

Right Turn Signal

18G-JN

RH Position/Tail Fused Power

18G-JN

RH Position/Tail Fused Power

18F-BN

LH Position/Tail Fused Power

18F-BN

LH Position/Tail Fused Power

35A-HN

Backup Alarm Relay Out

35A-HN

Backup Alarm Relay Out

245484C1

CAV

WIRE IDENT

CIRCUIT

18G-E

License Plate Light Fused Pwr

Backup Alarm Relay Out

35A-H

Backup Alarm Relay Out

Hood Ground (EURO)

0-JA

Hood Ground (EURO)

4002-142

CONNECTOR HDM-HOOD-LIFT-MOTOR

225316C1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR HDM-HOOD-LIFT-MOTOR

CONNECTOR HOT-RA-REAR-AX-OIL-TEMP

225316C1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR HOT-RA-REAR-AX-OIL-TEMP

225316C1

CAV

WIRE IDENT

CIRCUIT

225316C1

CAV

WIRE IDENT

CIRCUIT

60U-A

Hood UP RLY Out

36A-A

Rear Axle TEMP

60U-A

Hood UP RLY Out

36A-A

Rear Axle TEMP

60D-A

Hood Down RLYOut

0-BAS

Rear Axle TEMP

60D-A

Hood Down RLYOut

0-BAS

Rear Axle TEMP

CONNECTOR HN1-HORN-PWR CAV 1

WIRE IDENT 64

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

CONNECTOR HN1-HORN-PWR

CIRCUIT

CAV

Horn Power

CONNECTOR HN2-HORN-GRND CAV 1

WIRE IDENT 0-AF

WIRE IDENT

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

CIRCUIT Horn Power

CONNECTOR HN2-HORN-GRND

CIRCUIT

CAV 194788A1

Horn GND CAV

CONNECTOR HOT-FA-FRNT-AX-OIL-TEMP

WIRE IDENT

36H

0-HW

WIRE IDENT 0-AF

CIRCUIT 194788A1

Horn GND

CIRCUIT

CAV

Hydraulic Oil Temp Signal

CONNECTOR HOT-FA-FRNT-AX-OIL-TEMP

Hydraulic Oil Temp Ground

36H

0-HW

CONNECTOR HVAC1 - HVAC1

WIRE IDENT

CIRCUIT Hydraulic Oil Temp Signal Hydraulic Oil Temp Ground

CONNECTOR HVAC1 - HVAC1

225316C1

CAV

WIRE IDENT

225316C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

225295C1

36B-A

Front Axle TEMP

0-AR

Front AX TEMP SENS GND

CAV

WIRE IDENT

225295C1

36B-A

Front Axle TEMP

0-AR

Front AX TEMP SENS GND

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

61A-B

Trinary Pressure Switch Input

61A-B

Trinary Pressure Switch Input

18N-A

Blower Motor Fused Power

18N-A

Blower Motor Fused Power

49A

Back Light Power

49A

Back Light Power

4002-143 CONNECTOR HVAC2 - HVAC2

CONNECTOR ISS - INT-SPEED-SENSOR

291718A1

CAV 87552622

CAV

WIRE IDENT

CIRCUIT

0-ED

HVAC Grounds

18N-B

Blower Motor Fused Power

WIRE IDENT

291718A1

CIRCUIT

25B

INT Speed Signal

0-HG

INT Speed Sensor Ground

CAV 87552622

CAV

WIRE IDENT

CIRCUIT

0-ED

HVAC Grounds

18N-B

Blower Motor Fused Power

CIRCUIT

25B

INT Speed Signal

0-HG

INT Speed Sensor Ground

CONNECTOR K-WCO - WIPER CUTOUT CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC

WIRE IDENT

CONNECTOR K-WCO - WIPER CUTOUT CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC

245731C1

CAV

87315267

CAV

WIRE IDENT

CIRCUIT

CAN-HK

CAN High

CAN-LL

CAN Low

WIRE IDENT

63L-B

Front Wiper LS Relay Out

63HC-A

Wiper Cut Out Relay Control

19J-G

Wiper Cut Out Relay Fused Pwr Not Used

87A

63C3

Front Wiper Park Control

CONNECTOR L1-ECC-ECC-BATT-PWR CAV Cs01

WIRE IDENT 1-C

245731C1

CIRCUIT

CIRCUIT ECC BAT PWR

CAV

87315267

CAV

WIRE IDENT

CIRCUIT

CAN-HK

CAN High

CAN-LL

CAN Low

WIRE IDENT

CIRCUIT

63L-B

Front Wiper LS Relay Out

63HC-A

Wiper Cut Out Relay Control

19J-G

Wiper Cut Out Relay Fused Pwr Not Used

87A

63C3

Front Wiper Park Control

CONNECTOR L1-ECC-ECC-BATT-PWR CAV Cs01

WIRE IDENT 1-C

CIRCUIT ECC BAT PWR

4002-144

4002-144 CONNECTOR LDM2-DOME LIGHT AUTO

CONNECTOR LBEE - LIGHT BEACON EXTESION

CAV 1

WIRE IDENT 43-B

CONNECTOR LDM2-DOME LIGHT AUTO

CONNECTOR LBEE - LIGHT BEACON EXTESION

CIRCUIT

CAV

Dome LT AUTO MODE

CONNECTOR LDM3-DOME LIGHT GND CAV 1

291730A1

CAV

WIRE IDENT

WIRE IDENT 0-MB

CAV

Dome Light GND

291730A1

CONNECTOR LLF - LH FRONT LIGHTS CAV

WIRE IDENT

46-E

Beacon Light Power

46-E

Beacon Light Power

0-MD

Beacon Light Ground

0-MD

Beacon Light Ground

CONNECTOR LBEG-LIGHT BEACON GRND

WIRE IDENT 0-MD

Dome LT AUTO MODE

WIRE IDENT 0-MB

CIRCUIT Dome Light GND

CONNECTOR LLF - LH FRONT LIGHTS

CIRCUIT

CAV

43-B

CIRCUIT

CONNECTOR LDM3-DOME LIGHT GND

CIRCUIT

WIRE IDENT

CONNECTOR LBEG-LIGHT BEACON GRND

CIRCUIT

CAV

Beacon Light GND

WIRE IDENT 0-MD

CIRCUIT Beacon Light GND

225351C1

CAV

CONNECTOR LBEGRD-LIGHT BEACON GRND CAV 1

WIRE IDENT 0-MC

CIRCUIT Beacon Light GND

CONNECTOR LBEP-LIGHT BEACON PWR CAV 1

WIRE IDENT 46-E

CIRCUIT

WIRE IDENT

0-AJ

Lights Ground LH

18D

Low Beam LH

CAV

CONNECTOR LBEGRD-LIGHT BEACON GRND

18B

High Beam LH

CAV

18F

Position LH Fused Power

45L

Left Turn Signal

Not Used

WIRE IDENT 46-D

WIRE IDENT 0-MC

CIRCUIT Beacon Light GND

CONNECTOR LBEP-LIGHT BEACON PWR

CONNECTOR LLFW - LH FRONT WORK LAMP

Beacon Light PWR

CAV 1

CONNECTOR LBEPWR-LIGHT BEACON PWR CAV

225351C1

CIRCUIT

WIRE IDENT 46-E

CIRCUIT

WIRE IDENT

CIRCUIT

0-AJ

Lights Ground LH

18D

Low Beam LH

18B

High Beam LH

18F

Position LH Fused Power

45L

Left Turn Signal

Not Used

CONNECTOR LLFW - LH FRONT WORK LAMP

Beacon Light PWR

CONNECTOR LBEPWR-LIGHT BEACON PWR

CIRCUIT

CAV

Beacon SW PWR

WIRE IDENT 46-D

CIRCUIT Beacon SW PWR

245483C1

CONNECTOR LDM1-DOME LIGHT B+

CAV A

CAV 1

WIRE IDENT 19U-C

CIRCUIT Dome LT FSD PWR

WIRE IDENT 42C-H 0-MU

245483C1

CONNECTOR LDM1-DOME LIGHT B+

CIRCUIT LH Front Work Lamp Power LH Front Work Lamp Ground

CAV 1

WIRE IDENT 19U-C

CIRCUIT Dome LT FSD PWR

CAV

WIRE IDENT

CIRCUIT

42C-H

LH Front Work Lamp Power

0-MU

LH Front Work Lamp Ground

4002-145 CONNECTOR LLR-9 - LH REAR COMBINATION LAMP

CONNECTOR LLRW- LH REAR WORK LAMP

4002-145 CONNECTOR LLR-9 - LH REAR COMBINATION LAMP

CONNECTOR LLRW- LH REAR WORK LAMP

245483C1 225351C1

CAV

WIRE IDENT

CIRCUIT

44A-L

Brake Light Power

45L-9

Left Turn Signal

18F-F

Left Tail Fused Power

35A-N

Reverse Lamp

0-LB

CAV

WIRE IDENT

245483C1

CIRCUIT

225351C1

42R-H

LH Rear Work Lamp Fused Pwr

0-ME

LH Rear Work Lamp Ground

CAV

WIRE IDENT

CIRCUIT

44A-L

Brake Light Power

45L-9

Left Turn Signal

18F-F

Left Tail Fused Power

35A-N

Reverse Lamp

LH Rear Ground

0-LB

LH Rear Ground

Not Used

CONNECTOR LPL - LICENSE PLATE LAMP

CONNECTOR LLR-N - LH REAR COMBINATION LAMP

CAV

WIRE IDENT

CIRCUIT

42R-H

LH Rear Work Lamp Fused Pwr

0-ME

LH Rear Work Lamp Ground

CONNECTOR LPL - LICENSE PLATE LAMP

Not Used

CONNECTOR LLR-N - LH REAR COMBINATION LAMP

245482C1

CAV

WIRE IDENT

245482C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

18G-E

License Plate Lamp Fused Pwr

18G-E

License Plate Lamp Fused Pwr

18G-EN

License Plate Lamp Fused Pwr

18G-EN

License Plate Lamp Fused Pwr

0-JC

License Plate Lamp Ground

0-JC

License Plate Lamp Ground

245715C1

CAV

WIRE IDENT

245715C1

CAV

WIRE IDENT

CIRCUIT

44A-FN

Brake Lamp Relay Out

44A-FN

Brake Lamp Relay Out

18F-BN

LH Tail Lamp Fused Pwr

18F-BN

LH Tail Lamp Fused Pwr

45L-BN

Left Turn Signal

45L-BN

Left Turn Signal

0-BR-N

LH Rear Light Ground (NA)

0-BR-N

LH Rear Light Ground (NA)

4002-146

CONNECTOR LRF - RH FRONT COMBINATION LAMP

CONNECTOR LRR-9 - RH REAR COMBINATION LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR LRF - RH FRONT COMBINATION LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR LRR-9 - RH REAR COMBINATION LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

225351C1

CAV

WIRE IDENT

CIRCUIT

0-AH

RH Front Lights Ground

44A-K

Brake Light Power

0-AH

RH Front Lights Ground

44A-K

Brake Light Power

18E

RH Low Beam Fused Pwr

45R-9

Right Turn Signal

18E

RH Low Beam Fused Pwr

45R-9

Right Turn Signal

18C

RH High Beam Fused Pwr

18G-M

Right Position/Tail Fused Pwr

18C

RH High Beam Fused Pwr

18G-M

Right Position/Tail Fused Pwr

18G-A

RH Position/Tail Fused Pwr

35A-P

Reverse Lamp

18G-A

RH Position/Tail Fused Pwr

35A-P

Reverse Lamp

45R

Right Turn Signal

0-BR

Rear LH Ground

45R

Right Turn Signal

0-BR

Rear LH Ground

Not Used

CONNECTOR LRFW - RH FRONT WORK LAMP

CONNECTOR LRR-N - RH REAR COMBINATION LAMP

CONNECTOR LRFW - RH FRONT WORK LAMP

245483C1

CAV

WIRE IDENT 42C-G

RH Front Work Lamp Fused Pwr

0-MJ

RH Front Work Lamp Ground

CONNECTOR LRR-N - RH REAR COMBINATION LAMP

245483C1

CIRCUIT

Not Used

CAV 245715C1

CAV A

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

42C-G

RH Front Work Lamp Fused Pwr

0-MJ

RH Front Work Lamp Ground

245715C1

CAV

44A-GN

Brake Lamp Relay Out

18G-CN

RH Position/Tail Lamp Fused Pwr

45R-BN

Right Turn Signal

0-BT-N

RH Rear Light Ground (NA)

WIRE IDENT

CIRCUIT

44A-GN

Brake Lamp Relay Out

18G-CN

RH Position/Tail Lamp Fused Pwr

45R-BN

Right Turn Signal

0-BT-N

RH Rear Light Ground (NA)

4002-147 CONNECTOR LRRW - RH REAR WORK LAMP

CONNECTOR LRRW - RH REAR WORK LAMP

CONNECTOR P-A1-B+ POWER CAV 1

WIRE IDENT 1-C

4002-147

CIRCUIT

CONNECTOR P-A1-B+ POWER CAV

ECC BAT PWR

1-C

CONNECTOR P-A3-B+ POWER CAV

WIRE IDENT

CIRCUIT

CAV

1CB-A

CAB CB Protected PWR

CIRCUIT

CAV

42R-G

RH Rear Work Lamp Fused Pwr

0-MF

RH Rear Work Lamp Ground

CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

WIRE IDENT 42R-G

RH Rear Work Lamp Fused Pwr

0-MF

RH Rear Work Lamp Ground

65L

Left Speaker Signal

0-PA

Left Speaker Ground

291718A1

CAV

CONNECTOR OSS - OUTPUT SPEED SENSOR

WIRE IDENT

CIRCUIT

31F

Air Filter Restriction Switch Signal

0-BY

Air Filter Restriction Switch Grnd

CAV

WIRE IDENT

CIRCUIT

65L

Left Speaker Signal

0-PA

Left Speaker Ground

291718A1

CAV

CONNECTOR OSS - OUTPUT SPEED SENSOR

0-HE

Output Speed Ground

25D

Output Speed Signal

19A

Output Speed Fused Pwr

CIRCUIT

31F

Air Filter Restriction Switch Signal

0-BY

Air Filter Restriction Switch Grnd

291719A1

CIRCUIT

WIRE IDENT

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

291719A1

WIRE IDENT

CAB CB Protected PWR

CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

CAV

1CB-A

195552A1

CIRCUIT

CONNECTOR LSPK - LEFT SPEAKER

195552A1

WIRE IDENT

CIRCUIT

CONNECTOR LSPK - LEFT SPEAKER

CAV

ECC BAT PWR

245483C1

1 WIRE IDENT

CIRCUIT

CONNECTOR P-A3-B+ POWER

245483C1

CAV

WIRE IDENT

245482C1

CAV A B

WIRE IDENT 19A-A 25G

CIRCUIT Brake Declutch Sw Fused Pwr Brake Declutch Switch Control

CAV

WIRE IDENT

CIRCUIT

0-HE

Output Speed Ground

25D

Output Speed Signal

19A

Output Speed Fused Pwr

245482C1

CAV

WIRE IDENT

CIRCUIT

19A-A

Brake Declutch Sw Fused Pwr

25G

Brake Declutch Switch Control

4002-148

4002-148 CONNECTOR PHF-HYD OIL FILT RES SW

CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH

CAV 1

WIRE IDENT 31H

CONNECTOR PHF-HYD OIL FILT RES SW

CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH

CIRCUIT

CAV

HYD FLTR REST SW SGNL

CONNECTOR PO1 - POWER OUTLET

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

1-AA

Brake Lamp Switch Power

1-AA

Brake Lamp Switch Power

Brake Lamp Control Power

CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH

12176446

CAV A

WIRE IDENT 12V

B C

0-EK

CIRCUIT

12176446

CAV

12V Pwr to Outlet 1

Not Used

Aux Power Outlet 1 Gnd

CONNECTOR PO2 - POWER OUTLET

CIRCUIT

CAV

WIRE IDENT

Low Brake Press Warning

33P

Low Brake Press Warning

0-AL

Brake Press Warn Sw Ground

0-AL

Brake Press Warn Sw Ground

CONNECTOR P-C5-B+ PWR-FRM-PRMC

1-B9

CAV

PRM C PWR

12176446

CAV A

WIRE IDENT 12V

B CAV 1

WIRE IDENT 36D-B

CIRCUIT Rear Axle FLTR SNSR

Not Used 0-EK

Aux Power Outlet 1 Gnd

CONNECTOR P-C5-B+ PWR-FRM-PRMC

CIRCUIT

CONNECTOR PFA-FRONT AXLE FILTER

12V Pwr to Outlet 1

CIRCUIT

33P

WIRE IDENT

12V

CIRCUIT

225316C1

CAV

WIRE IDENT

CONNECTOR PO2 - POWER OUTLET

225316C1

WIRE IDENT

HYD FLTR REST SW SGNL

222136A1

CAV

31H

CIRCUIT

CONNECTOR PO1 - POWER OUTLET

222136A1

CAV

WIRE IDENT

WIRE IDENT 1-B9

CIRCUIT PRM C PWR

CIRCUIT

CAV

12V Pwr to Outlet 2

CONNECTOR PFA-FRONT AXLE FILTER

Not Used 0-EK

Aux Power Outlet 2 Gnd

12176446

WIRE IDENT 12V

B CAV 1

WIRE IDENT 36D-B

CIRCUIT Rear Axle FLTR SNSR

CIRCUIT 12V Pwr to Outlet 2 Not Used

0-EK

Aux Power Outlet 2 Gnd

4002-149 CONNECTOR PR - TRINARY PRESSURE SWITCH

CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

4002-149 CONNECTOR PR - TRINARY PRESSURE SWITCH

CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

245483C1 182068A1

CAV

WIRE IDENT

61-A

Trinary Pressure Switch Input

61R

AC Relay Control

CONNECTOR PRA-REAR AXLE FILTER CAV 1

WIRE IDENT 36D-C

CAV

WIRE IDENT

CIRCUIT

245483C1 182068A1

CIRCUIT CAV

WIRE IDENT

33R-B

RDNT Brake Accumulator Press Low

61-A

Trinary Pressure Switch Input

0-HL

Ground

61R

AC Relay Control

CONNECTOR PRA-REAR AXLE FILTER

CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH

CIRCUIT

CAV

Front Axle FLTR SNSR

CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

WIRE IDENT 36D-C

CAV

WIRE IDENT

CIRCUIT

33R-B

RDNT Brake Accumulator Press Low

0-HL

Ground

CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH

CIRCUIT Front Axle FLTR SNSR

CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

245483C1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Ride Control Solenoid Power

58-B

Ride Control Solenoid Power

58-B

Ride Control Solenoid Power

CONNECTOR PRM-A1 - PRM SIGNAL

245483C1

CAV

WIRE IDENT

245483C1

CONNECTOR PRM-A1 - PRM SIGNAL

245483C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

33R-C

RDNT Brake Accumulator Press Low

33R-C

RDNT Brake Accumulator Press Low

0-HM

Ground

0-HM

Ground

256340A1

CAV

WIRE IDENT

CIRCUIT

256340A1

CAV

WIRE IDENT

CIRCUIT

13K-B

Ignition Switch Power

13K-B

Ignition Switch Power

0-EB

Ignition Relay Control Ground

0-EB

Ignition Relay Control Ground

4002-150

CONNECTOR PRM-B1 - PRM SIGNAL

CONNECTOR PRM-C2 - PRM SIGNAL

409084A1

CAV

WIRE IDENT

A C

409084A1

CIRCUIT

CAV

Not Used 13H

256340A1

Time Delay Power

CAV

CONNECTOR PRM-B2 - PRM SIGNAL

CONNECTOR PRM-C2 - PRM SIGNAL

WIRE IDENT

A C

CIRCUIT

28E

Ether Relay Signal

28F

Fuel Filter Heater Relay Control

0-BAM

Ether Relay Signal Ground

0-BN

Filter Heater Control

WIRE IDENT

CIRCUIT Not Used

13H

256340A1

Time Delay Power

CAV

CONNECTOR PRM-B2 - PRM SIGNAL

28E

Ether Relay Signal

28F

Fuel Filter Heater Relay Control

0-BAM

Ether Relay Signal Ground

0-BN

Filter Heater Control

CONNECTOR PRM-D1 - PRM SIGNAL

256340A1

WIRE IDENT

CIRCUIT

CONNECTOR PRM-D1 - PRM SIGNAL

CAV

WIRE IDENT

256340A1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

13D

Time Delay Relay Control Pwr

13D

Time Delay Relay Control Pwr

0-EA

Time Delay Relay Control Gnd

0-EA

Time Delay Relay Control Gnd

256340A1

CONNECTOR PRM-C1 - PRM OUTPUT

CAV

WIRE IDENT

256340A1

CIRCUIT

CONNECTOR PRM-C1 - PRM OUTPUT

CAV

12ACC-B

ACC PRM Control Power

12ACC-B

ACC PRM Control Power

0-EC

ACC Relay Control Ground

0-EC

ACC Relay Control Ground

CONNECTOR PRM-E1 - PRM SIGNAL

409084A1

WIRE IDENT

CIRCUIT

CONNECTOR PRM-E1 - PRM SIGNAL

CAV

WIRE IDENT

409084A1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

18R

Voltmeter Relay Fused Pwr

18R

Voltmeter Relay Fused Pwr

28P

Ether Solenoid Power

28P

Ether Solenoid Power

1-GA

Filter Heater Power

1-GA

Filter Heater Power

409084A1

CAV

WIRE IDENT

A C

19L

CIRCUIT

409084A1

CAV

Not Used

Power Converter FSD Power

WIRE IDENT

CIRCUIT Not Used

19L

Power Converter FSD Power

4002-151 CONNECTOR PRM-E2 - PRM SIGNAL

CONNECTOR PXH - HEIGHT CONTROL RTT

245485C1

CAV 256340A1

CAV

WIRE IDENT

CIRCUIT

12ACC-C

Pwr Converter PRM Control Pwr

0-DL

Pwr Converter Relay Ctrl Gnd

WIRE IDENT 54B

CIRCUIT

CAV 256340A1

RTT Signal

0-AA

Proximity Switch Ground

53P-J

Pilot Control Relay Out

CAV

CONNECTOR PXM - RTD

CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

245485C1

WIRE IDENT

CIRCUIT

12ACC-C

Pwr Converter PRM Control Pwr

0-DL

Pwr Converter Relay Ctrl Gnd

WIRE IDENT 54B

CIRCUIT RTT Signal

0-AA

Proximity Switch Ground

53P-J

Pilot Control Relay Out

CONNECTOR PXM - RTD

CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

245485C1 245485C1

CAV A

CIRCUIT

Secondary Steer High Pressure

B C

WIRE IDENT 51P-A

CAV

0-CC

Sec. Steer Press Switch Ground

35X-A

Secondary Steer Low Press Sig

WIRE IDENT 53B-A

245485C1

CIRCUIT

245485C1

RTD Control Signal

CAV

0-AM

RTD Ground

53P-I

Pilot Control Relay Out

Secondary Steer High Pressure

0-AM

RTD Ground

53P-I

Pilot Control Relay Out

0-CC

Sec. Steer Press Switch Ground

35X-A

Secondary Steer Low Press Sig

53B-A

CIRCUIT

CONNECTOR PXT - RTD

CONNECTOR PXF - RTD

WIRE IDENT

CIRCUIT

WIRE IDENT 51P-A

CAV

RTD Control Signal

CONNECTOR PXT - RTD

CONNECTOR PXF - RTD

245485C1

CAV CAV

WIRE IDENT

CIRCUIT

53B

RTD Signal

0-AC

Proximity Switch Ground

53P-H

Pilot Control Relay Out

WIRE IDENT

CIRCUIT

53B-A

RTD Control Signal

0-AM

RTD Ground

53P-I

Pilot Control Relay Out

CAV CAV

WIRE IDENT

CIRCUIT

53B

RTD Signal

0-AC

Proximity Switch Ground

53P-H

Pilot Control Relay Out

WIRE IDENT

CIRCUIT

53B-A

RTD Control Signal

0-AM

RTD Ground

53P-I

Pilot Control Relay Out

4002-152

CONNECTOR QSM11-ENGINE CONTROLLER CAV

WIRE IDENT

CONNECTOR RAD-J1 - RADIO POWER

CIRCUIT

CONNECTOR QSM11-ENGINE CONTROLLER CAV

WIRE IDENT

CIRCUIT

18J-M

QSM11 Time Delay PWR

18J-M

QSM11 Time Delay PWR

18J-N

QSM11 Time Delay PWR

18J-N

QSM11 Time Delay PWR

18J-L

QSM11 Time Delay PWR

18J-L

QSM11 Time Delay PWR

18J-P

QSM11 Time Delay PWR

18J-P

QSM11 Time Delay PWR

18J-Q

QSM11 Time Delay PWR

18J-Q

QSM11 Time Delay PWR

0-BAH

QSM11 GND

0-BAH

QSM11 GND

0-BAI

QSM11 GND

0-BAI

QSM11 GND

CAN-LM

CAN Low from ENG

CAN-LM

CAN Low from ENG

13M-B

KEY SW PWR DISC SW

38 39

13M-B 0-BAJ

292497A1

KEY SW PWR DISC SW QSM11 GND

0-BAJ

QSM11 GND

CAV

Not Used

0-BAK

QSM11 GND

Not Used

0-BAL

QSM11 GND

Not Used

CAN-HJ

CAN High from ENG

0-BAK

QSM11 GND

0-BAL

QSM11 GND

CAN-HJ

CAN High from ENG

3 RAD3

CIRCUIT

292497A1

CAV 1

WIRE IDENT

CONNECTOR RAD-J1 - RADIO POWER

12V Fused Power to Radio

24B-A

Throt Signal

WIRE IDENT

CIRCUIT

Not Used

24B-A

Throt Signal

24S-A

Throt Supply

Not Used

24S-A

Throt Supply

Not Used

24R-A

Throt GND

Not Used

24R-A

Throt GND

Not Used

0-BAP

QSM11 GRND

RAD2

12V Fused Power to Radio

0-BAP

QSM11 GRND

RAD2

12V Fused Power to Radio

RAD1

Radio Ground

RAD1

Radio Ground

CONNECTOR RAD - RADIO POWER

CONNECTOR RAD-J2 - SPEAKER

292495A1

WIRE IDENT

Not Used

3 4

Not Used 12V-HB

12V Fused Power to Radio Not Used

292495A1 292501A1

CIRCUIT Not Used

12V Fused Power to Radio

CONNECTOR RAD - RADIO POWER CONNECTOR RAD-J2 - SPEAKER

CAV

RAD3

Not Used

12V-HA

12V Fused Power to Radio

0-EN

Radio Ground

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

CAV

WIRE IDENT

Not Used

12V-HB

12V Fused Power to Radio Not Used

292501A1

CIRCUIT

Not Used

12V-HA

12V Fused Power to Radio

0-EN

Radio Ground

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

4002-153 CONNECTOR RFLG-FUEL SEND GRND

CONNECTOR RAD-J3 - RADIO JUMPER CAV 1

WIRE IDENT

WIRE IDENT 0-BU

CONNECTOR RFLG-FUEL SEND GRND

CONNECTOR RAD-J3 - RADIO JUMPER

CIRCUIT

CAV

Fuel Level Sender GRND

CONNECTOR ROOF - ROOF TO CAB CONNECTION

411311A1

CAV

4002-153

CAV

WIRE IDENT

0-BU

CIRCUIT Fuel Level Sender GRND

CONNECTOR ROOF - ROOF TO CAB CONNECTION

411311A1

CIRCUIT

WIRE IDENT

CIRCUIT

RAD10

Right Speaker Ground

RAD10

Right Speaker Ground

RAD8

Not Used

RAD8

Not Used

RAD4

Left Speaker Ground

RAD4

Left Speaker Ground

RAD6

Not Used

RAD6

Not Used

RAD1

Radio Ground

RAD1

Radio Ground

RAD3

12V Fused Power to Radio

CAV

RAD3

12V Fused Power to Radio

CAV

RAD11

Right Speaker

43-B

Dome Light Auto Mode

RAD11

Right Speaker

43-B

Dome Light Auto Mode

RAD9

Not Used

42R-F

Rear Work Light Fused Power

RAD9

Not Used

42R-F

Rear Work Light Fused Power

RAD5

Left Speaker

42C-F

Front Work Lights Fused Power

RAD5

Left Speaker

42C-F

Front Work Lights Fused Power

RAD7

Not Used

19U-C

Done Light Fused Power

RAD7

Not Used

19U-C

Done Light Fused Power

RAD2

12V Fused Power to Radio

46-D

Beacon Switch Power

RAD2

12V Fused Power to Radio

46-D

Beacon Switch Power

Not Used

0-MN

Roof Grounds

Not Used

0-MN

Roof Grounds

Not Used

0-MK

Roof Grounds

Not Used

0-MK

Roof Grounds

19K-D

Rear Wiper Motor Fused Power

19K-D

Rear Wiper Motor Fused Power

68C-A

Rear Wiper Park Control

68C-A

Rear Wiper Park Control

68L-A

Rear Wiper Switched Power

68L-A

Rear Wiper Switched Power

0-EN

Radio Ground

0-EN

Radio Ground

12V-H

12V Fused Power to Radio

12V-H

12V Fused Power to Radio

43S-B

Door Open Signal

43S-B

Door Open Signal

19U-F

Door Switch Fused Power

19U-F

Door Switch Fused Power

Not Used

388708A1

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

WIRE IDENT

CIRCUIT

Not Used

388708A1

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

CONNECTOR RSPK - RIGHT SPEAKER

WIRE IDENT

CIRCUIT

CONNECTOR RSPK - RIGHT SPEAKER

194788A1

CAV

WIRE IDENT

194788A1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

36C

Radiator Coolant Temp Signal

36C

Radiator Coolant Temp Signal

0-BAE

EDC7 Sender Ground

0-BAE

EDC7 Sender Ground

CONNECTOR RFL-FUEL SENDER

CONNECTOR RFL-FUEL SENDER 195552A1

CAV 1

WIRE IDENT 36F

CIRCUIT Fuel Level Analog

CAV

WIRE IDENT

CIRCUIT

65R

Right Speaker Signal

0-PB

Right Speaker Ground

195552A1

CAV 1

WIRE IDENT 36F

CIRCUIT Fuel Level Analog

CAV

WIRE IDENT

CIRCUIT

65R

Right Speaker Signal

0-PB

Right Speaker Ground

4002-154

CONNECTOR RTHP - THROTTLE PEDAL

CONNECTOR RWMG - REAR WIPER MOTOR GROUND

225351C1

CAV 1

WIRE IDENT 21F-C

CONNECTOR RWMG - REAR WIPER MOTOR GROUND

225351C1

CIRCUIT

245480C1

EDC7 DIGITAL Ground

CAV

Not Used

WIRE IDENT 0-MA

CAV 1

CIRCUIT Rear Wiper Motor Ground

WIRE IDENT 21F-C

CIRCUIT

245480C1

EDC7 DIGITAL Ground

CAV

Not Used

24B

Throttle Signal

24B

Throttle Signal

24B-A

Throttle Signal

24B-A

Throttle Signal

24R

Throttle Position Sensor Ground

24R

Throttle Position Sensor Ground

CONNECTOR RWW - REAR WASHER

0-MA

CIRCUIT Rear Wiper Motor Ground

CONNECTOR RWW - REAR WASHER

24R-A

Throttle Position Sensor Ground

24R-A

Throttle Position Sensor Ground

24S

Throttle Supply

24S

Throttle Supply

24S-A

Throttle Supply

24S-A

Throttle Supply

24L

Low Idle Switch

24L

Low Idle Switch

CONNECTOR RWM - REAR WIPER MOTOR

WIRE IDENT

CONNECTOR RWM - REAR WIPER MOTOR

3227856R1

CAV

WIRE IDENT

3227856R1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

68W-A

Rear Washer Pump

68W-A

Rear Washer Pump

0-BL

Rear Washer Ground

0-BL

Rear Washer Ground

245715C1

CAV

WIRE IDENT

245715C1

CAV

Not Used

WIRE IDENT

CIRCUIT Not Used

68L-A

Rear Wiper Switch Power

68L-A

Rear Wiper Switch Power

19K-D

Rear Wiper Motor Fused Power

19K-D

Rear Wiper Motor Fused Power

68C-A

Rear Wiper Park Control

68C-A

Rear Wiper Park Control

4002-155 CONNECTOR S-KEY - IGNITION SWITCH

CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH

225253C1

CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH

225253C1 382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

Ign Sw Fused Power

21K

Ign Switch Start Signal

13K

Ignition Switch Power

12ACC

Ign Switch Accessory Power

Not Used

WIRE IDENT 35R-C

Backup Alarm Switch

35A-B

Backup Alarm Disable Switch Not Used

Not Used

CONNECTOR SBE - BEACON SWITCH

CIRCUIT

Not Used

0-B21

Back Light Ground

49-L

Back Light Power

382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

Ign Sw Fused Power

21K

Ign Switch Start Signal

13K

Ignition Switch Power

12ACC

Ign Switch Accessory Power

Not Used

CONNECTOR SBE - BEACON SWITCH

Beacon Switch Fused Power

46-C

Beacon Switched Power

Not Used

Backup Alarm Switch

35A-B

Backup Alarm Disable Switch

Not Used

0-B21

Back Light Ground

49-L

Back Light Power Not Used

Not Used

CONNECTOR SC - SEAT COMPRESSOR MOTOR

382391A1

CAV

Not Used 19U-H

35R-C

CIRCUIT

Not Used

382391A1

WIRE IDENT

CIRCUIT

CONNECTOR SC - SEAT COMPRESSOR MOTOR

CAV

WIRE IDENT

1 245482C1

CAV

WIRE IDENT

CIRCUIT

CIRCUIT Not Used

19U-H

Beacon Switch Fused Power

46-C

Beacon Switched Power

Not Used

A B

19N 0-DK

Seat Compressor Fused Pwr Seat Compressor Motor Ground

0-B15

Back Light Ground

0-B15

Back Light Ground

49-B

Back Light Power

49-B

Back Light Power

Not Used

245482C1

CAV

WIRE IDENT

CIRCUIT

19N

Seat Compressor Fused Pwr

0-DK

Seat Compressor Motor Ground

4002-156

CONNECTOR SCS - COMFOR STEER SWITCH

CONNECTOR SDR - DRIVING LIGHTS SWITCH

382391A1

CAV

WIRE IDENT

51S

2 3

CIRCUIT

CAV 1

18L-D

Comfort Steering Fused Power

51CS

Comfort Steering Switch Not Used

Not Used

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

Not Used

51S

Driving lights Switch Fused Pwr

Position Lights Switch Power

4 5

19Z-A 41T

19Z-B

CONNECTOR SDR - DRIVING LIGHTS SWITCH

382391A1

Standard Steering Signal

CONNECTOR SCS - COMFOR STEER SWITCH

CIRCUIT

382391A1

CAV

18L-D

Comfort Steering Fused Power

19Z-A

Driving lights Switch Fused Pwr

51CS

Comfort Steering Switch

41T

Position Lights Switch Power

Not Used

Driving Lights Switch Fused Power

Not Used

51B-A

Comfort Steering Solenoid Pwr

Not Used

19Z-B

Driving Lights Switch Fused Power

Back Light Ground

41J

Driving Lights Power

Back Light Power

0-B19

Back Light Ground

Not Used

49-P

Back Light Power

Not Used

51B-A

Comfort Steering Solenoid Pwr

0-B9

Back Light Ground

41J

Driving Lights Power

0-B9

49-U

Back Light Power

0-B19

Back Light Ground

49-U

Not Used

49-P

Back Light Power

Not Used

CONNECTOR SDC - DECLUTCH SWITCH

CONNECTOR SDC - DECLUTCH SWITCH CONNECTOR SETHR - ETHER SWITCH

CONNECTOR SETHR - ETHER SWITCH

382391A1

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

Standard Steering Signal

382391A1

CIRCUIT

382391A1

25G-B

Brake Declutch Switch Control

CAV

WIRE IDENT

CIRCUIT

19A-R

Declutch Switch Fused Power

Not Used

28J

Ether AIC OK Signal

Not Used

28H

Not Used

CAV

WIRE IDENT

CIRCUIT

382391A1

25G-B

Brake Declutch Switch Control

CAV

19A-R

Declutch Switch Fused Power

Not Used

28J

Ether AIC OK Signal

Ether Switch Signal

Not Used

28H

Ether Switch Signal

Not Used

0-B18

Back Light Ground

Not Used

49-R

Back Light Power

0-B30

Back Light Ground

49U

Back Light Power

Not Used

WIRE IDENT

CIRCUIT Not Used

0-B18

Back Light Ground

49-R

Back Light Power

0-B30

Back Light Ground

Not Used

49U

Back Light Power

Not Used

4002-157 CONNECTOR SFC - FAN CONTROL SWITCH

WIRE IDENT

CIRCUIT

CONNECTOR SFC - FAN CONTROL SWITCH

CONNECTOR SFNR - FNR SWITCH

382391A1

CAV

4002-157

382391A1

CAV

WIRE IDENT

CIRCUIT

CONNECTOR SFNR - FNR SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

382391A1

CAV

WIRE IDENT

CIRCUIT

Not Used

26R-A

FNR Reverse Signal

Not Used

26R-A

FNR Reverse Signal

52J

Fan Control Switch Jumper

26J

FNR Switch Jumper

52J

Fan Control Switch Jumper

26J

FNR Switch Jumper

52-AU

Fan Reverse Auto

26N-A

FNR Neutral Signal

52-AU

Fan Reverse Auto

26N-A

FNR Neutral Signal

52J

Fan Control Switch Jumper

26J

FNR Switch Jumper

52J

Fan Control Switch Jumper

26J

FNR Switch Jumper

19P-C

Fan Reverse Switch Fused Pwr

19A-V

FNR Switch Fused Power

19P-C

Fan Reverse Switch Fused Pwr

19A-V

FNR Switch Fused Power

52M

Fan Reverse Manual

26F-A

FNR Forward Signal

52M

Fan Reverse Manual

26F-A

FNR Forward Signal

0-B7

Back Light Ground

32J-A

Trans Enable Indication

0-B7

Back Light Ground

32J-A

Trans Enable Indication

49-Q

19A-G

49-Q

19A-G

Back Light Power

FNR Switch Fused Power

Back Light Power

Not Used

CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH

CONNECTOR SFWW - FRONT WIPER AND WASHER SWITCH

CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH

FNR Switch Fused Power

CONNECTOR SFWW - FRONT WIPER AND WASHER SWITCH

87345132 382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT Not Used

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 Switch Control

54B-C

HC-RTT Control Signal

0-B2

Back Light Ground

63W

49-K

Back Light Power

Not Used

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT Not Used

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 Switch Control

Not Used

54B-C

HC-RTT Control Signal

Front Washer Pump

0-B2

Back Light Ground

63W

49-T

Back Light Power

49-K

Back Light Power

49-T

Back Light Power

63HC

Front Wiper HS Relay Control

Not Used

63HC

Front Wiper HS Relay Control

Not Used

0-DT

Front Wiper/Washer Sw Gnd

63LC

Front Wiper LS Relay Control

4 5

87345132 382391A1

Not Used 19J-B

INT Wiper/Washer Sw Fused Pwr

0-DT

Front Wiper/Washer Sw Gnd

63LC

Front Wiper LS Relay Control

4 5

Not Used 19J-B

INT Wiper/Washer Sw Fused Pwr Not Used Front Washer Pump

Not Used

4002-158

CONNECTOR SHC - HEIGHT CONTROL SWITCH

CONNECTOR SPB - PARKING BRAKE SWITCH

382391A1

CAV

WIRE IDENT

CAV

CIRCUIT

CONNECTOR SHC - HEIGHT CONTROL SWITCH

WIRE IDENT

CIRCUIT

CAV

Not Used Pilot Control Relay Out

19A-L

Park Brk Switch Fused Power

Not Used

33U

Park Brake Switch

Not Used

6 7

53P-D

382391A1

CONNECTOR SPB - PARKING BRAKE SWITCH

Not Used

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

Not Used

Pilot Control Relay Out

19A-L

Park Brk Switch Fused Power

Not Used

33U

Park Brake Switch

Not Used

54A

HC Control Switch Power

Not Used

0-B3

Back Light Ground

0-B29

RTT/Float Ground

49-V

Back Light Power

54A

HC Control Switch Power

0-B3

Back Light Ground

0-B29

RTT/Float Ground

49-V

Back Light Power

53P-D

Not Used

Back Light Power

Not Used

49-M

CONNECTOR SHZ - HAZARD SWITCH

CONNECTOR SPC - PILOT CONTROL SWITCH

WIRE IDENT

CIRCUIT

CONNECTOR SHZ - HAZARD SWITCH

382391A1

CAV

49-M

CAV

WIRE IDENT

CIRCUIT

CONNECTOR SPC - PILOT CONTROL SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

Not Used

1-KA

Hazard Switch Power

19A-J

Pilot Control Switch Fused Pwr

1-KA

Hazard Switch Power

19A-J

Pilot Control Switch Fused Pwr

45H

Hazard Switch Power

31L

Pilot Control Switch High

45H

Hazard Switch Power

31L

Pilot Control Switch High

Not Used

CIRCUIT

Not Used

WIRE IDENT

Not Used

0-B24

Back Light Ground

0-B1

Back Light Ground

0-B24

Back Light Ground

0-B1

Back Light Ground

49-D

Back Light Power

49-N

Back Light Power

49-D

Back Light Power

49-N

Back Light Power

Not Used

4002-159 CONNECTOR SPE - PIN ENGAGE SWITCH

CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT POWER

382391A1

CAV

WIRE IDENT

CAV

57-B

Pin Engage Solenoid Power

19P-A

Pin Engage Sw Fused Power

3 4

Not Used

87324393

CAV

Not Used

382391A1

CIRCUIT

WIRE IDENT 49

Not Used

0-B5

Back Light Ground

49-F

Back Light Power

CONNECTOR SPK - SPEAKER

CIRCUIT Back Light Power Not Used

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

49S

WIRE IDENT

CIRCUIT

57-B

Pin Engage Solenoid Power

19P-A

Pin Engage Sw Fused Power

3 4

Not Used

WIRE IDENT

CIRCUIT

87324393

CAV

Not Used

WIRE IDENT 49

CIRCUIT Back Light Power Not Used

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

Not Used

0-B5

Back Light Ground

49-F

Back Light Power

CONNECTOR SPK - SPEAKER

49-E

Back Light Power

49-B

Back Light Power

49-B

Back Light Power

49-A

Back Light Power

49-A

Back Light Power

292494A1

CAV

CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT POWER

292494A1

CAV

WIRE IDENT

CIRCUIT

65R

Right Speaker

65R

Right Speaker

0-PB

Right Speaker Ground

0-PB

Right Speaker Ground

Not Used

65L

Left Speaker

65L

Left Speaker

0-PA

Left Speaker Ground

0-PA

Left Speaker Ground

4002-160

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT POWER

CAV

WIRE IDENT

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT POWER

CIRCUIT Not Used

0-B17

Back Light Ground

0-B18

Back Light Ground

0-B18

Back Light Ground

0-B19

Back Light Ground

0-B19

Back Light Ground

0-B8

Front Wiper Motor Ground

0-B8

Front Wiper Motor Ground

0-B21

Back Light Ground

0-B21

Back Light Ground

0-DAP

Back Light Ground

0-DAP

Back Light Ground

0-B23

Back Light Ground

0-B23

Back Light Ground

Not Used

87324393

CIRCUIT

CAV

Back Light Power

Not Used

49-J

Back Light Power

49-M

WIRE IDENT

CIRCUIT

49-E

Back Light Power

49-J

Back Light Power

49-M

Back Light Power

49-K

Back Light Power

49-K

Back Light Power

49-F

Back Light Power

49-F

Back Light Power

49-Q

Back Light Power

49-Q

Back Light Power

49-T

Back Light Power

49-T

Back Light Power

49-G

Back Light Power

49-G

Back Light Power

J K

Not Used

L M

49-S

Not Used

J 87324393

Not Used

CAV

Back Light Power

CONNECTOR SPL-BCK-LT-GD - SPLICE BACK LIGHT GROUND

WIRE IDENT

CIRCUIT Not Used

0-B2

Back Light Ground

0-B3

Back Light Ground

0-B4

Back Light Ground

0-B5

0-B6

0-B26

Not Used

L M

49-S

WIRE IDENT

CIRCUIT

87324393

Not Used

CAV

Back Light Power

WIRE IDENT

CIRCUIT Not Used

0-B2

Back Light Ground

0-B3

Back Light Ground

0-B4

Back Light Ground

0-B5

Back Light Ground

CAB2 Ground

0-B6

CAB2 Ground

Buzzer Switch Pad Ground

0-B26

Buzzer Switch Pad Ground

Not Used

CONNECTOR SPL-BCK-LT-GD - SPLICE BACK LIGHT GROUND

Not Used

0-B20

Back Light Ground

0-B20

Back Light Ground

0-29

RTT/Float Ground

0-29

RTT/Float Ground

0-B11

Back Light Ground

0-B11

Back Light Ground

0-B7

Back Light Ground

0-B7

Back Light Ground

87324393

CAV

Not Used

CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK LIGHT GROUND

49-E

Not Used

Back Light Ground

87324393

CIRCUIT

0-B17

CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK LIGHT GROUND WIRE IDENT

WIRE IDENT

CAV

87324393

CAV

WIRE IDENT

CIRCUIT

0-B13

Back Light Ground

0-B13

Back Light Ground

0-B14

Back Light Ground

0-B14

Back Light Ground

0-B15

Back Light Ground

0-B15

Back Light Ground

4002-161 CONNECTOR SPL-ENG-GND - GROUND SPLICE 6 PACK

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

87324391

CAV

WIRE IDENT

CIRCUIT

4002-161 CONNECTOR SPL-ENG-GND - GROUND SPLICE 6 PACK

87324391

CAV

WIRE IDENT

CIRCUIT

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

87324391

CAV

WIRE IDENT

CIRCUIT

87324391

CAV

WIRE IDENT

CIRCUIT

0-BM

Engine Splice Grounds

49-U

Back Light Power

0-BM

Engine Splice Grounds

49-U

Back Light Power

0-BY

Air Filter Restriction Switch Gnd

49-N

Back Light Power

0-BY

Air Filter Restriction Switch Gnd

49-N

Back Light Power

Not Used

49-D

Back Light Power

Not Used

49-D

Back Light Power

C D

0-BS

Fan Control Ground

49U

Back Light Power

0-BS

Fan Control Ground

49U

Back Light Power

0-B

Front Washer Ground

49-V

Back Light Power

0-B

Front Washer Ground

49-V

Back Light Power

0-BL

Rear Washer Ground

49-S

Back Light Power

0-BL

Rear Washer Ground

49-S

Back Light Power

CONNECTOR SPL-HOOD-GRND HOOD GRND 6PCK CAV

WIRE IDENT

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

CIRCUIT

CONNECTOR SPL-HOOD-GRND HOOD GRND 6PCK CAV

WIRE IDENT

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

CIRCUIT

0-B12

Hood Down Relay GND

0-B12

Hood Down Relay GND

0-B16

Hood Down Control GND

0-B16

Hood Down Control GND

0-B22

Hood Up Relay GND

0-B22

Hood Up Relay GND

0-B25

Hood Up Control GND

0-B25

Hood Up Control GND

0-B10

Hood GND

0-B10

Hood GND

87324391

CAV

WIRE IDENT

CIRCUIT

87324391

CAV

WIRE IDENT

CIRCUIT

0-B9

Back Light Ground

0-B9

Back Light Ground

0-B1

Back Light Ground

0-B1

Back Light Ground

0-B24

Back Light Ground

0-B24

Back Light Ground

0-B30

Back Light Ground

0-B30

Back Light Ground

0-B29

RTT/Float Ground

0-B29

RTT/Float Ground

0-B11

Back Light Ground

0-B11

Back Light Ground

4002-162

CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK

CAV

WIRE IDENT

CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK

CIRCUIT

CAV

35A-B

Backup Alarm Disable Switch

35A-B

Backup Alarm Disable Switch

35A-A

Backup Alarm Relay Out

35A-A

Backup Alarm Relay Out

35A-C

Backup Alarm Relay Out

35A-C

Backup Alarm Relay Out

CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY

87324391

WIRE IDENT

87324391

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

19P-A

Pin Engage Switch Fused Pwr

19P-A

Pin Engage Switch Fused Pwr

19P

Pin Engage/Fan Fused Power

19P

Pin Engage/Fan Fused Power

19P-C

Ran Reverse Switch Fused Pwr

19P-C

Ran Reverse Switch Fused Pwr

87324462

Not Used

19P-D

Fan Reverse Relay Fused Pwr

CAV

19P-E

Fan Reverse Relay Fused Pwr

41T-B

Position Lights LH Switch Pwr

41T-E

Position Lights Switch Pwr

41T

Position Lights Switch Pwr

41T-A

Position Lights RH Switch Pwr

19Z-A

19Z-B

CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY

WIRE IDENT

CIRCUIT

87324462

Not Used

19P-D

Fan Reverse Relay Fused Pwr

CAV

19P-E

Fan Reverse Relay Fused Pwr

41T-B

Position Lights LH Switch Pwr

41T-E

Position Lights Switch Pwr

41T

Position Lights Switch Pwr

41T-A

Position Lights RH Switch Pwr

Driving Light Switch Fused Pwr

19Z-A

Driving Light Switch Fused Pwr

19Z-B

Driving Light Switch Fused Pwr

19Z

Driving Light Switch Fused Pwr

19Z

Driving Light Switch Fused Pwr

19Z-C

High Beam Flash Fused Pwr

19Z-C

High Beam Flash Fused Pwr

41H-C

High Beam RH Power

41H-C

High Beam RH Power

41H-B

High Beam LH Power

41H-B

High Beam LH Power

41H-A

High Beam Power

41H-A

High Beam Power

41H-D

High Beam Power

41H-D

High Beam Power

CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY

87324462

CAV

WIRE IDENT

CIRCUIT

CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY

CAV

WIRE IDENT

87324462

CAV

WIRE IDENT

CIRCUIT

42C-A

Front Work Lights Fused Pwr

42C-A

Front Work Lights Fused Pwr

42C-E

Front Work Lights Fused Pwr

42C-E

Front Work Lights Fused Pwr

42C-D

Front Work Lights Fused Pwr

42C-D

Front Work Lights Fused Pwr

42C-C

Front Work Lights Fused Pwr

42C-C

Front Work Lights Fused Pwr

13K

Ignition Switch Power

13K

Ignition Switch Power

13K-B

Ignition Switch Power

13K-B

Ignition Switch Power

13K-A

Ignition Switch Power

13K-A

Ignition Switch Power

13K-C

Ignition Switch Power

13K-C

Ignition Switch Power

35A-D

Backup Alarm Relay Out

35A-D

Backup Alarm Relay Out

WIRE IDENT

CIRCUIT

4002-163 CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

CAV

WIRE IDENT

4002-163 CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

CIRCUIT

CAV

0-MF

RH Rear Work Light Ground

0-MF

RH Rear Work Light Ground

0-MA

Rear Wiper Motor Ground

0-MA

Rear Wiper Motor Ground

Not Used

0-MJ

RH Front Work Light Ground

Not Used

Roof Grounds

0-MN

Roof Grounds

0-MK

Roof Grounds

0-MK

Roof Grounds

CONNECTOR SPL-SEC-STR - SEC STR 6PK 87324462

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

45L-E

Left Turn Signal

45L-E

Left Turn Signal

45L-D

Left Turn Signal

45L-D

Left Turn Signal

45L-C

Left Turn Signal

45L-C

Left Turn Signal

45L-B

Left Turn Signal

45L-B

Left Turn Signal

45R-C

Right Turn Signal

45R-C

Right Turn Signal

45R-E

Right Turn Signal

45R-E

Right Turn Signal

45R-D

Right Turn Signal

45R-D

Right Turn Signal

45R-B

Right Turn Signal

45R-B

Right Turn Signal

19J-B

Front Wiper/Washer Sw Fused Pwr

19J-B

Front Wiper/Washer Sw Fused Pwr

19J

87324391

Front Wiper Fused Power

19J

Front Wiper Fused Power

CAV

0-CB

Sec. Steering Signal Ground

19J-C

Front Wiper Relay Fused Power

0-CB

Sec. Steering Signal Ground

0-CA

Sec. Steering Signal Ground

19J-A

Front Wiper Motor Fused Power

0-CA

Sec. Steering Signal Ground

0-CC

Sec. Steering Press Switch Gnd

0-CC

Sec. Steering Press Switch Gnd

0-CF

Sec. Steering Solenoid Ground

0-CF

Sec. Steering Solenoid Ground

19J-C

Front Wiper Relay Fused Power

19J-A

Front Wiper Motor Fused Power

CONNECTOR SPL-ROOF - SPLICE ROOF GROUND

WIRE IDENT

E F

CIRCUIT

CONNECTOR SPL-ROOF - SPLICE ROOF GROUND

Not Used 0-CD

Sec. Steering Splice Ground

CIRCUIT

87324393

CAV

0-MC

Beacon Light Ground

0-MB

Dome Light Ground

0-MU

LH Front Work Light Ground

0-ME

LH Rear Work Light Ground

WIRE IDENT

CIRCUIT

0-MC

Beacon Light Ground

0-MB

Dome Light Ground

0-MU

LH Front Work Light Ground

0-ME

LH Rear Work Light Ground

WIRE IDENT

E F

87324393

WIRE IDENT

87324391

CAV A

CAV

RH Front Work Light Ground Not Used

0-MN

CONNECTOR SPL-SEC-STR - SEC STR 6PK

0-MJ

87324462

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Not Used 0-CD

Sec. Steering Splice Ground

4002-164

CONNECTOR SPL-TRN-GRD - SPLICE TRANSMISSION GROUND

CAV

WIRE IDENT

CONNECTOR SPL-TRN-GRD - SPLICE TRANSMISSION GROUND

CIRCUIT

19A-M

Output Speed Sensor Fused Pwr

19A-S

19A-H

CAV

19A-M

Output Speed Sensor Fused Pwr

Trans Fused Pwr

19A-S

Trans Fused Pwr

Trans Shifter Fused Pwr

19A-H

Trans Shifter Fused Pwr

87324391

CAV A

WIRE IDENT 0-HC

WIRE IDENT 21C-D

CONNECTOR SR-9-STR REL signal

CIRCUIT

CAV

STRTR RLY Signal

CONNECTOR SRC - RIDE CONTROL SWITCH

CIRCUIT

87324391

CAV

WIRE IDENT

Transmission Splice Grounds

Not Used

0-HC

HOT Ground

0-HW

0-HV

Coolant Level Sender Ground

0-HV

Coolant Level Sender Ground

0-HL

Redundant Brake Switch Grd

0-HL

Redundant Brake Switch Grd

0-HM

Redundant Brake Switch Grd

0-HM

Redundant Brake Switch Grd

382391A1

CIRCUIT

WIRE IDENT

CIRCUIT

CONNECTOR SRC - RIDE CONTROL SWITCH

HOT Ground

CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

382391A1

CAV

WIRE IDENT

Not Used

Ride Ctrl Switch Fused Pwr

19C-D

CIRCUIT Not Used

19C-D

58C

Ride Ctrl Switch Jumper

58C

Ride Ctrl Switch Jumper

58T

Ride Ctrl Relay Switch Pwr

58T

Ride Ctrl Relay Switch Pwr

58C

Ride Ctrl Switch Jumper

58C

Ride Ctrl Switch Jumper

58-F

Ride Ctrl Solenoid Pwr

58-F

Ride Ctrl Solenoid Pwr

Ride Ctrl Switch Fused Pwr

0-B20

Back Light Ground

0-B20

Back Light Ground

49-G

Back Light Power

49-G

Back Light Power

Not Used

87324393

CAV

STRTR RLY Signal

Transmission Splice Grounds

WIRE IDENT

21C-D

CIRCUIT

Not Used

0-HW

CAV

WIRE IDENT

CIRCUIT

CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

CIRCUIT

CONNECTOR SR-9-STR REL signal CAV

WIRE IDENT

87324393

CAV

WIRE IDENT

CIRCUIT

19A-N

Trans Fused Power

19A-N

Trans Fused Power

19A-F

Trans Enable Switch Fused Pwr

19A-F

Trans Enable Switch Fused Pwr

19A-Q

Trans/Auto Switch Fused Pwr

19A-Q

Trans/Auto Switch Fused Pwr

19A-T

Brake Declutch Sw Fused Pwr

19A-T

Brake Declutch Sw Fused Pwr

19A-W

Diagnostic Conn. Fused Pwr

19A-W

Diagnostic Conn. Fused Pwr

19A-C

FNR Switch Fused Pwr

19A-C

FNR Switch Fused Pwr

19A-P

Backup Alarm Rly Ctrl Fused Pwr

19A-P

Backup Alarm Rly Ctrl Fused Pwr

19A-R

Declutch Switch Fused Pwr

19A-R

Declutch Switch Fused Pwr

19A-K

TECM Fused Pwr

19A-K

TECM Fused Pwr

4002-165 CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

4002-165 CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CAV 1

WIRE IDENT 68C

382391A1

CIRCUIT

CAV

Rear Wiper Park Control

87318288

31b 49a

WIRE IDENT 64C 19B

68L

Rear Wiper Switch Power

CIRCUIT

CAV 3

Horn Relay Control

56a

41H-A

High Beam Power

56b

41L-A

Low Beam Power

19K-A

Turn Signal Fused Power

56d

19Z-C

High Beam Flash Fused Power

0-EP

Horn Switch Ground

41J

Drive Lights Power

45A-A

Left Turn Switch Power

45B-A

Right Turn Switch Power

68C

Rear Wiper Park Control

Rear Wiper Switch Fused Power Not Used

19K-B

Rear Wiper Switch Fused Power

68W

Rear Washer Pump

0-B23

Back Light Ground

49-C

Back Light Power

Not Used

31b

WIRE IDENT

68L

Rear Wiper Switch Power

64C

19K-A

CIRCUIT 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 Fused Power

0-EP

Horn Switch Ground

41J

Drive Lights Power

45A-A

Left Turn Switch Power

45B-A

Right Turn Switch Power

19K-B

Rear Wiper Switch Fused Power

68W

Rear Washer Pump

0-B23

Back Light Ground

49-C

Back Light Power

Not Used

CONNECTOR SS-SEC STR FUSED PWR

CONNECTOR SRTD - DETENT SWITCH

CONNECTOR SRTD - DETENT SWITCH CAV 1

WIRE IDENT 19S1

CIRCUIT

CAV

SEC STR FSD PWR

CONNECTOR SSS-SS MAG SWITCH CAV 1

WIRE IDENT 51-B

WIRE IDENT

CIRCUIT

WIRE IDENT 19S1

CIRCUIT SEC STR FSD PWR

CONNECTOR SSS-SS MAG SWITCH

CIRCUIT

CAV

SEC STR Motor CTRL

382391A1

CAV

Rear Wiper Switch Fused Power Not Used

CONNECTOR SS-SEC STR FUSED PWR

CIRCUIT

87318288

2 CAV

WIRE IDENT

382391A1

CAV

Not Used

WIRE IDENT

CIRCUIT Not Used

53P-E

Pilot Control Relay Out

53P-E

Pilot Control Relay Out

53A

RTD Switched Power

53A

RTD Switched Power

Not Used

0-B4

Back Light Ground

0-B4

Back Light Ground

49-J

Back Light Power

Not Used

WIRE IDENT 51-B

CIRCUIT SEC STR Motor CTRL

4002-166

CONNECTOR SS-TR - SS-MOD-TRANS

CONNECTOR STA - TRANSMISSION AUTO SWITCH

245489C1

CAV

WIRE IDENT

245489C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

19M-C

Sec. Str Accessory Fused Pwr

19M-C

Sec. Str Accessory Fused Pwr

19R-C

Sec. Str Ignition Fused Pwr

19R-C

Sec. Str Ignition Fused Pwr

35X-C

Sec. Str Low Press Signal

35X-C

Sec. Str Low Press Signal

0-CD

Sec. Str Splice Ground

0-CD

Sec. Str Splice Ground

19S1-X

Sec. Str Fused Power

19S1-X

Sec. Str Fused Power

382391A1

CAV

WIRE IDENT

Not Used

CONNECTOR SSM - SECONDARY STEERING MODULE

CIRCUIT Not Used

19A-Q

Trans Auto Sw Fused Power

25H

Trans Auto Signal

Not Used

382391A1

CAV

Not Used

CONNECTOR SSM - SECONDARY STEERING MODULE

0-B17

Back Light Ground

0-B17

Back Light Ground

49S

Back Light Power

49S

Back Light Power

Not Used

CONNECTOR STE - TRANSMISSION ENABLE SWITCH 225389C1

CAV

WIRE IDENT

CIRCUIT Sec. Steering Ignition Fused Pwr

51-A

Secondary Steer Control

51-A

Secondary Steer Control

19S1-X

Secondary Steer Fused Power

19S1-X

Secondary Steer Fused Power

0-CE

Secondary Steer Chassis Grnd

0-CE

Secondary Steer Chassis Grnd

Not Used

Secondary Steer Low Press Sig

51P-A

Secondary Steer High Press

Not Used

0-CA

Secondary Steer Signal Grnd

0-CB

Secondary Steer Signal Grnd

Trans Auto Signal

Not Used

19R-C

35X-D

25H

Not Used

Sec. Steering Ignition Fused Pwr

Trans Auto Sw Fused Power

Not Used

CIRCUIT

Secondary Steer ACC Fused Pwr

19A-Q

Not Used

19R-C

19M-C

CIRCUIT Not Used

225389C1

WIRE IDENT

CONNECTOR STE - TRANSMISSION ENABLE SWITCH CAV

CONNECTOR STA - TRANSMISSION AUTO SWITCH

382391A1

CAV

WIRE IDENT

1 2 3

Not Used 19A-D 26E

19M-C

CIRCUIT

Trans Enable Sw Fused Power Trans Enable Signal Not Used

Secondary Steer ACC Fused Pwr

35X-D

Secondary Steer Low Press Sig

51P-A

Secondary Steer High Press

Not Used

0-CA

Secondary Steer Signal Grnd

0-CB

Secondary Steer Signal Grnd

382391A1

CAV 1

Not Used 19A-D

Trans Enable Sw Fused Power

26E

Trans Enable Signal

Not Used

Not Used Not Used

Not Used

Back Light Ground

0-DAP

CIRCUIT

WIRE IDENT

0-DAP

Back Light Ground

4002-167 CAV

WIRE IDENT

CAV

CIRCUIT

49-H

Back Light Power

32J-C

Trans Enable Indiction

19A-E

Trans Enable Sw Fused Pwr

CONNECTOR SWL - WORK LIGHTS SWITCH

WIRE IDENT 31F-A

CIRCUIT

4002-167 CAV

WIRE IDENT

CAV

CIRCUIT

49-H

Back Light Power

Not Used

32J-C

Trans Enable Indiction

CAN-HF

CAN High

19A-E

Trans Enable Sw Fused Pwr

CAN-HF

CAN High

CAN-LF

CAN Low

CAN-LF

CAN Low

17P-A

Switch Pad Pwr From AIC Pwr

17P-A

Switch Pad Pwr From AIC Pwr

0-B28

Switch Pad Ground

0-B28

Switch Pad Ground

CONNECTOR SWL - WORK LIGHTS SWITCH

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

Not Used

42-A

Work Lights Fused Power

42-A

Work Lights Fused Power

42FS

Front Work Lights Switch Power

42FS

Front Work Lights Switch Power

291718A1

Not Used

42-B

Work Lights Fused Power

CAV

42RS

Rear Work Lights Switch Power

36G

TCO Temperature Signal

36R-D

TCO Temperature Return

0-B14

Back Light Ground

49-A

Back Light Power

Not Used

382391A1

Air Filter Rest Switch Signal

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

382391A1

WIRE IDENT

31F-A

CIRCUIT

Air Filter Rest Switch Signal

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

CAV

WIRE IDENT

CIRCUIT

CONNECTOR TDM - TIME DELAY MODULE

Not Used

291718A1

Not Used

42-B

Work Lights Fused Power

CAV

42RS

Rear Work Lights Switch Power

36G

TCO Temperature Signal

36R-D

TCO Temperature Return

0-B14

Back Light Ground

49-A

Back Light Power

Not Used

CONNECTOR SW-PD - SWITCH PAD

WIRE IDENT

CIRCUIT

CONNECTOR TDM - TIME DELAY MODULE

CONNECTOR SW-PD - SWITCH PAD

225351C1

CAV

87552623

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

225351C1

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

13D

Time Delay Relay Ctrl Power

13D

Time Delay Relay Ctrl Power

1DN

Time Delay Fused Power

1DN

Time Delay Fused Power

0-DC

Time Delay Module Ground

0-DC

Time Delay Module Ground

43S-D

Time Delay Mod Door Sw Reset

43S-D

Time Delay Mod Door Sw Reset

13K-A

Ignition Switch Power

13K-A

Ignition Switch Power

Not Used

87552623

CAV

WIRE IDENT

CIRCUIT

41H-D

High Beam Power

41H-D

High Beam Power

41T-D

Position Lights Switch Pwr

41T-D

Position Lights Switch Pwr

42C-E

Front Work Light Fused Pwr

42C-E

Front Work Light Fused Pwr

31H-A

Hydraulic Filter Rest Sw Signal

31H-A

Hydraulic Filter Rest Sw Signal

Not Used

4002-168

CONNECTOR TECM - TRANSMISSION ELECTRONIC CONTROL MODULE

411398A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CONNECTOR TECM - TRANSMISSION ELECTRONIC CONTROL MODULE

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

52P-C

Park Brake Relay Out

52P-C

Park Brake Relay Out

25Y-A

Trans Kick Down Signal

25Y-A

Trans Kick Down Signal

19T-A

Time Delay Fused Power

19T-A

Time Delay Fused Power

CAN-HD

CAN High

CAN-HD

CAN High

CAN-LK

CAN Low

CAN-LK

CAN Low

CAN-LJ

CAN Low

CAN-LJ

CAN Low

25H

Trans Auto Signal

25H

Trans Auto Signal

26R-B

FNR Reverse Signal

26R-B

FNR Reverse Signal

26E

Trans Enable Signal

26E

Trans Enable Signal

25M-A

Trans Sol Valve Y3

25M-A

Trans Sol Valve Y3

36T-A

Valve Body Temp Signal

36T-A

Valve Body Temp Signal

25C-A

Turb Speed Signal

25C-A

Turb Speed Signal

25B-A

Int Speed Signal

25B-A

Int Speed Signal

25F

Forward Signal

25F

Forward Signal

26N-B

FNR Neutral Signal

26N-B

FNR Neutral Signal

19A-K

TECM Fused Power

19A-K

TECM Fused Power

36R-E

Trans Temp/Filter Return

36R-E

Trans Temp/Filter Return

36G-A

Torque Conv Out Temp Signal

36G-A

Torque Conv Out Temp Signal

25J-A

Trans Sol Valve Y6

25J-A

Trans Sol Valve Y6

25N-A

Trans Sol Valve Y4

25N-A

Trans Sol Valve Y4

25K-A

Trans Sol Valve Y1

25K-A

Trans Sol Valve Y1

58L

Ride Control Relay LSD

58L

Ride Control Relay LSD

25D-A

Output Speed Signal

25D-A

Output Speed Signal

25Z

1st and 4th Gear Signal

25Z

1st and 4th Gear Signal

25R-

Reverse Signal

25R-

Reverse Signal

25W

3rd and 4th Gear Signal

25W

3rd and 4th Gear Signal

25G-C

Brake Declutch Switch Control

25G-C

Brake Declutch Switch Control

25T-C

Neutral Signal

25T-C

Neutral Signal

411398A1

CAV

WIRE IDENT

CIRCUIT

0-DP

Diag TECM Ground

0-DP

Diag TECM Ground

0-DQ

Diag TECM Ground

0-DQ

Diag TECM Ground

0-DM

Speed Sensors Ground

0-DM

Speed Sensors Ground

0-DN

Out Speed Sensor Ground

0-DN

Out Speed Sensor Ground

32J-D

Trans Enable Indicator Lamp

32J-D

Trans Enable Indicator Lamp

35C

Backup Alarm Relay Control

35C

Backup Alarm Relay Control

58H-A

Ride Control Sw Power VPS2

58H-A

Ride Control Sw Power VPS2

25P-A

Trans Sol Valve Y5

25P-A

Trans Sol Valve Y5

25L-A

Trans Sol Valve Y2

25L-A

Trans Sol Valve Y2

25S-B

Output Sw Power VPS1

25S-B

Output Sw Power VPS1

25S-C

Output Sw Power VPS1

25S-C

Output Sw Power VPS1

37D-A

Diagnostic Signal

37D-A

Diagnostic Signal

32F-A

Trans Filter Maint Switch

32F-A

Trans Filter Maint Switch

37E

Diagnostic Signal Switched

37E

Diagnostic Signal Switched

25A-A

Engine Speed Signal

25A-A

Engine Speed Signal

26F-B

FNR Forward Signal

26F-B

FNR Forward Signal

4002-169 CONNECTOR TR-SS - SEC-STR-MOD-OPT

CONNECTOR TRANS - CAB TO TRANSMISSION

380838A1

CAV

245488C1

CAV A

WIRE IDENT

CIRCUIT

19M-A

Sec. Steering ACC Fused Pwr

19R-A

Sec. Steering Ignition Fused Pwr

35X-B

Sec. Steering Low Press Signal

0-HP

Sec. Steering Splice Ground

19S1-E

Sec. Steering Fused Power

Not Used

CONNECTOR TRAN-E - TRANS TO ENG

WIRE IDENT 33R-A

Redundant Brake Switch Signal

31D-B

Coolant Level Sender Eng Trans

31D

Coolant Level Signal

19M-A 19R-A

Sec. Steering Ignition Fused Pwr

36T

Valve Body Temp Signal

35X-B

WIRE IDENT

CIRCUIT

Sec. Steering Low Press Signal

25A

Engine Speed Signal

25C

Turb Speed Signal

25B

Intermediate Speed Signal

25D

Output Speed Signal

WIRE IDENT

CIRCUIT

19M-A

Sec. Steering ACC Fused Pwr

19R-A

Sec. Steering Ignition Fused Pwr

35X-B

Sec. Steering Low Press Signal

0-HP

Sec. Steering Splice Ground

19S1-E

Sec. Steering Fused Power

Not Used

CONNECTOR TRAN-E - TRANS TO ENG

31D-B

Coolant Level Sender Eng Trans

31D

Coolant Level Signal

19M-A

Sec. Steering ACC Fused Pwr

19R-A

Sec. Steering Ignition Fused Pwr

36T

Valve Body Temp Signal

35X-B

Sec. Steering Low Press Signal

25A

Engine Speed Signal

25C

Turb Speed Signal

25B

Intermediate Speed Signal

25D

Output Speed Signal

0-HD

Speed Sensor Ground

0-HD

Speed Sensor Ground

Trans Temp/Filter Return

36R-A

Trans Temp/Filter Return

36G

Torque Conv Output Temp Sig

36G

Torque Conv Output Temp Sig

Not Used

25K

Trans Solenoid Valve Y1

25K

Trans Solenoid Valve Y1

25K-9

Trans Solenoid Valve Y2

25K-9

Trans Solenoid Valve Y2

25L-9

Trans Solenoid Valve Y1

25L-9

Trans Solenoid Valve Y1

25L

Trans Solenoid Valve Y2

25L

Trans Solenoid Valve Y2

25M

Trans Solenoid Valve Y3

25M

Trans Solenoid Valve Y3

25N

Trans Solenoid Valve Y4

CAV

25N

Trans Solenoid Valve Y4

Trans Solenoid Valve Y5

0-HP

Sec. Steering Splice Ground

25P

Trans Solenoid Valve Y5

0-HC

Trans Splice Grounds

25J

Trans Solenoid Valve Y6

31D-B

Coolant Level Sender Eng Trans

25S

Output Sw Power VPS1

31H

Hyd Filter Restriction Sw Signal

Sec. Steering Splice Ground

0-HC

Trans Splice Grounds

25J

Trans Solenoid Valve Y6

31D-B

Coolant Level Sender Eng Trans

25S

Output Sw Power VPS1

31H

Hyd Filter Restriction Sw Signal

Not Used

CAV

CIRCUIT Redundant Brake Switch Signal

36R-A

0-HP

245488C1

WIRE IDENT 33R-A

CAV 1

CAV

Sec. Steering ACC Fused Pwr

239451A1

CIRCUIT

380838A1

25P

239451A1

3 4

WIRE IDENT

CIRCUIT

Not Used

Sec. Steering Fused Power

Not Used

0-HE

Output Speed Sensor Ground

19A

Output Speed Sensor Fused Pwr

36H

32F

19S1-E

27 28

19S1-E

Sec. Steering Fused Power Not Used

0-HE

Output Speed Sensor Ground

19A

Output Speed Sensor Fused Pwr

Hydraulic Oil Temperature Sign

36H

Hydraulic Oil Temperature Sign

Trans Filter Maint Switch

32F

Trans Filter Maint Switch

4002-170

CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TS1 - TRANSMISSION SHIFTER

CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TS1 - TRANSMISSION SHIFTER

245486C1 371566A1

CAV 1

WIRE IDENT 25K

CIRCUIT

CAV A

WIRE IDENT 19A-H

245486C1

CIRCUIT

371566A1

Trans Shifter Fused Power

CAV 1

Trans Solenoid Valve Y1

25F

Forward Signal

25R

Reverse Signal

25T-B

Neutral Signal

WIRE IDENT

CIRCUIT

25F

Forward Signal

25L-9

Trans Solenoid Valve Y1

25R

Reverse Signal

25K-9

Trans Solenoid Valve Y2

25T-B

Neutral Signal

25L

Trans Solenoid Valve Y2

25L-9

Trans Solenoid Valve Y1

25K-9

Trans Solenoid Valve Y2

25L

Trans Solenoid Valve Y2

25M

Trans Solenoid Valve Y3

25M

Trans Solenoid Valve Y3

25N

Trans Solenoid Valve Y4

25N

Trans Solenoid Valve Y4

25P

Trans Solenoid Valve Y5

25P

Trans Solenoid Valve Y5

25J

Trans Solenoid Valve Y6

25J

Trans Solenoid Valve Y6

25S

Output Sw Power VPS1

25S

Output Sw Power VPS1

36T

Valve Body Temp Signal

36T

Valve Body Temp Signal

36R-C

Valve Body Temp Return

36R-C

Valve Body Temp Return

Not Used

CAV

WIRE IDENT

CIRCUIT Not Used

25W

3rd and 4th Gear Signal

25Z

25Y

Trans Shifter Fused Power

19A-H

CIRCUIT

245487C1

WIRE IDENT

Trans Solenoid Valve Y1

25K

CONNECTOR TS2 - TRANSMISSION SHIFTER

CAV

CONNECTOR TS2 - TRANSMISSION SHIFTER

245487C1

CAV

WIRE IDENT

CIRCUIT Not Used

25W

3rd and 4th Gear Signal

1st and 4th Gear Signal

25Z

1st and 4th Gear Signal

Transmission Kick Down Signal

25Y

Transmission Kick Down Signal

Not Used

4002-171 CONNECTOR TSS - TURBINE SPEED SENSOR

CONNECTOR YFR - FAN REVERSING SOLENOID

4002-171 CONNECTOR TSS - TURBINE SPEED SENSOR

CONNECTOR YFR - FAN REVERSING SOLENOID

225316C1

CAV 291718A1

CAV

WIRE IDENT

CIRCUIT

25C

Turbine Speed Signal

0-HH

Turbine Speed Ground

1 2

WIRE IDENT 52A-B 0-BB

225316C1

CIRCUIT

CAV 291718A1

Fan Reversing Relay Out Fan Reversing Solenoid Ground

CAV

WIRE IDENT

CIRCUIT

25C

Turbine Speed Signal

0-HH

Turbine Speed Ground

52A-B

Fan Reversing Relay Out

0-BB

Fan Reversing Solenoid Ground

CONNECTOR YPB - PARKING BRAKE SOLENOID

CONNECTOR YCS - COMFOR STEERING SOLENOID

245482C1

WIRE IDENT

291718A1

CAV

CIRCUIT

CONNECTOR YPB - PARKING BRAKE SOLENOID

CAV

WIRE IDENT

CIRCUIT

245482C1

CAV

WIRE IDENT

291718A1

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

51B-D

Comfort Steering Solenoid Pwr

52P

Parking Brake Relay Out

51B-D

Comfort Steering Solenoid Pwr

52P

Parking Brake Relay Out

0-AQ

Comfort Steering Solenoid Gnd

0-AN

Park Brake Solenoid Ground

0-AQ

Comfort Steering Solenoid Gnd

0-AN

Park Brake Solenoid Ground

CONNECTOR YFN - FAN PWM SOLENOID

CONNECTOR YPP - PILOT PRESSURE SOLENOID

CONNECTOR YFN - FAN PWM SOLENOID

CONNECTOR YPP - PILOT PRESSURE SOLENOID

245482C1 256340A1

CAV

WIRE IDENT

CIRCUIT

56-A

Fan Control PWM

0-BQ

Fan Speed PWM Solenoid Gnd

CAV

WIRE IDENT

245482C1 256340A1

CIRCUIT

5P-A

Pilot Control Relay Out

CAV

WIRE IDENT

CIRCUIT

0-DU

Pilot Pressure Solenoid Gnd

56-A

Fan Control PWM

0-BQ

Fan Speed PWM Solenoid Gnd

CAV

WIRE IDENT

CIRCUIT

5P-A

Pilot Control Relay Out

0-DU

Pilot Pressure Solenoid Gnd

4002-172

CONNECTOR YRC - RIDE CONTROL OPT

291718A1

CAV

WIRE IDENT

CIRCUIT

291718A1

CAV

WIRE IDENT

CIRCUIT

Ride Control Solenoid Power

58S-E

Ride Control Sol To Front Cab

58S-E

Ride Control Sol To Front Cab

0-AD

Ride Control Ground

0-AD

Ride Control Ground

CONNECTOR YSS - SECONDARY STEERING SOLENOID

225316C1

CAV

WIRE IDENT

CIRCUIT

225316C1

CAV

WIRE IDENT

CIRCUIT

51-C

Sec. Steering Solenoid Control

51-C

Sec. Steering Solenoid Control

0-CF

Sec. Steering Solenoid Ground

0-CF

Sec. Steering Solenoid Ground

BATTERIES

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4003

Section 4003

4003

Section 4003

BATTERIES

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4003-2

TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 4 4 4 5 5 5 6 7 7 8 8

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4 5 5 5 6 7 7 8 8

4003-3

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

WARNING: Never cause sparks to occur or smoke near batteries that are charging or have been recently charged. 13-8A

WARNING: Disconnect the 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.

SAFETY RULES

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in enclosed area. Always shield eyes when working near batteries. Keep out of reach of children.

48-57B

SPECIAL TOOLS

D-47-53A

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

48-57B

SPECIAL TOOLS

B795328

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

D-47-53A

4003-4

MAINTENANCE

Electrolyte Level

Inspecting and Cleaning a Battery

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.

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.

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.

If the level of the electrolyte is low, add distilled water or other clean water until the electrolyte is 5 mm (Âź inch) below the level of the ring. 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.

4003-5

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

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

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.

Visual Checks

1. Make sure the cable connections are clean and tight. Clean foreign material from the top of the battery.

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.

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.

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

4003-6

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

B. Make sure the load control knob is in the OFF position. C. Select the ammeter range that will measure 0 to 1000 amperes. D. Move the volt lead switch to the NT. position. 3. Connect the tester to the battery as shown.

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

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

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.

B790499

1. LOAD CONTROL KNOB

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

4003-7

CHARGING A BATTERY

The charging rate must be decreased if: WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83

Before you charge the battery, check the level of the electrolyte. 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.

1. Too much gas causes the electrolyte to flow from the cells.

The charging rate must be decreased if: WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83

1. Too much gas causes the electrolyte to flow from the cells.

2. The temperature of the electrolyte rises above 52째C (125째F).

Before you charge the battery, check the level of the electrolyte.

2. The temperature of the electrolyte rises above 52째C (125째F).

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.

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.

The battery is fully charged when, over a three hour period at a low charging rate, no cell is giving too much gas, and the specific gravity does not change.

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

Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - See Reserve Capacity under Specifications 80 Minutes or Less

Battery Capacity - See Reserve Capacity under Specifications

Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

80 Minutes or Less

Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

*lnitial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been removed from the decal.

Continued on next page

4003-8

Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - See Reserve Capacity under Specifications 80 Minutes or Less

Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

Battery Capacity - See Reserve Capacity under Specifications 80 Minutes or Less

Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

Above 250 Minutes

24 Hours at 10 Amperes

Above 250 Minutes

24 Hours at 10 Amperes

*lnitial 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. 4. Connect a battery charger to 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 15.5째C (60째F). 6. If necessary, fill each cell with electrolyte until the electrolyte is just below split ring at the bottom of the cell opening.

4003-9

7 8

6 2

W270-7R018

1. 2. 3. 4.

BATTERY ANGLE CLAMP WASHER

5. 6. 7. 8.

BOLT NUT WASHER BOLT

W270-7R018

1. 2. 3. 4.

BATTERY ANGLE CLAMP WASHER

5. 6. 7. 8.

BOLT NUT WASHER BOLT

4003-10

NOTES

INSTRUMENT CLUSTER

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4005

Section 4005

4005

Section 4005

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

4005-2

TABLE OF CONTENTS INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 4 5 9 14 14 14 15 17 27 32

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 9 14 14 14 15 17 27 32

4005-3

INSTRUMENT CLUSTER

15 14

LOW BRAKE PRESSURE INDICATOR HIGH BEAM INDICATOR TRANSMISSION OIL TEMPERATURE GAUGE CAUTION MASTER INDICATOR MULTI FUNCTION LCD DISPLAY STOP MASTER INDICATOR HYDRAULIC OIL TEMPERATURE GAUGE WAIT TO START ENGINE PREHEAT

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

LACK OF AUX STEER PRESSURE (OPTIONAL) PARKING BRAKE INDICATOR RIGHT TURN INDICATOR FUEL LEVEL GAUGE FUEL LEVEL AT MINIMUM ENGINE COOLANT TEMPERATURE GAUGE LEFT TURN INDICATOR

The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a possible malfunction and when immediate action is needed due to a possible critical malfunction. When the machine is started, the instrument cluster will perform the following self-test:

BS06H240

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

BS06H240

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

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

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.

4005-4

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.

4. Four gauges will energize for 2 - 3 seconds.

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.

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.

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.

5. The warning alarm will sound for 2 - 3 seconds.

8. If only some of the LEDs illuminate, replace the instrument cluster.

9. If the LEDs illuminate, but the warning alarm does not sound, replace the instrument cluster.

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:

C. Check power relay module A for proper operation, see Section 4002. If the power relay module checks good, go to next step.

4005-5

LCD Multi-function Display

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.

4005-5

LCD Multi-function Display

NOTE: Forward and Reverse will blink if the transmission clutches are disconnected.

3. This example shows the maximum gear allowed when in Automatic mode. If display is blank the Manual mode has been selected.

4. This example shows the current transmission mode that has been selected.

A. If the Transmission is operating normally it will display either

BD06H036

1. LCD MULTI-FUNCTION DISPLAY

1 3

BD06H036

●

The LCD Multi-Function Display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps and the LCD Multi-Display will flash, NEW HOLLAND, with the machine model.

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.

●

1. LCD MULTI-FUNCTION DISPLAY

A - Automatic M - Manual operation.

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

C - Substitute Clutch.

●

L - Limp Home.

●

S - Transmission Shutdown.

●

U - TCU Shutdown.

5. This example (not displayed) will show the transmission clutches disengaged, if the Park Brake is OFF.

1 3

6. This example shows the Power Boost Status.

●

A - Automatic

●

M - Manual operation.

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

C - Substitute Clutch.

●

L - Limp Home.

●

S - Transmission Shutdown.

●

U - TCU Shutdown.

5. This example (not displayed) will show the transmission clutches disengaged, if the Park Brake is OFF. 6. This example shows the Power Boost Status.

●

MAX - Maximum Power.

●

MAX - Maximum Power.

●

STD - Normal/Standard mode of Operation.

●

STD - Normal/Standard mode of Operation.

●

AUTO - Switches automatically Maximum and Standard Power.

●

AUTO - Switches automatically Maximum and Standard Power.

●

ECO - Limited Power for fuel efficiency.

●

ECO - Limited Power for fuel efficiency.

between

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

BD06F185

LCD MULTI-FUNCTION DISPLAY

Information will be displayed in different zones on the LCD, as directed by the operator or machine. In most situations the operator or technician will be given specific information to follow if conditions are not correct.

1. In the example, above, the machine hours are 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.

between

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

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.

Navigating Through The LCD Multi-function Display Screens

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

BD06H037

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.

BD06H037

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

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 if selections are up or down from the current selection.

NOTE: Display units can be changed by the operator.

BD06H037

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

BD06F183

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

4005-7

BD06F027

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, as well as oil pressure PSI.

BD06F184

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

4005-7

BD06F169

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.

BD06F027

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, as well as oil pressure PSI.

BD06F170

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.

BD06F184

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

4005-8

Reset The Trip Information

BD06F172 BD06F170

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.

BD06F172 BD06F170

Highlight the trip screen you wish to set.

BD06H037

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

4005-9

Entering The Service Screens

After the machine has been started or the key switch has been turned to on the operator or service technican may use this service menu to adjust machine configurations to working conditions, test components, view faults that may have occurred, or select preferences.

NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.

BD06H038 / BD06H037

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. Power Mode Menu

●

Month

●

Year

●

Max - Maximum power possible

●

Std. - Normal/Standard operation

●

Auto - Will cycle between Max and Normal

●

Eco - Limited power for economy

2. Preferences Menu ●

Language - English, Italian, French, Spanish, Portuguese, German

●

Units - Metric, English or Imperial

●

Clock - 24 or 12 hour

3. Options Menu ●

Fan Auto - manual or automatic

●

Idle Auto - manual or automatic

●

Show RPM

●

Show MPH/KPH

4. Display Menu ●

Day Display

●

Day LED

●

Night Display

●

Night LED

5. Clock Menu ●

Hour

● ●

Items and selections in this menu are: 1. Power Mode Menu

●

Month

●

Year

●

Max - Maximum power possible

Part Number

●

Std. - Normal/Standard operation

●

Part Number

●

Serial Number

●

Auto - Will cycle between Max and Normal

●

Serial Number

●

Eco - Limited power for economy

●

Version

●

Version

6. Cluster H/W

●

Language - English, Italian, French, Spanish, Portuguese, German

●

Part Number

Loader Version

●

Units - Metric, English or Imperial

●

Loader Version

●

Clock - 24 or 12 hour

●

Version

7. Cluster S/W ● ● ● ●

Part Number

Version

● ● ● ● ● ● ●

3. Options Menu

7. Cluster S/W

●

Fan Auto - manual or automatic

Change Model *

●

Idle Auto - manual or automatic

●

Change Model *

Select Tires (Select tire sizes)

●

Show RPM

●

Select Tires (Select tire sizes)

Clutch Calibration (calibrate gear box)*

●

Show MPH/KPH

●

Clutch Calibration (calibrate gear box)*

8. Config Menu ●

2. Preferences Menu

6. Cluster H/W

4. Display Menu

8. Config Menu

●

Gear Limits (choose maximum gear)

Park Brake (Park brake test)

●

Day Display

●

Park Brake (Park brake test)

Cold Start (choose cold start system)

●

Day LED

●

Cold Start (choose cold start system)

FAN Test (sound level)

●

Night Display

●

FAN Test (sound level)

Special

●

Night LED

●

Special

Gear Limits (choose maximum gear)

- Reset Error

5. Clock Menu ●

Hour

Minute

●

Minute

Day

●

Day

- Factory Set

- Reset Error - Factory Set

4005-10

* 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 RPMâ&#x20AC;&#x2122;s.

Software Screen

* 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 RPMâ&#x20AC;&#x2122;s.

Select Screen

The select screen will allow you to make time settings as well as give access to machine information. Navigate this screen also by highlighting your selection and pressing confirm. This will allow you to change clock settings or view the hardware and software screens. No operator changes can be made to the hardware or software screens.

BD06F177

Hardware Screen Scroll to the hardware selection and press confirm to display machine information.

Software Screen

BD06H028

The cluster software selection will display the CNH part number, serial number, ID number and software version of the Instrument cluster. This display is a convenient source of information when ordering parts or accessories. Press escape to exit from this field and return to the selection menu or use the up or down arrow key to toggle to the software information screen.

Selecting Power Modes

The power mode allows the operator to choose the most effective machine power for the current job conditions. Most commonly auto is chosen, as the power will automatically increase or decrease between maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency.

BD06F177

Hardware Screen Scroll to the hardware selection and press confirm to display machine information.

Press and hold the confirmation button for two seconds to arrive at the service screen.

BD106F193

The cluster hardware selection will display the CNH part number, serial number, ID number and version of the Instrument cluster. This display is a convenient source of information when ordering parts or accessories. Press escape to exit from this field and return to the selection menu or use the up or down arrow key to toggle to the software information screen.

BD06H038

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

BD06H038

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

4005-11

Preferences

BD06F178

At the Power Mode Menu press the confirmation b u t t o n a g a i n to ac ti v ate the s el e c ti on s. Th e highlighted section will flash to indicate a new selection can be made. Press the up or down button to select the Power Mode, and then press the confirmation button again. This changes the mode and locks it into memory. The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected. NOTE: Selecting options and navigating through the screen menus are the same for all functions. The display will tell the operator if errors have occurred.

BD06F178 BD06F179

Language Screen, Measurement Units, and Clock The LCD screen can be set with language, units, and clock preferences. Use the arrow keys to scroll to the preferences menu. Press confirm. Choose the preferences desired, language in (English, Italian, Spanish, Portuguese, German, French, measurement units in English, Metric, or Imperial and clock units in either 12 or 24 hour). Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, use the confirm key to lock in the preference for the display. The escape key will allow you to leave this application.

At the Power Mode Menu press the confirmation button again to activate the selections. The highlighted section will flash to indicate a new selection can be made. Press the up or down button to select the Power Mode, and then press the confirmation button again. This changes the mode and locks it into memory. The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected. NOTE: Selecting options and navigating through the screen menus are the same for all functions. The display will tell the operator if errors have occurred.

BD06F176

Should an error me ssage display, press the confirmation button to acknowledge and begin again.

BD06F179

4005-12

Clutch Calibration

After warming the oil temperature:

1. Park the machine on a firm level surface. 2. Place the NEUTRAL.

Transmission

Control

1. Park the machine on a firm level surface.

Lever

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 Config.

BD06F202

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

BD06F196

If, conditions are not correct, an error message will appear and guide the operator or technican.

There are six, if conditions not met, screens:

●

Not in neutral

●

Not in neutral

●

Park Brake OFF

●

Park Brake OFF

●

Machine moving

●

Machine moving

●

Oil temp too low

●

Oil temp too low

●

Oil temp too high

●

Oil temp too high

●

Engine RPM low

●

Engine RPM 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:

BD06F202

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

●

Adjust K1

●

Adjust K1

●

Adjust K2

●

Adjust K2

●

Adjust K3

●

Adjust K3

●

Adjust K4

●

Adjust K4

●

Adjust KV

●

Adjust KV

●

Adjust KR

●

Adjust KR

Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start. BD06F195

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

If conditions are correct the operator or technican will see six calibration screens pass. They will display in this order:

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

Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start. BD06F195

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

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

4005-13

BD06F174

Options Menu Use the arrow keys to choose the options 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.

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

4005-13

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.

Display Menu

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 to lock the selection into memory. The screen display can be changed to suit working conditions for day and night separately.

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.

MPH/KPH 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.

BD06F174

Options Menu Use the arrow keys to choose the options 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.

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.

MPH/KPH 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.

4005-14

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.

1. 1000 to 1999 vehicle errors. 2. 2000 to 2999 not used.

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.

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.

ESCAPE KEY ENTER KEY UP KEY DOWN KEY

8. 8000 to 8999 optional equipment IE: GPS.

9. 9000 to 9999 internal AIC errors.

BD06H037

A. B. C. D.

BD06H037

A. B. C. D.

ESCAPE KEY ENTER KEY UP KEY 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,

2. 2000 to 2999 not used.

4. 4000 to 4999 transmission errors.

6. 6000 to 6999 reserved.

1. 1000 to 1999 vehicle errors.

3. 3000 to 3999 engine errors.

7. 7000 to 7999 reserved.

Fault Code Grouping

3. 3000 to 3999 engine errors.

5. 5000 to 5999 eltro-hydraulic system errors.

Fault Code Grouping

RETRIEVING FAULT CODES

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.

4005-15

VEHICLE FAULT CODES CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

VEHICLE FAULT CODES CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

1310

Hydraulic filter blocked

Change filter

1310

Hydraulic filter blocked

Change filter

1311

Engine air filter blocked

Change filter

1311

Engine air filter blocked

Change filter

1312

Hydraulic oil temperature above normal

1312

Hydraulic oil temperature above normal

1313

Hydraulic oil temperature to high

1313

Hydraulic oil temperature to high

1314

Transmission oil temperature above normal

1314

Transmission oil temperature above normal

1315

Transmission oil temperature to high

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

1316

1324

Check charging system Battery voltage high

1325

Oil temperature too high

1326

Coolant level low

1327

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

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

Fill radiator level

1326

Coolant level low

Fill radiator level

Moved during accelerated idle

No information available at time of print.

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.

1328

Moving when shifting to low idle

No information available at time of print.

1331

Electrical charging system voltage low critical level

1331

Electrical charging system voltage low critical level

1332

Water detected in fuel

Drain fuel filter

1332

Water detected in fuel

Drain fuel filter

1333

Engine overspeed

Check engine speeds

1333

Engine overspeed

Check engine speeds

1334

Intake manifold temperature high - critical

Check for defective or clogged after cooler

1334

Intake manifold temperature high - critical

Check for defective or clogged after cooler

1335

Brake pressure too low

1. Stop machine operations 2. Check charging system

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

1. Stop machine operations 2. Check charging system

1. 2. 3. 4.

Stop machine operations Run engine at 1500 rpm Check brake system pressure Check brake system for leaks

4005-16 CODE 1336

4005-16 DEFINITION Transmission oil filter blocked

POSSIBLE STEPS FOR REPAIR Replace filter

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

CODE 1336

DEFINITION Transmission oil filter blocked

POSSIBLE STEPS FOR REPAIR Replace filter

NOTE: The following fault codes are for optional climate controlled heating and air conditioning system. CODE 1909

DEFINITION Open circuit evaporator temperature sensor

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR AC relay compressor is disabled.

1910

Short circuit evaporator temperature sensor

1. Check sensor for short circuit to ground or open circuit. 2. Check harness between control module and relay.

1919

Water valve motor output failure, does not work correctly

1. Verify if the system controls are functioning properly when requesting heat or AC. 2. The motor is working in a degraded mode, replace valve.

Recirculation actuator DC motor output failure, does not work correctly

1. Turn system on with fan speed on low, verify position of flap. 2. Place the fan speed on high, check position of flap. 3. Check harness between controller and flap motor.

AC relay output failure, does not work.

1. Check for proper connection of relay. 2. Replace relay with known good relay and retest system. 3. Verify system activation when AC button is pressed. 4. Check charge level of AC system.

1920

1921

4005-17

ENGINE FAULT CODES CODE

DEFINITION

3002

Foot throttle sensor signal above range max.

3003

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

ENGINE FAULT CODES DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

Short circuit in wiring or in accelerator pedal. Check wiring 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.

Foot throttle sensor signal below range min.

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

3004

Foot throttle sensor - no signal

Check wiring or replace accelerator pedal

3007

Coolant temperature sensor signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

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.

3008

Coolant temperature sensor signal below range min.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3016

Fuel temperature signal below range min.

Sensor defective or short circuit to ground. 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.

3019

Boost pressure sensor signal above range max.

Sensor defective or short circuit to external source. 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.

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

3023

Atmospheric pressure sensor signal not plausible

3024

Atmospheric pressure sensor signal above range max.

3024

Atmospheric pressure sensor signal above range max.

3025

Atmospheric pressure sensor signal below range min.

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.

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.

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.

3030

Oil pressure sensor short-circuit to ground

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3034

Oil temperature sensor signal above range max.

Sensor defective or short circuit to external source. Check wiring or replace sensor.

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.

3035

Oil temperature sensor signal below range min.

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3037

Boost pressure sensor signal low

Sensor defective or short circuit to ground. Check wiring or replace sensor.

3037

Boost pressure sensor signal low

Sensor defective or short circuit to ground. Check wiring or replace sensor.

4005-18 CODE

4005-18 DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3043

Vehicle speed sensing hardware conversion error

No information available at time of print.

3043

Vehicle speed sensing hardware conversion error

No information available at time of print.

3046

Vehicle speed sensing signal not plausible

No information available at time of print.

3046

Vehicle speed sensing signal not plausible

No information available at time of print.

3051

Battery voltage to ECM too high

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

3051

Battery voltage to ECM too high

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

3052

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.

3052

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.

3062

Cylinder 1 signal low

Check the wiring and the injection signals, replace ECU

3062

Cylinder 1 signal low

Check the wiring and the injection signals, replace ECU

3066

Cylinder 5 signal low

Check the wiring and the injection signals, replace ECU.

3066

Cylinder 5 signal low

Check the wiring and the injection signals, replace ECU.

3070

Cylinder 3 signal low

Check the wiring and the injection signals, replace ECU.

3070

Cylinder 3 signal low

Check the wiring and the injection signals, replace ECU.

3074

Cylinder 6 signal low

Check the wiring and the injection signals, replace ECU.

3074

Cylinder 6 signal low

Check the wiring and the injection signals, replace ECU.

3078

Cylinder 2 signal low

Check the wiring and the injection signals, replace ECU.

3078

Cylinder 2 signal low

Check the wiring and the injection signals, replace ECU.

3082

Cylinder 4 signal low

Check the wiring and the injection signals, replace ECU.

3082

Cylinder 4 signal low

Check the wiring and the injection signals, replace ECU.

3161

Fan actuator signal low

No information available at time of print.

3161

Fan actuator signal low

No information available at time of print.

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

Sensor supply voltage 1 high

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 1 low

Sensor supply voltage 2 high

3280

3281

3283

3280

3281

3283

4005-19 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

4005-19 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3284

Sensor supply voltage 2 low

3290

Turbo compound monitoring signal not plausible

No information available at time of print.

3801

Engine oil pressure sensor circuit - data incorrect

Progressive power derate with increasing time from alert. If engine protection shutdown feature is enabled, engine will shut down 30 seconds after red lamp starts flashing. Check wiring or replace sensor.

3801

Engine oil pressure sensor circuit - data incorrect

3802

Engine speed/positions sensor circuit - lost one of two signals from sensors

Engine will die and will not start. Check wiring or replace sensors.

3802

Engine speed/positions sensor circuit - lost one of two signals from sensors

Engine will die and will not start. Check wiring or replace sensors.

3803

Engine control module - critical internal failure

Possible none on performance or severe derate.

3803

Engine control module - critical internal failure

Possible none on performance or severe derate.

3804

Engine coolant level sensor circuit - data incorrect

Progressive power derate with increasing time after alert. If Engine Protection Shutdown feature is enabled, engine will shut down 30 seconds after red lamp starts flashing. Check wiring or replace sensor.

3804

Engine coolant level sensor circuit - data incorrect

3805

Engine control module - critical internal hardware failure

Possible none on performance or severe derate.

3805

Engine control module - critical internal hardware failure

Possible none on performance or severe derate.

3806

Cylinder power imbalance between cylinders

Engine will possibly have rough idle or misfire.

3806

Cylinder power imbalance between cylinders

Engine will possibly have rough idle or misfire.

3807

Accelerator pedal position sensor circuit - low frequency

Calibration dependent power and speed derate.

3807

Accelerator pedal position sensor circuit - low frequency

Calibration dependent power and speed derate.

3808

Accelerator pedal position sensor circuit - high frequency

Calibration dependent power and speed derate.

3808

Accelerator pedal position sensor circuit - high frequency

Calibration dependent power and speed derate.

Water in fuel sensor circuit - shorted high

Possible white smoke, loss of power, or hard starting. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

Water in fuel sensor circuit - shorted high

Possible white smoke, loss of power, or hard starting. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

3810

Water in fuel sensor circuit - shorted low

Possible white smoke, loss of power, or hard starting. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

3810

Water in fuel sensor circuit - shorted low

Possible white smoke, loss of power, or hard starting. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

3811

Engine hot after shutdown

No action taken by the ECM.

3811

Engine hot after shutdown

No action taken by the ECM.

3812

Low oil level in the sentinel makeup oil tank

None on performance. Sentinel deactivated.

3812

Low oil level in the sentinel makeup oil tank

None on performance. Sentinel deactivated.

Temperature sensor signal input - shorted low

No engine protection for OEM temperature. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

Temperature sensor signal input - shorted low

No engine protection for OEM temperature. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

3809

3813

3284

Sensor supply voltage 2 low

3290

Turbo compound monitoring signal not plausible

No information available at time of print.

3809

3813

4005-20 CODE

4005-20 DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3814

External speed input (multiple un synchronization) - data incorrect

Engine will die and will not start. Check wiring or replace sensors.

3814

External speed input (multiple un synchronization) - data incorrect

Engine will die and will not start. Check wiring or replace sensors.

3815

Accelerator pedal idle validation circuit shorted low

Engine will idle only.

3815

Accelerator pedal idle validation circuit shorted low

Engine will idle only.

3816

Temperature sensor signal input - shorted high

No engine protection for OEM temperature. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

3816

Temperature sensor signal input - shorted high

No engine protection for OEM temperature. Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC.

3817

Data transmission error on J1587/J1922 data link

Electronic service tool or other datalink will possibly not operate. Check wiring.

3817

Data transmission error on J1587/J1922 data link

Electronic service tool or other datalink will possibly not operate. Check wiring.

3818

Accelerator pedal idle validation circuit - out of calibration

Engine will idle only.

3818

Accelerator pedal idle validation circuit - out of calibration

Engine will idle only.

3819

SAE J1939 multiplexing accelerator pedal sensor system error

Engine will idle only.

3819

SAE J1939 multiplexing accelerator pedal sensor system error

Engine will idle only.

3820

SAE J1939 multiplexing remote throttle - data error

The engine will not respond to the remote throttle.

3820

SAE J1939 multiplexing remote throttle - data error

The engine will not respond to the remote throttle.

3821

SAE J1939 multiplexing PGN time-out error

Electronic service tool or other datalink will possibly not operate.

3821

SAE J1939 multiplexing PGN time-out error

Electronic service tool or other datalink will possibly not operate.

3822

Data transmission error on J1587/J1922 data link

Electronic service tool or other datalink will possibly not operate.

3822

Data transmission error on J1587/J1922 data link

Electronic service tool or other datalink will possibly not operate.

3823

Supply voltage low at engine brake circuit 1

Engine brake 1 can not be activated.

3823

Supply voltage low at engine brake circuit 1

Engine brake 1 can not be activated.

3824

Engine shutdown commanded by J1939

No action taken by the ECM.

3824

Engine shutdown commanded by J1939

No action taken by the ECM.

3825

SAE J1939 data link - wrong transmission rate

Electronic service tool or other datalink will possibly not operate.

3825

SAE J1939 data link - wrong transmission rate

Electronic service tool or other datalink will possibly not operate.

3826

Injector solenoid valve cylinder #1 circuit open circuit

3826

Injector solenoid valve cylinder #1 circuit open circuit

3827

Injector solenoid valve cylinder #2 circuit open circuit

3827

Injector solenoid valve cylinder #2 circuit open circuit

3828

Injector solenoid valve cylinder #3 circuit open circuit

3828

Injector solenoid valve cylinder #3 circuit open circuit

3829

Injector solenoid valve cylinder #4 circuit open circuit

3829

Injector solenoid valve cylinder #4 circuit open circuit

3830

Injector solenoid valve cylinder #5 circuit open circuit

3830

Injector solenoid valve cylinder #5 circuit open circuit

3831

Injector solenoid valve cylinder #6 circuit open circuit

3831

Injector solenoid valve cylinder #6 circuit open circuit

3832

Fuel shutoff valve circuit - shorted low

The ECM turns off the FSO supply voltage. The engine will shut down.

3832

Fuel shutoff valve circuit - shorted low

The ECM turns off the FSO supply voltage. The engine will shut down.

3833

Fuel shutoff valve circuit - shorted high

None on performance. Fuel shutoff valve will stay open.

3833

Fuel shutoff valve circuit - shorted high

None on performance. Fuel shutoff valve will stay open.

3834

Supply voltage low at engine brake circuit 2

Engine brake 2 can not be activated.

3834

Supply voltage low at engine brake circuit 2

Engine brake 2 can not be activated.

Amperage to injector is shut off.

4005-21 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

4005-21 CODE

DEFINITION

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR

3835

Electrical charging system voltage high warning level

Yellow lamp is lit until high battery voltage condition is corrected. Check charging circuit.

3835

Electrical charging system voltage high warning level

Yellow lamp is lit until high battery voltage condition is corrected. Check charging circuit.

3836

Auxiliary input/output #2 circuit - shorted high

No action taken by the ECM.

3836

Auxiliary input/output #2 circuit - shorted high

No action taken by the ECM.

3837

Power lost without ignition off

3837

Power lost without ignition off

3838

Engine control module data lost

Possible no noticeable performance effects OR possibility of engine dying OR hard starting. Fault information, trip information, and maintenance monitor data will possibly be inaccurate.

3838

Engine control module data lost

Possible no noticeable performance effects OR possibility of engine dying OR hard starting. Fault information, trip information, and maintenance monitor data will possibly be inaccurate.

3839

Auxiliary input/output #3 circuit - shorted high

No action taken by the ECM.

3839

Auxiliary input/output #3 circuit - shorted high

No action taken by the ECM.

3840

Remote accelerator pedal position sensor circuit - shorted low

None on performance if remote throttle is not used. Check wiring or replace sensor.

3840

Remote accelerator pedal position sensor circuit - shorted low

None on performance if remote throttle is not used. Check wiring or replace sensor.

3841

SAE J1939 multiplexing configuration error

At least one multiplexed device will not operate properly.

3841

SAE J1939 multiplexing configuration error

At least one multiplexed device will not operate properly.

3842

SAE J1939 data link - cannot transmit

None on performance. J1939 devices will possibly not operate.

3842

SAE J1939 data link - cannot transmit

None on performance. J1939 devices will possibly not operate.

3843

External speed input (multiple un synchronization) - data incorrect

All engines (primary and secondary) are shut down with increasing time after alert if hard-coupled. Only secondary engines are shut down with increasing time after alert if soft-coupled.

3843

External speed input (multiple un synchronization) - data incorrect

All engines (primary and secondary) are shut down with increasing time after alert if hard-coupled. Only secondary engines are shut down with increasing time after alert if soft-coupled.

3844

Accelerator pedal position sensor supply voltage circuit - shorted low

Engine will idle only.

3844

Accelerator pedal position sensor supply voltage circuit - shorted low

Engine will idle only.

3845

Electrical charging system voltage low warning level

Yellow lamp is lit until low battery voltage condition is corrected. The ECM will possibly increase idle speed and deactivate idle decrement switch if idle speedup is enabled. The engine will run continuously if “ICON” is active (automotive only). Check charging circuit.

3845

Electrical charging system voltage low warning level

3846

Remote accelerator pedal position sensor circuit - shorted high

None on performance if remote throttle is not used. Check wiring or replace sensor.

3846

Remote accelerator pedal position sensor circuit - shorted high

None on performance if remote throttle is not used. Check wiring or replace sensor.

3847

Accelerator pedal position sensor supply voltage circuit - shorted high

Engine will idle only.

3847

Accelerator pedal position sensor supply voltage circuit - shorted high

Engine will idle only.

3848

Voltage low at waste gate actuator #1

Engine will run derated.

3848

Voltage low at waste gate actuator #1

Engine will run derated.

3849

Intake manifold pressure senor - general error

Engine is derated to no air setting.

3849

Intake manifold pressure senor - general error

Engine is derated to no air setting.

3850

Add OEM/vehicle diagnostic codes have been logged. Check ECM’s for DTC’s

None on engine performance.

3850

Add OEM/vehicle diagnostic codes have been logged. Check ECM’s for DTC’s

None on engine performance.

3851

Error detected at OEM harness Pin34 and 32

Multiple unit synchronization is disabled.

3851

Error detected at OEM harness Pin34 and 32

Multiple unit synchronization is disabled.

3852

Voltage high at waste gate actuator #1

Engine will run derated.

3852

Voltage high at waste gate actuator #1

Engine will run derated.

3853

Voltage low at waste gate actuator #2

Engine will run derated.

3853

Voltage low at waste gate actuator #2

Engine will run derated.

3854

Engine oil burn valve solenoid circuit - shorted low

None on performance. Sentinel deactivated.

3854

Engine oil burn valve solenoid circuit - shorted low

None on performance. Sentinel deactivated.

3855

Voltage high at waste gate actuator #2

Engine will run derated.

3855

Voltage high at waste gate actuator #2

Engine will run derated.

4005-22

TRANSMISSION FAULT CODES CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

TRANSMISSION FAULT CODES CODE

Logical error at FNR switch

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.

4114

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.

4116

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

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.

4133

Short circuit to battery voltage or open circuit at temperature sensor

1. Check the connectors. 2. Check the temperature sensor.

4134

Short circuit to ground at temperature sensor

4135

Short circuit to battery voltage or open circuit at converter output temperature sensor

4136

Short circuit to ground at converter output temperature sensor

4137

Short circuit to battery voltage or open circuit at parking brake sensor input

4145

Short circuit to battery voltage or open circuit at engine speed sensor

4146

Short circuit to ground at engine speed sensor

4113

4114

4116

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

DEFINITION

Logical error at FNR switch

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

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.

4133

Short circuit to battery voltage or open circuit at temperature sensor

1. Check the connectors. 2. Check the temperature sensor.

4134

Short circuit to ground at temperature sensor

4135

Short circuit to battery voltage or open circuit at converter output temperature sensor

4136

Short circuit to ground at converter output temperature sensor

4137

Short circuit to battery voltage or open circuit at parking brake sensor input

4145

Short circuit to battery voltage or open circuit at engine speed sensor

4146

Short circuit to ground at engine speed sensor

4113

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor. 4147

Logical error at engine speed sensor input

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

POSSIBLE STEPS FOR REPAIR

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

1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the parking brake sensor. 1. Check the parking brake fuse. 2. Check the parking brake relay. 3. Check the parking brake solenoid. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.

4147

Logical error at engine speed sensor input

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

4005-23 CODE

DEFINITION

4148

Short circuit to battery voltage or open circuit at turbine speed sensor input

4149

Short circuit to ground at turbine speed sensor input

4150

Logical error at turbine speed sensor input

POSSIBLE STEPS FOR REPAIR

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

4005-23 CODE

DEFINITION

4148

Short circuit to battery voltage or open circuit at turbine speed sensor input

4149

Short circuit to ground at turbine speed sensor input

4150

Logical error at turbine speed sensor input

NOTE: This fault code is reset after power up of the TCU. 4151

Short circuit to battery voltage or open circuit at intermediate speed sensor input

4152

Short circuit to ground at intermediate speed input

4153

Logical error at intermediate speed sensor input

4154

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

4155

Short circuit to ground at output speed sensor

4156

4158

Logical error at output speed sensor

Output speed zero, does not match other speeds.

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.

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

4151

Short circuit to battery voltage or open circuit at intermediate speed sensor input

4152

Short circuit to ground at intermediate speed input

4153

Logical error at intermediate speed sensor input

4154

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

4155

Short circuit to ground at output speed sensor

4156

Logical error at output speed sensor

Invalid gear range restriction (CAN)

4180

Vehicle controller time-out (CAN)

4185

Invalid test mode signal (CAN)

4186

Invalid park brake status (CAN)

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. 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. 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.

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.

4158

Output speed zero, does not match other speeds.

NOTE: This fault code is reset after power up of the TCU. 4160

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.

NOTE: This fault code is reset after power up of the TCU. 1. Check the cables from TCU to the sensor. 2. Check the connectors. 3. Check the speed sensor.

POSSIBLE STEPS FOR REPAIR

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

NOTE: This fault code is reset after power up of the TCU. 4160

Invalid gear range restriction (CAN)

4180

Vehicle controller time-out (CAN)

4185

Invalid test mode signal (CAN)

4186

Invalid park brake status (CAN)

4005-24 CODE

4005-24 DEFINITION

POSSIBLE STEPS FOR REPAIR

CODE

DEFINITION

4209

Short circuit to battery voltage at clutch K1

4209

Short circuit to battery voltage at clutch K1

4210

Short circuit to ground at clutch K1

4210

Short circuit to ground at clutch K1

4211

Open circuit at clutch K1

4211

Open circuit at clutch K1

4212

Short circuit to battery voltage at clutch K2

4212

Short circuit to battery voltage at clutch K2

4213

Short circuit to ground at clutch K2

4213

Short circuit to ground at clutch K2

4214

Open circuit at clutch K2

4214

Open circuit at clutch K2

4215

Short circuit to battery voltage at clutch K3

4215

Short circuit to battery voltage at clutch K3

4216

Short circuit to ground at clutch K3

4217

Open circuit at clutch K3

4225

Short circuit to battery voltage at clutch K4

4226

Short circuit to ground at clutch K4

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.

4216

Short circuit to ground at clutch K3

4217

Open circuit at clutch K3

4225

Short circuit to battery voltage at clutch K4

4226

Short circuit to ground at clutch K4

4227

Open circuit at clutch K4

4227

Open circuit at clutch K4

4228

Short circuit to battery voltage at clutch KV

4228

Short circuit to battery voltage at clutch KV

4229

Short circuit to ground at clutch KV

4229

Short circuit to ground at clutch KV

4230

Open circuit at clutch KV

4230

Open circuit at clutch KV

4231

Short circuit to battery voltage at clutch KR

4231

Short circuit to battery voltage at clutch KR

4232

Short circuit to ground at clutch KR

4232

Short circuit to ground at clutch KR

4233

Open circuit at clutch KR

4233

Open circuit at clutch KR

4241

Short circuit to ground at backup alarm relay

4241

Short circuit to ground at backup alarm relay

4242

Short circuit to battery voltage at backup alarm relay

4242

Short circuit to battery voltage at backup alarm relay

4243

Open circuit at backup alarm relay

4243

Open circuit at backup alarm relay

4273

4274

4275

1. Check the cable from the TCU to the backup. alarm relay. 2. Check the connectors from the backup alarm relay to TCU. 3. Check the resistance of backup alarm relay circuit.

Slippage at clutch K1

1. 2. 3. 4. 5.

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

Slippage at clutch K2

1. 2. 3. 4. 5.

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

Slippage at clutch K3

1. 2. 3. 4. 5.

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

4273

4274

4275

POSSIBLE STEPS FOR REPAIR

1. Check the cable from the TCU to the backup. alarm relay. 2. Check the connectors from the backup alarm relay to TCU. 3. Check the resistance of backup alarm relay circuit.

Slippage at clutch K1

1. 2. 3. 4. 5.

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

Slippage at clutch K2

1. 2. 3. 4. 5.

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

Slippage at clutch K3

1. 2. 3. 4. 5.

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

4005-25 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

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

Oil temperature at valve body is above limit

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

Engine speed is measured above 5,000 rpm for 0.2 seconds

4276

4277

4278

4282

TCU sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter)

4284

Overspeed output

4288

Check engine speed sensor 1. Check oil filter. 2. Check wiring from TCU to filter maintenance switch. 3. Check filter maintenance switch (measure resistance).

4005-25 CODE

DEFINITION

POSSIBLE STEPS FOR REPAIR

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

Oil temperature at valve body is above limit

4281

Engine speed is measured above 5,000 rpm for 0.2 seconds

4276

4277

4278

Check engine speed sensor 1. Check oil filter. 2. Check wiring from TCU to filter maintenance switch. 3. Check filter maintenance switch (measure resistance).

4282

TCU sensed a voltage at oil filter maintenance switch out of the allowed range (dirty filter)

No information available at time of print.

4284

Overspeed output

No information available at time of print.

Engine torque or engine power overload

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.

4289

Transmission output torque overload

No information available at time of print.

4290

Transmission input torque overload

No information available at time of print.

4290

Transmission input torque overload

No information available at time of print.

4291

4292

Oil temperature at converter output is above limit

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.

4291

4292

Oil temperature at converter output is above limit

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.

4005-26

CODE

DEFINITION

CODE

DEFINITION

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.

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.

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.

4305

Power supply for sensors short-circuit to battery voltage

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

4305

Power supply for sensors short-circuit to battery voltage

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

4306

Power supply for sensors short-circuit to ground

4306

Power supply for sensors short-circuit to ground

4307

Low voltage at battery

1. Check batteries. 2. Check B+ wires from batteries to TCU. 3. Check voltage at TCU connector pin 45.

4307

Low voltage at battery

4308

High voltage at battery

4308

High voltage at battery

4309

Error at VPS 1 for solenoid power supply

1. 2. 3. 4.

4309

Error at VPS 1 for solenoid power supply

4310

Error at VPS 2 for solenoid power supply

4310

Error at VPS 2 for solenoid power supply

4325

Vehicle ID #1 time out

No information available at time of print.

4325

Vehicle ID #1 time out

No information available at time of print.

4326

Undefined VIN request via CAN.

No information available at time of print.

4326

Undefined VIN request via CAN.

No information available at time of print.

4337

General EEPROM fault

Replace the TCU.

4337

General EEPROM fault

Replace the TCU.

4338

Configuration error

Reprogram the correct configuration for the vehicle.

4338

Configuration error

Reprogram the correct configuration for the vehicle.

4339

Application error (ZF internal)

Replace the TCU.

4339

Application error (ZF internal)

Replace the TCU.

4341

Clutch calibration fault

4341

Clutch calibration fault

4342

Clutch adjustment data lost

4342

POSSIBLE STEPS FOR REPAIR

Check fuse A2. Check cable from control valve to TCU. Check connectors from control valve to TCU. Replace TCU.

Do the transmission clutch calibration procedure. Clutch adjustment data lost

POSSIBLE STEPS FOR REPAIR

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.

Do the transmission clutch calibration procedure.

4005-27

INSTRUMENT CLUSTER FAULT CODES CODE

DEFINITION

9128

CAN timed out during operation

9129

CAN timed out during operation

9130

CAN timed out during operation

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR If error is permanent or repeats often, check CAN wiring harness and connections on the CAN bus circuits.

INSTRUMENT CLUSTER FAULT CODES CODE

DEFINITION

9128

CAN timed out during operation

9129

CAN timed out during operation

9130

CAN timed out during operation

DESCRIPTION AND POSSIBLE STEPS FOR REPAIR If error is permanent or repeats often, check CAN wiring harness and connections on the CAN bus circuits.

4005-28

NOTES

Section Title

SECTION INDEX

STEERING

STEERING Section Number

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5007

5001

5001 CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section 5001

REMOVAL AND INSTALLATION OF STEERING COMPONENTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

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

TABLE OF CONTENTS 3 3 6 10 10 10 12 12 12 14 14 14 16 16 16

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

3 3 6 10 10 10 12 12 12 14 14 14 16 16 16

5001-3

STEERING CONTROL VALVE Removal

STEP 7

STEP 1

Remove the cab skirts from the cab or canopy.

STEP 2

Remove all dirt and grease from steering control valve.

STEP 3

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

Remove hydraulic reservoir fill cap, attach a vacuum pump to the reservoir, start the pump. BD06J100

STEP 4

BD06J100

Tag hoses connected to steering control valve.

Remove the mounting nut and washers from the steering shaft.

STEP 4 Tag hoses connected to steering control valve.

Remove the mounting nut and washers from the steering shaft.

STEP 5

STEP 8

STEP 5

STEP 8

BD06G262

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

BD06G262

BD06J101

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

Remove the steering wheel from the shaft.

STEP 9

STEP 6

BD06J101

Remove the steering wheel from the shaft.

STEP 9

STEP 6

BD06J099

Remove the center cap from the steering wheel.

BD06J102

Remove the six mounting screws from the instrument cluster cover.

BD06J099

Remove the center cap from the steering wheel.

5001-4

STEP 10

STEP 13

BD06J103

Disconnect the wires to the switches on the instrument cluster cover.

STEP 10

STEP 13

BD06J106

Disconnect the ignition switch.

BD06J103

Disconnect the wires to the switches on the instrument cluster cover.

STEP 14

BD06J106

Disconnect the ignition switch.

STEP 14

STEP 11

BD06J107 BD06J104.

Remove the two mounting screws from the instrument cluster.

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

BD06J107 BD06J104.

Remove the two mounting screws from the instrument cluster.

STEP 15

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

STEP 15

STEP 12

BD06J108 BD06J105.

Disconnect the wires to the instrument cluster.

If equipped, remove the mounting bolts for the right side brake pedal.

BD06J108 BD06J105.

Disconnect the wires to the instrument cluster.

If equipped, remove the mounting bolts for the right side brake pedal.

5001-5

STEP 16

STEP 19

5001-5

STEP 16

STEP 19

BD06J109

BD06J112

BD06J109

BD06J112

Remove the spacer block from the slot in the floor mat.

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

Remove the spacer block from the slot in the floor mat.

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

STEP 17

STEP 20

STEP 17

STEP 20

BD06J110

BD06J113

BD06J110

BD06J113

Remove the snap ring from the pin, remove the right pedal.

Remove the four mounting bolts for the steering control valve.

Remove the snap ring from the pin, remove the right pedal.

Remove the four mounting bolts for the steering control valve.

STEP 18

IMPORTANT: Have an assistant support and remove the valve while removing the mounting bolts.

STEP 18

IMPORTANT: Have an assistant support and remove the valve while removing the mounting bolts.

BD06J111

Remove the two mounting screws from the lower console trim.

5001-6

Installation

STEP 24

STEP 21

STEP 24

STEP 21

BD06J111

BD06G264

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

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

STEP 25

BD06J111

BD06G264

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

STEP 22

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

STEP 23

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

STEP 25

BD06J110

If equipped, install the right pedal pivot onto the left pedal, install the snap ring onto the pin.

STEP 26

BD06J113

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

BD06J109

Place the spacer block into the slot in the floor mat.

BD06J109

Place the spacer block into the slot in the floor mat.

5001-7

STEP 27

STEP 30

BD06J108

Install and tighten the mounting bolts for the right side brake pedal.

5001-7

STEP 27

BD06J105.

Connect the wires to the instrument cluster.

STEP 30

BD06J108

Install and tighten the mounting bolts for the right side brake pedal.

STEP 31

BD06J105.

Connect the wires to the instrument cluster.

STEP 31

STEP 28

BD06J104. BD06J107

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

Install and tighten the two mounting screws for the instrument cluster.

BD06J104. BD06J107

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

STEP 32

STEP 29

BD06J103 BD06J106

Connect the ignition switch.

Install and tighten the two mounting screws for the instrument cluster.

Connect the wires to the switches on the instrument cluster cover.

BD06J103 BD06J106

Connect the ignition switch.

Connect the wires to the switches on the instrument cluster cover.

5001-8

STEP 33

STEP 36

STEP 33

BD06J102

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 34

BD06J100

STEP 36

BD06J102

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 34

STEP 37

Turn off and remove the vacuum pump from the reservoir, install and tighten the reservoir fill cap.

STEP 38

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 39

Install the skirts onto the cab or canopy.

BD06J100

Install the skirts onto the cab or canopy.

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

STEP 40

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

STEP 40

STEP 35

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

STEP 35

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

BD06J099

Install the center cap on the steering wheel.

BD06J099

Install the center cap on the steering wheel.

5001-9

NOTES

5001-9

NOTES

5001-10

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.

AUXILIARY STEERING PRIORITY VALVE Removal

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

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

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. Tighten pressure tube fitting (5).

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 11.

4. Tighten the nuts (6).

3. Remove all dirt and grease from auxiliary steering priority valve and adjacent area. See illustration on page 11.

4. Tighten the nuts (6).

4. Remove hydraulic reservoir fill cap.

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

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).

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).

6. Start vacuum pump.

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

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

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).

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. 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.

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).

15. Install fill cap on hydraulic reservoir.

11. Tag and disconnect the wiring from the pressure switch (3).

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.

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.

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.

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

15. Tag and disconnect pressure hose (7) from priority valve. Install a cap on the fitting and a plug in the hose.

16. Loosen fitting (5) connected to elbow installed in steering priority valve.

17. Support auxiliary steering priority valve. Remove four nuts (6), cap screws, and washers.

18. Remove auxiliary steering priority valve.

15. Install fill cap on hydraulic reservoir.

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

5001-11

17 7

18 1

13 8

11 4

16 5 7

5 7

W270-4R015

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

STEERING LOAD SENSING HOSE TO PRIORITY VALVE STEERING LOAD SENSING HOSE TO STEERING VALVE PRESSURE SWITCH SUCTION PORT PUMP OUT PRESSURE TUBE FITTING CAP SCREWS AND NUTS PRESSURE HOSE STEERING SOLENOID STEERING PRESSURE HOSE

10. 11. 12. 13. 14. 15. 16. 17. 18.

TANK RETURN TUBE REAR CHASSIS HYDRAULIC TANK FILTER MANIFOLD PRIORITY VALVE MANIFOLD AUXILIARY STEERING PUMP MOTOR STEERING ORBITROL TANK BOTTOM

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

W270-4R015

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

10. 11. 12. 13. 14. 15. 16. 17. 18.

TANK RETURN TUBE REAR CHASSIS HYDRAULIC TANK FILTER MANIFOLD PRIORITY VALVE MANIFOLD AUXILIARY STEERING PUMP MOTOR STEERING ORBITROL TANK BOTTOM

AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

5001-12

PRIORITY VALVE Removal NOTE: When disconnecting hydraulic fittings, plug hoses and cap fittings to prevent entry of foreign matter into hydraulic system. 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine.

PRIORITY VALVE Removal

Installation 1. Install all new O-rings. 2. Install four bolts with washers (7) through mounting holes in the priority valve. 3. Mount the priority valve on the pumps and hand tighten the four mounting bolts (7).

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

4. Install four bolts with washers (8) and hand tighten.

2. Put master disconnect switch in OFF position.

4. Install four bolts with washers (8) and hand tighten.

3. Remove all dirt and grease from the priority valve (9) and adjacent area. See illustration on page 9.

5. Tourque mounting bolts (7 and 8) to 73.5 to 90.5 Nm (750 to 900 pound-inches).

3. Remove all dirt and grease from the priority valve (9) and adjacent area. See illustration on page 9.

5. Tourque mounting bolts (7 and 8) to 73.5 to 90.5 Nm (750 to 900 pound-inches).

4. Remove hydraulic reservoir fill cap.

6. Connect loader valve hose (6).

4. Remove hydraulic reservoir fill cap.

6. Connect loader valve hose (6).

5. Connect a vacuum pump to hydraulic reservoir.

7. Install pilot pressure tubes (3 and 4).

5. Connect a vacuum pump to hydraulic reservoir.

7. Install pilot pressure tubes (3 and 4).

6. Start vacuum pump.

8. Connect steering pump pressure hose (5).

6. Start vacuum pump.

8. Connect steering pump pressure hose (5).

7. If equiped, tag and disconnect load sensing tube from elbows installed in auxiliary steering solenoid valve and the priority valve (9).

9. Connect the load sense hose (2).

7. If equiped, tag and disconnect load sensing tube from elbows installed in auxiliary steering solenoid valve and the priority valve (9).

9. Connect the load sense hose (2).

8. If equiped, loosen fitting, auxiliary steering supply tube, and tee. Disconnect fitting from elbow installed in the priority valve.

10. Connect tank return hose (1). 11. If equiped, connect fitting to elbow installed in the priority valve (9). Tighten tee, auxiliary steering supply tube, and fitting.

8. If equiped, loosen fitting, auxiliary steering supply tube, and tee. Disconnect fitting from elbow installed in the priority valve.

10. Connect tank return hose (1). 11. If equiped, connect fitting to elbow installed in the priority valve (9). Tighten tee, auxiliary steering supply tube, and fitting.

10. Disconnect the load sense hose (2).

12. If equiped, connect load sensing tube to elbows installed in auxiliary steering solenoid valve and steering priority valve (9).

10. Disconnect the load sense hose (2).

12. If equiped, connect load sensing tube to elbows installed in auxiliary steering solenoid valve and steering priority valve (9).

11. Disconnect steering pump pressure hose (5).

13. Stop vacuum pump.

11. Disconnect steering pump pressure hose (5).

13. Stop vacuum pump.

12. Remove pilot pressure tubes (3 and 4).

14. Disconnect reservoir.

12. Remove pilot pressure tubes (3 and 4).

14. Disconnect reservoir.

9. Disconnect tank return hose (1).

13. Disconnect loader valve hose (6). 14. Support steering priority valve (9). Remove four bolts and washers (8) and four bolts and washers (7). 15. Remove steering priority valve (9).

vacuum

pump

from

hydraulic

15. Install fill cap on hydraulic reservoir. 16. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks.

9. Disconnect tank return hose (1).

13. Disconnect loader valve hose (6). 14. Support steering priority valve (9). Remove four bolts and washers (8) and four bolts and washers (7). 15. Remove steering priority valve (9).

vacuum

pump

from

hydraulic

15. Install fill cap on hydraulic reservoir. 16. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks.

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

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

5001-13

4 3

9 6

BC06A243

1. 2. 3. 4. 5.

RETURNO TO TANK STEERING LOAD SENSE PILOT PRESSURE TUBE PILOT PRESSURE TUBE TO STEERING CONTROL VALVE

6. 7. 8. 9.

TO LOADER VALVE BOLT MOUNTING BOLTS PRIORITY VALVE

PRIORITY VALVE ILLUSTRATION

BC06A243

1. 2. 3. 4. 5.

RETURNO TO TANK STEERING LOAD SENSE PILOT PRESSURE TUBE PILOT PRESSURE TUBE TO STEERING CONTROL VALVE

6. 7. 8. 9.

TO LOADER VALVE BOLT MOUNTING BOLTS PRIORITY VALVE

PRIORITY VALVE ILLUSTRATION

5001-14

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, 2. Put master disconnect switch in OFF position. 3. Tag and disconnect two wiring harness wires (1) from auxiliary steering pump and motor (7) solenoid. See illustration on page 15.

7. Stop and disconnect vacuum pump. Install fill cap in hydraulic reservoir. 8. Connect ground cable (3) to ground stud of auxiliary steering pump and motor (7) following tag installed during removal. 9. Connect positive cable (2) to B+ stud of auxiliary steering pump and motor (7) following tag installed during removal.

4. Tag and disconnect positive cable (2) from B+ stud of auxiliary steering pump and motor (7).

10. Connect wiring harness wires (1) to auxiliary steering pump and motor (7) following tags installed during removal.

5. Tag and disconnect ground cable (3) from ground stud of auxiliary steering pump and motor (7).

11. Remove and discard tags installed during removal.

6. Remove hydraulic reservoir fill cap. 7. Connect a vacuum pump to hydraulic reservoir. 8. Start vacuum pump. 9. Disconnect suction hose (4) from elbow installed in auxiliary steering pump and motor (7). Install a plug in suction hose and cap on elbow. 10. Stop vacuum pump.

12. Put master disconnect switch in ON position. 13. 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.

13. Remove pressure tube (5) and auxiliary steering pump and motor (7).

14. 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.

Installation

15. Turn steering wheel all the way to left and right to make sure that auxiliary steering pump and motor operates correctly.

11. Loosen fittings on pressure tube (5). 12. Support auxiliary steering pump and motor (7). Remove nuts (6), bolts, and washers securing auxiliary steering pump and motor (7).

1. Connect and hand tighten pressure tube (5) to auxiliary steering pump and motor (7). See illustration on page 15. 2. Position auxiliary steering pump and motor (7) on its mounting plate while connecting and hand tightening pressure tube (5) to auxiliary steering priority valve (8).

16. 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. 17. Let engine run and allow batteries to recharge for a minimum of 10 minutes.

4. Tag and disconnect positive cable (2) from B+ stud of auxiliary steering pump and motor (7).

10. Connect wiring harness wires (1) to auxiliary steering pump and motor (7) following tags installed during removal.

5. Tag and disconnect ground cable (3) from ground stud of auxiliary steering pump and motor (7).

11. Remove and discard tags installed during removal.

13. Remove pressure tube (5) and auxiliary steering pump and motor (7).

Installation

15. Turn steering wheel all the way to left and right to make sure that auxiliary steering pump and motor operates correctly.

11. Loosen fittings on pressure tube (5). 12. Support auxiliary steering pump and motor (7). Remove nuts (6), bolts, and washers securing auxiliary steering pump and motor (7).

3. While supporting auxiliary steering pump and motor (7) have a n assistan t in sta ll bolts, washers, and nuts (6) to secure auxiliary steering pump and motor (7).

4. Tighten pressure tube (5) fittings securely.

5. Start vacuum pump.

6. Remove plug from suction hose (4) and cap from elbow. Connect suction hose to elbow installed in auxiliary steering pump and motor (7).

5001-15

12 9

5001-15

6 W270-4R016

1. 2. 3. 4.

WIRING HARNESS POSITIVE CABLE GROUND CABLE SUCTION HOSE

5. 6. 7. 8.

PRESSURE TUBE NUT (4) AUXILIARY STEERING PUMP AND MOTOR AUXILIARY STEERING PRIORITY VALVE

9. 10. 11. 12.

TANK BOTTOM HYDRAULIC TANK REAR CHASSIS MANIFOLD AUXILIARY STEERING

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

W270-4R016

1. 2. 3. 4.

WIRING HARNESS POSITIVE CABLE GROUND CABLE SUCTION HOSE

5. 6. 7. 8.

PRESSURE TUBE NUT (4) AUXILIARY STEERING PUMP AND MOTOR AUXILIARY STEERING PRIORITY VALVE

9. 10. 11. 12.

TANK BOTTOM HYDRAULIC TANK REAR CHASSIS MANIFOLD AUXILIARY STEERING

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

5001-16

STEERING CYLINDER Removal NOTE: When disconnecting hydraulic fittings, plug hoses and cap fittings to prevent entry of foreign matter into hydraulic system. 1. Loosen the fill cap for the hydraulic reservoir to release pressure in the reservoir, then tighten the fill cap. 2. Disconnect grease hoses (16 and 20) from steering cylinders (17). See illustration on page 17. 3. Disconnect hydraulic hoses (7, 8, 18, and 19) from steering cylinders (17). 4. Remove locknut (9), washer (10), sealing ring (11), and polymer spacer (12). 5. Remove bolt (15) and hardened washer (14).

Installation 1. Put steering cylinders (17) in position in machine. See illustration on page 17. 2. Install the pivot pin (4) to secure rear of steering cylinders (17) to machine frame. Install spacer (3), washer (2), and bolt (1) to secure pivot pin (4). 3. Install washer (5) and nut (6), tighten nut (6). 4. Install pin (13) in front of steering cylinders (17). 5. Install and tighten bolt and washer (21). 6. Install washer (14) on bolt (15), put bolt (15) through pin (13). 7. Install polymer washer (12), sealing ring (11), washer (10), and nut (9). Tighten nut (9).

6. Remove bolt and washer (21), remove pin (13).

8. Connect hose assemblies (7, 8, 18, and 19) to steering cylinders (17).

6. Remove bolt and washer (21), remove pin (13).

8. Connect hose assemblies (7, 8, 18, and 19) to steering cylinders (17).

7. Remove nut (6), wahser (5), bolt (1), washer (2), and spacer (3) securing pivot pin (4) at rear of steering cylinders (17).

9. Connect grease hoses (16 and 20) to steering cylinders (17).

7. Remove nut (6), wahser (5), bolt (1), washer (2), and spacer (3) securing pivot pin (4) at rear of steering cylinders (17).

9. Connect grease hoses (16 and 20) to steering cylinders (17).

8. Use a suitable driver and drive pivot pin (4) out of steering cylinders (17). 9. Remove steering cylinders (17).

10. Tighten hydraulic reservoir fill cap. 11. Start engine. 12. Turn steering wheel all the way to right and then to the left several times. 13. Stop engine. Check the hydraulic oil level. See Section 1002 for specifications.

8. Use a suitable driver and drive pivot pin (4) out of steering cylinders (17). 9. Remove steering cylinders (17).

5001-17

1 3

1 7

6 10

20 17

13 15

15 14

14 BC06A242

BOLT WASHER SPACER PIN WASHER NUT HOSE LEFT CYLINDER ROD END

19 9

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

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

HOSE LEFT CYLINDER CLOSED END NUT WASHER SEALING RING POLYMER SPACER PIN HARDENED WASHER STEERING CYLINDER ILLUSTRATION

15. 16. 17. 18. 19. 20. 21.

BOLT GREASE HOSE STEERING CYLINDERS HOSE RIGHT CYLINDER CLOSED END HOSE RIGHT CYLINDER ROD END GREASE HOSE BOLT AND WASHER

BC06A242

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

BOLT WASHER SPACER PIN WASHER NUT HOSE LEFT CYLINDER ROD END

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

HOSE LEFT CYLINDER CLOSED END NUT WASHER SEALING RING POLYMER SPACER PIN HARDENED WASHER STEERING CYLINDER ILLUSTRATION

15. 16. 17. 18. 19. 20. 21.

BOLT GREASE HOSE STEERING CYLINDERS HOSE RIGHT CYLINDER CLOSED END HOSE RIGHT CYLINDER ROD END GREASE HOSE BOLT AND WASHER

5001-18

NOTES

STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5002

Section 5002

Section 5002 STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

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

TABLE OF CONTENTS 3 3 4 4 4 5 5 5 6 7 7 8 9

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

3 3 4 4 4 5 5 5 6 7 7 8 9

5002-3

SPECIAL TOOLS

B785789

OEM1239 380001731 FLOWMETER

B009638

380001739 PRESSURE TEST FITTING KIT

B785789

OEM1239 380001731 FLOWMETER

B797157

B009638

380001739 PRESSURE TEST FITTING KIT

B797157

380001740 FLOWMETER FITTING KIT

TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual.

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

NOTE: The steering hydraulic schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual.

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

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

4. Test the steering cylinders for leakage, refer to instructions on page 9. If a steering cylinder is leaking, repair or replace the steering cylinder.

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

4. Test the steering cylinders for leakage, refer to instructions on page 9. If a steering cylinder is leaking, repair or replace the steering cylinder.

2. Do the steering limit valve pressure test. Refer to page 7. If the pressure is above or below specifications, adjust the steering limit valve.

5002-4

AUXILIARY STEERING SYSTEM PUMP TEST

Equipment Required

1. 380001731 Flowmeter

2. 380001740 Flowmeter fitting kit

Test Procedure

Test Procedure 1

BB830300

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

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

1. AMMETER CLAMP

W270-1R006

1. ARTICULATION LOCK

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

1. AMMETER CLAMP

W270-1R006

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.

1. ARTICULATION LOCK

8. Make sure that temperature.

the

oil

operating

5002-5

AUXILIARY STEERING SYSTEM MOTOR TEST Test Equipment

AUXILIARY STEERING SYSTEM MOTOR TEST

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.

1. 2. 3. 4. 5.

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

B795328

6. AMMETER 7. VOLTMETER 8. LOAD CONTROL

7. Hold the tachometer against the armature shaft. Look at the tachometer. Make a record of the indication.

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.

B790852

1. 2. 3. 4. 5.

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

B795328

6. AMMETER 7. VOLTMETER 8. LOAD CONTROL

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

Test Procedure

8. Release the button on the remote starter switch (1).

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.

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.

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.

3. A tachometer to check the armature speed.

1. Remove the connector that is between the terminals on the magnetic switch and the auxiliary steering motor.

1. A 24 volt battery that is fully charged.

4. A Sun Electric VAT-33 Starting and Charging System Tester.

Test Procedure

4. Connect the auxiliary steering motor (3), remote starter switch (1) and tester (2) to the 24 volt battery system (5) as illustrated.

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

2. A remote starter switch.

4. A Sun Electric VAT-33 Starting and Charging System Tester.

3. Remove the drive coupling from the auxiliary steering motor (3).

Test Equipment

5002-6

UNDERSTANDING THE RESULTS OF THE TEST 1. If the ammeter indication in step 6 was 30 amperes or less and the tachometer indication in step 7 was 6950 r/min (rpm) or more, the auxiliary steering motor is good. 2. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was higher than 30 amperes, possible causes include the following: A. Damaged bearings. B. Loose pole shoes. C. A short circuit in the armature coil. The armature coil must be checked on an armature tester after the motor is disassembled. D. A ground connection in the field coil. 3. If the armature did not turn and the ammeter indication was higher than 30 amperes, possible causes include the following: A. The motor terminal is in contact with the field frame. B. .A damaged bearing that will not let the armature turn.

4. If the armature did not turn, and the ammeter indication was zero amperes, possible causes include the following: A. An open field coil. B. An open armature coil. After the motor is disassembled, look at the commutator on the armature. If the commutator is badly burned, the armature coil is probably open. C. Broken brush springs or worn brush springs. 5. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was less than 30 amperes, possible causes include the following: A. Bad connections between the brushes and the field coil. B. Dirty commutator. 6. If the armature speed was 6950 r/min (rpm) or more and the ammeter indication was more than 30 amperes, there is probably a short circuit in the field coil. A short circuit in the field coil is difficult to find. It is recommended that a new field frame assembly be installed.

5002-7

STEERING 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

2. Make sure that the temperature of the hydraulic oil is at least 54째 C (129째 F).

W270-1R006

1. ARTICULATION LOCK

2. Make sure that the temperature of the hydraulic oil is at least 54째 C (129째 F).

3. To measure the temperature of the oil using the instrument panel:

A. Press the program switch (left side of the program/reset switch).

B. Press the up count switch to function 008.

C. Return the program switch to the OFF (center) position.

4. Apply the parking brake.

5. Start and run the engine at full throttle.

6. Lower the lift arms and hold the control lever in the FLOAT position.

W270-1R006

1. ARTICULATION LOCK

7. Hold the bucket control lever in the rollback position. 1. Install 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.

8. Continue holding until the specified temperature of the oil is reached. 9. Stop the engine. 10. Remove the cap on the hydraulic reservoir to release any pressure in the hydraulic system.

6. Lower the lift arms and hold the control lever in the FLOAT position. 7. Hold the bucket control lever in the rollback position.

1. Install 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.

8. Continue holding until the specified temperature of the oil is reached. 9. Stop the engine. 10. Remove the cap on the hydraulic reservoir to release any pressure in the hydraulic system.

BD03A086

1. STEERING PRIORITY VALVE 2. PUMP PRESSURE TEST PORT

11. Remove the dust cap from the test port (2).

12. Connect a 345 bar (5000 psi) pressure gauge to the test port (2).

NOTE: Make sure when you connect the pressure gauge that you do so in a manner that you can read the pressure gauge while sitting in the operators seat.

5002-8 13. Start the engine and operate the machine at full throttle.

5002-8

Pressure Setting Adjustment

13. Start the engine and operate the machine at full throttle.

14. With the articulation lock still in place, turn and hold the steering wheel for a hard right turn.

15. Continue holding the steering wheel, and read the pressure gauge.

16. The pressure gauge must indicate 239 to 243 bar (3465 to 3523 psi). If the pressure is not correct, adjust the steering relief valve.

Pressure Setting Adjustment

BD03A086

1 BD03A086

1. STEERING PRIORITY VALVE 2. “T” PORT

17. The adjusting screw is located inside the “T” port on the steering priority valve.

18. Turn the adjusting screw clockwise to increase the pressure setting. Turn the adjusting screw counterclockwise to decrease the pressure setting.

19. Repeat pressure test procedure.

20. If necessary, adjust the limit valve again until within the specified range.

21. Stop the engine before removing the pressure gauge.

5002-9

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

9. Connect the tube to the rod end of the left-hand steering cylinder. 10. Turn the machine all the way to the left. 11. Stop the engine. 12. Find the tube that is connected to the rod end of the right-hand steering cylinder. Disconnect the tube from the right-hand steering cylinder. 13. Install a plug in the tube. 14. Start and run the engine at full throttle. 15. Turn the steering wheel to the left. Hold the steering wheel for a full left turn. Have another person check for leakage at the opening of the rod end of the right-hand steering cylinder. 16. If there is constant leakage from the rod end, the piston packing in the right-hand steering cylinder is damaged. Repairs must be made. See Section 5005. 17. Connect the tube to the rod end of the right-hand steering cylinder.

5002-10

NOTES

STEERING CYLINDERS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5005

Section 5005

5005

Section 5005

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5005-2

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

TABLE OF CONTENTS 3 3 3 3 5

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 5

5005-3

SPECIFICATIONS

Torque for piston cap screw ..................................................................1600 to 1830 Nm (1180 to 1350 pound-feet) Torque for gland ............................................................................................339 to 475 Nm (250 to 350 pound-feet)

STEERING CYLINDER

Disassembly

Inspection

Disassembly

Inspection

1. Loosen and remove the lock screw (1) from the gland (2) and tube (18), see illustration on page 4.

1. Discard the O-ring (4), backup ring (3), wide seal (6), narrow seal (7), wiper (5), and bushing (8) that were removed from the gland (2).

1. Loosen and remove the lock screw (1) from the gland (2) and tube (18), see illustration on page 4.

1. Discard the O-ring (4), backup ring (3), wide seal (6), narrow seal (7), wiper (5), and bushing (8) that were removed from the gland (2).

2. Fasten the cylinder in a vise with soft jaws. Be careful not to damage the tube (18).

2. Discard the seal (12), loader ring (11), cast iron ring (10), and wear ring (13) that were removed from the piston (14).

2. Fasten the cylinder in a vise with soft jaws. Be careful not to damage the tube (18).

2. Discard the seal (12), loader ring (11), cast iron ring (10), and wear ring (13) that were removed from the piston (14).

3. Loosen and remove the gland (2) from the tube (18). 4. Pull the piston (14) straight out of the tube (18). 5. Fasten the rod eye on the piston rod (9) in the vise and put a support below the piston rod (9) near the piston (14). Use a shop cloth between the support and the piston rod (9) to prevent damage to the piston rod (9). 6. Loosen and remove the cap screw with washer (15) that hold the piston (14). 7. Remove the piston (14) from the piston rod (9). 8. Remove the seal (12), loader ring (11), cast iron ring (10), and wear ring (13) from the piston (14). 9. Remove the gland (2) from the piston rod (9). 10. Remove the O-ring (4), backup ring (3), wide seal (6), narrow seal (7), wiper (5), and bushing (8) from the gland (2).

3. Clean all parts in cleaning solvent. 4. Check to be sure that the piston rod (9) is straight. If the piston rod (9) is bent, a new piston rod (9) must be used. 5. Inspect the inside of the tube (18) for deep grooves and other damage. If there is any damage to the tube (18), a new tube (18) must be used. 6. Remove small scratches on the piston rod (9) or inside the tube (18) with emery cloth of medium grit. Use the emery cloth with a rotary motion. 7. Inspect the self-aligning bushings (17). Replace as required.

5005-4

5 16 17

2 3 4

16 17

10 11 12 13

16 17

2 3 4

10 11 12 13

BC06A176

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

LOCK SCREW GLAND BACKUP RING O-RING WIPER WIDE SEAL

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

NARROW SEAL BUSHING PISTON ROD CAST IRON RING LOADER RING PISTON SEAL

13. 14. 15. 16. 17. 18.

WEAR RING PISTON CAP SCREW WITH WASHER SNAP RING SELF-ALIGNING BUSHING TUBE

FIGURE 1 STEERING CYLINDER

16 17

BC06A176

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

LOCK SCREW GLAND BACKUP RING O-RING WIPER WIDE SEAL

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

NARROW SEAL BUSHING PISTON ROD CAST IRON RING LOADER RING PISTON SEAL

13. 14. 15. 16. 17. 18.

WEAR RING PISTON CAP SCREW WITH WASHER SNAP RING SELF-ALIGNING BUSHING TUBE

FIGURE 1 STEERING CYLINDER

5005-5

Assembly

18. Install the cap screw with washer (15) in the piston (14).

5005-5

Assembly

18. Install the cap screw with washer (15) in the piston (14).

1. If a new gland (2) is being installed, stamp the part number of the cylinder on the new gland (2), see illustration on page 4.

19. Install the piston (14) on the piston rod (9) and start the cap screw (15) into the piston rod (9).

1. If a new gland (2) is being installed, stamp the part number of the cylinder on the new gland (2), see illustration on page 4.

19. Install the piston (14) on the piston rod (9) and start the cap screw (15) into the piston rod (9).

2. Install the wide seal (6) in the gland (2) with the lips toward the small end of the gland (2).

20. Tighten the cap screw (15) to 1600 to 1830 Nm (1180 to 1350 pound-feet).

2. Install the wide seal (6) in the gland (2) with the lips toward the small end of the gland (2).

20. Tighten the cap screw (15) to 1600 to 1830 Nm (1180 to 1350 pound-feet).

3. Install the narrow seal (7) with the groove toward the inside of the gland (2).

21. Fasten the tube (18) in the vise. Be careful not to damage the tube (18).

3. Install the narrow seal (7) with the groove toward the inside of the gland (2).

21. Fasten the tube (18) in the vise. Be careful not to damage the tube (18).

4. Install the bushing (8) in the gland (2).

22. Apply petroleum jelly to the O-ring (4) and backup ring (3) on the gland (2) and to the sealing surface in the tube (18).

4. Install the bushing (8) in the gland (2).

22. Apply petroleum jelly to the O-ring (4) and backup ring (3) on the gland (2) and to the sealing surface in the tube (18).

5. Install the wiper (7) into the gland (2) with the lip out. 6. Install the O-ring (4) on the gland (2). The O-ring (4) must be toward the small end of the gland (2). 7. Install the backup ring (3) on the gland (2). The backup ring (3) must be toward the large end of the gland (2). If the backup ring (3) is not flat on both sides, the side that is not flat must be toward the O-ring (4). 8. Fasten the rod eye on the piston rod (9) in a vise. 9. Lubricate the piston rod (9) and the bore in the gland (2) with clean hydraulic oil. 10. Push the gland (2) onto the piston rod (9). If necessary, use a soft hammer to drive the gland (2) onto the piston rod (9). 11. Put a support below and near the end of the piston rod (9). Put a cloth between the support and the piston rod (9) to prevent damage to the piston rod (9). 12. Install a new wear ring (13) on the piston (14). 13. Install a new loader ring (11) on the piston (14). 14. Install a new seal (12) over the loader ring (11). 15. Install a new cast iron ring (10) on the piston (14). 16. Clean the threads on the end of the piston rod (9) and the threads of the cap screw (15) using Loctite cleaning solvent. Allow to dry. 17. 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.

5. Install the wiper (7) into the gland (2) with the lip out. 6. Install the O-ring (4) on the gland (2). The O-ring (4) must be toward the small end of the gland (2).

25. When the piston (14) is in the smooth part of the tube (18), start the gland (2) into the tube (18).

7. Install the backup ring (3) on the gland (2). The backup ring (3) must be toward the large end of the gland (2). If the backup ring (3) is not flat on both sides, the side that is not flat must be toward the O-ring (4).

26. If the original gland and tube are being used:

8. Fasten the rod eye on the piston rod (9) in a vise.

A. Tighten the gland to 340 to 475 Nm (251 to 350 pound-feet) until the holes for the lock screw (1) are aligned. B. Install and tighten the lock screw (1). C. If, after tightening the gland (2), the lock screw holes are not aligned, a new hole for the lock screw (1) must be drilled. See the next step. 27. If a new gland (2) or tube (18) is being used: A. Tighten the gland (2) to 339 to 475 Nm (250 to 350 pound-feet).

9. Lubricate the piston rod (9) and the bore in the gland (2) with clean hydraulic oil. 10. Push the gland (2) onto the piston rod (9). If necessary, use a soft hammer to drive the gland (2) onto the piston rod (9). 11. Put a support below and near the end of the piston rod (9). Put a cloth between the support and the piston rod (9) to prevent damage to the piston rod (9). 12. Install a new wear ring (13) on the piston (14).

B. Use a No. 26 drill and drill a hole half in the gland (2) and half in the tube (18). Drill to a depth of 11 mm (7/16 inch). Do not drill within 12 mm (1/2 inch) of a hole for the gland wrench.

13. Install a new loader ring (11) on the piston (14).

C. Install and tighten the lock screw (1).

16. Clean the threads on the end of the piston rod (9) and the threads of the cap screw (15) using Loctite cleaning solvent. Allow to dry.

14. Install a new seal (12) over the loader ring (11). 15. Install a new cast iron ring (10) on the piston (14).

17. 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.

23. Lubricate the piston (14) and the inside of the tube (18) with clean hydraulic oil. 24. Push the piston (14) straight into the tube (18). Be careful not to damage the wear ring (13), seal (12), and cast iron ring (10) on the piston (14). 25. When the piston (14) is in the smooth part of the tube (18), start the gland (2) into the tube (18). 26. If the original gland and tube are being used: A. Tighten the gland to 340 to 475 Nm (251 to 350 pound-feet) until the holes for the lock screw (1) are aligned. B. Install and tighten the lock screw (1). C. If, after tightening the gland (2), the lock screw holes are not aligned, a new hole for the lock screw (1) must be drilled. See the next step. 27. If a new gland (2) or tube (18) is being used: A. Tighten the gland (2) to 339 to 475 Nm (250 to 350 pound-feet). B. Use a No. 26 drill and drill a hole half in the gland (2) and half in the tube (18). Drill to a depth of 11 mm (7/16 inch). Do not drill within 12 mm (1/2 inch) of a hole for the gland wrench. C. Install and tighten the lock screw (1).

5005-6

NOTES

CENTER PIVOT

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5006

Section 5006

5006

Section 5006

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5006-2

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

TABLE OF CONTENTS 3 3 4 4 6 9

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

3 3 4 4 6 9

5006-3

SPECIFICATIONS

SPECIAL TORQUES M16 bolt for upper pivot pin.......................................................................220 to 250 Nm (162 to 184 pound-feet) M12 bolts for bearing retainers and lower pivot pin ..........................................................124 Nm (91 pound-feet) M12 bolts for lower pin plate .......................................................................128 to 136 Nm (94 to 100 pound-feet) Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)

LUBRICANT Pivot bearings and seals ........................................................................................................ 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)

CAS2212 .................................................................................. *Top bearing driver, bottom bearing driver and plate * (Requires screw, two nuts, and two washers from 380001735)

BC06A175

CAS2212 DRIVER SET

BC06A175

CAS2212 DRIVER SET

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.

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 front chassis (5), see illustration on page 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.

5006-5

4 2

8 9

9 5

15 12

W270-5R006

1. 2. 3. 4.

BOLT WASHER SPACER UPPER PIVOT PIN

5. 6. 7. 8.

FRONT CHASSIS SEAL BEARING RETAINER SHIM

9. 10. 11. 12.

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

FIGURE 1. CENTER PIVOT ASSEMBLY

13. 14. 15. 16.

BEARING RETAINER BOTTOM SPACER LOWER PIN PLATE REAR CHASSIS

W270-5R006

1. 2. 3. 4.

BOLT WASHER SPACER UPPER PIVOT PIN

5. 6. 7. 8.

FRONT CHASSIS SEAL BEARING RETAINER SHIM

9. 10. 11. 12.

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

FIGURE 1. CENTER PIVOT ASSEMBLY

13. 14. 15. 16.

BEARING RETAINER BOTTOM SPACER LOWER PIN PLATE REAR CHASSIS

5006-6 36. Remove the bottom spacer (14). 37. Release the parking brake. 38. Use prybars to turn the left rear wheel backwards and the right rear wheel forward to move the front of the rear frame to the left for access to the bearings. Install blocks under the wheels to prevent the rear frame from moving. 39. Apply the parking brake.

5006-6

Assembly

36. Remove the bottom spacer (14).

1. Pack the bearing cones with grease. Be careful not to mix the bearing cones.

37. Release the parking brake.

3. Install a bearing cup (20) in the top pivot (22), refer to Figure 2.

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.

4. Install the bearing driver (17) and plate (21).

39. Apply the parking brake.

2. Lubricate the bore in the top pivot with grease.

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.

17 18

41. Remove the bearing retainer (13) and shims (8).

42. Remove the lower bearing spacer (11) from the top of the lower pivot.

20 21

22 BC06A118

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

17. BEARING DRIVER 18. NUT 19. SREW

20. BEARING CUP 21. PLATE 22. TOP 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.

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.

7. Install the bearing driver (17) and plate (21).

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.

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).

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.

19 26

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

2. Lubricate the bore in the top pivot with grease. 3. Install a bearing cup (20) in the top pivot (22), refer to Figure 2. 4. Install the bearing driver (17) and plate (21).

17 18

20 21

22 BC06A118

17. BEARING DRIVER 18. NUT 19. SREW

20. BEARING CUP 21. PLATE 22. TOP PIVOT

FIGURE 2.

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), refer to Figure 3. 7. Install the bearing driver (17) and plate (21). 8. Tighten a nut (18) on the screw (19) until the bearing cup (26) is seated against the spacer (24). Remove the bearing driver (17) and plate (21) from the top pivot (22).

17 23

19 26

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.

FIGURE 2.

1. Pack the bearing cones with grease. Be careful not to mix the bearing cones.

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).

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.

Assembly

BC06A119

23. BEARING CONE 24. SPCAER

25. BEARING CONE 26. BEARING CUP FIGURE 3.

BC06A119

23. BEARING CONE 24. SPCAER

25. BEARING CONE 26. BEARING CUP FIGURE 3.

5006-7 9. Put the bearing retainer (7) in place on the upper pivot bearing assembly (9), refer to Figure 4. 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, refer to Figure 6. 19. The bottom of the seal (6) must be even with the bottom of the top pivot.

BC06A125

FIGURE 6. BC06A120

FIGURE 4.

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), refer to figure 1. 15. Install the washers (2) and bolts (1). Tighten the bolts (1) to 488 to 515 Nm (360 to 380 pound-feet).

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

BC06A120

21. Install the upper pivot pin (4) in the top pivot.

BC06A125

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), refer to Figure 7.

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), refer to Figure 5.

FIGURE 4.

20. Apply grease to the upper pivot pin (4). 21. Install the upper pivot pin (4) in the top pivot.

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) (figure 1) 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), refer to figure 1. 15. Install the washers (2) and bolts (1). Tighten the bolts (1) to 488 to 515 Nm (360 to 380 pound-feet).

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), refer to Figure 5.

FIGURE 6.

28 29

17 BC06A123

BC06A121

FIGURE 7.

26. Tighten a nut (18) on the screw (19) until the bearing cup (28) is seated in the bore in the bottom pivot (29).

FIGURE 5.

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

BC06A123

FIGURE 7.

BC06A121

FIGURE 5.

27. Remove the bearing driver (17) and plate (21) from the bottom pivot (29).

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

27. Remove the bearing driver (17) and plate (21) from the bottom pivot (29).

5006-8

28. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the bottom pivot (29), refer to Figure 8.

37. Install the shims (8), the bearing retainer (13), washers (2) and bolts (1), refer to figure 1.

29. Install the bearing driver (17) and plate (21).

39. Fill the seal (6) for the bearing retainer (13) with grease.

38. Tighten the bolts (1) to 488 to 515 Nm (360 to 380 pound-feet).

40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13), refer to Figure 10.

28. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the bottom pivot (29), refer to Figure 8.

37. Install the shims (8), the bearing retainer (13), washers (2) and bolts (1), refer to figure 1.

29. Install the bearing driver (17) and plate (21).

39. Fill the seal (6) for the bearing retainer (13) with grease.

40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13), refer to Figure 10.

26 17

BC06A124

FIGURE 8.

30. Tighten a nut (18) on the screw (19) until the bottom bearing cup (26) is seated against the spacer (24).

31. Remove the bearing driver (17) and plate (21) from the bottom pivot (29). 32. Put the bearing retainer (13) in place on the lower pivot bearing (12).

BC06A126

FIGURE 10.

41. Install the other seal (6) in the bottom pivot, refer to Figure 11. The top of the seal (6) must be even with the top of the bottom pivot.

33. Install the bearing driver and plate, refer to Figure 9.

31. Remove the bearing driver (17) and plate (21) from the bottom pivot (29). 32. Put the bearing retainer (13) in place on the lower pivot bearing (12).

41. Install the other seal (6) in the bottom pivot, refer to Figure 11. The top of the seal (6) must be even with the top of the bottom pivot.

29 30

BC06A126

FIGURE 10.

33. Install the bearing driver and plate, refer to Figure 9.

38. Tighten the bolts (1) to 488 to 515 Nm (360 to 380 pound-feet).

12 13

BC06A121

FIGURE 11. BC06A125

FIGURE 9.

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) (figure 1) equal to that value. 36. Remove the bearing driver (17), plate (21) and bearing retainer (13) from the bottom pivot.

BC06A121

FIGURE 11. BC06A125

FIGURE 9.

34. Tighten a nut (18) on the screw (19) until the bearing retainer (13) is tight against the lower pivot bearing assembly (12).

46. Rotate the lower pivot pin (10) to check the bearing assembly. The lower pivot pin (10) must rotate smoothly, but not easily.

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) (figure 1) equal to that value.

47. Remove the lower pivot pin (10) and the upper pivot pin (4).

36. Remove the bearing driver (17), plate (21) and bearing retainer (13) from the bottom pivot.

48. Remove the bottom spacer (14).

42. Install the lower bearing spacer (11) and the bottom spacer (14). 43. Apply grease to the lower pivot pin (10). 44. Install the lower pivot pin (10) in the bottom pivot. 45. Hold the bottom spacer (14) in place and lubricate the bottom pivot until grease is forced out of the seal (6). 46. Rotate the lower pivot pin (10) to check the bearing assembly. The lower pivot pin (10) must rotate smoothly, but not easily. 47. Remove the lower pivot pin (10) and the upper pivot pin (4). 48. Remove the bottom spacer (14).

5006-9

CONNECTING THE FRONT FRAME TO THE REAR FRAME 1. Release the parking brake. 2. Move the rear frame into alignment with the front frame. 3. Move the steering cylinders as required to move the rear frame into alignment with the front frame. 4. Apply the parking brake. 5. Apply grease to the upper pivot pin (4), see illustration on page 5. 6. Install the upper pivot pin (4), spacer (3), washer (2) and bolt (1). Be careful not to damage the seal (6). 7. Tighten the bolt (1) to 386 to 433 Nm (285 to 320 pound-feet).

24. Tighten the Ferry head screws to 61 to 81 Nm (45 to 60 pound-feet). 25. Put the steering cylinder rod eye in position in the frame. Install the washer between the steering cylinder rod eye and the rear frame. 26. Align the hole in the pivot pin with the holes in the steering cylinder rod eye, and install the pivot pin. 27. Install the bolt and self-locking nut that hold the pivot pin. 28. Repeat steps 25, 26 and 27 for the other steering cylinder. 29. Start the vacuum pump.

5006-9

30. Connect the return hose.

7. Tighten the bolt (1) to 386 to 433 Nm (285 to 320 pound-feet).

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

31. Connect the supply hose.

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

31. Connect the supply hose.

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

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).

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.

10. Use the ram and hand pump to install the bottom spacer (14). See Special Tools in this section. 11. Install the lower pin plate (15), three inner bolts (1), and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10). 12. Tighten the bolts (1) to 68 Nm (50 pound-feet). 13. Measure the gap between the lower pin plate (15) and the bottom pivot. Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims equal to that value. 14. Loosen the bolts (1) that fasten the lower pin plate (15) to the lower pivot pin (10). 15. Start the six outer bolts (1) into the lower pin plate (15) and the bottom pivot. 16. Install the shims (8). 17. Tighten the six outer bolts (1) to 488 to 515 Nm (360 to 380 pound-feet). 18. Tighten the three inner bolts (1) to 488 to 515 Nm (360 to 380 pound-feet). 19. Remove the jacks from the rear frame. 20. Remove the blocks from the rear axle. 21. Remove the stands from the front frame. 22. Put the drive shaft in position on the front yoke. 23. Install new Ferry head screws that fasten the drive shaft to the front yoke.

33. Put the bracket for the hoses in position on the front frame. 34. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the front frame. 35. Connect the hoses for the steering cylinders. 36. Connect the brake hose for the front brakes at the front bracket. 37. Stop the vacuum pump. 38. Connect the front wiring harness to the rear wiring harness. 39. Put the clamp on the wiring harness in position on the bracket. Install the bolt, lock washer, and nut that fasten the clamp on the wiring harness to the bracket. 40. Put the ground wire in position on the stud. Install the washer and nut that fasten the ground wire to the stud. 41. Install a tie strap to fasten the wiring harness to the tube. 42. Disconnect the vacuum pump from the hydraulic reservoir. 43. Check the fluid level in the hydraulic reservoir. Add oil as required. 44. Install the fill cap in the hydraulic reservoir.

30. Connect the return hose.

5006-10 45. Bleed air from the front axle bleed screws. Refer to Section 7002 for complete brake bleeding instructions.

5006-10 46. Lubricate the pivot pins for the steering cylinder rod eyes. 47. Install the covers on both sides of the machine.

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

46. Lubricate the pivot pins for the steering cylinder rod eyes. 47. Install the covers on both sides of the machine.

AUXILIARY STEERING MOTOR AND PUMP

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5007

Section 5007

5007

Section 5007

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

5007-2

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

TABLE OF CONTENTS 3 4 4 4 4

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 4 4

5007-3

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)

5007-4

AUXILIARY STEERING MOTOR AND PUMP Disassembly

Assembly

AUXILIARY STEERING MOTOR AND PUMP Disassembly

Assembly

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

1. Lubricate all parts with clean hydraulic oil before assembly.

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

1. Lubricate all parts with clean hydraulic oil before assembly.

NOTE: The pump is the only component that is disassembled. The switch (8) and motor (1) are replaced as units and are not serviced. Refer to the illustration on page 5.

2. Lubricate and install a new seal (4) and retaining ring (3) on the plate (17). Refer to the illustration on page 5.

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 only serviceable items on the pump assembly are the seals (6), backup rings (5), O-rings (7), seal (4), retaining ring (3) and gasket (13). If any of the other items are damaged, replace the pump assembly.

Inspection

1. Inspect the wear plates (23) for grooves, scoring and pitting. If damage is found replace the pump assembly. Refer to the illustration on page 5.

2. Inspect the drive gear (20) and driven gear (19). If the shafts are worn or damaged, replace the pump assembly.

3. Clean all parts in cleaning solvent and air dry.

4. Inspect the plate (17), end plate (21) and body (18). Replace the pump assembly as necessary.

5007-5

11 16

1 13

14 15

6 23

7 22

22 18

18 22

22 7

7 20

20 23

23 6

6 5

5 21

21 2

2 BS01C121

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

MOTOR BOLT RETAINING RING SEAL BACKUP RING SEAL

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

O-RING SWITCH CABLE SCREW LOCK WASHER WASHER

13. 14. 15. 16. 17. 18.

GASKET LOCK WASHER SCREW WIRE PLATE BODY

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

19. 20. 21. 22. 23.

DRIVEN GEAR DRIVE GEAR END PLATE PINS WEAR PLATE

BS01C121

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

MOTOR BOLT RETAINING RING SEAL BACKUP RING SEAL

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

O-RING SWITCH CABLE SCREW LOCK WASHER WASHER

13. 14. 15. 16. 17. 18.

GASKET LOCK WASHER SCREW WIRE PLATE BODY

AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

19. 20. 21. 22. 23.

DRIVEN GEAR DRIVE GEAR END PLATE PINS WEAR PLATE

5007-6

NOTES

Section Title

SECTION INDEX

POWER TRAIN

POWER TRAIN Section Number

Section Title

Section Number

Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003

Front and Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004

Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6005

Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6006

Transmission Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007

6001

6001 CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section 6001

REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6001-2

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

TABLE OF CONTENTS 4 4 14 25 25 25 26 27 27 27 28

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE AND TRUNNIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 14 25 25 25 26 27 27 27 28

6001-3

SPECIAL TORQUES

Self-locking nuts for front axle mounting bolts . . . . . . . . . . . . . . . . . . 1877 to 1985 Nm (1380 to 1460 pound-feet) Drive shaft mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 108 Nm (70 to 80 pound-feet) Nuts for trunnion mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563 to 590 Nm (415 to 435 pound-feet) Rear trunnion spacer to axle bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 to 210 Nm (140 to 155 pound-feet) Cap screws for cover plate to rear trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 to 95 Nm (60 to 70 pound-feet) Nuts for transmission mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929 to 1044 Nm (685 to 770 pound-feet) Cap screws for transmission to bracket. . . . . . . . . . . . . . . . . . . . . . . . . . .1125 to 1274 Nm (830 to 940 pound-feet) Nuts for bolt in rear engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386 to 434 Nm (285 to 320 pound-feet) Cap screws for hydraulic pump to transmission . . . . . . . . . . . . . . . . . . . . . . . .102 to 113 Nm (75 to 83 pound-feet) Transmission to flywheel housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 to 60 Nm (40 to 44 pound-feet) Flywheel to flex plate nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 to 53 Nm (420 to 468 pound-inches) Cab and canopy mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .786 to 841 Nm (580 to 620 pound-feet) Wheel mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary 298 Nm (220 pound feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final 640 to 720 Nm (475 to 530 pound-feet)

6001-4

TRANSMISSION Removal NOTE: The transmission must be removed with the engine. Do the procedure for engine removal in Section 2000 but DO NOT disconnect the engine from the transmission remove both from the machine as a single unit.

7. Disconnect the hose from the reservoir tube (9) from the hydraulic filter, refer to illustration on page 5. 8. Disconnect the suction hoses (10) from the reservoir to the hydraulic pumps.

1. Remove the filler cap for the hydraulic reservoir.

9. Disconnect the hydraulic pump case drain hoses (11) at the reservoir.

2. Drain the hydraulic reservoir. Approximately 118 liters (31 U.S. gallons) will be drained. 3. Remove the cap screw (1), lock washers (2) and flat washers (3) that hold the cover (4) to the relay mounting plate (5).

10. Disconnect the hose for the brake pump (12) at the reservoir.

2. Drain the hydraulic reservoir. Approximately 118 liters (31 U.S. gallons) will be drained.

10. Disconnect the hose for the brake pump (12) at the reservoir.

11. Disconnect the hose loader valve pressure (13).

3. Remove the cap screw (1), lock washers (2) and flat washers (3) that hold the cover (4) to the relay mounting plate (5).

11. Disconnect the hose loader valve pressure (13).

4. Remove the nuts (6) and lock washers (7) that hold the relay mounting plate (5) to the reservoir.

5. Remove the relay mounting plate (5).

6. Remove the spacers (8) from the studs for the relay mounting plate (5).

6 7

B910705J

1. 2. 3. 4.

CAP SCREW LOCK WASHER FLAT WASHER COVER

5. 6. 7. 8.

RELAY MTG PLATE NUT LOCK WASHER SPACER

RELAY MOUNTING PLATE

8. Disconnect the suction hoses (10) from the reservoir to the hydraulic pumps. 9. Disconnect the hydraulic pump case drain hoses (11) at the reservoir.

4. Remove the nuts (6) and lock washers (7) that hold the relay mounting plate (5) to the reservoir.

7. Disconnect the hose from the reservoir tube (9) from the hydraulic filter, refer to illustration on page 5.

B910705J

1. 2. 3. 4.

CAP SCREW LOCK WASHER FLAT WASHER COVER

5. 6. 7. 8.

RELAY MTG PLATE NUT LOCK WASHER SPACER

RELAY MOUNTING PLATE

6001-5

W270-2R003

9. RETURN FROM HYDRAULIC FILTER 10. SUCTION HOSES TO HYDRAULIC PUMPS 11. HYDRAULIC PUMP CASE DRAIN HOSES

12. BRAKE PUMP SUCTION HOSE 13. HOSE LOADER VALVE PRESSURE 14. HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR

W270-2R003

9. RETURN FROM HYDRAULIC FILTER 10. SUCTION HOSES TO HYDRAULIC PUMPS 11. HYDRAULIC PUMP CASE DRAIN HOSES

12. BRAKE PUMP SUCTION HOSE 13. HOSE LOADER VALVE PRESSURE 14. HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR

6001-6

NOTE: If equipped with air conditioning, do step 12. If not equipped with air conditioning, go to step 13.

NOTE: The equipment pump has a weight of approximately 130 pounds (59 kg). Use suitable equipment to support the equipment pump while the transmission is out of the machine.

NOTE: If equipped with air conditioning, do step 12. If not equipped with air conditioning, go to step 13.

16. Remove the washers and cap screws that fasten the equipment pump to the transmission.

15 20

16. Remove the washers and cap screws that fasten the equipment pump to the transmission.

15 20

18. Remove the cap screws (22) from the rear drive shaft (24) at the transmission.

19 17

17. Remove the cap screws (22) from the center drive shaft (23) at the transmission, refer to illustration on page 7.

18 BC06A071

19. Remove the cap screws from the rear drive shaft (24) at the rear axle. Remove the rear drive shaft (24).

NOTE: The equipment pump has a weight of approximately 130 pounds (59 kg). Use suitable equipment to support the equipment pump while the transmission is out of the machine.

18. Remove the cap screws (22) from the rear drive shaft (24) at the transmission.

19 17

17. Remove the cap screws (22) from the center drive shaft (23) at the transmission, refer to illustration on page 7.

18 BC06A071

15. DOUBLE CLAMP 17. COMPRESSOR 19. WASHER HOSE 16. DRYER HOSE 18. NUT 20. RESERVOIR

12. If equipped with air conditioning, remove the nut (18), lock washer (19) and clamp (15) that holds the hoses (16 and 17) the hydraulic reservoir.

13. Fasten acceptable lifting equipment to the hydraulic reservoir.

14. Remove the nuts, hardened washers, and bolts that mount the hydraulic reservoir to the frame.

15. Carefully raise the reservoir and remove the reservoir.

19. Remove the cap screws from the rear drive shaft (24) at the rear axle. Remove the rear drive shaft (24).

6001-7

24 BC06A077

21. DRIVE SHAFT FLANGE 22. CAP SCREW

23. CENTER DRIVE SHAFT 24. REAR DRIVE SHAFT DRIVE SHAFTS

BC06A077

21. DRIVE SHAFT FLANGE 22. CAP SCREW

23. CENTER DRIVE SHAFT 24. REAR DRIVE SHAFT DRIVE SHAFTS

6001-8

20. Loosen the clamp and remove the sight gauge upper hose (30) from the fitting at the top of the transmission, refer to illustration on page 9. 21. Loosen the clamp and remove the sight gauge lower hose (29) from the fill tube (31). 22. Remove the transmission.

filler

tube

(31)

from

the

23. Tag and remove the filter bypass hose (25). 24. Tag and remove the filter inlet hose (26). 25. Tag and remove the filter return hose (27). 26. Tag and disconnect the parking brake hose (not shown). 27. Tag and disconnect the oil cooler hoses (not shown).

filler

tube

(31)

from

the

6001-9

W270-2R004

25. FILTER BYPASS HOSE 26. FILTER INLET HOSE 27. FILTER RETURN HOSE

28. FILTERS 29. SIGHT GAUGE LOWER HOSE 30. SIGHT GAUGE UPPER HOSE TRANSMISSION LINES

31. FILLER TUBE 32. SIGHT GAUGE BRACKET

W270-2R004

25. FILTER BYPASS HOSE 26. FILTER INLET HOSE 27. FILTER RETURN HOSE

28. FILTERS 29. SIGHT GAUGE LOWER HOSE 30. SIGHT GAUGE UPPER HOSE TRANSMISSION LINES

31. FILLER TUBE 32. SIGHT GAUGE BRACKET

6001-10 28. Tag and disconnect hydraulic oil temperature sender (33), refer to illustration on page 11-12. 29. Tag and disconnect the transmission filter clogged switch (34). 30. Tag and disconnect the hydraulic filter clogged switch (35).

6001-10 36. Remove the harness retaining clamp (41). 37. Tag and disconnect the intermediate speed sensor (42). 38. Tag and disconnect the turbine speed sensor (43).

31. Remove the harness retaining clamp (36).

39. Tag and disconnect the engine speed sensor (44).

32. Tag and disconnect the transmission controller (37).

28. Tag and disconnect hydraulic oil temperature sender (33), refer to illustration on page 11-12. 29. Tag and disconnect the transmission filter clogged switch (34). 30. Tag and disconnect the hydraulic filter clogged switch (35).

36. Remove the harness retaining clamp (41). 37. Tag and disconnect the intermediate speed sensor (42). 38. Tag and disconnect the turbine speed sensor (43).

31. Remove the harness retaining clamp (36).

39. Tag and disconnect the engine speed sensor (44).

40. Tag and disconnect the PRB2 redundant brake switch (45).

32. Tag and disconnect the transmission controller (37).

40. Tag and disconnect the PRB2 redundant brake switch (45).

33. Tag and disconnect the torque converter output sender (38).

41. Tag and disconnect the PRB1 redundant brake switch (46).

33. Tag and disconnect the torque converter output sender (38).

41. Tag and disconnect the PRB1 redundant brake switch (46).

34. If equipped, tag and disconnect the secondary steering harness (39).

42. Tag and disconnect the output speed sensor (47).

34. If equipped, tag and disconnect the secondary steering harness (39).

42. Tag and disconnect the output speed sensor (47).

35. Tag and disconnect the transmission ground (40).

43. Move the wiring harness out and away from the transmission.

35. Tag and disconnect the transmission ground (40).

43. Move the wiring harness out and away from the transmission.

6001-11

39 41

47 W270-2R005

33. 34. 35. 36. 37.

HYDRAULIC OIL TEMPERATURE SENDER TRANSMISSION FILTER CLOGGED SWITCH HYDRAULIC FILTER CLOGGED SWITCH CLAMP TRANSMISSION CONTROLLER

38. 39. 40. 41. 42.

TORQUE CONVERTER OUTPUT SENDER SECONDARY STEERING (OPT) TRANSMISSION GROUND CLAMP INTERMEDIATE SPEED SENSOR

TRANSMISSION WIRING HARNESS

43. 44. 45. 46. 47.

TURBINE SPEED SENSOR ENGINE SPEED SENSOR PRB2 BRAKE SWITCH PRB1 BRAKE SWITCH OUTPUT SPEED SENSOR

W270-2R005

33. 34. 35. 36. 37.

HYDRAULIC OIL TEMPERATURE SENDER TRANSMISSION FILTER CLOGGED SWITCH HYDRAULIC FILTER CLOGGED SWITCH CLAMP TRANSMISSION CONTROLLER

38. 39. 40. 41. 42.

TORQUE CONVERTER OUTPUT SENDER SECONDARY STEERING (OPT) TRANSMISSION GROUND CLAMP INTERMEDIATE SPEED SENSOR

TRANSMISSION WIRING HARNESS

43. 44. 45. 46. 47.

TURBINE SPEED SENSOR ENGINE SPEED SENSOR PRB2 BRAKE SWITCH PRB1 BRAKE SWITCH OUTPUT SPEED SENSOR

6001-12

43 42

W270-2R006

TRANSMISSION WIRING HARNESS

W270-2R006

TRANSMISSION WIRING HARNESS

6001-13

44. Remove the self-locking nuts (53), hardened washers (54), bolts (48), and washers (49).

45. Loosen the nuts on the front ROPS cab or canopy mounting bolts and raise the rear of the ROPS cab or canopy approximately 152 mm (6 inches).

49 48

45. Loosen the nuts on the front ROPS cab or canopy mounting bolts and raise the rear of the ROPS cab or canopy approximately 152 mm (6 inches).

49 48

46. Install a block on each side. 47. Raise the engine and transmission, move the engine and transmission to the rear of the machine. Do this as required until the transmission is free of the ROPS cab or canopy.

BOLT WASHER MOUNTING BRACKETS BOLT WASHER

NUT WASHER SPACER RESILIENT MOUNT

TRANSMISSION MOUNTING BRACKETS

53. Remove the cap screws that hold transmission to the flywheel housing. 54. Remove the transmission.

50. Fasten acceptable lifting equipment to the transmission.

52. Remove the twelve hardened washers and nuts from the flex plate.

53. 54. 55. 56.

49. Remove the starter from the engine.

51. Using the engine turning tool, turn the flywheel for access to the flex plate nuts.

BC06A075

48. 49. 50. 51. 52.

50. Fasten acceptable lifting equipment to the transmission.

48. Remove the engine and transmission from the machine. Put the engine and transmission on an acceptable support.

49. Remove the starter from the engine.

47. Raise the engine and transmission, move the engine and transmission to the rear of the machine. Do this as required until the transmission is free of the ROPS cab or canopy.

48. Remove the engine and transmission from the machine. Put the engine and transmission on an acceptable support.

46. Install a block on each side.

51. Using the engine turning tool, turn the flywheel for access to the flex plate nuts.

52. Remove the twelve hardened washers and nuts from the flex plate. BC06A075

the 48. 49. 50. 51. 52.

BOLT WASHER MOUNTING BRACKETS BOLT WASHER

53. 54. 55. 56.

NUT WASHER SPACER RESILIENT MOUNT

TRANSMISSION MOUNTING BRACKETS

53. Remove the cap screws that hold transmission to the flywheel housing. 54. Remove the transmission.

the

6001-14

Installation

NOTE: The transmission must be installed with the engine. See Section 2001 for engine installation.

1. Fasten acceptable lifting equipment to the transmission.

2. Replace the cap screws that hold the transmission to the flywheel housing. Tighten the cap screws to 54 to 60 Nm (40-44 pound-feet).

3. Using the engine turning tool, turn the flywheel to access, install and tighten the twelve hardened washers and nuts for the flex plate.

1. Fasten acceptable lifting equipment to the transmission.

3. Using the engine turning tool, turn the flywheel to access, install and tighten the twelve hardened washers and nuts for the flex plate.

4. Replace the engine starter.

5. Replace the engine and transmission in the machine. 6. Lower the ROPS cab or canopy and tighten the front mounting bolt nuts to 786 to 841 Nm (580 to 620 pound-feet).

6. Lower the ROPS cab or canopy and tighten the front mounting bolt nuts to 786 to 841 Nm (580 to 620 pound-feet).

50 55 54

7. Install the self-locking nuts on the bolts. Tighten the nuts to 786 to 841 Nm (580 to 620 pound-feet).

50 55 54

7. Install the self-locking nuts on the bolts. Tighten the nuts to 786 to 841 Nm (580 to 620 pound-feet).

5. Replace the engine and transmission in the machine.

BC06A075

48. 49. 50. 51. 52.

BOLT WASHER MOUNTING BRACKETS BOLT WASHER

53. 54. 55. 56.

NUT WASHER SPACER RESILIENT MOUNT

TRANSMISSION MOUNTING BRACKETS

8. Install the self-locking nuts (53), hardened washers (54), insulators (56), washers (49), and bolts (48) that hold the transmission mounting brackets (50) to the machine. Tighten the self-locking bolts to 685 to 929 to 1044 Nm (770 pound-feet), refer to Figure.

BC06A075

48. 49. 50. 51. 52.

BOLT WASHER MOUNTING BRACKETS BOLT WASHER

53. 54. 55. 56.

NUT WASHER SPACER RESILIENT MOUNT

TRANSMISSION MOUNTING BRACKETS

6001-15 9. Place the wiring harness into position over the transmission, refer to illustration on page 16-17.

17. Connect the transmission ground (40).

6001-15 9. Place the wiring harness into position over the transmission, refer to illustration on page 16-17.

17. Connect the transmission ground (40).

10. Connect the output speed sensor (47).

18. If equipped, connect the secondary steering harness (39).

10. Connect the output speed sensor (47).

18. If equipped, connect the secondary steering harness (39).

11. Connect the PRB1 redundant brake switch (46).

19. Connect the torque converter output sender (38).

11. Connect the PRB1 redundant brake switch (46).

19. Connect the torque converter output sender (38).

12. Connect the PRB2 redundant brake switch (45).

20. Connect the transmission controller (37).

12. Connect the PRB2 redundant brake switch (45).

20. Connect the transmission controller (37).

13. Connect the engine speed sensor (44).

21. Install the harness retaining clamp (36).

13. Connect the engine speed sensor (44).

21. Install the harness retaining clamp (36).

14. Connect the turbine speed sensor (43).

22. Connect the hydraulic filter clogged switch (35).

14. Connect the turbine speed sensor (43).

22. Connect the hydraulic filter clogged switch (35).

15. Connect the intermediate speed sensor (42).

23. Connect the transmission filter clogged switch (34).

15. Connect the intermediate speed sensor (42).

23. Connect the transmission filter clogged switch (34).

16. Install the harness retaining clamp (41).

24. Connect hydraulic oil temperature sender (33).

16. Install the harness retaining clamp (41).

24. Connect hydraulic oil temperature sender (33).

6001-16

39 41

47 W270-2R005

33. 34. 35. 36. 37.

HYDRAULIC OIL TEMPERATURE SENDER TRANSMISSION FILTER CLOGGED SWITCH HYDRAULIC FILTER CLOGGED SWITCH CLAMP TRANSMISSION CONTROLLER

38. 39. 40. 41. 42.

TORQUE CONVERTER OUTPUT SENDER SECONDARY STEERING (OPT) TRANSMISSION GROUND CLAMP INTERMEDIATE SPEED SENSOR

TRANSMISSION WIRING HARNESS

43. 44. 45. 46. 47.

TURBINE SPEED SENSOR ENGINE SPEED SENSOR PRB2 BRAKE SWITCH PRB1 BRAKE SWITCH OUTPUT SPEED SENSOR

W270-2R005

33. 34. 35. 36. 37.

HYDRAULIC OIL TEMPERATURE SENDER TRANSMISSION FILTER CLOGGED SWITCH HYDRAULIC FILTER CLOGGED SWITCH CLAMP TRANSMISSION CONTROLLER

38. 39. 40. 41. 42.

TORQUE CONVERTER OUTPUT SENDER SECONDARY STEERING (OPT) TRANSMISSION GROUND CLAMP INTERMEDIATE SPEED SENSOR

TRANSMISSION WIRING HARNESS

43. 44. 45. 46. 47.

TURBINE SPEED SENSOR ENGINE SPEED SENSOR PRB2 BRAKE SWITCH PRB1 BRAKE SWITCH OUTPUT SPEED SENSOR

6001-17

43 42

W270-2R006

TRANSMISSION WIRING HARNESS

W270-2R006

TRANSMISSION WIRING HARNESS

6001-18 25. Install the sight gauge upper hose (30) to the fitting at the top of the transmission and tighten the clamp., refer to illustration on page 19. 26. Install the filler tube (31) on the transmission. 27. Install the sight gauge lower hose (29) to the fill tube (31) and tighten the clamp.

6001-18 28. Install the filter bypass hose (25). 29. Install the filter inlet hose (26). 30. Install the filter return hose (27). 31. Install the parking brake hose (not shown). 32. Install the oil cooler hoses (not shown).

25. Install the sight gauge upper hose (30) to the fitting at the top of the transmission and tighten the clamp., refer to illustration on page 19. 26. Install the filler tube (31) on the transmission. 27. Install the sight gauge lower hose (29) to the fill tube (31) and tighten the clamp.

28. Install the filter bypass hose (25). 29. Install the filter inlet hose (26). 30. Install the filter return hose (27). 31. Install the parking brake hose (not shown). 32. Install the oil cooler hoses (not shown).

6001-19

W270-2R004

25. FILTER BYPASS HOSE 26. FILTER INLET HOSE 27. FILTER RETURN HOSE

28. FILTERS 29. SIGHT GAUGE LOWER HOSE 30. SIGHT GAUGE UPPER HOSE TRANSMISSION LINES

31. FILLER TUBE 32. SIGHT GAUGE BRACKET

W270-2R004

25. FILTER BYPASS HOSE 26. FILTER INLET HOSE 27. FILTER RETURN HOSE

28. FILTERS 29. SIGHT GAUGE LOWER HOSE 30. SIGHT GAUGE UPPER HOSE TRANSMISSION LINES

31. FILLER TUBE 32. SIGHT GAUGE BRACKET

6001-20 33. Install the washers and cap screws that fasten the equipment pump to the transmission. Tighten the cap screws to 102 to 113 Nm (75 to 83 pound-feet) of torque. 34. Install the cap screws (22) to fasten the center drive shaft (23) to the transmission. Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet). refer to illustration on page 21.

6001-20 35. Put the rear drive shaft (24) into position on the machine. 36. Replace the cap screws to the rear drive shaft (24) at the rear axle. Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet). 37. Install the cap screws (22) to the rear drive shaft (24) to the transmission. Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet).

33. Install the washers and cap screws that fasten the equipment pump to the transmission. Tighten the cap screws to 102 to 113 Nm (75 to 83 pound-feet) of torque. 34. Install the cap screws (22) to fasten the center drive shaft (23) to the transmission. Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet). refer to illustration on page 21.

35. Put the rear drive shaft (24) into position on the machine. 36. Replace the cap screws to the rear drive shaft (24) at the rear axle. Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet). 37. Install the cap screws (22) to the rear drive shaft (24) to the transmission. Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet).

6001-21

24 BC06A077

21. DRIVE SHAFT FLANGE 22. CAP SCREW

23. CENTER DRIVE SHAFT 24. REAR DRIVE SHAFT DRIVE SHAFTS

BC06A077

21. DRIVE SHAFT FLANGE 22. CAP SCREW

23. CENTER DRIVE SHAFT 24. REAR DRIVE SHAFT DRIVE SHAFTS

6001-22

38. Carefully place the reservoir into position onto the machine. 39. Install the nuts, hardened washers, and bolts that mount the hydraulic reservoir to the frame, tighten the bolts. NOTE: If equipped with air conditioning, do step 40. If not equipped with air conditioning, go to step 41.

15 20

41. Connect the hose to the reservoir tube (9) from the hydraulic filter, refer to illustration on page 23.

38. Carefully place the reservoir into position onto the machine.

42. Connect the suction hoses (10) to the reservoir and the hydraulic pumps.

39. Install the nuts, hardened washers, and bolts that mount the hydraulic reservoir to the frame, tighten the bolts.

43. Connect the hydraulic pump case drain hoses (11) to the reservoir.

NOTE: If equipped with air conditioning, do step 40. If not equipped with air conditioning, go to step 41.

45. Connect the hose loader valve pressure (13).

15 20

17 BC06A071

43. Connect the hydraulic pump case drain hoses (11) to the reservoir. 44. Connect the hose for the brake pump (12) to the reservoir.

42. Connect the suction hoses (10) to the reservoir and the hydraulic pumps.

44. Connect the hose for the brake pump (12) to the reservoir.

19 17

41. Connect the hose to the reservoir tube (9) from the hydraulic filter, refer to illustration on page 23.

18 BC06A071

15. DOUBLE CLAMP 17. COMPRESSOR 19. WASHER HOSE 16. DRYER HOSE 18. NUT 20. RESERVOIR

40. If equipped with air conditioning, install the clamp (15), lock washer (19), and nut (18) that holds the hoses (16 and 17) the hydraulic reservoir, tighten the nut.

6001-23

W270-2R003

9. RETURN FROM HYDRAULIC FILTER 10. SUCTION HOSES TO HYDRAULIC PUMPS 11. HYDRAULIC PUMP CASE DRAIN HOSES

12. BRAKE PUMP SUCTION HOSE 13. HOSE LOADER VALVE PRESSURE 14. HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR

W270-2R003

9. RETURN FROM HYDRAULIC FILTER 10. SUCTION HOSES TO HYDRAULIC PUMPS 11. HYDRAULIC PUMP CASE DRAIN HOSES

12. BRAKE PUMP SUCTION HOSE 13. HOSE LOADER VALVE PRESSURE 14. HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR

6001-24

47. Install the mounting plate (5).

50. Fill the hydraulic reservoir. Approximately 118 liters (31 U.S. gallons) will be required.

51. Replace the filler cap for the hydraulic reservoir.

53. Refer to section 2000 and complete the engine installation procedures.

3 B910705J

CAP SCREW LOCK WASHER FLAT WASHER COVER

5. 6. 7. 8.

RELAY MTG PLATE NUT LOCK WASHER SPACER

RELAY MOUNTING PLATE

49. Install the cap screw (1) that holds the cover (4) for relay mounting plate (5).

52. Fill the transmission with proper lubricant, refer to section 1002.

48. Install the nuts (6) and lock washers (7) that hold the mounting plate (5) for the relay.

49. Install the cap screw (1) that holds the cover (4) for relay mounting plate (5).

1. 2. 3. 4.

46. Install the spacers (8) on the studs for the relay mounting plate (5).

48. Install the nuts (6) and lock washers (7) that hold the mounting plate (5) for the relay.

46. Install the spacers (8) on the studs for the relay mounting plate (5).

54. Start and run the machine until all systems are at operating temperature, check for leaks and repair as needed.

52. Fill the transmission with proper lubricant, refer to section 1002.

6 7 1

53. Refer to section 2000 and complete the engine installation procedures.

3 B910705J

1. 2. 3. 4.

CAP SCREW LOCK WASHER FLAT WASHER COVER

5. 6. 7. 8.

RELAY MTG PLATE NUT LOCK WASHER SPACER

RELAY MOUNTING PLATE

54. Start and run the machine until all systems are at operating temperature, check for leaks and repair as needed.

6001-25

FRONT AXLE Removal 1. Remove the four bolts (2) that fasten the front drive shaft (3) universal joint to the front axle (1), refer to illustration on page 26. 2. Use a prybar and disengage the front drive shaft (3) universal joint from the front axle (1). 3. Tag and disconnect the brake and cooler lines from the front axle. Install caps and plugs. 4. Raise the front wheels off the floor and use acceptable supports to hold the machine. 5. Remove the wheels from the front axle.

FRONT AXLE

6. Using a crisis-cross pattern, tighten the eight axle mounting nuts (4) to a torque of 1877 to 1985 Nm (1380 to 1460 pound-feet). 7. Engage the front drive shaft (3) universal joint with the front axle (1) and install the four bolts (2). Tighten the bolts (2) to a torque of 95 to 108 Nm (70 to 80 pound-feet). 8. Install the wheels, washers, and wheel nuts. 9. Torque the wheel bolts in the sequence shown to a preliminary torque of 298 Nm (220 pound-feet). Final torque the wheel bolts to 640 to 720 Nm (475 to 530 pound-feet) in the same sequence.

Removal 1. Remove the four bolts (2) that fasten the front drive shaft (3) universal joint to the front axle (1), refer to illustration on page 26. 2. Use a prybar and disengage the front drive shaft (3) universal joint from the front axle (1). 3. Tag and disconnect the brake and cooler lines from the front axle. Install caps and plugs. 4. Raise the front wheels off the floor and use acceptable supports to hold the machine. 5. Remove the wheels from the front axle.

6. Use acceptable lifting equipment (transmission jack) to hold and lower the front axle.

7. Fasten the jack to the front axle to keep the front axle from moving when the mounting bolts are removed. The weight of the axle is approximately 3039 kg (6700 pounds).

8. Remove the self-locking nuts (4), washers (5), and bolts (6) on each side of the front axle (1).

9. Carefully lower and remove the front axle (1) from the machine.

Installation

1. Position front axle into position using a suitable jack.

2. Install one bolt (6) and washer (5) on each side of the front axle (1). The bolts (6) should be placed through the top of the frame and then through the axle mounting holes.

4. Place the remaining six bolts (6) and washers (5) through the top of the frame and then through the front axle (1) mounting holes. From the bottom of the front axle (1), secure the front axle to the frame with six washers (5) and six self-locking nuts (4). 5. Slowly tighten the bolt (6) on each side of the front axle (1) and raise the front axle against the frame. Tighten the bolts (6) until snug.

7. Engage the front drive shaft (3) universal joint with the front axle (1) and install the four bolts (2). Tighten the bolts (2) to a torque of 95 to 108 Nm (70 to 80 pound-feet). 8. Install the wheels, washers, and wheel nuts. 9. Torque the wheel bolts in the sequence shown to a preliminary torque of 298 Nm (220 pound-feet). Final torque the wheel bolts to 640 to 720 Nm (475 to 530 pound-feet) in the same sequence.

Installation

1. Position front axle into position using a suitable jack.

3. From the bottom of the front axle (1), secure the front axle to the frame with washer (5) and a self-locking nut (4).

6. Using a crisis-cross pattern, tighten the eight axle mounting nuts (4) to a torque of 1877 to 1985 Nm (1380 to 1460 pound-feet).

BC06A079

WHEEL BOLT TIGHTENING SEQUENCE

10. Lower the machine to the ground. 11. Connect the brake and cooler line to the front axle. 12. Fill the axle with proper lubricant, see section 1002. 13. Bleed the brakes, see section 7002.

3. From the bottom of the front axle (1), secure the front axle to the frame with washer (5) and a self-locking nut (4). 4. Place the remaining six bolts (6) and washers (5) through the top of the frame and then through the front axle (1) mounting holes. From the bottom of the front axle (1), secure the front axle to the frame with six washers (5) and six self-locking nuts (4). 5. Slowly tighten the bolt (6) on each side of the front axle (1) and raise the front axle against the frame. Tighten the bolts (6) until snug.

BC06A079

WHEEL BOLT TIGHTENING SEQUENCE

10. Lower the machine to the ground. 11. Connect the brake and cooler line to the front axle. 12. Fill the axle with proper lubricant, see section 1002. 13. Bleed the brakes, see section 7002.

6001-26

BC06A074

1. FRONT AXLE 2. BOLT 3. FRONT DRIVE SHAFT

4. SELF LOCKING NUT 5. WASHER 6. BOLT

FRONT AXLE MOUNTING

BC06A074

1. FRONT AXLE 2. BOLT 3. FRONT DRIVE SHAFT

4. SELF LOCKING NUT 5. WASHER 6. BOLT

FRONT AXLE MOUNTING

6001-27

REAR AXLE AND TRUNNIONS Removal

REAR AXLE AND TRUNNIONS

4. Tighten the cap screws (8) to a torque of 190 to 210 Nm (140 to 155 pound-feet).

1. Remove the grease hoses from the rear axle trunnions (2 and 3), refer to illustration on page 28. 2. Tag and disconnect the brake and oil cooler lines from the rear axle (1). Install caps and plugs. 3. Remove the cap screws that fasten the rear drive shaft (12) to the rear axle (1). 4. Use a prybar and disengage the rear drive shaft (12) from the rear axle (1).Raise the rear wheels off the floor and use acceptable supports to hold the machine in place. 5. Remove the rear wheels. 6. Put acceptable lifting equipment (transmission jack) under the rear axle (1) and trunnions (2 and 3). The weight of the axle is approximately 3039 kg (6700 pounds). 7. Remove the self-locking nuts (11) from the bolts (10). 8. Remove the rear axle (1) and trunnions (2 and 3) from the machine. Place the rear axle (1) and trunnions (2 and 3) onto blocks or suitable work bench. 9. Remove the front trunnion (2) from the rear axle (1). 10. Remove the cap screws (8) and washers (9) from the rear cover (7) on the rear trunnion (3).

5. Install the other thrust washer (5). Fasten the rear cover (7) to the rear trunnion (3) using six washers (9) and cap screws (8). 6. Tighten the cap screws (8) to a torque of 81 to 95 Nm (60 to 70 pound-feet). 7. Install the front trunnion (2) to the rear axle (1). Ensure trunnion is properly positioned, see illustration on page 28. 8. Using acceptable lifting equipment, slowly move the rear axle (1) and trunnions (2 and 3) into position under the rear chassis. 9. Install the bolts (10), hardened washers (9), and self-locking nuts (11) to fasten the trunnions (2 and 3) to the rear chassis. 10. Tighten the self-locking nuts (11) to a torque of 660 to 741 Nm (485 to 545 pound-feet). 11. Fasten the rear drive shaft (12) to the rear axle (1). Use four cap screws and tighten to a torque of 95 to 108 Nm (70 to 80 pound-feet). 12. Install the rear wheels, hardened washers and bolts. 13. Torque the wheel bolts in the sequence shown to a preliminary torque of 298 Nm (220 pound-feet). Final torque the wheel bolts to 640 to 720 Nm (475 to 530 pound-feet) in the same sequence.

Removal

4. Tighten the cap screws (8) to a torque of 190 to 210 Nm (140 to 155 pound-feet).

11. Remove the rear cover (7) from the rear trunnion (3).

12. Remove the thrust washer (5).

13. Remove the cap screws (8) and washers (9) that fasten the spacer (6) to the rear axle (1).

14. Remove the spacer (6) and thrust washer (5).

15. Remove the rear trunnion (3) from the rear axle (1).

NOTE: Replace the trunnions as required.

seals

and

busings

the

Installation

seals

and

busings

6. Tighten the cap screws (8) to a torque of 81 to 95 Nm (60 to 70 pound-feet). 7. Install the front trunnion (2) to the rear axle (1). Ensure trunnion is properly positioned, see illustration on page 28. 8. Using acceptable lifting equipment, slowly move the rear axle (1) and trunnions (2 and 3) into position under the rear chassis. 9. Install the bolts (10), hardened washers (9), and self-locking nuts (11) to fasten the trunnions (2 and 3) to the rear chassis. 10. Tighten the self-locking nuts (11) to a torque of 660 to 741 Nm (485 to 545 pound-feet). 11. Fasten the rear drive shaft (12) to the rear axle (1). Use four cap screws and tighten to a torque of 95 to 108 Nm (70 to 80 pound-feet). 12. Install the rear wheels, hardened washers and bolts. 13. Torque the wheel bolts in the sequence shown to a preliminary torque of 298 Nm (220 pound-feet). Final torque the wheel bolts to 640 to 720 Nm (475 to 530 pound-feet) in the same sequence.

the

Installation

1. Put the rear axle (1) on blocks.

2. Install the rear trunnion (3) to the rear axle (1). Ensure bushing is properly positioned.

3. Install a thrust washer (5) and the spacer (6). Use eight cap screws (8) and hardened washers (9) to fasten the spacer (6) to the rear axle (1).

5. Install the other thrust washer (5). Fasten the rear cover (7) to the rear trunnion (3) using six washers (9) and cap screws (8).

BC06A079

WHEEL BOLT TIGHTENING SEQUENCE

3. Install a thrust washer (5) and the spacer (6). Use eight cap screws (8) and hardened washers (9) to fasten the spacer (6) to the rear axle (1).

BC06A079

WHEEL BOLT TIGHTENING SEQUENCE

6001-28

6001-28 17. Fill the axle with proper lubricant, see section 1002.

14. Lower the machine to the ground. 15. Connect the brake and cooler lines to the rear axle.

18. Pump grease into front and rear trunnions until grease is extruded through seals.

16. Connect the grease hoses to the trunnions (2 and 3).

19. Bleed the brakes, see section 7002.

15. Connect the brake and cooler lines to the rear axle.

5 10

10 5

19. Bleed the brakes, see section 7002.

5 7

18. Pump grease into front and rear trunnions until grease is extruded through seals.

16. Connect the grease hoses to the trunnions (2 and 3).

17. Fill the axle with proper lubricant, see section 1002.

14. Lower the machine to the ground.

9 10

4 11

1 2

2 12

BC06A076

1. REAR AXLE 2. FRONT TRUNNION 3. REAR TRUNNION

4. OIL SEAL 5. THRUST WASHER 6. SPACER

7. COVER 8. CAP SCREW 9. WASHER

REAR AXLE MOUNTING

10. BOLT 11. SELF-LOCKING NUT 12. REAR DRIVE SHAFT

12 BC06A076

1. REAR AXLE 2. FRONT TRUNNION 3. REAR TRUNNION

4. OIL SEAL 5. THRUST WASHER 6. SPACER

7. COVER 8. CAP SCREW 9. WASHER

REAR AXLE MOUNTING

10. BOLT 11. SELF-LOCKING NUT 12. REAR DRIVE SHAFT

TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6002

Section 6002

Section 6002 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6002-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 9 9 9 10 11 11 12 13 14 16 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 19 20 20 20

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . .

3 3 9 9 9 10 11 11 12 13 14 16 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 19 20 20 20

6002-3

SPECIAL TOOLS 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

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 (230 to 265 psi) Converter in pressure .................................................................................................8.5 to 10.5 bar (125 to 154 psi) Pressure reduction for solenoids ......................................................................................9 to 11 bar (130 to 160 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) ...................................................................................115 L/min (30 U.S. gpm) Transmission oil operating temperature .........................................................................80 to 120 째C (176 to 248 째F) Clutch KV........................................................................................................................16 to 18 bar (230 to 265 psi) Clutch KR .......................................................................................................................16 to 18 bar (230 to 265 psi) Clutch K1 ........................................................................................................................16 to 18 bar (230 to 265 psi) Clutch K2 ........................................................................................................................16 to 18 bar (230 to 265 psi) Clutch K3 ........................................................................................................................16 to 18 bar (230 to 265 psi) Clutch K4 ........................................................................................................................16 to 18 bar (230 to 265 psi)

6002-4

3 2

5 8

8 9

13 7

GS99C601

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

TRANSMISSION ELECTRONIC CONTROL MODULE DOWNSHIFT BUTTON DECLUTCH ROCKER SWITCH MANUAL/AUTOMATIC ROCKER SWITCH SHIFTER SUPPLY SYSTEM CONNECTIONS B+ AND RETURN TRANSMISSION

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

INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR HALL SENSOR - OUTPUT SPEED SENSOR TRANSMISSION CONTROL VALVE CABLE DECLUTCH LIMIT SWITCH FILTER RESTRICTION SWITCH (REMOTE MOUNTED)

FIGURE 1. COMPONENT LOCATIONS SYSTEMS

GS99C601

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

TRANSMISSION ELECTRONIC CONTROL MODULE DOWNSHIFT BUTTON DECLUTCH ROCKER SWITCH MANUAL/AUTOMATIC ROCKER SWITCH SHIFTER SUPPLY SYSTEM CONNECTIONS B+ AND RETURN TRANSMISSION

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

FIGURE 1. COMPONENT LOCATIONS SYSTEMS

6002-5

13 11

GS98K624

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

ENGINE CONNECTION (DIRECT MOUNTING) CONVERTER BREATHER DRIVE ELECTRO-HYDRAULIC SHIFT VALVE 1ST POWER TAKE-OFF (PUMP DRIVE) CONVERTER CHARGE AND CONTROL PRESSURE PUMP CLUTCH K1 (FIRST GEAR)

9. 10. 11. 12. 13. 14. 15. 16.

CLUTCH K2 (2ND GEAR) CLUTCH K3 (3RD&4TH GEAR) OUTPUT FRONT AXLE OUTPUT REAR AXLE LAYSHAFT CLUTCH K4 (FORWARD, HIGH SPEED) CLUTCH KR (REVERSE, LOW SPEED CLUTCH KV (FORWARD, LOW SPEED)

FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

GS98K624

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

ENGINE CONNECTION (DIRECT MOUNTING) CONVERTER BREATHER DRIVE ELECTRO-HYDRAULIC SHIFT VALVE 1ST POWER TAKE-OFF (PUMP DRIVE) CONVERTER CHARGE AND CONTROL PRESSURE PUMP CLUTCH K1 (FIRST GEAR)

9. 10. 11. 12. 13. 14. 15. 16.

CLUTCH K2 (2ND GEAR) CLUTCH K3 (3RD&4TH GEAR) OUTPUT FRONT AXLE OUTPUT REAR AXLE LAYSHAFT CLUTCH K4 (FORWARD, HIGH SPEED) CLUTCH KR (REVERSE, LOW SPEED CLUTCH KV (FORWARD, LOW SPEED)

FIGURE 2. COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6

6 GS99C623

1. 2. 3. 4.

LIFTING LUGS BREATHER ELECTRO-HYDRAULIC SHIFT CONTROL ENGINE CONNECTION DIRECT MOUNTING

5. 6. 7. 8.

OIL DRAIN PLUG ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK OUTPUT REAR AXLE OIL FILLER PIPE WITH OIL DIPSTICK

FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

GS99C623

1. 2. 3. 4.

LIFTING LUGS BREATHER ELECTRO-HYDRAULIC SHIFT CONTROL ENGINE CONNECTION DIRECT MOUNTING

5. 6. 7. 8.

OIL DRAIN PLUG ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK OUTPUT REAR AXLE OIL FILLER PIPE WITH OIL DIPSTICK

FIGURE 3. COMPONENT LOCATIONS FRONT VIEW

6002-7

16 7

7 8

11 15

12 14

GS99C622

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

ENGINE CONNECTION DIRECT MOUNTING LIFTING LUGS BREATHER ELECTRO-HYDRAULIC SHIFT CONTROL CONNECTION TO CLUTCH K1 CONNECTION TO CLUTCH KV CONNECTION TO CLUTCH KR CONNECTION TO LUBRICATION K2/KR

9. 10. 11. 12. 13. 14. 15. 16.

CONNECTION TO CLUTCH K2 CONNECTION TO CLUTCH K3 CONNECTION TO LUBRICATION K3/K4 OUTPUT FRONT AXLE OUTPUT REAR AXLE TRANSMISSION SUSPENSION HOLES CONNECTION CLUTCH K4 MOUNTING HOLE

FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

GS99C622

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

ENGINE CONNECTION DIRECT MOUNTING LIFTING LUGS BREATHER ELECTRO-HYDRAULIC SHIFT CONTROL CONNECTION TO CLUTCH K1 CONNECTION TO CLUTCH KV CONNECTION TO CLUTCH KR CONNECTION TO LUBRICATION K2/KR

9. 10. 11. 12. 13. 14. 15. 16.

CONNECTION TO CLUTCH K2 CONNECTION TO CLUTCH K3 CONNECTION TO LUBRICATION K3/K4 OUTPUT FRONT AXLE OUTPUT REAR AXLE TRANSMISSION SUSPENSION HOLES CONNECTION CLUTCH K4 MOUNTING HOLE

FIGURE 4. COMPONENT LOCATIONS SIDE VIEW

6002-8

12 4

11 6

8 GS98K621

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

2ND POWER TAKE-OFF PRESSURE LINE CLUTCH K1 PRESSURE LINE CLUTCH K3 PRESSURE LINE CLUTCH KV PRESSURE LINE CLUTCH K4 PRESSURE LINE CLUTCH KR

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

OIL FILLER PIPE WITH OIL DIPSTICK MODEL IDENTIFICATION PLATE OUTPUT FRONT AXLE LUBRICATING LINE CLUTCH KR/K2 LUBRICATING LINE CLUTCH K4/K3 PRESSURE LINE CLUTCH K2

FIGURE 5. COMPONENT LOCATIONS REAR VIEW

GS98K621

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

2ND POWER TAKE-OFF PRESSURE LINE CLUTCH K1 PRESSURE LINE CLUTCH K3 PRESSURE LINE CLUTCH KV PRESSURE LINE CLUTCH K4 PRESSURE LINE CLUTCH KR

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

OIL FILLER PIPE WITH OIL DIPSTICK MODEL IDENTIFICATION PLATE OUTPUT FRONT AXLE LUBRICATING LINE CLUTCH KR/K2 LUBRICATING LINE CLUTCH K4/K3 PRESSURE LINE CLUTCH K2

FIGURE 5. COMPONENT LOCATIONS REAR VIEW

6002-9

TRANSMISSION OPERATION General The transmissions 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 relies on signal from several solenoids that are incorporated into the design. These solenoids measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. In addition, the transmission incorporates a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise.

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.

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.

Transmission ECM Tasks The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM: A. Determines which clutches to engage in the transmission.

TRANSMISSION OPERATION

B. Protect 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 clutch speed sensor and the transmission output 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. 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.

General The transmissions 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 relies on signal from several solenoids that are incorporated into the design. These solenoids measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. In addition, the transmission incorporates a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise.

calibrate

the

H. Establishes clutch modulation pressure during transmission shifts.

Transmission Sensor Data Collection

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.

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:

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.

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.

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.

Transmission ECM Tasks The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM: A. Determines which clutches to engage in the transmission.

6002-10 The transmission ECM also reviews voltage 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 l l s t i ll 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.

6002-10 If the Transmission ECM generates a code, the wrench over the service m anual icon will be displayed on the Information Center.

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. 4. The park brake is applied. 5. If steps 1 through 4 have been accomplished, calibrate the transmission clutches as follows: A. Put the transmission in the manual shift mode and the gear selector in 3rd gear neutral. B. Press the program/reset switch to program. C. Press the up/down count switch to up count until the display reads 011. D. Put the program/reset switch in the OFF (center) position. E. Press the up/down count switch to up count twice, so the display reads 02. F. 2 00 00 will begin to flash in the display center. G. After one second, the Clutch Calibration Main Code status will be displayed in the 3rd and 4th spaces (2 XX 00, the XX represents the 3rd and 4th spaces). H. The Modulation Cycle Number will be displayed in the 1st and 2nd spaces (2 00 XX, the XX represents the 1st and 2nd spaces). I. During Clutch Calibration, the Clutch Calibration Main Code will change from 01 to 07 as the process is completed. Code 07 indicates that the calibration process is complete and the information center will return to normal working status.

The transmission ECM also reviews voltage information from the shifter and transmission solenoids to determine if there are any short circuits or open circuits in the system.

If the Transmission ECM generates a code, the wrench over the service m anual icon will be displayed on the Information Center.

6002-11 J. If any of the Clutch Calibration parameters are incorrect, the display center will stop flashing and display a code in the 1st, 2nd, 3rd, and 4th spaces.

CLUTCH CALIBRATION SUB CODES Sub Code

Meaning

Calibration in process.

Fault present.

Shift lever not in neutral.

The 1st and 2nd spaces will produce the Clutch Calibration Sub Code, which is the code that informs the operator of the reason the process was aborted.

Park brake not applied.

Output speed not 0 kph/mph.

Low transmission oil temperature.

K. After completing the Clutch Calibration procedure, turn the machine OFF for 15 seconds. This sets the calibration in the controller.

High transmission oil temperature.

Low engine RPM.

High engine RPM.

If this occurs, the code in the 3rd and 4th spaces will be a Clutch Calibration Main Code 09 through 14 and indicate what process the calibration was in when it was aborted.

CLUTCH CALIBRATION MAIN CODES Main Code

Meaning

6002-11 J. If any of the Clutch Calibration parameters are incorrect, the display center will stop flashing and display a code in the 1st, 2nd, 3rd, and 4th spaces.

CLUTCH CALIBRATION SUB CODES Sub Code

Meaning

Calibration in process.

Fault present.

Shift lever not in neutral.

The 1st and 2nd spaces will produce the Clutch Calibration Sub Code, which is the code that informs the operator of the reason the process was aborted.

Park brake not applied.

Output speed not 0 kph/mph.

Low transmission oil temperature.

K. After completing the Clutch Calibration procedure, turn the machine OFF for 15 seconds. This sets the calibration in the controller.

High transmission oil temperature.

Low engine RPM.

High engine RPM.

If this occurs, the code in the 3rd and 4th spaces will be a Clutch Calibration Main Code 09 through 14 and indicate what process the calibration was in when it was aborted.

CLUTCH CALIBRATION MAIN CODES

Gear Selections

Clutch Calibration Mode was not initiated because one of the requirements was not met.

Adjusting 1st gear.

Adjusting 2nd gear.

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).

Adjusting 3rd gear.

Adjusting 4th gear.

Adjusting Forward gear.

Adjusting Reverse gear.

Clutch Calibration Completed.

Main Code

Meaning

Gear Selections

Clutch Calibration Mode was not initiated because one of the requirements was not met.

Adjusting 1st gear.

Adjusting 2nd gear.

Automatic/Manual Modes

Adjusting 3rd gear.

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.

Adjusting 4th gear.

Adjusting Forward gear.

Adjusting Reverse gear.

Clutch Calibration Completed.

Operator aborted calibration procedure.

Aborted while adjusting 1st gear.

Aborted while adjusting 2nd gear.

Aborted while adjusting 3rd gear.

Aborted while adjusting 4th gear.

Aborted while adjusting Forward gear.

Aborted while adjusting Reverse gear.

6002-12

Upshifting in Automatic Mode

Cold Start Protection System

Upshifting in Automatic Mode

Cold Start Protection System

Upshifting is determined by machine speed and the torque on the transmission.

The transmission has a cold start protection system. When the transmission sump temperature is minus 10° C (14° F), the Transmission ECM will keep the transmission in neutral.

Upshifting is determined by machine speed and the torque on the transmission.

The transmission has a cold start protection system. When the transmission sump temperature is minus 10° C (14° F), the Transmission ECM will keep the transmission in neutral.

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.

When the transmission sump temperature warms up to minus 10° C (14°F) (within approximately one minute), the machine will operate in all gears.

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.

Downshift Button

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.

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.

As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.

With the number of different ways the downshift button functions, the operator can tailor the use of the machine to the application at hand.

Upshifting in Manual Mode

In the manual mode, the transmission starts out in the selected gear and stays in that gear until the operator selects another gear or direction. The transmission can be upshifted without reducing engine speed or machine speed.

If the gear selected is two or more gears higher than the present gear, the transmission will shift up through the gears at 2.5 second intervals until the selected gear has been reached.

Downshifting in Manual Mode

The transmission can be downshifted in the manual mode without reducing engine speed or machine speed.

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.

When the transmission sump temperature warms up to minus 10° C (14°F) (within approximately one minute), the machine will operate in all gears.

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.

6002-13

Automatic Mode

Brake Pedal Transmission Declutch

Automatic Mode

Brake Pedal Transmission Declutch

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.

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 will automatically downshift and then upshift, as needed, to the last gear that was selected with the downshift button.

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.

Manual Mode

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.

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.

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.

Manual Mode

In the manual mode, the downshift button toggles between 1st and 2nd gear. The manual mode is useful in short haul operations. In this mode, the downshift button functions in two ways in 1st and 2nd gear.

When the operator is in 2nd gear and pushes the downshift button, the transmission instantly shifts into 1st gear. When the operator pushes the downshift button again, the transmission upshifts into 2nd gear.

If 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.

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.

6002-14

TRANSMISSION PRESSURE TEST POINTS DIAGRAM No.

IDENTIFICATION/LOCATION

CONNECTION

TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON VALVE BLOCK

No.

Measuring Points for Pressure Oil and Temperature 51

IDENTIFICATION/LOCATION

CONNECTION

DESIGNATION ON VALVE BLOCK

M10x1

Measuring Points for Pressure Oil and Temperature M10x1

Before the Converter - Opening Pressure 9 bar

Behind the Converter - Opening Pressure 3.5 bar

Clutch Forward 16+2 bar

KV M10x1

Clutch Reverse 16+2 bar

M14x1.5

Before the Converter - Opening Pressure 9 bar

M14x1.5

Behind the Converter - Opening Pressure 3.5 bar

Clutch Forward 16+2 bar

KV M10x1

KR M10x1

Clutch Reverse 16+2 bar

KR M10x1

Clutch 16+2 bar

K1 M10x1

Clutch 16+2 bar

K1 M10x1

Clutch 16+2 bar

K2 M10x1

Clutch 16+2 bar

K2 M10x1

Clutch 16+2 bar

K3 M10x1

Clutch 16+2 bar

K3 M10x1

Clutch 16+2 bar

K4 M10x1

Clutch 16+2 bar

K4 M10x1

Behind the Converter Temperature 100째 C, Short Time 120째 C

M14x1/5

Behind the Converter Temperature 100째 C, Short Time 120째 C

M14x1/5

System Pressure 16+2 bar

M10x1

System Pressure 16+2 bar Connections

Connection to the Heat Exchanger

M10x1

Connections M42x2

Connection to the Heat Exchanger

M42x2

Connection from the Heat Exchanger

M42x2

Connection from the Heat Exchanger

M42x2

Connection from filter

M42x2

Connection from filter

M42x2

Connection to filter

1-11/16 UN 2A

Connection to filter

Connection to Brake Valve

M16x1.5

Connection to Brake Valve

M16x1.5

Connection Return Line from Brake Valve

M26x1.5

Plug Connection on the Hydraulic Control Unit

Pilot Pressure

M16x1.5

System Pressure

M16x1.5

1-11/16 UN 2A

Connection Return Line from Brake Valve

Plug Connection on the Hydraulic Control Unit

Pilot Pressure

M16x1.5

System Pressure

M16x1.5

Inductive Transmitter and Speed Sensor 5

Inductive Transmitter and Speed Sensor

Inductive Transmitter n Central Gear Chain

M18x1.5

Inductive Transmitter n Central Gear Chain

M18x1.5

Inductive Transmitter n Engine

M18x1.5

Inductive Transmitter n Engine

M18x1.5

Speed Sensor n Output and Speedometer

Inductive Transmitter n Turbine

NOTE: See Figure 6 for Measuring Point, Transmitter, Sensor and Connection locations.

M18x1.5

NOTE: See Figure 6 for Measuring Point, Transmitter, Sensor and Connection locations.

M18x1.5

6002-15

FIGURE 6. MEASURING POINTS AND CONNECTIONS

BC00E065

6002-15

FIGURE 6. MEASURING POINTS AND CONNECTIONS

BC00E065

6002-16

6002-16 ENGAGED CLUTCHES

* PRESSURE REGULATOR UNDER VOLTAGE DRIVING DIRECTION

SPEED

FORWARD

4 REVERSE

* * * *

DRIVING DIRECTION

SPEED

FORWARD

KR KR

REVERSE

* * *

NEUTRAL

* * * *

NEUTRAL

CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.

P.I.N. Number:

Date:

P.I.N. Number:

Date:

TEST POINTS Shift Speed

ENGAGED CLUTCHES

* PRESSURE REGULATOR UNDER VOLTAGE

P 65

V 53

R 55

1 56

2 57

TEST POINTS 3 58

4 60

5 51

6 52

Shift Speed

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

R= REVERSE CLUTCH

3= THIRD GEAR CLUTCH

LP= LUBE PRESSURE

P 65

V 53

R 55

1 56

2 57

3 58

P= MAIN PRESSURE

1= FIRST GEAR CLUTCH

4= FOURTH GEAR CLUTCH

5= CONVERTER IN

V= FORWARD CLUTCH

2= SECOND GEAR CLUTCH

5= CONVERTER IN

6= CONVERTER OUT

R= REVERSE CLUTCH

3= THIRD GEAR CLUTCH

6= CONVERTER OUT

4 60

5 51

LP= LUBE PRESSURE

6 52

6002-17

PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low Possible causes include:

Not Enough Power Possible causes include:

1. Oil level not correct.

1. Check Electrical Troubleshooting in this Section to verify actual gear selected.

2. Oil type and grade not correct.

2. Engine RPM below Stall Test specified RPM.

PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low Possible causes include:

Not Enough Power Possible causes include:

1. Oil level not correct.

1. Check Electrical Troubleshooting in this Section to verify actual gear selected.

2. Oil type and grade not correct.

2. Engine RPM below Stall Test specified RPM.

3. Oil operating temperature high.

A. Check engine and fuel system for problem.

3. Oil operating temperature high.

A. Check engine and fuel system for problem.

4. Screen for suction tube plugged.

B. Check that torque converter installation is correct.

4. Screen for suction tube plugged.

B. Check that torque converter installation is correct.

5. Suction tube or gaskets leak. 6. Main pressure valve, springs, or valve bore. 7. Reduction valve, springs, or valve bore. 8. Charge pump seals or gaskets leak. 9. Charge pump worn.

3. Engine RPM above Stall Test specified RPM. A. Check converter pressures and flow. B. Check that torque converter installation is correct.

5. Suction tube or gaskets leak. 6. Main pressure valve, springs, or valve bore. 7. Reduction valve, springs, or valve bore. 8. Charge pump seals or gaskets leak. 9. Charge pump worn.

3. Engine RPM above Stall Test specified RPM. A. Check converter pressures and flow. B. Check that torque converter installation is correct.

10. Oil supply flange not sealing correctly.

Machine Stops or Hesitates While Shifting - Intermittent

10. Oil supply flange not sealing correctly.

Machine Stops or Hesitates While Shifting - Intermittent

Some Pressures Low

Possible causes include:

Some Pressures Low

Possible causes include:

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.

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.

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.

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.

6002-18

CONVERTER OUT PRESSURE CHECK

Test Equipment Required

2. Apply the parking brakes.

Test Equipment Required

2. Apply the parking brakes.

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

3. Install the pressure gauge.

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

3. Install the pressure gauge.

Test Procedure

5. While in the cab, put the transmission in NEUTRAL. Run the engine at full throttle. Record the reading in the chart on page 6002.16. Pressure must be 3.5 to 6.5 bar (51 to 96 psi).

Test Procedure

5. While in the cab, put the transmission in NEUTRAL. Run the engine at full throttle. Record the reading in the chart on page 6002.16. Pressure must be 3.5 to 6.5 bar (51 to 96 psi).

1. Block the machine tires.

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

1. Block the machine tires.

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 6002-16. Pressure must be 0.2 to 1.2 bar (3 to 18 psi).

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

LUBRICATION PRESSURE CHECK 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.

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 6002-16. 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.

2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 °F). 4. Install the flowmeter to converter outlet line (line to cooler) in series. 5. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The flow must be 9.1 L/min (2 U.S. gpm).

6. Repeat the procedure with the transmission in FORWARD in third gear. The flow must be 9.1 L/min (2 U.S. gpm). 7. Repeat the procedure with the transmission in REVERSE in third gear. The flow must be 9.1 L/min (2 U.S. gpm).

2. Apply the parking brakes.

CONSUMPTION TEST PROCEDURE 1. Block the machine tires.

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

0 to 7 bar (100 psi) gauge.

FLOWMETER TEST Test Equipment Required

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

CONSUMPTION TEST PROCEDURE 1. Block the machine tires. 2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 °F). 4. Install the flowmeter to converter outlet line (line to cooler) in series. 5. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The flow must be 9.1 L/min (2 U.S. gpm).

6002-19

TRANSMISSION OVERHEATING 1. Operate machine in normal operating conditions and observe:

6002-19

TRANSMISSION OVERHEATING 1. Operate machine in normal operating conditions and observe:

A. Verify actual oil temperature at test point. Normal operating temperature can be 56 degrees C (100 degrees 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 operatorâ&#x20AC;&#x2122;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 Understanding Results to determine possible cause of any test results not within specifications.

6002-20

ERROR CODES

In case of possible errors in the system, a wrench appears on the display, combined with indication of the error number. See section 4005 for error code retrieval procedures and definitions. See electrical schematic to assist in fault isolation.

TRANSMISSION SHIFTER LOGIC INFORMATION

Function

Shifter

Shifter Wire Color

Shifter Tower Connector

Shifter Shroud Connector

Harness Wire #

Harness ped/cab #

Trans. ECM #

Function

Shifter

Shifter Wire Color

Shifter Tower Connector

Shifter Shroud Connector

Harness Wire #

Harness ped/cab #

Trans. ECM #

power

B+

black/red

19A

power

B+

black/red

19A

forward

yellow

25F

forward

yellow

25F

reverse

pink

25R

reverse

pink

25R

neutral

gray

25T

neutral

gray

25T

gear2(3-4)

green

25W

gear2(3-4)

green

25W

gear1(1-2)

blue

25Z

gear1(1-2)

blue

25Z

downshift

purple

25Y

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 #

Transmission ECM Function

Transmission ECM Pin #

Transmission Valve

Clutch #

Transmission Valve Pin #

Wire #

Trans/Cab Pin #

A1P1

25K

A1P1

25K

A1P2

25L

A1P2

25L

A1P3

25M

A1P3

25M

A1P4

25N

A1P4

25N

A1P5

25P

A1P5

25P

A1P6

25J

A1P6

25J

VPSI

12,13

all Y

all K

25S

VPSI

12,13

all Y

all K

25S

TEMP

none

36T

TEMP

none

36T

TEMP

none

36R

TEMP

none

36R

TRANSMISSION

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6003

Section 6003

6003

Section 6003

TRANSMISSION

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD AND FIRST CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Disc Clearance Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD AND FIRST CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECOND AND REVERSE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECOND AND REVERSE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPUR GEAR BEARING END PLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPUR GEAR BEARING END PLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THIRD AND FOURTH CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THIRD AND FOURTH CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fourth Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Idler (Countershaft) Bearing Preload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Shaft Bearing End Play Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second / Reverse Clutch Bearing End Play Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward / First Clutch Bearing End Play Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converter Bearing Preload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Sensing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOW IT WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 5 5 6 17 19 21 23 24 24 26 30 33 33 35 38 39 42 44 44 46 48 50 52 54 56 58 59 67 71 76

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD AND FIRST CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Disc Clearance Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORWARD AND FIRST CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECOND AND REVERSE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECOND AND REVERSE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPUR GEAR BEARING END PLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPUR GEAR BEARING END PLAY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THIRD AND FOURTH CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THIRD AND FOURTH CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fourth Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Idler (Countershaft) Bearing Preload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Shaft Bearing End Play Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second / Reverse Clutch Bearing End Play Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward / First Clutch Bearing End Play Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converter Bearing Preload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Sensing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOW IT WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 5 6 17 19 21 23 24 24 26 30 33 33 35 38 39 42 44 44 46 48 50 52 54 56 58 59 67 71 76

6003-3

SPECIAL TOOLS

A15350

A15355

1. 2. 3. 4.

SPECIAL TOOLS

COLLETT HOLDER CAS-2263-1 COLLET CAS-2263-2 COLLET CAS-2263-3 COLLET CAS-2263-4

A15350

A15355

PRESSING TUBE CAS-2266-1 1. 2. 3. 4.

PRESSING TUBE CAS-2266-1

COLLETT HOLDER CAS-2263-1 COLLET CAS-2263-2 COLLET CAS-2263-3 COLLET CAS-2263-4

A15348

PRESSING TUBE CAS-2267

A15347

1. SLOTTED NUT SOCKET CAS-2262 2. SLOTTED NUT SOCKET CAS-2261 3. SLOTTED NUT SOCKET CAS-2260

A15351

1. 2. 3. 4.

A15351

CLUTCH DISC ALIGNMENT SLEEVE CAS-2265-1 TUBE SPACER CAS-2265-2 TUBE SPACER CAS-2265-3 TUBE SPACER CAS-2265-4

1. 2. 3. 4.

A15356

TRANSMISSION ADAPTER PLATE CAS-10916

A15356

TRANSMISSION ADAPTER PLATE CAS-10916

CLUTCH DISC ALIGNMENT SLEEVE CAS-2265-1 TUBE SPACER CAS-2265-2 TUBE SPACER CAS-2265-3 TUBE SPACER CAS-2265-4

6003-4

A15344

CLUTCH SPRING PRESSING TUBE

A15354

PULLER CAS-2268

A15344

CLUTCH SPRING PRESSING TUBE

A15354

PULLER CAS-2268

6003-5

SPECIAL TORQUES

Transmission Cover......................................................................................................................................... 46 Nm Oil Baffle Plate................................................................................................................................................. 23 Nm Brake Rotor ..................................................................................................................................................... 46 Nm Emergency Steering Cover .............................................................................................................................. 23 Nm Parking Brake ................................................................................................................................................. 185 Nm Clutch End Cap (all) ......................................................................................................................................... 46 Nm Reverse Idler (Countershaft) ............................................................................................................................ 46 Nm Output Drive Flange ......................................................................................................................................... 46 Nm Filter Cover ....................................................................................................................................................... 23 Nm Oil Pump Supply Flange................................................................................................................................... 46 Nm Converter Housing M12-8.8 Bolts .................................................................................................................... 79 Nm Converter Housing M12-10.9 Bolts ................................................................................................................ 117 Nm Converter Housing M8 Bolts............................................................................................................................. 34 Nm Oil Pump Flange............................................................................................................................................... 79 Nm Pump Shaft....................................................................................................................................................... 32 Nm

SPECIFICATIONS

Converter Charge Pump Maximum End Play................................................................................................0.04 mm

All Clutch Packs Disc Clearance ...........................................................................................................2.1 to 2.5 mm

Reverse Spur Gear Bearing End Play.................................................................................................0.0 to 0.05 mm

Second Spur Gear Bearing End Play ................................................................................................0.05 to 0.15 mm

First Spur Gear Oil Ring and Retaining

Ring Thickness (Smaller than Combined Dimension).....................................................................0.0 to 0.05 mm

Reverse Idler (Countershaft Bearing Preload) ....................................................................................0.0 to 0.10 mm

Final Drive Bearing End Play.................................................................................................................0.3 to 0.5 mm

Third/Fourth Clutch Bearing Preload .................................................................................................0.15 to 0.20 mm

Reverse/Second Clutch Bearing Preload ............................................................................................0.2 to 0.25 mm

Forward/First Clutch Bearing Preload ...............................................................................................0.15 to 0.20 mm

6003-6

TRANSMISSION DISASSEMBLY STEP 1

TRANSMISSION DISASSEMBLY

STEP 4

STEP 1

STEP 4

A15356

A15053

A15356

A15053

Install the transmission adapter plate CAS-10916 on the transmission.

Tag all lines as to location and remove from the transmission.

Install the transmission adapter plate CAS-10916 on the transmission.

Tag all lines as to location and remove from the transmission.

STEP 2

STEP 5

STEP 2

STEP 5

BD07B001

BD07B009

Install the transmission on engine stand, OEM-4314.

STEP 3

Remove the mounting bolts and remove the valve body.

Install the transmission on engine stand, OEM-4314.

STEP 3

STEP 6

BD07B010

Remove the mounting bolts and remove the valve body.

STEP 6

BD07B010 BD07B002

Drain the transmission and remove the internal oil filter.

BD07B001

BD07B009

Remove the mounting bolts, remove the port plate from the transmission.

BD07B002

Drain the transmission and remove the internal oil filter.

Remove the mounting bolts, remove the port plate from the transmission.

6003-7

STEP 7

STEP 10

A15055

Remove the torque converter and flexplate.

STEP 7

A15060

Install alignment marks on the oil supply flange and the converter housing for installation. Install the puller CAS-2268 and remove the oil supply flange. Discard the gasket.

STEP 8

6003-7

STEP 10

A15055

Remove the torque converter and flexplate.

Install alignment marks on the oil supply flange and the converter housing for installation. Install the puller CAS-2268 and remove the oil supply flange. Discard the gasket.

STEP 8

STEP 11

A15057

Remove the bolts and install two (2) in threaded holes and force the cover off. Discard the gasket.

STEP 9

A15336

STEP 9

Remove the check ball and spring.

A15336

Remove the check ball and spring.

STEP 12

A15210

Remove the seal and needle bearing from the cover. Discard the seal.

A15060

A15210 A15065

Remove the converter housing.

Remove the seal and needle bearing from the cover. Discard the seal.

A15065

Remove the converter housing.

6003-8

STEP 13

STEP 16

A15066

Remove the shim and oil control ring from the input shaft.

STEP 13

A15071

Remove the rear bearing.

STEP 16

A15066

Remove the shim and oil control ring from the input shaft.

STEP 17

STEP 14

A15071

Remove the rear bearing.

STEP 17

STEP 14

A15073 A15068

Press the shaft with front bearing from the housing.

A15073

Remove the converter control valve.

A15068

Press the shaft with front bearing from the housing.

STEP 18

STEP 15

Remove the converter control valve.

STEP 18

STEP 15

BD07B011 A15069

Remove the spur gear.

BD07B011

Remove the transmitter.

A15069

Remove the spur gear.

Remove the transmitter.

6003-9

STEP 19

STEP 22

BD07B012

6003-9

STEP 19

BD07B015

STEP 22

BD07B012

BD07B015

Invert the transmission and remove the input shaft.

Pull the bearing from the spur gear.

Invert the transmission and remove the input shaft.

Pull the bearing from the spur gear.

STEP 20

STEP 23

STEP 20

STEP 23

BD07B016

BD07B013

Place the input shaft in a vice with soft caps. Loosen the cap screw and remove the retaining plate.

Remove retaining ring.

STEP 21

Place the input shaft in a vice with soft caps. Loosen the cap screw and remove the retaining plate.

Remove retaining ring.

STEP 21

STEP 24

BD07B014

STEP 24

BD07B014 BD07B017

Remove the spur gear from the shaft and remove the snap ring from the shaft.

BD07B016

BD07B013

Remove the bearing and driver from the shaft, watch for shims when removed. IMPORTANT: Put cap over bolt hole prior to installing puller to protect the threads in the shaft.

BD07B017

Remove the spur gear from the shaft and remove the snap ring from the shaft.

Remove the bearing and driver from the shaft, watch for shims when removed. IMPORTANT: Put cap over bolt hole prior to installing puller to protect the threads in the shaft.

6003-10

STEP 25

STEP 28

STEP 25

STEP 28

BD07B018

A15081

BD07B018

A15081

Remove the bearing from the driver, watch for shims.

Install the puller CAS-2268 and remove the charge pump.

Remove the bearing from the driver, watch for shims.

Install the puller CAS-2268 and remove the charge pump.

STEP 26

STEP 29

STEP 195

STEP 195 BD07B023

Remove the pump mounting adapter.

Remove the screw in sleeve.

STEP 27

BD07B023

Remove the pump mounting adapter.

Remove the screw in sleeve.

STEP 27

STEP 30

A15080

STEP 30

A15080 BD07B024

Remove the two (2) small socket head screws and the one (1) large socket head screw opposite each other.

Drill a hole in the plug, use a slide hammer to remove the plug.

BD07B024

Remove the two (2) small socket head screws and the one (1) large socket head screw opposite each other.

Drill a hole in the plug, use a slide hammer to remove the plug.

6003-11

STEP 31

STEP 34

BD07B025

6003-11

STEP 31

BD07B028

STEP 34

BD07B025

BD07B028

Use a slide hammer and pull the shaft partially out.

Remove the snap ring.

Use a slide hammer and pull the shaft partially out.

Remove the snap ring.

STEP 32

STEP 35

STEP 32

STEP 35

BD07B029

BD07B026

BD07B029

BD07B026

Reach inside the transmission and hold the gear and remove the shaft, watch for shims.

Use a soft faced hammer and drive the gear from the housing.

Reach inside the transmission and hold the gear and remove the shaft, watch for shims.

Use a soft faced hammer and drive the gear from the housing.

STEP 33

STEP 36

STEP 33

STEP 36

BD07B030 BD07B027

Remove the bolts and cover.

Remove the soft plug, remove the retaining bolt from the idler shaft.

BD07B030 BD07B027

Remove the bolts and cover.

Remove the soft plug, remove the retaining bolt from the idler shaft.

6003-12

STEP 37

STEP 40

BD07B031

Use a slide hammer and remove the idler shaft and bearings from the housing.

STEP 37

A15086

Remove the brake rotor.

STEP 40

BD07B031

Use a slide hammer and remove the idler shaft and bearings from the housing.

STEP 41

STEP 38

A15086

Remove the brake rotor.

STEP 41

STEP 38

A15087 BD07B032

Remove the turbine and internal speed transmitters.

A15087

Remove and discard the output shaft seal.

BD07B032

Remove the turbine and internal speed transmitters.

STEP 42

STEP 39

Remove and discard the output shaft seal.

STEP 42

STEP 39

A15088 BD07B033

Remove the output speed transmitter.

A15088

Remove and discard expansion plugs.

BD07B033

Remove the output speed transmitter.

Remove and discard expansion plugs.

6003-13

STEP 43

STEP 46

A15092

6003-13

STEP 43

A15097

STEP 46

A15092

A15097

Remove the first forward clutch end cover.

Remove the third/fourth clutch end cover.

Remove the first forward clutch end cover.

Remove the third/fourth clutch end cover.

STEP 44

STEP 47

STEP 44

STEP 47

A15098

A15094

A15098

A15094

Remove the second/reverse clutch end cover.

Remove third/fourth clutch shims.

Remove the second/reverse clutch end cover.

Remove third/fourth clutch shims.

STEP 45

STEP 48

STEP 45

STEP 48

A15099 A15095

Remove the second/reverse clutch shims.

Remove and discard all oil control rings from all clutch shafts.

A15099 A15095

Remove the second/reverse clutch shims.

Remove and discard all oil control rings from all clutch shafts.

6003-14

STEP 49

STEP 52

STEP 49

STEP 52

A15101

A15105

A15101

A15105

Remove the snap ring and spacer washers from the output shaft.

Remove the cover mounting bolts. Install two (2) bolts in the threaded holes to force the cover off.

Remove the snap ring and spacer washers from the output shaft.

Remove the cover mounting bolts. Install two (2) bolts in the threaded holes to force the cover off.

STEP 50

STEP 53

STEP 50

STEP 53

A15100

A15308

Using sockets CAS-2260, CAS-2261, and CAS-2262 remove all clutch shaft retaining nuts.

Remove companion flange.

Using sockets CAS-2260, CAS-2261, and CAS-2262 remove all clutch shaft retaining nuts.

STEP 54

STEP 51

A15100

A15308

Remove companion flange.

STEP 54

STEP 51

A15110 A15102

Install blocks between the output shaft companion flange and housing.

Remove the upper oil baffle.

A15110 A15102

Install blocks between the output shaft companion flange and housing.

Remove the upper oil baffle.

6003-15

STEP 55

STEP 58

A15111

6003-15

STEP 55

A15114

STEP 58

A15111

A15114

Remove the output shaft and gear.

Remove reverse/second clutch pack.

Remove the output shaft and gear.

Remove reverse/second clutch pack.

STEP 56

STEP 59

STEP 56

STEP 59

A15115

A15112

A15115

A15112

Remove the lower oil baffle.

Remove forward/first clutch pack.

Remove the lower oil baffle.

Remove forward/first clutch pack.

STEP 57

STEP 60

STEP 57

STEP 60

A15116 A15113

Remove third/fourth speed clutch pack. Pull the other clutch packs away to get clearance.

Remove reverse idler (countershaft) gear and bearing.

A15116 A15113

Remove third/fourth speed clutch pack. Pull the other clutch packs away to get clearance.

Remove reverse idler (countershaft) gear and bearing.

6003-16

STEP 61

STEP 64

A15117

STEP 61

STEP 64

BD07B035

A15117

BD07B035

Remove output shaft roller bearing and spacer.

Remove the shaft from the housing.

Remove output shaft roller bearing and spacer.

Remove the shaft from the housing.

STEP 62

STEP 65

STEP 62

STEP 65

A15211

A15208

Remove the snap rings and spacer washers from clutch pack mounting bores in the housing.

STEP 63

Remove the transmission breather.

Remove the snap rings and spacer washers from clutch pack mounting bores in the housing.

STEP 63

BD07B034

Remove the bearing cups from the housing bores.

A15211

A15208

BD07B034

Remove the bearing cups from the housing bores.

Remove the transmission breather.

6003-17

FORWARD AND FIRST CLUTCH DISASSEMBLY STEP 66

FORWARD AND FIRST CLUTCH DISASSEMBLY

STEP 69

A15120

Using bearing collet CAS-2263-3 and collet holder CAS-2263-1, remove the bearing from the first clutch.

STEP 66

A15169

Remove the snap ring.

STEP 69

A15120

Using bearing collet CAS-2263-3 and collet holder CAS-2263-1, remove the bearing from the first clutch.

STEP 70

STEP 67

A15169

Remove the snap ring.

STEP 70

STEP 67

A15122

Remove the spacer ring and lubrication ring. A15121

Remove the spur gear.

Remove the spacer ring and lubrication ring. A15121

STEP 71

Remove the spur gear.

STEP 68

STEP 71

STEP 68

A15123

Remove the ball bearing.

A15168

Remove the ball bearing.

A15168

Remove the ball bearing.

6003-18

STEP 72

STEP 74

A15128

Remove the spur gear and bearing cone from the forward clutch.

STEP 73

STEP 72

A15130

Remove the tapered roller bearing.

STEP 74

A15128

Remove the spur gear and bearing cone from the forward clutch.

STEP 73

A15129

869L92

Remove the bearing cups and spacer from the spur gear.

A15130

Remove the tapered roller bearing.

6003-19

CLUTCH CARRIER DISASSEMBLY STEP 75

6003-19

CLUTCH CARRIER DISASSEMBLY STEP 78

A15131

STEP 75

A15134

STEP 78

A15131

A15134

Remove the clutch disc retaining ring.

Remove the retainer and spring.

Remove the clutch disc retaining ring.

Remove the retainer and spring.

STEP 76

STEP 79

STEP 76

STEP 79

A15135

A15132

Remove the clutch backing plates, top friction plate and adjustment steel disc. Remove remainder of discs.

Remove the spacer washer.

Remove the clutch backing plates, top friction plate and adjustment steel disc. Remove remainder of discs.

STEP 80

STEP 77

A15135

A15132

Remove the spacer washer.

STEP 80

STEP 77

A15133

Using tube CAS-2264, comp ress the spring. Remove the retaining ring.

A15139

Using compressed air, remove the piston from each clutch. Discard the O-rings from the piston.

A15133

Using tube CAS-2264, comp ress the spring. Remove the retaining ring.

6003-20

STEP 81

A15142

Remove plugs from the shaft only if you plan to clean the oil channels in the shaft.

6003-21

CLUTCH CARRIER DISASSEMBLY

6003-21

CLUTCH CARRIER DISASSEMBLY

703L92

STEP 82

STEP 83

A15143

Install new O-rings on the piston. Lubricate with petroleum jelly. Install the piston on the first side of the housing (shaft end with oil grooves). Be careful not to cut O-rings when installed. Honey combed side of piston faces out.

STEP 82

A15144

Install the 1.10 mm shim.

703L92

STEP 83

A15143

A15144

Install the 1.10 mm shim.

6003-22

STEP 84

STEP 87

STEP 84

STEP 87

A15145

A15126

A15145

A15126

Install the spring and retainer. The chamfered side of the retainer faces out.

Install a steel disc and then a friction disc until there are 12 steel and 13 friction discs in place. The last steel disc must be the adjustment steel disc. Install the backing plate. The raised contact surface side must face out.

Install the spring and retainer. The chamfered side of the retainer faces out.

STEP 85

STEP 88

A15146

Using tool CAS-2264, compress spring and install retaining ring.

STEP 86

A15149

Install the retaining ring.

STEP 86

A15149

Install the retaining ring.

A15147

Install the disc with friction material on one side only. The side of the disc with no material goes against the piston.

6003-23

CLUTCH DISC CLEARANCE ADJUSTMENT

STEP 89

A15151

Measure from the edge of the carrier housing to the face of the backing plate.

A15152

Pry the backing plate up as high as possible and measure from the edge of the clutch housing to the face of the backing plate again.

A15151

Measure from the edge of the carrier housing to the face of the backing plate.

A15152

Pry the backing plate up as high as possible and measure from the edge of the clutch housing to the face of the backing plate again.

The difference between the two dimensions must be 2.1 to 2.5 mm.

There are three (3) adjustment steel discs available to set the correct clearance, 2.5 mm, 3.0 mm, or 3.5 mm thick. Use the disc required to get the correct clearance.

6003-24

CLUTCH CARRIER DISASSEMBLY

Forward Clutch

702L92

STEP 90

STEP 91

702L92

STEP 90

STEP 91

869L92

A15257

869L92

A15257

Install the bearing cups into the spur gear until tight against the gear shoulder.

Using tube CAS-2266-1 and adapter ring CAS-2263-3, install bearing on forward pack side of shaft until tight against the shaft shoulder.

Install the bearing cups into the spur gear until tight against the gear shoulder.

Using tube CAS-2266-1 and adapter ring CAS-2263-3, install bearing on forward pack side of shaft until tight against the shaft shoulder.

6003-25

STEP 92

STEP 95

6003-25

STEP 92

STEP 95

A15162

A15165

A15162

A15165

Align the clutch discs using alignment tool CAS-2265-1 and spacer CAS-2265-3.

Using press tube CAS-2266-1 and adapter ring CAS-2263-3, press bearing on until tight against spacer.

Align the clutch discs using alignment tool CAS-2265-1 and spacer CAS-2265-3.

Using press tube CAS-2266-1 and adapter ring CAS-2263-3, press bearing on until tight against spacer.

STEP 93

STEP 96

A15163

Install the spur gear until engaged with all clutch discs. Apply compressed air to the inlet port on the shaft and observe the spur gear. If the ear goes up and down, all clutch discs are not engaged. The gear must not move when air is applied.

STEP 94

A15163 A15166

Install tapered bearing using tube CAS-2266-1 and adapter ring CAS-2266-3. Install slotted nut on shaft.

STEP 94

A15164

Install the spacer ring.

A15164

Install the spacer ring.

A15166

Install tapered bearing using tube CAS-2266-1 and adapter ring CAS-2266-3. Install slotted nut on shaft.

6003-26

FIRST CLUTCH

700L92

STEP 97

STEP 98

A15167

Turn clutch pack over to first (short) clutch side and install the ball bearing until against the shaft shoulder.

STEP 97

A15173

Measure the thickness of the oil control ring.

700L92

STEP 98

A15167

Turn clutch pack over to first (short) clutch side and install the ball bearing until against the shaft shoulder.

A15173

Measure the thickness of the oil control ring.

6003-27

STEP 99

STEP 102

6003-27

STEP 99

STEP 102

A15172

A15175

A15172

A15175

Measure the thickness of spacer and snap ring together. This dimension must be 0.05 mm smaller than the oil control ring thickness. Select the correct size spacer to get the correct combined thickness. Spacers come in 14.1, 14.2, and 14.3 mm sizes.

Using alignment tool CAS-2265-1 and spacer CAS-2265-4, align the clutch discs.

STEP 103

STEP 100

A15174

Install the spacer and oil control ring.

STEP 101

A15176

Install the spur gear until all discs are fully engaged. Apply compressed air to the inlet port on the shaft and observe the spur gear. If the gear goes up and down, all the clutch discs are not engaged. The gear must not move when air is applied.

A15174

Install the spacer and oil control ring.

STEP 101

STEP 104

A15169

Install the snap ring in the spur gear.

STEP 103

STEP 104

A15169 A15177

Install the ball bearing.

Install the snap ring in the spur gear.

A15177

Install the ball bearing.

6003-28

STEP 105

STEP 107

A15178

Install a 1.5 mm thick shim on the shaft.

STEP 105

A15181

Install collet CAS-2263-5 on lower bearing with collet holder CAS-2263-1. Apply a 100 000 N load with press at the upper bearing to assure all parts are seated.

STEP 106

STEP 107

A15178

Install a 1.5 mm thick shim on the shaft.

A15181

Install collet CAS-2263-5 on lower bearing with collet holder CAS-2263-1. Apply a 100 000 N load with press at the upper bearing to assure all parts are seated.

STEP 106

A15179

Using tube CAS-2266-1 and step plate CAS-2266-4, press tapered bearing on until tight against shim.

6003-29

STEP 108

6003-29

STEP 108

A15183

Install slotted nut on the shaft.

798L92

FORWARD / FIRST CLUTCH ASSEMBLY

798L92

FORWARD / FIRST CLUTCH ASSEMBLY

6003-30

SECOND AND REVERSE CLUTCH DISASSEMBLY STEP 109

SECOND AND REVERSE CLUTCH DISASSEMBLY

STEP 111

A15184

Using collet holder CAS-2263-1 and collet CAS-2263-2, remove the tapered roller bearing from the second clutch side.

STEP 109

STEP 111

A15184

A15186

Using collet holder CAS-2263-1 and collet CAS-2263-2, remove the tapered roller bearing from the second clutch side.

Remove the shim and spacer.

STEP 112

STEP 110

A15186

Remove the shim and spacer.

STEP 112

STEP 110

A15187

A15185

Remove the spur gear and speed sensing ring. The upper bearing will also come off. If necessary, grind rivets off and remove sensing ring. The spur gear has no other parts serviced separately.

Using collet holder CAS-2263-1 and collet CAS-2263-4, remove the tapered roller bearing.

A15187

A15185

Remove the spur gear and speed sensing ring. The upper bearing will also come off. If necessary, grind rivets off and remove sensing ring. The spur gear has no other parts serviced separately.

STEP 113

Using collet holder CAS-2263-1 and collet CAS-2263-4, remove the tapered roller bearing.

STEP 113

A15189

Using collet holder CAS-2263-1 and collet CAS-2263-4, remove the tapered roller bearing from the reverse clutch side.

6003-31

STEP 114

STEP 117

A15190

6003-31

STEP 114

A15130

STEP 117

A15190

A15130

Remove the spur gear.

Remove the roller bearing.

Remove the spur gear.

Remove the roller bearing.

STEP 115

STEP 118

STEP 115

STEP 118

A15248

A15132

Disassemble both clutch carriers. See the steps for the Clutch Carrier Disassembly, 56 through 62 for this procedure.

Remove the bearing cups and snap ring.

STEP 116

A15248

Remove the shim.

Disassemble both clutch carriers. See the steps for the Clutch Carrier Disassembly, 56 through 62 for this procedure.

Remove the bearing cups and snap ring.

STEP 116

A15191

Remove the shim.

A15132

6003-32

STEP 119

A15132

Assemble both clutch carriers. See Clutch Carrier Assembly steps 63 to 69. The reverse clutch has 12 steel discs including the adjustment disc, and 13 friction discs including the disc with friction material only on one side. The reverse clutch side of the housing is bigger than the second clutch side.

The second clutch has 8 steel discs including the adjustment disc and 9 friction discs including the disc with friction material only on one side.

6003-33

SECOND AND REVERSE CLUTCH ASSEMBLY

Reverse Clutch

704L92

STEP 120

STEP 121

704L92

STEP 120

STEP 121

A15161

A15162

A15161

A15162

Install the bearing against the shaft shoulder using press tube CAS-2266-1 and step plate CAS-2266-3 for the reverse clutch pack.

Align all clutch discs using the alignment tool CAS-2265-1 and spacer CAS-2265-3.

Install the bearing against the shaft shoulder using press tube CAS-2266-1 and step plate CAS-2266-3 for the reverse clutch pack.

Align all clutch discs using the alignment tool CAS-2265-1 and spacer CAS-2265-3.

6003-34

STEP 122

STEP 123

A15169

Install the snap ring into the spur gear.

STEP 122

A15249

Install a bearing cup tight against the gear bore shoulder.

STEP 123

A15169

Install the snap ring into the spur gear.

A15249

Install a bearing cup tight against the gear bore shoulder.

6003-35

SPUR GEAR BEARING END PLAY PROCEDURE

STEP 124

A15253 A15252

Install a bearing cup tight against the gear bore shoulder.

A15253 A15252

Install a bearing cup tight against the gear bore shoulder.

Take the difference between the two dimensions. This is the reference dimension.

EXAMPLE:

Dimension 1

25.95

Dimension 1

25.95

Dimension 2

20.85

Dimension 2

20.85

Reference #

4.10

Reference #

4.10

740L92

Install the lower bearing cone. Support the bearing on the inner race. Measure from the spur gear to the bearing inner race, Dimension 1.

6003-36

731L92

732L92

731L92

732L92

Measure the upper bearing assembly as shown for plus or minus adjustment. Add or subtract this dimension to the reference dimension to get spacer size needed. If the bearing inner race is above the outer race, you will add the difference between the two to the referenced dimension.

If the inner race is below the outer race, you will subtract the difference between the two from the reference dimension.

Spacer sizes available in mm: 3.8, 3.85, 3.9, 4.0, 4.15, 4.2, 4.25, 4.3, 4.4, and 4.5.

STEP 125

STEP 127

A15257

A15258

A15257

A15258

Install lower bearing on shaft against shaft shoulder using tube CAS-2266-1 and step plate CAS-22-66-3.

Install the spur gear until all clutch discs are fully engaged. Apply compressed air to the inlet port on the shaft and observe the spur gear. If the gear goes up and down, all the clutch discs are not engaged. The gear must not move when air is applied.

Install lower bearing on shaft against shaft shoulder using tube CAS-2266-1 and step plate CAS-22-66-3.

STEP 126

A15254

Install the upper bearing cup into the spur gear against the snap ring.

6003-37

STEP 128

STEP 130

6003-37

STEP 128

STEP 130

A15259

A15261

A15259

A15261

Install adjustment spacer with the oil control notches up.

Install the outer bearing on the shaft using tube CAS-2266-1 and step plate CAS-2266-2.

Install adjustment spacer with the oil control notches up.

Install the outer bearing on the shaft using tube CAS-2266-1 and step plate CAS-2266-2.

STEP 129

STEP 131

STEP 129

STEP 131

A15260

Install the upper bearing using tube CAS-2266-1 and step plate CAS-2266-4.

A15262

Install washer and slotted nut.

A15260

Install the upper bearing using tube CAS-2266-1 and step plate CAS-2266-4.

A15262

Install washer and slotted nut.

6003-38

Second Clutch

701L92

STEP 132

701L92

STEP 132

A15265

If removed, install sensing ring. Install lower bearing into spur gear using press tube CAS-2266-1 and step plate CAS-2266-2 to support the bearing.

6003-39

SPUR GEAR BEARING END PLAY PROCEDURE STEP 133

SPUR GEAR BEARING END PLAY PROCEDURE

STEP 135

STEP 133

STEP 135

A15266

A15269

A15266

A15269

Install sleeve and 3.55 mm shim on lower bearing race. Install the upper bearing.

Align all the clutch discs using alignment tool CAS-2265-1 and spacer CAS-2265-2.

Install sleeve and 3.55 mm shim on lower bearing race. Install the upper bearing.

Align all the clutch discs using alignment tool CAS-2265-1 and spacer CAS-2265-2.

STEP 134

STEP 136

STEP 134

STEP 136

A15264

A15270

A15264

A15270

Press bearing assembly together. Install a dial indicator on press and indicate to the spur gear. Move the spur gear up and down and check end play. End play must be 0.05 to 0.15 mm. Select the correct size shim for the correct end play.

Install the lower bearing against the shaft shoulder using tube CAS-2266-1 and step plate CAS-2266-2.

6003-40

STEP 137

STEP 140

STEP 137

STEP 140

A15271

A15275

A15271

A15275

Install the spur gear until all clutch discs are fully engaged. Apply compressed air to the inlet port on the shaft and observe the spur gear. If the gear goes up and down all the clutch discs are not engaged. The gear must not move when air is applied.

Install the outer bearing on the shaft using tube CAS-2266-1 and step plate CAS-2266-2.

STEP 141

STEP 138

STEP 141

STEP 138

A15272

A15276

Support the clutch assembly lower bearing on the inner race. Apply a 100 000 N load with the press to assure the parts are seated.

A15272

Install the sleeve and shim.

STEP 139

A15274

Install the upper bearing using tube CAS-2266-1 and step plate CAS-2266-2.

6003-41

STEP 142

6003-41

STEP 142

A15277

Install the slotted nut.

796L92

6003-42

THIRD AND FOURTH CLUTCH DISASSEMBLY STEP 143

THIRD AND FOURTH CLUTCH DISASSEMBLY

STEP 146

A15193

Using holder CAS-2263-1 only, remove the bearing.

STEP 143

A15200

Turn the clutch over. Using holder CAS-2263-1 and collet CAS-2263-5, remove the other bearing.

STEP 144

STEP 146

A15193

Using holder CAS-2263-1 only, remove the bearing.

A15200

Turn the clutch over. Using holder CAS-2263-1 and collet CAS-2263-5, remove the other bearing.

STEP 144 STEP 147

STEP 147

A15194

Remove the shim and upper bearing.

A15202

Remove the shim and upper bearing.

A15202

Remove spur gear and upper bearing.

STEP 145

STEP 145 STEP 148

STEP 148

A15198

Remove the three (3) rings.

A15203

Remove the spacer.

Remove the three (3) rings.

A15203

Remove the spacer.

6003-43

STEP 149

STEP 152

A15204

Remove the lower bearing.

6003-43

STEP 149

A15207

Press the lower bearing and sleeve from the shaft. Do no press on the bearing, only on the sleeve.

STEP 150

STEP 152

A15204

Remove the lower bearing.

Press the lower bearing and sleeve from the shaft. Do no press on the bearing, only on the sleeve.

STEP 150 STEP 153

STEP 153

A15205

Press the shaft from the clutch.

A15219

Press the shaft from the clutch.

A15219

Remove the piston ring from the shaft.

STEP 151

STEP 151 STEP 154

STEP 154

A15220

Remove the clutch packs from the spur gear.

A15207

A15220 A15213

Disassemble both clutch packs. See Clutch Carrier Disassembly steps 56 through 62 for this procedure.

Remove the clutch packs from the spur gear.

A15213

Disassemble both clutch packs. See Clutch Carrier Disassembly steps 56 through 62 for this procedure.

6003-44

STEP 155

The third clutch has 8 steel discs including the adjustment disc and 9 friction discs including the disc with friction material on one side.

STEP 155

The third clutch has 8 steel discs including the adjustment disc and 9 friction discs including the disc with friction material on one side.

The fourth clutch has 7 steel discs including the adjustment disc and 8 friction discs including the disc with friction material only on one side.

A15213

Assemble both clutch packs. See Clutch Carrier Assembly steps 63 through 69 for this procedure.

THIRD AND FOURTH CLUTCH ASSEMBLY

Third Clutch

699L92

6003-45

STEP 156

STEP 159

6003-45

STEP 156

STEP 159

A15220A

A15224

A15220A

A15224

Install the oil control ring on clutch shaft. Lock the ring ends together.

Install the spur gear on the third side of the clutch pack (long side of carrier) until all clutch discs are fully engaged. Apply compressed air to the inlet port on the shaft and observe the spur gear. If the gear goes up and down, all the clutch discs are not engaged. The gear must not move when air is applied.

Install the oil control ring on clutch shaft. Lock the ring ends together.

STEP 157

STEP 160

A15222

Press the sleeve and lower bearing onto the clutch shaft so the bearing is against the shaft ridge.

STEP 158

STEP 158 A15225

A15225

Install the shaft into the clutch pack assembly.

STEP 161

A15223

Align all clutch discs on the third clutch (long side of carrier) using aligning tool CAS-2265-1.

Align all clutch discs on the third clutch (long side of carrier) using aligning tool CAS-2265-1. 733L92

Install three (3) rings as shown in illustration.

733L92

Install three (3) rings as shown in illustration.

6003-46

STEP 162

STEP 163

A15229

Install the upper bearing and washer.

STEP 162

A15230

Install the tapered roller bearing against the upper bearing using tube CAS-2267.

Fourth Clutch

STEP 163

A15229

Install the upper bearing and washer.

A15230

Install the tapered roller bearing against the upper bearing using tube CAS-2267.

Fourth Clutch

703L92

6003-47

STEP 164

STEP 167

A15231

Align clutch discs on fourth clutch side using alignment tool CAS-2265-1 and spacer CAS-2265-3.

6003-47

STEP 164

A15234B

Install the oil control spacer.

STEP 167

A15231

Align clutch discs on fourth clutch side using alignment tool CAS-2265-1 and spacer CAS-2265-3.

STEP 168

A15234B

Install the oil control spacer.

STEP 168

STEP 165

A15233 A15234

A15233

Install the upper ball bearing.

A15234

Install the ball bearing against the shaft shoulder.

Install the upper ball bearing.

Install the ball bearing against the shaft shoulder.

STEP 169

STEP 166

A15236 A15234A

Install the spur gear until all clutch discs are fully engaged. Apply compressed air to the inlet port on the shaft and observe the spur gear. If the gear goes up and down, all clutch discs are not engaged. The gear must not move when air is applied.

Install the tapered bearing against the upper bearing.

A15236 A15234A

Install the tapered bearing against the upper bearing.

6003-48

STEP 170

STEP 171

A15237

Press assembly together to a load of 100 000 N. Press only on the inner races of the two (2) bearings.

STEP 170

A15237A

Install the spacers and slotted nuts on the shaft.

STEP 171

A15237

Press assembly together to a load of 100 000 N. Press only on the inner races of the two (2) bearings.

A15237A

Install the spacers and slotted nuts on the shaft.

794L92

FOURTH/THIRD CLUTCH ASSEMBLY

CHARGE PUMP DISASSEMBLY

STEP 172

STEP 173

STEP 172

STEP 173

A15279

A15280

A15279

A15280

Remove the shaft from the pump. Do not lose shims that may be on the shaft.

Remove the cover from the pump. If necessary, drive the needle bearing from the cover.

Remove the shaft from the pump. Do not lose shims that may be on the shaft.

Remove the cover from the pump. If necessary, drive the needle bearing from the cover.

6003-49

STEP 174

STEP 176

A15281

Mark the gear set for assembly later and remove it from the coupling with the square key.

6003-49

STEP 174

A15283

Remove the bearing.

STEP 176

A15281

Mark the gear set for assembly later and remove it from the coupling with the square key.

STEP 177

A15283

Remove the bearing.

STEP 177

STEP 175

A15284 A15282

Remove the snap ring, drive coupling, and bearing. If necessary, remove the three rings inside the coupling.

Measure from the pump housing to the surface of the gears. If there is more than 0.05 mm of end play, replace the pump assembly. The pump housing, c o v er , an d g ea r s e t ar e o nl y s e r v i c e d a s a n assembly.

A15284 A15282

Remove the snap ring, drive coupling, and bearing. If necessary, remove the three rings inside the coupling.

6003-50

CHARGE PUMP ASSEMBLY

742L92

STEP 178

STEP 180

742L92

STEP 178

STEP 180

A15282

A15280

A15282

A15280

Install the three rings inside the coupling and the bearing on the coupling. Install the coupling and snap ring.

Install the needle bearing in the cover and the cover on the pump housing.

Install the three rings inside the coupling and the bearing on the coupling. Install the coupling and snap ring.

Install the needle bearing in the cover and the cover on the pump housing.

STEP 179

A15281

Install the gear set into the housing with a square key.

6003-51

STEP 181

6003-51

STEP 181

A15279

Install the shaft with shim. Apply Loctite 242 to screw and tighten to a torque of 32 Nm.

Install the shaft with shim. Apply Loctite 242 to screw and tighten to a torque of 32 Nm. 799L92

CHARGE PUMP

799L92

CHARGE PUMP

6003-52

TRANSMISSION ASSEMBLY STEP 182

TRANSMISSION ASSEMBLY

STEP 184

A15208

Install all bearing cups, spacers, and snap rings into the transmission housing.

STEP 182

A15289

Install the first and forward clutch pack assembly.

STEP 184

A15208

Install all bearing cups, spacers, and snap rings into the transmission housing.

STEP 185

A15289

Install the first and forward clutch pack assembly.

STEP 185

STEP 183

A15290 A15116

Install the reverse idler (countershaft) gear with bearings and shim.

Install the second and reverse fourth clutch assembly.

A15290 A15116

Install the reverse idler (countershaft) gear with bearings and shim.

STEP 186

Install the second and reverse fourth clutch assembly.

STEP 186

793L92

793L92 A15291

A15291

Install the third and fourth clutch assembly. Move the other clutch packs to help install the clutches. Install and lock together all oil control rings on the clutch shafts.

6003-53

759L92

OUTPUT SHAFT GROUP

STEP 187

STEP 188

A15112

Install the lower baffle plate.

OUTPUT SHAFT GROUP

STEP 187

A15292

Install the shim and bearing for the output shaft.

STEP 188

A15112

Install the lower baffle plate.

A15292

Install the shim and bearing for the output shaft.

STEP 189

Install the control valve assembly. See Section 6001 for procedure.

6003-54

Reverse Idler (Countershaft) Bearing Preload Procedure

STEP 190

A15286

A15288

Measure from the upper shoulder to the lower s h o u l d e r o f t h e r e v e r se i d l e r ( c o u n t e r s h a f t ) Dimension 1.

Install the reverse idler (countershaft). Measure from the housing to the countershaft (Dimension 3). Select the correct shim size needed from the following procedure:

A15286

A15288

Measure from the upper shoulder to the lower s h o u l d e r o f t h e r e v e r se i d l e r ( c o u n t e r s h a f t ) Dimension 1.

Install the reverse idler (countershaft). Measure from the housing to the countershaft (Dimension 3). Select the correct shim size needed from the following procedure:

EXAMPLE: Dimension 2

53.95

Dimension 2

53.95

Dimension 3

+0.60

Dimension 3

+0.60

Dimension X

54.55

Dimension X

54.55

Dimension 1

57.11

Dimension 1

57.11

Dimension X

-54.55

Dimension X

-54.55

2.56

Difference

2.56

+0.04

Bearing Preload

+0.04

2.60

Difference Bearing Preload 743L92

EXAMPLE:

Shim Size Needed

743L92

Shim Size Needed

Preload must be within 0 to 0.10 mm.

STEP 191

A15287

Assemble the gear and both bearings. Measure between the outside of both inner races (Dimension 2).

A15294

Install the output gear.

A15294

Install the output gear.

6003-55

STEP 192

STEP 194

6003-55

STEP 192

STEP 194

A15295

A15297

A15295

A15297

Install the output shaft. The longer splined end goes into the gear.

Install the cover without bearing cups. Tighten the bolts to a torque of 46 Nm.

Install the output shaft. The longer splined end goes into the gear.

Install the cover without bearing cups. Tighten the bolts to a torque of 46 Nm.

STEP 193

A15296

Install the upper oil baffle. Tighten the bolts to a torque of 23 Nm.

6003-56

Output Shaft Bearing End Play Procedure

STEP 195

STEP 196

A15300

Measure from the case surface to the shoulder on the output shaft (Dimension 1).

STEP 196

A15302

Install the correct shim.

A15300

Measure from the case surface to the shoulder on the output shaft (Dimension 1).

STEP 197

A15298 A15303

Install the bearing on the output shaft.

STEP 198

EXAMPLE:

Measure from the case surface to the shoulder in the case bore (Dimension 2). Subtract Dimension 2 from Dimension 1. Subtract 0.4 mm from your difference for the shaft end play. Select a shim of the correct size.

A15303

Install the bearing on the output shaft.

STEP 198

EXAMPLE:

Dimension 1

53.20

Dimension 1

53.20

Dimension 2

-50.40

Dimension 2

-50.40

2.80

Difference

2.80

Subtract for the Play

-0.40

Subtract for the Play

-0.40

Shim Size Needed

2.40

Shim Size Needed

2.40

Difference

Install the correct shim.

STEP 197

A15298

A15302

A15304

Install the correct number / size shims and snap ring so the bearing will not move up or down.

6003-57

STEP 199

STEP 200

6003-57

STEP 199

STEP 200

A15305

A15308

A15305

A15308

Install the seal so the lip is to the inside. Apply RTV sealant between the outer diameter of the seal and the housing.

Tighten all the slotted nuts on the clutch packs to a torque of 550 Nm.

Install the seal so the lip is to the inside. Apply RTV sealant between the outer diameter of the seal and the housing.

Tighten all the slotted nuts on the clutch packs to a torque of 550 Nm.

STEP 201

792L92

STEP 201

A15306

Install bearing cup for the second / reverse and third / fourth clutch assemblies.

792L92

6003-58

Second / Reverse Clutch Bearing End Play Procedure

STEP 202

EXAMPLE:

Dimension 1

7.58

Dimension 1

7.58

Dimension 2

-5.95

Dimension 2

-5.95

Difference

0.63

Difference

0.63

+0.17

Bearing Preload

+0.17

1.80

Shim Needed

1.80

Bearing Preload Shim Needed

STEP 203

A15310

Clamp the bearing cup in place. Measure from the bearing cup to the cover surface (Dimension 1).

A15097

A15312

Measure from the mounting surface of the end cap to the shoulder inside the cap (Dimension 2).

47L92

Install the correct shim in the end cap and hold in place with grease. Install the end cap with a new O-ring and tighten the bolts to a torque of 46 Nm. Make sure the cap ports face the correct direction.

STEP 204

Duplicate step 183 for the third / fourth clutch pack.

A15095

Select the correct size shim using the procedure here:

6003-59

Forward / First Clutch Bearing End Play Procedure

STEP 205

STEP 207

A15315

A15317

A15315

A15317

Install the bearing cup on the forward / first clutch bearing cone. Measure from the cover surface to the bearing cup (Dimension 1).

Measure from the end of the end cap to the inner shoulder of the cap (bearing mounting surface) for Dimension 3.

Install the bearing cup on the forward / first clutch bearing cone. Measure from the cover surface to the bearing cup (Dimension 1).

Measure from the end of the end cap to the inner shoulder of the cap (bearing mounting surface) for Dimension 3.

STEP 206

Select the correct shim size from the following procedure:

STEP 206

Select the correct shim size from the following procedure:

A15316

Measure from the end cap mounting flange to the end of the cap (Dimension 2).

Measure from the end cap mounting flange to the end of the cap (Dimension 2). 745L92

EXAMPLE:

745L92

EXAMPLE:

Dimension 1

128.90

Dimension 1

128.90

Dimension 3

-40.00

Dimension 3

-40.00

Dimension 4

88.90

Dimension 4

88.90

Subtract Dimension 4 from Dimension 1.

Dimension 1

89.90

Dimension 1

89.90

Dimension 4

-88.90

Dimension 4

-88.90

1.00

Difference

1.00

+0.15

Bearing Preload

+0.15

1.15

Shim Size Needed

1.15

Difference Bearing Preload Shim Size Needed

6003-60

STEP 208

STEP 210

STEP 208

STEP 210

A15221

A15320

A15221

A15320

Install the correct shim and bearing cup into the end cap. Install the end cap with a new O-ring and tighten the bolts to a torque of 46 Nm.

Install all new expansion plugs until flush with the housing. The lips must be toward the inside of the housing. Apply Loctite 277 to sealing surfaces of each plug.

Install the correct shim and bearing cup into the end cap. Install the end cap with a new O-ring and tighten the bolts to a torque of 46 Nm.

Install all new expansion plugs until flush with the housing. The lips must be toward the inside of the housing. Apply Loctite 277 to sealing surfaces of each plug.

STEP 209

STEP 209 STEP 211

STEP 211

A15318

Install the reverse idler (countershaft). Be sure the spring pin in the bottom of the shaft aligns with the hose in the housing. Tighten the bolt to a torque of 46 Nm.

A15318 A15321

Install the brake rotor. Tighten the bolts to a torque of 46 Nm. Install the bolt locking washer.

STEP 212

Install the reverse idler (countershaft). Be sure the spring pin in the bottom of the shaft aligns with the hose in the housing. Tighten the bolt to a torque of 46 Nm.

A15321

Install the brake rotor. Tighten the bolts to a torque of 46 Nm. Install the bolt locking washer.

STEP 212

A15322

Install the parking brake caliper. Tighten the bolts to a torque of 185 Nm.

6003-61

STEP 213

STEP 216

6003-61

STEP 213

STEP 216

BD07B036

BD07B039

BD07B036

BD07B039

Install idler shaft gear and layshaft and align. Heat the components.

Remove the guide bolt, use Loctite 243 on the threads, install and torque the retaining bolt to 46 Nm (34 pound-feet).

Install idler shaft gear and layshaft and align. Heat the components.

Remove the guide bolt, use Loctite 243 on the threads, install and torque the retaining bolt to 46 Nm (34 pound-feet).

STEP 214

STEP 214 STEP 217

STEP 217

BD07B037

Install and aligning screw.

BD07B040

Use Loctite 262 on sealing plugs, install plugs until flush with housing.

STEP 215

Install and aligning screw.

BD07B040

Use Loctite 262 on sealing plugs, install plugs until flush with housing.

STEP 215

STEP 218

BD07B038

Install idler shaft.

Install idler shaft. A15323

A15323

Apply Loctite 221 to the area around the openings on the side of the pump and install into the transmission.

6003-62

STEP 219

STEP 222

STEP 219

STEP 222

STEP 195

STEP 198

STEP 195

STEP 198

Install the pump flange. Tighten the bolts to a torque of 79 Nm.

Install the filter and cover with a new O-ring. Tighten the bolts to a torque of 23 Nm.

Install the pump flange. Tighten the bolts to a torque of 79 Nm.

Install the filter and cover with a new O-ring. Tighten the bolts to a torque of 23 Nm.

STEP 220

A15325

Install the output shaft seal with the lip inward. Apply RTV sealant to outer diameter of seal and housing after installed.

STEP 221

A15326

Install the companion flange. Tighten the bolts to a torque of 46 Nm. Install the locking washers on bolts.

6003-63

746L92

INPUT GROUP

STEP 223

INPUT GROUP

STEP 224

BD07B041

Install the three V-rings into the recess of the shaft, install the key.

STEP 223

BD07B042

Install a 2 MM. (0.078 inch) shim and bearing.

STEP 224

BD07B041

Install the three V-rings into the recess of the shaft, install the key.

BD07B042

Install a 2 MM. (0.078 inch) shim and bearing.

6003-64

STEP 225

STEP 228

BD07B043

STEP 225

BD07B046

STEP 228

BD07B043

BD07B046

Install a 2 MM. (0.078 inch) shim.

Install a snap ring on the shaft, install the input gear.

Install a 2 MM. (0.078 inch) shim.

Install a snap ring on the shaft, install the input gear.

STEP 226

STEP 229

STEP 226

STEP 229

BD07B044

Install the shaft and bearing, use Loctite 243 on the threads of the bolt, install and torque the bolt to 32 Nm (23.5 pound-feet).

BD07B047

Install the snap ring onto the shaft.

Install the shaft and bearing, use Loctite 243 on the threads of the bolt, install and torque the bolt to 32 Nm (23.5 pound-feet).

STEP 230

STEP 227

BD07B047

Install the snap ring onto the shaft.

STEP 230

STEP 227

BD07B045

Press a new bearing onto the spur gear.

BD07B044

BD07B048

Install the input shaft into the housing, align key into the keyway by turning the shaft.

BD07B045

Press a new bearing onto the spur gear.

6003-65

STEP 231

STEP 234

STEP 199

6003-65

STEP 231

A15330

STEP 234

STEP 199

A15330

Install the bearing cup into the converter housing.

Install the spur gear into the housing.

Install the bearing cup into the converter housing.

Install the spur gear into the housing.

STEP 232

STEP 235

STEP 232

STEP 235

A15073

A15331

A15073

A15331

Install the converter control valve.

Install the drive shaft.

Install the converter control valve.

Install the drive shaft.

STEP 233

STEP 236

STEP 233

STEP 236

A15329

Install the bearing cone into the cup.

A15332

Install the bearing cone using tube CAS-2266-1 and step plate CAS-2266-4.

A15329

Install the bearing cone into the cup.

A15332

Install the bearing cone using tube CAS-2266-1 and step plate CAS-2266-4.

6003-66

STEP 237

A15333

Install the bearing cup.

A15333

Install the bearing cup.

6003-67

Converter Bearing Preload Procedure

STEP 238

STEP 206

A15338

STEP 206

A15338

Install converter housing. Tighten the bolts to a torque of 34 Nm (M8 bolts), 79 Nm (M12-8.8 bolts) and 117 Nm (M12-10.9 bolts).

Measure from the bottom of the housing to the bearing outer race locating surface (Dimension 3). Determine shim size needed by using the following:

Install converter housing. Tighten the bolts to a torque of 34 Nm (M8 bolts), 79 Nm (M12-8.8 bolts) and 117 Nm (M12-10.9 bolts).

Measure from the bottom of the housing to the bearing outer race locating surface (Dimension 3). Determine shim size needed by using the following:

Measure from the bearing outer race (cup) to the flange mounting surface (Dimension 1).

EXAMPLE:

Measure from the bearing outer race (cup) to the flange mounting surface (Dimension 1).

EXAMPLE:

STEP 239

Dimension 2

65.37

Dimension 3

-4.50

Dimension X

60.87

STEP 239

Dimension 2

65.37

Dimension 3

-4.50

Dimension X

60.87

Dimension 1

62.10

Dimension 1

62.10

Dimension X

-60.87

Dimension X

-60.87

1.23

Difference

1.23

+0.07

Bearing Preload

+0.07

1.30

Shim Size Needed

1.30

Difference Bearing Preload Shim Size Needed

STEP 240

A15337

A15335

Install the oil control ring on the drive shaft. Lock the ends of the ring together.

751L92

Install the gasket on the flange and measure from the gasket to the bottom of the oil supply housing (Dimension 2).

6003-68

STEP 241

STEP 244

A15366

Install the relief valve spring and ball.

STEP 241

A15341

Install the oil supply housing. Align the marks you made before removal. The openings in the housing must align with the openings in the converter housing.

STEP 242

STEP 244

A15366

Install the relief valve spring and ball.

STEP 242

STEP 245

A15340

Install the correct shim. Apply grease on shim to hold in place.

Install the correct shim. Apply grease on shim to hold in place. A15342

STEP 243

Install the cover. Tighten the bolts to a torque of 46 Nm.

A15339

Apply Loctite 221 to the area around the two ports.

A15341

Install the oil supply housing. Align the marks you made before removal. The openings in the housing must align with the openings in the converter housing.

A15342

STEP 243

Install the cover. Tighten the bolts to a torque of 46 Nm.

A15339

Apply Loctite 221 to the area around the two ports.

6003-69

STEP 246

STEP 247

6003-69

STEP 246

STEP 247

6 5 4

A15055

BD07B003

A15055

BD07B003

Install the flexplate on the converter and tighten the bolts to a torque of 46 Nm. Apply Loctite 270 to threads of the bolts. Install a new sealing ring on the shaft of the converter. Install the converter.

Install pipe connectors (1 - 4), install plug (5) and torque to 40 Nm (29.5 pound feet), and install plug (6) and torque to 6 Nm (53 pound inch).

STEP 248

797L92

STEP 248

BD07B004

Install new O-ring and tighten plug to 80 Nm (59 pound feet).

STEP 249

797L92

INPUT ASSEMBLY

STEP 249

INPUT ASSEMBLY

BD07B005

Install two aligning studs (M8) and new gasket.

BD07B005

Install two aligning studs (M8) and new gasket.

6003-70

STEP 250

STEP 252

STEP 250

STEP 252

BD07B006

BD07B008

BD07B006

BD07B008

Install the duct plate and torque mounting bolts to 23 Nm (17 pound feet).

Install 6 M6 x 100 MM. and 17 M6 x 76 MM. bolts and torque to 12 Nm (106 pound inch).

Install the duct plate and torque mounting bolts to 23 Nm (17 pound feet).

Install 6 M6 x 100 MM. and 17 M6 x 76 MM. bolts and torque to 12 Nm (106 pound inch).

STEP 251

NOTE: M6 x 100 MM. bolts are located at the arrows.

STEP 251

NOTE: M6 x 100 MM. bolts are located at the arrows.

BD07B007

Install two aligning studs (M6) and new gasket.

BD07B007

Install two aligning studs (M6) and new gasket.

6003-71

Speed Sensing Adjustment

6003-71

Speed Sensing Adjustment

STEP 253

STEP 254

STEP 253

STEP 254

BS07B001

1. ENGINE

2. TURBINE

BS07B001

3. INTERNAL

1. ENGINE

Location of sensor.

2. TURBINE

3. INTERNAL

Location of sensor. BS07B002

Output speed sensor (4).

BS07B002

Output speed sensor (4).

6003-72

STEP 255

STEP 256

S I

STEP 255

STEP 256

BD07B049

Measure dimension (I) on the transmitter from contact face to the screw-in face. Dim. (I) e.g.... 30.00 MM.

S I

STEP 257

Turn the input shaft until a tooth tip is centered in the bore of the gauge plug hole.

STEP 258

BS07B003

1. ENGINE 2. TURBINE 3. INTERNAL

BS07B003

4. X = 0.5 +0.3 MM. 5. X = 0.5 +0.3 MM. 6. X = 0.3 Âą0.1 MM.

1. ENGINE 2. TURBINE 3. INTERNAL

Gap X must be determined for each of the speed sensors 1, 2, and 3.

4. X = 0.5 +0.3 MM. 5. X = 0.5 +0.3 MM. 6. X = 0.3 Âą0.1 MM.

Gap X must be determined for each of the speed sensors 1, 2, and 3. BD07B050

BD07B050

Install the plug gauge making sure that the gauge is fully seated. Loosen the set screw and push the plunger against the gear tooth, tighten the set screw.

NOTE: The tool shown is not offered, use a depth mike or caliper in this procedure.

6003-73

STEP 259

STEP 261

6003-73

STEP 259

STEP 261

Calculation of needed shims as below.

Example A

Dimension II

30.10

Dimension II

30.10

Dimension X

-0.60

Dimension X

-0.60

Dimension A

29.50

Dimension A

29.50

Example B

Dimension I

30.00

Dimension I

30.00

Dimension A

-29.50

Dimension A

-29.50

0.50

Dimension S (shims)

0.50

Dimension S (shims)

STEP 262

BS07B004

Example of correctly installed gauge, dimension II. NOTE: The tool shown is not offered, use a depth mike or caliper in this procedure.

STEP 260

BD07B052

Install shim (s) as required, apply Loctite 574 to the threads.

STEP 263

Install transmitter and torque to 30 Nm (22 pound feet).

STEP 264 Repeat the procedure for turbine and internal speed transmitters.

BS07B004

Example of correctly installed gauge, dimension II. NOTE: The tool shown is not offered, use a depth mike or caliper in this procedure.

STEP 260

BD07B051

Measure dimension (II) on the gauge from contact face to the screw-in face. Dim. (II) e.g.... 30.10 MM.

Install transmitter and torque to 30 Nm (22 pound feet).

STEP 264 Repeat the procedure for turbine and internal speed transmitters.

6003-74

STEP 265

STEP 267

STEP 265

STEP 267

BS07B005

BD07B056

Measure dimension (II) on the transmitter from contact face to the mounting face. Dim. (I) e.g.... 40.00 MM.

STEP 268

BS07B005

Calculation of needed shims as below. 1. SPUR GEAR 2. TRANSMITTER

Calculation of needed shims as below.

3. HOUSING

1. SPUR GEAR 2. TRANSMITTER

Example A

Dimension X for the output speed transmitter is 1.0 + 0.5 MM.

STEP 266

STEP 268

Dimension I

39.70

Dimension X

-1.20

Instal. Dimension

38.50

Example B

3. HOUSING

Example A

Dimension X for the output speed transmitter is 1.0 + 0.5 MM.

STEP 266

Dimension I

39.70

Dimension X

-1.20

Instal. Dimension

38.50

Example B

Dimension II

40.00

Dimension II

40.00

Instal. Dimension

-38.50

Instal. Dimension

-38.50

1.50

Dimension (shims)

1.50

Dimension (shims)

BD07B055

Determine dimension from housing face (3) to spur gear (1). Dim (I) e.g.....39.70 MM.

6003-75

STEP 269

Install required shims, Molydisulfide grease.

STEP 270

lubricate

O-ring

6003-75

STEP 269

BD07B057

BD07B058

with

Install and torque the mounting screw to 23 Nm (17 pound feet).

Install required shims, Molydisulfide grease.

STEP 270

lubricate

O-ring

BD07B057

BD07B058

with

Install and torque the mounting screw to 23 Nm (17 pound feet).

6003-76

HOW IT WORKS

764L92

1. 2. 3. 4. 5.

INPUT GEAR FORWARD CLUTCH AND GEAR FIRST CLUTCH AND GEAR REVERSE CLUTCH AND GEAR SECOND CLUTCH AND GEAR

6. 7. 8. 9.

REVERSE IDLER (COUNTERSHAFT) GEAR FOURTH CLUTCH AND GEAR THIRD CLUTCH AND GEAR OUTPUT GEAR

POWER FLOW

Gears 1, 2, 4, 6, and 7 are in constant mesh. When converter turns, all gears are running.

858L92

FOURTH GEAR FORWARD ONLY - You energize M5 solenoid which locks up fourth clutch. The fourth clutch now drives the carrier, which drives the third gear clutch, and in turn, third gear which drives the outer gear. Third gear is locked hydraulically at this time. (No solenoids needed). THIRD GEAR FORWARD - Energize M3 which permits oil flow to forward clutch. Third clutch is still hydraulically locked up.

SECOND GEAR FORWARD - Energize M3 which permits oil flow to forward clutch. Energize M4 which permits oil flow to second clutch and dumps third clutch to reservoir.

764L92

1. 2. 3. 4. 5.

INPUT GEAR FORWARD CLUTCH AND GEAR FIRST CLUTCH AND GEAR REVERSE CLUTCH AND GEAR SECOND CLUTCH AND GEAR

6. 7. 8. 9.

REVERSE IDLER (COUNTERSHAFT) GEAR FOURTH CLUTCH AND GEAR THIRD CLUTCH AND GEAR OUTPUT GEAR

POWER FLOW

Gears 1, 2, 4, 6, and 7 are in constant mesh. When converter turns, all gears are running.

SECOND GEAR FORWARD - Energize M3 which permits oil flow to forward clutch. Energize M4 which permits oil flow to second clutch and dumps third clutch to reservoir.

Gears 3, 5, 8, and 9 are in constant mesh only with each other.

(Poppet valves are inside the valve body)

FIRST GEAR FORWARD - Energize M3 which permits oil flow to forward clutch. Energize M2 which positions poppet valve (M2) to redirect oil flow from M3 poppet to second clutch. Energize M4 which permits oil flow to through poppet valve (M4) to poppet valve (M2).

FIRST GEAR REVERSE - Energize M1 which permits oil flow to reverse clutch. Energize M2 to redirect oil flow from poppet valve (M4) to poppet valve (M2) and out to first clutch (also dumps third clutch). Energize M4 to permit oil flow to poppet valve (M2).

858L92

6003-77 SECOND GEAR REVERSE - Energize M1 which permits oil flow to reverse clutch. Energize M4 which permits oil flow through M4 poppet valve to M2 poppet valve which is open to second clutch and also dumps third clutch oil.

THIRD GEAR REVERSE - Energize M1 which permits oil flow to reverse clutch. Third clutch is still hydraulically locked up.

782L92A

THIRD GEAR REVERSE - Energize M1 which permits oil flow to reverse clutch. Third clutch is still hydraulically locked up.

782L92A

6003-78

NOTES

FRONT AND REAR AXLE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6004

Section 6004 6004

Section 6004

FRONT AND REAR AXLE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6004-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 6 6 7 7 13 23 23 23 24 27 28 29 31 34 34 35 36 38 41

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL END AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY OF THE BRAKE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determine Shim Thickness for a Perfect Tooth Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Rolling Moment of Drive Pinion Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY OF LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 6 6 7 7 13 23 23 23 24 27 28 29 31 34 34 35 36 38 41

6004-3

SPECIAL TOOLS

Differential bearing cone puller collet set..................................................................................................... CAS2839 Differential bearing cone puller collet set.................................................................................................... CAS2840 Pinion seal installer...................................................................................................................................... CAS2841 Pinion locknut wrench.................................................................................................................................. CAS2842 Pinion bearing puller collet set..................................................................................................................... CAS2843 Puller body and forcing screw ..................................................................................................................... CAS2844 Forcing screw, nut, and trust washers......................................................................................................... CAS2845 Pinion shaft lifting bail.................................................................................................................................. CAS2846 Differential assembly holding bracket set ..................................................................................................380001562 Planetary ring gear puller ..........................................................................................................................380001563 Planetary bearing puller collet set .............................................................................................................. CAS2849 Brake housing puller..................................................................................................................................380001564 Differential bearing preload wrench...........................................................................................................380001565 Brake housing outer bearing cup installer ................................................................................................... CAS2852 Brake housing inner bearing cup installer .................................................................................................380001751 Pinion outer bearing cup installer ................................................................................................................ CAS2854 Pinion inner bearing cup installer ................................................................................................................ CAS2855 Locknut socket and nuts.............................................................................................................................. CAS2856 Differential lifting bracket ............................................................................................................................. CAS2857 Pinion depth gauge set................................................................................................................................ CAS2858 Wheel end guide stud set ......................................................................................................................... 380001752 Puller body and screw .............................................................................................................................. 380001575 Support bracket .........................................................................................................................................380001576 Slide hammer adapter ............................................................................................................................ CAS10846-3 Slide hammer ..............................................................................................................................................OEM4252 Handle (included in CAS1773 or CAS1716)............................................................................................ CAS1716-3 Replacer ..................................................................................................................................................... CAS2205 Puller plate (included in CAS40040)............................................................................................................ CAS2510 Magnetic base with indicator .....................................................................................................................380001725 Heat gun ....................................................................................................................................................380001544 Lifting sling.................................................................................................................................................380001579 Pulling attachment .....................................................................................................................................380001578 Engine stand..............................................................................................................................................380001580 Holding bar ................................................................................................................................................380001546 Step plate (included in 380001539)...........................................................................................................380001539 Step plate (included in 380001539)...........................................................................................................380001541 Drive plate (included in OEM6231)....................................................................................................................27555

6004-4

GEAR TOOTH CONTACT PATTERNS Ideal Tooth Contact Pattern

GEAR TOOTH CONTACT PATTERNS

Pinion Distance Must Be Increased

BS01D011

Ideal Tooth Contact Pattern

BS01D009

COAST SIDE (CONCAVE)

Pinion Distance Must Be Increased

BS01D011

BS01D009

COAST SIDE (CONCAVE)

BS01D013 BS01D012

BS01D013

COAST SIDE (CONCAVE)

BS01D012

DRIVE SIDE (CONVEX)

COAST SIDE (CONCAVE)

DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

BS01D014

DRIVE SIDE (CONVEX)

6004-5

Pinion Distance Must Be Decreased

6004-5

Pinion Distance Must Be Decreased

BS01D016 BS01D010

BS01D016

DRIVE SIDE (CONVEX)

BS01D010

BS01D015

COAST SIDE (CONCAVE)

BS01D015

COAST SIDE (CONCAVE)

DRIVE SIDE (CONVEX)

6004-6

LUBRICATION

LUBRICATION 1

1 1

5 3 3

3 3. OIL DRAIN HOLE (OUTPUTS) OIL 4. DRAIN HOLE (AXLE CASING)

BS00M069

1. BRAKE BLEEDER 2. BLEEDER

BS00M069

1. BRAKE BLEEDER 2. BLEEDER

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BS00M070

5. OIL FILLER HOLE

BD00M234

3. OIL DRAIN HOLE (OUTPUTS) OIL 4. DRAIN HOLE (AXLE CASING)

BS00M070

5. OIL FILLER HOLE

WEAR MEASUREMENT ON MULTI-DISC BRAKE

BS00M071

BD00M234

BS00M071

NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a changed braking behavior.

A wear measurement has to be made on both wheel ends.

Remove screw plug, actuate brake and determine dimension “X” using a feeler gauge.

If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.

Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pound-feet).

6004-7

WHEEL END AND BRAKES Disassembly

STEP 3

STEP 1

STEP 3

STEP 1

BD00M238

Pry the cover off the wheel end.

BD00M235

STEP 4

Fasten the axle on a stand.

STEP 4

Fasten the axle on a stand.

STEP 2

BD00M236

BD03B008

Use 380001582 slide hammer and 380001545 adapter, remove the slotted pin from wheel end lock nut.

BD00M236

STEP 5

BD00M237

BD00M237 BD03B009

Loosen the screw plugs and drain the oil from the axle casting.

Using 380001571 locknut socket and 380001576 support bracket, loosen and remove the locknut.

BD03B009

Loosen the screw plugs and drain the oil from the axle casting.

Using 380001571 locknut socket and 380001576 support bracket, loosen and remove the locknut.

6004-8

STEP 6

STEP 9

BD00M241

Use acceptable lifting equipment and hold the wheel end in place. Loosen and remove the bolts.

STEP 6

BD00M244

Remove the shim(s) from the sun gear shaft.

STEP 9

BD00M241

Use acceptable lifting equipment and hold the wheel end in place. Loosen and remove the bolts.

STEP 10

BD00M244

Remove the shim(s) from the sun gear shaft.

STEP 10

STEP 7

BD00M245 BD03B010

BD00M245

Pull the sun gear shaft out of the planet gears.

BD03B010

Separate the wheel end from the axle casing.

STEP 11

STEP 8

BD03B011 BD00M243

Pull the stub shaft out of the sun gear shaft. NOTE: Watch for released shim(s).

Pull the sun gear shaft out of the planet gears.

Lift planet carrier out of the brake housing using 380001578 pulling attachment.

BD03B011 BD00M243

Pull the stub shaft out of the sun gear shaft. NOTE: Watch for released shim(s).

Lift planet carrier out of the brake housing using 380001578 pulling attachment.

6004-9

STEP 12

STEP 15

6004-9

STEP 12

BD03B012

Remove the snap rings from the planet gear shaft using 380001585 snap ring pliers.

STEP 15

BD03B012 BD03B015

Using suitable puller, remove planetary ring gear from brake housing.

STEP 13

Remove the snap rings from the planet gear shaft using 380001585 snap ring pliers.

BD03B015

Using suitable puller, remove planetary ring gear from brake housing.

STEP 13 STEP 16

STEP 16

BD03B013

Remove the planet gear using 380001563 gear puller and 380001539 step plate.

BD03B016

Remove O-rings from the annular grooves of the ring gear.

STEP 14

BD03B016

Remove O-rings from the annular grooves of the ring gear.

STEP 14

STEP 17

BD03B014

Remove the bearing from the planetary using 380001757 collet set, 380001575 puller body and screw, and 8061 step plate.

BD03B017

Remove O-ring from recess of the brake housing.

BD03B017

Remove O-ring from recess of the brake housing.

6004-10

STEP 18

STEP 21

STEP 18

STEP 21

BD03B021

Remove the brake disc pack from the brake housing.

Use compressed air to raise piston out of the brake housing.

Remove the brake disc pack from the brake housing.

Use compressed air to raise piston out of the brake housing.

STEP 19

STEP 22

STEP 19

STEP 22

BD00M253

BD03B019

Drive slotted pins in the support shim until they are flush with the top of the support shim.

STEP 20

BD03B019

Remove the support shim out of the piston.

Drive slotted pins in the support shim until they are flush with the top of the support shim.

Remove the support shim out of the piston.

STEP 23

STEP 20

STEP 23

BD00M257

BD03B020

Remove the circlip using 380001584 external pliers.

BD03B022

Drive slotted pins out of the support shim.

BD00M257

BD03B020

Remove the circlip using 380001584 external pliers.

BD03B022

Drive slotted pins out of the support shim.

6004-11

STEP 24

STEP 27

BD00M259

Preload the cup springs using a press and remove the retaining ring.

6004-11

STEP 24

BD00M262

Lift the piston out of the brake housing.

STEP 27

BD00M259

Preload the cup springs using a press and remove the retaining ring.

STEP 28

BD00M262

Lift the piston out of the brake housing.

STEP 28

STEP 25

BD00M263 BD00M260

Pull the pin out of the support shim and remove the released cup springs.

STEP 26

Remove and discard the guide ring, support rings and U-rings from the grooves of the brake housing. NOTE: If replacing brakes only, go to step 44.

BD00M263 BD00M260

Pull the pin out of the support shim and remove the released cup springs.

STEP 26

STEP 29

BD00M261

Press the gripping rings off of the pins.

Remove and discard the guide ring, support rings and U-rings from the grooves of the brake housing. NOTE: If replacing brakes only, go to step 44.

STEP 29

BD00M261 BD03B023

Using 38001564 puller bridge and 380001542 step plate, remove the brake housing from the wheel end shaft.

Press the gripping rings off of the pins.

BD03B023

Using 38001564 puller bridge and 380001542 step plate, remove the brake housing from the wheel end shaft.

6004-12

STEP 30

STEP 32

STEP 30

BD03B024

Use acceptable lifting equipment and lift the brake housing from the wheel end shaft.

STEP 31

BD03B024

Remove the shaft seal from the brake housing.

Use acceptable lifting equipment and lift the brake housing from the wheel end shaft.

Remove the shaft seal from the brake housing.

STEP 33

STEP 31

STEP 33

BD00M267

BD00M266

If necessary drive both bearing outer rings out of the brake housing.

STEP 32

W270-2R037

Pull bearing inner from the output shaft.

BD00M266

If necessary drive both bearing outer rings out of the brake housing.

STEP 34

BD00M267

W270-2R037

Pull bearing inner from the output shaft.

STEP 34

BD00M269

If the wheel end pressure ring needs to be replaced, remove the pressure ring from the wheel end shaft.

6004-13

Assembly

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

STEP 35

6004-13

Assembly

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

STEP 35

SM121A

STEP 38

W270-2R007

Insert wheel bolt into the output shaft until contact.

STEP 36

BD00M273

STEP 36

BD00M273

Heat the bearing inner ring and install it onto the wheel end shaft.

STEP 39

BD00M271

Install a new pressure ring on the wheel end shaft.

STEP 37

STEP 37 BD03B026

BD03B026

Freeze the bearing outer ring. Press the bearing outer ring into the brake housing using 380001756.

STEP 40

Freeze the bearing outer ring. Press the bearing outer ring into the brake housing using 380001751.

W270-2R008

Press bearing sheet over the collar of the output shaft.

NOTE: The exact installation position of the bearing sheet will be obtained by using the specified pressure ring.

6004-14

STEP 41

STEP 42

STEP 41

STEP 42

BD03B024 BD03B027

Use a solution of 50% water and 50% mineral spirits to wet the outer diameter of the shaft seal. Using 380001574 install the shaft seal with the sealing lip showing to the oil chamber. See illustration below.

Use acceptable lifting equipment and install the brake housing over the wheel end shaft until contact. WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

BD03B024 BD03B027

SM121A

STEP 43

BS00M073

SHAFT SEAL 1. BRAKE HOUSING 2. SHAFT SEAL * GREASE FILLING

SHAFT SEAL BD00M277

Heat the bearing inner ring and install it into the brake housing until contact.

1. BRAKE HOUSING 2. SHAFT SEAL * GREASE FILLING

BD00M277

Heat the bearing inner ring and install it into the brake housing until contact.

6004-15

STEP 44

STEP 45

BD00M263

6004-15

STEP 44

BD00M279

BD00M263

BRAKE HOUSING GUIDE RING SUPPORT RING U-RING

Clean the groove of the brake housing with solvent. Install the guide ring into the groove and fix it with Loctite 415.

NOTE: Upon installation the guide ring must have contact on the whole circumference and the orifice must show upwards (12 o’clock).

STEP 46

BS00M072

5. U-RING 6. SUPPORT RING 7. WHEEL END SHAFT

Install the guide ring, support rings and U-rings in the grooves of the brake housing.

BD00M279

Clean the groove of the brake housing with solvent. Install the guide ring into the groove and fix it with Loctite 415.

BS00M072

1. 2. 3. 4.

STEP 45

1. 2. 3. 4. BD00M280

Apply oil on the sliding surface of the piston. Care fully insert the piston into the brake housing.

BRAKE HOUSING GUIDE RING SUPPORT RING U-RING

5. U-RING 6. SUPPORT RING 7. WHEEL END SHAFT

Install the guide ring, support rings and U-rings in the grooves of the brake housing.

BD00M280

Apply oil on the sliding surface of the piston. Care fully insert the piston into the brake housing.

6004-16

STEP 47

BD00M281

Insert the pins into the assembly fixture until contact.

STEP 48

STEP 48 BS00M074

1. PIN 2. GRIPPING RINGS 3. CUP SPRINGS

BS00M074

4. SUPPORT SHIM 5. RETAINING RING X. 10.5 MM +0.3 (0.41 IN +0.02)

1. PIN 2. GRIPPING RINGS 3. CUP SPRINGS

STEP 50

4. SUPPORT SHIM 5. RETAINING RING X. 10.5 MM +0.3 (0.41 IN +0.02)

STEP 50

BD00M282

1. GRIPPING RINGS

Press the gripping rings onto the pins until contact on the assembly fixture.

ATTENTION: Observe the installation position, install the gripping rings with the orifices offset by 180q to each other.

BD00M284

Insert the assembled pins into the support shim and install the snap ring.

STEP 49

BD00M284

Insert the assembled pins into the support shim and install the snap ring.

STEP 49 STEP 51

STEP 51

BD00M283

Install the cup springs onto the pins. See illustration below.

BD00M283 BD00M285

Insert the assembled support shim into the piston.

Install the cup springs onto the pins. See illustration below.

BD00M285

Insert the assembled support shim into the piston.

6004-17

STEP 52

STEP 54

6004-17

STEP 52

STEP 54

1 BD00M286

1 BD00M288

1. SPLINE

Install the circlip into the brake housing.

Drive the stop bolt into the planet carrier. Then coat the spline with anti-corrosive antiseize.

STEP 53

STEP 55

BD03B028

BD00M289

Insert the planet carrier into the spline of the wheel end shaft until contact.

STEP 56

BD03B034

1. BRAKE HOUSING 2. CIRCLIP 3. SLOTTED PIN

BD00M288

1. SPLINE

Install the circlip into the brake housing.

Drive the stop bolt into the planet carrier. Then coat the spline with anti-corrosive antiseize.

STEP 53

BD00M286

BD03B034

4. SUPPORT SHIM 5. PISTON X INSTALLATION DIMENSION 4.0 - 0.5 MM

1. BRAKE HOUSING 2. CIRCLIP 3. SLOTTED PIN

Drive slotted pins into the bores of the support shim to lock the circlip.

4. SUPPORT SHIM 5. PISTON X INSTALLATION DIMENSION 4.0 - 0.5 MM

Drive slotted pins into the bores of the support shim to lock the circlip. W270-2R009

W270-2R009

Mount outer and inner disks (lining disks with paper or sinter lining).

NOTE: Quantity and arrangement of the disks please take related spare parts list.

6004-18

Version with additional damping disks

STEP 59

STEP 57

STEP 59

STEP 57

BD03B016

Grease both O-rings.

STEP 60

W270-2R010

WARNING: When mounting damping disks (outer disks coated on one side, see arrows) pay attention to the position of the coated side (see sketch left).

SM121A

STEP 58

BD03B029

Insert O-ring into the recess of the brake housing.

BD03B030

Install two aligning dowels in the brake housing, install ring gear onto the brake housing.

NOTE: Make sure alignment is correct on ring gear.

BD03B029

Insert O-ring into the recess of the brake housing.

6004-19 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

SM121A

STEP 61

6004-19 WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

SM121A

STEP 63

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

SM121A

STEP 61

SM121A

STEP 63

BD00M292

BD00M294

BD00M292

BD00M294

Install the bearings with the big radius showing to the planet carrier (downwards).

Heat the bearing inner rings and install into the planet gears.

Install the bearings with the big radius showing to the planet carrier (downwards).

Heat the bearing inner rings and install into the planet gears.

STEP 62

STEP 64

STEP 62

STEP 64

BD00M293

Put the planet gears onto the bearing inner rings.

BD03B031

Install the snap rings on the planet gear shafts using 380001585 snap ring pliers.

BD00M293

Put the planet gears onto the bearing inner rings.

BD03B031

Install the snap rings on the planet gear shafts using 380001585 snap ring pliers.

6004-20

Adjust end play of sun gear shaft 0.5 to 2.0 mm (0.02 to 0.08 inch)

STEP 67

Adjust end play of sun gear shaft 0.5 to 2.0 mm (0.02 to 0.08 inch)

STEP 65

STEP 67

STEP 65

BD00M298

Insert the sun gear shaft onto the stub shaft until contact.

BD00M296

Determine dimension I, from the mounting face of the brake housing up to the face of the stop bolt. Dimension I e.g. . . . . . . . . . . . 67.90 mm (2.67 inch)

BD00M296

STEP 68

Determine dimension I, from the mounting face of the brake housing up to the face of the stop bolt. Dimension I e.g. . . . . . . . . . . . 67.90 mm (2.67 inch)

STEP 66

STEP 68

STEP 66

BD00M297

Insert the stub shaft into the spline of the axle bevel gear until contact.

BD00M299

Determine dimension II from the face of the sun gear shaft up to the mounting face of the axle casing. Dimension II e.g. . . . . . . . . . . . 63.00 mm (2.5 inch) Example:

Dimension I 67.90 mm (2.67 inch) Dimension II 63.00 mm (2.5 inch) Difference 4.90 mm (0.17 inch) Required end play e.g. 1.10 mm (0.04 inch) Difference = shim e.g. s 3.80 mm (0.13 inch)

BD00M297

Insert the stub shaft into the spline of the axle bevel gear until contact.

Dimension I 67.90 mm (2.67 inch) Dimension II 63.00 mm (2.5 inch) Difference 4.90 mm (0.17 inch) Required end play e.g. 1.10 mm (0.04 inch) Difference = shim e.g. s 3.80 mm (0.13 inch)

6004-21

STEP 69

STEP 72

BD00M245

Insert the sun gear shaft into the planet carrier.

6004-21

STEP 69

BD00M300

Install the washers and bolts by hand. Tightening torque . . . . . . . 390 Nm (288 pound-feet)

STEP 70

STEP 72

BD00M245

Insert the sun gear shaft into the planet carrier.

BD00M300

Install the washers and bolts by hand. Tightening torque . . . . . . . 390 Nm (288 pound-feet)

STEP 70 STEP 73

STEP 73

BD00M244

Install the determined shim(s), e.g. S. = 3.80 mm (0.14 inch) into the sun gear shaft with grease.

STEP 71

BD00M244 BD03B033

Install the locknut by hand and tighten it using 380001571 locknut socket and 380001576 support bracket. Tighten torque . 1500+200 Nm (1106 +147 pound-feet)

Install the determined shim(s), e.g. S. = 3.80 mm (0.14 inch) into the sun gear shaft with grease.

STEP 71

STEP 74

BD03B033

Install the locknut by hand and tighten it using 380001571 locknut socket and 380001576 support bracket. Tighten torque . 1500+200 Nm (1106 +147 pound-feet)

STEP 74

BD03B032

Install O-ring and hold into place with grease, install output housing onto axle.

Install O-ring and hold into place with grease, install output housing onto axle. BD00M302

Secure the locknut with the slotted pin.

BD00M302

Secure the locknut with the slotted pin.

6004-22

STEP 75

STEP 76

STEP 75

1 BD00M303

1. O-RING

Install an O-ring on the cover.

STEP 76

BD00M304

Insert the cover into the wheel end.

BD00M303

1. O-RING

Install an O-ring on the cover.

BD00M304

Insert the cover into the wheel end.

6004-23

LEAKAGE TEST OF THE BRAKE HYDRAULICS

1. Open the bleeder.

2. Slowly actuate the HP-pump until oil flows out of the bleeder.

3. Close the bleeder egein.

4. Slowly pressurize the HP-pump with > 10 bar and hold the pressure for some seconds.

NOTE: The brake piston extends and the cylinder chamber fills up with oil. The air accumulates in the upper section of the cylinder chamber. 5. Loosen the shut-off valve on the HP-pump.

NOTE: The reversing piston presses the air from the upper section of the cylinder into the brake line.

6. Open the bleeder again.

7. Slowly actuate the HP-pump until oil flows out of the bleeder.

ATTENTION: Repeat procedure Item 3 - 7- until -at Item 7- from the beginning of the actuation no more air exist from bleeder.

NOTE: Then pressurize the brake temporarily (5x) with p = 100 bar max.

High Pressure Test

High Pressure Test Low Pressure Test

STEP 77

Low Pressure Test

STEP 77

Reduce test pressure to p = 5 bar (72.5 psi) and close the shutoff valve again.

During a 5 minute testing time a pressure drop is not allowed.

BD00M305

Increase test pressure up to p =100 bar (1450 psi) maximum and close connection to HD pump by means of shutoff valve. During a 5 minute testing time, a pressure drop of maximum 2 bar (29 psi) is allowed.

ATTENTION: If the maximum pressure of 100 bar (1450 psi) is exceeded, there will be an excessive piston adjustment and a repeated disassembly of the brake or the adjusting is required to reset the gripping rings to the adjusting dimension.

6004-24

DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES STEP 1

DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES

STEP 3

BD00M235

Fasten the axle on a stand.

STEP 1

BD00M241

Use acceptable lifting equipment to hold the wheel end in place. Loosen and remove the bolts.

STEP 2

STEP 3

BD00M235

Fasten the axle on a stand.

BD00M241

Use acceptable lifting equipment to hold the wheel end in place. Loosen and remove the bolts.

STEP 2 STEP 4

BD00M236

STEP 4

BD03B032

BD00M236

BD03B032

Separate the wheel end from the axle housing. Remove O-ring.

STEP 5

BD00M237

Loosen the screw plugs and drain the oil from the axle casing.

Loosen the screw plugs and drain the oil from the axle casing. BD00M243

BD00M243

Pull the stub shaft out of the sun gear shaft. Repeat steps 3 through 5 for the other wheel end.

NOTE: Pay attention to the released shim(s).

6004-25

STEP 6

STEP 9

BD00M395

6004-25

STEP 6

BD00M398

STEP 9

BD00M395

BD00M398

Remove the bolts from the differential carrier.

Drive out the slotted pins from the differential carrier.

Remove the bolts from the differential carrier.

Drive out the slotted pins from the differential carrier.

NOTE: Mark the location of the differential carrier to the axle casing.

STEP 10

NOTE: Mark the location of the differential carrier to the axle casing.

STEP 10

STEP 7

BD03B035

Use suitable lifting equipment and lift the differential carrier out of the axle casing.

BD01F072

Loosen and remove both adjusting nuts using 380001565 wrench.

BD03B035

Use suitable lifting equipment and lift the differential carrier out of the axle casing.

STEP 11

STEP 8

STEP 11

STEP 8

BD00M400

Heat the axle drive housing with a hot air gun. BD03B036

Fasten the differential carrier on 380001580 engine stand using 380001562 mounting bracket.

NOTE: Bolts are installed with Loctite.

Heat the axle drive housing with a hot air gun. BD03B036

Fasten the differential carrier on 380001580 engine stand using 380001562 mounting bracket.

NOTE: Bolts are installed with Loctite.

6004-26

STEP 12

STEP 13

BD00M401

Loosen the bolts and take off both bearing brackets. NOTE: Make an alignment mark between the bearing bracket and the housing.

STEP 12

BD00M402

Remove both bearing outer rings from the differential carrier.

STEP 14

ATTENTION: Loosen the bolts by hand only.

STEP 13

BD00M401

Loosen the bolts and take off both bearing brackets. NOTE: Make an alignment mark between the bearing bracket and the housing.

BD00M402

Remove both bearing outer rings from the differential carrier.

STEP 14

ATTENTION: Loosen the bolts by hand only.

BD00M403

Use acceptable lifting equipment and lift the differential out of the differential carrier.

6004-27

DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL STEP 15

DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 18

W270-2R013

W270-2R011

Pull bearing iner ring from the differential housing.

STEP 16

STEP 15

Loosen cap screws and remove released housing cover.

W270-2R013

W270-2R011

Pull bearing iner ring from the differential housing.

STEP 16

STEP 19

W270-2R012

Loosen cap screws and remove released housing cover.

STEP 19

W270-2R012

Pull bearing inner ring from the housing cover.

BD00M407

Remove all the single parts from the differential housing.

STEP 17

STEP 18

Pull bearing inner ring from the housing cover.

BD00M407

Remove all the single parts from the differential housing.

STEP 17

STEP 20

BD00M406

Place the differential in a press to prevent it from turning. Remove the bolts and the released housing cover.

BD00M408

Press off the ring gear from the differential housing.

BD00M408

Press off the ring gear from the differential housing.

6004-28

DISASSEMBLY OF DRIVE PINION STEP 21

DISASSEMBLY OF DRIVE PINION

STEP 24

BD00M409

Heat the pinion shaft locknut with a hot air gun. NOTE: Locknut is held with Loctite Type No. 262.

STEP 21

STEP 24

BD00M412

Remove the shaft seal from the differential carrier.

BD00M409

Heat the pinion shaft locknut with a hot air gun. NOTE: Locknut is held with Loctite Type No. 262.

STEP 25

STEP 22

BD00M412

Remove the shaft seal from the differential carrier.

STEP 25

STEP 22

W270-2R014

Loosen slotted nut and remove the washer behind it.

STEP 23

W270-2R015

Press drive pinion out of the axle drive housing by means of two-armed puller (S) and remove the released bearing inner ring.

W270-2R014

Loosen slotted nut and remove the washer behind it.

STEP 23

STEP 26

BD00M411

Pull the input yoke from the drive pinion shaft.

STEP 26

BD00M411 W270-2R016

Take off spacer ring and pull bearing inner ring from the drive pinion.

Pull the input yoke from the drive pinion shaft.

W270-2R016

Take off spacer ring and pull bearing inner ring from the drive pinion.

6004-29

STEP 27

STEP 30

BD00M414

If necessary drive out both bearing outer rings from the differential carrier.

6004-29

STEP 27

W270-2R019

Loosen pipe union.

STEP 30

BD00M414

If necessary drive out both bearing outer rings from the differential carrier.

STEP 31

Loosen pipe union.

STEP 31

STEP 28

W270-2R020 W270-2R017

Loosen both pipe unions (also see arrow).

STEP 29

Loosen hexagon screw and remove released cooling pipe from the axle casing.

W270-2R020 W270-2R017

Loosen both pipe unions (also see arrow).

STEP 29

W270-2R018

Loosen hexagon srew.

W270-2R019

W270-2R018

Loosen hexagon srew.

Loosen hexagon screw and remove released cooling pipe from the axle casing.

6004-30

STEP 32

STEP 35

STEP 32

STEP 35

BD00M334

BD00M337

BD00M334

BD00M337

Remove the screw plug with the vent valve from the axle casing.

Disconnect the pipe union and remove the released brake tube from the axle casing.

Remove the screw plug with the vent valve from the axle casing.

Disconnect the pipe union and remove the released brake tube from the axle casing.

STEP 33

STEP 36

STEP 33

STEP 36

BD00M335

Loosen and remove the hexagon screw from the axle.

BD00M338

Remove the vent valve from the connection part.

BD00M335

Loosen and remove the hexagon screw from the axle.

STEP 37

BD00M338

Remove the vent valve from the connection part.

STEP 37

STEP 34

BD00M339 BD00M336

Loosen and remove the union screw from the axle.

Loosen the connection part and remove it from the axle. Repeat steps 33 to 37 for the other wheel end.

BD00M339 BD00M336

Loosen and remove the union screw from the axle.

Loosen the connection part and remove it from the axle. Repeat steps 33 to 37 for the other wheel end.

6004-31

ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER STEP 38

ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER

STEP 41

STEP 38

STEP 41

2 3

4 1

BD00M340

1. VENT VALVE

2. CONNECTION 3. O-RING 4. RECTANGULAR PART RING

BD00M343

1. O-RING

Install an O-ring into the groove of the brake tube.

Assemble the part as shown in the photo above.

BD00M340

1. VENT VALVE

2. CONNECTION 3. O-RING 4. RECTANGULAR PART RING

BD00M343

1. O-RING

Install an O-ring into the groove of the brake tube.

Assemble the part as shown in the photo above.

STEP 42

STEP 39

2 1

BD00M344 BD00M341

Install the connection part on the axle casing. Tightening torque . . . . . . . . 130 Nm (96 pound feet)

STEP 40

1. BRAKE TUBE 2. UNION SCREW

Insert the brake tube into the axle casing, assembling the connection part through the union screw.

BD00M344 BD00M341

Install the connection part on the axle casing. Tightening torque . . . . . . . . 130 Nm (96 pound feet)

STEP 40

BD00M342

Install the union screw with a new O-ring on the axle. Tightening torque . . . . . . 150 Nm (110 pound-feet)

1. BRAKE TUBE 2. UNION SCREW

Insert the brake tube into the axle casing, assembling the connection part through the union screw.

6004-32

STEP 43

STEP 46

STEP 43

STEP 46

BD00M345

W270-2R021

BD00M345

W270-2R021

Fasten the brake tube with the hexagon nut and union nut. Tightening torque . . . . . . . . 100 Nm (73 pound-feet)

Install connection socket. Tightening torque . . . . . . . . . 80 Nm (59 pound-feet)

Fasten the brake tube with the hexagon nut and union nut. Tightening torque . . . . . . . . 100 Nm (73 pound-feet)

Install connection socket. Tightening torque . . . . . . . . . 80 Nm (59 pound-feet)

STEP 47

STEP 44

W270-2R022

Tightening torque . . . . . . . . . 80 Nm (60 pound-feet)

Place cooling pipe into the axle casing and preliminarily fasten union or union hut by hand.

Tightening torque . . . . . . . . . 80 Nm (60 pound-feet)

Place cooling pipe into the axle casing and preliminarily fasten union or union hut by hand.

NOTE: Repeat steps 38 to 44 for the other wheel end.

STEP 48

NOTE: Repeat steps 38 to 44 for the other wheel end.

STEP 48

BD00M346

STEP 45

BD00M346

STEP 45

MD00M348

Install the screw plug on the axle casing. Tightening torque . . . . . . . . 100 Nm (73 pound-feet)

W270-2R023

Place connection tube into the axle casing and preliminary fasten it by hand.

MD00M348

Install the screw plug on the axle casing. Tightening torque . . . . . . . . 100 Nm (73 pound-feet)

6004-33

STEP 49

STEP 52

W270-2R024

Fasten collection tube by means of hexagon screw and washer. Tightening torque (M8/8.8) . 23 Nm (17 pound-feet)

STEP 50

6004-33

STEP 49

W270-2R027

Install vent valve.

STEP 52

W270-2R024

Fasten collection tube by means of hexagon screw and washer. Tightening torque (M8/8.8) . 23 Nm (17 pound-feet)

STEP 50

W270-2R025

Fasten cooling pipes by means of hexagon screw and washer. Tightening torque (M8/8.8) . 23 Nm (17 pound-feet)

STEP 51

W270-2R026

Finally fasten all unions of the cooling pipes. Tightening torque . . . . . . . . 80 Nm (59 pound-feet)

W270-2R027

Install vent valve.

6004-34

ASSEMBLY OF DIFFERENTIAL CARRIER NOTE: If the ring gear or drive pinion are damaged, both parts have to be replaced together. For new installation of a complete bevel gear set pay attention to the same pair number of drive pinion and ring gear.

Example A: Dimension A (= Measuring pin + stop washer Dimension B

Determine Shim Thickness for a Perfect Tooth Contact Pattern NOTE: Make the following measuring steps at maximum accuracy. In exact measurements result in a faulty tooth contact pattern and require a repeated disassembly and assembly of the drive pinion as well as of the differential.

ASSEMBLY OF DIFFERENTIAL CARRIER

Dimension C Results in Dimension X

225.00 mm (8.858 inch) 5.60 mm (0.220 inch) mm (0.590 inch) 245.60 mm (9.669 inch)

STEP 54

STEP 53

NOTE: If the ring gear or drive pinion are damaged, both parts have to be replaced together. For new installation of a complete bevel gear set pay attention to the same pair number of drive pinion and ring gear.

Example A: Dimension A (= Measuring pin + stop washer Dimension B

Dimension C Results in Dimension X

225.00 mm (8.858 inch) 5.60 mm (0.220 inch) mm (0.590 inch) 245.60 mm (9.669 inch)

STEP 54

STEP 53

BD00M350

Determine Dimension I (bearing width). Dimension I e.g. . . . . . . . . . . 42.65 mm (1.680 inch)

1 a

BD00M350

Determine Dimension I (bearing width). Dimension I e.g. . . . . . . . . . . 42.65 mm (1.680 inch)

W270-2R028

Install adapter pieces (1) and preliminary fasten the bearing bracket by means of hexagon screws.

Then install stop washer (4) and measuring pin (3) and assemble measuring shaft (2) (see sketch).

Determine the gap between the measuring shaft and the measuring pin with a feeler gauge. Dim. B e.g. . . . . . . . . . . . . . . . 5.60 mm (0.220 inch)

6004-35

STEP 55

STEP 57

6004-35

STEP 55

BD00M351

1. 202.0 +0.05

Read Dimension II (dimension for pinion). Dimension II e.g. . . . . . . . . . . 202.05 mm (7.95 inch) Example B: Dimension I Dimension II Results in Dimension Y

W270-2R030

Undercool bearing outer ring and insert it into the bearing bore until contact.

STEP 58

42.65 mm ------(1.680 inch) + 202.05 mm (7.95 inch) s 244.70 mm -----(9.63 inch)

BD00M351

1. 202.0 +0.05

Read Dimension II (dimension for pinion). Dimension II e.g. . . . . . . . . . . 202.05 mm (7.95 inch) Example B: Dimension I Dimension II Results in Dimension Y

Example C: Dimension X Dimension Y Difference = Shim e.g.

STEP 57

W270-2R030

Undercool bearing outer ring and insert it into the bearing bore until contact.

STEP 58

42.65 mm ------(1.680 inch) + 202.05 mm (7.95 inch) s 244.70 mm -----(9.63 inch)

Example C: 245.60 mm (9.670 inch) - 244.70 mm (9.63 inch) s 0.90 mm (0.04)

Dimension X Dimension Y Difference = Shim e.g. W270-2R031

Install the Drive Pinion

Undercool bearing outer ring on the input flange side and insert it until contact.

STEP 56

245.60 mm (9.670 inch) - 244.70 mm (9.63 inch) s 0.90 mm (0.04) W270-2R031

Install the Drive Pinion

Undercool bearing outer ring on the input flange side and insert it until contact.

STEP 56

STEP 59

BD00M352

Place the determined shim e.g. S. =0.90 mm (0.04 inch) into the bearing bore in the differential carrier.

BD01F065

Press the bearing inner ring on the drive pinion shaft using 380001552 and 380001542 step plate.

BD01F065

Press the bearing inner ring on the drive pinion shaft using 380001552 and 380001542 step plate.

6004-36

Adjust Rolling Moment of Drive Pinion Bearing

STEP 62

STEP 60

STEP 62

STEP 60

W270-2R032

Press dust protection on the input flange until contact.

BD00M356

STEP 63

Install the spacer ring on the pinion shaft.

STEP 63

Install the spacer ring on the pinion shaft.

NOTE: As per experience the required rolling movement is obtained by use of the spacer ring [e.g. s=8.10 mm (0.31 inch)] available at disassembly. However, a later checking of the rolling movement must be done.

WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts.

SM121A

STEP 61

STEP 61 BD00M359

BD00M359

Install the input yoke on the pinion shaft.

STEP 64

BD00M357

Insert the assembled drive pinion into the differential carrier and install the heated bearing inner ring.

BD00M360

Install the washer on the pinion shaft.

BD00M360

Install the washer on the pinion shaft.

6004-37

STEP 65

STEP 68

6004-37

STEP 65

STEP 68

W270-2R033

W270-2R034

W270-2R033

W270-2R034

Unscrew slotted nut by hand and tighten it. Tightening torque . . . . . 1200 Nm (885 pound-feet)

Install shaft seal with the sealing lip showing to the oil chamber (downwards).

Unscrew slotted nut by hand and tighten it. Tightening torque . . . . . 1200 Nm (885 pound-feet)

Install shaft seal with the sealing lip showing to the oil chamber (downwards).

NOTE: When tightening rotate the drive pinion in both directions several times.

ATTENTION: Just before the installation wet the outer diameter of the shaft seal with a solution of 50% water and 50% mineral spirits. Fill the space between the sealing and dust lip with grease.

NOTE: When tightening rotate the drive pinion in both directions several times.

ATTENTION: Just before the installation wet the outer diameter of the shaft seal with a solution of 50% water and 50% mineral spirits. Fill the space between the sealing and dust lip with grease.

STEP 66

STEP 69

BD00M362

Check rolling movement. Rolling movement should be 3.5 to 4.5 Nm (2.58 to 3.31 pound-feet).

NOTE: For new bearings it should be tried to achieve the maximum value of the rolling movement. ATTENTION: If the required rolling movement is not obtained, correct it with an adequate spacer ring, according to the following indications: Rolling movement too low - install a thinner spacer ring. Rolling movement too high - install a thicker spacer ring.

W270-2R035

Assemble input flange and finally fasten it by means of washer and slotted nut. Tighten torque . . . . . . . . 1200 Nm (885 pound-feet) ATTENTION: Apply Loctite, Type No. 262, onto the thread of the locknut.

STEP 67

Then loosen the slotted nut again and pull input flange from the drive pinion.

W270-2R035

6004-38

ASSEMBLY OF LIMITED SLIP DIFFERENTIAL STEP 70

ASSEMBLY OF LIMITED SLIP DIFFERENTIAL

STEP 73

STEP 70

STEP 73

BD00M427

BD00M430

BD00M427

BD00M430

Place both thrust washers into the differential housing.

Insert the axle bevel gear and slide the splined shaft into the clutch discs.

Place both thrust washers into the differential housing.

Insert the axle bevel gear and slide the splined shaft into the clutch discs.

STEP 71

STEP 74

STEP 71

STEP 74

BD00M428

BD00M431

BD00M428

BD00M431

Starting with an outer clutch disc install alternately the outer and inner clutch discs.

Assemble the differential spider and insert it into the differential housing.

Starting with an outer clutch disc install alternately the outer and inner clutch discs.

Assemble the differential spider and insert it into the differential housing.

ATTENTION: Thickness of the disc pack must be identical on both sides.

STEP 75

ATTENTION: Thickness of the disc pack must be identical on both sides.

STEP 75

STEP 72

BD00M432

Insert the second axle bevel gear. BD00M429

Insert the pressure ring into the differential housing.

Insert the second axle bevel gear. BD00M429

Insert the pressure ring into the differential housing.

6004-39

Determine the Disc Clearance

STEP 76

6004-39

Determine the Disc Clearance

STEP 76

STEP 78

BD00M433

Insert the second pressure ring into the differential housing.

BD00M435

Determine dimension I, from the mounting face of the differential housing to the plane face of the outer clutch disc. Dimension I e.g. . . . . . . . . . . 49.30 mm (1.94 inch)

STEP 77

Insert the second pressure ring into the differential housing.

Determine dimension I, from the mounting face of the differential housing to the plane face of the outer clutch disc. Dimension I e.g. . . . . . . . . . . 49.30 mm (1.94 inch)

STEP 77

STEP 79

BD00M434

Starting with an inner clutch disc install alternately the inner and outer clutch disc.

ATTENTION: The thickness of the clutch disc pack must be identical on both sides.

BD00M436

Determine dimension II, from the contact surface of the outer clutch disc to the mounting face of the housing cover. Dimension II e.g. . . . . . . . . . . 48.95 mm (1.92 inch) Dimension I Dimension II Difference = Disc clearance

BD00M435

49.30 mm -------(1.94 inch) + 48.95 mm -------(1.92 inch) 0.35 mm ------(0.01 inch)

NOTE: If the required disc clearance is not obtained, correct it with the adequate outer clutch discs [s=2.7, s=2.9, s=3.0, s=3.1 or s=3.3 mm (0.106, 0.114, 0.118, 0.122, 0.129 inch)], taking care that the difference in thickness between the left and the right disc pack must only be 0.1 mm (0.004 inch) at a maximum.

ATTENTION: The thickness of the clutch disc pack must be identical on both sides.

BD00M436

49.30 mm -------(1.94 inch) + 48.95 mm -------(1.92 inch) 0.35 mm ------(0.01 inch)

6004-40

STEP 80

STEP 83

STEP 80

STEP 83

BD00M437

BD00M440

BD00M437

BD00M440

Fix the thrust washer with grease into the recess of the differential housing cover.

Press both bearing inner rings onto the differential housing.

Fix the thrust washer with grease into the recess of the differential housing cover.

Press both bearing inner rings onto the differential housing.

STEP 81

STEP 84

STEP 81

STEP 84

BD00M438

BD00M441

BD00M438

BD00M441

Put the housing cover in place on the differential housing. Heat the ring gear and install onto the differential housing.

Use acceptable lifting equipment and insert the differential into the differential carrier.

Put the housing cover in place on the differential housing. Heat the ring gear and install onto the differential housing.

Use acceptable lifting equipment and insert the differential into the differential carrier.

STEP 85

STEP 82

BD00M442 BD00M439

Put the differential in a press to prevent it from turning and install the bolts on the ring gear. Tightening torque . . . . . . . 390 Nm (287 pound-feet) ATTENTION: Use new locking bolts.

Place the bearing outer ring into the differential carrier.

BD00M442 BD00M439

Put the differential in a press to prevent it from turning and install the bolts on the ring gear. Tightening torque . . . . . . . 390 Nm (287 pound-feet) ATTENTION: Use new locking bolts.

Place the bearing outer ring into the differential carrier.

6004-41

STEP 86

STEP 89

6004-41

STEP 86

STEP 89

BC00M443

BD00M446

BC00M443

BD00M446

Install the adjusting nut by hand on the differential carrier.

Install both bearing brackets and install the bolts and washers. Tighten torque . . . . . . . . . 390 Nm (287 pound-feet)

Install the adjusting nut by hand on the differential carrier.

Install both bearing brackets and install the bolts and washers. Tighten torque . . . . . . . . . 390 Nm (287 pound-feet)

STEP 87

ATTENTION: Apply Loctite Type No. 262 onto threads of the bolts.

STEP 87

Adjust Backlash and Bearing Preload

STEP 90

BD00M444

Install the ring gear sided bearing outer ring.

STEP 88

BD00M445

Install the adjusting nut by hand on the differential carrier.

ATTENTION: Apply Loctite Type No. 262 onto threads of the bolts.

BD00M447

Place a dial indicator right-angled at the outer diameter of the tooth flank (ring gear).

Adjust the pinion to ring gear backlash to the low side of specifications (see value etched on the outer diameter of the ring gear) by alternately turning each of the adjusting nuts to move the ring gear closer to or further away from the pinion. Backlash is checked using a dial indicator against a tooth on the ring gear.

NOTE: Rotate the differential several times and recheck the backlash.

BD00M445

Install the adjusting nut by hand on the differential carrier.

NOTE: Rotate the differential several times and recheck the backlash.

6004-42

STEP 91

W270-2R036

Determine bracket width and correct it on both adjusting nuts, if required. Bracket width . . . . . . . 448-0.05 mm (17.6-0.002 inch)

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6005

Section 6005

6005

Section 6005

6005-2

TABLE OF CONTENTS SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER O REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING YOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 5 5 5 7 7 7 9 9 9 9 9 9 9 9 9

SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER O REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING YOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 5 5 7 7 7 9 9 9 9 9 9 9 9 9

6005-3

SPECIAL TORQUES

Center, Rear and Front Drive Shaft Bolts............................................................95 to 108 Nm (70 to 80 pound feet)

Carrier Bearing Bolts .....................................................................................149 to 163 Nm (110 to 120 pound feet)

Lock Nut for Yoke on Front Drive Shaft.........................................................339 to 375 Nm (250 to 275 pound feet)

6005-4

8 9

3 4

5 6 8

11 12 13 14 5

5 18

17 W270-2R002

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

6 8

11 12 13 14

FRONT DRIVESHAFT REAR DRIVESHAFT CENTER DRIVESHAFT ELBOW BOLT BOLT FRONT AXLE WASHER NUT NUT

11. 12. 13. 14. 15. 16. 17. 18. 19.

WASHER CLAMP WASHER NUT HOSE BRACKET REAR AXLE FRONT CHASSIS TRANSMISSION

W270-2R002

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

FRONT DRIVESHAFT REAR DRIVESHAFT CENTER DRIVESHAFT ELBOW BOLT BOLT FRONT AXLE WASHER NUT NUT

11. 12. 13. 14. 15. 16. 17. 18. 19.

WASHER CLAMP WASHER NUT HOSE BRACKET REAR AXLE FRONT CHASSIS TRANSMISSION

6005-5

FRONT DRIVE SHAFT Removal 1. Remove the cap screws that fasten the center drive shaft to the yoke (4) at the rear of the front drive shaft. Use a prybar to disengage the universal joint from the yoke (4) and move the center drive shaft out of the way. 2. Loosen the lock nut (8) and set screw (9) in the center bearing (13) of the housing (12). 3. Remove the self-locking nut (11) and flat washer (10) that fasten the yoke (4) to the rear of the front drive shaft (1). 4. Make an alignment mark on the yoke (4) and the end of the front drive shaft (1) to make sure that the yoke is installed correctly. 5. Use an acceptable puller and remove the yoke (4) from the end of the front drive shaft (1). 6. Remove paint or rust from the rear of the front drive shaft (1) and apply WD40 or similar oil to loosen any rust between the inner race and the front drive shaft (1). 7. Remove the cap screws (2) that fasten the universal joint (3) to the front drive shaft (1). 8. Use a prybar to disengage the front drive shaft (1) from the universal joint (3) and remove the front drive shaft (1). If necessary, use a brass hammer to drive the front drive shaft (1) out of the center bearing.

Installation 1. Apply antiseize compound to the bearing area of the front drive shaft (1), refer to Figure 1. 2. Put the front drive shaft (1) into position on the machine. 3. Fasten the front drive shaft (1) to the universal joint (3) with cap screws (2). Tighten the cap screws (2) to 95 to 108 Nm (70 to 80 pound-feet). 4. Apply antiseize compound to the splines on the front drive shaft (1). 5. Install the yoke (4) so that the alignment marks are aligned. If a new front drive shaft has been installed, make sure this yoke is parallel with yoke at the other end of the front drive shaft. 6. Install the self-locking nut (11) and flat washer (10) that fasten the yoke to the front drive shaft. Tighten the self-locking nut to 339 to 373 Nm (250 to 275 pound-feet). 7. Align the set screw (9) with the slot in the front drive shaft (1). 8. Tighten the set screw (9) until it bottoms out in the slot, loosen the set screw (9) one full turn. 9. Hold the set screw (9) so it will not turn, tighten the lock nut (8). 10. Engage the universal joint of the center drive shaft with the yoke (4). 11. Install the cap screws that fasten the center drive shaft to the yoke (4). Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet).

6005-6

6 12

16 10

15 16

15 8

11 17

8 B910790J

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

FRONT DRIVE SHAFT CAP SCREW UNIVERSAL JOINT YOKE BOLT LOCK WASHER

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

NUT LOCK NUT SET SCREW WASHER SELF-LOCKING NUT HOUSING

13. 14. 15. 16. 17.

CENTER BEARING NIPPLE ELBOW HOSE CLAMP

B910790J

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

FRONT DRIVE SHAFT CAP SCREW UNIVERSAL JOINT YOKE BOLT LOCK WASHER

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

NUT LOCK NUT SET SCREW WASHER SELF-LOCKING NUT HOUSING

13. 14. 15. 16. 17.

CENTER BEARING NIPPLE ELBOW HOSE CLAMP

6005-7

CENTER BEARING Removal 1. Remove the hardware (10 and 11) that holds the clamp (17) for the lubrication hose (16). 2. Remove the lock nut (8) from the end of the lubrication hose (16). 3. Remove the lubrication hose (16). 4. Remove the cap screws that fastens the center drive shaft to the yoke (4) at the rear of the front drive shaft (1). Use a prybar to disengage the universal joint from the yoke. Move the center drive shaft out of the way. 5. Loosen the lock nut (8) and set screw (9) in the center bearing (13). 6. Remove the self-locking nut (11) and flat washer (10) that fasten the yoke (4) to the rear of the front drive shaft (1). 7. Make an alignment mark on the yoke (4) and the end of the front drive shaft (1) to make sure that the yoke (4) is installed correctly. 8. Use an acceptable puller and remove the yoke (4) from the end of the front drive shaft (1). 9. Remove paint or rust from the rear of the front drive shaft (1) and apply WD40 or similar oil to loosen any rust between the inner race and the front drive shaft. 10. Remove the nuts (7), lock washers (6), and bolts (5) that hold the housing (12). 11. Install two longer bolts, approximately 3 inches (75 mm) to hold the housing (12) during removal. Use an acceptable puller to remove the housing (12).

Installation NOTE: The center bearing (13) and housing (12) are not serviced separately. If the center bearing (13) is worn or damaged or if the housing (12) has cracks, a new housing (12) and center bearing (13) must be used. 1. Apply antiseize compound to the bearing area of the front drive shaft (1). 2. Install the housing (12) so that the lubrication fitting is to the right. 3. Install the bolts (5), lock washers (6), and nuts (7) that hold the housing (12). Tighten the nuts (7) to 149 to 163 Nm (110 to 120 pound-feet). 4. Apply antiseize compound to the splines on the front drive shaft (1). 5. Install the yoke (4) so that the alignment marks are aligned. If a new front drive shaft (1) has been installed, make sure this yoke (4) is parallel with the yoke (4) at the other end of the front drive shaft (1). 6. Install the self-locking nut (11) and flat washer (10) that fasten the yoke (4) to the front drive shaft (1). Tighten the self-locking nut (11) to 339 to 373 Nm (250 to 275 pound-feet). 7. Align the set screw (9) with the slot in the front drive shaft (1). 8. Tighten the set screw (9) until it bottoms out in the slot, loosen the set screw (9) one full turn. 9. Hold the set screw (9) so it will not turn, tighten the lock nut (8). 10. Engage the universal joint at the front of the center drive shaft with the yoke (4).

11. Install the cap screws that fasten the center drive shaft to the yoke (4). Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet).

12. Install the 45 degree elbow (15) and the nipple (14) in the housing (12).

13. Install the lubrication hose (16).

14. Install the lock nut (8) to end of the lubrication hose (16).

15. Install the hardware (10 and 11) that holds the clamp (17) for the lubrication hose (16).

16. Lubricate the center bearing (13).

6005-8

6 12

16 10

15 16

15 8

11 17

8 B910790J

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

FRONT DRIVE SHAFT CAP SCREW UNIVERSAL JOINT YOKE BOLT LOCK WASHER

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

NUT LOCK NUT SET SCREW WASHER SELF-LOCKING NUT HOUSING

13. 14. 15. 16. 17.

CENTER BEARING NIPPLE ELBOW HOSE CLAMP

B910790J

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

FRONT DRIVE SHAFT CAP SCREW UNIVERSAL JOINT YOKE BOLT LOCK WASHER

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

NUT LOCK NUT SET SCREW WASHER SELF-LOCKING NUT HOUSING

13. 14. 15. 16. 17.

CENTER BEARING NIPPLE ELBOW HOSE CLAMP

6005-9

CENTER OR REAR DRIVE SHAFT Installation

Removal

CENTER OR REAR DRIVE SHAFT Installation

Removal

1. Remove the cap screws (2) that hold both universal joints (3).

1. Lubricate the center or the rear drive shaft (1 or 8) with the grease.

1. Remove the cap screws (2) that hold both universal joints (3).

1. Lubricate the center or the rear drive shaft (1 or 8) with the grease.

2. Use a prybar to disengage the rear universal joint (3) from the yoke (4).

2. Engage the front universal joint (3) with the yoke (4) and install the cap screws (2). Tighten the cap screws (2) to 95 to 108 Nm (70 to 80 pound-feet).

2. Use a prybar to disengage the rear universal joint (3) from the yoke (4).

2. Engage the front universal joint (3) with the yoke (4) and install the cap screws (2). Tighten the cap screws (2) to 95 to 108 Nm (70 to 80 pound-feet).

3. Hold the drive shaft (1 or 8) and disengage the front universal joint (3) from the yoke (4) and remove the drive shaft.

3. Engage the rear universal joint (3) with the yoke (4) and install the cap screws (2). Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet).

3. Hold the drive shaft (1 or 8) and disengage the front universal joint (3) from the yoke (4) and remove the drive shaft.

SLIDING YOKE Installation

Removal 1. Make an alignment mark on the sliding yoke (5) and the drive shaft (1 or 8) so that the parts are assembled correctly. 2. Remove the retainer (7) from the sliding yoke (5). 3. Remove the sliding yoke (5). 4. Clean the parts in cleaning solvent. Inspect the splines for damage and wear.

1. Install the retainer (7) on the drive shaft (1 or 8). 2. Install the sliding yoke (5) so that the alignment marks are aligned. If a new part is being installed, the yokes must be parallel. 3. Turn the retainer (7) onto the sliding yoke (5) and tighten the retainer (7). 4. Lubricate the sliding yoke.

SLIDING YOKE

1. Remove the cap screws (2) that fasten the universal joint (3) to the drive shaft (1 or 8) or the yoke (4). 2. Remove the universal joint (3).

Installation NOTE: The bearing race and journal that make up the universal joint are not serviced separately. If the bearing race or the journal is worn or damaged, a new universal joint (3) must be used.

Installation

UNIVERSAL JOINT Removal

3. Engage the rear universal joint (3) with the yoke (4) and install the cap screws (2). Tighten the cap screws to 95 to 108 Nm (70 to 80 pound-feet).

UNIVERSAL JOINT Removal 1. Remove the cap screws (2) that fasten the universal joint (3) to the drive shaft (1 or 8) or the yoke (4). 2. Remove the universal joint (3).

1. Clean the slots in the yoke (4) or the drive shaft (1 or 8). Clean the tabs on the universal joint (3).

2. Install the universal joint (3) and install the cap screws (2). Tighten the cap screws (2) to 95 to 108 Nm (70 to 80 pound-feet).

3. Lubricat the universal joints.

6005-10

5 2

3 2

4 6

8 2

5 4

3 B910791J

1. CENTER DRIVE SHAFT 2. CAP SCREW

3. UNIVERSAL JOINT 4. YOKE

5. SLIDING YOKE 6. GREASE FITTING

7. RETAINER 8. REAR DRIVE SHAFT

B910791J

1. CENTER DRIVE SHAFT 2. CAP SCREW

3. UNIVERSAL JOINT 4. YOKE

5. SLIDING YOKE 6. GREASE FITTING

7. RETAINER 8. REAR DRIVE SHAFT

WHEELS AND TIRES

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6006

Section 6006

6006

Section 6006

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6006-2

TABLE OF CONTENTS WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 3 3 4 4

WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 4 4

6006-3

WHEELS AND BOLTS

General Information

Torque Specification

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.

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

PRESSURE (bar)

WORK

TRAVEL

WORK

MODEL

FRONT

REAR

FRONT

REAR

26.5R25 GP-2B

4.00 (58)

2.75 (39.8)

26.5R25 XHA

4.25 (61.6)

2.00 (29)

26.5R25 XLDD2

4.25 (61.6)

2.00 (29)

26.5R25 RL-5K

4.00 (58)

2.75 (39.8)

26.5R25 XLDD1

4.25 (61.6)

26.5R25 XMINE D2 750/65 R25 XLD (*)

TRAVEL

MODEL

FRONT

REAR

FRONT

REAR

26.5R25 GP-2B

4.00 (58)

2.75 (39.8)

26.5R25 XHA

4.25 (61.6)

2.00 (29)

26.5R25 XLDD2

4.25 (61.6)

2.00 (29)

(**)

26.5R25 RL-5K

4.00 (58)

2.75 (39.8)

(**)

2.00 (29)

26.5R25 XLDD1

4.25 (61.6)

2.00 (29)

4.25 (61.6)

2.00 (29)

26.5R25 XMINE D2

4.25 (61.6)

2.00 (29)

4.25 (61.6)

2.00 (29)

750/65 R25 XLD (*)

4.25 (61.6)

2.00 (29)

26.5R25 RT-5C

4.00 (58)

2.75 (39.8)

26.5R25 RT-5C

4.00 (58)

2.75 (39.8)

26.5R25 GP-4B

4.00 (58)

2.75 (39.8)

26.5R25 GP-4B

4.00 (58)

2.75 (39.8)

2.40 (34.8)

1.50 (21.7)

26.5X25 L3 20PR

2.40 (34.8)

1.50 (21.7)

4.00 (58)

2.75 (39.8)

26.5R25 RT-3B

4.00 (58)

2.75 (39.8)

26.5X25 L3 20PR 26.5R25 RT-3B

(*) The pressure can be increased 0.5 bar when the working conditions do not require particular floating capabilities.

(**) It is suggested to load the machine on a trailer for road transit.

6006-4

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

CHANGING TIRES

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.

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

INSTALLING A WHEEL

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.

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.

BC06A079

FIGURE 1. WHEEL BOLT TORQUE SEQUENCE

BC06A079

FIGURE 1. WHEEL BOLT TORQUE SEQUENCE

TRANSMISSION CONTROL VALVE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6007

Section 6007

6007

Section 6007

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

6007-2

TABLE OF CONTENTS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 5 5

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 5

6007-3

CONTROL VALVE Disassembly

STEP 4

STEP 1

STEP 4

STEP 1

BD06A010

BD06A007

Mark the installation position of the wiring harness to the valve block.

BD06A010

Loosen and remove the cap screws, remove the cover. Remove the opposite cover.

BD06A007

Mark the installation position of the wiring harness to the valve block.

STEP 5

STEP 2

Loosen and remove the cap screws, remove the cover. Remove the opposite cover.

STEP 5

STEP 2

BD06A011 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.

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

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.

Remove the wiring harness.

BD06A009

Remove the wiring harness retaining clamp.

6007-4

STEP 7

STEP 9

BD06A013

Loosen and remove two cap screws, install two adjusting screws. Loosen and remove the remaining cap screws.

STEP 7

BD06A015

Remove the components.

STEP 9

BD06A013

Loosen and remove two cap screws, install two adjusting screws. Loosen and remove the remaining cap screws.

STEP 10

STEP 8

BD06A015

Remove the components.

STEP 10

STEP 8

BD06A016

BD06A014

Separate the housing from the valve body by equally loosening the adjusting screws.

Remove the opposite solenoids, housing, and components.

BD06A016

BD06A014

Separate the housing from the valve body by equally loosening the adjusting screws.

Remove the opposite solenoids, housing, and components.

6007-5

Inspection 1. Clean all metal parts in cleaning solvent. 2. Immerse end housings, valve housing, valve plate, and distribution plate in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of housings and plates and to ensure that all bores are clear of foreign matter.

Assembly

6007-5

Inspection

NOTE: Apply clean engine oil (15W-40) to pistons and springs, orifices, new O-rings, and filter screens before assembly.

STEP 11

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.

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.

BD06A017

Place the valve body on the bench with the orifices up.

STEP 12

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.

Assembly NOTE: Apply clean engine oil (15W-40) to pistons and springs, orifices, new O-rings, and filter screens before assembly.

STEP 11

BD06A017

Place the valve body on the bench with the orifices up.

STEP 12

3 1

1 2

2 BD06A018

1. VIBRATION DAMPER 2. PISTONS

3. PRESSURE REDUCING VALVE

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.

Install components in positions shown.

STEP 13

9. Inspect pistons for cracks, breaks, chipping, grooves, or other damage. Replace if any of these conditions are seen.

3 1

1 2

2 BD06A018

1. VIBRATION DAMPER 2. PISTONS

3. PRESSURE REDUCING VALVE

Install components in positions shown.

STEP 13

9. Inspect pistons for cracks, breaks, chipping, grooves, or other damage. Replace if any of these conditions are seen.

BD06A019

Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch).

6007-6

STEP 14

STEP 17

STEP 14

STEP 17

BD06A020

BD06A023

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).

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

STEP 15

STEP 18

BD06A021

BD06A024

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).

Tighten the adjusting screws equally until the cover is flush on the valve body.

Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch).

STEP 16

NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.

STEP 16

NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.

STEP 19

BD06A022

Push the pistons down through the pressure controller wholes and remove the roll pins.

STEP 19

1 2

BD06A022

Push the pistons down through the pressure controller wholes and remove the roll pins.

1 2

BD06A025

1. VIBRATION DAMPER 2. PISTONS

3. MAIN PRESSURE VALVE

Install components in positions shown.

BD06A025

1. VIBRATION DAMPER 2. PISTONS

3. MAIN PRESSURE VALVE

Install components in positions shown.

6007-7

STEP 20

STEP 23

6007-7

STEP 20

STEP 23

BD06A026

BD06A028

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.

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 21

STEP 24

STEP 21

STEP 24

BD06A023

BD06A029

BD06A023

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).

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 22 STEP 25

STEP 25

BD06A027

Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch). NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.

BD06A027 BD06A030

Install the wiring harness retaining clamp.

BD06A030

Install the wiring harness retaining clamp.

6007-8

STEP 26

STEP 28

STEP 26

STEP 28

BD06A031

BD06A033

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).

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 27 STEP 29

STEP 29

BD06A032

Install two adjusting screws. Place the intermediate plate with the screens facing up.

BD06A032 BD06A034

Install new o-rings on the plugs, install and torque plugs to 6 Nm (53 pound-inch).

Install two adjusting screws. Place the intermediate plate with the screens facing up.

BD06A034

Install new o-rings on the plugs, install and torque plugs to 6 Nm (53 pound-inch).

Section Title

SECTION INDEX

BRAKES

BRAKES Section Number

Section Title

Section Number

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002

Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

7001

7001 CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section 7001

REMOVAL AND INSTALLATION OF BRAKE COMPONENTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

7001-2

TABLE OF CONTENTS BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 4 4 4 6 6 6 8 8 8

BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 4 6 6 6 8 8 8

7001-3

3 4

5 6

8 7

1 2

BC05M136

1. 2. 3. 4.

FRONT AXLE PARKING BRAKE ACCUMULATOR BRAKE VALVE REAR ACCUMULATOR

5. 6. 7. 8.

FRONT ACCUMULATOR BRAKE PUMP FAN VALVE REAR AXLE

COMPONENT LOCATION ILLUSTRATION

BC05M136

1. 2. 3. 4.

FRONT AXLE PARKING BRAKE ACCUMULATOR BRAKE VALVE REAR ACCUMULATOR

5. 6. 7. 8.

FRONT ACCUMULATOR BRAKE PUMP FAN VALVE REAR AXLE

COMPONENT LOCATION ILLUSTRATION

7001-4

BRAKE VALVE Removal

Installation

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.

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).

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.

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).

7001-5

1 6

6 2

3 9

5 BC05M137

1. 2. 3. 4. 5.

BRAKE VALVE FRONT ACCUMULATOR LINE (REAR AXLE) PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE TO FAN VALVE

6. 7. 8. 9. 10.

FRONT BRAKE LINE REAR BRAKE LINE REAR ACCUMULATOR (FRONT AXLE) RETURN TO TANK PARKING BRAKE ACCUMULATOR

BRAKE VALVE ILLUSTRATION

BC05M137

1. 2. 3. 4. 5.

BRAKE VALVE FRONT ACCUMULATOR LINE (REAR AXLE) PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE TO FAN VALVE

6. 7. 8. 9. 10.

FRONT BRAKE LINE REAR BRAKE LINE REAR ACCUMULATOR (FRONT AXLE) RETURN TO TANK PARKING BRAKE ACCUMULATOR

BRAKE VALVE ILLUSTRATION

7001-6

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 (8) and the parking brake accumulator (1) 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).

Installation

Removal

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.

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 (8) and the parking brake accumulator (1) 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).

10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump.

11. Disconnect the accumulators (1).

tubes

from

both

brake

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

(1)

from

the

14. Install plugs in the tubes. from

parking

brake

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.

the

parking

brake

7001-7

2 4

4 8 5

8 5

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

BC05M138

1. 2. 3. 4.

BRAKE ACCUMULATORS PARKING BRAKE ACCUMULATOR MOUNTING NUT HOSE PARKING BRAKE ACCUMULATOR

5. 6. 7. 8.

TUBE FRONT BRAKE ACCUMULATOR TUBE REAR BRAKE ACCUMULATOR CLAMP ACCUMULATOR CLAMP STUD

BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

7001-8

BRAKE PUMP Installation

Removal

BRAKE PUMP Installation

Removal

1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine.

1. Install the brake pump (1), mounting bolts (2) and washers. Refer to the illustration on page 9.

1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine.

1. Install the brake pump (1), mounting bolts (2) and washers. Refer to the illustration on page 9.

2. Put blocks on both sides of each tire to prevent machine movement.

2. Torque mounting bolts (2) to 57 to 65 Nm (42 to 48 pound feet).

2. Put blocks on both sides of each tire to prevent machine movement.

2. Torque mounting bolts (2) to 57 to 65 Nm (42 to 48 pound feet).

3. Turn the master disconnect switch to the OFF position.

3. Remove the plugs or caps and connect the lines to the brake pump (1).

3. Turn the master disconnect switch to the OFF position.

3. Remove the plugs or caps and connect the lines to the brake pump (1).

4. Clean the brake pump (1) and lines, refer to the illustration on page 9.

4. Stop the vacuum pump and remove.

4. Clean the brake pump (1) and lines, refer to the illustration on page 9.

4. Stop the vacuum pump and remove.

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.

5. Turn the master disconnect switch to the ON position. 6. Bleed the brake system. See Section 7002. 7. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.

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.

7. Disconnect the lines from the brake pump (1) and put plugs in each line.

8. Remove the mounting bolts (2) and washers from the brake pump (1) and remove the brake pump (1).

7001-9

4 1

2 W270-3R003

1. BRAKE PUMP 2. MOUNTING BOLTS (2) 3. PRESSURE HOSE

4. FAN VALVE HOSE 5. SUCTION HOSE

BRAKE PUMP ILLUSTRATION

W270-3R003

1. BRAKE PUMP 2. MOUNTING BOLTS (2) 3. PRESSURE HOSE

4. FAN VALVE HOSE 5. SUCTION HOSE

BRAKE PUMP ILLUSTRATION

7001-10

NOTES

HYDRAULIC BRAKE TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

7002

Section 7002

Section 7002 HYDRAULIC BRAKE TROUBLESHOOTING

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

7002-2

TABLE OF CONTENTS 3 3 4 5 5 6 7 7 8 9

3 3 4 5 5 6 7 7 8 9

7002-3

SPECIFICATIONS

Brake pump output ...........................................................................................................41.5 to 43 L/min at 172 bar (10.9 to 11.3 gpm at 2500 psi at 2000 rpm)

Accumulator nitrogen charge pressure........................................................................53.5 to 57 bar (775 to 825 psi) Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2277 to 2420 psi) Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2842 psi) Brake warning pressure switch (normally closed) opening set point..................96.5 to 110.3 bar (1400 to 1600 psi) Brake redundant pressure switch (normally closed) opening set point ..............................................62 bar (900 psi) Brake light pressure switch (normally open) closing set point.............................................................4.1 bar (60 psi) Modulation pressure front brake cylinders..................................................................76 to 83 bar (1100 to 1200 psi) Modulation pressure rear brake cylinders ..................................................................74 to 81 bar (1070 to 1170 psi)

SPECIAL TOOLS

94L95

380001737 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN.

380001737 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN. BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

7002-4

TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM NOTE: The hydraulic brake schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual. 1. Check the oil level in the hydraulic reservoir; add oil as necessary. 2. Push and release the brake pedal many times with the engine stopped to remove all hydraulic pressure from the brake system until there is no pressure on the pedal. 3. Install two 207 bar (3000 psi) pressure gauges to front and rear hydraulic brake accumulator test ports. The test ports are located behind the left cab skirt across from the transmission mounted on the diagnostic panel. If your loader does not have a diagnostic panel, 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 96.5 to 110.3 bar (1400 to 1600 psi). 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 (2277 to 2420 psi), the system pressure must start to increase. This is the valve cut in pressure.

8. Stop the engine. Push and release the brake several times while reading the pressure on the gauges. Each push and release of the pedal will result in a slight drop in pressure, but not necessarily equal on the two gauges. 9. As the lowest pressure reaches 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. 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: Nominal temperature of 20째 C (68째 F), colder temperature will reduce pressure, hotter temperature will increase pressure.

NOTE: The brake cut-in and cut-out pressures of the brake system charge valve are factory preset and are not adjustable.

NOTE: If the pressure on one of the pressure gauges is lower than specified, the problem can be a bad accumulator valve.

7002-5

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine.

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.

7002-5

B. Push down and release the brake pedal many times to release the pressure.

2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit.

3. Close valves B and C on the nitrogen charging kit, refer to the illustration.

4. Turn the stem out of valve F until the stem stops.

94L95

5. Remove the cap screws and guard from the accumulator. 6. Remove the cap from the accumulator valve stem. 7. Connect valve F to the accumulator valve stem.

NITROGEN CHARGING KIT

8. Make sure that valve D is open. 9. Turn the stem into valve F and read the pressure gauge E. 10. The pressure must be 53.5 to 57 bar (775 to 825 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 53.5 to 57 bar (775 to 825 psi). Stop turning valve A.

4. Turn the stem out of valve F until the stem stops.

5. If the pressure increases above 57 bar (825 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.

94L95

5. Remove the cap screws and guard from the accumulator. 6. Remove the cap from the accumulator valve stem. 7. Connect valve F to the accumulator valve stem.

NITROGEN CHARGING KIT

7002-6

BLEEDING THE BRAKE SYSTEM 1. Check the level of hydraulic fluid in the reservoir. Add fluid to the reservoir if necessary. IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.

8. Start the engine and run at low idle. 9. Push the brake pedal all the way down and slowly release for one cycle. 10. Close all four wheel end bleed screws.

BD03A092

2. Raise loader arms and install the safety link (1) for safe access to the front axle bleed screws.

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.

1. SAFETY LINK

8. Start the engine and run at low idle.

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.

14. Open the bleed screw on the left rear axle. Repeat step 12.

BD03A092

1. SAFETY LINK

2. Raise loader arms and install the safety link (1) for safe access to the front axle bleed screws.

3. Apply the parking brake.

4. Keep the engine speed at low idle until both brake accumulators are fully charged.

NOTE: This will be approximately 30 seconds after the low brake pressure light goes out.

5. Stop the engine.

6. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps).

7. Remove the plastic and rubber caps from each wheel end and slowly open all four bleed screws.

NOTE: Attach a hose to the bleed screws to prevent spilling any fluids.

15. Open the bleed screw on the right rear axle. Repeat step 12. 16. Replace all bleed screws, caps and plugs. 17. Check the hydraulic fluid and add as necessary.

7002-7

BRAKE MODULATION PRESSURE CHECK

2 3

W270-3R004

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

11. The rear axle brake pressure should read 74 to 81 bar (1070 to 1170 psi). 12. If the pressures are not within the specified range, it will be necessary to adjust the modulation pressures.

W270-3R004

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.

2. Stop the engine. Pump the brake pedal until there is no pressure in the brake system.

3. Remove the cab skirts to gain access to the brake test ports.

4. Connect two 207 bar (3000 psi) pressure gauges to the front axle test port (1) and the rear axle 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).

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.

9. Make a note of the pressure on the gauges for the front and rear axles.

10. The front axle brake pressure should read 76 to 83 bar (1100 to 1200 psi). This is the modulation pressure for the front axle.

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

11. The rear axle brake pressure should read 74 to 81 bar (1070 to 1170 psi). 12. If the pressures are not within the specified range, it will be necessary to adjust the modulation pressures.

7002-8

Adjusting the Brake Modulation Pressure NOTE: The adjusting bolt to adjust the modulation pressure is located in the cab, under the brake pedal.

2. Turn the adjusting bolt (2) to adjust the modulation pressure. NOTE: The rear brake modulation pressure cannot be adjusted separately from the front brake modulation pressure.

Adjusting the Brake Modulation Pressure NOTE: The adjusting bolt to adjust the modulation pressure is located in the cab, under the brake pedal.

3. Repeat steps 5 through 10 in the Testing the Brake Modulation Pressure procedure.

4. Repeat these steps until the brake modulation pressure is within the specified range.

BD00N121

1. Remove the tamper resistant cover (1). NOTE: This is a tamper resistant cover and it will be necessary to install a new cover after the modulation pressure is adjusted.

NOTE: The rear brake modulation pressure cannot be adjusted separately from the front brake modulation pressure.

3. Repeat steps 5 through 10 in the Testing the Brake Modulation Pressure procedure.

1. TAMPER RESISTANT COVER 2. ADJUSTING BOLT

2. Turn the adjusting bolt (2) to adjust the modulation pressure.

BD00N121

1. TAMPER RESISTANT COVER 2. ADJUSTING BOLT

1. Remove the tamper resistant cover (1). NOTE: This is a tamper resistant cover and it will be necessary to install a new cover after the modulation pressure is adjusted.

7002-9

CHECKING THE BRAKE SYSTEM

2 3

W270-3R004

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

1. Check the level of the hydraulic fluid in the reservoir, add as needed.

W270-1R006

1. ARTICULATION LOCK

2. Install the articulation lock before doing this test. 3. Remove the left side cab skirt to gain access to the brake accumulator test ports. 4. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps).

7. Stop the engine. 8. Push the brake pedal down slowly, allowing for full piston actuation.

W270-3R004

1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT

3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT

1. Check the level of the hydraulic fluid in the reservoir, add as needed.

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 96.5 to 110 bar (1400 to 1600 psi). After the low brake pressure light activates, press the brake pedal eight more times.

10. Record the readings on the pressure gauges. The pressure gauges should read at or above 53.5 to 57 bar (775 to 825 psi).

11. If the pressures are at or above 53.5 to 57 bar (775 to 825 psi), the test is complete. 12. If the pressures are not within the required specifications, then the brake system must be bled. 13. After bleeding the brake system, perform the brake system check again.

W270-1R006

1. ARTICULATION LOCK

5. Connect two 207 bar (3000 psi) pressure gauges to the test ports 3 and 4.

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).

7002-10

1 3

1 4

34 36

30 7

7 5

26 11

16 24

11 16

14 12

17 5

23 22 21

5 20

13 5 20

BC05G011

BRAKE VALVE EXPLODED VIEW

BC05G011

BRAKE VALVE EXPLODED VIEW

7002-11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CAP SCREW (T 22 NM (16 LB-FT)) O-RING BUSHING SLEEVE SPRING SPRING RETAINER SPRING RETAINER CIRCLIP SHAFT SEAL SLEEVE LVE GUIDE RING O-RING

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

CAP (T 60 NM (44 LB-FT)) SPOOL PLUG (T 10 NM (88.5 LB-IN)) PLUG (T 60 NM (44 LB-FT)) PLUG (T 22NM (16 LB-FT)) VALVE SEAT THROTTLE SCREW PLUG (T 22NM (16 LB-FT)) CAP SLEEVE SPRING RETAINER SLEEVE

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

CHECK VALVE CARTRIDGE PLUG (T 60 NM (44 LB-FT)) JET WVI UNIT PLUG (T 60 NM (44 LB-FT)) PLUG (T 100 NM (74 LB-FT)) RV UNIT SPRING RETAINER SLEEVE THRUST RING SLEEVE LVV

7002-11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CAP SCREW (T 22 NM (16 LB-FT)) O-RING BUSHING SLEEVE SPRING SPRING RETAINER SPRING RETAINER CIRCLIP SHAFT SEAL SLEEVE LVE GUIDE RING O-RING

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

CAP (T 60 NM (44 LB-FT)) SPOOL PLUG (T 10 NM (88.5 LB-IN)) PLUG (T 60 NM (44 LB-FT)) PLUG (T 22NM (16 LB-FT)) VALVE SEAT THROTTLE SCREW PLUG (T 22NM (16 LB-FT)) CAP SLEEVE SPRING RETAINER SLEEVE

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

CHECK VALVE CARTRIDGE PLUG (T 60 NM (44 LB-FT)) JET WVI UNIT PLUG (T 60 NM (44 LB-FT)) PLUG (T 100 NM (74 LB-FT)) RV UNIT SPRING RETAINER SLEEVE THRUST RING SLEEVE LVV

7002-12

NOTES

BRAKE ACCUMULATORS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

7004

Section 7004 7004

Section 7004

BRAKE ACCUMULATORS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

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

TABLE OF CONTENTS 3 3 3 4 4

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 4

7004-3

SPECIAL TOOL

G D

A 94L95

380001737 NITROGEN CHARGING KIT

BC04A001

380001168 ACCUMULATOR CHARGING ADAPTER

A 94L95

380001737 NITROGEN CHARGING KIT

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

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.

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.

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.

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.

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.

5. Turn the T-handle on valve F fully out.

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.

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. charge

4. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise.

10. Once the accumulator is fully discharged, disconnect valve F from the valve stem and remove adapter.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

5. Remove the cap from the accumulator. Loosen the Allen screw in the charge port.

10. If the pressure is too low, accumulator with dry nitrogen.

3. Close valves B, C and D.

9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator.

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.

the

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.

charge

the

7004-4

CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator.

6. Connect valve F to the adapter valve stem. Turn the stem into valve F until the stem stops moving and open valve G and D to charge the accumulator.

NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator.

6. Connect valve F to the adapter valve stem. Turn the stem into valve F until the stem stops moving and open valve G and D to charge the accumulator.

1. Close (turn counterclockwise) valve A and open valve B. Close valves C, D, and G.

7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving and close valve G.

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

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

PARKING BRAKE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

7008

Section 7008

7008

Section 7008

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

7008-2

TABLE OF CONTENTS PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 4 4 6

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 6

7008-3

PARKING BRAKE Disassembly

STEP 6

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

W270-1R006

BD07A212-01

Loosen and remove the cover from the parking brake.

STEP 7

Start the machine and run the engine at low idle with the bucket resting on the ground.

IMPORTANT: It will be necessary to have an assistant help for this procedure. An operator must be present in the cab at all times to apply the service brakes and shut down the machine in the event of mechanical failure.

Install the articulation lock.

W270-1R006

Install the articulation lock.

STEP 8

STEP 4 Pump the brake pedal at least 30 times to discharge the accumulators.

STEP 5

Disengage the parking brake. 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.

STEP 8

STEP 4 Pump the brake pedal at least 30 times to discharge the accumulators.

STEP 5

A. Place the parking brake rocker switch in the OFF position.

B. Apply the service brake and put the machine into gear.

C. The parking brake light on the cluster will turn off at this time.

Place the transmission back into neutral before proceeding.

BD07A211-01

Remove bolts from bracket attached to frame and secure out of the way.

7008-4

Inspection

STEP 9

Inspection

STEP 9

1. Clean and inspect all parts for wear and damage.

2. Inspect the brake disc for wear and damage.

3. Replace all parts that are worn or damaged.

Assembly

STEP 1

BD07A213-01

Loosen the jam nut, turn adjusting bolt counterclockwise until the brake pads are loose.

STEP 10

BD07A216-01

Install the two brake pads in the parking brake assembly.

STEP 2

BD07A215

Remove the retainer pins and brake pins.

STEP 11

BD07A215-01

BD07A216-01

Remove the two brake pads from the parking brake assembly.

BD07A215-01

Install the brake pins and retainer pins.

STEP 3

Start the machine and run the engine at low idle with the bucket resting on the ground.

BD07A216-01

Remove the two brake pads from the parking brake assembly.

7008-5

STEP 4

STEP 6

STEP 4

STEP 6

Disengage the parking brake.

Install the cover on the parking brake.

Disengage the parking brake.

Install the cover on the parking brake.

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.

STEP 7 Perform the Parking Brake Test Procedure as described in this section.

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.

STEP 7 Perform the Parking Brake Test Procedure as described in this section.

A. Place the parking brake rocker switch in the OFF position.

STEP 8

A. Place the parking brake rocker switch in the OFF position.

STEP 8

B. Apply the service brake and put the machine into gear.

Remove the articulation lock.

B. Apply the service brake and put the machine into gear.

Remove the articulation lock.

C. The parking brake light on the cluster will turn off at this time.

Place the transmission back into neutral before proceeding.

STEP 5

BD07A213-01

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.

7008-6

PARKING BRAKE TEST PROCEDURE STEP 1

PARKING BRAKE TEST PROCEDURE

STEP 5

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.

STEP 1

3 1

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 2

Start the machine and run the engine at low idle in third gear neutral.

Place the Transmission-Auto switch to the manual position.

SA015

STEP 2

STEP 3

STEP 5

While testing, the machine must be on a clear level surface with the bucket in the travel position.

BD06F141-01

1. ESCAPE 2. ENTER 3. PARK BRAKE SWITCH

Start the machine and run the engine at low idle in third gear neutral.

STEP 3

STEP 4

Press and hold the enter key (2) for 2 to 3 seconds until the instrument cluster monitor display changes to the select screen.

Place the Parking Brake switch (3) to the ON position.

NOTE: If you press the escape key (1) it will back up one step.

STEP 6

Place the Transmission-Auto switch to the manual position.

BD06F141-01

1. ESCAPE 2. ENTER 3. PARK BRAKE SWITCH

STEP 4

Press and hold the enter key (2) for 2 to 3 seconds until the instrument cluster monitor display changes to the select screen.

Place the Parking Brake switch (3) to the ON position.

NOTE: If you press the escape key (1) it will back up one step.

STEP 6

BD07B060-01

Use the up or down arrow to select “Config”, press the enter key (2).

7008-7

STEP 7

STEP 9

7008-7

STEP 7

STEP 9

BD07B061-01

BD07B063-01

BD07B061-01

BD07B063-01

Use up or down arrow and highlight “Park Brake”, press the enter key to select the park brake menu.

Monitor will display “Test Park Brake Engage 3rd Manual” if all conditions are met to test the brake.

Use up or down arrow and highlight “Park Brake”, press the enter key to select the park brake menu.

Monitor will display “Test Park Brake Engage 3rd Manual” if all conditions are met to test the brake.

STEP 8

NOTE: If all conditions are not met to test the brake the monitor will display the condition that needs corrected prior to proceeding.

STEP 8

NOTE: If all conditions are not met to test the brake the monitor will display the condition that needs corrected prior to proceeding.

BD07B062-01

Display come up “Test Park Brake Confirm Please” press enter.

STEP 10

Shift the gear selector into third gear forward and slowly increase the engine speed to high idle.

STEP 11

Monitor will display “Test Park Break Ready”.

STEP 12

Verify that the machine does not move.

STEP 13 Reduce the engine speed to low idle and return the transmission neutral display will go back to “Engage 3rd manual”.

BD07B062-01

Display come up “Test Park Brake Confirm Please” press enter.

STEP 13 Reduce the engine speed to low idle and return the transmission neutral display will go back to “Engage 3rd manual”.

STEP 14

Shift the gear selector to third gear reverse and slowly increase the engine speed to high idle display will go to “Ready”.

7008-8

STEP 15

Verify that the machine does not move.

STEP 16

Reduce the engine speed to low idle and return the transmission to neutral.

STEP 17

BD06F141-01

Press the escape switch on the key pad to exit the test mode.

STEP 18

If any machine movement was detected, the parking brake must be adjusted, see procedures this section.

Section Title

SECTION INDEX

HYDRAULICS

HYDRAULICS Section Number

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

Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013

Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

8001

8001 CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section 8001

REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8001-2

TABLE OF CONTENTS

REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Loader Control Valve Line Connections Top Of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Loader Control Valve Line Connections Bottom Of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Joystick and 2 Lever Hose Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Joystick and 1 Lever Hose Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Joystick Hose Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Bucket Cylinder Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . 27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8001-3

REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE

8001-3

REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE

Removal

STEP 5

Removal

STEP 5

STEP 1

Park the machine on a level surface.

Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve, see ride control valve remove page 33.

Park the machine on a level surface.

Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve, see ride control valve remove page 33.

STEP 2

STEP 6

STEP 2

STEP 6

Loosen the filler cap on the reservoir to release any pressure in the reservoir.

STEP 7

Attach a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 8

BD03A092

Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 3

Stop the engine and apply the parking brake.

IMPORTANT: Pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit.

STEP 4 Place the master disconnect switch in the OFF position.

COVER

Loosen and remove the top bolts and washers, loosen the bottom bolts that fasten the access cover plate for the loader control valve. Remove the cover plate.

STEP 4 Place the master disconnect switch in the OFF position.

COVER

Loosen and remove the top bolts and washers, loosen the bottom bolts that fasten the access cover plate for the loader control valve. Remove the cover plate.

8001-4

REAR OF MACHINE

1 2

11 8

8 BC05M094

1. 2 SPOOL VALVE 2. RED BLACK BLACK (HOSE PILOT LOWER) 3. GREEN BLACK BLACK (HOSE PILOT DUMP) 4. ORANGE BLACK BLACK (HOSE PILOT ROLLBACK)

5. YELLOW BLACK BLACK (HOSE PILOT RAISE) 6. 3 SPOOL VALVE 7. RED WHITE BLACK (HOSE THIRD SPOOL PILOT) 8. RED WHITE BLACK (HOSE THIRD SPOOL PILOT)

9. 4 SPOOL VALVE 10. GREEN WHITE BLACK (HOSE FOURTH SPOOL PILOT) 11. GREEN WHITE BLACK (HOSE FOURTH SPOOL PILOT)

BC05M094

1. 2 SPOOL VALVE 2. RED BLACK BLACK (HOSE PILOT LOWER) 3. GREEN BLACK BLACK (HOSE PILOT DUMP) 4. ORANGE BLACK BLACK (HOSE PILOT ROLLBACK)

HYDRAULIC VALVE PILOT LINE CONNECTIONS

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

STEP 9 Disconnect the hoses (2,3, 4, 5, if equipped 7, 8, 10, and 11) from the remote control valve(s) at the loader control valve (1, 6, or 9). Refer to the illustration on page 4 for color coding. NOTE: Line 7, 8, 10, and 11 will need to be tagged as left or right side of the valve.

STEP 10 Tag and disconnect the load sensing hose (not shown) from the LS port on the top of the control valve.

STEP 11 Tag and slowly disconnect the pilot accumulator hose (not shown) from the from the ACC port on the top of the control valve.

5. YELLOW BLACK BLACK (HOSE PILOT RAISE) 6. 3 SPOOL VALVE 7. RED WHITE BLACK (HOSE THIRD SPOOL PILOT) 8. RED WHITE BLACK (HOSE THIRD SPOOL PILOT)

9. 4 SPOOL VALVE 10. GREEN WHITE BLACK (HOSE FOURTH SPOOL PILOT) 11. GREEN WHITE BLACK (HOSE FOURTH SPOOL PILOT)

HYDRAULIC VALVE PILOT LINE CONNECTIONS

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

STEP 10 Tag and disconnect the load sensing hose (not shown) from the LS port on the top of the control valve.

STEP 11 Tag and slowly disconnect the pilot accumulator hose (not shown) from the from the ACC port on the top of the control valve.

8001-5

14 20

19 16

20 19

15 W270-6R005

12. ELBOW ROD END LEFT LIFT 13. ELBOW CLOSED END RIGHT LIFT 14. CLOSED END BUCKET

15. ROD END BUCKET 16. RETURN PORT 17. INLET PORT

W270-6R005

18. U BOLT (2) 19. NUT (4) 20. WASHER (4)

12. ELBOW ROD END LEFT LIFT 13. ELBOW CLOSED END RIGHT LIFT 14. CLOSED END BUCKET

LOADER CONTROL VALVE LINE CONNECTIONS TOP OF VALVE

15. ROD END BUCKET 16. RETURN PORT 17. INLET PORT

18. U BOLT (2) 19. NUT (4) 20. WASHER (4)

LOADER CONTROL VALVE LINE CONNECTIONS TOP OF VALVE

STEP 12

STEP 14

STEP 12

STEP 14

Remove the tilt cylinder “U” bolts (18) from the frame.

Loosen and remove right lift cylinder line from elbow (13).

Remove the tilt cylinder “U” bolts (18) from the frame.

Loosen and remove right lift cylinder line from elbow (13).

STEP 13 Loosen and remove tilt cylinder lines (14 and 15).

STEP 13 STEP 15 Loosen and remove left lift cylinder line from elbow (12).

Loosen and remove tilt cylinder lines (14 and 15).

STEP 15 Loosen and remove left lift cylinder line from elbow (12).

8001-6

W270-6R006

21. CLAMP 22. ROD END RIGHT LIFT 23. CLOSED END LEFT LIFT

W270-6R006

24. CLAMP 25. TUBE TILT CYLINDER ROD PLATED

21. CLAMP 22. ROD END RIGHT LIFT 23. CLOSED END LEFT LIFT

LOADER CONTROL VALVE LINE CONNECTIONS BOTTOM OF VALVE

24. CLAMP 25. TUBE TILT CYLINDER ROD PLATED

LOADER CONTROL VALVE LINE CONNECTIONS BOTTOM OF VALVE

STEP 16

STEP 17

STEP 16

STEP 17

Loosen clamp (24), disconnect tube (23) from the loader valve.

Loosen clamp (21), disconnect tube (22) from the loader valve. Disconnect tube (25).

Loosen clamp (24), disconnect tube (23) from the loader valve.

Loosen clamp (21), disconnect tube (22) from the loader valve. Disconnect tube (25).

8001-7

Installation

STEP 18 Attach lifting equipment to loader control valve.

STEP 19

8001-7

Installation

STEP 18

IMPORTANT: Before installing, replace all O-rings on the fittings, tubes, and hoses.

Attach lifting equipment to loader control valve.

STEP 19

STEP 20

IMPORTANT: Before installing, replace all O-rings on the fittings, tubes, and hoses.

STEP 20

BC05M096

Loosen and remove the three bolts and washers that hold the loader control valve to the valve mounting plate. Remove the loader control valve.

BC05M096

Install and align the loader control valve with the valve mounting plate.

BC05M096

Install and align the loader control valve with the valve mounting plate.

STEP 21

Install the bolts and washers that fasten the loader control valve to the valve mounting plate. Tighten the bolts.

STEP 22

Connect tube (22) to the loader valve, tighten the clamp (21) leaving a 30 mm (1 ¼ inch) space between tube spud and clamp, refer to illustration on page 6.

STEP 23

Connect tube (23) to the loader valve, tighten the clamp (24) leaving a 30 mm (1 ¼ inch) space between tube spud and clamp. Connect tube (25).

STEP 24

Install and tighten the supply and return lines (16 and 17), refer to illustration on page 5.

STEP 25

Connect and tighten to elbow (12) the left lift cylinder line.

STEP 26

Connect and tighten to elbow (13) the right lift cylinder line.

STEP 27

Install and tighten tilt cylinder lines (14 and 15).

STEP 28

Install the tilt cylinder line “U” bolts (18).

8001-8

STEP 29

STEP 34

STEP 29

STEP 34

Connect the hoses (2,3, 4, 5, if equipped 7, 8, 10, and 11) to the remote control valve(s) on the loader control valve (1, 6, or 9). Refer to the illustration on page 4 for color coding.

Run engine at half throttle.

Connect the hoses (2,3, 4, 5, if equipped 7, 8, 10, and 11) to the remote control valve(s) on the loader control valve (1, 6, or 9). Refer to the illustration on page 4 for color coding.

Run engine at half throttle.

STEP 30

STEP 35 Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.

Connect the load sensing hose (not shown) and the pilot accumulator hose (not shown) to the top of the control valve.

STEP 36

STEP 31 Turn off and disconnect the vacuum pump from the reservoir.

Place the master disconnect switch in the ON position.

STEP 33

STEP 36

Stop the engine and check for leaks.

STEP 37

STEP 31

STEP 37

Install the access cover on the front of the machine.

Turn off and disconnect the vacuum pump from the reservoir.

Install the access cover on the front of the machine.

Check the level of the hydraulic oil and add hydraulic oil as required. Refer to Section 1002 for the correct oil.

Raise the loader arms and remove the safety link.

Stop the engine and check for leaks.

STEP 38

STEP 32 Place the master disconnect switch in the ON position.

STEP 33

BD03A092

Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.

Connect the load sensing hose (not shown) and the pilot accumulator hose (not shown) to the top of the control valve.

STEP 38

STEP 32

STEP 30

STEP 35

BD03A092

Raise the loader arms and remove the safety link.

Check the level of the hydraulic oil and add hydraulic oil as required. Refer to Section 1002 for the correct oil.

8001-9

REMOTE CONTROL VALVE Removal

STEP 44

STEP 39

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 40

BD06F208

Place the master disconnect switch in the OFF position.

Open and remove the access panel.

STEP 40

BD06F208

Place the master disconnect switch in the OFF position.

STEP 45

STEP 41

Unlatch and open the right hand side access door.

STEP 42

Lift the access door up and remove the access door from the pins.

STEP 43

Open and remove the access panel.

STEP 45

BD06F210

Disconnect the electrical connectors for the remote control valve.

STEP 46

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.

W270-8R016

Unlatch and open the compartment door on the right hand side.

8001-10

STEP 47

Installation

STEP 47

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 51

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 51

Install new O-rings on the adapters for the remote control valve.

STEP 48 Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.

STEP 49 Loosen and remove the screws that fasten the remote control valve to the hydraulic control tower.

STEP 50 Remove the remote control valve from the hydraulic control tower.

Install new O-rings on the adapters for the remote control valve.

STEP 48 STEP 52 Install the remote control valve and screws in the hydraulic control tower and tighten the screws.

STEP 53 Install the cover over the remote control valve and install the screws and washers.

STEP 54 Remove the plugs from the hoses and the caps from the fittings and connect the hydraulic hoses to the fittings according to the identification tags. (Refer to illustrations on pages 11, 12, and 13 as necessary.

Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.

STEP 49 Loosen and remove the screws that fasten the remote control valve to the hydraulic control tower.

STEP 50 Remove the remote control valve from the hydraulic control tower.

STEP 52 Install the remote control valve and screws in the hydraulic control tower and tighten the screws.

STEP 53 Install the cover over the remote control valve and install the screws and washers.

STEP 55

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 56

BD06F210

Connect the electrical connectors for the remote control valve.

STEP 57

Place the master disconnect switch in the ON position.

STEP 58

Start the engine and run the engine at low idle.

STEP 59

Check to see that the remote control valve works correctly.

8001-11

STEP 60

STEP 62

8001-11

STEP 60

Check for hydraulic oil leakage at the remote control valve.

STEP 61

Check the level of hydraulic oil in the reservoir and add as required.

STEP 62

BD06F2081

Install and close the access panel.

STEP 63

W270-8R016

Close the right hand compartment door.

W270-8R016

Close the right hand compartment door.

8001-12

4 8

6 1

8 5

7 1

2 8

3 6

7 2

3 6

W270-6R008

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK BLACK (RAISE)

4. ORANGE BLACK BLACK (ROLLBACK) 5. GREEN BLACK BLACK (DUMP) 6. RED BLACK BLACK (LOWER)

7. GREEN WHITE BLACK (4TH SPOOL) 8. RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 2 LEVER HOSE COLOR CODING

W270-6R008

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK BLACK (RAISE)

4. ORANGE BLACK BLACK (ROLLBACK) 5. GREEN BLACK BLACK (DUMP) 6. RED BLACK BLACK (LOWER)

7. GREEN WHITE BLACK (4TH SPOOL) 8. RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 2 LEVER HOSE COLOR CODING

8001-13

1 4

7 4

1 3

2 3

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL) 3 LEVER HOSE COLOR CODING

1 3

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 1 LEVER HOSE COLOR CODING

1 3

6 4

W270-6R010

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

W270-6R009

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

7 1

8001-13

W270-6R009

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL) 3 LEVER HOSE COLOR CODING

W270-6R010

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 1 LEVER HOSE COLOR CODING

8001-14

5 4

1 5 6

5 6

1 3

1 5

1 3

2 7

1 3 4

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) 2 LEVER HOSE COLOR CODING

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) JOYSTICK HOSE COLOR CODING

1 3

6 4

W270-6R012

6 4

W270-6R011

1 3

W270-6R011

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) 2 LEVER HOSE COLOR CODING

W270-6R012

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) JOYSTICK HOSE COLOR CODING

8001-15

NOTES

8001-15

NOTES

8001-16

REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP

5 2

11 14

11 9

W270-6R007

1. 2. 3. 4.

PUMP MAIN HYDRAULIC MOUNT BOLTS DRAIN HOSE BOLT

5. 6. 7. 8.

SPLIT FLANGE 9. BOLT TUBE 10. CLAMPS HOSE SUCTION 11. SPLIT FLANGE HOSE CASE DRAIN 12. TUBE PUMP DISCHARGE

13. 14. 15. 16.

LOADER HIGH PRESSURE STEERING PRIORITY MANIFOLD CLAMPS FITTINGS

W270-6R007

1. 2. 3. 4.

PUMP MAIN HYDRAULIC MOUNT BOLTS DRAIN HOSE BOLT

5. 6. 7. 8.

SPLIT FLANGE 9. BOLT TUBE 10. CLAMPS HOSE SUCTION 11. SPLIT FLANGE HOSE CASE DRAIN 12. TUBE PUMP DISCHARGE

13. 14. 15. 16.

LOADER HIGH PRESSURE STEERING PRIORITY MANIFOLD CLAMPS FITTINGS

8001-17

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

STEP 64 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 73 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

8001-17

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

STEP 64 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

NOTE: Install new O-rings where required.

STEP 65 Place the master disconnect switch in the OFF position.

STEP 66 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 67 Refer to Section 9007 and remove the ROPS cab or ROPS canopy.

STEP 68 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.

Loosen clamps (10). Tag and disconnect suction hoses (7) from hydraulic reservoir and remove from machine.

STEP 70 Tag and disconnect case drain hoses (8) from fittings (16); remove hoses (8). Remove and discard O-ring face seals from fittings.

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 65 STEP 74 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 75 Connect pump pressure hose (13) to steering priority manifold (14).

STEP 76 Connect drain hose (3).

STEP 77 Install and connect case drain hoses (8).

Place the master disconnect switch in the OFF position.

STEP 66 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 67 Refer to Section 9007 and remove the ROPS cab or ROPS canopy.

STEP 78 STEP 69

STEP 73

Install suction hoses (7), tighten clamps (10) to 10 to 11 Nm (90 to 100 pound inches).

STEP 79 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 74 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 75 Connect pump pressure hose (13) to steering priority manifold (14).

STEP 76 Connect drain hose (3).

STEP 77 Install and connect case drain hoses (8).

STEP 78 STEP 69 Loosen clamps (10). Tag and disconnect suction hoses (7) from hydraulic reservoir and remove from machine.

STEP 70

Install suction hoses (7), tighten clamps (10) to 10 to 11 Nm (90 to 100 pound inches).

STEP 79 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 80

Tag and disconnect case drain hoses (8) from fittings (16); remove hoses (8). Remove and discard O-ring face seals from fittings.

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

STEP 71

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

Tag and disconnect drain hose (3). Remove and discard O-ring face seals from fittings.

STEP 81

Tag and disconnect drain hose (3). Remove and discard O-ring face seals from fittings.

STEP 81

STEP 72

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 72

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 82

Tag and disconnect pump pressure hose (13) from steering priority manifold (14). Remove and discard O-ring face seals from flange heads of hoses.

STEP 82

STEP 71

Tag and disconnect pump pressure hose (13) from steering priority manifold (14). Remove and discard O-ring face seals from flange heads of hoses.

Place the master disconnect switch in the ON position.

STEP 80

Place the master disconnect switch in the ON position.

8001-18

STEP 83

STEP 84

STEP 83

STEP 84

Start the engine and run the engine at low idle for two minutes.

Stop the engine and check for hydraulic oil leakage at the hydraulic pump.

Start the engine and run the engine at low idle for two minutes.

Stop the engine and check for hydraulic oil leakage at the hydraulic pump.

NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.

STEP 85

NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.

STEP 85

Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.

8001-19

REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS Removal

STEP 91

NOTE: The photoâ&#x20AC;&#x2122;s may vary from your machine, the procedure is the same.

STEP 86

Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 87

Pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, then move the loader control lever back and forth several times to release any hydraulic pressure in the pilot control circuit.

STEP 88 Relieve the pressure in the ride control accumulator with the manual bleeder valve located in the ride control valve.

BD01D709

Loosen and remove the bolt, washer and spacer that hold the pivot pin for the yoke.

STEP 88

STEP 92

Relieve the pressure in the ride control accumulator with the manual bleeder valve located in the ride control valve.

STEP 89

Loosen the filler cap on the hydraulic reservoir to release any pressure.

STEP 90

BD01D709

Loosen and remove the bolt, washer and spacer that hold the pivot pin for the yoke.

STEP 92

BD01D711

Use a proper lifting device and secure a strap around the lift cylinder.

STEP 93

BD01D708

Tag and disconnect the hoses on each side of the lift cylinder. Install plugs in the hoses and caps on the fittings.

BD01D712

Remove the pivot pin from the yoke end of the lift cylinder.

8001-20

Installation

STEP 94

Installation

STEP 94

STEP 97

Apply antiseize compound to the bores in the front frame and the yoke on the piston rod.

STEP 98

BD01D710

Loosen and remove the bolt, washer and spacer that hold the pivot pin at the closed end of the lift cylinder.

STEP 95

STEP 95 BD01D714

BD01D714

Use a proper lifting device and position the lift cylinder on the machine.

STEP 99

BD01D713

Remove the pivot pin from the closed end of the lift cylinder.

STEP 96

Remove the lift cylinder from the machine

Remove the lift cylinder from the machine BD01D713

BD01D713

Align the closed end of the lift cylinder with the front frame and install the pivot pin.

8001-21

STEP 100

STEP 103

BD01D710

Align the pivot pin with the front frame and install the spacer, washer and bolt. Tighten the bolt.

8001-21

STEP 100

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 103

BD01D710

Align the pivot pin with the front frame and install the spacer, washer and bolt. Tighten the bolt.

STEP 104

BD01D712

Install the pivot pin for the yoke. Stop the engine.

STEP 104

STEP 101

BD01D709 BD01D708

Remove the caps and plugs and connect the hoses to the lift cylinder.

Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.

BD01D709 BD01D708

Remove the caps and plugs and connect the hoses to the lift cylinder.

STEP 105 STEP 102 If the yoke of the lift cylinder is not aligned with the loader frame, have another person start and run the engine at low idle and use the loader control lever to SLOWLY move the yoke into alignment with the loader frame.

SLOWLY extend and retract the piston rod three times to remove any air from the lift cylinders.

STEP 106 Lubricate the pivot pins with molydisulfide grease.

Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.

SLOWLY extend and retract the piston rod three times to remove any air from the lift cylinders.

STEP 106 Lubricate the pivot pins with molydisulfide grease.

STEP 107

Check the level of hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-22

REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER 1

REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER 2

11 5

5 6

9 W270-5R015

1. 2. 3. 4. 5.

BRACKET WASHER BOLT TARGET BAR PROXIMITY SWITCH BRACKET

6. 7. 8. 9. 10.

BOLTS WASHERS PROXIMITY SWITCH GAP 3.2 - 5 MM (0.125 - 0.197 INCH) BOLT

BUCKET CYLINDER PROXIMITY SWITCH

11. 12. 13. 14. 15.

WASHER WIRING HARNESS GAURD BOLT WASHER BUCKET CYLINDER

W270-5R015

1. 2. 3. 4. 5.

BRACKET WASHER BOLT TARGET BAR PROXIMITY SWITCH BRACKET

6. 7. 8. 9. 10.

BOLTS WASHERS PROXIMITY SWITCH GAP 3.2 - 5 MM (0.125 - 0.197 INCH) BOLT

BUCKET CYLINDER PROXIMITY SWITCH

11. 12. 13. 14. 15.

WASHER WIRING HARNESS GAURD BOLT WASHER BUCKET CYLINDER

8001-23

Removal

8001-23

Removal

STEP 112

NOTE: The photoâ&#x20AC;&#x2122;s may vary from your machine, the procedure is the same.

STEP 108

Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 109

With the engine stopped, move the bucket control lever to release pressure in the bucket circuit.

With the engine stopped, move the bucket control lever to release pressure in the bucket circuit. BD01D697

STEP 110

Loosen and remove the two bolts (6) and washers (7) that fasten the proximity switch bracket (5) to the cylinder (15). Remove the proximity switch bracket (5) and proximity switch (8).

BD01D697

STEP 110

Loosen and remove the two bolts (6) and washers (7) that fasten the proximity switch bracket (5) to the cylinder (15). Remove the proximity switch bracket (5) and proximity switch (8).

STEP 113

Remove bolts and washers(10 and 11), remove bolts and wahsers (13 and 14), remove the wiring harness gaurd (12) with wiring harness.

STEP 114

BD01D694

Disconnect the proximity switch connector from the wiring harness connector.

STEP 111

BD01D699

Disconnect the hoses from each side of the bucket cylinder. Install plugs in the hoses and caps on the fittings.

BD01D695

Loosen and remove the two bolts (3) and washers (2) that fasten the bracket (1) to the cylinder (15). Remove the bracket (1) with target bar (4).

8001-24

STEP 115

STEP 118

STEP 115

STEP 118

BD01D700

BD06H199

BD01D700

BD06H199

Use acceptable equipment to hold the bucket cylinder.

Remove the pivot pin from the head end of the bucket cylinder.

Use acceptable equipment to hold the bucket cylinder.

Remove the pivot pin from the head end of the bucket cylinder.

STEP 116

NOTE: It is not necessary to remove the grease line from the pivot pin unless the pivot pin is to be replaced.

STEP 116

NOTE: It is not necessary to remove the grease line from the pivot pin unless the pivot pin is to be replaced.

STEP 119

BD01D698

Loosen and remove the bolt, washer and spacer that fasten the pivot pin from both ends of the bucket cylinder.

STEP 117

BD06H200

Raise the bucket cylinder and remove the cylinder from the machine.

STEP 117

BD01D701

Remove the pivot pin from the rod end of the bucket cylinder.

BD06H200

Raise the bucket cylinder and remove the cylinder from the machine.

8001-25

Installation

8001-25

Installation

STEP 124

STEP 120

Apply antisieze compound to the bores in the front frame and the bores in the loader arm for the bucket cylinder.

STEP 121

BD01D699

Connect the hoses to each side of the bucket cylinder.

STEP 125

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.

Use acceptable lifting equipment to lower the bucket cylinder into position.

STEP 122

STEP 126

STEP 122

STEP 126

BD01D706

Install the pivot pin and stop the engine.

STEP 127

BD01D704

Install the pivot pin to the head end of the bucket cylinder.

Install the pivot pin to the head end of the bucket cylinder. BD01D698

STEP 123 Install the spacer, washer and bolt that fasten the pivot pin to the front frame. Tighten the bolt. NOTE: If a new pivot pin is being installed, connect the grease line to the pivot pin.

Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.

STEP 128 Install the wiring harness gaurd (12) with wiring harness, install and tighten bolts and washers (10 and 11), bolts and wahsers (13 and 14), refer to illstation on page 22.

BD01D698

STEP 123 Install the spacer, washer and bolt that fasten the pivot pin to the front frame. Tighten the bolt. NOTE: If a new pivot pin is being installed, connect the grease line to the pivot pin.

Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.

STEP 128 Install the wiring harness gaurd (12) with wiring harness, install and tighten bolts and washers (10 and 11), bolts and wahsers (13 and 14), refer to illstation on page 22.

8001-26

STEP 129

STEP 131

STEP 129

STEP 131

BD01D697

BD01D694

BD01D697

BD01D694

Install the two bolts (6) and wahsers (7) that fasten the proximity switch bracket (5) to the bucket cylinder (15).

Connect the proximity switch connector to the wiring harness connector.

Install the two bolts (6) and wahsers (7) that fasten the proximity switch bracket (5) to the bucket cylinder (15).

Connect the proximity switch connector to the wiring harness connector.

STEP 132 STEP 130

See Section 9006 for the adjustment procedure for adjusting the proximity switch.

BD01D695

Install the bracket (1) with target bar (4). Install and tighten the two bolts (3) and washers (2) that fasten the bracket (1) to the cylinder (15).

STEP 132 STEP 130

See Section 9006 for the adjustment procedure for adjusting the proximity switch.

STEP 133

Start and run the engine at low idle.

STEP 134

SLOWLY extend and retract the piston rod three times to remove any air from the bucket cylinder.

STEP 135

Lubricate the pivot pins with molydisulfide grease.

STEP 136 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

BD01D695

Install the bracket (1) with target bar (4). Install and tighten the two bolts (3) and washers (2) that fasten the bracket (1) to the cylinder (15).

STEP 136 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-27

REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATORS

Removal

STEP 139

STEP 137

Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 138

With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, move the loader control lever back and forth several times to release any hydraulic pressure in the pilot control circuit.

BD06A218

STEP 139

BD06A218

Relieve the pressure in the ride control accumulators with the manual bleeder valve located on the side of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

STEP 140

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.

8001-28

17 18 5

18 5

3 20 4

9 23

8 10

BC06A217

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

BOLT (3) WASHER (3) RIDE CONTROL VALVE RIGHT ACCUMULATOR TUBE LEFT ACCUMULATOR TUBE HOSE TO LEFT CYLINDER HOSE TO RETURN TUBE HOSE TO RIGHT CYLINDER

9. 10. 11. 12. 13. 14. 15. 16.

BRACKET RIGHT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2) WASHER (2) NUT (2)

17. 18. 19. 20. 21. 22. 23. 24.

NUT (2) WASHER (2) BRACKET LEFT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2)

BC06A217

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

BOLT (3) WASHER (3) RIDE CONTROL VALVE RIGHT ACCUMULATOR TUBE LEFT ACCUMULATOR TUBE HOSE TO LEFT CYLINDER HOSE TO RETURN TUBE HOSE TO RIGHT CYLINDER

9. 10. 11. 12. 13. 14. 15. 16.

BRACKET RIGHT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2) WASHER (2) NUT (2)

17. 18. 19. 20. 21. 22. 23. 24.

NUT (2) WASHER (2) BRACKET LEFT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2)

STEP 141

STEP 143

STEP 141

STEP 143

Disconnect the tube (4 or 5) from the elbow at the accumulator (10 or 20). Install a plug in the tube and a cap on the fitting.

Loosen and remove the two nuts (16 or 24) and washers (15 or 23) that fasten the accumulator bracket (12 or 22) to the front frame.

Disconnect the tube (4 or 5) from the elbow at the accumulator (10 or 20). Install a plug in the tube and a cap on the fitting.

Loosen and remove the two nuts (16 or 24) and washers (15 or 23) that fasten the accumulator bracket (12 or 22) to the front frame.

STEP 142

STEP 144

STEP 142

STEP 144

Loosen and remove the two nuts (14 or 17) and washers (13 or 18) that fasten the accumulator bracket (9 or 19) to the front frame.

Remove the ride control accumulator (10 or 20) from the machine.

Loosen and remove the two nuts (14 or 17) and washers (13 or 18) that fasten the accumulator bracket (9 or 19) to the front frame.

Remove the ride control accumulator (10 or 20) from the machine.

8001-29

Installation

STEP 149

Installation

STEP 149

STEP 145

Turn off and disconnect the vacuum pump from the hydraulic reservoir.

STEP 145

Turn off and disconnect the vacuum pump from the hydraulic reservoir.

Place the ride control accumulators (10 or 20) in position on the front frame.

STEP 150

Place the ride control accumulators (10 or 20) in position on the front frame.

STEP 150

STEP 146

Refer to Section 8013, Charging The Accumulator With Nitrogen and charge the accumulators.

STEP 146

Refer to Section 8013, Charging The Accumulator With Nitrogen and charge the accumulators.

Install the two nuts (16 or 24) and washers (15 or 23) that fasten the accumulator bracket (12 or 22) to the front frame. Tighten the nuts.

STEP 151 Refer to Section 8002 Testing the Ride Control and test the ride control system, check for leaks.

STEP 147 Install the two nuts (14 or 17) and washers (13 or 18) that fasten the accumulator bracket (9 or 19) to the front frame. Tighten the nuts.

Install the two nuts (16 or 24) and washers (15 or 23) that fasten the accumulator bracket (12 or 22) to the front frame. Tighten the nuts.

STEP 151 Refer to Section 8002 Testing the Ride Control and test the ride control system, check for leaks.

STEP 147 STEP 152 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

Install the two nuts (14 or 17) and washers (13 or 18) that fasten the accumulator bracket (9 or 19) to the front frame. Tighten the nuts.

STEP 148

Remove the caps and plugs and install the tubes (4 or 5) to the elbows on the ride control accumulators.

STEP 152 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

8001-30

RIDE CONTROL VALVE Removal

STEP 156

STEP 153 Park the machine on a level surface and apply the parking brake.

STEP 154

With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, then move the loader control lever back and forth several times to release any hydraulic pressure in the pilot control circuit.

STEP 153 Park the machine on a level surface and apply the parking brake.

STEP 154

STEP 157

BD03A092

Raise the loader arms and install the safety link.

STEP 155

STEP 157

BD03A092 BD06A218

Relieve the pressure in the ride control accumulators with the manual bleeder valve located on the side of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

Raise the loader arms and install the safety link.

STEP 155

BD06A218

Relieve the pressure in the ride control accumulators with the manual bleeder valve located on the side of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.

STEP 158

Loosen the filler cap on the hydraulic reservoir to release any pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.

STEP 159

Place the master disconnect switch in the OFF position.

BD06A213

Remove the access cover.

STEP 156

BD06A213

STEP 160 Disconnect the electrical connector from the ride control valve.

Remove the access cover.

STEP 160 Disconnect the electrical connector from the ride control valve.

8001-31

17 18 5

18 5

3 20 4

9 23

8 10

BC06A217

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

BOLT (3) WASHER (3) RIDE CONTROL VALVE RIGHT ACCUMULATOR TUBE LEFT ACCUMULATOR TUBE HOSE TO LEFT CYLINDER HOSE TO RETURN TUBE HOSE TO RIGHT CYLINDER

9. 10. 11. 12. 13. 14. 15. 16.

BRACKET RIGHT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2) WASHER (2) NUT (2)

17. 18. 19. 20. 21. 22. 23. 24.

NUT (2) WASHER (2) BRACKET LEFT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2)

BC06A217

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

BOLT (3) WASHER (3) RIDE CONTROL VALVE RIGHT ACCUMULATOR TUBE LEFT ACCUMULATOR TUBE HOSE TO LEFT CYLINDER HOSE TO RETURN TUBE HOSE TO RIGHT CYLINDER

9. 10. 11. 12. 13. 14. 15. 16.

BRACKET RIGHT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2) WASHER (2) NUT (2)

17. 18. 19. 20. 21. 22. 23. 24.

NUT (2) WASHER (2) BRACKET LEFT ACCUMULATOR U-BOLT BRACKET WASHER (2) NUT (2)

STEP 161

STEP 163

STEP 161

STEP 163

Tag and disconnect the hoses (6, 7, and 8) and tubes (4 and 5) from the ride control valve. Install a plug in the hoses and caps on fittings.

Remove the ride control valve from the machine.

Tag and disconnect the hoses (6, 7, and 8) and tubes (4 and 5) from the ride control valve. Install a plug in the hoses and caps on fittings.

Remove the ride control valve from the machine.

STEP 162 Loosen and remove the three bolts (1) and washers (2) that fasten the ride control valve to the frame.

STEP 164 Remove and discard all O-rings.

STEP 162 Loosen and remove the three bolts (1) and washers (2) that fasten the ride control valve to the frame.

STEP 164 Remove and discard all O-rings.

8001-32

Installation

STEP 174

Installation

STEP 174

STEP 165

Stop the engine and check for hydraulic oil leakage at the ride control valve.

STEP 165

Stop the engine and check for hydraulic oil leakage at the ride control valve.

Install the ride control valve in position on the front frame.

STEP 175

Install the ride control valve in position on the front frame.

STEP 175

STEP 166

Install the washers (2) and bolts (1) through the frame and into the ride control valve. Tighten the bolts.

STEP 167

BD06A213

Install the access cover.

STEP 176

BD06A218

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 168

Lubricate and install new O-rings.

STEP 169 Connect the tubes (4 and 5) and hoses (6, 7, and 8) to the ride control valve.

BD03A092

Raise the loader arms and remove the safety link.

STEP 169 Connect the tubes (4 and 5) and hoses (6, 7, and 8) to the ride control valve.

STEP 177 STEP 170

BD03A092

Raise the loader arms and remove the safety link.

STEP 177 STEP 170

Connect the electrical connector to the ride control valve.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

Connect the electrical connector to the ride control valve.

Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.

STEP 171

STEP 178

STEP 171

STEP 178

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

Refer to Section 8002 and perform the Ride Control Test Procedure.

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

Refer to Section 8002 and perform the Ride Control Test Procedure.

STEP 172

Place the master disconnect switch in the ON position.

STEP 173

Start and run the engine at low idle for two minutes.

8001-33

REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE

1 6

6 5

BC06A214

1. SOLENOIDS 2. OUTLET

3. INLET 4. FAN RETURN

5. FAN SUPPLY 6. FAN VALVE

BC06A214

1. SOLENOIDS 2. OUTLET

3. INLET 4. FAN RETURN

5. FAN SUPPLY 6. FAN VALVE

8001-34

Removal

STEP 185

STEP 179

Tag and disconnect the fan valve outlet hose (2) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

STEP 180 With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, then move the loader control lever back and forth several times to release any hydraulic pressure in the pilot control circuit.

STEP 186 Tag and disconnect the fan valve inlet hose (3) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 187 8 7

STEP 181

Removal

STEP 185

STEP 179

Tag and disconnect the fan valve outlet hose (2) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.

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 182

Disconnect the electrical connector from the solenoids (1) on the fan reversing valve.

STEP 183 Tag and disconnect the fan supply hose (5) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

W270-6R015

8. REAR AXLE TRUNNION MOUNT

Loosen and remove the nuts and washers (7).

STEP 188

STEP 183 Tag and disconnect the fan supply hose (5) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

Remove the fan reversing valve from the machine.

STEP 184 Tag and disconnect the fan return hose (4) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

Tag and disconnect the fan valve inlet hose (3) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 187 8 7

STEP 181

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.

7. NUT AND WASHER

STEP 186

STEP 189 Remove and discard all O-rings from the fittings.

W270-6R015

7. NUT AND WASHER

8. REAR AXLE TRUNNION MOUNT

Loosen and remove the nuts and washers (7).

STEP 188 Remove the fan reversing valve from the machine.

STEP 184 Tag and disconnect the fan return hose (4) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.

STEP 189 Remove and discard all O-rings from the fittings.

8001-35

Installation

STEP 196

STEP 190

Connect the fan supply hose (5) to the fitting on the fan reversing valve.

Lubricate and install new O-rings in the fittings.

STEP 191 Place the fan reversing valve into position on the machine.

STEP 192

STEP 197 Connect the electrical connector to the solenoids (1) on the fan reversing valve.

STEP 198

8001-35

Installation

STEP 196

STEP 190

Connect the fan supply hose (5) to the fitting on the fan reversing valve.

Lubricate and install new O-rings in the fittings.

STEP 191 Place the fan reversing valve into position on the machine.

STEP 197 Connect the electrical connector to the solenoids (1) on the fan reversing valve.

STEP 198

STEP 192

Install the washers and nuts (7). Tighten the nuts.

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

Install the washers and nuts (7). Tighten the nuts.

Turn off the vacuum pump and disconnect from the hydraulic reservoir.

STEP 193

STEP 199

STEP 193

STEP 199

Connect the fan valve inlet hose (3) to the fitting on the fan reversing valve.

Check the level of the hydraulic oil in the reservoir.

Connect the fan valve inlet hose (3) to the fitting on the fan reversing valve.

Check the level of the hydraulic oil in the reservoir.

STEP 194

Start the engine and run the engine at low idle for two minutes.

STEP 194

Start the engine and run the engine at low idle for two minutes.

Connect the fan valve outlet hose (2) to the elbow on the fan reversing valve.

STEP 195 Connect the fan return hose (4) to the fitting on the fan reversing valve.

STEP 200

STEP 201 Stop the engine and check for hydraulic oil leakage at the fan reversing valve.

STEP 202 NOTESCheck the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

Connect the fan valve outlet hose (2) to the elbow on the fan reversing valve.

STEP 195 Connect the fan return hose (4) to the fitting on the fan reversing valve.

STEP 200

STEP 201 Stop the engine and check for hydraulic oil leakage at the fan reversing valve.

STEP 202 NOTESCheck the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.

8001-36

NOTES

HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8002

Section 8002

Section 8002 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

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 PUMP 1 DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Pump 1 Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING PUMP 2 DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Pump 2 Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Cycle of Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 5 5 5 5 6 6 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15 16 16 16 18 18 18 19 20

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 PUMP 1 DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Pump 1 Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING PUMP 2 DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Pump 2 Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Cycle of Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 5 5 5 6 6 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15 16 16 16 18 18 18 19 20

8002-3

SPECIFICATIONS

Manufacturer ....................................................................................................................................... Bosch-Rexroth

Pump 1 (closest to transmission) .....................................................................169.5 L/min at 250 bar, at 2100 r/min (44.8 gpm at 3626 psi, at 2100 r/min)

Pump 2 (furthest from transmission) ................................................................169.5 L/min at 250 bar, at 2100 r/min (44.8 gpm at 3626 psi, at 2100 r/min)

Combined pump flow...........................................................................................339 L/min at 250 bar, at 2100 r/min (89.6 gpm at 3626 psi, at 2100 r/min)

Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)

Circuit relief valve pressure setting Auxiliary A and B port.................................................................................................................290 bar (4200 psi) Bucket A and B port ...................................................................................................................290 bar (4200 psi) Pilot accumulator pressure ............................................................................................13 to 15 bar (188 to 218 psi) Steering relief valve pressure setting ............................................................................................ See Section 5002 Accumulator pressure .................................................................................................................... See Section 7002

NOTE: Both pump sections provide flow for both the steering and loader functions.

8002-4

SPECIAL TOOLS

B877168V

633L95

380001740 FLOWMETER FITTING KIT

380001741 PRESSURE FITTING KIT

B877895M

632L95

380001726 HAND PUMP

380001742 PRESSURE FITTING KIT

380001739 PRESSURE FITTING KIT

380001740 FLOWMETER FITTING KIT

B877895M

632L95

380001726 HAND PUMP

380001742 PRESSURE FITTING KIT

B877558M

B785789M

380001731 FLOWMETER

B877168V

633L95

380001741 PRESSURE FITTING KIT

B877558M

B785789M

380001731 FLOWMETER

380001739 PRESSURE FITTING KIT

8002-5

TROUBLESHOOTING PROCEDURE Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts. Check the oil level in the hydraulic reservoir. Is the oil level correct?.

TROUBLESHOOTING PROCEDURE Visually check the machine for oil leakage and damaged or missing parts. Repair or replace any damaged or missing parts.

Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.

Yes

Check the oil level in the hydraulic reservoir. Is the oil level correct?.

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 2002. Do the stall test to see if the engine is good. No

See Page 15. Do the flow meter test of the hydraulic pump.

Yes

See Section 8003 and check for contaminated oil. Is the oil contaminated?

See Page 15. Do the flow meter test of the hydraulic pump.

Adjust the limit pressure. See page 10 in this section.

Yes

See Section 8003 and clean or replace the oil.

Problem in All Loader Circuits

See Page 10 and check the pressure setting of the limit pressure in the loader control valve. Is the pressure setting correct?

Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.

Yes

Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.

See Section 8003 and check for contaminated oil. Is the oil contaminated?

Adjust the limit pressure. See page 10 in this section.

See Page 10 and check the pressure setting of the limit pressure in the loader control valve. Is the pressure setting correct?

Problem in the Braking Circuit

See Section 7002 and check the braking circuit.

8002-6

Problem in a Single Loader Circuit Start and run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

Problem in a Single Loader Circuit No

The loader control valve is damaged. See Section 8005 and repair the loader control valve

Yes Check the cylinder piston packing. Is the packing good?

See Section 8006 and repair the cylinder.

Check the cylinder piston packing. Is the packing good?

See Section 8005. Disassemble the loader control valve and check for worn or damaged parts.

See Page 18. 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

Problem in the Steering Circuit No

Repair the component as necessary.

Yes

See Section 5002 and check the steering circuit. Is the steering circuit good?

See Page 13. Do the Steering Pump Limit Pressure Test and Adjustment

Problem in the Ride Control

Yes Check the manual bleed valve for the ride control accumulator to be sure that it is closed.

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 19 in this section.

Yes

See Page 13. Do the Steering Pump Limit Pressure Test and Adjustment

Lift arms rapidly and continuously sink towards the ground.

The loader control valve is damaged. See Section 8005 and repair the loader control valve

Yes

See Section 5002 and check the steering circuit. Is the steering circuit good?

Yes

Yes See Page 18. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly?

Start and run the engine at full throttle. Operate the control for the bad circuit. Does the cylinder move in both directions?

See the Ride Control Test Procedure page 19 in this section.

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.

8002-7

TESTING AND ADJUSTING PUMP 1 DIFFERENTIAL PRESSURE Pressure Check

STEP 3 After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and turn key to “RUN” position and operate joystick and relieve the pressure in the hydraulic system and pilot accumulator. Turn ignition switch to OFF.

STEP 1

WARNING: Before doing any maintenance on the hydraulic system, make sure that all hydraulic pressure has been released by operating the control levers several times and the hydraulic reservoir air pressure has been released. Failure to do so could cause serious injury.

CSM120

STEP 4 W270-1R006

1. ARTICULATION LOCK

STEP 4 W270-1R006

1. ARTICULATION LOCK

3 Install articulation lock.

WARNING: Keep clear of this area when engine is running. Machine could pivot unless the transport and service link is in its LOCKED position. After servicing is completed, unlock the transport and service link and secure in place on the rear frame.

3 Install articulation lock. WARNING: Keep clear of this area when engine is running. Machine could pivot unless the transport and service link is in its LOCKED position. After servicing is completed, unlock the transport and service link and secure in place on the rear frame.

7 6 5

SA069

7 6 5

SA069 BS06N368

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

To heat the hydraulic oil do the following: A. Apply the service brake. B. Start the engine and run at high idle. C. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height. D. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

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

PUMP 2 LOAD SENSE PRESSURE TAP PUMP 1 LOAD SENSE PRESSURE TAP PUMP 1 LOAD SENSE PRESSURE ADJUSTMENT PUMP 1 MAIN LINE PRESSURE TAP (G1) STEERING PRIORITY VALVE PUMP 2 MAIN LINE PRESSURE TAP (G2) STEERING RELIEF PRESSURE ADJUSTMENT PUMP 2 LOAD SENSE PRESSURE ADJUSTMENT

Connect two 69 bar (1000 psi) test gauges. One to pump 1 main line pressure tap G1 (4) on the bottom left face of the priority valve. And the other to pump 1 load sense pressure tap (2) on the top of the pump closest to the transmission. IMPORTANT: Do not steer or operate loader controls while the gauges are connected, gauges could be damaged.

STEP 5 Start the engine and run at low idle.

BS06N368

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

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

STEP 5 Start the engine and run at low idle.

8002-8

STEP 6 Make sure all of the controls are in the neutral position and record the readings on the test gauges located on test ports (2) and (4).

8002-8

Adjusting Pump 1 Differential Pressure

STEP 6 Make sure all of the controls are in the neutral position and record the readings on the test gauges located on test ports (2) and (4).

STEP 10

STEP 7

Subtract the reading of the test port (2) from the reading of the test port (4).

Adjusting Pump 1 Differential Pressure STEP 10

STEP 7

2 3

Subtract the reading of the test port (2) from the reading of the test port (4).

8 STEP 8

The difference between the two readings should be 28 to 31bar (405 to 450 psi).

If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

STEP 9

4 BS06N368

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

The difference between the two readings should be 28 to 31bar (405 to 450 psi).

STEP 9

If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

4 BS06N368

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

The load-sense adjusting screw (3) is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the load-sense pressure.

NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

8002-9

TESTING AND ADJUSTING PUMP 2 DIFFERENTIAL PRESSURE Pressure Check

STEP 1

CSM120

STEP 4 W270-1R006

1. ARTICULATION LOCK

STEP 4 W270-1R006

1. ARTICULATION LOCK

3 Install articulation lock.

7 6 5

SA069

7 6 5

SA069 BS06N368

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

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

Connect two 69 bar (1000 psi) test gauges. One to pump 2 main line pressure tap G2 (6) on the top left face of the priority valve. And the other to pump 2 load sense pressure tap (1) on the top of the pump furthest from the transmission. IMPORTANT: Do not steer or operate loader controls while the gauges are connected, gauges could be damaged.

STEP 5 Start the engine and run at low idle.

BS06N368

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

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

STEP 5 Start the engine and run at low idle.

8002-10

STEP 6 Make sure all of the controls are in the neutral position and record the readings on the test gauges located on test ports (1) and (6).

8002-10

Adjusting Pump 2 Differential Pressure

STEP 6 Make sure all of the controls are in the neutral position and record the readings on the test gauges located on test ports (1) and (6).

STEP 10

STEP 7

Subtract the reading of the test port (1) from the reading of the test port (6).

Adjusting Pump 2 Differential Pressure STEP 10

STEP 7

2 3

Subtract the reading of the test port (1) from the reading of the test port (6).

8 STEP 8

The difference between the two readings should be 27 to 30 bar (391 to 435 psi).

If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

STEP 9

4 BS06N368

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

The difference between the two readings should be 27 to 30 bar (391 to 435 psi).

STEP 9

If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.

4 BS06N368

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

The load-sense adjusting screw (8) is directly below the load-sense pressure tap. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the load-sense pressure.

NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).

8002-11

TESTING AND ADJUSTING THE LOADER RELIEF PRESSURE Pressure Check

STEP 1

CSM120

STEP 4 W270-1R006

1. ARTICULATION LOCK

STEP 4 W270-1R006

1. ARTICULATION LOCK

3 Install articulation lock.

8 7

6 5

SA069

6 5

SA069 BS06N368

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

To heat the hydraulic oil do the following:

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

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. Apply the service brake. B. Start the engine and run at high idle. C. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on.

NOTE: Make sure that the differential pressures are correct for the pump 1 and pump 2 prior to proceeding. Connect a 345 bar (5000 psi) test gauge to pump 1 main line pressure tap G1 (4).

D. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

BS06N368

STEP 2

●

To heat the hydraulic oil do the following:

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

NOTE: Make sure that the differential pressures are correct for the pump 1 and pump 2 prior to proceeding.

A. Apply the service brake.

Connect a 345 bar (5000 psi) test gauge to pump 1 main line pressure tap G1 (4).

STEP 5

B. Start the engine and run at high idle.

STEP 5

Start the engine and run at high idle.

C. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

Start the engine and run at high idle.

STEP 6 Roll the loader bucket back against the stops (or fully retract the bucket cylinder if the if the unit does not have a bucket) and maintain this position.

D. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

STEP 6 Roll the loader bucket back against the stops (or fully retract the bucket cylinder if the if the unit does not have a bucket) and maintain this position.

8002-12

STEP 7 Record the reading on the test gauge.

8002-12

Adjusting the Loader Limit Pressure

STEP 7 Record the reading on the test gauge.

STEP 8

Reading should be 248 to 255 bar (3595 to 3700 psi).

STEP 9

If this reading is more or less than specified, it will be necessary to adjust the loader relief pressure.

Adjusting the Loader Limit Pressure

BS06H193

STEP 10

Turn the screw (1) clockwise to increase the loader relief. Turning the screw counterclockwise will decrease the loader relief pressure.

NOTE: 1/4 turn of the adjustment screw will change the pressure approximately 35 bar (500 psi).

8002-13

TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE Pressure Check

STEP 1

CSM120

STEP 4 W270-1R006

1. ARTICULATION LOCK

STEP 4 W270-1R006

1. ARTICULATION LOCK

3 Install articulation lock.

7 6 5

SA069

7 6 5

SA069 BS06N368

STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

To heat the hydraulic oil do the following: A. Apply the service brake.

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

BS06N368

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. ●

B. Start the engine and run at high idle.

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on.

NOTE: Make sure that the differential pressures are correct for the pump 1 and pump 2 prior to proceeding. Connect a 345 bar (5000 psi) test gauge to pump 1 main line pressure tap G1 (4), located on the bottom left of the priority valve.

To measure the instrument cluster:

●

To heat the hydraulic oil do the following: A. Apply the service brake.

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

B. Start the engine and run at high idle.

C. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

STEP 5

D. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

Steer hard in either direction over relief pressure. Maintain this position.

Start the engine and run at high idle.

STEP 6

C. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

STEP 5

D. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

Steer hard in either direction over relief pressure. Maintain this position.

Start the engine and run at high idle.

STEP 6

8002-14

STEP 7 Record the reading on the test gauge.

8002-14

Adjusting the Steering Limit Pressure

STEP 8

Reading should be 239 to 243 bar (3465 to 3525 psi).

STEP 7 Record the reading on the test gauge.

Adjusting the Steering Limit Pressure

STEP 8

Reading should be 239 to 243 bar (3465 to 3525 psi).

3 STEP 9 If this reading is more or less than specified, it will be necessary to adjust the steering limit pressure.

STEP 9

If this reading is more or less than specified, it will be necessary to adjust the steering limit pressure.

6 5

BS06N368

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

BS06N368

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

STEP 10

The steering priority valve is located on the hydraulic pump closest to transmission, 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.

8002-15

TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE NOTE: This pressure is factory preset and is not adjustable.

Pressure Check Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

Open the right side compartment to gain access to the loader control handle.

STEP 7

STEP 1

●

STEP 6

To heat the hydraulic oil do the following: A. Start the engine and run at full throttle. B. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height. C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

Attach a gauge capable of reading 70 bar (1000 psi) to the test port under loader control handle.

STEP 8 Start and run the machine at low idle, hold the bucket control lever in the ROLLBACK position to increase the system pressure.

TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE NOTE: This pressure is factory preset and is not adjustable.

Pressure Check 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.

STEP 10 Lower the bucket to the ground and turn off the engine. Turn the ignition switch to the “RUN” position.

STEP 11

STEP 3

Operate the pilot controls several times until the gauge pressure suddenly drops to zero. The last pressure reading before the drop to zero is the nitrogen charge pressure in the accumulator. If the pressure is below 13 to 15 bar (188 to 218 psi), replace the accumulator. If accumulator test is good, go to next step.

Repeatedly put the loader control lever into “FLOAT” position and back to neutral.

STEP 12

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on.

STEP 9 A pressure reading of 29 to 40 bar (420 to 580 psi) should be obtained, if pressure is not as specified do the following steps.

To measure the instrument cluster:

●

Open the right side compartment to gain access to the loader control handle.

STEP 7

STEP 1

●

STEP 6

Attach a gauge capable of reading 70 bar (1000 psi) to the test port under loader control handle.

STEP 8 Start and run the machine at low idle, hold the bucket control lever in the ROLLBACK position to increase the system pressure.

STEP 9 A pressure reading of 29 to 40 bar (420 to 580 psi) should be obtained, if pressure is not as specified do the following steps.

STEP 10 Lower the bucket to the ground and turn off the engine. Turn the ignition switch to the “RUN” position.

STEP 11

STEP 3

Repeatedly put the loader control lever into “FLOAT” position and back to neutral.

STEP 12

STEP 4

Replace the pilot controls, see section 8001, retest the system, if test fails go to next step.

STEP 4

Replace the pilot controls, see section 8001, retest the system, if test fails go to next step.

The system should allow a minimum of 10 actuations into float and still cause the lift arms to come down.

STEP 13

The system should allow a minimum of 10 actuations into float and still cause the lift arms to come down.

STEP 13

STEP 2 Raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position.

NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists, proceed to next step.

Replace the loader control valve, see section 8001, retest the system.

STEP 2 Raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position.

NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists, proceed to next step.

STEP 5

Start machine and lower the bucket to the ground and turn off the engine. Turn the ignition switch to the “RUN” position, operate the pilots controls a minimum of 30 strokes to relieve any pressure in the system.

Replace the loader control valve, see section 8001, retest the system.

8002-16

PUMP FLOW TEST Timing Cycle of Loader

STEP 2

NOTE: If you perform a cycle time test on the loader and it meets specifications you do not need to do the pump flow test.

NOTE: This is the line that returns to the pump compensator valve.

STEP 1 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on. ●

Disconnect the load sense hose (7) and install a cap on the fitting at the loader valve (14) for the load sense hose fitting (not shown).

STEP 3 Connect a “T” fitting (10) into the loader control valve inlet hose (6) and to the flow meter inlet hose (11).

PUMP FLOW TEST Timing Cycle of Loader NOTE: If you perform a cycle time test on the loader and it meets specifications you do not need to do the pump flow test.

Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. ●

To measure the instrument cluster:

oil

temperature

with

the

A. Press the down arrow key until the info screen with temperatures that need to be monitored are on.

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). ●

Disconnect the load sense hose (7) and install a cap on the fitting at the loader valve (14) for the load sense hose fitting (not shown). NOTE: This is the line that returns to the pump compensator valve.

STEP 1

STEP 4

To heat the hydraulic oil do the following:

STEP 2

STEP 3 Connect a “T” fitting (10) into the loader control valve inlet hose (6) and to the flow meter inlet hose (11).

STEP 4 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).

To heat the hydraulic oil do the following:

A. Start the engine and run at full throttle.

STEP 5

A. Start the engine and run at full throttle.

STEP 5

B. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

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.

B. Hold the bucket control lever in the ROLLBACK position while raising and lowering the lift arms from ground level to full height.

C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

STEP 6

C. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 135°F).

STEP 6

STEP 2 Start engine and run at high idle, with bucket empty and rolled back on the ground (to get the cylinders all the way down). raise to full height.

STEP 3 Specification for loader cycle time from ground to full height is 7 seconds. Anything over 7 seconds indicates a problem and pump flow test should be performed.

Pump Flow Test NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 7 of this section.

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

Start engine and run at high idle, with bucket empty and rolled back on the ground (to get the cylinders all the way down). raise to full height.

Run the engine at low idle, fully open the flow meter valve.

STEP 3

STEP 8 Open the needle valve (8) and operate the engine at 2100 rpm. At 0 bar (0 psi) the flow should be 352 to 362 L/min (93.0 to 95.6 gpm).

STEP 9 Close the flow meter valve slowly and read the flow at 34.5 bar (500 psi) @ 2100 rpm. The flow should be 348 to 358 L/min (91.9 to 94.6 gpm).

STEP 1 Connect the flow meter (3) by disconnecting the inlet hose (6) from connector (13), install a cap on the connector (13). Refer to illustration on page 17.

STEP 2

Specification for loader cycle time from ground to full height is 7 seconds. Anything over 7 seconds indicates a problem and pump flow test should be performed.

Pump Flow Test NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 7 of this section.

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 2100 rpm. At 0 bar (0 psi) the flow should be 352 to 362 L/min (93.0 to 95.6 gpm).

STEP 9 Close the flow meter valve slowly and read the flow at 34.5 bar (500 psi) @ 2100 rpm. The flow should be 348 to 358 L/min (91.9 to 94.6 gpm).

STEP 1 STEP 10 Close the flow meter valve slowly and read the flow at 3600 psi @ 2100 rpm. The flow should read 334 to 344 L/min (88.2 to 90.9 gpm).

Connect the flow meter (3) by disconnecting the inlet hose (6) from connector (13), install a cap on the connector (13). Refer to illustration on page 17.

STEP 10 Close the flow meter valve slowly and read the flow at 3600 psi @ 2100 rpm. The flow should read 334 to 344 L/min (88.2 to 90.9 gpm).

STEP 11

If any of the pump flow readings are not within specifications, the pump may be out of calibration and Technical Support Services should be contacted.

8002-17

See note

8002-17

See note

11 5

3 6

6 12

14 8

BS06N556

1. 2. 3. 4. 5.

HYDRAULIC RETURN MANIFOLD FLOW METER RETURN HOSE FLOW METER PUMP PRIORITY VALVE

6. 7. 8. 9. 10.

HOSE LOAD SENSE HOSE M14 ORB NEEDLE VALVE UNION T FITTING

11. 12. 13. 14.

FLOW METER INLET HOSE CAP CONNECTOR STR THD 30 MM ORFS X M42 ORB LOADER VALVE

NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.

BS06N556

1. 2. 3. 4. 5.

HYDRAULIC RETURN MANIFOLD FLOW METER RETURN HOSE FLOW METER PUMP PRIORITY VALVE

6. 7. 8. 9. 10.

HOSE LOAD SENSE HOSE M14 ORB NEEDLE VALVE UNION T FITTING

11. 12. 13. 14.

FLOW METER INLET HOSE CAP CONNECTOR STR THD 30 MM ORFS X M42 ORB LOADER VALVE

NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.

8002-18

TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Pressure Check

STEP 4

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.

STEP 1

Remove the safety strut and lower the bucket to the floor. Shut off the engine. Find an easy place to disconnect the line for the circuit to be tested.

Circuit relief valves are located as shown below.

STEP 5

4 1

1 4

Connect the hand pump to the disconnected line that goes to the loader control valve.

STEP 5

4 1

CIRCUIT RELIEF VALVES PUMP LIMIT PRESSURE ADJUSTMENT BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL LOADER CONTROL VALVE

STEP 2 Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 3 Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

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 21째C (70째F).

STEP 7

Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 8

Compare the reading to the specifications on Page 3.

STEP 9

1 3

Adjustment

If the pressure is not correct, adjust the circuit relief valve.

1 4

BS03B022

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

STEP 6

If the pressure is not correct, adjust the circuit relief valve.

1 3

Circuit relief valves are located as shown below.

Adjustment

BS03B022

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.

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

CIRCUIT RELIEF VALVES PUMP LIMIT PRESSURE ADJUSTMENT BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL LOADER CONTROL VALVE

STEP 1

Raise the lift arms and install the safety link on the lift arm cylinder.

STEP 2

STEP 3 Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.

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).

Check the pressure again. Repeat the adjustment as necessary.

8002-19

TESTING THE RIDE CONTROL

STEP 1

STEP 6

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.

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

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.

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 5

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 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.

Raise the lift arms to the top of their travel and dump the bucket.

NOTE: If test was done to slowly repeat in the allotted time.

Raise the lift arms to the top of their travel and dump the bucket.

NOTE: If test was done to slowly repeat in the allotted time.

NOTE: Keep rocker switch in the “Off” position during this steps 5, 6, 7.

STEP 10

NOTE: Keep rocker switch in the “Off” position during this steps 5, 6, 7.

STEP 10

If test was completed in the allotted time and the lift arms still do not rise, test the nitrogen charge in the accumulator, see section 8013.

8002-20

HYDRAULIC COMPONENT LOCATIONS

3 8

PILOT CONTROL VALVE PILOT PRESSURE DIAGNOSTIC COUPLER BRAKE LIGHT PRESSURE SWITCH BRAKE WARNING PRESSURE SWITCH BUCKET CYLINDER (TILT CYLINDER) PILOT PRESSURE ACCUMULATOR LOADER CONTROL VALVE LIFT CYLINDER RIDE CONTROL ACCUMULATOR FRONT BRAKE CYLINDER RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND RIDE CONTROL VALVE (OPTIONAL) 12. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC COUPLERS

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

STEERING CYLINDER BRAKE ACCUMULATORS BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER PARKING BRAKE CYLINDER STEERING PRESSURE DIAGNOSTIC COUPLER STEERING PRIORITY VALVE AUXILIARY STEERING PRESSURE SWITCH REAR BRAKE CYLINDER FAN VALVE AUXILIARY STEERING PUMP AND MOTOR HYDRAULIC COOLER

24. FAN DRIVE MOTOR

7 8

W270-6R017

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

W270-6R017

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

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

24. FAN DRIVE MOTOR

8002-21

41 40 39 38 35 33 32 36 34

30 29

41 40 39 38 35 33 32 36 34

30 29

37 W270-6R018

25. 26. 27. 28. 29. 30. 31. 32. 33.

RIDE CONTROL ACCUMULATOR LIFT CYLINDER HYDRAULIC RESERVOIR BREATHER HYDRAULIC RESERVOIR HYDRAULIC COOLER AUXILIARY STEERING PUMP AND MOTOR REAR BRAKE CYLINDER BRAKE HYDRAULIC PUMP AUXILIARY STEERING PRIORITY VALVE

34. 35. 36. 37. 38. 39. 40. 41. 42.

AUXILIARY STEERING PRESSURE SWITCH PUMP PRESSURE DIAGNOSTIC COUPLER LOAD SENSING DIAGNOSTIC COUPLER IMPLEMENT HYDRAULIC PUMP HYDRAULIC FILTER STEERING CYLINDER PARKING BRAKE ACCUMULATOR BRAKE AND ACCUMULATOR CHARGING VALVE FRONT BRAKE CYLINDER

W270-6R018

25. 26. 27. 28. 29. 30. 31. 32. 33.

34. 35. 36. 37. 38. 39. 40. 41. 42.

8002-22

NOTES

CLEANING THE HYDRAULIC SYSTEM

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8003

Section 8003

8003

Section 8003

CLEANING THE HYDRAULIC SYSTEM

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8003-2

TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 4 5 7

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5 7

8003-3

SPECIAL TOOLS

806128

380001733, fitting kit.

806127

380001727, filter unit, portable.

806127

380001727, filter unit, portable.

TR98H032

380001728, vacuum pump.

TR98H032

380001728, vacuum pump.

8003-4

GENERAL INFORMATION Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1. When you drain the oil or disconnect any line.

1. Cylinder rod seals leak. 2. Control valve spools do not return to neutral. 3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot.

2. When you disassemble a component.

5. Pump gears, housing, and other parts wear rapidly.

3. From normal wear of the hydraulic components. 4. From damaged or worn seals. 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.

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: A. Cylinder rod seal leak. B. Control valve NEUTRAL.

spools

not

return

C. The hydraulic system has a high operating temperature.

3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot. 5. Pump gears, housing, and other parts wear rapidly.

6. Relief valves or check valves held open by dirt.

3. From normal wear of the hydraulic components.

6. Relief valves or check valves held open by dirt.

7. Quick failure of components that have been repaired.

4. From damaged or worn seals.

7. Quick failure of components that have been repaired.

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.

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.

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.

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: A. Cylinder rod seal leak.

2. Control valve spools do not return to neutral.

2. When you disassemble a component.

TYPES OF CONTAMINATION There are two types of contamination, microscopic and visible.

1. Cylinder rod seals leak.

B. Control valve NEUTRAL.

spools

not

return

C. The hydraulic system has a high operating temperature.

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:

8003-5

CLEANING THE HYDRAULIC SYSTEM

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:

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:

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.

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.

B. Do steps 5 through 35.

B. Return the blade control lever NEUTRAL position for five seconds.

5. Check the amount of contamination in the hydraulic system by doing the following steps: A. Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. B. If, in your judgment, the damage to the cylinders was caused by sever contamination and is not the result of normal wear, it is necessary to remove, clean and repair valves, pump, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Remove the breather from the reservoir and connect the vacuum pump to the opening. Start the vacuum pump. 7. Loosen and remove the drain plug from the reservoir.

the

C. Repeat steps A and B until the oil in the hydraulic system is at operating temperature. 17. Continue to run the engine at full throttle. Continue to run the portable filter. 18. Operate each hydraulic circuit to completely extend and retract the cylinders. Continue to operate each hydraulic circuit two times, one after the other for 45 minutes. 19. Decrease the engine speed to low idle. 20. Continue to run the portable filter for 10 minutes. 21. Stop the portable filter. 22. Stop the engine. 23. Remove the hose from the hydraulic reservoir.

the

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.

8003-6 30. Stop the vacuum pump. Disconnect the vacuum pump from the opening in the reservoir and install the breather.

24. Close the valve that is installed in the hole for the drain plug.

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.

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.

26. Connect a vacuum pump to the breather hose of the hydraulic reservoir.

32. Install new hydraulic filter elements on 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.

27. Start the vacuum pump.

33. Start the engine. Check for oil leakage around the new hydraulic filters.

28. Remove the valve from the hole for the drain plug. 29. Install the drain plug.

34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

28. Remove the valve from the hole for the drain plug. 29. Install the drain plug.

31. Remove the hydraulic filter elements from the machine.

34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

8003-7

FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1. Start and run the engine at 1500 rpm (r/min). 2. Completely retract the cylinders of all attachments on the machine. Angle the blade to the right, the right cylinder will be fully retracted and the left will be fully extended. Stop the engine. WARNING: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before proceeding to the next step! 39-4

13. Slowly move each control lever in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 14. Stop the engine. 15. Connect the system line to the CLOSED end of each cylinder. 16. Connect a suitable drain line to the OPEN end of each cylinder and place the other end in an acceptable container for contaminated oil.

8003-7

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

39-4

NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

10. Disconnect the line from the OPEN end and CLOSED end of each cylinder. 11. Be sure all control levers are in the NEUTRAL position.

12. Start and run the engine at low idle.

IMPORTANT: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13.

27. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.

8003-8

NOTES

HYDRAULIC PUMP

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8004

Section 8004 8004

Section 8004

HYDRAULIC PUMP

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8004-2

TABLE OF CONTENTS PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 4 5 9 11

PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 9 11

8004-3

PUMP SPECIFICATIONS

Manufacturer .................................................................................................................................................. Rexroth

High pressure pump (steering pump next to transmission) .............170 L/min at 20 680 kPa, 207 bar, at 2000 r/min (44.6 U.S. gpm at 3000 psi at 2000rpm)

Low pressure pump output ..............................................................170 L/min at 20 680 kPa, 170 bar, at 2000 r/min (44.5 U.S. gpm at 3000 psi at 2000rpm)

Rotation ................................................................................................. Clockwise as seen from the end of the shaft

Special torques Pump end cover bolts ..................................................................................................165 Nm (121.5 pound-feet) Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet) Control piston plug ..............................................................................................................90 Nm (66 pound-feet)

PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new or overhauled equipment pump: 1. Start and run the engine at half throttle for three minutes. 2. With the engine running at half throttle, move the bucket control lever into roll back position. Hold the bucket control lever in this position until the bucket stops moving. 3. Hold the bucket control lever in the roll back position for five seconds. Then put the bucket control lever in the NEUTRAL position for five seconds.

4. Repeat Step 3 for three minutes. 5. Increase the engine speed to full throttle and repeat Steps 3 and 4. 6. Stop the engine and check for leaks. 7. Replace the hydraulic filter.

8004-4

EQUIPMENT PUMP 7

3 10

12 13 21

11 12

13 21

20 19

29 15 26

29 15

BC06F550

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SNAP RING SEAL MAIN BODY O-RING PLUG CONTROL VALVE CAP SCREW PISTON ROD CONTROL PISTON SHAFT

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

TAPERED BEARING BEARING RACE SHIM SPRING HALF BEARING SWASH PLATE PISTONS RETAINING PLATE BALL CYLINDER

21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

PRESSURE PINS BACKUP PLATE SPRING SNAP RING PORT PLATE SHIM TAPERED BEARING BEARING RACE DOWEL PIN END COVER

BC06F550

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SNAP RING SEAL MAIN BODY O-RING PLUG CONTROL VALVE CAP SCREW PISTON ROD CONTROL PISTON SHAFT

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

TAPERED BEARING BEARING RACE SHIM SPRING HALF BEARING SWASH PLATE PISTONS RETAINING PLATE BALL CYLINDER

21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

PRESSURE PINS BACKUP PLATE SPRING SNAP RING PORT PLATE SHIM TAPERED BEARING BEARING RACE DOWEL PIN END COVER

8004-5

Disassembly

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.

BC06F553

Remove the four bolts.

8004-6

STEP 5

STEP 6

BC06F555

BC06F554

Remove the end cover. NOTE: Watch for the flow plate, it can be stuck to either the end cover or pump body.

STEP 5

Use a suitable bearing race puller and pull the bearing race from the end cover. NOTE: Do not damage the sealing surfaces.

STEP 6

BC06F555

BC06F554

Remove the end cover. NOTE: Watch for the flow plate, it can be stuck to either the end cover or pump body.

Use a suitable bearing race puller and pull the bearing race from the end cover. NOTE: Do not damage the sealing surfaces.

8004-7

STEP 7

STEP 9

8004-7

STEP 7

STEP 9

BC06F558

Remove plug, pull control piston using a suitable tool as shown.

NOTE: Do not use a magnet to pull the piston.

STEP 10

BC06F556

Remove the bearing and shim.

STEP 8

BC06F559

Remove the piston rod and swash plate. Turn the swash plate slightly to break it free from the bearings.

BC06F557

Remove the rotary group from the housing in a horizontal position.

8004-8

STEP 11

STEP 14

STEP 11

BC06F560

STEP 14

BC06F560

Remove the bearing and spring.

STEP 12

STEP 12 BC06F563

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.

BC06F562

Remove the retaining ring an seal.

8004-9

Inspection

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.

8004-10

STEP 22

STEP 24

BC06F570

Check the cylinder bores and splines for damage.

STEP 23

STEP 22

BC06F572

Check cylinder surface for grooves, wear, embedded particles. Check flow plate for scratches or wear.

BC06F570

Check the cylinder bores and splines for damage.

STEP 23

STEP 25

BC06F571

Check ball for grooves and wear.

STEP 24

BC06F572

Check cylinder surface for grooves, wear, embedded particles. Check flow plate for scratches or wear.

STEP 25

BC06F571 BC06F573

Check mounting surface for the flow plate for damage.

Check ball for grooves and wear.

BC06F573

Check mounting surface for the flow plate for damage.

8004-11

Assembly

8004-11

Assembly

STEP 27

STEP 26

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

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.

BC06F576

Press in a new race into the end cover.

8004-12

STEP 29

STEP 31

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.

8004-13

STEP 33

STEP 34

8004-13

STEP 33

STEP 34

BC06F582

Install the piston into the housing with flat surface out. Lubricate the O-ring and install the plug, tighten the plug to 90 Nm (66 pound-feet).

STEP 35

BC06F581

Install the swash plate into the housing, work the swash plate from side to side to seat it in the bearings and spring. Install the piston rod.

BC06F583

Use grease to hold the pressure pins into position, install the spacer, spring and snap ring.

8004-14

STEP 36

STEP 39

STEP 36

STEP 39

BC06F584

Use a suitable compressor, compress the spring and install the snap ring.

STEP 37

BC06F585

BC06F587

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.

Place the ball onto the pressure pins, install the pistons into the retaining plate.

Hold the pistons in the rotating housing using an O-ring, install the rotating group into the housing, remove the O-ring.

STEP 38

BC06F586

Lubricate the piston and retaining plate with clean oil, install the piston into the rotating housing.

8004-15

STEP 40

STEP 41

8004-15

STEP 40

STEP 41

BC06F588

Use the shim that was required for the bearing pre load in step 30. Install the shim and bearing onto the shaft.

BC06F589

Install a new O-ring on the end cover, place the flow plate onto the rotating group with aligning notch up. Place the end cover onto the housing, make sure that the aligning pin in the end cover aligns with the slot in the flow plate.

8004-16

STEP 42

STEP 43

STEP 42

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).

STEP 43

BC06F590

Instal and tighten the four bolts to 165 Nm (121.5 pound-feet).

LOADER CONTROL VALVE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8005

Section 8005

8005

Section 8005

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8005-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 5 6 7 8 9 14 14 18 18

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6 7 8 9 14 14 18 18

8005-3

SPECIFICATIONS

Manufacturer .................................................................................................................................................. Rexroth

Special Torques End plate mounting bolts..................................................................................................70 Nm (51.5 pound feet) Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound inches) Allen head plugs..............................................................................................................240 Nm (177 pound feet) Allen head locking screw................................................................................................100 Nm (73.7 pound feet) Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches) Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches) Anticavitation valves.......................................................................................................100 Nm (73.7 pound feet) Combination anticavitation and circuit relief .................................................................200 Nm (147.5 pound feet)

8005-4

4 2

22 10

10 16

8 9

13 10

10 14

15 17

W270-6R013

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

HOUSING PLATE BOLT WASHER NOT USED NOT USED

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

NOT USED PRESSURE RELIEF VALVE FLOW LIMIT VALVE O-RINGS LOCKING SCREW SPRING

13. 14. 15. 16. 17. 18.

CONE REGENERATION CHECK VALVE LOCKING SCREW LOAD SENSE SHUTTLE CHEK LOCKING SCREW NOT USED

19. 20. 21. 22.

2 SPOOL VALVE HOUSING CONFIGURATION

ANTICAVITATION AND CIRCUIT RELIEF PILOT PRESSURE REDUCING VALVE ANTICAVITATION AND CIRCUIT RELIEF ANTICAVITATION VALVE

W270-6R013

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

HOUSING PLATE BOLT WASHER NOT USED NOT USED

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

NOT USED PRESSURE RELIEF VALVE FLOW LIMIT VALVE O-RINGS LOCKING SCREW SPRING

13. 14. 15. 16. 17. 18.

CONE REGENERATION CHECK VALVE LOCKING SCREW LOAD SENSE SHUTTLE CHEK LOCKING SCREW NOT USED

19. 20. 21. 22.

2 SPOOL VALVE HOUSING CONFIGURATION

ANTICAVITATION AND CIRCUIT RELIEF PILOT PRESSURE REDUCING VALVE ANTICAVITATION AND CIRCUIT RELIEF ANTICAVITATION VALVE

8005-5

24 10

10 10

28 30

32 31

29 25

32 30

W270-6R014

23. 24. 25. 26.

COVER BOLT PISTON JAM NUT

27. 28. 29. 30.

CAP NUT BOLT COVER ADJUSTING ROD

31. SPRING RETAINER 32. SPRING 33. SPOOL

2 SPOOL VALVE SPOOL CONFIGURATION

W270-6R014

23. 24. 25. 26.

COVER BOLT PISTON JAM NUT

27. 28. 29. 30.

CAP NUT BOLT COVER ADJUSTING ROD

31. SPRING RETAINER 32. SPRING 33. SPOOL

2 SPOOL VALVE SPOOL CONFIGURATION

8005-6

35 BS03C036

34. HOUSING

35. ANTICAVITATION AND CIRCUIT RELIEF 3 SPOOL MOUNTING CONFIGURATION

BS03C036

34. HOUSING

35. ANTICAVITATION AND CIRCUIT RELIEF 3 SPOOL MOUNTING CONFIGURATION

8005-7

36 4

BS03C035

36. NUT

37. STUD

4 SPOOL MOUNTING CONFIGURATION

BS03C035

36. NUT

37. STUD

4 SPOOL MOUNTING CONFIGURATION

8005-8

26 29 10

31 28

31 32

10 30

32 31

31 32

BS03C037

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION

BS03C037

3 AND 4 SPOOL VALVE SPOOL CONFIGURATION

8005-9

DISSASEMBLY

STEP 1

STEP 6

STEP 1

STEP 6

Remove valve from machine, see section 8001.

Remove pressure relief valve (8).

Remove valve from machine, see section 8001.

Remove pressure relief valve (8).

STEP 2

STEP 7

STEP 2

STEP 7

Remove bolts (24), cover (23), spring retainers (31), and spring (32).

Remove flow limit valve (9).

Remove bolts (24), cover (23), spring retainers (31), and spring (32).

Remove flow limit valve (9).

STEP 8 STEP 3 Remove bolts (28), covers (29), spring retainers (31), and springs (32).

Remove locking screw (11), spring (12), and cone (13).

STEP 8 STEP 3 Remove bolts (28), covers (29), spring retainers (31), and springs (32).

STEP 9 STEP 4 Use wooden dowel or brass drift and push spools (33) from housing (1).

Remove regeneration check valve (14).

STEP 10

Use wooden dowel or brass drift and push spools (33) from housing (1).

STEP 10

Remove locking screw (15).

NOTE: Repeat steps 3 and 4 for 3 and 4 spool valve configuration.

Remove load sense shuttle check valve (16).

STEP 5

Remove locking screws (17).

NOTE: Repeat step for 3 and 4 spool anticavitation valves (35).

STEP 9 STEP 4

IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.

Remove anticavitation valves (19, 21, and 22).

Remove locking screw (11), spring (12), and cone (13).

STEP 11 STEP 12 STEP 13 Remove pilot pressure reducing valve (20).

IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.

Remove locking screw (15).

NOTE: Repeat steps 3 and 4 for 3 and 4 spool valve configuration.

Remove load sense shuttle check valve (16).

STEP 5

Remove locking screws (17).

Remove anticavitation valves (19, 21, and 22). NOTE: Repeat step for 3 and 4 spool anticavitation valves (35).

STEP 11 STEP 12 STEP 13 Remove pilot pressure reducing valve (20).

STEP 14

Remove bolts (3) and washers (4), remove plate (2) from housing (1).

NOTE: For 4 spool configuration remove nut (36) from stud (37), remove housings (34) from housing (1).

8005-10

STEP 15

STEP 17

STEP 15

STEP 17

2 1

BS03C027

2. THRUST RINGS

1. O-RINGS

Remove and discard O-rings and thrust rings from pilot pressure reducing valve (20).

BS03C025

1. O-RINGS

BS03C025

2. THRUST RING

1. O-RINGS

Remove and discard O-rings and thrust ring from locking screw (15).

STEP 16

BS03C027

2. THRUST RINGS

1. O-RINGS

Remove and discard O-rings and thrust rings from pilot pressure reducing valve (20).

2. THRUST RING

Remove and discard O-rings and thrust ring from locking screw (15).

STEP 16 STEP 18

STEP 18

2 1

1 1

2 BS03C028

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Remove and discard O-rings, thrust ring, and spool seal from anticavitation valve (22).

1. O-RINGS

BS03C026

2. THRUST RINGS

Remove and discard O-rings and thrust rings from flow limit valve (9).

BS03C026

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from flow limit valve (9).

BS03C028

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

Remove and discard O-rings, thrust ring, and spool seal from anticavitation valve (22).

8005-11

STEP 19

8005-11

STEP 19

1 2

2 BS03C029

1. O-RINGS

BS03C029

2. THRUST RINGS

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (8).

STEP 20

STEP 20 1

1 1

1 2

1 BS03C030

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (19).

BS03C030

1. O-RINGS

2. THRUST RINGS

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (19).

8005-12

STEP 21

STEP 21 1

BS03C031

1. O-RINGS

2. COIL

Remove and discard O-rings and thrust rings from anticavitation valve (18).

BS03C031

1. O-RINGS

2. COIL

Remove and discard O-rings and thrust rings from anticavitation valve (18).

8005-13

STEP 22

8005-13

STEP 22

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 (21 and 35).

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 (21 and 35).

8005-14

INSPECTION 1. Discard all O-rings, thrust rings, and spool seals. 2. Clean all parts in cleaning solvent. 3. Check the spools and the spool bores for damage and wear.

INSPECTION

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.

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.

ASSEMBLY

STEP 1

A 2

See Note

BS03C032

1. O-RINGS

2. THRUST RING

3. SPOOL SEAL

4. LOCK NUT

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 (21 and 35). Torque relief valve (A) into anticavitation valve to 200 Nm (147.5 pound feet).

NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in direction of arrow.

8005-15

STEP 2

8005-15

STEP 2 1

1 1

1 2

1 BS03C030

1. O-RINGS

BS03C030

2. THRUST RINGS

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on anticavitation and pressure relief valves (19). Torque cap (A) to 100 Nm (73.7 pound feet).

STEP 3

1 2

2 BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (8).

BS03C029

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (8).

8005-16

STEP 4

STEP 7

STEP 4

STEP 7 2

1 1

BS03C025

1. O-RINGS

2. THRUST RINGS

BS03C028

1. O-RINGS

2. THRUST RING

BS03C025

3. SPOOL SEAL

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 (20).

Install new O-rings, thrust ring, and spool seal on anticavitation valve (22).

Install new O-rings and thrust rings on pilot pressure reducing valve (20).

Install new O-rings, thrust ring, and spool seal on anticavitation valve (22).

STEP 5

STEP 8

STEP 5

STEP 8

Install and torque regeneration check valve (14) to 100 Nm (73.7 lb-ft).

STEP 9

Install and torque locking screw (15) to 100 Nm (73.7 lb-ft).

2 1

Install and torque locking screw (15) to 100 Nm (73.7 lb-ft).

2 1

STEP 10

Install and tighten load sense chuttle check valve (16). BS03C026

1. O-RINGS

2. THRUST RINGS

Install new O-rings and thrust rings on flow limit valve (9).

STEP 6

Install and tighten load sense chuttle check valve (16).

STEP 11 Install and torque locking screws (17) to 240 Nm (177 lb-ft).

STEP 12 Install and torque pilot pressure reducing valve (20) to 60 Nm (44 lb-ft).

BS03C026

1. O-RINGS

Install new O-rings and thrust rings on flow limit valve (9).

STEP 6

Install new O-rings on housing (1). Install plate (2), bolts (3) and washers (4), onto housing (1). Torque bolts to 70 Nm (51.5 lb-ft).

2 1

NOTE: For 4 spool configuration install new O-rings between housings (34) and housing (1), install nuts (36) on studs (37). Torque nuts to 70 Nm (51.5 lb-ft).

1. O-RINGS

2. THRUST RING

Install new O-rings and thrust ring on locking screw (15).

Install anticavitation valves (21, and 22) and torque to 100 Nm (73.7 lb-ft). NOTE: Repeat step for a 3 and 4 spool anticavitation valves (35).

STEP 12

STEP 13

Install new O-rings on housing (1). Install plate (2), bolts (3) and washers (4), onto housing (1). Torque bolts to 70 Nm (51.5 lb-ft).

2 1

NOTE: For 4 spool configuration install new O-rings between housings (34) and housing (1), install nuts (36) on studs (37). Torque nuts to 70 Nm (51.5 lb-ft).

STEP 14 BS03C027

Install and torque locking screws (17) to 240 Nm (177 lb-ft).

Install and torque pilot pressure reducing valve (20) to 60 Nm (44 lb-ft).

STEP 13

2. THRUST RINGS

STEP 11

STEP 14 BS03C027

Install anticavitation valves (21, and 22) and torque to 100 Nm (73.7 lb-ft).

Install new O-rings and thrust ring on locking screw (15).

NOTE: Repeat step for a 3 and 4 spool anticavitation valves (35).

1. O-RINGS

2. THRUST RING

8005-17

Circuit Relief Pressure Test

STEP 15

Circuit Relief Pressure Test

Install anticavitation valves (19) and torque to 200 Nm (147.5 lb-ft).

STEP 1

Install anticavitation valves (19) and torque to 200 Nm (147.5 lb-ft).

STEP 1

STEP 16

Connect the hand pump to the port for anticavitation and circuit relief valves (21).

STEP 16

Connect the hand pump to the port for anticavitation and circuit relief valves (21).

STEP 15

Install and torque flow limit valve (9) to 20 to 25 Nm (177 to 221 lb-in).

STEP 17 Install cone (13), spring (12), locking screw (11). Torque locking screw to 100 Nm (73.7 lb-ft).

STEP 18 Lubricate spools with hydraulic oil and push spools (33) into housing (1). IMPORTANT: Do not force spools into housing.

NOTE: Repeat steps for machines that are configured with a 3 or 4 spool valve.

STEP 2 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21째C (70째F).

STEP 3 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 19 Install spring retainers (31), springs (32), covers (29), and bolts (28). Torque bolts to 10.4 Nm (92 lb-ft).

Install and torque flow limit valve (9) to 20 to 25 Nm (177 to 221 lb-in).

STEP 17 Install cone (13), spring (12), locking screw (11). Torque locking screw to 100 Nm (73.7 lb-ft).

STEP 18 Lubricate spools with hydraulic oil and push spools (33) into housing (1). IMPORTANT: Do not force spools into housing.

NOTE: Repeat steps for machines that are configured with a 3 or 4 spool valve.

STEP 2 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21째C (70째F).

STEP 3 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.

STEP 19 STEP 4

STEP 4

Compare the reading to the specifications on Page 3.

Install spring retainers (31), springs (32), covers (29), and bolts (28). Torque bolts to 10.4 Nm (92 lb-ft).

NOTE: Repeat step 17 for a 3 and 4 spool valve configuration.

STEP 5

NOTE: Repeat step 17 for a 3 and 4 spool valve configuration.

STEP 5

STEP 20

If the pressure is not correct, adjust the circuit relief valve.

STEP 20

If the pressure is not correct, adjust the circuit relief valve.

Install spring retainers (31), spring (32), cover (23), and bolts (24). Torque bolts to 6 Nm (53 lb-in).

Circuit Relief Adjustment

Install spring retainers (31), spring (32), cover (23), and bolts (24). Torque bolts to 6 Nm (53 lb-in).

Circuit Relief Adjustment

NOTE: Prior to installation in the machine, circuit reliefs can be tested.

STEP 1

NOTE: Prior to installation in the machine, circuit reliefs can be tested.

STEP 1

STEP 21 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.

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

STEP 21 Install valve in machine, see section 8001.

STEP 22 Check loader limit pressure, see section 8002.

Compare the reading to the specifications on Page 3.

Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure.

STEP 2 Check the pressure again. Repeat the adjustment as necessary.

8005-18

NOTES

CYLINDERS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8006

Section 8006

8006

Section 8006

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8006-2

TABLE OF CONTENTS SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 3 3 5 7 7 7 9 11 11 11

SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 5 7 7 7 9 11 11 11

8006-3

SPECIAL TORQUES

Gland Cap Screws for Lift Cylinder .........................................................402 to 500 Nm (296.5 to 368.7 pound-feet)

Gland Cap Screws for Bucket Cylinders .................................................402 to 500 Nm (296.5 to 368.7 pound-feet)

LIFT CYLINDER

Disassembly 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (22) in an acceptable repair stand or other holding equipment, refer to Figure 1. Do not damage the tube (22). 3. Loosen and remove the cap screws (1) and hardened washers (2) from the gland (3) and the tube (22). 4. Pull the piston rod (19) straight out of the tube (22) to prevent damage to the tube (22). 5. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (19) near the piston (12). Put a shop cloth between the support and the piston rod (19) to prevent damage to the piston rod (19). 6. Remove the retaining ring (10) that fastens the pin (11) in the piston (12) and piston rod (19). 7. Remove the pin (11) from the piston (12) and the piston rod (19). 8. Turn the piston (12) off the piston rod (19) and remove the piston (12). 9. Remove the gland (3) from the piston rod (19).

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. 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 (13) and the backup ring (14) from the OD of the piston (12).

11. Remove the wear ring (15) from the OD of the piston (12).

12. Remove the backup rings (16 and 18) and the O-ring (17) from the ID of the piston (12).

13. Remove the O-ring (8), backup ring (9), wiper (4), wide seal (5), narrow seal (6), and bushing (7) from the gland (3).

8006-4

5 6

8 1

16 11

18 17

13 22

21 20

W270-5R007

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

CAP SCREW HARDENED WASHER GLAND WIPER WIDE SEAL NARROW SEAL

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

BUSHING O-RING BACKUP RING RETAINING RING PIN PISTON

13. 14. 15. 16. 17. 18.

SEAL BACKUP RING WEAR RING BACKUP RING O-RING BACKUP RING

FIGURE 1. LIFT CYLINDER

19. 20. 21. 22.

PISTON ROD SEAL BUSHING TUBE

W270-5R007

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

CAP SCREW HARDENED WASHER GLAND WIPER WIDE SEAL NARROW SEAL

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

BUSHING O-RING BACKUP RING RETAINING RING PIN PISTON

13. 14. 15. 16. 17. 18.

SEAL BACKUP RING WEAR RING BACKUP RING O-RING BACKUP RING

FIGURE 1. LIFT CYLINDER

19. 20. 21. 22.

PISTON ROD SEAL BUSHING TUBE

8006-5

Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland. 1. Install the bushing (7) in the gland (3), refer to Figure 1. 2. Install the wide seal (5) in the gland (3). The wide seal (5) is to be installed so that the lips of the wide seal (5) are toward the bushing (7). The wide seal (5) can be difficult to install. 3. Install a new wiper (4) in the gland (3). The lips of the wiper (4) must be toward the outside end of the gland (3). 4. Install the narrow seal (6) in the gland (3). The side of the narrow seal (6) with the groove must be toward the bushing (7). 5. Install a new backup ring (9) in the groove on the outside of the gland (3). If both sides of the backup ring (9) are not flat, the side that is not flat must be toward the small end of the gland (3).

15. Start the piston (12) onto the piston rod (19). Turn the piston (12) onto the piston rod (19) until the piston (12) is seated against the shoulder of the piston rod (19). 16. If none of the holes in the piston (12) align with the holes in the piston rod (19), turn the piston (12) counterclockwise until one of the holes in the piston (12) aligns with one of holes in the piston rod (19). Do not turn the piston (12) more than 90 degrees. Refer to Figure 2 for pin placement and hole alignment.

8. Lubricate the bore of the gland (3) and the piston rod (19) with clean oil. 9. Push the gland (3) onto the piston rod (19). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (19). 10. Put a support below and near the end of the piston rod (19). Use a shop cloth between the support and the piston rod (19) to prevent damage to the piston rod (19). 11. Install a new backup ring (18) in the groove in the ID of the piston (12). If both sides of the backup ring (18) are not flat, the side that is not flat must be toward the O-ring (17). 12. Install a new O-ring (17) in the groove in the ID of the piston (12) next to the backup ring (18). 13. Install the other new backup ring (16) in the groove in the ID of the piston (12) next to the O-ring (17). If both sides of the backup ring (16) are not flat, the side that is not flat must be toward the O-ring (17). 14. Lubricate the ID of the piston (12) with clean oil.

12 10

6. Install the O-ring (8) next to the backup ring (9) in the groove on the outside of the gland (3). The O-ring (8) must be toward the small end of the gland (3). 7. Remove any marks and sharp edges on the chamfer at the end of the piston rod (19). Make sure that the piston rod (19) is clean.

8006-5

5. Install a new backup ring (9) in the groove on the outside of the gland (3). If both sides of the backup ring (9) are not flat, the side that is not flat must be toward the small end of the gland (3).

12 10

6. Install the O-ring (8) next to the backup ring (9) in the groove on the outside of the gland (3). The O-ring (8) must be toward the small end of the gland (3).

7. Remove any marks and sharp edges on the chamfer at the end of the piston rod (19). Make sure that the piston rod (19) is clean. GS98J804

FIGURE 2. PISTON AND PISTON ROD HOLE ALIGNMENT

17. Install the pin (11) in the piston (12) and the piston rod (19). 18. Install the retaining ring (10) in the pin (11). 19. Install a new wear ring (15) in the wide groove on the OD of the piston (12), refer to Figure 1. 20. Install a new seal (13) in the groove on the OD of the piston (12). 21. Install the backup ring (14) on top of the seal (13). 22. Fasten the tube (22) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (22). 23. Lubricate the inside of the tube (22) and the outside of the piston (12) with clean oil. 24. Push the piston (12) straight into the tube (22). 25. Lubricate the O-ring (8) on the gland (3) with clean oil.

GS98J804

FIGURE 2. PISTON AND PISTON ROD HOLE ALIGNMENT

8006-6

26. Push the gland (3) into the tube (22) and align the holes in the tube (22), refer to Figure 3. 27. Install the cap screws (1) and hardened washers (2). 28. Tighten the cap screws (1) in the sequence shown for the cylinder being repaired. Torque to 402 to 500 Nm (296.5 to 368.7 pound-feet).

W270-5R009

FIGURE 3. TUBE AND GLAND HOLE ALIGNMENT

29. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the fittings. Lubricate the O-rings with clean oil. Install the hoses.

W270-5R009

FIGURE 3. TUBE AND GLAND HOLE ALIGNMENT

29. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the fittings. Lubricate the O-rings with clean oil. Install the hoses.

8006-7

BUCKET CYLINDER Disassembly 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (21) in an acceptable repair stand or other holding equipment, refer to Figure 4. Do not damage the tube (21). 3. Loosen and remove the cap screws (1) and hardened washers (2) from the gland (3) and the tube (21). 4. Pull the piston rod (18) straight out of the tube (21) to prevent damage to the tube (21). 5. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (18) near the piston (12). Put a shop cloth between the support and the piston rod (18) to prevent damage to the piston rod (18). 6. Remove the retaining ring (10) that fastens the pin (11) in the piston (12) and piston rod (18). 7. Remove the pin (11) from the piston (12) and the piston rod (18). 8. Turn the piston (12) off the piston rod (18) and remove the piston (12). 9. Remove the gland (3) from the piston rod (18).

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 (13) from the OD of the piston (12).

11. Remove the wear ring (14) from the OD of the piston (12).

12. Remove the backup rings (15 and 17) and the O-ring (16) from the ID of the piston (12).

13. Remove the O-ring (8), backup ring (9), wiper (4), wide seal (5), narrow seal (6), and bushing (7) from the gland (3).

8006-8

19 20

20 19

18 1

8 11 12

5 6

9 11

5 6

15 17

14 21

20 19

W270-5R008

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

CAP SCREW HARDENED WASHER GLAND WIPER WIDE SEAL NARROW SEAL

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

BUSHING O-RING BACKUP RING RETAINING RING PIN PISTON

13. 14. 15. 16. 17. 18.

SEAL WEAR RING BACKUP RING O-RING BACKUP RING PISTON ROD

FIGURE 4. BUCKET CYLINDER

19. SEAL 20. BUSHING 21. TUBE

W270-5R008

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

CAP SCREW HARDENED WASHER GLAND WIPER WIDE SEAL NARROW SEAL

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

BUSHING O-RING BACKUP RING RETAINING RING PIN PISTON

13. 14. 15. 16. 17. 18.

SEAL WEAR RING BACKUP RING O-RING BACKUP RING PISTON ROD

FIGURE 4. BUCKET CYLINDER

19. SEAL 20. BUSHING 21. TUBE

8006-9

Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland. 1. Install the bushing (7) in the gland (3), refer to Figure 4. 2. Install the wide seal (5) in the gland (3). The wide seal (5) is to be installed so that the lips of the wide seal (5) are toward the bushing (7). The wide seal (5) can be difficult to install. 3. Install a new wiper (4) in the gland (3). The lips of the wiper (4) must be toward the outside end of the gland (3). 4. Install the narrow seal (6) in the gland (3). The side of the narrow seal (6) with the groove must be toward the bushing (7). 5. Install a new backup ring (9) in the groove on the outside of the gland (3). If both sides of the backup ring (9) are not flat, the side that is not flat must be toward the small end of the gland (3).

15. Start the piston (12) onto the piston rod (18). Turn the piston (12) onto the piston rod (18) until the piston (12) is seated against the shoulder of the piston rod (18). 16. If none of the holes in the piston (12) align with the holes in the piston rod (18), turn the piston (12) counterclockwise until one of the holes in the piston (12) aligns with one of holes in the piston rod (18). Do not turn the piston (12) more than 90 degrees. Refer to Figure 5 for pin placement and hole alignment.

8. Lubricate the bore of the gland (3) and the piston rod (18) with clean oil. 9. Push the gland (3) onto the piston rod (18). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (18). 10. Put a support below and near the end of the piston rod (18). Use a shop cloth between the support and the piston rod (18) to prevent damage to the piston rod (18). 11. Install a new backup ring (17) in the groove in the ID of the piston (12). If both sides of the backup ring (17) are not flat, the side that is not flat must be toward the O-ring (16). 12. Install a new O-ring (16) in the groove in the ID of the piston (12) next to the backup ring (17). 13. Install the other new backup ring (15) in the groove in the ID of the piston (12) next to the O-ring (16). If both sides of the backup ring (15) are not flat, the side that is not flat must be toward the O-ring (16). 14. Lubricate the ID of the piston (12) with clean oil.

12 10

8006-9

12 10

6. Install the O-ring (8) next to the backup ring (9) in the groove on the outside of the gland (3). The O-ring (8) must be toward the small end of the gland (3).

7. Remove any marks and sharp edges on the chamfer at the end of the piston rod (18). Make sure that the piston rod (18) is clean. GS98J804

FIGURE 5. PISTON AND PISTON ROD HOLE ALIGNMENT

17. Install the pin (11) in the piston (12) and the piston rod (18). 18. Install the retaining ring (10) in the pin (11). 19. Install a new wear ring (14) in the wide groove on the OD of the piston (12), refer to Figure 4. 20. Install a new seal (13) in the groove on the OD of the piston (12). 21. Fasten the tube (21) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (21). 22. Lubricate the inside of the tube (21) and the outside of the piston (12) with clean oil. 23. Push the piston (12) straight into the tube (21). 24. Lubricate the O-ring (8) on the gland (3) with clean oil.

GS98J804

FIGURE 5. PISTON AND PISTON ROD HOLE ALIGNMENT

8006-10

25. Push the gland into the tube (21) and align the holes in the tube (21), refer to Figure 6. 26. Install the cap screws (1) and hardened washers (2). 27. Tighten the cap screws (1) in the sequence shown for the cylinder being repaired. Torque to 402 to 500 Nm (296.5 to 368.7 pound-feet).

W270-5R010

FIGURE 6. TUBE AND GLAND HOLE ALIGNMENT

28. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the fittings. Lubricate the O-rings with clean oil. Install the hoses.

W270-5R010

FIGURE 6. TUBE AND GLAND HOLE ALIGNMENT

28. If the hoses were removed with the cylinder, install new O-rings, if equipped, on the fittings. Lubricate the O-rings with clean oil. Install the hoses.

8006-11

REPLACING BUSHINGS FOR THE BUCKET AND LIFT CYLINDERS

Disassembly

Disassembly 3

1. Put the piston rod eye (3) in a press, refer to Figure 7. 2. Use an acceptable driver to press the seals (1) and bushing (2) out of the piston rod eye (3). 3. Put the tube (4) in a press.

8006-11

2 1 1

2. Use an acceptable driver to press the seals (1) and bushing (2) out of the piston rod eye (3). 3. Put the tube (4) in a press.

4. Use an acceptable driver to press the seals (1) and bushing (2) out of the tube (4).

5. Clean the bore for the bushings (2) in the piston rod eye (3) and the tube (4).

Assembly

1. Use an acceptable driver to press a new bushing (2) into the piston rod eye (3) until the bushing (2) is centered in the piston rod eye (3), refer to Figure 7.

2. Use an acceptable seal driver to install the seals (1) in the piston rod eye (3). The lips of the seals (1) must be toward the outside of the bore.

3. Use an acceptable driver to press a new bushing (2) into the tube (4) until the bushing (2) is centered in the tube (4).

4. Use an acceptable seal driver to install the seals (1) in the tube (4). The lips of the seals (1) must be toward the outside of the bore.

2 W270-5R011

1. SEAL 2. BUSHING

1. Put the piston rod eye (3) in a press, refer to Figure 7.

3. PISTON ROD EYE 4. TUBE

FIGURE 7. BUSHING REMOVAL AND REPLACEMENT

2 1 1

4. Use an acceptable seal driver to install the seals (1) in the tube (4). The lips of the seals (1) must be toward the outside of the bore.

2 W270-5R011

1. SEAL 2. BUSHING

3. PISTON ROD EYE 4. TUBE

FIGURE 7. BUSHING REMOVAL AND REPLACEMENT

8006-12

NOTES

RIDE CONTROL ACCUMULATOR

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8013

Section 8013

8013

Section 8013

RIDE CONTROL ACCUMULATOR

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8013-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 3 4 5 5 5 5 7

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 5 5 5 5 7

8013-3

SPECIFICATIONS

Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8

Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)

Ride Control Accumulator Maximum Operating Pressure...........................................................248.4 bar (3600 psi)

ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap.................................................................................13.6 Nm (10 pound-feet)

Gas Charging Valve ............................................................................................88 to 102 Nm (65 to 75 pound-feet)

Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)

Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)

SPECIAL TOOLS

94L95

380001737 NITROGEN ACCUMULATOR CHARGING KIT

B786441M

380001738 GLAND WRENCH

94L95

380001737 NITROGEN ACCUMULATOR CHARGING KIT

B786441M

380001738 GLAND WRENCH

8013-4

DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

94L95

CAS10899 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. 6. Connect valve F to the valve stem on the accumulator.

7. Turn the T-handle inward on valve F to engage the pin in the valve stem. 8. Open valve D and check the charge pressure on gauge E. 9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem. 11. The accumulator can now be disassembled.

CAS10899 NITROGEN CHARGING KIT

8013-5

ACCUMULATOR

Assembly

Disassembly NOTE: Refer to Section 8001 for the proper procedure for the removal of the ride control accumulator. WARNING: DO NOT attempt to disassemble any accumulator until the nitrogen charge is properly discharged. SM386

1. Fasten the body (1) in a vise. Be careful not to damage the body (1), refer to the illustration on page 6. 2. Remove the screws (9) and guard (11) from the body (1). 3. Remove the pressure valve (12) from the body (1). 4. Remove and discard the O-ring (10) from the pressure valve (12). 5. Loosen and remove the cap (8) from the body (1). 6. Loosen and remove the gland (3) from the body (1).

1. Fasten the body (1) in a vise. Be careful not to damage the body (1). Refer to the illustration on page 6. 2. Install a new wear ring (5), O-ring (7) and backup ring (6) on the piston (4). 3. Lubricate the bore of the body (1) and the piston (4) with clean oil. 4. Start the piston (4) into the body (1), round surface first. Then push the piston (4) farther into the body (1). NOTE: The piston (4) must be installed squarely and slowly into the body (1). Once the piston (4) is started straight into the bore of the body (1), use a hammer and wood block to gently tap the piston into the polished area of the bore. Keep force on the piston (4) while tapping into the bore or damage may occur to the O-ring. 5. Install and tighten the cap (8) into the body (1). 6. Install new seals (2) on the gland (3).

7. Remove the piston (4) from the body (1).

7. Lubricate the seals (2) with clean oil and start the gland (3) into the body (1).

8. Remove and discard the wear ring (5), O-ring (7) and the backup ring (6) from the piston (4). 9. Remove the seals (2) from the gland (3).

Inspection 1. Clean body (1), gland (3), cap (8) and piston (4) in cleaning solvent, refer to the illustration on page 6. 2. Inspect the piston (4) for cracks, burrs or other damage. 3. Inspect the bore of the body (1) for scratches or scoring using a light.

Assembly

7. Remove the piston (4) from the body (1).

7. Lubricate the seals (2) with clean oil and start the gland (3) into the body (1).

8. Tighten the gland (3).

8. Remove and discard the wear ring (5), O-ring (7) and the backup ring (6) from the piston (4).

8. Tighten the gland (3).

9. Install a new O-ring (10) on the pressure valve (12).

9. Remove the seals (2) from the gland (3).

9. Install a new O-ring (10) on the pressure valve (12).

10. Install the pressure valve (12) in the body (1). 11. Install the guard (11), screws (9) in the body (1). 12. Charge the accumulator with dry nitrogen according to instructions on page 7. WARNING: Use only nitrogen when charging the accumulator. DO NOT use air or oxygen that will cause an explosion. SM115A

NOTE: Minor scratches or scoring in the bore of the body (1) can be removed using crocus cloth.

4. Inspect the pressure valve (12) and replace as needed.

8013-6

2 3

BS01B224

1. 2. 3. 4.

BODY SEALS (2) GLAND PISTON

5. 6. 7. 8.

WEAR RING BACKUP RING O-RING CAP

9. 10. 11. 12.

SCREW O-RING GUARD PRESSURE VALVE

RIDE CONTROL ACCUMULATOR ILLUSTRATION

BS01B224

1. 2. 3. 4.

BODY SEALS (2) GLAND PISTON

5. 6. 7. 8.

WEAR RING BACKUP RING O-RING CAP

9. 10. 11. 12.

SCREW O-RING GUARD PRESSURE VALVE

RIDE CONTROL ACCUMULATOR ILLUSTRATION

8013-7

CHARGING THE ACCUMULATOR WITH NITROGEN

GS98N801

1. VALVE C 2. TO NITROGEN TANK 3. VALVE A

4. VALVE B 5. VALVE D 6. TO ACCUMULATOR

GS98N801

1. VALVE C 2. TO NITROGEN TANK 3. VALVE A

NITROGEN CHARGING KIT 380001737

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 49째 C (120째 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.

WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. M253A

M407

IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.

IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high pressure (10 bar/150 psi and above) applications.

8013-8 1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to the illustration on page 7. 2. Open valve B by turning it out all the way to the left (counterclockwise). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the two cap screws (9) and the protection bracket (11) from the body (1) on the accumulator, refer to the illustration on pages 6. 8. Remove the valve cap from the pressure valve (12) on the accumulator. 9. Back off the needle valve on the accumulator end of the charging hose by 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. 10. Install the charging hose fitting onto the accumulator pressure valve (12). 11. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

8013-8 12. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, slightly open the needle valve on the accumulator charge hose. By regulating the needle valve, fill the accumulator to pressure according to temperature chart below. Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. TEMPERATURE 10° C 50° F 13° C 55° F 16° C 60° F 18° C 65° F 21° C 70° F 24° C 75° F 27° C 80° F 29° C 85° F 32° C 90° F 35° C 95° F 38° C 100° F

CHARGE PRESSURE 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

13. Close valve B by turning to the right (clockwise). After a few minutes, check the accumulator for leakage. 14. Back off the needle valve on the accumulator end of the charging hose by turning it counterclockwise the maximum amount. This will prevent nitrogen from escaping from the accumulator as the hose is removed. Remove the charging hose from the accumulator pressure valve (12). 15. Install the valve cap onto the pressure valve (12) on the accumulator. 16. Install the protection bracket (11) over the pressure valve (12) and secure it with cap screws (9). 17. Remove the charging hose from the nitrogen supply tank.

1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to the illustration on page 7. 2. Open valve B by turning it out all the way to the left (counterclockwise). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the two cap screws (9) and the protection bracket (11) from the body (1) on the accumulator, refer to the illustration on pages 6. 8. Remove the valve cap from the pressure valve (12) on the accumulator. 9. Back off the needle valve on the accumulator end of the charging hose by 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. 10. Install the charging hose fitting onto the accumulator pressure valve (12). 11. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

12. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, slightly open the needle valve on the accumulator charge hose. By regulating the needle valve, fill the accumulator to pressure according to temperature chart below. Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. TEMPERATURE 10° C 50° F 13° C 55° F 16° C 60° F 18° C 65° F 21° C 70° F 24° C 75° F 27° C 80° F 29° C 85° F 32° C 90° F 35° C 95° F 38° C 100° F

TEMPERATURE/CHARGE PRESSURE RIDE CONTROL ACCUMULATOR

RIDE CONTROL VALVE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8014

Section 8014 8014

Section 8014

RIDE CONTROL VALVE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

8014-2

TABLE OF CONTENTS RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 4 4

RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 4

8014-3

RIDE CONTROL VALVE

4 8

9 10

12 10

BC06A224

1. 2. 3. 4.

PLUG CAP SCREW BUSHING SPRING CARRIER

5. 6. 7. 8.

SPRING SPRING SPOOL PLUG

9. 10. 11. 12.

SOLENOID ORFICE POPPET ORFICE

12 BC06A224

1. 2. 3. 4.

PLUG CAP SCREW BUSHING SPRING CARRIER

5. 6. 7. 8.

SPRING SPRING SPOOL PLUG

9. 10. 11. 12.

SOLENOID ORFICE POPPET ORFICE

8014-4

Dissasembly

Assembly

Dissasembly

Assembly

STEP 1

Remove ride control valve, refer to section 8001.

Install new O-rings.

Remove ride control valve, refer to section 8001.

Install new O-rings.

STEP 2

Remove plugs (1 and 8).

Install and torque pressure relief valve to 50 Nm (37 lb-ft).

Remove plugs (1 and 8).

Install and torque pressure relief valve to 50 Nm (37 lb-ft).

STEP 3

Remove the solenoid (9).

STEP 3

Remove the solenoid (9).

STEP 3

STEP 4

Remove the spool (7) from the valve block.

Install and torque accumulator drain screw to 3.5 Nm (31 lb-in). Install the plug for accumulator drain screw and torque to 7 Nm (62 lb-in).

Remove the spool (7) from the valve block.

Install and torque accumulator drain screw to 3.5 Nm (31 lb-in). Install the plug for accumulator drain screw and torque to 7 Nm (62 lb-in).

STEP 5

STEP 4

STEP 5

STEP 4

Remove cap screw (2), bushing (3), spring carrier (4), springs (5 & 6) from spool (7).

Install and torque orifice (12) to 15 Nm (11 lb-ft), install poppet (11), install and torque orifice (10) to 15 Nm (11 lb-ft).

Remove cap screw (2), bushing (3), spring carrier (4), springs (5 & 6) from spool (7).

Install and torque orifice (12) to 15 Nm (11 lb-ft), install poppet (11), install and torque orifice (10) to 15 Nm (11 lb-ft).

STEP 6 Remove orifice (10), poppet (11), and orifice (12).

STEP 7

STEP 5 Install and torque solenoid valve (9) to 12 Nm (106 lb-in).

STEP 6 Remove orifice (10), poppet (11), and orifice (12).

STEP 7

STEP 5 Install and torque solenoid valve (9) to 12 Nm (106 lb-in).

Remove accumulator drain screw.

STEP 6

Remove accumulator drain screw.

STEP 6

STEP 8

Remove the pressure relief valve.

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).

Remove the pressure relief valve.

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).

Inspection

STEP 7

Inspection

STEP 7

1. Discard all O-rings.

Install spool (7) into valve block.

1. Discard all O-rings.

Install spool (7) into valve block.

2. Clean all parts in cleaning solvent.

STEP 8

2. Clean all parts in cleaning solvent.

STEP 8

3. Check the spools and the spool bores for damage and wear.

Install and torque plug (1) to 270 Nm (199 lb-ft).

3. Check the spools and the spool bores for damage and wear.

Install and torque plug (1) to 270 Nm (199 lb-ft).

4. Check the parts of the pressure relief valve.

STEP 9

4. Check the parts of the pressure relief valve.

STEP 9

If any of the parts are damaged, install new parts.

Install plug (8) and torque to 90 Nm (66 lb-ft).

If any of the parts are damaged, install new parts.

Install plug (8) 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.

Section Title

SECTION INDEX

MOUNTED EQUIPMENT

MOUNTED EQUIPMENT Section Number

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

AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A REFRIGERANT

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9002

Section 9002

Section 9002 AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A REFRIGERANT

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

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

TABLE OF CONTENTS 3 5 6 6 8 8 9 10 11 12 12 13 13 13 14 14 15 16 16 17 17 18 18 18 19 19 20 20 21 22 22 23 23 24 24 25 25 26

SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 6 6 8 8 9 10 11 12 12 13 13 13 14 14 15 16 16 17 17 18 18 18 19 19 20 20 21 22 22 23 23 24 24 25 25 26

9002-3

ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC’s) which are harmful to the earth’s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury.

1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause serious injury. Do the following if you get refrigerant near or in your eyes:

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.

A. Flush your eyes with water for 15 minutes.

8. Always reclaim refrigerant from the system before removing any air conditioning component.

A. Flush your eyes with water for 15 minutes.

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.

9002-4

299L7C

BELT TENSION TOOL 380001325

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, 380001326

A22090

ELECTRONIC LEAK DETECTOR 380001327

299L7C

BELT TENSION TOOL 380001325

A22090

BS03H012

SAFETY GOGGLES CAS10073-3

A22094

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, 380001326

ELECTRONIC LEAK DETECTOR 380001327

BS03H012

SAFETY GOGGLES CAS10073-3

9002-5

OPERATION

The refrigerant, still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The expansion valve then causes a restriction in flow of refrigerant to the evaporator core. The 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.

5 4

208L95

1. EXPANSION VALVE 2. EVAPORATOR

3. COMPRESSOR 4. CONDENSER

5. RECEIVER-DRIER

208L95

1. EXPANSION VALVE 2. EVAPORATOR

3. COMPRESSOR 4. CONDENSER

5. RECEIVER-DRIER

9002-6

TROUBLESHOOTING Perform a visual inspection of the machine. Check the following and correct as necessary: 1. - Obtain service history if possible.

5. - Are there heavy accumulations of oil, or oily dust around the fittings, indicating refrigerant leakage? 6. - Are air ducts undamaged, sealed properly and in position?

2. - Is compressor drive belt in place and tensioned? 3. - Are grille screens, fan blades, condenser, air filter, and evaporator unobstructed?

7. - Condensate drain hoses and check valves present and unobstructed?

TROUBLESHOOTING Perform a visual inspection of the machine. Check the following and correct as necessary: 1. - Obtain service history if possible.

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?

4. - Are there any sharp bends or kinks in the hoses?

Problem: No Cooling

Compressor Runs

Yes Internal System Problem See Pressure Testing, Page 13

Mechanical - See Mechanical Compressor Check Page 8 Electrical - See Blower and Compressor Clutch Check Page 9

Compressor Runs

Yes Internal System Problem See Pressure Testing, Page 13

5. - Are there heavy accumulations of oil, or oily dust around the fittings, indicating refrigerant leakage?

7. - Condensate drain hoses and check valves present and unobstructed?

Mechanical - See Mechanical Compressor Check Page 8 Electrical - See Blower and Compressor Clutch Check Page 9

9002-7

Problem: Not Enough Cooling

Problem: Erratic Cooling

9002-7

Problem: Not Enough 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.

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

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.

Make sure the sealing material is correctly in place. INTERNAL SYSTEM PROBLEMS

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

Problem: System Makes Noise

ELECTRICAL

See Blower and Compressor Clutch Check on Page 9.

See Blower and Compressor Clutch Check on Page 9. MECHANICAL

MECHANICAL

See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.

REFRIGERANT

See Cab Temperature Check Page 10.

See Cab Temperature Check Page 10. ELECTRICAL

ELECTRICAL

See Compressor Clutch Check Page 9.

INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

Problem: Erratic Cooling

INTERNAL SYSTEM PROBLEM INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

See Pressure Testing, Page 13.

INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.

9002-8

SYSTEM CHECKS Mechanical Compressor Check

Compressor and Fan Belts

1. Too much belt wear - replace a worn belt, because a worn belt will cause too much slippage.

Compressor Mounting Brackets

1. Loose bracket mounting bolts - tighten the bolts to the correct torque. 2. Bracket has cracks or breaks - replace the bracket.

Compressor Clutch

1. The compressor belt will slip on the compressor pulley if there is compressor seizure. Remove the compressor for service or replacement. 2. Remove the dust cover and check the air gap on the compressor clutch. The gap 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.

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

Pulley and Belt Alignment

9002-9

Blower and Compressor Clutch Check

9002-9

Blower and Compressor Clutch Check NOTE: Check supply voltage with compressor lead plugged in and engaged. Voltage drops will not be apparent without current flow.

Compressor Clutch

1. If there is electrical system voltage to the clutch, check for excessive voltage drop in the ground circuit, then see Section 9004 and replace the compressor.

NOTE: Check supply voltage with compressor lead plugged in and engaged. Voltage drops will not be apparent without current flow. Compressor Clutch

1. If there is electrical system voltage to the clutch, check for excessive voltage drop in the ground circuit, then see Section 9004 and replace the compressor.

Low and High Pressure Switches

1. See Section 4002 and check the high and low pressure switches.

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 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 Fan Switch

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.

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.

Temperature Control Switch

1. With key in ON position, turn switch to maximum cold. Compressor clutch must engage.

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.

Temperature Control Switch

9002-10

Cab Temperature Check Air Louvers

Cab Temperature Check 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.

Air Louvers

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

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.

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.

Temperature Sensing Probe Check

9002-11

Visual and Leak Check Compressor Hoses

9002-11

Visual and Leak Check 1. Make sure that all hose connections are tight. 2. Check hoses for bends or cracks. Replace all hoses that have damage.

Compressor Hoses

1. Shut off the engine.

Leak Finding Check

Condenser

WARNING: When refrigerant comes in contact with an open flame, it can form dangerous gas. Never breathe these fumes. 2. Use electronic leak detector OEM -1437 to inspect all connections. Use instructions from manufacturer of leak finding tool.

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

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.

1. Make sure the condenser is clean and the seals are in place. Make sure condenser fans run when temperature control switch is ON.

Condenser

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.

Evaporator/Heater Core

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.

Evaporator/Heater Core Sealing

Filters

1. Make sure the filters are clean.

Filters

1. Make sure the filters are clean.

9002-13

PRESSURE TESTING Manifold Gauge Set NOTE: The gauge set is not accurate enough to optimize an existing charge of HFC-134a. The best use of the gauge set is to determine whether undercharge or overcharge exists, and then evacuate, reclaim and recharge system with the recommended quantity (charge) of HFC-134a. The manifold gauge set is the most important tool used to service the air conditioning system. The manifold gauge set is used to measure the high and low pressures of the system, as a tool to troubleshoot for correct refrigerant charge quantity, system diagnosis, and operating efficiency. The manifold gauge set can read both the high (discharge) and low (suction) sides at the same time, since pressure must be compared in order to make a diagnosis of system operation. LOW PRESSURE GAUGE - The low pressure gauge is a compound gauge. It is best used to judge 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.

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.

9002-14

PRESSURE-TEMPERATURE CHART

AIR LOUVER (BEHIND SEAT) MAXIMUM TEMP. TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) psi (bar) psi (bar) °F (°C)

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)

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)

63 (20)

95 (35)

66 (22)

100 (38)

68 (23)

105 (41)

72 (25)

110 (43)

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

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

AMBIENT

QUICK REFERENCE TROUBLESHOOTING CHART

LOW PRESSURE

HIGH PRESSURE

SEE

GAUGE

PAGE

NO COOLING

VERY LOW

NO COOLING

HIGH

NOT ENOUGH COOLING

NORMAL TO HIGH

NOT ENOUGH COOLING

PROBLEM

LOW PRESSURE

HIGH PRESSURE

SEE

GAUGE

PAGE

NO COOLING

VERY LOW

NO COOLING

HIGH

NORMAL

NOT ENOUGH COOLING

NORMAL TO HIGH

NORMAL

LOW

NOT ENOUGH COOLING

LOW

NOT ENOUGH COOLING

HIGH

LOW

NOT ENOUGH COOLING

HIGH

LOW

NOT ENOUGH COOLING

HIGH

NOT ENOUGH COOLING

HIGH

INTERMITTENT COOLING

NORMAL

INTERMITTENT COOLING

NORMAL

NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

NOISE IN SYSTEM

NORMAL TO HIGH

HIGH

9002-15

A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1

STEP 4

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.

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

STEP 2 Connect the hoses from the test gauges to the service ports by turning the knurled knobs on the depressors.

STEP 3 Connect the hose from the low pressure gauge to the port on the suction hose.

WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A

STEP 5 Make sure the charging station manifold gauge valves are in the closed position.

STEP 6 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.

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

STEP 2 Connect the hoses from the test gauges to the service ports by turning the knurled knobs on the depressors.

STEP 3 Connect the hose from the low pressure gauge to the port on the suction hose.

WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A

STEP 5 Make sure the charging station manifold gauge valves are in the closed position.

9002-16

PROBLEM: NO COOLING

VERY LOW

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Indication of No Refrigerant or Low Refrigerant Charge:

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).

VERY LOW

A. Discharge air from evaporator warm. Yes

4. Check level of oil in compressor - possible for compressor to have an oil loss.

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.

9002-17

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Yes

HIGH

476L7

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

Indication of Large Quantity of Air in System:

Discharge air from evaporator warm

9002-17

Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from system. See Section 9003.

2. Replace receiver-drier.

3. Remove air and moisture from the system. See Section 9003.

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:

A. Liquid line (between evaporator and condenser) is very hot. B. Discharge air from evaporator warm.

476L7

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.

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 condenser.

remove oil from

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 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.

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.

Expansion Valve Malfunctioning - Indications: A. Discharge air from heater/evaporator warm.

See Section 9004 and replace the expansion valve.

evaporator

B. Much condensation on suction hose at compressor. C. Much condensation outlet.

Refrigerant Contamination:

evaporator

Refrigerant Contamination: 1. See table below and check stable saturation pressures at given temperature to determine if contamination exists.

Refrigerant Contamination

See Section 9004 and replace the expansion valve.

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 qF (q C)

Pressure PSIG (Bar)

Temperature qF (q 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)

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)

9002-19

PROBLEM: NOT ENOUGH COOLING

NORMAL TO SLIGHTLY HIGH

476L7

Air in the System - Indications:

A. Suction line warm to your hand. B. Discharge air from heater/evaporator only a little cool.

PROBLEM: NOT ENOUGH COOLING

NORMAL TO SLIGHTLY HIGH

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

9002-19

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.

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.

3. Repair system leak as necessary.

A. Suction line warm to your hand.

3. Repair system leak as necessary.

4. Replace receiver-drier.

B. Discharge air from heater/evaporator only a little cool.

4. Replace receiver-drier.

5. Check compressor oil level.

6. Remove air and moisture from the system. See Section 9003.

7. Charge system with new refrigerant. See Section 9003.

9002-20

LOW

LO W

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

LOW

476L7

Not Enough Refrigerant - Indications:

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

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. 3. Repair system leaks as needed.

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

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.

476L7

Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.

A. Discharge air from evaporator cool or warm - not cold.

LO W

High Side Restriction - Indications: 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.

A. Discharge air from heater/evaporator only a little cool. B. Condensation receiver-drier.

frost

C. Liquid line to receiver-drier cool, with frost or condensation. NOTE: The frost will form downstream from or at the point of the restriction

1. Discharge refrigerant from system-restriction in receiver-drier or liquid line must be removed. 2. Remove and replace part with restriction. 3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

9002-21

Expansion Valve Not Operating - Indications: A. Discharge air from evaporator warm or cool - not cold. B. Condensation or frost on expansion valve outlet. C. Inlet end of expansion valve is warm.

1. Expansion valve outlet with condensation or frost is an indication of a restriction in the expansion valve. Replace expansion valve. See Section 9004. 2. Inlet end of expansion valve is warm (not hot), indicating expansion valve is not completely open. If the valve is stuck closed, there will be little or no flow of refrigerant through the valve. Replace expansion valve. See Section 9004.

9002-21

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.

9002-22

HIGH

LOW

SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14

HIGH

476L7

Compressor Turning But Not Pumping Properly - Indications:

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.

A. System is fully charged.

4. Replace compressor.

B. Cool discharge air from evaporator.

5. Replace receiver-drier if:

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

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

Expansion Valve Stuck Open

1. Replace expansion valve. See Section 9004.

9002-23

HIGH

9002-23

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

HIGH

476L7

Condenser Not Operating - Indications:

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

B. Discharge air from evaporator warm.

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.

B. Add refrigerant until gauge pressures are normal. See Section 9003. C. If there is still a problem, do step 4.

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:

Warm discharge air from evaporator.

476L7

Condenser Not Operating - Indications:

A. Remove refrigerant from system until gauge pressure is below normal. See Section 9003. A. Liquid line very hot.

HIGH

Air in the System - Indications: 1. Discharge refrigerant from system. See Section 9003.

1. Discharge refrigerant from system. See Section 9003.

2. Replace receiver-drier.

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

Warm discharge air from evaporator.

3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.

9002-24

PROBLEM: INTERMITTENT COOLING

NORMAL

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

NORMAL

476L7

Moisture in the System - Indications:

Cooling is acceptable during cool part of day but not acceptable during hot part of day.

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.

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.

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.

Cooling is acceptable during cool part of day but not acceptable during hot part of day.

3. Remove air and moisture from the system. See Section 9003.

NOTE: The time needed to remove a large amount of moisture will be two to three hours minimum.

4. Charge system with new refrigerant. See Section 9003.

9002-25

PROBLEM: NOISE IN SYSTEM

NORMAL TO HIGH

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.

9002-25

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.

HIGH

SEE PRESSURE - TEMPERATURE CHART ON PAGE 14

476L7

Too Much Refrigerant in System - Indications: A. Cool discharge air from heater/evaporator. B. Compressor makes noise.

1. Remove refrigerant from system until gauge readings are below normal. See Section 9003. 2. Add new refrigerant until gauge readings are normal. See Section 9003.

9002-26

TUBE CONNECTIONS TORQUE CHART TUBING SIZE

3/8 inch

1/2 inch

TUBE CONNECTIONS TORQUE CHART 5/8 inch

TUBING SIZE

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

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

45-52 Nm

STEEL TO STEEL

31-36 Nm

40-46 Nm

45-52 Nm

ALUMINUM TO BRASS

10-14 Nm

24-30 Nm

30-37 Nm

45-52 Nm

NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.

IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these connections are easily distorted.

AIR CONDITIONER SYSTEM SERVICE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9003

Section 9003

9003

Section 9003

AIR CONDITIONER SYSTEM SERVICE

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9003-2

TABLE OF CONTENTS 3 3 4 5 7 10

3 3 4 5 7 10

9003-3

SPECIFICATIONS

Air conditioning system refrigerant capacity ........................................................................................ 1.6 kg (3.5 lbs)

SPECIAL TOOLS

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION 380001326

109L7

SAFETY GOGGLES CAS-10073-3

A22094

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION 380001326

109L7

SAFETY GOGGLES CAS-10073-3

9003-4

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.

A. Flush your eyes with water for 15 minutes.

8. Always reclaim refrigerant from the system before removing any air conditioning component.

A. Flush your eyes with water for 15 minutes.

8. Always reclaim refrigerant from the system before removing any air conditioning component.

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.

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

STEP 3

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.

If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding.

STEP 1

STEP 3

A22114

Open the high and low valves.

STEP 4

BD06N047

Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.

STEP 2

STEP 2 A22107

A22107

Make certain the refrigerant tank gas and liquid valves are open.

BD06N048

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.

9003-6

STEP 5

STEP 7

STEP 5

STEP 7

A22112

A22110

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.

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

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.

BD06N047

Remove the hoses from the service ports and install the caps.

9003-7

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING IMPORTANT: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system. A. The system has been opened for service before. B. Receiver-drier has operated two or more years. C. Disassembly of compressor shows small particles of moisture removing material (gold or brown particles).

9003-7

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

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

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).

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

STEP 11

STEP 10 A22113

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

BD06N048

With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports as follows:

1. Connect the hose from the low pressure gauge to the port on the suction hose.

2. Connect the hose from the high pressure gauge to the port on the discharge hose.

3. Turn in both thumbscrews to depress the service valves.

Removal of air and moisture from the system is necessary after the refrigerant has been removed after the system has been opened for maintenance. Air enters the system when the system is opened. Air has moisture that must be removed to prevent damage to the system components. NOTE: The pump on the reclamation unit will not pull a sufficient vacuum to remove air and moisture.

A22115

Press the Charge key. “Program” and “Charge” will appear on the display.

A22115

Press the Charge key. “Program” and “Charge” will appear on the display.

9003-8

STEP 13

STEP 16

STEP 13

STEP 16

A22113

A22123

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.

Program 3.5 lbs and press the enter key. The display will flash once indicating the programmed data has been accepted.

STEP 14

When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 to 29-1/2 inches of mercury (Hg). The low pressure gauge must not increase faster than one inch of mercury (Hg) in 10 minutes. A previously charged, 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.

A22114

Fully open the low and high pressure valves.

A22114

Fully open the low and high pressure valves.

STEP 17

STEP 15

STEP 17

STEP 15

A22107

Open the red (vapor) and blue (liquid) valves on the tank.

A22113

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”.

A22107

Open the red (vapor) and blue (liquid) valves on the tank.

9003-9

STEP 18

STEP 21

9003-9

STEP 18

STEP 21

A22114

BD06N048

A22114

BD06N048

Completely close the high and low pressure manifold valves.

Stop the engine, close any open valves and carefully remove the manifold gauge hoses.

Completely close the high and low pressure manifold valves.

Stop the engine, close any open valves and carefully remove the manifold gauge hoses.

ATTENTION: Check the OEM equipment manual before performing Step 19 to avoid damaging the recovery unit. The pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the valves accidently open or if either or both valves are opened while the A/C system is operating.

STEP 22

STEP 19

Start the engine and run at 1500 RPM. Operate the air conditioner system at maximum cooling setting and blower speed with the doors and windows open.

NOTE: The compressor will not operate if the system pressure is too low or too high. The pressure indicator lamp will illuminate when the relay is actuated by a low or high pressure and the compressor clutch will disengage. To restart the compressor, the air conditioner control or blower switch must be turned to the OFF position and then to the ON position.

STEP 20

BD06N047

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.

STEP 22

BD06N047

Install the caps on the service ports on the suction and discharge hoses.

9003-10

PRESSURE - TEMPERATURE CHART NORMAL HIGH AMBIENT NORMAL LOW TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) psi (bar) psi (bar)

PRESSURE - TEMPERATURE CHART

AIR LOUVER MAXIMUM TEMP. °F (°C)

NORMAL HIGH AMBIENT NORMAL LOW TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION °F (°C) psi (bar) psi (bar)

AIR LOUVER MAXIMUM TEMP. °F (°C)

80 (27)

9 to 12 (0.62 to 0.83)

145 to 165 (10 to 11.5)

55 (14)

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)

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)

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)

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)

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)

110 (43)

22 to 24 (1.93 to 2.14)

290 to 310 (20 to 21.4)

72 (25)

The pressure-temperature chart is based on the following conditions: 1. Engine operating at 1500 RPM 2. No engine load 3. Fan speed control in maximum position and all louvers open. 4. Cab temperature control set to maximum cooling.

5. Both cab doors open 6. All panels and access doors installed and closed. 7. Cab filters clean and installed. 8. Heater valve at engine closed. 9. Measurements taken 15 minutes after start-up.

REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9004

Section 9004 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 4 5 5 6 8 9 14 19 19 20

SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 5 6 8 9 14 19 19 20

9004-3

SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFC’s) which are harmful to the earth’s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause serious injury. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes. B. See a physician immediately. 2. A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is necessary to service the air conditioner system. Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.

3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can form a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.

9004-4

SPECIAL TOOLS

A22094-01

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION 380001326

BS03H012

SAFETY GOGGLES CAS-10073-3

A22094-01

REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION 380001326

A22090-01

ELECTRONIC LEAK DETECTOR 380001327

A22090-01

ELECTRONIC LEAK DETECTOR 380001327

BS03H012

SAFETY GOGGLES CAS-10073-3

9004-5

COMPRESSOR Removal

STEP 5

STEP 1

STEP 5

STEP 1

BD07A222

Move the battery cut-off switch into OFF as indicated in the figure.

Disconnect the low pressure line from the suction port and the high pressure line from the discharge port on the compressor. Immediately install protective caps on the open ports and lines.

Move the battery cut-off switch into OFF as indicated in the figure.

Disconnect the low pressure line from the suction port and the high pressure line from the discharge port on the compressor. Immediately install protective caps on the open ports and lines.

STEP 2

STEP 6

STEP 2

STEP 6

W270-1R007

Discharge the air conditioning system according to the instructions in Section 9003.

STEP 3

BD07A220

Disconnect the compressor clutch wire from the engine harness assembly.

BD07A222

Loosen the three bolts holding the compressor tension adjusting bracket. Loosen tension on belt.

STEP 4

Remove the belt.

9004-6

Installation

STEP 7

Installation

STEP 7

STEP 1

Place the compressor into position on the machine.

STEP 2

BD07A222

Loosen and remove the three compressor mounting bolts.

STEP 8

Remove the compressor from the machine.

BD07A222

Remove the compressor from the machine.

BD07A222

Install the three bolts to mount the compressor.

STEP 3

BD07A220

Connect the compressor clutch wire to the engine harness assembly.

9004-7

STEP 4

STEP 5

9004-7

STEP 4

STEP 5

Carefully remove the protective cap, install a new O-ring, and connect the low pressure line to the suction port on the compressor.

STEP 6

Install the belt.

STEP 7

Charge the air conditioning system according to the instructions in Section 9003..

BD07A222

Slowly remove the protective cap, install a new O-ring, and connect the high pressure line to the discharge port on the compressor.

IMPORTANT: Use caution when removing cap as new compressors have internal pressure when shipped.

9004-8

EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS 3

EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS 6

1 8

17 12

16 15

15 BS06G118

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

EVAPORATOR UPPER BOX PPE COVER PPE SOLENOID DRIVER UPPER BOX BOLT

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

WASHER GROMMET HEATER CORE HEATER VALVE 24V THERMOSTAT LOWER BOX

13. 14. 15. 16. 17. 18.

LOWER BOX PPE EXPANSION VALVE BLOWER RECIRCULATING VAIN RECIRCULATING MOTOR RESISTOR BLOWER MOTOR

BS06G118

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

EVAPORATOR UPPER BOX PPE COVER PPE SOLENOID DRIVER UPPER BOX BOLT

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

WASHER GROMMET HEATER CORE HEATER VALVE 24V THERMOSTAT LOWER BOX

13. 14. 15. 16. 17. 18.

LOWER BOX PPE EXPANSION VALVE BLOWER RECIRCULATING VAIN RECIRCULATING MOTOR RESISTOR BLOWER MOTOR

9004-9

Removal

STEP 5

Removal

STEP 5

STEP 1

Disconnect the wiring harness from the operator’s seat (if equipped with air seat option).

STEP 1

Disconnect the wiring harness from the operator’s seat (if equipped with air seat option).

Park the machine on a level surface and lower the bucket to the floor.

STEP 6

Park the machine on a level surface and lower the bucket to the floor.

STEP 6

STEP 2

If changing any air conditioning components, discharge the air conditioning system according to the instructions in Section 9003.

STEP 3

BD07A202

Remove the four bolts that fasten the operator’s seat to the upper box, remove the seat from the machine.

BD07A202

Remove the four bolts that fasten the operator’s seat to the upper box, remove the seat from the machine.

BD07A217

1. ENGINE COOLING SYSTEM DRAIN VALVE 2. ENGINE COOLING SYSTEM DRAIN HOSE 3. FUEL TANK

BD07A217

1. ENGINE COOLING SYSTEM DRAIN VALVE 2. ENGINE COOLING SYSTEM DRAIN HOSE 3. FUEL TANK

If changing the heater core, put a 57 liter (15 gallon) container below the engine cooling system drain hose (2). Remove deaeration cap, open drain valve and drain coolant into container. Close drain valve after coolant has drained. Install deaeration cap.

STEP 4

W270-1R007

1. HOOD SWITCH 2. MASTER DISCONNECT

Move the battery cut-off switch into OFF as indicated in the figure.

W270-1R007

1. HOOD SWITCH 2. MASTER DISCONNECT

Move the battery cut-off switch into OFF as indicated in the figure.

9004-10

STEP 7

STEP 10

STEP 7

STEP 10

Fold the rubber mat over to gain access to the upper box mounting bolts.

Place the air selector on the control panel to outside air.

Fold the rubber mat over to gain access to the upper box mounting bolts.

Place the air selector on the control panel to outside air.

STEP 8

NOTE: In step 11 and 14 the upper box is shown removed for clarity only, these steps must be done prior to removing the upper box.

STEP 8

NOTE: In step 11 and 14 the upper box is shown removed for clarity only, these steps must be done prior to removing the upper box.

STEP 11

BD06G215

Remove the six bolts securing the upper box.

STEP 9

BD06G217

STEP 9

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 it is in the outside air, “closed”, position.

STEP 12

BD06G216

Remove two screws, one on each side of the upper box, securing the upper box to the lower box.

BD06G218

The above photo shows that the recirculating vain is not in the outside air “closed” position.

9004-11

STEP 13

STEP 17

BD06G240

9004-11

STEP 13

BD06G203

STEP 17

BD06G240

BD06G203

Use a screw driver and disconnect the linkage.

Disconnect the solenoid driver.

Use a screw driver and disconnect the linkage.

Disconnect the solenoid driver.

STEP 14

STEP 18

STEP 14

STEP 18

BD06G219

Close the vain so the upper cover can be removed.

STEP 15 Remove the upper box and rest it against the console.

STEP 16

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.

BD06G219

Close the vain so the upper cover can be removed.

STEP 15 Remove the upper box and rest it against the console.

STEP 16

BD06G220

Pull the wiring harness loose from the upper PPE.

BD06G220

Pull the wiring harness loose from the upper PPE.

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.

9004-12

NOTE: If replacing the heater control valve, heater core, air conditioning expansion valve, air conditioning evaporator core do steps 19 through 28, if replacing electrical components go to step 32.

STEP 21

STEP 19

STEP 21

STEP 19

BD06G206

Remove the thermostat probe and clamp from the evaporator core.

STEP 22

W270-8R010

Remove the right side cab skirt.

STEP 20

STEP 20 1

BD06G205

1. AIR CONDITIONING HOSES 2. HEATER HOSES

BD06G237

Disconnect the electrical connectors from the thermostat control.

STEP 23

BD06G205

1. AIR CONDITIONING HOSES 2. HEATER HOSES

Fasten identification tags on the hoses. Disconnect the hoses for the heater core and evaporator core, install plugs in the hoses and caps on the fittings.

STEP 23

Fasten identification tags on the hoses. Disconnect the hoses for the heater core and evaporator core, install plugs in the hoses and caps on the fittings.

BD06G236

Disconnect the electrical connectors from the heater control valve.

9004-13

STEP 24

STEP 30

9004-13

STEP 24

STEP 30

Pull the heater core and evaporator core from the lower box PPE.

STEP 25

Remove the expansion valve from the evaporator core.

STEP 26

Remove and discard the O-rings from the openings in the expansion valve.

STEP 27

BD06G208

Remove the screws from the heater core and remove the control valve.

STEP 28 Remove and discard the O-rings from the heater control valve.

STEP 29

Disconnect the electrical connector for the recirculating vain motor, disconnect the linkage from the vain. Remove the mounting screws and remove the motor.

STEP 31

STEP 27

BD06G208

Remove the screws from the heater core and remove the control valve.

STEP 28 Remove and discard the O-rings from the heater control valve.

STEP 29

Disconnect the electrical connector for the recirculating vain motor, disconnect the linkage from the vain. Remove the mounting screws and remove the motor.

STEP 31 1

1 3

2 BD06G209

BD06G209

1. FAN SPEED AND A/C SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

BD06G207

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

Remove the fans from the lower PPE, disconnect the electrical connectors. Remove the two mounting screws for the resistor, remove the resistor.

BD06G207

Remove the switch panel from the console. Disconnect the electrical connectors and remove switches as required.

1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR

Remove the fans from the lower PPE, disconnect the electrical connectors. Remove the two mounting screws for the resistor, remove the resistor.

Remove the switch panel from the console. Disconnect the electrical connectors and remove switches as required.

9004-14

Installation

STEP 3

STEP 1

STEP 3

STEP 1 1 1

1 1

BD06G207

BD06G209

1. FAN SPEED SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

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

BD06G209

Install the resistor, install the two mounting screws and tighten. Install the fans in the lower PPE, connect the electrical connectors.

STEP 4 Install new O-rings on the heater control valve.

STEP 2

BD06G207

1. FAN SPEED SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT

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

Install the resistor, install the two mounting screws and tighten. Install the fans in the lower PPE, connect the electrical connectors.

STEP 4 Install new O-rings on the heater control valve.

STEP 2

STEP 5

Install the control valve, install and tighten the screws to the heater core.

STEP 6

Install new O-rings on the openings of the expansion valve.

STEP 7

Install the heater core and evaporator core into the lower box PPE.

BD06G208

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.

STEP 8

BD06G236

Connect the electrical connectors to the heater control valve.

9004-15

STEP 9

STEP 11

STEP 9 1

BD06G237

Connect the electrical connectors to the thermostat control.

STEP 11 1

BD06G205

1. AIR CONDITIONING HOSES 2. HEATER HOSES

BD06G237

Connect the electrical connectors to the thermostat control.

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 disassembly.

STEP 10

9004-15

BD06G205

1. AIR CONDITIONING HOSES 2. HEATER HOSES

STEP 10

STEP 12

BD06G206

Install the thermostat probe coil and clamp to the evaporator core “cold” tube.

W270-8R010

Install the right side cab skirt.

STEP 13

BD06G238

Install the upper PPE on the heater and air conditioning cores.

9004-16

STEP 14

STEP 17

BD06G203

Connect the solenoid driver.

STEP 14

BD06G210

Make sure that the recirculating vain is in the closed position.

STEP 15

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 17

BD06G203

Connect the solenoid driver.

Make sure that the recirculating vain is in the closed position.

STEP 15

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 18

BD06G239

Push the wiring harness into the preformed notches in the upper PPE.

STEP 16 Place the air selector on the control panel to outside air.

BD06G210

BD06G241

Set the upper box into position on the heater and evaporator cores.

STEP 19

STEP 16 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 19

BD06G216

Install two screws, one on each side of the upper box securing the upper box to the lower box.

9004-17

STEP 20

STEP 24

BD06G242

Install the PPE cover in the center of the upper box.

STEP 21

9004-17

STEP 20

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).

STEP 24

BD06G242

Install the PPE cover in the center of the upper box.

STEP 21

BD06G215

Install and tighten the six bolts securing the upper box.

STEP 22

W270-8R011

Install the right rear floor mat into the cab, if machine is equipped with air ride seat make sure to pull the wiring up above the mat for the seat.

STEP 23

Install the remainder of the floor mat.

BD06G202

Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).

9004-18

STEP 25

STEP 27

STEP 25

STEP 27

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.

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 26

W270-1R086

W270-8R012

Fill dearation tank with a solution of 50% Ethylene Glycol and 50% water. Fill until you see the coolant in in the sight bubble on the side Install the deaeration cap.

9004-19

CONDENSER AND RECIEVER DRIER Removal

STEP 6

STEP 1

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

STEP 2

W270-8R015

Pull the pin so the condensor can be slid out on the channel.

STEP 7

W270-1R007

Move the battery cut-off switch into OFF as indicated in the figure.

STEP 3

Discharge the air conditioning system according to the instructions in Section 9003.

STEP 4

STEP 4 W270-8R013

W270-8R013

Pull the condensor out from the right side, sliding on the channel and remove the two bolts from the top side of the condensor, through the opening in the top of the channel. Tilt condensor upward when the bottom bolt is at the opening in the bottom channel remove the condensor.

BD07A227

Fasten identification tags on the hoses and disconnect the hoses from the condensor.

STEP 5

Install plugs in the hoses and caps on the fittings.

9004-20

Installation

STEP 8

Installation

STEP 8

STEP 11

Position bolt on the bottom of the condensor and position it in the hole of the bottom channel.

STEP 12

W270-8R014

Fasten identification tags on the hoses and disconnect the hoses from the receiver drier.

STEP 9

Install plugs in the hoses and caps on the fittings.

Install plugs in the hoses and caps on the fittings. W270-8R013

STEP 10 Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket.

Slide the condensor on the channel till the first bolt hole in condensor is exposed in the hole of the top channel and install the bolt. Continue sliding the condensor in the channel till the second bolt hole is exposed in the channel and install the bolt. Slide to the end of the channel.

STEP 13

W270-8R013

STEP 10 Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket.

STEP 13

BD07A227

Remove the plugs from the hoses and the caps from the fittings. Install new O-rings and connect the hoses to the fittings on the condensor. Remove and discard identification tags that were used during disassembly.

9004-21

STEP 14

STEP 17

9004-21

STEP 14

STEP 17

Charge the air conditioning system according to the instructions in Section 9003.

W270-8R015

Install the pin.

STEP 15

Mount the receiver drier and bracket, install and tighten the mounting bolt.

STEP 16

W270-8R014

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 disassembly.

9004-22

NOTES

LOADER

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9006

Section 9006

9006

Section 9006

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9006-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS 3 3 3 3 3 4 6 9 11

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 4 6 9 11

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

Replacement of the Tooth Points 3

1. Use a hammer and punch to drive the retaining pin (1) for the tooth point (2) out of the tooth shank (3), refer to the illustration on this page.

2. Remove the tooth point (2).

3. Install a new tooth point (2) on the tooth shank (3).

4. Install the retaining pin (1) into the tooth point (2) and tooth shank (3). Make sure the shoulder on the retaining pin is toward the cutting edge. Use a hammer to hit the retaining pin (1) until the retaining pin (1) is even with the outside of the tooth shank (3).

7 8

3 2

6 10

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.

7 8

Replacement of the Bucket Teeth

6 10

Replacement of the Bucket Teeth

1. Loosen and remove the nuts (4), hardened washers (5), and bolts (6) from the bucket teeth.

9 7

NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off.

1. Loosen and remove the nuts (4), hardened washers (5), and bolts (6) from the bucket teeth.

9 7

NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off.

2. Remove the tooth.

2. Remove the tooth. B0740A88J

3. Install the new tooth on the bucket cutting edge (7). 4. Use new nuts (4), hardened washers (5), and bolts (6) for the tooth being installed. 5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to 1090 pound-feet).

Replacement of the Bucket Corner Teeth

1. 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

B0740A88J

Replacement of the Bucket Corner Teeth

1. Loosen and remove the nuts (9) and bolts (8) from the bucket corner teeth (10).

NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off.

2. Remove the corner tooth (10).

3. Install the new corner tooth (10) on the bucket cutting edge (7).

4. Use new nuts (9) and bolts (8) for the corner tooth being installed.

5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to 1090 pound-feet).

1. 2. 3. 4. 5.

RETAINING RING TOOTH POINT TOOTH SHANK NUT HARDENED WASHER

6. 7. 8. 9. 10.

BOLT CUTTING EDGE PLOW BOLT NUT CORNER TOOTH

BUCKET TEETH ILLUSTRATION

9006-4

RETURN TO DIG ADJUSTMENT

BC06A223

1. TARGET MOUNTING BRACKET 2. BUCKET CYLINDER

3. TARGET BAR 4. PROXIMITY SWITCH MOUNTING BRACKET RETURN TO DIG ADJUSTMENT ILLUSTRATION

5. PROXIMITY SWITCH 6. PROXIMITY SWITCH GUARD

BC06A223

1. TARGET MOUNTING BRACKET 2. BUCKET CYLINDER

3. TARGET BAR 4. PROXIMITY SWITCH MOUNTING BRACKET RETURN TO DIG ADJUSTMENT ILLUSTRATION

5. PROXIMITY SWITCH 6. PROXIMITY SWITCH GUARD

9006-5 IMPORTANT: Before adjusting the return-to-dig, make sure that the target bar on the bucket linkage is not damaged. Slowly roll back and dump the bucket and make sure that the target bar stays the same distance from the switch. The switch mounting bracket protects the switch. Make sure the target bar cannot touch the switch when the bucket is dumped. 1. Park the machine on a level surface. Raise the lift arms until they are approximately horizontal and dump the bucket. Lower the bucket until the bucket edge is on the ground. 2. Apply the parking brake and stop the engine. 3. Loosen the bolts holding the target mounting bracket (1) to the tilt cylinder eye. Align the target mounting bracket (1) parallel to the tilt cylinder (2). Tighten the bolts, refer to the illustration on this page. 4. Loosen the bolts holding the proximity switch mounting bracket (4) to the tilt cylinder (2). Position the proximity switch (5) parallel to the target bar (3) and tighten the bolts. 5. Adjust the proximity switch (5) out towards the target bar (3), until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. Torque the jam nut to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). NOTE: The proximity switch (5) must not protrude past the proximity switch guard (6). 6. Start the engine, position the bucket to the correct digging angle and stop the engine.

7. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). Slide the target bar (3) towards the proximity switch (5) until the face of the proximity switch (5) is completely covered. 8. Align the target bar (3) parallel to the tilt cylinder (2) and tighten the bolts. 9. Turn the ignition switch to the ON position. Do NOT start the engine. 10. Place the bucket control lever in the ROLLBACK position. 11. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). 12. Slide the target bar (3) slowly away from the proximity switch (5), until the control lever returns to the center position. Tighten the bolts holding the target bar (3). 13. Check to make sure that the 3.2 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained. 14. Start the engine. 15. Place the detent switch in the ON position and place the return to travel/float detent switch to the TRAVEL position. 16. Raise the lift arms approximately horizontal, and put the bucket in the fully dumped position. 17. Place the loader control lever in the ROLLBACK position, and verify that the electromagnet holds it in that position until the end of the target bar (3) passes in front of the proximity switch (5). 18. Lower the lift arms and verify that the bucket is at the correct digging angle.

9006-6

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

1 5

1 6

W270-5R012

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)

W270-5R012

1. TARGET MOUNTING PLATE 2. HEIGHT CONTROL TARGET

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

3. Lower the lift arms and place the bucket flat on the ground. 4. Stop the engine. NOTE: To avoid damge to the proximity switchs (3), they must be adjusted back to clear everything on the lift arm as it passes. Refer to the illustration on this page.

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. PROXIMITY SWITCH 4. LIFT ARM

1. Park the machine on a level surface. 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).

2. Start the engine and apply the parking brake. 3. Lower the lift arms and place the bucket flat on the ground. 4. Stop the engine. NOTE: To avoid damge to the proximity switchs (3), they 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).

6. Adjust the proximity switch (3) out towards the return to travel target (5) until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained.

7. Lock the proximity switch (3) in this position with the jam nut. Torque the jam nut to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).

9006-7

A 2

B 1

W270-5R013

1. HEIGHT CONTROL TARGET

2. RETURN TO TRAVEL TARGET

MACHINE

APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT

W270B

44 mm (1.73 inch)

380 mm (14.96 inches)

3. TARGET MOUNTING PLATE

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT

MACHINE

38 mm (1.50 inches)

3302 mm (130 inches)

W270B

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).

W270-5R013

1. HEIGHT CONTROL TARGET

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 6. 12. Start the engine.

2. RETURN TO TRAVEL TARGET

3. TARGET MOUNTING PLATE

APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT

APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT

44 mm (1.73 inch)

380 mm (14.96 inches)

38 mm (1.50 inches)

3302 mm (130 inches)

HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION

9006-8 13. Place the detent switch in the ON position, and set the return to travel/float detent switch to the return to travel position. 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 6.

9006-8 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 6. 16. Repeat steps 8 through 15 until the desired heights are reached. 17. Lower the bucket to the ground and stop 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. 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 6.

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 6. 16. Repeat steps 8 through 15 until the desired heights are reached. 17. Lower the bucket to the ground and stop the engine.

9006-9

REMOVING THE LOADER FRAME 1. Park the machine on a level surface and apply the parking brake. Roll the bucket all the way forward and lower the bucket to the floor. Stop the engine. 2. Loosen the filler plug in the reservoir to release the air in the reservoir.

9006-9

REMOVING THE LOADER 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).

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 crossmember (1) of the loader frame (2), refer to the illustration on page 10.

4. Loosen and remove the bolt (12), flat washer (13), and spacer (14) that fasten the pivot pin (3) to the piston rod yoke of the right lift cylinder (4).

5. Use an acceptable driver and drive the pivot pin (3) out of the piston rod yoke of the right lift cylinder (4). Do not remove the driver.

6. Repeat Steps 4 and 5 for the left lift cylinder.

6. Repeat Steps 4 and 5 for the left lift cylinder. BD01G009

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.

19. Remove the proximity switch cover. Left-hand side of the machine only.

BD01G009

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.

8. Raise the lift cylinder slightly and remove the driver.

9. Repeat steps 7 and 8 for the other lift cylinder.

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 bellcrank (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.

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 bellcrank (11).

BD01G010

1. ELECTRICAL CONNECTION

2. PROXIMITY SWITCH

20. Disconnect the electrical connector (1), remove the lock nut from the proximity switch (2) and remove the proximity 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).

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.

16. Connect the chain hoist to the loader frame (2).

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.

19. Remove the proximity switch cover. Left-hand side of the machine only.

1 2

BD01G010

1. ELECTRICAL CONNECTION

2. PROXIMITY SWITCH

9006-10

17 5

1 2

22 13

18 14

21 20

20 19

5 W270-5R014

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

CROSSMEMBER LOADER FRAME PIVOT PIN LIFT CYLINDER PIVOT PIN NOT USED

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

PIVOT PIN BUCKET CYLINDER PIVOT PIN PIVOT PIN BELLCRANK BOLT

13. 14. 15. 16. 17. 18.

WASHER SPACER BOLT WASHER SPACER WASHER

LOADER FRAME ILLUSTRATION

19. 20. 21. 22. 23.

BOLT WASHER SPACER WIPER DUMP LINK

W270-5R014

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

CROSSMEMBER LOADER FRAME PIVOT PIN LIFT CYLINDER PIVOT PIN NOT USED

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

PIVOT PIN BUCKET CYLINDER PIVOT PIN PIVOT PIN BELLCRANK BOLT

13. 14. 15. 16. 17. 18.

WASHER SPACER BOLT WASHER SPACER WASHER

LOADER FRAME ILLUSTRATION

19. 20. 21. 22. 23.

BOLT WASHER SPACER WIPER DUMP LINK

9006-11

INSTALLING THE LOADER FRAME 1. Apply antiseize compound to the inner bores and outer bores for the pivot pins of the front frame, refer to the illustration on page 10. 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.

9006-11

INSTALLING THE LOADER FRAME

17. Disconnect the chain hoist from the bucket cylinder (8). 18. Fasten the chain hoist to one of the lift cylinders. 19. Raise the piston rod yoke of the lift cylinder 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. 22. Disconnect the chain hoist from the lift cylinder. 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 crossmember (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 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

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 10. 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.

28. Install the bolt (12), washer (13), and spacer(14) that fasten the pivot pin (3). Tighten the bolt.

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.

28. Install the bolt (12), washer (13), and spacer(14) that fasten the pivot pin (3). Tighten the bolt.

12. Connect the chain hoist to the bucket cylinder (8) and lower the bucket cylinder (8).

29. Repeat Steps 26, 27, and 28 for the other lift cylinder. Stop the engine.

12. Connect the chain hoist to the bucket cylinder (8) and lower the bucket cylinder (8).

29. Repeat Steps 26, 27, and 28 for the other lift cylinder. Stop the engine.

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

30. Lubricate the pivot pins with molydisulfide grease.

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

30. Lubricate the pivot pins with molydisulfide grease.

14. Have another person help you at this time. Move the bucket control lever as required to align the piston rod eye of the bucket cylinder (8) with the bellcrank (11). Stop the engine.

31. Disconnect the chain hoist from crossmember (1) of the loader frame (2).

14. Have another person help you at this time. Move the bucket control lever as required to align the piston rod eye of the bucket cylinder (8) with the bellcrank (11). Stop the engine.

31. Disconnect the chain hoist from crossmember (1) of 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

15. Install the pivot pin (7) in the bellcrank (11) and the piston rod eye of the bucket cylinder (8). 16. Install the bolt (15), washer (16), and spacer (17) that fasten the pivot pin (7). Tighten the bolt.

27. Remove the driver and install the pivot pin (3).

the

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.

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).

the

9006-12

NOTES

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF)

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9007

Section 9007

9007

Section 9007

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

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

TABLE OF CONTENTS 3 3 4 4 9

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 9

9007-3

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) Attention

The Rollover Protective Structure (ROPS) or Cab 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:

ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) Attention

●

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.

The Rollover Protective Structure (ROPS) or Cab Structural Frame (CSF) is a special safety component of your machine.

All damaged parts MUST be replaced.

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 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.

9007-3

●

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS OR CAB STRUCTURAL FRAME.

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.

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS OR CAB STRUCTURAL FRAME.

MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six months, whichever comes first, do the following:

1. Check the torque on the CSF cab or ROPS canopy mounting bolts; torque should be 773 to 854 Nm (570 to 630 lb-ft). If necessary, tighten the bolts to the correct torque. 2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators seat mounting bolts; torque should be 73 to 87 Nm (54 to 64 lb-ft). If necessary, tighten the bolts to the correct torque. Replace parts that are worn or damaged. WARNING: Grade 8 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those shown in the parts catalog. 47-27A

WARNING: Do not install attachments that will make the total weight of the machine more than the weight shown in the maximum gross vehicle weight section of the ROPS serial number plate. 47-26 WARNING: Do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE ROPS. 47-25

9007-4

CSF CAB AND ROPS CANOPY Removal

STEP 5

NOTE: Procedures and photos in following steps cover in detail removal and installation of CSF structure. Removal and installation of ROPS is similar to removal and installation of CSF structure.

STEP 1

Park machine on a level surface and lower bucket to floor. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.

W270-8R001

Remove skirting under each side and front of cab.

STEP 2

STEP 6

W270-1R006

Put articulation lock in LOCKED position.

BD06G186

Remove the ducts from the machine.

STEP 3 Put battery disconnect switch in OFF position.

W270-8R001

Remove skirting under each side and front of cab.

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

STEP 7

STEP 4

W270-1R010

If machine is equipped with a heater, put a 57 liters (15 Gallons) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.

W270-8R002

At RH rear, bottom of cab, disconnect ground strap from rear chassis.

W270-1R010

If machine is equipped with a heater, put a 57 liters (15 Gallons) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.

9007-5

STEP 8

STEP 10

9007-5

STEP 8

STEP 10

BD06G194

W270-8R003

BD06G194

W270-8R003

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.

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 9 STEP 11 2

STEP 11

BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

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.

BD06G205 W270-8R009

Disconnect throttle connector and the air duct.

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

STEP 12 2

W270-8R009

Disconnect throttle connector and the air duct.

STEP 12 2

1 W270-8R004

W270-8R004

Unlatch and open the compartment door on the right hand side (1). Open and remove the access panel (2).

9007-6

STEP 13

STEP 17

BD06F210

Disconnect the electrical connectors for the remote control valve.

STEP 14 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 13

STEP 17

BD06F210

BD06G187

Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment

Disconnect the electrical connectors for the remote control valve.

STEP 18

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 14

STEP 15

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 16

Push the hoses out of the bottom of the cab with the rubber gromment.

BD06G187

Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment

STEP 18

BD06G188

Raise floor mat up and away from brake pedal to gain access to mounting hardware.

STEP 19

BD06G185

Remove hardware securing brake valve to cab floor. Let brake valve rest on the frame.

9007-7

STEP 20

STEP 23

9007-7

STEP 20

STEP 23

W270-8R005

W270-8R008

W270-8R005

W270-8R008

Remove the four bolts securing the cab cover, install lifting eyes in threaded holes at top of the cab.

Slowly raise cab from rear chassis. Check that all tie straps and clamps have been removed and all hoses, tubes, and wires are disconnected and free. Check that brake valve with hoses attached are free and clear of cab. Remove the ROPS or CSF from the machine. Lower ROPS or CSF onto wooden blocks to prevent damaging cab or canopy.

Remove the four bolts securing the cab cover, install lifting eyes in threaded holes at top of the cab.

STEP 21

W270-8R006

Connect lifting equipment to cab at lifting eyes. Take up all slack in lifting equipment.

STEP 22

W270-8R007

Remove nuts, bolts, and washers securing cab to rear chassis.

9007-8

4 5

5 6

6 BC06G031

1. NUT 2. WASHER 3. RUBBER MOUNT

4. RUBBER MOUNT 5. WASHER 6. BOLT

BC06G031

1. NUT 2. WASHER 3. RUBBER MOUNT

4. RUBBER MOUNT 5. WASHER 6. BOLT

9007-9

Installation

9007-9

Installation

STEP 30

STEP 24

Check rubber mounts (3 an 4) for deterioration, tears, deformation, or other damage; replace rubber mounts as necessary.

STEP 25

BD06G188

Position floor mat.

STEP 31

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 26

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)

W270-8R009

Connect throttle connector and mount air duct.

STEP 32

STEP 27

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)

Disconnect lifting equipment from cab.

STEP 28

Remove lifting eyes.

STEP 29

Connect throttle connector and mount air duct.

STEP 32

STEP 27

Disconnect lifting equipment from cab.

W270-8R009

W270-8R003

Remove plugs from hoses and caps from fittings. Connect hoses to steering control valve following tags installed during removal. Remove and discard tags.

BD06G185

Align mounting holes in brake valve with associated holes in cab or canopy floor. Install hardware to secure brake valve to floor.

9007-10

STEP 33

STEP 36

STEP 33 2

STEP 36

BD06G186

BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

Install the ducts on the machine.

STEP 34

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.

BD06G186

BD06G205

1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES

Install the ducts on the machine.

STEP 34

STEP 37

Remove plugs from hoses and caps from fittings. Connect hoses to joystick and two-lever controller and install in hose mounting grommet halves as shown on pages 11, 12, and 13.

W270-8R002

At RH rear, bottom of cab, connect ground strap to rear chassis.

STEP 35

BD06G194

If machine is equipped with windshield washers, connect front and rear windshield washer nozzle hoses following tags installed during removal. Remove and discard tags.

9007-11

4 8

6 1

8 5

7 1

2 8

3 6

7 2

3 6

W270-6R008

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK BLACK (RAISE)

4. ORANGE BLACK BLACK (ROLLBACK) 5. GREEN BLACK BLACK (DUMP) 6. RED BLACK BLACK (LOWER)

7. GREEN WHITE BLACK (4TH SPOOL) 8. RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 2 LEVER HOSE COLOR CODING

W270-6R008

1. PILOT TANK HOSE 2. PILOT PRESSURE HOSE 3. YELLOW BLACK BLACK (RAISE)

4. ORANGE BLACK BLACK (ROLLBACK) 5. GREEN BLACK BLACK (DUMP) 6. RED BLACK BLACK (LOWER)

7. GREEN WHITE BLACK (4TH SPOOL) 8. RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 2 LEVER HOSE COLOR CODING

9007-12

1 4

7 4

1 3

2 3

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL) 3 LEVER HOSE COLOR CODING

1 3

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 1 LEVER HOSE COLOR CODING

JOYSTICK AND 2 LEVER HOSE COLOR CODING

1 3

6 4

W270-6R010

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

W270-6R009

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

7 1

W270-6R009

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL) 3 LEVER HOSE COLOR CODING

W270-6R010

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) RED WHITE BLACK (3RD SPOOL)

JOYSTICK AND 1 LEVER HOSE COLOR CODING

JOYSTICK AND 2 LEVER HOSE COLOR CODING

9007-13

5 4

1 5 6

5 6

1 3

1 5

1 3

2 7

1 3 4

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) 2 LEVER HOSE COLOR CODING

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) JOYSTICK HOSE COLOR CODING

1 3

6 4

W270-6R012

6 4

W270-6R011

1 3

W270-6R011

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) 2 LEVER HOSE COLOR CODING

W270-6R012

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

PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK BLACK (LOWER) ORANGE BLACK BLACK (ROLLBACK) YELLOW BLACK BLACK (RAISE) GREEN BLACK BLACK (DUMP) JOYSTICK HOSE COLOR CODING

9007-14

STEP 38

STEP 40

STEP 38

STEP 40

BD06F210

Connect the electrical connectors for the remote control valve.

BD06F210 W270-8R004

Close the right hand compartment door (1, 2).

STEP 39

Connect the electrical connectors for the remote control valve.

Close the right hand compartment door (1, 2).

STEP 39 STEP 41

STEP 41

BD06G187

Connect wiring harness connectors.

W270-8R004

BD06G187 W270-8R001

Install skirting under each side and front of cab.

Connect wiring harness connectors.

W270-8R001

Install skirting under each side and front of cab.

9007-15

STEP 42

STEP 45

If the machine is equipped with air conditioning, charge the refrigerant making reference to the procedure described in section 9003.

STEP 43

Put articulation lock in OPERATING position.

9007-15

STEP 42

STEP 45

If the machine is equipped with air conditioning, charge the refrigerant making reference to the procedure described in section 9003.

STEP 43

W270-1R086

Fill the engine cooling system through the filler neck located on the engine hood with a 50% mixture of water and ethylene glycol. For the specifications, please refer to section 1002. Install the radiator cap.

STEP 44

W270-1R088

Move the main battery cut off switch onto ON. Start the engine and run it at idle speed. Let the engine run for about five minutes to completely mix the water and ethylene glycol. Once the coolant reaches the operational temperature, cut-off the engine. Once the engine has cooled-off, check the coolant level in the tank.

WARNING: hot coolant can be ejected when removing the radiator cap. When removing the radiator cap, let the cooling system cool-off, turn the cap very slowly and let the pressure drain completely.

Put articulation lock in OPERATING position.

9007-16

NOTES

CAB GLASS INSTALLATION

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

9010

Section 9010

9010

CNH Italia S.p.A. Viale delle Nazioni, 55 41100 Modena Italia

Section 9010

9010-2

TABLE OF CONTENTS

PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3

PREPARATION FOR GLASS REPLACEMENT 1. Remove all of the damaged glass section and the silicone sealant from the window frame 2. Remove all the adhesive from the window frame. 3. The window frame recesses must be free of oil and dust. Clean the frame with rubbing alcohol with a clean rag. Do not reuse the rag.

5. Clean the new glass section. Apply a 25 mm (1 inch) wide band of glass primer (349-110) to the black ceramic painted edges of the window. 6. When replacing a front window section, a silicone forming tool is needed, refer to Figure 2. Use the template and instructions provided to make the tool.

4. Apply a 25 mm (1 inch) wide band of metal primer (349-108) to the window recesses.

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.

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.

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.

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.

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.

PREPARATION FOR GLASS REPLACEMENT

4. Apply a 25 mm (1 inch) wide band of metal primer (349-108) to the window recesses.

9010-3

SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side windows. Use glass cleaning primer.

7. Remove the polyester tape from the inside joint.

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.

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.

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.

5. The tape must be smooth to get the best result when using the silicone forming tool.

6. Fill the joint with the clear silicone sealant (114328A1), refer to Figure 1. The silicone must completely penetrate and fill the gap between the glass sections. The sealant must extend at least 1.5 mm (1/16 inch) above the outside surface of the glass section for the length of the gap. Be sure the sealant fills against the adhesive at each end of the joint. 7. Remove the polyester tape from the inside joint. 8. Remove the extra silicone from the outside joint by carefully sliding the forming tool down the length of the joint. The tool must remain in contact with the glass sections during this process. Refer to Figure 2 for forming tool template.

9010-4

9. Remove all the silicone from the forming tool immediately after use.

3 498L93

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.

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 1. FRONT RH SIDE GLASS

9. Remove all the silicone from the forming tool immediately after use.

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.

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.

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

13. Remove the inside joint masking tape. 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.

120째

6 MM (1/2 INCH) R

120째

4 MM (3/16 INCH) R

FIGURE 2. SILICONE FORMING TOOL TEMPLATE

496L93

FIGURE 2. SILICONE FORMING TOOL TEMPLATE

496L93

9010-5

1 3

6 1

497L93

1. SIDE GLASS ADHESIVE 2. CENTER GLASS ADHESIVE

4. RIGHT HAND SIDE GLASS SPACER LOCATIONS 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES) FROM TOP OF FRONT SIDE GLASS 3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF CENTER AND SIDE PANELS CENTER GLASS

497L93

1. SIDE GLASS ADHESIVE 2. CENTER GLASS ADHESIVE

FIGURE 3 SILICONE APPLICATION

NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set.

9010-6

NOTES