SERVICE MANUAL Wheel Loader W270C W300C
Print No. 84547255A
W270C W300C Wheel Loader 84547255A
Use for Service Manual
W270C - W300C Wheel Loader Service Manual 84547255A
Table of Contents Description General
Section No. Tab 1
Section Index - General Standard Torque Specifications
1001
Fluids and Lubricants
1002
Metric Conversion Chart
1003 Tab 2
Engines Section Index - Engines Engine and Radiator Removal and Installation
2000
Stall Tests
2002
After Cooler
2003
For Engine Repair, See the Engine Service Manual 84394558 Fuel System
Tab 3
Section Index - Fuel System For Fuel System Repair, See the Engine Service Manual 84394558 SCR System
3002
Electrical
Tab 4
Section Index - Electrical Removal and Installation of Starter and Alternator
4001
Electrical Specifications and Troubleshooting
4002
Batteries
4003
Jump post option
4003a
Instrument Cluster
4005
Rear view Camera and Monitor
4006
Steering
Tab 5
Section Index - Steering Removal and Installation of Steering Components
5001
Steering Specifications, Pressure Checks, and Troubleshooting
5002
Steering Cylinders
5005
Center Pivot
5006
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright Š 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
W270C - W300C Wheel Loader Service Manual 84547255A
Table of Contents Description
Section No.
Auxiliary Steering Motor and Pump
5008
Joystick Steering System (JSS) (Optional)
5009
Power Train
Tab 6
Section Index - Power Train Removal and Installation of Power Train Components
6001
Transmission Specifications, Pressure Checks, and Troubleshooting
6002
Transmission
6003
Front Axle
6004
Rear Axle
6004
Drive Shafts, Center Bearing, and Universal Joints
6005
Wheels and Tires
6006
Transmission Control Valve
6007
Brakes
Tab 7
Section Index - Brakes Removal and Installation of Brake Components
7001
Hydraulic Brake Troubleshooting
7002
Brake Pump
7003
Brake Accumulators
7004
Parking Brake
7008
Hydraulics
Tab 8
Section Index - Hydraulics 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
W270C - W300C Wheel Loader Service Manual 84547255A
Table of Contents Description Mounted Equipment
Section No. Tab 9
Section Index - Mounted Equipment Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant
9002
Air Conditioner System Service
9003
Removal and Installation of Air Conditioning and Heater Components
9004
Loader
9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF)
9007
Cab Glass Installation
9010
Electrical Schematic Foldouts and Hydraulic Schematic Foldout
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
In Rear Pocket
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
SECTION INDEX
GENERAL Section Title
Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
1001 Section 1001 GENERAL TORQUE SPECIFICATIONS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
1001-2
TABLE OF CONTENTS TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 5 6
Printed in E.C.
1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts, and Studs
Grade 8 Bolts, Nuts, and Studs
PoundInches
Newton metres
1/4 inch
144 to 180
16 to 20
5/16 inch
288 to 348
33 to 39
3/8 inch
540 to 648
61 to 73
Size
PoundInches
Newton metres
Size
PoundFeet
Newton metres
1/4 inch
108 to 132
12 to 15
7/16 inch
70 to 84
95 to 114
5/16 inch
204 to 252
23 to 28
1/2 inch
110 to 132
149 to 179
3/8 inch
420 to 504
48 to 57
9/16 inch
160 to 192
217 to 260
5/8 inch
220 to 264
298 to 358
Size
PoundFeet
Newton metres
3/4 inch
380 to 456
515 to 618
7/16 inch
54 to 64
73 to 87
7/8 inch
600 to 720
814 to 976
1/2 inch
80 to 96
109 to 130
1.0 inch
900 to 1080
1220 to 1465
9/16 inch
110 to 132
149 to 179
1-1/8 inch
1280 to 1440
1736 to 1953
5/8 inch
150 to 180
203 to 244
1-1/4 inch
1820 to 2000
2468 to 2712
3/4 inch
270 to 324
366 to 439
1-3/8 inch
2380 to 2720
3227 to 3688
7/8 inch
400 to 480
542 to 651
1-1/2 inch
3160 to 3560
4285 to 4827
1.0 inch
580 to 696
787 to 944
1-1/8 inch
800 to 880
1085 to 1193
1-1/4 inch
1120 to 1240
1519 to 1681
1-3/8 inch
1460 to 1680
1980 to 2278
1-1/2 inch
1940 to 2200
2631 to 2983
Size
84547255A
NOTE: Use thick nuts with Grade 8 bolts.
Issued 11-11
Printed in E.C.
1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.
Grade 8.8 Bolts, Nuts, and Studs 8.8
Size
PoundInches
Grade 10.9 Bolts, Nuts, and Studs 10.9
Size
PoundInches
Newton metres
M4
36 to 48
4 to 5
M5
84 to 96
9 to 11
M6
132 to 156
15 to 18
M8
324 to 384
37 to 43
PoundFeet
Newton metres
Newton metres
M4
24 to 36
3 to 4
Size
M5
60 to 72
7 to 8
M10
54 to 64
73 to 87
M6
96 to 108
11 to 12
M12
93 to 112
125 to 150
M8
228 to 276
26 to 31
M14
149 to 179
200 to 245
M10
456 to 540
52 to 61
M16
230 to 280
310 to 380
M20
450 to 540
610 to 730
Newton metres
M24
780 to 940
1050 to 1275
Size
PoundFeet
M30
1470 to 1770
2000 to 2400
M12
66 to 79
90 to 107
M36
2580 to 3090
3500 to 4200
M14
106 to 127
144 to 172
M16
160 to 200
217 to 271
M20
320 to 380
434 to 515
M24
500 to 600
675 to 815
M30
920 to 1100
1250 to 1500
M36
1600 to 1950
2175 to 2600
84547255A
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.
Issued 11-11
Printed in E.C.
1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting
Straight Threads with O-ring
Tube OD Hose ID
Thread Size
PoundInches
Newton metres
Tube OD Hose ID
Thread Size
PoundInches
Newton metres
1/4 inch 6.4 mm
7/16-20
72 to 144
8 to 16
1/4 inch 6.4 mm
7/16-20
144 to 228
16 to 26
5/16 inch 7.9 mm
1/2-20
96 to 192
11 to 22
5/16 inch 7.9 mm
1/2-20
192 to 300
22 to 34
3/8 inch 9.5 mm
9/16-18
120 to 300
14 to 34
3/8 inch 9.5 mm
9/16-18
300 to 480
34 to 54
1/2 inch 12.7 mm
3/4-16
180 to 504
20 to 57
1/2 inch 12.7 mm
3/4-16
540 to 804
57 to 91
5/8 inch 15.9 mm
7/8-14
300 to 696
34 to 79 Tube OD Hose ID
Thread Size
PoundFeet
Newton metres
Tube OD Hose ID
Thread Size
PoundFeet
Newton metres
5/8 inch 15.9 mm
7/8-14
58 to 92
79 to 124
3/4 inch 19.0 mm
1-1/16-12
40 to 80
54 to 108
3/4 inch 19.0 mm
1-1/16-12
80 to 128
108 to 174
7/8 inch 22.2 mm
1-3/16-12
60 to 100
81 to 135
7/8 inch 22.2 mm
1-3/16-12
100 to 160
136 to 216
1.0 inch 25.4 mm
1-5/16-12
75 to 117
102 to 158
1.0 inch 25.4 mm
1-5/16-12
117 to 187
159 to 253
1-1/4 inch 31.8 mm
1-5/8-12
125 to 165
169 to 223
1-1/4 inch 31.8 mm
1-5/8-12
165 to 264
224 to 357
1-1/2 inch 38.1 mm
1-7/8-12
210 to 250
285 to 338
1-1/2 inch 38.1 mm
1-7/8-12
250 to 400
339 to 542
Split Flange Mounting Bolts PoundInches
Newton metres
5/16-18
180 to 240
20 to 27
3/8-16
240 to 300
27 to 34
7/16-14
420 to 540
47 to 61
Size
PoundFeet
Newton metres
1/2-13
55 to 65
74 to 88
5/8-11
140 to 150
190 to 203
Size
84547255A
Issued 11-11
Printed in E.C.
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS O-ring Boss End Fitting or Lock Nut
O-ring Face Seal End Nom. SAE Dash Size
Tube OD
Thread Size
PoundInches
Newton metres
Thread Size
PoundInches
Newton metres
-4
1/4 inch 6.4 mm
9/16-18
120 to 144
14 to 16
7/16-20
204 to 240
23 to 27
-6
3/8 inch 9.5 mm
11/16-16
216 to 240
24 to 27
9/16-18
300 to 360
34 to 41
-8
1/2 inch 12.7 mm
13/16-16
384 to 480
43 to 54
3/4-16
540 to 600
61 to 68
Thread Size
PoundFeet
Newton metres
7/8-14
60 to 65
81 to 88
1-1/16-12
85 to 90
115 to 122
-10
Nom. SAE Dash Size
5/8 inch 15.9 mm
Tube OD
1-14
552 to 672
62 to 76
Thread Size
PoundFeet
Newton metres
1-3/16-12
95 to 100
129 to 136
-12
3/4 inch 19.0 mm
1-3/16-12
65 to 80
90 to 110
1-5/16-12
115 to 125
156 to 169
-14
7/8 inch 22.2 mm
1-3/16-12
65 to 80
90 to 110
1-5/8-12
150 to 160
203 to 217
-16
1.0 inch 25.4 mm
1-7/16-12
92 to 105
125 to 140
1-7/8-12
190 to 200
258 to 271
-20
1-1/4 inch 31.8 mm
1-11/16-12
125 to 140
170 to 190
-24
1-1/2 inch 38.1 mm
2-12
150 to 180
200 to 254
84547255A
Issued 11-11
Printed in E.C.
1002
Section 1002 FLUIDS AND LUBRICANTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
1002-2
TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 5 5 5
Printed in E.C.
1002-3
CAPACITIES AND LUBRICANTS W270C CAPACITIES AND SPECIFICATIONS Engine Type of oil
AMBRA Mastergold HSP (SAE 15W-40)
Capacity (with filter change)
28.5 l (30.1 US qt)
Cooling system System capacity
56.8 l (60.0 US qt)
Fuel system System capacity
473.0 l (125.0 US gal)
Hydraulic system Type of fluid
AMBRA Hydrosystem 46 HV
Total system capacity
250.0 l (66.0 US gal)
Reservoir capacity
134.0 l (35.4 US gal)
Transmission Type of oil
AMBRA Supergold (SAE 10W-30)
Service capacity - with filter change
45.4 l (48 US qt)
Type of oil
AMBRA TRX Transaxle Fluid
Front axle STD
42 l (44 US qt)
Rear axle STD
42 l (44 US qt)
Front axle HD
62 l (65.5 US qt)
Rear axle HD
65.7 l (69.4 US qt)
Axles
Tank Urea (AD Blue) Type of fluid
Fluid Diesel exhaust (Spec ES-B5001)
Capacity
91 l (96 US qt)
84547255A
Issued 11-11
Printed in E.C.
1002-4 W300C Capacities and Specifications Engine Type of oil
AMBRA Mastergold HSP (SAE 15W-40)
Capacity (with filter change)
28.5 l (30.1 US qt)
Cooling system System capacity
56.8 l (60.0 US qt)
Fuel system System capacity
473.0 l (125.0 US gal)
Hydraulic system Type of fluid
AMBRA Hydrosystem 46 HV
Total system capacity
250.0 l (66.0 US gal)
Reservoir capacity
134.0 l (35.4 US gal)
Transmission Type of oil
AMBRA Supergold (SAE 10W-30)
Service capacity - with filter change
45.4 l (48 US qt)
Type of oil
AMBRA TRX Transaxle Fluid
Front axle STD
64.0 l (67.6 US qt)
Rear axle STD
64.0 l (67.6 US qt)
Front axle HD
62 l (65.5 US qt)
Rear axle HD
65.7 l (69.4 US qt)
Axles
Tank Urea (AD Blue) Type of fluid
Fluid Diesel exhaust (Spec ES-B5001)
Capacity
91 l (96 US qt)
84547255A
Issued 11-11
Printed in E.C.
1002-5
HYDRAULIC OIL TEMPERATURE CHART
LEEN11T0128EA
TRANSMISSION OIL TEMPERATURE CHART
LEEN11T0127EA
ENGINE OIL TEMPERATURE CHART
LEEN11T0126FA
84547255A
Issued 11-11
Printed in E.C.
1002-6
Coolant solution
Fuel storage
Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e . D o n o t u se n o n - a p p r o v e d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.
Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.
Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the ambient temperature is over -36 째C (-32.8 째F) use a blend of 50 % ethylene-glycol based anti-freeze. For areas where the temperature is below -36 째C (-32.8 째F)- it is advisable to use a blend of 40 % water and 60 % anti-freeze.
Fuel Use diesel fuel suitable for the ambient temperature conditions ( ASTM D975). Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard (North America). In Europa, fuel must comply with Specification Standard EN 590 or ITS EQUIVALENT. Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption. In very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier for appropriate fuel supply. If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting. In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.
Hydraulic fluid Ambra Hydrosystem 46 HV Ultra hydraulic fluid is specifically designed for high pressure applications and for New Holland hydraulic systems. Your New Holland Dealer can provide hydraulic fluid to fulfill different climate/temperature conditions. Refer to the charts at the beginning of this section.
Transmission component oil Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for your climate/temperature conditions such as Ambra Supergold SAE 10W-30. See charts at the beginning of this section.
Grease The type of grease to use depends on ambient temperature such as: Ambra GR 75 MD.
Environment Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.
Engine oil Ambra Mastergold engine oil is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures. If Ambra Mastergold engine oil cannot be obtained, use only oil of the API SERVICE CI-4 category. NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out utilizing New Holland lubricants. LEEN11T0129AA
84547255A
Issued 11-11
Printed in E.C.
1003
Section 1003 METRIC CONVERSION CHART
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
1003-2
TABLE OF CONTENTS CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84547255A
Issued 11-11
Printed in E.C.
1003-3
CONVERSION FACTORS Metric to U.S. MULTIPLY
BY
TO OBTAIN
Area:
sq. meter hectare
10.763 91 2.471 05
square foot acre
Force:
newton newton
3.596 942 0.224 809
ounce force pound force
Length:
millimeter meter kilometer
0.039 370 3.280 840 0.621 371
inch foot mile
Mass:
kilogram
2.204 622
pound
Mass/Area:
kilogram/hectare
0.000 466
ton/acre
Mass/Energy:
gr/kW/hr.
0.001 644
lbs/hp/hr.
Mass/Volume:
kg/cubic meter
1.685 555
lb/cubic yd.
Power:
kilowatt
1.341 02
horsepower
Pressure:
kilopascal bar
0.145 038 14.50385
lb/sq. inch lb/sq. inch
Temperature:
degree C
1.8 x C +32
degree F
Torque:
newton meter newton meter
8.850 748 0.737 562
lb/inch lb/foot
Velocity:
kilometer/hr.
0.621 371
miles/hr.
Volume:
cubic centimeter cubic meter cubic meter milliliter litre litre litre litre
0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969
cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial)
Volume/Time:
litre/min. litre/min.
0.264 172 0.219 969
gallon/min. (US liquid) gallon/min. (Imperial)
84547255A
Issued 11-11
Printed in E.C.
1003-4
U.S. to Metric MULTIPLY
BY
TO OBTAIN
Area:
square foot acre
0.092 903 0.404 686
square meter hectare
Force:
ounce force pound force
0.278 014 4.448 222
newton newton
Length:
inch foot mile
25.4 * 0.304 8 * 1.609 344 *
millimeter meter kilometer
Mass:
pound ounce
0.453 592 28.35
kilogram gram
Mass/Area:
ton/acre
2241 702
kilogram/hectare
Mass/Energy:
lb/hp/hr
608.277 4
gr/kW/hr
Mass/Volume:
lb/cubic yd.
0.593 276
kg/cubic meter
Power:
horsepower
0.745 700
kilowatt
Pressure:
lbs/sq. in. lbs/sq. in. lbs/sq. in.
6.894 757 0.069 0.070 303
kilopascal bar kg/sq. cm
Temperature:
degree F
1.8 F - 32
degree C
Torque:
pound/inch pound/foot
0.112 985 1.355 818
newton meter newton meter
Velocity:
miles/hr.
1.609 344 *
kilometer/hr.
Volume:
cubic inch cubic foot cubic yard ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US) gallons (Imperial)
16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092
cubic centimeter cubic meter cubic meter milliliter litre litre litre litre
Volume/Time:
gallon/min.
3.785 412
litre/min.
* = exact
84547255A
Issued 11-11
Printed in E.C.
SECTION INDEX
ENGINES Section Title
Section Number
Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002 After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003
FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL 84394558
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
Section 2000
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
2000-2
TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 12 21 21 22
Printed in E.C.
2000-3
ENGINE Removal
STEP 8
NOTE: Put caps on the fittings and plugs in the hoses to prevent foreign material from entering the system when disconnecting fuel lines or hydraulic hoses.
STEP 1
W270R613
Put the master disconnect switch (1) in the off position. W270R612
Park the machine on a level surface and lower the bucket to the ground. Put the articulation lock (1) in the locked position.
STEP 2 Key in the run position, engine off, place the pilot control switch in the normal operation position.
STEP 9 Drain the engine radiator coolant.
STEP 10 Drain the engine oil.
STEP 11
STEP 3 Move the loader hydraulic control handle to the raise and lower position in order to release any hydraulic pressure in the lift circuit.
STEP 4 Move the loader control handle in and out of the tilt position several times, this will relieve any pressure in the pilot accumulator.
STEP 5 Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve.
STEP 6 Depress the brake pedal several times to discharge brake accumulators.
W270R614
Loosen the hose clamp (1) on the air box snorkel under the air inlet hood.
STEP 7 Slowly loosen the filler cap on the hydraulic oil tank to release air pressure.
84547255A
Issued 11-11
Printed in E.C.
2000-4
STEP 12
STEP 14
W270R615
W270R617
Remove the mounting bolts on the exhaust stack hood. Attach lifting equipment to the exhaust stack. Remove the exhaust stack hood (1).
Disconnect the deaeration tank overflow hose (2). Remove the P-clamps (1) that secure the overflow hose to the wall and brackets. Position the overflow hose away from the engine and engine wall.
STEP 13 STEP 15
W270R616
Remove the SCR line support bracket (1).
W270R618
Remove the left bracket (1) and right bracket (2).
84547255A
Issued 11-11
Printed in E.C.
2000-5
STEP 16
STEP 18
W270R651
Remove the hydraulic oil lines (1).
W270R620
Remove the oil dipstick P-clamp (3) . Pull the oil dipstick tube (1) through the wall. Label and disconnect the hood lift strut electrical connector (2).
STEP 17
STEP 19
W270R619
Remove the after air cooler tube (1) . Remove the bulkheads (2). W270R621
Remove the before air coller tube (1). Remove the upper radiator tube (2).
84547255A
Issued 11-11
Printed in E.C.
2000-6
STEP 20
STEP 22
W270R622
Label and disconnect the humidity sensor electrical connector (1). Remove the turbo inlet tube (2). Label and disconnect the air filter restriction sensor electrical connector (3).
W270R624
Remove the lower, right panel (1) on the engine wall.
STEP 23
STEP 21
W270R625
Remove the air box assembly. W270R623
Remove the wire harness P-clamp (1). Loosen the hose clamp on the air box snorkel (2). Disconnect the air box snorkel (3).
STEP 24
W270R626
Remove the lower radiator tube (1) . 84547255A
Issued 11-11
Printed in E.C.
2000-7
STEP 25
STEP 27
W270R627
W270R629
Attach lifting equipment to the engine wall. Remove the engine wall’s hold-down bolts. Lift and remove the engine wall.
Disconnect the SCR coolant solenoid heater hose (1).
STEP 28 STEP 26
W270R630 W270R628
Remove the turbo exhaust tube (1).
84547255A
Remove two bolts (2), washers (3), and nuts (4). Remove the air box snorkel (1) .
Issued 11-11
Printed in E.C.
2000-8
STEP 29
STEP 31
W270R631
W270R633
Disconnect the inlet and outlet heater core heater hoses (1).
Disconnect the following from the crank case ventilation/fuel filter bracket assembly: ●
STEP 30
● ● ● ● ● ● ● ●
Fuel pump electrical connector; Water sensor electrical connector; Ground wire; Wire harness P-clamp; Crank case filter inlet hose; Crank case filter outlet hose; Crank case filter oil return hose; Fuel pump inlet tube; Fuel pump outlet tube.
STEP 32 Remove the crank case ventilation/fuel filter bracket assembly.
STEP 33 W270R632
Disconnect the starter battery cables (1) and starter switch wire (2).
W270R634
Label and disconnect the engine control module electrical connector (1). 84547255A
Issued 11-11
Printed in E.C.
2000-9
STEP 34
STEP 36
W270R635
Disconnect the fuel return line (1). Disconnect the battery positive wire (2) on the air grid heater.
W270R637
Remove the engine serpentine belt (1).
STEP 37 STEP 35
W270R638
W270R636
Disconnect the engine ground wires (1). Remove the wire harness P-clamp (2).
84547255A
Label and disconnect the A/C compressor electrical connector (1). Label and disconnect the A/C pressure switch electrical connector (4). Remove the alternator power wire (3). Label and disconnect the bulk electrical connector (5). Remove the A/C compressor (2). Position the A/C compressor (2) away from the engine.
Issued 11-11
Printed in E.C.
2000-10
STEP 38
STEP 40
W270R641
Remove the wire harness P-clamps (1).
Attach lifting equipment to the engine. Support the engine.
STEP 39
STEP 41
W270R639
W270R640
Remove the engine oil drain tube (1).
84547255A
W270R642
Remove the hydraulic oil return tube P-clamp (1). Position the hydraulic oil return tube away from the converter housing cover plate.
Issued 11-11
Printed in E.C.
2000-11
STEP 42
STEP 45
W270R646 W270R643
Remove the converter housing cover plate (1).
Remove the front engine mounts (1) and engine mount plate (2).
STEP 43
STEP 46
W270R644
W270R647
Remove the flex plate bolts (1).
Remove the bell housing bolts (1).
STEP 44
STEP 47
W270R645
Remove the harmonic balancer (1). 84547255A
W270R641
Remove the engine. Issued 11-11
Printed in E.C.
2000-12
Install
STEP 50
STEP 48
W270R649
W270R641
Carefully lower the engine into the chassis.
STEP 49
Install the engine mount plate (5) and the engine mount brackets (1), but do not tighten the bolts to a torque value. Tighten the engine bracket upper bolts (2) to a torque of 171 - 231 N·m (126 - 170 lb ft). Tighten the engine bracket lower bolts (3) to a torque of 69 - 80 N·m (51 - 59 lb ft). Tighten the engine mount plate bolts (4) to a torque of 386 - 434 N·m (285 - 320 lb ft). Tighten the engine bracket-to-engine mount plate bolts (6) to a torque of 397 - 447 N·m (293 - 330 lb ft).
STEP 51
W270R647
Install the bell housing bolts (1). Tighten the bell housing bolts (1) to a torque of 54 - 60 N·m (40 - 44 lb ft).
W270R650
Install the harmonic balancer (1). Tighten the harmonic balancer bolts (2) to a torque of 115 N·m (85 lb ft).
84547255A
Issued 11-11
Printed in E.C.
2000-13
STEP 52
STEP 54
W270R644
W270R631
Install the flex plate bolts (1). Tighten the flex plate bolts (1) to a torque of 33 - 41 N¡m (24 - 30 lb ft).
Connect the inlet and outlet heater core heater hoses (1).
STEP 53
STEP 55
W270R642 W270R643
Apply DOW 732 RTV SILICONE CLEAR to the converter housing cover plate (1). Install the converter housing cover plate (1).
84547255A
Reposition the hydraulic oil return tube. Install the hydraulic oil return tube P-clamp (1).
Issued 11-11
Printed in E.C.
2000-14
STEP 56
STEP 58
W270R630
Install the air box snorkel (1). Install two bolts (2), washers (3), and nuts (4).
W270R628
Install the turbo exhaust tube (1).
STEP 59 STEP 57
W270R641 W270R629
Remove lifting equipment from the engine.
Connect the SCR coolant solenoid heater hose (1).
STEP 60
W270R627
Install the engine wall. 84547255A
Issued 11-11
Printed in E.C.
2000-15
STEP 61
STEP 63
W270R626
Install the lower radiator tube (1).
W270R623
Install the wire harness P-clamp (1). Connect the air box snorkel (3). Tighten the hose clamp on the air box snorkel (2).
STEP 62
STEP 64
W270R625
Install the air box. W270R624
Install the lower, right panel (1) on the engine wall.
84547255A
Issued 11-11
Printed in E.C.
2000-16
STEP 65
STEP 67
W270R622
Install the turbo intlet tube (2). Connect the humidity sensor electrical connector (1). Connect the air filter restriction sensor electrical connector (3).
W270R640
Install the engine oil drain tube (1).
STEP 68
STEP 66
W270R639 W270R621
Install the upper radiator tube (2). Install the before air cooler tube (1).
Install the wire harness P-clamps (1).
STEP 69
W270R637
Install the engine serpentine belt (1). 84547255A
Issued 11-11
Printed in E.C.
2000-17
STEP 70
STEP 72
W270R638
Install the A/C compressor (2). Connect the A/C compressor electrical connector (1). Connect the A/C pressure switch electrical connector (4). Connect the alternator power wire (3). Connect the bulk electrical connector (5).
W270R635
Connect the fuel return line (1). Connect the battery positive wire (2) on the air grid heater.
STEP 73
STEP 71
W270R636
Connect the engine ground wires (1). Install the wire harness P-clamp (2).
W270R634
Connect the engine control module electrical connector (1).
STEP 74 Install the crank case ventilation/fuel filter bracket assembly.
84547255A
Issued 11-11
Printed in E.C.
2000-18
STEP 75
STEP 77
W270R633
W270R620
Connect the following on the crank case ventilation/ fuel filter bracket assembly:
Connect the hood lift strut electrical connector (2). Slip the oil dipstick tube (1) through the engine wall. Install the dipstick tube P-clamp (3).
● ● ● ● ● ● ● ● ●
Fuel pump electrical connector Water sensor electrical connector Ground wire Wire harness P-clamp Crankcase filter inlet hose Crankcase filter outlet hose Crankcase filter oil return hose Fuel pump inlet tube Fuel pump outlet tube
STEP 78
STEP 76
W270R619
Install the bulkheads (2). Install the after air cooler tube (1).
W270R632
Connect the starter battery cables (1) and starter switch wire (2).
84547255A
Issued 11-11
Printed in E.C.
2000-19
STEP 79
STEP 82
W270R651
W270R616
Install the hydraulic lines (1).
Install the SCR line support bracket (1).
STEP 80
STEP 83
W270R618
Install the left bracket (1) and right bracket (2).
STEP 81
W270R615
Lower the exhaust stack hood (1) in front of the engine wall and onto the left bracket, right bracket, and hydraulic oil tank. Install the exhaust stack hood mounting bolts.
W270R652
Install the P-clamps (2) and overflow tube (1) to the engine wall, left bracket, and deaeration tank (3). 84547255A
Issued 11-11
Printed in E.C.
2000-20
STEP 84
W270R614
Attach the air box snorkel to the air inlet hood. Tighten the air box snorkel hose clamp (1).
STEP 85 Check and adjust all fluid levels.
84547255A
Issued 11-11
Printed in E.C.
2000-21
RADIATOR Removal
STEP 5
STEP 1 Park the machine on a level surface and lower the bucket to the ground. stop the engine and apply the parking brake.
STEP 2 Raise the engine hood.
STEP 3 Place the master disconnect switch in the OFF position.
STEP 4 W270R606
Disconnect the top hose and install a plug in the hose and a cap on the fitting.
STEP 6
W270R571
W270R608
Put a 30 liter (8 gallon) container below radiator drain. Remove radiator cap then remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.
Disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting.
84547255A
Issued 11-11
Printed in E.C.
2000-22
STEP 7
STEP 9 4
5
4 3
2 1 W270R608 W270R607
Loosen and remove the bolt (1) and washer (2), the nut (3), washer (4) and bolt (5) that fasten the oil cooler to the cooling frame. Remove radiator from machine.
Connect the lower hose to the oil cooler to cooling frame.
STEP 10
Insallation STEP 8 4
5
4 3
W270R606
Connect the hose to the top of the oil cooler.
2 1 W270R607
Place the oil cooler in position in the cooling frame. Install and tighten the two mounting bolts (5), washer (4) and nuts (3), the washers (2) and bolts (1).
84547255A
Issued 11-11
Printed in E.C.
2000-23
STEP 11
STEP 13 Put master disconnect switch in ON position.
STEP 14 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol and water. When the coola nt is a t ope ratin g temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.
STEP 15 Put articulation lock in OPERATING position.
W270R571
Check that coolant drain cap is tight.
STEP 12 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liter (8 gallon). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.
84547255A
Issued 11-11
Printed in E.C.
2000-24
NOTES
84547255A
Issued 11-11
Printed in E.C.
2002
Section 2002 STALL TEST
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
2002-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 3 5 5 5 6 7 7 7 7 7 8 8
Printed in E.C.
2002-3
SPECIFICATIONS ENGINE W/4 Speed Trans. (W270C-W300C) A. Idle RPM
870-930
Alternate Low Idle
570-630
Alternate Accelerated Idle
1170-1230
B. Maximum No Load RPM
2187Âą25
C. Converter Stall
1st gear 1970 - 2nd/4th gear 2075
D. Hydraulic Stall
1885-2195
E. Converter & Hydraulic Stall
1665
Note: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode.
STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.
INSTRUMENT CLUSTER DISPLAYS 1. With the engine running, press the up or down key and scroll through the information screens and trip screens. The following sequence is using the down key only. NOTE: Pressing the escape key will return the LCD back to the normal driving screen.
W230R435
3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, fuel level, and the Urea level.
BD06F188
2. From the driving screen push the down arrow, as shown.
84547255A
Issued 11-11
Printed in E.C.
2002-4
W230R436
W230R438
4. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Fahrenheit or Celsius, and the Urea level.
7. Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.
W230R437
5. Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and the Urea level.
Info Voltage Air Turbo DefTemp DefLvl
W230R439
8. By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.
4 V 24.2 °C 42 °C 32 % 24 W230M171
6. Push the down key again to display the info 4 screen. This screen display the voltage level, turbocharger air temperature, Urea temperature and Urea level.
84547255A
Issued 11-11
Printed in E.C.
2002-5
PROCEDURE TO HEAT THE OIL Torque Converter
Hydraulic System
1. Sit in the seat.
1. Apply the parking brake.
2. Start the engine and run the engine at low idle.
2. Start the engine and run at full throttle.
3. To measure the oil temperature with the instrument cluster:
3. To measure the oil temperature with the instrument cluster:
A. Press the up or down arrow key.
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures that need to be monitored.
B. Stop at the info screen with the temperatures that need to be monitored are on.
4. Place the declutch switch in the OFF position. 5. Place the automatic switch in the manual mode position. Push down and hold the brake pedal for the remainder of this procedure. 6. Release the parking brake.
4. Hold the bucket control lever in the ROLLBACK position and hold the lift control lever in the FLOAT position. 5. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).
7. Move the transmission control lever to Forward and turn the transmission control lever to 3rd gear. 8. Increase the engine speed to full throttle and run the engine at this speed for 30 seconds. 9. Decrease the engine speed to low idle and move the transmission control lever to the Neutral position for 15 seconds. 10. Repeat steps 7, 8, and 9 until the temperature of the torque converter oil is 82° to 104°C (180° to 220°F).
84547255A
Issued 11-11
Printed in E.C.
2002-6
POWER MODE SELECTION 1. After the oil temperatures have been raised to operating temperatures the power mode must be set to “Auto”.
3. Use down arrow to scroll through the menu’s. 4. High light Power Mode and press the enter key. 5. Power Mode Menu
W230R440
2. Press and hold the confirmation “enter” button for two seconds to arrive at the above service screen.
W230R441
A. Max - Maximum power possible B. Standard - Standard operation C. Auto - Will cycle between Max and Standard D. Eco - Limited power for economy 6. High light Auto mode and press the enter key. 7. Press the escape key to return to the normal driving screen.
84547255A
Issued 11-11
Printed in E.C.
2002-7
PERFORMING STALL TESTS Test No. 1 - Torque Converter and Hydraulic Stall Together 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward.
Test No. 2 - Torque Converter Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. Run the engine at low idle.
4. Run engine at low idle. Push the clutch cutout switch to OFF. Put the transmission in manual mode. Push down and hold the brake pedal for the remainder of this procedure.
6. Turn the transmission control lever to third gear.
5. Turn the transmission control lever to third gear.
7. Increase the engine speed to full throttle.
6. Increase the engine speed to full throttle.
8. Check the engine speed.
7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. The stall speed must be read while the lift arms are in motion.
9. Decrease the engine speed to low idle.
8. Check the engine speed.
5. Push down and hold the brake pedal for the remainder of this test.
10. Place the transmission in neutral and apply the parking brake. 11. Stop the engine.
9. Release the bucket control lever. 10. Decrease the engine speed to low idle. 11. Lower the bucket to the ground, place the transmission in neutral and apply the parking brake. 12. Stop the engine.
Understanding the Results of Test No. 1 1. If the engine speed was as specified, the engine, torque converter, transmission and hydraulic system are probably good.
Understanding the Results of Test No. 2 1. If the engine speed was as specified, the engine, torque converter and transmission are probably good. 2. If the engine speed was more than specified, the problem can be in the torque converter or the transmission. See Section 6002 for troubleshooting information. 3. If the engine speed was less than specified, do Test No. 3.
2. If the engine speed was not as specified, do Test No. 2 and 3.
84547255A
Issued 11-11
Printed in E.C.
2002-8
Test No. 3 - Hydraulic Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Increase the engine speed to full throttle. 4. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. The stall speed must be read while the lift arms are in motion. 5. Check the engine speed. 6. Release the bucket control lever.
Understanding the Results of Test No. 3 1. If the engine speed was as specified, the engine and hydraulic system are good. 2. If the engine speed was more or less than specified the main relieef setting may be too low or too high. See Section 8002 for troubleshooting information. 3. If the engine speed was less than specified in all tests, the engine is probably the cause.
7. Decrease the engine speed to low idle. 8. Lower the bucket to the ground. 9. Stop the engine.
84547255A
Issued 11-11
Printed in E.C.
2003
Section 2003 AFTER COOLER
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
2003-2
TABLE OF CONTENTS TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 4 6 6
Printed in E.C.
2003-3
TROUBLESHOOTING AFTER COOLER STEP 1
STEP 6
Park machine on level ground, lower the bucket. Put transmission in neutral, apply the parking brake. Turn off engine.
STEP 2 Raise hood. Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.
STEP 3 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. If the pressure difference is greater than 60 mbar (0.87 psi), inspect cooler components for damaged or missing parts.
W230R429
Inspect the after cooler outlet flex hose for leaks or holes and insure that the clamps are tight.
STEP 7
STEP 4
W270R602 W270R601
Inspect the turbocharger flex hose for leaks or holes and insure that the clamps are tight.
Inspect the intake manifold flex hose for leaks or holes and insure that the clamps are tight.
STEP 8
STEP 5
W270R603 BD03A115
Inspect the after cooler inlet flex hose for leaks or holes and insure that the clamps are tight.
84547255A
Visually inspect top of after cooler for damage or leaks NOTE: If the leak source has not been located, remove and test the after cooler.
Issued 11-11
Printed in E.C.
2003-4
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. W270R602
Drain of coolant from engine cooling system.
Loosen clamps and remove Intake hose.
STEP 3
STEP 6
W270R601
Loosen clamps and remove turbocharger outlet components.
W230R429
Loosen clamps and remove air cooler outlet hose.
STEP 4
BD03A115
Loosen clamps and remove air cooler inlet hose.
84547255A
Issued 11-11
Printed in E.C.
2003-5
STEP 7 1
2
3 W270R604
Remove the two nuts (1), washer (2) and U-bolt (3) of the plate of the after cooler mounting frame.
STEP 8 1
1 3
2
2 4
2
W270R605
Remove four bolts (1), washers (2) and springs (3) of the after cooler mounting frame (4). Remove air cooler from frame.
84547255A
Issued 11-11
Printed in E.C.
2003-6
Leak Test
Installation STEP 1 1
1 3
2
2
4
2
BS03B028
Check the core for leaks by closing off the outlet tube and attaching regulated air pressure 550kPa (80psi) to the inlet tube. Submerge the cooler in water and watch for air leakage. NOTE: If leakage is detected replace the after cooler.
W270R605
Install after cooler in its frame (4). Install four mounting washers (2), springs (3) and bolts (1).
STEP 2 1
2
3 W270R604
Install U-bolt (3), washers (2) and nuts (1) of the plate of the after cooler mounting frame.
84547255A
Issued 11-11
Printed in E.C.
2003-7
STEP 3
STEP 6
W270R601
Install air cooler inlet hose. Tighten clamps at turbocharger outlet.
STEP 4
W230R429
Tighten clamps at air cooler outlet.
STEP 7 Refill the cooling system.
STEP 8 Install ‘T’ fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.
STEP 9 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. confirm that the pressure difference is less than 60 Bar (0.87 psi). BD03A115
Tighten clamps at air cooler inlet.
STEP 5
W270R602
Install air cooler outlet hose and tighten clamps at engine intake.
84547255A
Issued 11-11
Printed in E.C.
2003-8
NOTES
84547255A
Issued 11-11
Printed in E.C.
SECTION INDEX
FUEL SYSTEM Section Title
Section Number
SCR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL 84394558
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
3002
Section 3002 SCR SYSTEM
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
3002-2
TABLE OF CONTENTS Selective catalytic reduction (SCR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Storage, handling and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SCR System Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 NOx Sensor Reinstall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Intake Temperature/Humidity Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DEF/ADBLUE Heater Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DEF/ADBLUE DNOx Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DEF/Adblue Dosing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DEF/AdBlue Supply Tank Level and Temperature Sensor Pickup and Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DEF/adblue supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation Supply Tank Filler Neck Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Removal Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Installation Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Installation DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
84547255A
Issued 11-11
Printed in E.C.
3002-3 SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Your machine is equipped with additional components to comply with national and local exhaust emissions requirements. The main components of the SCR system include the SCR catalyst, the Diesel Exhaust Fluid (DEF) /AdBlue (27), injection unit (7), the DEF/AdBlue tank (1), and the DEF/AdBlue electronic control unit (26). During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx olecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue solution. Storage, handling, and transport NOTE: Storage temperatures above 30 °C (86 °F) greatly reduce the shelf life of DEF/AdBlue. DEF/AdBlue has a typical shelf life of 6-12 months. In order for DEF/AdBlue to remain in a useable condition, storage requirements need to be met. ●
Store between -11 °C (12 °F) and 30 °C (86 °F).
●
Use only an approved DEF/AdBlue container. Contact your dealer to obtain proper storage container(s).
●
Keep container tightly closed.
●
Keep container in a cool, well-ventilated area.
●
Keep away from heat and direct sunlight.
●
Your machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue. Your machine will still function until the DEF/AdBlue begins to flow. The SCR system will then function normally.
●
No additives are required.
NOTE: Contaminated DEF/AdBlue performance of your machine.
can
affect
the
Shelf life Constant ambient storage temperature Minimum shelf life Less than or equal to 10 °C (50 °F) 36 months Less than or equal to 25 °C (77 °F) ¹ 18 months Less than or equal to 30 °C (86 °F) 12 months Less than or equal to 35 °C (95 °F) 6 months Greater than 35 °C (95 °F) -² ¹ To prevent decomposition of DEF/AdBlue, prolonged transportation or storage above 25 °C (77 °F) should be avoided. ² Significant loss of shelf life: check every batch before use. See your New Holland dealer for more information on testing. Disposal ●
Dispose of DEF/AdBlue and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal.
Do not heat DEF/AdBlue for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life. NOTE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue mixture will lessen its ability to perform correctly and may cause damage to the SCR components. Handling and supply of additives, if any. ●
Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, impervious gloves are recommended.
84547255A
Issued 11-11
Printed in E.C.
3002-4 COMPONENT LOCATION ILLUSTRATION SCR SYSTEM (table 1) 1. Tank - 90 liter (24 gallon) 2. Bracket tank 3. Cap 4. Hose 5. Clamp 6. Clamp 7. Module DNOX2 UREA dosing 8. Bracket module 9. Filler neck 10.Screw 11.Bolt 15.Hose UREA fill 16.Washer 17.Bracket sensor mount 19.Nut 20.Bracket DEF support 21.Hose 22.Screw - torque 7 ± 0.5 Nm (5 ± 0.36 lb-ft) 23.Muffler 24.Rear chassis 25.Clamp 27.Solution aqueous UREA (Ad Blue) A1.White connection A2.Black connection A3.Blue connection A4.White connection
84547255A
Issued 11-11
Printed in E.C.
3002-5
19 25 21 11
16 16 19
22
16
20
6
17
16
A2
A1
7
5 A3
A4 23 4 3 A
19 16 11 10 16
9
19
5
16 11 24
16 19
8
15
1 27 11 2
A
W270R093
84547255A
Issued 11-11
Printed in E.C.
3002-6
32 42 28 34 28 33
32
26 34 28
28
33
32
30
41
43
40
36 37 38 33 28 35
28
31
39
28 29
42
32
W270R094
84547255A
Issued 11-11
Printed in E.C.
3002-7 COMPONENT LOCATION ILLUSTRATION SCR SYSTEM (table 2) 26.Electronic control unit DNOX2 UREA 28.Washer 29.Bolt - torque 24 ± 4 Nm (17.7 ± 3 lb-ft) 30.Valve, heater 31.Bolt - torque 18 ± 2 Nm (13 ± 1.5 lb-ft) 32.Clamp 33.Bolt 34.Nut 35.Clamp 36.Fitting 37.Clamp 38.Hose 39.Clamp 40.Clamp 41.Sleeve protective heat 42.Clamp 43.Engine cap
84547255A
Issued 11-11
Printed in E.C.
3002-8
SCR SYSTEM SENSORS Upstream Exhaust Temperature Sensor Removal
STEP 3
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
2 1
STEP 1
W270R097
Locate exhaust temperature sensor (1) on exhaust system before the catalyst (2).
STEP 4 W270R095
Raise the hood using controls located behind the access cover.
STEP 2
W270R098
Loosen hex nut on sensor.
W270R096
Turn master electric switch to the “off� position.
84547255A
Issued 11-11
Printed in E.C.
3002-9
Upstream Exhaust Temperature Sensor Reinstall
STEP 5
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R099
Remove temperature sensor from exhaust system.
STEP 6
W270R099
Install temperature sensor into exhaust pipe.
STEP 2
W270R100
Remove wire ties securing wire harness to support brackets. Unplug sensor from machine wiring harness and remove it.
W270R098
Secure sensor into exhaust pipe. Sensor torque 40 to 50 Nm (30 to 36 lb ft.). Reconnect sensor to wire harness and secure harness to support brackets using new wire ties.
84547255A
Issued 11-11
Printed in E.C.
3002-10
STEP 3
STEP 2
W270R096
Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.
W270R096
Turn master electric switch to the “off” position.
STEP 3
Downstream Exhaust Temperature Sensor Removal NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
2 1
STEP 1
W270R101
Locate the exhaust temperature sensor (1) on exhaust system after catalyst (2).
STEP 4
W270R095
Raise the hood using controls located behind the access panel.
W270R102
Loosen hex nut and remove sensor from exhaust system. 84547255A
Issued 11-11
Printed in E.C.
3002-11
Downstream Exhaust Temperature Sensor Reinstall
STEP 5
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R659
Loosen hex nut and remove P-clamp securing sensor wiring harness to catalyst mounting support bracket. Remove any wire ties securing wiring harness to machine.
STEP 6
W270R102
Install temperature sensor into exhaust system. Secure sensor by tightening hex nut. Sensor torque 40 to 50 Nm (30 to 36 lb ft.).
STEP 2
W270R660
Disconnect sensor from wiring harness.
STEP 7
W270R661
Install hex nut and P-clamp holding sensor wiring harness to catalyst mounting support bracket.
W270R100
Remove sensor and wiring harness as one component from machine. 84547255A
Issued 11-11
Printed in E.C.
3002-12
NOx Sensor Removal
STEP 3
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R662
Reconnect sensor to machine wiring harness.
STEP 4
W270R095
Raise the hood using controls located behind the access cover.
STEP 2
W270R096
Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.
W270R096
Turn master electric switch to the “off” position.
84547255A
Issued 11-11
Printed in E.C.
3002-13
STEP 3
STEP 5 1
2
W270R103
Locate NOx sensor (1) on exhaust system down stream of catalyst (2).
W270R104
Loosen hex nut on NOx sensor.
STEP 6
STEP 4
1
2
W270R105 W270R663
Loosen hex nut and remove P-clamp (1) holding sensor wiring harness to catalyst mounting support bracket (2).
Remove NOx sensor from exhaust system.
STEP 7
1
W270R106
Locate NOx sensor module (1) on the backside of the SCR catalyst mounting support bracket (2). 84547255A
Issued 11-11
Printed in E.C.
3002-14
NOx Sensor Reinstall
STEP 8
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R664
Disconnect NOx sensor module from machine wiring harness.
STEP 9
W270R105
Install NOx sensor into exhaust system.
STEP 2
W270R107
Remove hex bolts securing NOx sensor module to mounting support bracket and remove module.
STEP 10 W270R104
Secure NOx sensor with hex nut. Sensor torque 40 to 60 Nm (30 to 44 lb ft.)
W270R665
Remove wire ties securing NOx sensor wiring harness to machine and remove sensor.
84547255A
Issued 11-11
Printed in E.C.
3002-15
STEP 3
STEP 5 2 1
W270R107
W270R667
Install NOx sensor module and secure it to mounting support bracket using hex bolts. NOx sensor module torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.).
Secure NOx sensor wire harness with P-clip (1) to catalyst mounting support bracket (2) using hex bolts. Secure wire harness with wire ties where appropriate.
STEP 4
STEP 6
W270R096 W270R666
Reconnect machine wiring harness to NOx sensor module.
84547255A
Turn master electric switch to “on� position. Clear any fault code. Start engine and check to see if problem has been corrected.
Issued 11-11
Printed in E.C.
3002-16
INTAKE TEMPERATURE/HUMIDITY SENSOR Removal
STEP 3
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R108
Locate the intake temperature/humidity sensor on air intake pipe between the air filter housing and turbocharger.
STEP 4 W270R095
Raise the engine compartment hood using controls located behind the access cover.
STEP 2
W270R109
Disconnect wiring harness plug.
W270R096
Turn the master electric switch to the “off� position.
84547255A
Issued 11-11
Printed in E.C.
3002-17
Installation
STEP 5
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R110
Remove hex bolts.
STEP 6
W270R111
Remove plug covering hole in intake pipe. Insert sensor.
STEP 2
W270R111
Remove sensor. NOTE: Cover hole in the intake pipe to prevent debris from entering the system.
W270R110
Secure sensor with hex bolts. Maximum tightening torque: 17 Nm (12.5 lb ft).
84547255A
Issued 11-11
Printed in E.C.
3002-18
STEP 3
W270R109
Reconnect wiring harness plug.
STEP 4
W270R096
Turn master electric switch “on�. Clear any fault code. Start machine and confirm that problem has been corrected.
84547255A
Issued 11-11
Printed in E.C.
3002-19
DEF/ADBLUE HEATER CONTROL VALVE Removal
STEP 3
STEP 1
W270R095
Raise the hood using controls located behind the access cover. W270R571
STEP 2
Place a suitable container below radiator drain located behind access cover. Remove radiator cap. Remove drain cap and drain engine coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area prior to draining the system.
STEP 4
W270R096
Turn master electric switch to the “off� position.
W270R668
Locate DEF/AdBlue Heater Control valve next to the DNOx Supply Module on the left hand side of the engine.
84547255A
Issued 11-11
Printed in E.C.
3002-20
STEP 5
STEP 7
W270R669
W270R671
Disconnect the machine wiring harness from the DEF/AdBlue heater control valve.
Remove hex bolts securing heater control valve to mounting support bracket.
STEP 6
STEP 8
W270R670
Using a small flat blade screw driver, pull up on the fitting retaining clip and disconnect the coolant inlet/outlet lines from the heater control valve.
84547255A
W270R672
Remove heater control valve from machine.
Issued 11-11
Printed in E.C.
3002-21
Installation
STEP 3
STEP 1
W270R0962
W270R673
Turn master electric switch to the “on� position. Clear any fault code. Start the machine and check for engine coolant leaks. Confirm that problem has been corrected.
Position DEF/AdBlue heater control valve on the mounting support bracket and secure it with hex bolts.
STEP 2
W270R674
Reconnect coolant inlet/outlet lines and wiring harness. Refill engine cooling system.
84547255A
Issued 11-11
Printed in E.C.
3002-22
DEF/ADBLUE DNOX SUPPLY MODULE Removal
STEP 3
STEP 1
W270R095
W270R112
Raise the hood using controls located behind the access cover.
On the left hand side of engine mark supply and return line connection locations for reference during reassembly.
STEP 2 STEP 4
W270R096
Turn the master electric switch to the “off� position. W270R113
From the bottom of the module disconnect DEF/AdBlue supply and return lines from underneath DNOx supply module. NOTE: To disconnect fittings, squirt water into the fitting connection to lubricate the O-ring. Squeeze the locking tabs together while slightly pushing the fitting ends together and then pulling them apart. If the fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be used. NOTE: Use compressed air and water to clean debris from supply and return line connections.
84547255A
Issued 11-11
Printed in E.C.
3002-23
Installation
STEP 5
STEP 1 2
1
W270R114
Remove hex bolts securing the DNOx supply module to the mounting support bracket.
STEP 6
1
W270R676
Position the DNOx supply module on its mounting support bracket. Connect wiring harness to back of supply module. Be sure the lever (1) is fully engaged and the plug (2) is fully seated.
2
STEP 2
W270R675
Partially remove DNOx supply module from its mounting support bracket to gain access to the wiring harness (1). Open the lever (2) and disconnect wiring harness from DNOx supply module. Remove DNOx supply module from the machine.
84547255A
W270R114
Fit the DNOx supply module into mounting support bracket and secure with hex bolts. Bolts torque 24 Âą 4 Nm (17.7 Âą l Lb ft).
Issued 11-11
Printed in E.C.
3002-24
STEP 3
STEP 4
W270R113
Reconnect supply and return lines underneath DNOx control module. To connect, push the two fitting ends together until an audible snap is heard. NOTE: Test fitting connections to be sure they are secure. Match supply and return markings to ensure correct connections are made.
W270R112
Check wire harness and supply lines for proper positioning. NOTE: Make sure wire harness and supply lines do not contact anything that would cause damage.
STEP 5
W270R096
Turn master switch to “on� position. Clear any fault codes. Start engine. Check for fluid leaks at connections. Confirm problem has been corrected. Close engine compartment hood.
84547255A
Issued 11-11
Printed in E.C.
3002-25
DEF/ADBLUE DOSING INJECTOR Removal
STEP 3
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R116
Clean dirt and debris from around engine air intake pipe connections and DEF/AdBlue dosing injector.
STEP 4
W270R095
Raise the hood using controls located behind the access cover.
STEP 2
1
W270R115
NOTE: The dosing injector (1) is located in the exhaust system upstream from the SCR catalyst and downstream of the turbocharger. W270R096
Turn master electric switch “off�.
84547255A
Issued 11-11
Printed in E.C.
3002-26
STEP 5 1
STEP 7 2
W270R658
W270R678
Remove fuel pipe emissions (1) for easier access to dosing injector (2).
Mark location of DEF/AdBlue supply and return lines for reference dur ing reassembly. Remove DEF/AdBlue supply and return lines. Cap lines to prevent debris from entering the system.
NOTE: Mark location and routing of coolant lines for reference during reassembly.
NOTE: To separate connections, squirt water into fittings to lubricate O-rings. Squeeze fitting locking tabs slightly and push fitting together then pull it apart. If fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be applied.
STEP 6
STEP 8
W270R677
Disconnect dosing injector wiring harness.
W270R679
Remove bolts securing dosing injector into mixing pipe.
84547255A
Issued 11-11
Printed in E.C.
3002-27
Installation
STEP 9
NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.
STEP 1
W270R680
Remove dosing injector. Cover opening to prevent debris from entering exhaust system.
STEP 10
W270R682
Remove cover from exhaust system and install dosing injector. NOTE: Use markings made during disassembly to determined proper positioning.
STEP 2 W270R681
Inspect dosing injector and service or replace as recommended.
W270R683
Secure dosing injector to exhaust pipe. Torque screws to 7 +/- 0.5 Nm (62 +/- 4 lb in.).
84547255A
Issued 11-11
Printed in E.C.
3002-28
STEP 3
STEP 5
W270R684
Connect DEF/AdBlue supply and return lines and wiring harness to dosing injector. NOTE: Use marks made during disassembly to determine proper positioning.
W270R096
Turn master electric switch to “on�. Clear any fault code. Start machine. Check for leaks at DEF/AdBlue, exhaust and intake system connections. Confirm problem has been corrected.
STEP 4
W270R685
Secure fuel pipe emissions.
84547255A
Issued 11-11
Printed in E.C.
3002-29
DEF/ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER Removal
STEP 3
STEP 1
W270R095
Raise the hood using controls located behind the access cover.
1
STEP 2
W270R118
Open the frame (1) of the engine cooling system.
W270R096
Turn master electric switch “off”.
84547255A
Issued 11-11
Printed in E.C.
3002-30
STEP 4
STEP 6
W270R119
Place a suitable container below DEF/AdBlue supply tank drain plug. Remove filler neck cap from supply tank. Loosen drain plug and drain DEF/AdBlue. Install drain plug and access cover after DEF/AdBlue has drained. W270R571
STEP 7
Place a suitable container below radiator drain located beneath the access cover at rear left hand side of machine. Remove radiator cap. Remove drain cap. Drain coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area.
STEP 5
W270R125
Remove bolts securing filler neck screen assembly. NOTE: Place a plug in filler neck hole to prevent loose screws from entering the supply tank.
W270R117
Loosen hex bolts and remove access cover below supply tank to gain access to the drain. NOTE: Use compressed air and water, to clean debris from around drain plug area.
84547255A
Issued 11-11
Printed in E.C.
3002-31
STEP 8
STEP 10
W270R686
W270R126
Remove filler neck/screen assembly and O-ring from supply tank by pulling upward while twisting assembly left and right.
STEP 9
Unplug wiring harness. Disconnect engine coolant lines and DEF/AdBlue lines by pushing coupling together, squeezing tabs and then pulling connection apart. Pull wire and hose harness up and off to the side out of the way. NOTE: Plug all lines to prevent debris from entering the system.
STEP 11
1
W270R120
Remove rubber boot cover (1) from liquid level/temp sensor sending unit wires, DEF/AdBlue and engine coolant supply lines. Mark wire and hose connection positions. NOTE: Use compressed air and water to clean debris from top of DEF/AdBlue supply tank around liquid level/temp sensor sending unit area.
84547255A
W270R687
Mark location of pickup unit within tank before removal. Twist DEF/AdBlue level temperature sensor unit counter clockwise to loosen it from tank.
Issued 11-11
Printed in E.C.
3002-32
Installation
STEP 12
STEP 1 3
2
1
2
W270R122 W270R121
Lift DEF/AdBlue level/temp sensor unit out of tank. NOTE: Cover tank opening to prevent debris from entering it.
STEP 13 3
Install DEF/AdBlue supply tank into the fuel tank cradle and secure it using hex bolts (1) and upper support mounting bracket. Fix the tank urea through the belts (2). Connect the hose urea fill with the clamp (3).
STEP 2 2
1
2
W270R122
Remove hex bolts (1) from mounting support bracket above tank, remove belts fuel tank (2) and loosen hose clamp urea fill (3). Lift tank urea up and out of its cradle from the fuel tank.
W270R121
Lower DEF/AdBlue level temp sensor and pick-up unit into tank.
84547255A
Issued 11-11
Printed in E.C.
3002-33
STEP 3
STEP 6
W270R688
Use reference marks from disassembly procedure to position DEF/AdBlue level temp sensor and pick-up unit. Secure by turning it clockwise.
STEP 4
W270R690
Reinstall the O-ring onto the DEF/AdBlue supply tank with the radius surface facing upward. NOTE: Lubricate O-ring with petroleum jelly.
STEP 7
W270R689
Remove plugs from all lines. Reconnect DEF/AdBlue supply/return and purge lines, engine coolant supply/return lines and liquid level gage sensor wiring harness. To connect, push connections together all the way, and then pull back to lock.
W270R691
Reinstall filler neck assembly onto supply tank.
STEP 5
1
W270R120
Replace rubber boot protective cover (1).
84547255A
Issued 11-11
Printed in E.C.
3002-34
STEP 8
W270R692
Secure filler neck assembly using Torx bolts. Refill DEF/AdBlue storage tank and engine cooling system.
STEP 9
W270R096
Turn master electric power switch to “on� position. Clear any fault codes. Start machine and check for DEF/AdBlue and coolant leaks. Confirm that the problem has been corrected.
84547255A
Issued 11-11
Printed in E.C.
3002-35
DEF/ADBLUE SUPPLY FILTERS Removal Supply Tank Filler Neck Screen
STEP 3
STEP 1
W270R096
Turn off master electric switch to the “off” position. W270R123
STEP 4
Locate the DEF/AdBlue supply tank on the left hand side of the machine beneath an access cover.
STEP 2
W270R124
W270R095
Raise the hood using controls located behind the access cover.
84547255A
Open access cover and remove filler cap from filler neck of supply tank. NOTE: Use compressed air and water, to clean debris from around filler cap/neck area.
Issued 11-11
Printed in E.C.
3002-36
STEP 5
STEP 7
W270R693 W270R125
Remove bolts securing filler cap/neck screen assembly. NOTE: Place a stopper into filler neck hole to prevent loose screws and debris from entering supply tank.
STEP 6
Remove plug from filler neck. Rinse screen with water to remove accumulated debris. Reinstall plug into filler hole. NOTE: If the screen is damaged replace it. To replace, remove bolts and separate filler neck from screen. Attach new screen to filler neck and secure with bolts.
Installation Supply Neck Screen
Tank
Filler
STEP 1
1
W270R126
Remove filler cap/neck screen assembly and O-ring. Pull upwards while twisting assembly left and right. NOTE: Cap opening of supply tank to prevent debris from entering tank.
W270R127
Reinstall O-ring (1) with radius surface facing upward. NOTE: Lubricate O-ring with petroleum jelly.
84547255A
Issued 11-11
Printed in E.C.
3002-37
Removal Supply Line Screen
STEP 2
STEP 1
W270R126
Reinstall filler cap/neck screen assembly.
W270R128
DEF/AdBlue supply line screen is located under the engine hood on the left side of engine at rear of machine.
STEP 3
STEP 2
W270R125
Secure assembly with bolts and remove stopper from filler neck hole. Reinstall supply tank filler neck cap.
STEP 4
W270R095
Raise the hood using controls located behind the access cover.
STEP 3
W270R096
Close side cover concealing supply tank. Turn master electric switch to “on” position. Lower engine compartment hood. 84547255A
W270R096
Turn master electric switch to “off” position. Issued 11-11
Printed in E.C.
3002-38
STEP 4
STEP 6
2
1 W270R130
W270R129
Locate supply line filter screen housing within supply line between supply tank (1) and DNOx supply module (2) mounted on left hand side of engine. NOTE: Use compressed air and water to clean debris from around screen assembly.
Remove filter screen from housing with needle nose pliers. Rinse filter screen with water to remove accumulated debris. NOTE: If filter screen is damaged, replace it.
Installation Supply Line Screen STEP 1
STEP 5
W270R130 W270R694
To open fitting, push fitting together, squeeze locking tabs slightly, and then pull apart.
Install filter screen into supply line filter housing.
STEP 2
NOTE: Squirt water into fitting connection to lubricate O-ring. If fitting will not release, but is free to rotate, O-ring is likely stuck and additional water should be used to free connection. NOTE: Use a suitable container to catch any fluid discharged during hose and filter disassembly.
W270R695
Reconnect supply line coupling.
84547255A
Issued 11-11
Printed in E.C.
3002-39
STEP 3
STEP 2
W270R096
W270R095
Turn master electric switch to “on” position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.
Raise the hood using controls located behind the access cover.
Removal DNOx Supply Module Filter
STEP 3
STEP 1
W270R096
Turn master electric switch to the “off” position.
STEP 4 W270R128
The DEF/AdBlue Supply filter is located inside the DNOx supply module under the hood on the left side of the engine at the rear of the machine.
1
2 W270R131
Locate the DNOx supply module (1). The filter element assembly (2) is located on the underside of the module. NOTE: Clean dirt and debris from filter element housing using compressed air and water. 84547255A
Issued 11-11
Printed in E.C.
3002-40
STEP 5
STEP 7
1
2
W270R696
W270R698
Squirt water into fitting connections to lubricate O-rings. Disconnect fittings by pushing them together. Then squeeze locking tabs and pull fitting down and off.
Remove filter element (1) from housing (2) by turing it counter clockwise. Discard filter element following local environmental and waste regulations.
NOTE: If the fitting will not release, but is free to rotate, the O-ring is likely stuck and lubrication of the O-ring should be repeated.
Installation DNOx Supply Module Filter STEP 1
STEP 6
2
1
W270R699 W270R697
Remove the DEF/AdBlue filter element assembly from DNOx supply module by turning it counter clockwise. Pull straight down and away from module. NOTE: Use a suitable container to catch any fluid discharged during disassembly.
84547255A
Lubricate filter element O-ring (1) on housing side. Lubricate housing O-ring (2). Install filter element on housing by turing it clockwise. NOTE: Lubricate O-ring with petroleum jelly. NOTE: Hand tighten filter only.
Issued 11-11
Printed in E.C.
3002-41
STEP 2
STEP 5
W270R700
Lubricate filter element O-ring on control module side. NOTE: Lubricate O-ring with petroleum jelly.
W270R096
Turn master electric switch to “on� position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.
STEP 3
W270R697
Insert filter housing assembly into DNOx supply module and turn clockwise to tighten. NOTE: Hand tighten filter only.
STEP 4
W270R701
Reinstall DEF/AdBlue supply line. Push connection together and then pull back to make sure it is secure.
84547255A
Issued 11-11
Printed in E.C.
3002-42
AIR FILTRATION Primary/Secondary Fillter Element Disassembly
STEP 3
STEP 1 1
W270R133
Release all clips securing air filter element housing cover.
2
STEP 4
W270R702
Raise engine compartment hood using controls located behind access cover (1). Airfilter housing/element (2) is located in main engine compartment on right hand side of engine. W270R134
STEP 2
Remove cover from air filter element housing.
STEP 5
W270R096
Turn master electric switch “off�. W270R135
Remove primary filter element by lifting up on handle.
84547255A
Issued 11-11
Printed in E.C.
3002-43
STEP 6
STEP 2
W270R136
W270R135
Remove secondary filter element from right side of housing. Remove debris from inside filter element housing before installing new filter elements.
Install new primary filter element by sliding it down into housing.
NOTE: Do not clean the seconday filter element. It must be replaced if damaged or clogged.
NOTE: Make sure primary and secondary filter elements form an effective seal.
STEP 3
Primary/Secondary Element Reassembly STEP 1
W270R134
Install housing cover.
W270R136
Install new secondary filter element by inserting it into positioning slot. NOTE: Make sure filter element is firmly seated into housing.
84547255A
Issued 11-11
Printed in E.C.
3002-44
STEP 4
W270R133
Lock clips to secure filter housing cover. NOTE: If cover does not fit properly, recheck filter element installation. Cover will be difficult to install if filter elements are not properly installed.
STEP 5
W270R096
Turn master electric power switch “on�. Clear any fault codes. Start machine and confirm problem has been corrected.
84547255A
Issued 11-11
Printed in E.C.
SECTION INDEX
ELECTRICAL Section Title
Section Number
Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001 Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003 Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003a Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005 Rear view Camera and Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4006
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
4001 Section 4001 REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
4001-2
TABLE OF CONTENTS STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 5 5 6 7
Printed in E.C.
4001-3
STARTER Removal
STEP 4
STEP 1 Park machine on a level surface and lower bucket to ground.
STEP 2
BD06F135
Remove the ground strap from the starter, remove the starter mounting bolts, remove the stater.
1
2 W270R587
1. HOOD SWITCH 2. MASTER DISCONNECT
Raise the engine compartment with lifting motor. Place the master disconnect switch in the OFF position.
STEP 3
BD06F134
Place identification tags on the positive cables and remove the positive cables from the starter.
84547255A
Issued 11-11
Printed in E.C.
4001-4
Installation
STEP 7
STEP 5
1 2
BD06F134
Install and tighten the wires on the starter solenoid. Remove and discard tags.
STEP 8 BC05G047
1. STUDS 2. NUTS
Place the master disconnect switch in the ON position. Lower the engine compartment with lifting motor.
Apply Loctite 747 primer to studs and holes, apply 2 drops of Loctite 271 to each hole and stud. Immediately install and torque studs to 19 to 29 Nm (14 to 21 pound-feet). Allow adhesive to cure for 20 minutes before installing starter.
STEP 6
1 2 BD06F135
Position the starter on the machine, attach the ground cable to the bottom mounting stud (2) and install the nut, attach the ground strap and wire to the outer stud (1) and install the nut, install the lower nut. Torque the three nuts to 40 to 48 Nm (29 to 35 pound-feet).
84547255A
Issued 11-11
Printed in E.C.
4001-5
ALTERNATOR Removal
STEP 4
STEP 1 Park machine on a level surface and lower bucket to ground.
STEP 2
W270R589
Use a wrench to move the belt tensioner to loosen the tension on the belt. Remove the belt.
1
2
STEP 5 W270R587
1. HOOD SWITCH 2. MASTER DISCONNECT
Raise the engine compartment with lifting motor. Place the master disconnect switch in the OFF position.
STEP 3
W270R590
Remove mounting bolts for alternator, remove alternator. W270R588
Disconnect wires from the alternator.
84547255A
Issued 11-11
Printed in E.C.
4001-6
Installation
STEP 8
STEP 6
W270R588
Connect wires to the alternator, place rubber boot over positive post.
STEP 9
W270R590
Place alternator onto engine, install mounting bolts for alternator and tighten.
STEP 7 1
2 W270R587
1. HOOD SWITCH 2. MASTER DISCONNECT
Place the master disconnect switch in the ON position. Lower the engine compartment with lifting motor.
W270R589
Use a wrench to move the belt tensioner, install the belt. NOTE: Belt routing instructions are on belt cover.
84547255A
Issued 11-11
Printed in E.C.
4001-7
BELT INSTALLATION
W270R591
84547255A
Issued 11-11
Printed in E.C.
4001-8
NOTES
84547255A
Issued 11-11
Printed in E.C.
4002
Section 4002 ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
4002-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
84547255A
Issued 11-11
Printed in E.C.
4002-3
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, 65 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 Pin Engage Solenoid DC Resistance At 20qC (68qF) (Nominal) ............................................................... 28.8 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) ...................................................................xx.x ohms Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi) Fuel Temperature Sensor At 20qC (68qF) (Nominal) ................................................................................ 2500 ohms Grid Heater .................................................................................................................................................. 500 ohms Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7) Analog Throttle ................................................................................. Idle Validation Switch Closes At 0.775V ± 0.1V Throttle Position Potentiometer ................................................................................................. 5V Reference ± 0.2V Low Idle Position .............................................................................................................................. 0.4V ± 0.025V High Idle Position ................................................................................................................................. 4.0V ± 0.1V
84547255A
Issued 11-11
Printed in E.C.
4002-4
ELECTRICAL WIRE IDENTIFICATION Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
1
W0 8 GXL TWIST
JUMP1, JSS LOAD SENSE
A
JUMP2, JSS LOAD SENSE
C
2
BK0 8 GXL TWIST
JUMP1, JSS LOAD SENSE
B
JUMP2, JSS LOAD SENSE
A
14
Alternator D+
Lg 1.0 SXL
AD, Alternator D+
1
ENG, Engine Cab
26
30
Battery sensing
R 1.0 SXL
ALT_5, Alternator D+
2
AB_5, Alternator B+
1
31
EDC Relay CNTL
OR 0.8 GXL
EDC7, Engine controller
13
SPL_EDC4, Ultrasonic
A
38
Doser valve B+
R 0.8 GXL
DNOX2, NOX Controller
12
DEFDM, Doser metering VLV
1
42
Work Lights Switched Fused Pwr R 2.0 GXL
SPL-WL, Ultrasonic
A
ECC, ELect CNTR C
A2
44
Brake Lt Control Power
T 1.0 SXL
BTM_C, CAB Bottom bulkhd
J
PBL, Brake Light Press Switch
2
49
Back Lt Power
DU1.0 GXL
D-OR, Diode OR
C
SPL-BCK-LGT, Spl Back Lgt Pwr
A
52
Fan Reverse LSD
W 0.8 TXL
AIC-1, Adv Instr Clust 1
23
ECB, Electrical Center B
B8
56
Fan Control PWM
W 0.8 TXL
CAB-E, Cab Engine
23
AIC-1, Adv Instr Clust 1
26
57
Pin Engage Sol Pwr
W 1.0 SXL
FRONT, Cab Front Chassis
17
YPE, Pin Engage Option
A
58
Ride Control Sol Pwr
W 1.0 SXL
PRBF, Rollback Press Sw
A
YRC, Ride Control Option
1
64
Horn Power
Or 1.0 SXL
FRONT, Cab Front Chassis
13
HN1, Horn Power
1
460
Fan speed sensor signal
Y 1.0 GXL
FSS, Fan_speed_sens
1
ENG, Engine-CAB1
16
016B
Pedal Sensor Grnd
DU 0.8 GXL
BTM_C, CAB BOTTOM BULKHD
D
BPP, Pedal position
6
017A
Fan speed sensor GND
BK 1.0 GXL
GND_ENG7, Tranny, cool temp
1
FSS, Fan_speed_sens
2
OD_C DIAG2 GRND
BK 0.8 GXL
DIA_2, Diagnostic
A
GND_CAB_SPL, CAB GRND SPLICE
D
OE_A Exht temp up GND
BK 0.8 GXL
UTS, Upstream temp sense
2
DNOX2, NOX Controller
17
0 29
RTT/Float Ground
Bk 0.8 GXL
SFL, Return To Travel Sw
4
SPL-BCK-LT-GD2, Spl Back Lgt Gnd
K
0 AA
Proximity Switch Grnd
Bk 1.0 SXL
PXH, Height Control RTT
B
SPL-A2, Ultrasonic
A
0 AB
Proximity Switch Grnd
Bk 1.0 SXL
SPL-A2, Ultrasonic
A
GND-FC, Ground A
1
0 AC
Proximity Switch Grnd
Bk 1.0 SXL
PXF, RTD
B
SPL-A2, Ultrasonic
A
0 AD
Ride Control Ground
Bk 1.0 SXL
YRC, Ride Control Option
2
SPL-A1, Ultrasonic
A
0 AE
Pin Engage Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
A
YPE, Pin Engage Jumper
B
0 AF
Horn Ground
Bk 1.0 SXL
HN2, Horn Ground
1
SPL-A1, Ultrasonic
A
84547255A
Issued 11-11
Printed in E.C.
4002-5
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
0 AG
Front Chassis Ground
Bk 2.0 SXL
SPL-A1, Ultrasonic
A
GND-FC, Ground A
1
0 AH
RH Front Lights Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
A
LRF, Lights RH
1
0 AJ
LH Front Lights Ground
Bk 1.0 SXL
SPL-A1, Ultrasonic
A
LLF, Lights LH
1
0 AK
Park Brake/Warning Ground
Bk 1.0 SXL
SPL-A4, Ultrasonic
A
BTM_E, CAB BOTTOM
2
0 AL
Brake Warning Press Sw Gnd
Bk 1.0 SXL
PBW, Brake Warn Press Sw
2
SPL-A4, Ultrasonic
A
0 AM
RTD Grnd
Bk 1.0 SXL
PXM, RTD
B
PXT, RTD
B
0 AN
Park Brake Solenoid Ground
Bk 1.0 SXL
YPB, Park Brake Solenoid
2
SPL-A4, Ultrasonic
A
0 AP
Front To Rear Chassis Ground
Bk 5.0 SXL
GND-S1, Ground A
1
GND-S2, Ground A
1
0_AS
GRND, Joystick
BK 1.0 GXL
JSS_FRM, JSS Frame to cab
G
SPL_JSS_17, Ultrasonic
A
0_AT
GRND, JSS VLV
BK 1.0 GXL
JSS_Valve, JSS HYD Valve
3
SPL_JSS_17, Ultrasonic
A
0_AU
GRND, Pilot dump
BK 1.0 GXL
SPL_JSS_17, Ultrasonic
A
JSS_PIL_Dump, JSS Pilot dump
2
0_AV
GRND
BK 1.0 GXL
SPL_JSS_17, Ultrasonic
A
GND_JSS, Ground_A
1
BK 1.0 SXL
YPE1, PIN Engage jumper
B
YPE2, PIN_Engage_OPT
B
0_AW PIN Engage GND 0B
Front Washer Ground
Bk 1.0 SXL
FWW, Front Washer
2
SPL_ENG, ULTRASONIC
A
0 B1
Back Light Ground
Bk 0.8 GXL
SPC, Pilot Control Switch
7
SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck
B
0 B2
Back Light Ground
Bk 0.8 GXL
SFL, Return To Travel Switch
7
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
B
0 B3
Back Light Ground
Bk 0.8 GXL
SHC, Height Control Switch
7
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
C
0 B4
Back Light Ground
Bk 0.8 GXL
SRTD, Detent Switch
7
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
D
0 B5
Back Light Ground
Bk 0.8 GXL
SPE, Pin Engage Switch
9
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
E
0 B6
Cab2 Ground
Bk 1.0 GXL
SPL_BCK_LT_GD, SPL BACK LGHT GD
D
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
F
0 B7
Back Light Ground
Bk 0.8 GXL
SFC, Fan Control Switch
7
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
M
0 B8
Front Wiper Motor Ground
Bk 0.8 GXL
GND_CAB2, GROUND_A
1
FWMG, Wiper Ground
A
0 B10 Hood Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Grnd 6 Pck
E
GND-CAB2, Ground A
1
0 B11 Back Light Ground
Bk 0.8 GXL
SPL-BCK-LT-GD2, Spl Bk Lgt Grnd
L
SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck
F
84547255A
Issued 11-11
Printed in E.C.
4002-6
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
0 B12 Hood Down Relay Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Grnd 6 Pck
A
ECC, Elect Cntrc
C4
0 B13 Back Light Ground
Bk 1.0 GXL
SPL-BCK-LT-GD, Spl Bk Lght Grnd
A
SPL_WL1, ULTRASONIC
A
0 B14 Back Light Ground
Bk 0.8 GXL
SWL, Work Lights Switch
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
B
0 B15 Back Light Ground
Bk 0.8 GXL
SBE, Beacon Switch
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
C
0 B16 Hood Down Control Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Grnd 6 Pck
B
ECC, ELECT CNTR C
B4
0 B17 Back Light Ground
Bk 0.8 GXL
STA, Trans Auto Switch
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
E
0 B18 Back Light Ground
Bk 0.8 GXL
SDC, Declutch Switch
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
F
0 B19 Back Light Ground
Bk 0.8 GXL
SDR, Driving Lights Switch
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
G
0 B20 Back Light Ground
Bk 0.8 GXL
SRC, Ride Control Switch
7
SPL-BCK-LT-GD2, Spl Bk ghLt Grnd
J
0 B21 Back Light Ground
Bk 0.8 GXL
SBU, Backup Alarm Disc Sw
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
J
0 B22 Hood Up Relay Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Gnd 6 Pck
C
ECC, ELECT CNTR C
0 B23 Back Light Ground
Bk 0.8 GXL
SRWP, Rear Wiper Switch
7
SPL-BCK-LT-GD, Spl Bk Lght Grnd
L
0 B24 Back Light Ground
Bk 0.8 GXL
SHZ, Hazard Switch
7
SPL-PED-BL-GD, Spl Bk Lght Grnd 6 Pck
C
0 B25 Hood Up Control Ground
Bk 1.0 GXL
SPL-HOOD-GRND, Hood Gnd 6 Pck
D
ECC, ELECT CNTR C
B2
0 B26 Buzzer/Switch Pad Ground
Bk 0.8 GXL
SPL-BUZ, Ultrasonic
A
GND_CAB2, Ground_A
1
0 B27 Buzzer Ground
Bk 0.8 GXL
SPL-BUZ, Ultrasonic
A
BUZ, AIC Buzzer
2
0 B28 Switch Pad Ground
Bk 0.8 TXL
SW-PD, Switch Pad
10
SPL-BUZ, Ultrasonic
A
0 B29 RTT/Float Ground
Bk 0.8 GXL
SPB, Parking Brake Switch
7
SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck
E
0_B31 SDA GND
BK 0.8 GXL
SPL_BCK_LT_GD2, SPL_Back LGT GRND
A
SDA, Diff lock switch
7
0_B32 Back light GND
BK 0.8 GXL
SRP, Work lights SW
7
SPL_BCK_LT_GD, SPL Back lght GD
M
Bk 5.0 SXL.
GND-PDST, Ground A
1
GND-PDST2, Ground A
1
0 BAC EDC7 Ground
Bk 2.0 SXL
SPL-EDC1, Ultrasonic
A
GND-ENG2 Dedicated, WIF, EDC
1
0 BAE EDC7 Sender Ground
Bk 1.0 GXL
RECT, Engine Coolant Temp
B
GND-ENG7Grnd Trans. Clnt
1
0 BAG Hood Grounds (EURO)
Bk 1.0 SXL
GND-ENG4, Rear Lighting
1
E-HD, Trans Hood
C
0 BA
Pedestal Gnd Strap
84547255A
Issued 11-11
C2
Printed in E.C.
4002-7
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
0 BAG Hood Grounds (NA) N
Bk 1.0 SXL
ENG-H, Engine to Hood
1
GND-ENG4, Rear Lighting
1
0 BAR WIF Body Ground
Bk 1.0 SXL
GND-WIF, Gnd WIF Ring Term
1
GND-ENG6, Dedicated
1
0_BAT Crank request GND
BK 1.0 SXL
ENG, Engine-CAB1
6
GND_ENG2 Dedicated, WIF, EDC
1
0_BAU EVGT_2 GND
BK 1.0 TXL
Turbo, ENG DASH_Turbo
5
GND_ENG2 Dedicated, WIF, EDC
1
Bk 1.0 SXL
YFR, Fan Reverse Sol Opt
2
SPL-FAN, Ultrasonic
A
0_BBA Joystick ground
BK 0.8 GXL
SPL_JSS_1, Ultrasonic
A
SJS, Joystick_control_SW
4
0_BBB Joystick ground
BK 0.8 GXL
SJS, Joystick_control_SW
7
SPL_JSS_1, Ultrasonic
A
0_BBC Joystick ground
BK 0.8 GXL
GND_CAB_SPL2, SPL Back lght GD
F
SPL_JSS_1, Ultrasonic
A
0_BBD Joystick ground
BK 0.8 GXL
JSS_Cab, JSS Cab
8
SPL_JSS_1, Ultrasonic
A
0_BBE Joystick ground
BK 0.8 GXL
SJS, Joystick_control_SW
9
SPL_JSS_1, Ultrasonic
A
0_BBF DNOX2 Module GND
BK 2.0 SXL
SPL_DCUG, Ultrasonic
A
GND, ENG7 GRND, Trans Clnt
1
0_BBR Ground
BK 1.0 SXL
ENG_B, Cab bottom
2
GND_ENG3, SPLC_PK, WSHR MTR
1
0_BC
EDC7 GND
BK 1.0 GXL
SPL_EDC1, Ultrasonic
A
EDC7, Engine controller
11
0 BD
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
10
0 BE
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
5
0 BF
EDC7 Grnd
Bk 1.0 GXL
SPL-EDC1, Ultrasonic
A
EDC7, Engine Controller
6
0 BG
AIC Power Ground
Bk 0.8 GXL
ENG, Engine Cab 1
19
GND-ENG6, Dedicated
1
0 BH
AIC Power Ground Red
Bk 0.8 GXL
ENG, Engine Cab 1
20
GND-ENG6, Dedicated
1
0 BJ
AIC Sensor Ground
Bk 0.8 GXL
ENG, Engine Cab 1
17
GND-ENG6, Dedicated
1
0 BK
Tele Ground
Bk1 0 SXL
ENG, Engine Cab 1
7
GND, ENG7, Grnd Trans Clnt
1
0 BL
Rear Washer Ground
Bk 1.0 SXL
RWW, Rear Washer
2
SPL_ENG, Ultrasonic
A
0 BM
Engine Splice Grounds
Bk 1.0 SXL
SPL_ENG, Ultrasonic
A
GND-ENG3, SPLC-PK, Washer Motor
1
0 BP
WIF Sensor Ground
Bk 1.0 GXL
GND-ENG2 Dedicated, WIF, EDC
1
WIF, Water In Fuel Sensor
2
0 BQ
Fan Speed PWM Sol Grd
Bk 1.0 SXL
YFN, Fan PWM Solenoid
B
SPL-FAN, Ultrasonic
A
0 BR
RH Rear Light Ground (EURO)
Bk 1.0 SXL
LRR-E, RH Rear Comb Lamp
5
GND-ENG4, Rear Lighting
1
Bk 1.0 SXL
LLR-N, LH Rear Comb Lamp
1
SPL-J1, Ultrasonic
A
0 BB
Fan Reverse Solenoid Ground
0 BR N LH Rear Light Ground (NA) 84547255A
Issued 11-11
Printed in E.C.
4002-8
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
To Connector
Wire
Circuit
0 BS
Fan Control Ground
Bk 1.0 SXL
SPL-FAN, Ultrasonic
A
SPL_ENG, Ultrasonic
A
0 BT
LH Rear Light Ground (EURO)
Bk 1.0 SXL
LLR-E, LH Rear Comb Lamp
5
GND-ENG4, Rear Lighting
1
Bk 1.0 SXL
LRR-N, RH Rear Comb Lamp
1
SPL-J1, Ultrasonic
A
0 BT N RH Rear Light Ground (NA)
Connector
K = Pink U = Blue Y = Yellow
Cavity
Connector
Cavity
0 BU
Fuel Level Sender Ground
Bk 1.0 SXL
RFLG, Fuel Send Ground
1
GND-ENG7, Grnd Trans Clnt
1
0 BV
Grid Heater Control Grnd
Bk 0.8 TXL
GHC, Grid Heater Relay
2
EDC7, Engine Controller
75
0 BW
Water Separator Htr Ground
Bk 2.0 SXL
GND-ENG1, Start, FFH, WSH
1
WSH, Water Separator Heater
A
0 BX
Fuel Filter Heater Ground
Bk 2.0 SXL
FFH, Fuel Filter Heater
B
GND_ENG1, STRT, FFH, WAT_SEP_HTR
1
0 BY
Air Filter Restriction Sw Grd
Y 1.0 GXL
SPL_ENG, Ultrasonic
A
PAF, Air Filter Restriction Sw
2
0 BZ
Fuel level sender GND
Bk 1.0 SXL
RFL_23, Fuel_level_send
B
GND_ENG7, Grnd Trans Clnt
1
0 CA
Sec. Steering Signal Ground
Bk 1.0 SXL
SSM, Sec. Steering Mod
11
SPL_SEC, Ultrasonic
A
0 CB
Sec. Steering Signal Ground
Bk 1.0 SXL
SSM, Sec. Steering Mod
12
SPL_SEC, Ultrasonic
A
0 CC
Sec. Steering Press Sw Ground
Bk 1.0 SXL
PSS, Sec. Steer Press Switch
B
SPL_SEC, Ultrasonic
A
0 CD
Sec. Steering Splice Ground
Bk 1.0 SXL
SPL_SEC, Ultrasonic
A
GND_SSMOD, SEC STR Chasis GND
1
0 CE
Sec. Steering Chassis Ground
Bk 1.0 SXL
SSM, Sec. Steering Mod
4
GND-SSMOD, Sec. Str Chas Gnd
1
0 CF
Sec. Steering Sol Ground
Bk 1.0 SXL
YSS, Sec. Strg Sol
2
SPL_SEC, Ultrasonic
A
0_CG SEC STR Flyback GND
BK 1.0 SXL
245F, SEC_STR_Flyback
1
SSD, SEC_STR_Diode
B
0_CH
SEC STR Flyback GND
BK 1.0 SXL
245F, SEC_STR_Flyback
1
SSD, SEC_STR_Diode
A
0 DA
AIC Chassis Ground
Bk 0.8 TXL
GND-PDST1, Ground A
1
AIC-2, Advanced Inst Cluster 2
22
0 DAP Back Light Ground
S 0.8 GXL
STE, Trans Enable Switch
7
SPL-BCK-LT-GD, Splice Back Light Ground
K
0 DAV TECM Diagnostic Ground
Bk 0.8 GXL
108F, Diagnostic connector
3
GND-CAB3D, Ground A
1
0 DB
AIC Power Ground Red
Bk 0.8 TXL
CAB-E, Cab Engine
20
AIC-2, And Instr Cluster 2
15
0 DD
Work Lights GRND
BK 2.0 GXL
SPL_WL1, Ultrasonic
A
GND, Cab 1, Ground A
1
0 DE
Neutral Start Relay Control Grd
Bk 0.8 GXL
GND-CAB-SPL2, Spl Back Light Ground
G
ECB, Elect Center B
B4
0 DF
Crank Request Relay Control Ground
Bk 0.8 GXL
Cab_E, Cab-Engine
6
ECB, Elect Center B
B6
0 DG
Cab Splice Grounds
Bk 1.0 GXL
GND-CAB-SPL, Cab Grd Spl
F
GND-CAB3, Ground C
1
0 DH
Diagnostic Connector Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
M
DIA, Diagnostic
A
84547255A
Issued 11-11
Printed in E.C.
4002-9
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
K = Pink U = Blue Y = Yellow
To Connector
Connector
Cavity
Connector
Cavity
0 DJ
AC Relay Control Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
K
ECD, Elect Center D
B10
0 DK
Seat Compressor Motor Ground
Bk 1.0 GXL
GND-CAB-SPL, Cab Grd Spl
J
SC, Seat Comp Motor
B
0 DM
Speed Sensor Grounds
Bk 0.8 TXL
CAB-T, Cab Transmission
11
TECM, Trans
3
0 DN
Output Speed Sensor Ground
Bk 0.8 TXL
CAB-T, Cab Transmission
28
TECM, Trans
4
0 DP
DIAG TECM Ground
Bk 0.8 TXL
GND-CAB3D, Ground A
1
TECM, Trans
1
0 DQ
DIAG TECM Ground
Bk 0.8 TXL
GND-CAB3D, Ground A
1
TECM, Trans
2
0 DR
Roof Splice Grounds
Bk 1.0 GXL
CAB-RF, Cab to Roof Conn.
F
GND-CAB1, Ground A
1
0 DS
Roof Splice Grounds
Bk 1.0 GXL
CAB-RF, Cab to Roof Conn.
G
GND-CAB1, Ground A
1
0 DT
Front Wiper/Washer Sw Grd
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
G
SFWW, Front Wiper/Washer
2
0 DU
Pilot Pressure Sol Grd
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
L
YPP, Pilot Press Sol
B
0 DV
Cigar Lighter Ground
Bk 3.0 SXL
CL, Cigar Lighter
2
GND-CAB3, Ground C
1
0 DW
AIC Power Ground
Bk 0.8 TXL
CAB-E, Cab Engine
19
AIC-1, Adv Instr Cluster 1
12
0 DX
AIC Sensor Ground
Bk 0.8 TXL
CAB-E, Cab Engine
17
AIC-1, Adv Instr Cluster 1
6
0 DY
Roof Splice GNDS
BK 1.0 GXL
SPL_WL1, Ultrasonic
A
Cab_RF, Cab to Roof Connection
B
0_DZ
Work Lights GRND
BK 2.0 GXL
Cab_RF, Cab to Roof Conn.
A
SPL_WL1, Ultrasonic
A
0 EA
PWR Relay GND
BK0_8-GXL
ECB, Elect CNTR B
C2
SPL_SD3, Ultrasonic
A
0 EB
Ignition Relay Control Ground
Bk 0.8 GXL
SPL_SD3, Ultrasonic
A
PRM-C1, PRM Signal
B
0 EC
ACC Relay Control Ground
Bk 0.8 GXL
SPL_SD3, Ultrasonic
A
PRM-B1, PRM Signal
B
0 ED
HVAC Grounds
Bk 3.0 SXL
HVAC2, HVAC2
2
GND-CAB4, Ground C
1
0 EE
DIODE Suppression Grounds
Bk 0.8 GXL
GND-CAB-SPL, Cab Grnd Spl
A
140M, DIODE Module
C
0 EF
Brake Lights Relay Ctrl Grnd
Bk 0.8 GXL
GND-CAB-SPL2, Spl Back Light Ground
M
ECD, ELEC CNTR D
A1
0 EG
Flasher Module Ground
Bk 0.8 GXL
FLSHR, Flasher Module
4
GND-CAB-SPL2, Spl Back Light Ground
L
0 EH
Flasher Module Ground
Bk 0.8 GXL
FLSHR, Flasher Module
3
GND-CAB-SPL2, Spl Back Light Ground
K
0 EJ
Power Converter Ground
Bk 1.0 GXL
CNV, 24V to 12V Pwr Convert
3
GND-CAB4, Ground C
1
0 EK
AUX Power Outlet 1 Grnd
Bk 1.0 GXL
PO1, Power Outlet
C
GND-CAB5, Ground C
1
0 EL
AUX Power Outlet 2 Grnd
Bk 1.0 GXL
PO2, Power Outlet
C
GND-CAB5, Ground C
1
0 EM
Radio Ground
Bk 0.8 GXL
CAB-RF, Cab to Roof Conn.
M
GND-CAB-SPL, Cab Grnd Spl
B
84547255A
Issued 11-11
Printed in E.C.
4002-10
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
0 EN
Radio Ground
Bk 0.8 GXL
ROOF, Roof to Cab Conn.
M
RAD, Radio Power
8
0 EP
Horn Switch Ground
Bk 0.8 GXL
GND-CAB-SPL, Cab Grd Spl
C
SRHSTLK, RH Stalk Switch
31
0 EQ
Splice Pack GND-CAB-SPL2 Grnd
Bk 0.8 GXL
GND-CAB-SPL2, Spl Back Light Ground
H
GND-CAB6, Start, FFH, Water Sep Htr
1
0 ER
Power Converter Grnd
Bk 1.0 GXL
CNV, 24V to 12V Pwr Conv
6
GND-CAB4, Ground C
1
0 ES
Grid Heater Ground
Bk 19.0 SXL
GH-1, Grid Heater
1
GND-GH1, STRT, FFH, Water Sep Htr
1
0 ET
Power Relat GND
BK 0.8 GXL
ECB, ELECT CNTR B
D2
SPL_SD1, Ultrasonic
A
0 EU
PWR Converter RLY CTRL GND BK 0.8 GXL
SPL_SD3. Ultrasonic
A
PRM_A2, PRM Signal
B
0 EV
IGN Latch GND
BK 0.8 GXL
ECB, ELECT CNTR B
B2
SPL_SD1, Ultrasonic
A
0 EW
Power Relay GND
BK 0.8 GXL
GND_Cab_SPL2, SPL Back Light GD
E
ECB, ELECT CNTR B
B1
0 EY
Power Relay GND
BK 0.8 GXL
SPL_SD1, Ultrasonic
A
ECD, ELEC CNTR D
A4
0 EZ
Power Relay Control
W 0.8 GXL
ECD, ELEC CNTR D
A3
AIC_1, ADV Instr Cluster 1
22
BK2 0 SXL
GND CB Ground, on Cooling Box
1
GND GL, Ground, Rear Grill
1
0G 0 GB
Starter Relay Control Ground
Bk 1.0 SXL
SRC-1, Relay
2
GND-ENG1, STRT, FFH, Water Sep Htr
1
0 HD
Speed Sensor Grounds
Bk 1.0 SXL
TRANS, Cab Transmission
11
SPL-H2, Ultrasonic
A
0 HE
Output Speed Sensor Grnd
Bk 1.0 SXL
TRANS, Cab Transmission
28
OSS, Out Speed Sensor
1
0 HF
Engine Speed Sensor Grnd
Bk 0.8 GXL Twist
ESS, Engine Speed Sensor
2
SPL-H2, Ultrasonic
A
0 HG
Inter Speed Sensor Grnd
Bk 0.8 GXL Twist
ISS, Inter Speed Sensor
2
SPL-H2, Ultrasonic
A
0 HH
Turbine Speed Sensor Grnd
Bk 0.8 GXL Twist
TSS, Turbine Speed Sensor
2
SPL-H2, Ultrasonic
A
0 HL
Redundant Brake Switch Grnd
Bk 1.0 SXL
PRB2, Redundant Brake Sw
B
GND_Trans, Ground_Trans
1
0 HM
Redundant Brake Switch Grnd
Bk 1.0 SXL
PRB1, Redundant Brake Sw
B
GND_Trans, Ground_Trans
1
0 HR
HYD FLTR SW GRND
BK 1.0 SXL
PHF9, HYD_FLTR_RES_SW
1
GND_Trans, Ground_Trans
1
0 HW
Hot Ground
Bk 1.0 SXL
HOT, Hydraulic Oil Temp Send
B
GND_Trans, Ground_Trans
1
0J
Start Lockout RLY GND
BK 0.8 GXL
ECC, ELECT CNTR C
85
GND_CAB_SPL2, SPL Back LGHT GD
A
0 JA
Hood Grounds (EURO)
Bk 1.0 SXL
HD-E, Hood Trans
C
SPL-J1, Ultrasonic
A
84547255A
Issued 11-11
Printed in E.C.
4002-11
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
0 JA N Hood Grounds (NA)
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
Bk 1.0 SXL
HD-N, Hood to Engine
1
SPL-J1, Ultrasonic
A
0 JB
Backup Alarm Grnd
Bk 1.0 SXL
BU1, Backup Alarm Grnd
1
SPL-J1, Ultrasonic
A
0 JC
License Plate Light Grnd
Bk 1.0 SXL
LPL, Lic Plate Light
B
SPL-J1, Ultrasonic
A
0K
Camera GND
BK 0.8 GXL
GND_Cab_SPL2, SPL Back Light GD
C
MON, Camera/Monitor
2
0 KA
IGN PWR Control GND
BK0_8-GXL
ECD, ELEC CNTR D
AA3
GND_Cab_SPL2, SPL Back Light GD
B
0L
Telematics GRND
BK 1.0 GXL
CAB-E, Cab Engine
7
TEL, Telematics
H
0 LB
DNOX2 Module GND
BK 1.0 GXL
DNOX2, NOX Controller
14
SPL_DCUG, Ultrasonic
A
0 LC
DNOX2 Module GND
BK 1.0 GXL
SPL_DCUG, Ultrasonic
A
DNOX2, NOX Controller
15
0 LD
Heat Load Vlv Sol
BK1 0 SXL
YLV, Heated Valve Opt.
2
SPL, FAN, Ultrasonic
A
0 LE
Heat Load Vlv Sol
BK1 0 SXL
YLV2, Heated Valve Opt.
2
YLV3, Heated Valve OPT
2
0 MA
Rear Wiper Motor Grnd
Bk 1.0 GXL
SPL-ROOF, Spl Rood Grnd
C
RWMG, Rear Wiper Motor Grnd
1
0 MB
Dome Light Grnd
Bk 0.8 GXL
LDM3, Dome Light Grnd
1
SPL-ROOF, Spl Rood Grnd
B
0 MC
Beacon Light Grnd
Bk 1.0 GXL
LBEGRD, Light Beacon Grnd
1
SPL-ROOF, Spl Rood Grnd
A
0 ME
LH Rear Work Light Grnd
Bk 1.0 GXL
LLRW, LH Rear Work Light
2
SPL_WR, Ultrasonic
A
0 MF
RH Rear Work Light Grnd
Bk 1.0 GXL
LRRW, RH Rear Work Light
2
SPL_WR, Ultrasonic
A
0 MG
RH Front Work Light GND
Bk 1.0 GXL
LRFS, Front_WK_LT_OPT
2
SPL_WRK2, Ultrasonic
A
0 MH
Rear Work Light GND
Bk 1.0 GXL
ROOF, Roof to Cab Conn.
B
SPL_WR, Ultrasonic
A
0 MJ
RH Front Work Light Grnd
Bk 1.0 GXL
LRFW, RH Front Work Light
2
SPL_WR, Ultrasonic
A
0 MK
Roof Grounds
Bk 1.0 GXL
ROOF, Roof to Cab Conn.
G
SPL-ROOF, Spl Rood Grnd
E
0 ML
RH Front Work Light GND
Bk 1.0 GXL
SPL_WRK2, Ultrasonic
A
LRFR, Front_WK_LT_OPT
2
0 MN
Roof Grounds
Bk 1.0 GXL
ROOF, Roof to Cab Conn.
F
SPL-ROOF, Spl Rood Grnd
D
0 MP
RH Front Work Light GND
Bk 1.0 GXL
SPL_WRK2, Ultrasonic
A
LRFO, Front_WK_LT_OPT
2
0 MU
LH Front Work Light Grnd
Bk 1.0 GXL
LLFW, LH Front Work Light
2
SPL_WK, Ultrasonic
A
0 MV
RH Front Work Light GND
Bk 2.0 SXL
SPL_WK, Ultrasonic
A
ROOF, Roof to Cab Connector
A
0 NA
Hood Grounds (EU)
Bk 1.0 SXL
HD 9, Hood to ENG
1
SPL, B1
A
0 NB
Master Disconnect Grnd
Bk 62.0 SGR
DC2, Discon Black Grnd
1
B3, Starter Battery
1
0 NC
Battery Disconnect
Bk 62.0 SGR
BT4, Discon Black Grnd
1
STTR GRN, Grid HTR Fuse
1
0 ND
SSM Ground
Bk 62.0 SGR
242F, Chassis Grnd Sec. Strg Motor
1
GND-SSCHAS, SSM Ground Cable
1
0 NE
Hood Grounds (EU)
Bk 1.0 SXL
SPL, B1
A
LLR 9, LH Rear Comb. LT
5
84547255A
Issued 11-11
Printed in E.C.
4002-12
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
To Connector
Wire
Circuit
0 NF
Hood Grounds (EU)
Bk 1.0 SXL
SPL, B1
A
LRR 9, RH Rear Comb. LT
5
0 NG
Hood Grounds (EU)
Bk 1.0 SXL
SPL, B1
A
SPL_J1, Ultrasonic
A
0 PA
Left Speaker Grnd
Bk 0.8 GXL
LSPK, Left Speaker
B
SPK, Speaker
8
0 PB
Right Speaker Grnd
Bk 0.8 GXL
RSPK, Right Speaker
B
SPK, Speaker
2
0 RD
Ride Control GND
Bk 1.0 SXL
YRC_J, Ride Cntrl_Jumper
2
YRC_J2, Ride_Control_opt
2
0 SC
GRND, Joystick
Bk 0.8 GXL
JSS_Arm, JSS Armrest to Cab
7
PVRES, JSS Joystick
V
0 SD
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
Cab_Arm, Cab to Armrest
7
0 SE
GRND
Bk 0.8 TXL
SPL_JSS_10, Ultrasonic
A
CAN_MOD_2, JSS CAN MOD
10
0 SF
GRND
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
Cab_FRM, Cab to JSS Frame
G
0 SG
COMMON
Bk 0.8 GXL
SPL_JSS_10, Ultrasonic
A
Arm_pos, Arm position
1
0 SH
GRND, CAN MOD
Bk 0.8 GXL
JSS_Arm, JSS Armrest to Cab
2
SPL_JSS_10, Ultrasonic
A
0 SJ
GRND, CAN MOD
Bk 0.8 GXL
SPL_JSS_9, Ultrasonic
A
Cab_Arm, Cab to Armrest
2
0 SK
GRND, CAN MOD
Bk 0.8 GXL
Cab_Arm_FRM, Cab to Arm to FRM
8
SPL_JSS_9, Ultrasonic
A
0 SL
GROUND
Bk 0.8 GXL
JSS_RLY, Relay K2
87A
SPL_JSS_9, Ultrasonic
A
0 SM
GRND, Joystick
Bk 0.8 GXL
JSS_CNT, JSS Controller
10
SPL_JSS_20, Ultrasonic
A
0 SN
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_20, Ultrasonic
A
JSS_CNT, JSS Controller
11
0 SP
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
R1, Resistor
0 SR
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_14, Ultrasonic
A
JSS_CNT, JSS Controller
15
0 SS
GRND, Joystick
Bk 0.8 GXL
JSS_197F, Main_Cab_FNR
1
FNR_RLY, Relay K2
87A
0 ST
GRND, Joystick
Bk 0.8 GXL
FNR_RLY, Relay K2
85
SPL_JSS_9, Ultrasonic
A
0 SU
GRND, Joystick
Bk 0.8 GXL
SPL_JSS_20, Ultrasonic
A
SPL_JSS_9, Ultrasonic
A
0T
DEF Sensor GND
Bk 0.8 GXL
UBJ, DEF Level Temp
2
DNOX2, NOX Controller
19
0 TA
DEF Sensor GND
LU 0.8 GXL
UBJM, DEF Level Temp
2
DTLTS, DEF_Tank Level Temp Sensor
2
0U
EXHT Temp DWN GND
BK 0.8 SXL
DNOX2, NOX Controller
25
DTS, Downstream Temp Sens
2
0 VA
Heated Mirrors GND
Bk 1.0 SXL
MH, Heated Mirrors
B
GND, CAB SPL, CAB GRND SPLICE
H
0 VB
Heated Mirrors GND
Bk 1.0 GXL
SPL1, Ultrasonic
A
MH C, Heated Mirrors
B
0 VC
Heated Mirrors GND
Bk 1.0 GXL
TRLY, Timer Relay
SPL1, Ultrasonic
A
84547255A
Connector
K = Pink U = Blue Y = Yellow
Cavity
87A
Connector
Issued 11-11
Cavity
CS0
Printed in E.C.
4002-13
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
To Connector
Wire
Circuit
0 VD
Heated Mirrors GND
Bk 1.0 GXL
SPL1, Ultrasonic
A
MHS, Trans. Enable SW
9
0 VE
Heated Mirrors GND
Bk 1.0 GXL
SPL1, Ultrasonic
A
MHS, Trans. Enable SW
7
0 VH
Heated Mirrors GND
Bk 1.0 GXL
SPL1, Ultrasonic
A
MH L, Mirror HTR
2
0 VJ
Heated Mirrors GND
Bk 1.0 GXL
SPL1, Ultrasonic
A
MH R, Mirror HTR
2
12ACC Ignition Switch ACC Power
W 0.8 GXL
S-KEY, Ignition Switch
4
SPL-ACC, Ultrasonic
A
12ACC ACC PRM control Power B
W 0.8 GXL
SPL-ACC, Ultrasonic
A
PRM-B1, PRM Signal
A
12ACC Power Converter PRM Control C Power
W 0.8 GXL
SPL-ACC, Ultrasonic
A
PRM-A2, PRM Signal
A
12V Pwr To Outlet 1
Or 1.0 GXL
PO1, Power Outlet
A
ECB, Elect Center B
AA1
12V A 12V Pwr To Outlet 2
Or 1.0 GXL
PO2, Power Outlet
A
ECB, Elect Center B
AA2
12V B 12V Fused Pwr to Radio
Or 1.0 GXL
CAB-RF, Cab to Roof Conn.
N
ECB Elect Center B
AA9
12V C 12V Switched Power
Or 2.0 GXL
CNV, 24V to 12V Pwr Conver
5
SPL-12V, Ultrasonic
A
12V D Plug 1 12V Switched Power
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A1
12V E Plug 2 12V Switched Power
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A2
12V F Radio 12V Switched Power
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A9
12V G 2 Way Radio 12V Switched Pwr
Or 1.0 GXL
SPL-12V, Ultrasonic
A
ECB, Elect Center B
A10
12V H 12V Fused Power to Radio
Or 0.8 GXL
ROOF, Roof to Cab Conn.
N
SPL-RAD, Ultrasonic
A
12V
Connector
K = Pink U = Blue Y = Yellow
Cavity
Connector
Cavity
12V HA
12V Fused Power to Radio
Or 0.8 GXL
SPL-RAD, Ultrasonic
A
RAD, Radio Power
7
12V HB
12V Fused Power to Radio
Or 0.8 GXL
SPL-RAD, Ultrasonic
A
RAD, Radio Power
4
13A
EVGT Relay
OR 0.8 TXL
EVGT_4, EVGT
D
EDC7, ENGINE Controller
51
13B
EVGT Relay PWR
OR 1.0 GXL
Turbo, ENG DASH_Turbo
6
EVGT_4, EVGT
A
13C
Fuel Shutoff Fused Power
Or 1.0 SXL
DC3, Fuel Solenoid Disc
1
DISC, Disconnect Engine
A
13C A Fuel Shutoff Fused Power
Or 1.0 SXL
ENG-D, Disc Harness
A
ENG, Engine Cab 1
21
13C B Fuel Shutoff Fused Power
Or 1.0 SXL
CAB-E, Cab Engine
21
ECA, Elect Center A
A9
Or 1.0 GXL
S-KEY, Ignition Switch
3
SPL_SD2, Ultrasonic
A
13K A IGN PWR Control B+
W 0.8 GXL
SPL_SD2, Ultrasonic
A
ECD, Elect Center D
AA4
13K B IGN PWR Latch B+
W 0.8 GXL
ECB, ELECT CNTR B
D1
SPL_SD2, Ultrasonic
A
13K C Ignition Switch Pwr
Or 1.0 GXL
SPL_SD2, Ultrasonic
A
PRM_C1, PRM Signal
A
Or 1.0 SXL
DC4, Fuel Sol Disconnect
1
DISC, Disconnect Engine
B
13K
13M
Ignition Switch Pwr
Fuel Shutoff Fused Power
84547255A
Issued 11-11
Printed in E.C.
4002-14
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
13M A Fuel Shutoff Fused Power
Or 0.8 TXL
SPL, 13M, Ultrasonic
A
EDC7, Engine Controller
40
13M B WIF IGN PWR
Or 1.0 SXL
ENG D, Disc Harness
B
SPL, 13M, Ultrasonic
A
13M C WIF Sensor Fused PWR
Or 1.0 GXL
SPL, 13M, Ultrasonic
A
WIF, Water in Fuel Sensor
3
14_5
Alternator D+
LG 1.0 SXL
ALT_5, Alternator D+
3
ENG, Engine-Cab1
26
14 A
Alternator D+
LG 0.8 GXL
SPL_ALT, Ultrasonic
A
215F, Alternator Resistor
1
14 AB Alternator D+
LG 0.8 GXL
SPL_ALT, Ultrasonic
A
Cab_E, Cab-Engine
26
14 AC Altenator Running
LG 0.8 GXL
SPL_ALT, Ultrasonic
A
TEL, Telematics
D
16R C FNR reverse Signal
LU 0.8 GXL
JSS_197M, FNR-Main_Cab
4
RVS_Diode, Diode Assy
C
17P A Switch Pad Power From AIC Pwr Or 0.8 TXL
SW-PD, Switch Pad
9
SPL_SW_PD, Ultrasonic
A
17P B SW PAD PWR FR0M AIC PWR
OR 0.8 TXL
SPL_SW_PD, Ultrasonic
A
AIC_1, ADV INSTR Cluster 1
25
17P C B+, CAN Module
OR 0.8 GXL
SPL_SW_PD, Ultrasonic
A
JSS_Cab, JSS Cab
2
17P D B+, CAN Module
OR 0.8 GXL
SPL_JSS_18, Ultrasonic
A
Cab_Arm, Cab to Armrest
4
17P E B+, CAN Module
BK 0.8 TXL
JSS_Arm, JSS Armrest to Cab
4
CAN_MOD_2, JSS CAN MOD
9
17P F B+, JSS Controller
OR 0.8 GXL
SPL_JSS_18, Ultrasonic
A
JSS_CNT, JSS Controller
3
17P G B+, Joystick
OR 0.8 GXL
SPL_JSS_18, Ultrasonic
A
Cab_Arm_FRM, Cab to Arm to FRM
2
LH High Beam Fused Power
OR 2.0 SXL
FRONT, Cab Front Chassis
6
LLF, Lights LH
3
18B A LH High Beam Fused Power
OR 2.0 GXL
CAB-F, Cab Front Chassis
6
ECB, Elect Center B
RH High Beam Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
16
LRF, Lights RH
18C A RH High Beam Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
16
ECB, Elect Center B
LH Low Beam Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
14
LLF, Lights LH
18D A LH Low Beam Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
14
ECB, Elect Center B
RH Low Beam Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
15
LRF, Lights RH
18E A RH Low Beam Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
15
ECB, Elect Center B
LH Position/Tail Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
10
LLF, Lights LH
4
18F A LH Position/Tail Fused Power
Or 0.8 GXL
CABE2, CAB TO ENG2 BULKHD
M
SPL-POS-L, Ultrasonic
A
LH Position/Tail Fused Power
Or 1.0 SXL
ENG2, ENG BULKHD 2
M
ENG-H, Engine to Hood
6
18F B LH Position/Tail Fused Power
Or 1.0 SXL
ENG2, ENG BULKHD 2
M
LLR-E, LH Rear Comb Light
3
LH Position/Tail Fused Power
Or 1.0 SXL
HD-N, Hood to Engine
6
LLR-N LH Rear Combination Light
3
18F C LH Position/Tail Fused Power
Or 1.0 GXL
SPL-POS-L, Ultrasonic
A
ECB, Electric Center B
18B
18C
18D
18E
18F
18F AN
18F BN
84547255A
Issued 11-11
AA3 3 AA4 2 AA6 2 AA5
AA7 Printed in E.C.
4002-15
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
18F E LH Position/Tail Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
10
SPL-POS-L, Ultrasonic
A
18F F LH Position/Tail Fused Power
Or 1.0 SXL
HD 9, Hood to ENG
6
LLR 9, LH Rear Comb. LT
3
RH Position/Tail Fused Power
Or 1.0 GXL
SPL-POS-R, Ultrasonic
A
ECB, Elect Center B
18G A RH Position/Tail Fused Power
Or 1.0 SXL
FRONT, Cab Front Chassis
5
LRF, Lights RH
4
RH Position/Tail Fused Power
Or 1.0 SXL
SPL-POS-NA, Ultrasonic
A
LRR-N, RH Rear Combination Light
3
18G D Licence Plate Light Fused Pwr
Or 1.0 SXL
SPL-POS, Ultrasonic
A
E-HD, Trans Hood
A
18G E Licence Plate Light Fused Pwr
Or 0.8 GXL
HD-E, Hood Trans
A
LPL, Licence Plate Light
A
Licence Plate Light Fused Pwr
Or 1.0 SXL
LPL, Licence Plate Light
A
SPL-POS-NA, Ultrasonic
A
18G F RH Position/Tail Fused Power
Or 0.8 GXL
CABE2, CAB TO ENG2 BULKHD
N
SPL-POS-R, Ultrasonic
A
18G G RH Position/Tail Fused Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
5
SPL-POS-R, Ultrasonic
A
18G H RH Position/Tail Fused Power
Or 1.0 SXL
ENG2, ENG BULKHD 2
N
SPL-POS, Ultrasonic
A
RH Position/Tail Fused Power
Or 1.0 SXL
ENG2, ENG BULKHD 2
N
ENG-H, Engine to Hood
5
18G J RH Position/Tail Fused Power
Or 1.0 SXL
LRR-E, RH Rear Combination Light
3
SPL-POS, Ultrasonic
A
RH Position/Tail Fused Power
Or 1.0 SXL
HD-N, Hood to Engine
5
SPL-POS-NA, Ultrasonic
A
18G K RH Position/Tail Fused Power
Or 1.0 SXL
HD-9, Hood to Engine
5
SPL-P9
A
18G L LIC Plate LT Fused Power
Or 1.0 SXL
SPL-P9
A
LPL, LIC Plate Light
A
18G M RH Position/Tail Fused Power
Or 1.0 SXL
SPL-P9
A
LRR-9, RH Rear Comb. LT
3
18J B EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
3
18J C EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
2
18J D EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
8
18J E EDC7 Fused Power
Or 1.0 GXL
SPL-EDC2, Ultrasonic
A
EDC7, Engine Controller
9
18J F
OR 3.0 GXL
PRM_D1, PRM OUTPUT
A
SPL-EDC2, Ultrasonic
A
18K A Diagnostic Fused PWR
OR 0.8 GXL
SPL_PK1, Splice 3-4Way
K
ECC, Elect Cntr C
A9
18K B Diagnostic Fused B+
OR 0.8 GXL
SPL_PK1, Splice 3-4Way
L
DIA_2, Diagnostic
B
18K D Diagnostic Fused B+
OR 0.8 GXL
SPL_PK1, Splice 3-4Way
J
DIA, Diagnostic
B
Blower Motor Fused Power
Or 3.0 GXL
SPL-BLWR, Ultrasonic
A
ECA, Elect Center A
C1
18N A Blower Motor Fused Power
Or 0.8 GXL
SPL-BLWR, Ultrasonic
A
HVAC1, HVAC1
18G
18G CN
18G EN
18G HN
18G JN
18N
EDC7 Fused Power
84547255A
Issued 11-11
AA8
2 Printed in E.C.
4002-16
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
18N B Blower Motor Fused Power
Or 3.0 GXL
SPL-BLWR, Ultrasonic
A
HVAC2, HVAC2
1
18S A B+, JSS Fused
OR 0.8 GXL
SPL_JSS_3, Ultrasonic
A
ECA, ELECT CNTR A
A2
18S B B+, JSS Fused
OR 0.8 GXL
SPL_JSS_3, Ultrasonic
A
SJS, Joystick_Control_SW
2
18S C B+, JSS Fused
OR 0.8 GXL
JSS_Cab, JSS Cab
11
SPL_JSS_3, Ultrasonic
A
18S D B+, JSS Fused
OR 0.8 GXL
Cab_FRM, Cab to JSS Frame
J
Cab_Arm_FRM, Cab to Arm to FRM
11
18S E B+, JSS Fused
OR 1.0 SXL
JSS_PIL_PR, JSS Pilot Pressure
A
JSS_FRM, JSS Frame to Cab
J
OR 0.8 GXL
ECA, ELECT CNTR A
A10
Cabe2, Cab to ENG2 BULKHD
H
18T A DNOX2 SW B+
OR 1.0 SXL
ENG2, ENG BULKHD 2
H
DNOX2, NOX Controller
24
18U A DCU B+ N0N Disconnectd
OR 5.0 GXL
PRM A1, PERM Output
A
SPL TEL, Ultrasonic
A
18U B DCU B+ N0N Disconnectd
OR 3.0 GXL
ENG2, ENG BULKHD 2
E
DNOX2, NOX Controller
4
18U C DCU B+ N0N Disconnectd
OR 3.0 GXL
Cabe2, Cab to ENG2 BULKHD
B
SPL TEL, Ultrasonic
A
18U D DCU B+ N0N Disconnectd
OR 3.0 GXL
DNOX2, NOX Controller
3
ENG2, ENG BULKHD 2
B
18U E DCU B+ N0N Disconnectd
OR 3.0 GXL
CABE2, CAB to ENG2 Bulkhd
E
SPL TEL, Ultrasonic
A
18U F Telematics FSD ND PWR
OR 0.8 GXL
SPL TEL, Ultrasonic
A
TEL, Telematics
A
Heated Mirror PWR
OR 1.0 GXL
MH, Heated Mirror
A
ECA, ELECT CNTR A
C5
18V A Heated Mirror PWR
OR 1.0 GXL
SPL2, Ultrasonic
A
MH-C, Heated Mirror
A
18V B Heated Mirror PWR
OR 1.0 GXL
TRLY, Timer Relay
30
SPL2, Ultrasonic
A
18V C Heated Mirror PWR
OR 1.0 GXL
MHS, Trans Enable SW
2
SPL2, Ultrasonic
A
TRANS, Cab Transmission
29
OSS, Out Speed Sensor
3
18T
18V
19A
DNOX SW B+
Output Speed Sensor Fused Pwr Or 1.0 SXL
19A A Brake Declutch Sw Fused Pwr
Or 1.0 SXL
Trans, Transmission-Cab
24
PBD, Dec. Pressure Switch
A
19A B FNR Switched Fused Power
Or 0.8 GXL
197M, FNR Main Cab
1
SPL-FNR, Ultrasonic
A
19A C FNR Switched Fused Power
Or 0.8 GXL
197F, Main Cab FNR
1
SPL-TRNS-PWR, Trans Pwr
F
19A D Trans Enable Switch Fused Pwr
Or 0.8 GXL
STE, Trans Enable Switch
2
SPL-D15, Ultrasonic
A
19A E AIC Fused PWR
Or 0.8 GXL
STE, Trans Enable Switch
10
SPL-D15, Ultrasonic
A
19A F Trans Enable Switch Fused Pwr
Or 0.8 GXL
SPL-TRNS-PWR, Trans Pwr
B
SPL-D15, Ultrasonic
A
19A G FNR Sw Fused Power
Or 0.8 GXL
SPL-FNR, Ultrasonic
A
SFNR, FNR Switch
8
19A H Trans Shifter Fused Power
Or 0.8 GXL
TS1, Transmission Shifter
A
SPL-TRNS-PWR, Trans Pwr
M
19A K TECM Fused Power
Or 0.8 TXL
SPL-TRANS-PWR, Trans Pwr
J
TECM, Trans
45
84547255A
Issued 11-11
Printed in E.C.
4002-17
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
19A L Park Brake Switched Fused Pwr
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
SPB, Parking Brake Switch
2
SPL-PBS, Ultrasonic
A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL
CAB-T, Cab Transmission
29
SPL-TRNS-PWR, Trans Power
K
19A N Trans Fused Power
Or 1.0 GXL
SPL-TRANS-PWR, Trans Pwr
A
ECA, Elect Center A
A1
19A P Backup Alarm Relay
OR1_0-GXL
ECD, ELEC CNTR D
SPL_TRNS_PWR, TRANS_PWR
G
19A Q Trans/Auto Switch Fused Power
Or 0.8 GXL
STA, Trans Auto Switch
2
SPL-TRANS-PWR, Trans Pwr
C
19A R Declutch Switch Fused Power
Or 0.8 GXL
SDC, Declutch Switch
2
SPL-TRANS-PWR, Trans Pwr
H
19A T Brake Declutch Switch Fused Power
Or 0.8 GXL
CAB-T, Cab Transmission
24
SPL-TRANS-PWR, Trans Pwr
D
19A U Trans Dick Down Switch Fused Power
Or 0.8 GXL
SPL-FNR, Ultrasonic
A
20M, Trans Kick Down
1
19A V FNR Switch Fused Power
Or 0.8 GXL
SFNR, FNR Switch
5
SPL-FNR, Ultrasonic
A
19A W Diagnostic Conn. Fused Power
Or 0.8 GXL
108F, Diagnostic Connector
1
SPL-TRANS-PWR, Trans Pwr
E
Turn Signal Fused Power
Or 0.8 GXL
SRHSTLK, RH Stalk Switch
49a
ECA, Elect Center A
A8
19B A FNR Switch Fused Power
W 0.8 GXL
FNR_RLY, Relay K2
30
JSS_197M, FNR-Main Cab
1
19B B FNR Switch Fused Power
OR 0.8 GXL
Cab FNR, Main Cab FNR
1
FNR_RLY, Relay K2
87
19B C FNR Switch Fused Power
OR 0.8 GXL
Arm FNR, FNR-Main Cab
1
SPL_AJ, Ultrasonic
A
19B D FNR Switch Fused Power
OR 0.8 GXL
21M, Trans_Kick-Down
1
SPL_AJ, Ultrasonic
A
19B E FNR Switch Fused Power
OR 0.8 GXL
SAJ, FNR Switch
5
SPL_AJ, Ultrasonic
A
19B F FNR Switch Fused Power
OR 0.8 GXL
SAJ, FNR Switch
8
SPL_AJ, Ultrasonic
A
19C A Pilot Ctrl Rly Fused Pwr
Or 1.0 GXL
SPL-D24, Ultrasonic
A
ECA, Elect Center A
A5
19C B Pilot Ctrl Rly Fused Pwr
Or 1.0 GXL
SPL-D24, Ultrasonic
A
ECD, Elect Center D
B5
19C C Pilot Ctrl Rly Fused Pwr
Or 0.8 GXL
SPL-D24, Ultrasonic
A
ECD, Elect Center D
D5
19C D Ride Control SW Fused Pwr
Or 1.0 GXL
SRC, Ride Control Switch
2
SPL-D24, Ultrasonic
A
19C E Pilot Control SW Fused Pwr
OR 0.8 GXL
TEL, Telematics
C
SPL_D24, Ultrasonic
A
19C F Pilot Control SW Fused Pwr
OR 0.8 GXL
SPC, Pilot Control Switch
2
SPL_D24, Ultrasonic
A
19D A Parking Brake Relay Fused Pwr
Or 1.0 GXL
SPL-PBS, Ultrasonic
A
ECA, Elect Center A
A6
19D B Parking Brake Relay Fused Pwr
Or 0.8 GXL
SPL-PBS, Ultrasonic
A
ECB, Elect Center B
D9
19D C Parking Brake Relay Fused Pwr
Or 1.0 GXL
SPL-PBS, Ultrasonic
A
ECB, Elect Center B
B9
19E A AIC Wake Up Ignition
Or 0.8 TXL
SPL_AP, Ultrasonic
A
ECA, Elect Center A
A3
19B
Or 0.8 GXL
AA10
19H
Backup Alarm B+
OR 1.0 GXL
ECD, ELEC CNTR D
A10
ECA, Elect Center A
C4
19J
Front Wiper Fused Pwr
Or 0.8 GXL
SPL-FW, Ultrasonic
A
ECA, Elect Center A
C2
84547255A
Issued 11-11
Printed in E.C.
4002-18
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
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
19J A Front Wiper Motor Fused Pwr
Or 0.8 GXL
SPL-FW, Ultrasonic
A
FWM, Front Wiper Motor
C
19J B Front Wip Wash Sw Fused Pwr
Or 0.8 GXL
SFWW, Front Wiper/Washer
5
SPL-PK3, Splice 3-4 Way
J
19J C Front Wiper Relay Fused Power
Or 0.8 GXL
SPL-PK3, Splice 3-4 Way
K
SPL-FW, Ultrasonic
A
19J D Front Wiper Relay Fused Power
Or 0.8 GXL
SPL-PK3, Splice 3-4 Way
L
ECD, Elect Center D
D1
19J E Front Wiper Relay Fused Power
Or 0.8 GXL
SPL-FW, Ultrasonic
A
ECD, Elect Center D
B1
Or 0.8 GXL
SPL-PK3, Splice 3-4 Way
M
ECD, Elect Center D
D3
Or 0.8 GXL
SPL-FW, Ultrasonic
A
K-WCO, Wiper Cutout
86
Or 1.0 GXL
SPL-RWW, Ultrasonic
A
ECA, Elect Center A
C3
19K A Rear Wiper Sw Fused Pwr
Or 1.0 GXL
SRWP, Rear Wiper Sw
3
SPL-RWW, Ultrasonic
A
19K B Rear Wip Wash Fused Pwr
Or 0.8 GXL
SRWP, Rear Wiper Sw
5
SPL-RWW, Ultrasonic
A
19K C Rear Wiper Motor Fused Pwr
Or 1.0 GXL
CAB-RF, Cab to Roof Connect
J
SPL-RWW, Ultrasonic
A
19K D Rear Wiper Motor Fused Pwr
Or 1.0 SXL
ROOF, Roof to Cab Connect
J
RWM, rear Wiper Motor
C
Pwr Converter Fused Power
Or 3.0 GXL
PRM-A1, PRM Output
C
SPL-CNV, Ultrasonic
A
19L A Pwr Converter Fused Power
Or 2.0 GXL
CNV, 24V to 12V Pwr Conver
1
SPL-CNV, Ultrasonic
A
19L B Pwr Converter Fused Power
Or 2.0 GXL
CNV, 24V to 12V Pwr Conver
2
SPL-CNV, Ultrasonic
A
Sec. Steering Accessory Fused Pwr
Or 0.8 GXL
CAB-T, Cab Transmission
3
ECA, Elect Center A
C7
19M A Sec. Steering Accessory Fused Pwr
Or 1.0 SXL
TRANS, Cab Transmission
3
TR-SS, Sec. Steering Module Opt
A
19M C Sec. Steering Accessory Fused Pwr
Or 1.0 SXL
SSM, Sec. Steering Module
7
SS-TR, Sec. Steering Mod Trans
A
19J F
Front Wiper Relay LS Control Fused Power
19J G Wiper Cutout Relay Fused Pwr 19K
19L
19M
Rear Wiper Fused Pwr
19N
Seat Compressor Fused Pwr
Or 1.0 GXL
SC, Seat Compressor Motor
A
ECA, Elect Center A
C6
19P
Pin Engage/Fan Fused Pwr
Or 0.8 GXL
SPL-PIN, Spl Back Lgt Pwr
B
ECA, Elect Center A
A7
19P A Pin Engage Sw Fused Pwr
Or 0.8 GXL
SPE, Pin Engage Sw
2
SPL-PIN, Spl Back Lgt Pwr
A
19P C Fan Rev Sw Fused Pwr
Or 0.8 GXL
SFC, Fan Control Switch
5
SPL-PIN, Spl Back Lgt Pwr
C
19P D Fan Rev Relay Fused Pwr
Or 0.8 GXL
SPL-PIN, Spl Back Lgt Pwr
E
ECB, Elect Center B
D7
19P E Fan Rev Relay Fused Pwr
Or 0.8 GXL
SPL-PIN, Spl Back Lgt Pwr
F
ECB, Elect Center B
B7
19R
Sec. Steering Ign Fused Pwr
Or 0.8 GXL
DM, Diode OR
C
SPL-2 Ultrasonic
A
19RR
Sec. Steering Ign Fused Pwr
Or 0.8 GXL
DM, Diode OR
A
ECA, Elect Center A
A4
19R A Sec. Steering Ign Fused Pwr
Or 1.0 SXL
TRANS, Cab Transmission
4
TR-SS, Sec. Steering Module Opt
B
84547255A
Issued 11-11
Printed in E.C.
4002-19
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
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
19R C Sec. Steering Ign Fused Pwr
Or 1.0 SXL
SSM, Sec. Steering Module
1
SS-TR, Sec. Steering Mod Trans
B
19R D Alternator Resistor Fused Pwr
Or 0.8 GXL
SPL-2, Ultrasonic
A
216F, Alternator Resistor
1
19R E Sec. Steering Ign Fused Pwr
Or 0.8 GXL
SPL-2, Ultrasonic
A
CAB-T, Cab Transmission
4
19S1
Sec. Steering Pwr
Or 3.0 GXL
PRMB L2, B+ Power
1
SPL, 19S, Ultrasonic
A
19S2
Sec. Steering Fused Pwr
Or 1.0 GXL
SPL, 19S, Ultrasonic
A
CAB-T, Cab Transmission
26
19S1 E Sec. Steering Fused Pwr
Or 1.0 SXL
TRANS, Cab Transmission
26
TR-SS, Sec. Steering Module Opt
E
19S1 X Sec. Steering Fused Pwr
R 1.0 SXL
SSM, Sec. Steering Module
3
SS-TR, Sec. Steering Module Trans
E
19S B AIC Delay Fused Power
Or 0.8 GXL
SPL-DLY3, Ultrasonic
A
ECC, Elect Center C
A8
19S C AIC Delay Fused Power
Or 0.8 TXL
SPL-DLY3, Ultrasonic
A
AIC-2, Advanced Instr Cluster 2
20
19S D AIC Delay Fused Power
Or 0.8 TXL
SPL-DLY3, Ultrasonic
A
AIC-2, Advanced Instr Cluster 2
14
19S E AIC Batt B+
OR 0.8 GXL
SPL_AP, Ultrasonic
A
AIC_1, Advanced Instr Cluster 1
1
19S F AIC Batt B+
OR 0.8 GXL
SPL_AP, Ultrasonic
A
AIC-2, Advanced Instr Cluster 2
21
19T A Fused Batt. Power
Or 0.8 TXL
TECM, Trans
23
SPL_D17, Ultrasonic
A
19T B Fused Batt. Power
OR 0.8 TXL
TECM, Trans
68
SPL_D17, Ultrasonic
A
19T C Fused Batt. Power
OR 0.8 TXL
SPL_D17, Ultrasonic
A
ECC, Elect Center C
A10
Horn Relay Fused Power
Or 0.8 GXL
SPL-HRN, Ultrasonic
A
ECC, Elect Center C
A6
19U A Horn Relay Fused Power
Or 0.8 GXL
SPL-HRN, Ultrasonic
A
ECC, Elect Center C
B7
19U B Beacon Dome Lt Fused Pwr
Or 1.0 GXL
SPL-LT, Ultrasonic
A
ECC, Elect Center C
A1
19U C Dome Lt Fused Pwr
Or 0.8 GXL
ROOF, Roof to Cab Connection
D
LDM1, Dome Light B+
1
19U D Dome Lt Fused Pwr
Or 0.8 GXL
CAB-RF, Cab to Roof Connection
D
SPL-LT, Ultrasonic
A
19U E Horn Relay Fused Power
Or 0.8 GXL
SPL-HRN, Ultrasonic
A
ECC, Elect Cntr C
D7
19U F Door Sw Fused Power
Or 0.8 GXL
ROOF, Roof to Cab Connection
P
DS, Door Switch
A
19U G Door Sw Fused Power
Or 0.8 GXL
CAB-RF, Cab to Roof Connection
P
SPL-LT, Ultrasonic
A
19U H Beacon Switch Fused Power
Or 1.0 GXL
SBE, Beacon Switch
2
SPL-LT, Ultrasonic
A
19U
19W
Cigar Lighter Fused Power
Or 3.0 GXL
CL, Cigar Lighter
1
ECA, Elect Cntr A
C8
19Y
Hood control Fused Power
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A
ECC, Elect Cntr C
A7
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A
ECC, Elect Cntr C
D2
19Y A Hood Up Relay Fused Power
84547255A
Issued 11-11
Printed in E.C.
4002-20
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
19Y B Hood Down Relay Fused Power
Or 1.0 GXL
SPL-HOOD, Ultrasonic
A
ECC, Elect Cntr C
D4
19Y C Hood Switch Fused Power
Or 1.0 GXL
Cabe2, Cab to ENG2 BULKHD
T
SPL-HOOD, Ultrasonic
A
19Y D Hood Switch Fused Power
Or 1.0 GXL
ENG2, ENG BULKHD 2
T
HD, Hood Switch
B
Driving Lights Sw Fused Power
Or 1.0 GXL
SPL_DR, Ultrasoic
A
ECC, Elect Cntr C
A3
19Z A Driving Lights Sw Fused Power
Or 1.0 GXL
SDR, Driving Lights Sw
2
SPL_DR, Ultrasoic
A
19Z B Driving Lights Sw Fused Power
Or 1.0 GXL
SDR, Driving Lights Sw
5
SPL_DR, Ultrasoic
A
19Z C High Beam Flash Fused Power
Or 1.0 GXL
SRHSTLK, RH Stalk Switch
56d
SPL_DR, Ultrasoic
A
Cab CB Protected Power
R 19.0 SXL
P C3, B+ PWR FRM PRMD
1
CBPW, Cab Power
1
1CB A Cab CB Protected Power
R 19.0 SXL
P-A3, B+ Power
1
CAB-PW, Cab Power
1
19Z
1CB
1DM
Time Delay/Ign Sw Fused Pwr
R 1.0 GXL
S_KEY, Ignition Switch
1
ECC, Elect Cntr C
A5
1 AA
Brake Lt Sw Pwr
R 1.0 SXL
BTM_C, Cab Bottom BULKHD
K
PBL, Brake Light Press Switch
1
1B
EVGT Relay Power
R 1.0 GXL
EVGT 3, EVGT Fuse
B
EVGT 4, EVGT
A
1 BA
Alternator B+
R 13.0 SXL
AB+, Alternator B+
1
B2 Starter Power
1
1 BB
Starter Solenoid Pwr
R 8.0 SXL
193 Starter Relay
1
194 Starter Signal
1
1 BE
Grid Htr Pwr
R 19.0 SXL
115 Grid Htr Pwr
1
GH, Grid Htr
1
1 BF
Alternator B+
R 13.0 SXL
AB 5, Alternator B+
1
B6, Starter Power
1
1 BG
B+ PWR PRMC
R19_0-SXL
B5, Starter Pwr Stud
1
P C1, B+ Pwr frm prmd
1
1C
ECC Bat Power
R 8.0 GXL
P-A1, B+ Power
1
L1-ECC, ECC Battery Power
1
1 DR
Brake Light Switch Power
R 1.0 GXL
Cab B, Cab BTM Bulkhead
K
SPL-FLSHR-PWR, Ultrasonic
A
1 DU
Flasher Module Pwr
R 1.0 GXL
FLSHR, Flasher Module
1
SPL-FLSHR-PWR, Ultrasonic
A
1 DV
Brake Lights/Flasher Bat Pwr
R 2.0 GXL
SPL-FLSHR-PWR, Ultrasonic
A
ECC, Elect Cntr C
A4
1 DW
Brake Lt Relay Bat Pwr
R 1.0 GXL
SPL-FLSHR-PWR, Ultrasonic
A
ECD, Elect Cntr D
A2
Grid heater Fuse Bat Power
R 19.0 SXL
P-C2, B+ Power from PRMD
1
GHF1, Grid Heater Fuse
1
1 GA
Filter Htr Pwr
R 3.0 SXL
PRM-D1, PRM Output
C
SPL-HTR, Ultrasonic
A
1 GB
Fuel Filter Htr Pwr
R 2.0 SXL
SPL-HTR, Ultrasonic
A
FFH, Fuel Filter Heater
A
1 GC
Water Sep Htr Pwr
R 2.0 SXL
SPL-HTR, Ultrasonic
A
WSH, Water Separator Heater
B
1 KA
Hazard Switch Pwr
R 1.0 GXL
SHZ, Hazard Switch
2
SPL-FLSHR-PWR, Ultrasonic
A
1 NA
Battery Crossover
R 62.0 SGR
BT3, Starter Battery
1
BT2, Disconnect Battery
1
1 NB
Battery Starter
R 62.0 SGR
BT1, Battery Starter
1
DC1, Disconnect Battery
1
1E
84547255A
Issued 11-11
Printed in E.C.
4002-21
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
1 NC
B+ Power PRMC
R 19.0 SXL
B1, Starter Power Stud
1
P-C1, B+ Power From PRMD
1
1 ND
SSM Power
R 62.0 SGR
244F Starter Sec. Strg Mtr
1
B4, Starter Power
1
1 NE
Battery Starter
R 62.0 SGR
B7, Starter Battery
1
BT1, Battery Starter
1
1 NF
SSM Pwr
R 62.0 SGR
B8, Starter Power
1
244F, Starter-Sec Strg Mtr
1
1 NG
Power Non Disconnected
R 8.0 SXL
BT1, Battery Starter
1
PW-B, Cab Power
1
1 NH
Power Non Disconnected
R 8.0 SXL
SPL 1N, Ultrasonic
A
PW-E, Cab Power
1
1 NJ
Power Non Disconnected
R 3.0 SXL
ENG2, ENG BULKHD 2
G
SPL 1N, Ultrasonic
A
1 NK
Power Non Disconnected
R 3.0 SXL
ENG2, ENG BULKHD 2
D
SPL 1N, Ultrasonic
A
1 NL
Power Non Disconnected
R 3.0 GXL
CABE2, Cab to ENG2 BULKHD
G
P A2, B+ Power
1
1 NM
Power Non Disconnected
R 3.0 GXL
CABE2, Cab to ENG2 BULKHD
D
P A2, B+ Power
1
1T
EVGT 3 Pwr
R 1.0 SXL
P C6, B+ Pwr Frm prmd
1
EVGT 3, EVGT Fuse
A
1Y
Grid Heater Fused Power
R 19.0 SXL
GHF3, Grid heater Fuse
1
GHF4, Grid Heater
1
1Z
Starter Relay Battery Power
R 8.0 SXL
P-C4, B+, Power From PRMD
1
195, Starter Relay Power
1
20G A EDC7 ISO-K Interface
W 0.8 TXL
ENG, Engine Cab 1
31
EDC7, Engine Controller
89
20G B EDC7 ISO-K Interface
W 0.8 GXL
CAB-E, Cab Engine
31
DIA, Diagnostic
E
Neutral Start Relay Output
W 0.8 GXL
SPL-CR, Ultrasonic
A
ECB, Elect Center B
D4
21C A Neutral Start Relay Output
W 0.8 GXL
SPL-CR, Ultrasonic
A
ECB, Elect Center B
D5
21C B Neutral Start Relay Output
W 0.8 GXL
SPL-CR, Ultrasonic
A
ECB, Elect Center D
A6
Starter Relay Signal
W 1.0 SXL
SRC-1, Relay
1
ENG, Engine Cab 1
15
21D A Starter Relay Signal
W 0.8 GXL
Cab E, Cab-Engine
15
ECB, Elect Center D
AA5
Key Switch Crank
W 0.8 GXL
ECC, Elect Cntr C
B9
ECB, Elect Center B
D6
21E A Key Switch Crank
W 0.8 TXL
ENG, Engine Cab 1
27
EDC7, Engine Controller
32
21E B Key Switch Crank
W 0.8 GXL
Cab E, Cab-Engine
27
ECC, Elect Cntr C
C10
EDC7 Digital Ground
W 0.8 GXL
CAB-E, Cab Engine
11
ECB, Elect Center B
B5
21F A EDC7 Digital Ground
W 0.8 GXL
ENG, Engine Cab 1
11
SPL-EDC3, Ultrasonic
A
21F B EDC7 Digital Ground
W 0.8 TXL
SPL-EDC3, Ultrasonic
A
EDC7, Engine Controller
29
21F C EDC7 Digital Ground
W 0.8 TXL
ENG_B, Cab Bottom
1
SPL-EDC3, Ultrasonic
A
21F D EDC7 Digital Ground
W 0.8 TXL
RTHP, Throttle Pedal
1
BTM E, Cab Bottom
1
W 0.8 GXL
CAB-E, Cab Engine
3
ECB, Elect Center D
AA6
21C
21D
21E
21F
21G
EDC7 Crank Control relay
84547255A
Issued 11-11
Printed in E.C.
4002-22
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
21G A EDC7 Crank Control relay
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
W 0.8 TXL
ENG, Engine Cab 1
3
EDC7, Engine Controller
37
Crank control relay LSD
W 0.8 GXL
CAB-E, Cab Engine
4
ECD, Elect Center D
A5
21H A Crank control relay LSD
W 0.8 TXL
ENG, Engine Cab 1
4
EDC7, Engine Controller
17
TEL, Telematics
S
21H
21J
Restart Prevent
W 0.8 GXL
ECC, Elect Cntr C
D9
21K
Ign Sw Start Signal
W 0.8 GXL
S-KEY, Ignition Switch
2
SPL-CRK, Ultrasonic
A
21K A Ign Sw Start Signal
W 0.8 TXL
SPL-CRK, Ultrasonic
A
AIC-2, Adv Instrument Cluster 2
17
21K B Ign Sw Start Signal
W 0.8 GXL
SPL-CRK, Ultrasonic
A
ECB, Elect Center B
B3
22A
Declutch SW
DU 0.8 TXL
SDC, Declutch Switch
3
TECM, Trans
21
22B
Pedal Sensor +5V
K 0.8 TXL
Cab_B, Cab BTM BULKHEAD
B
TECM, Trans
37
22C
Pedal Pos Signal
Y 0.8 TXL
TECM, Trans
38
Cab B, Cab BTM BULKHEAD
C
22D
Pedal Sensor Grnd
LU 0.8 TXL
Cab_B, Cab BTM BULKHEAD
A
TECM, Trans
24
22E
Pedal Sensor +5V
K 0.8 TXL
BTM_C, Cab Bottom BULKHD
B
BPP, Pedal Position
2
22F
Pedal Pos Signal
Y 0.8 GXL
BTM_C, Cab Bottom BULKHD
C
BPP, Pedal Position
3
22G
Pedal Sensor Grnd
LU 0.8 GXL
BTM_C, Cab Bottom BULKHD
A
BPP, Pedal Position
1
23A A DNOX2 Module B+
N 0.8 TXL
NOXS, NOX Sensor
1
ENG2, ENG BULKHD 2
C
23B A NOX Sensor B+
OR 0.8 GXL
CabE2, Cab to ENG2 BULKHD
F
ECD, Elec Cntr D
A8
23B B NOX Sensor B+
N 0.8 GXL
CabE2, Cab to ENG2 BULKHD
C
ECD, Elec Cntr D
AA7
23B C NOX Relay Gnd
BK 0.8 GXL
ECD, Elec Cntr D
A7
GND Cab_SPL, Cab Grnd Splice
23B D NOX Relay, B+
OR 0.8 GXL
CabE2, Cab to ENG2 BULKHD
A
ECD, Elec cntr D
23B E NOX Sensor B+
OR 1.0 GXL
SPL EDC2, Ultrasonic
A
ENG2, ENG BULKHD 2
F
23B F NOX Relay B+
OR 1.0 SXL
SPL EDC4, Ultrasonic
A
ENG2, ENG BULKHD 2
A
23D D NOX Sensor Gnd
BK 0.8 TXL
NOXS, NOX Sensor
2
GND ENG2 Dedicated, WIF, EDC
1
23J B DNOX2 K-Line
W 0.8 GXL
Cab E, Cab-Engine
18
DIA 2, Diagnostic
E
23K A Temp/Humd B+
K 0.8 TXL
HTS, HMDTY And AMB Temp
1
EDC7, Engine Controller
68
23K B Temp/Humd Temp
Y 0.8 GXL
HTS, HMDTY And AMB Temp
2
EDC7, Engine Controller
26
23K C Temp/Humd Humd
Y 0.8 GXL
HTS, HMDTY And AMB Temp
4
EDC7, Engine Controller
27
23K E Temp/Humd Gnd
LU 0.8 GXL
EDC7, Engine Controller
28
HTS, HMDTY And Amb Temp
3
Throttle Signal
W 0.8 TXL
ENG B, Cab Bottom
3
EDC7, Engine Controller
79
24B A Throttle Signal
W 0.8 TXL
RTHP, Throttle Pedal
3
BTM E, Cab Bottom
3
24B
84547255A
Issued 11-11
E AA8
Printed in E.C.
4002-23
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire 24L
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
W 0.8 TXL
ENG B, Cab Bottom
6
EDC7, Engine Controller
48
W 0.8 TXL
RTHP, Throttle Pedal
6
BTM_E, Cab Bottom
6
Throttle Grnd
W 0.8 TXL
ENG B, Cab Bottom
4
EDC7, Engine Controller
78
24R A Throttle Grnd
W 0.8 TXL
RTHP, Throttle Pedal
4
BTM E, Cab Bottom
4
Throttle Supply
W 0.8 TXL
ENG B, Cab Bottom
5
EDC7, Engine Controller
77
24S A Throttle Supply
W 0.8 TXL
RTHP, Throttle Pedal
5
BTM E, Cab Bottom
5
24T B TC Lockup Sol Gnd
LU 1.0 SXL
YLS, TC Lockup Valve
2
Trans, Transmission-Cab
25
255E
Pedal Sensor +5V
K 0.8 TXL
BTM-C, Cab Bottom Bulkhd
E
BPP, Pedal Position
5
25A
Eng Speed Sig
LU 0.8 GXL Twist
TRANS, Cab Transmission
7
ESS, Engine speed Sensor
1
25A A Eng Speed Sig
LU 0.8 TXL
CAB-T, Cab Transmission
7
TECM, Trans
19
Int Speed Sig
LU 0.8 GXL Twist
TRANS, Cab Transmission
9
ISS, Int Speed Sensor
1
25B A Int Speed Sig
LU 0.8 TXL
CAB-T, Cab Transmission
9
TECM, Trans
42
Turbine Speed Sig
LU 0.8 GXL Twist
TRANS, Cab Transmission
8
TSS, Turbine Speed Sensor
1
25C A Turbine Speed Sig
LU 0.8 TXL
CAB-T, Cab Transmission
8
TECM, Trans
41
Output Speed Sig
LU 1.0 SXL
TRANS, Cab Transmission
10
OSS, Output Speed Sensor
2
25D A Output Speed Sig
LU 0.8 TXL
CAB-T, Cab Transmission
10
TECM, Trans
62
Low Idle Sw
24L A Low Idle Switch 24R
24S
25B
25C
25D
25F
Forward Signal
LU 0.8 TXL
TS1, Transmission Shifter
B
TECM, Trans
43
25G
Brake Declutch Switch Ctrl
LU 1.0 SXL
Trans, Transmission-Cab
14
PBD, Declutch Pressure Switch
B
25G A Brake Declutch Switch Ctrl
LU 0.8 GXL
Cab T, Cab-Transmission
14
SPL-DC, Ultrasonic
A
25G B Brake Declutch Switch Ctrl
LU 0.8 GXL
SDC, Declutch Switch
1
SPL-DC, Ultrasonic
A
25G C Brake Declutch Switch Ctrl
LU 0.8 TXL
SPL-DC, Ultrasonic
A
TECM, Trans
66
25H
Trans Auto Signal
LU 0.8 TXL
STA, Trans Auto Switch
3
TECM, Trans
29
25J
Trans Sol Valve Y6
LU 0.8 TXL
TRANS, Cab Transmission
21
TRC, Trans Control
6
25J A Trans Sol Valve Y6
LU 0.8 TXL
CAB-T, Cab Transmission
21
TECM, Trans
51
Trans Sol Valve Y1
LU 0.8 TXL
TRANS, Cab Transmission
16
TRC, Trans Control
1
25K 9 Trans Sol Valve Y2
LU 0.8 TXL
TRANS, Cab Transmission
16
TRC, Trans Control
2
25K A Trans Sol Valve Y1
LU 0.8 TXL
CAB-T, Cab Transmission
16
TECM, Trans
56
25K
25L
Trans Sol Valve Y2
LU 0.8 TXL
TRANS, Cab Transmission
17
TRC, Trans Control
2
25L 9
Trans Sol Valve Y1
LU 0.8 TXL
TRANS, Cab Transmission
17
TRC, Trans Control
1
84547255A
Issued 11-11
Printed in E.C.
4002-24
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
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
25L A Trans Sol Valve Y2
LU 0.8 TXL
CAB-T, Cab Transmission
17
TECM, Trans
10
25M
Trans Sol Valve Y3
LU 0.8 TXL
TRANS, Cab Transmission
18
TRC, Trans Control
3
25M A Trans Sol Valve Y3
LU 0.8 TXL
CAB-T, Cab Transmission
18
TECM, Trans
32
Trans Sol Valve Y4
LU 0.8 TXL
TRANS, Cab Transmission
19
TRC, Trans Control
4
25N A Trans Sol Valve Y4
LU 0.8 TXL
CAB-T, Cab Transmission
19
TECM, Trans
55
Trans Sol Valve Y5
LU 0.8 TXL
TRANS, Cab Transmission
20
TRC, Trans Control
5
25P A Trans Sol Valve Y5
LU 0.8 TXL
CAB-T, Cab Transmission
20
TECM, Trans
9
LU 0.8 TXL
TS1, Transmission Shifter
C
TECM, Trans
64
25R A TC Lockup Sol Power
LU 0.8 TXL
TECM, Transmission
50
Cab T, Cab-Transmission
15
25R B TC Lockup Sol Power
LU 1.0 SXL
YLS, TC Lockup Valve
1
Trans, Transmission-Cab
15
Output Sw Power VPS1
LU 0.8 TXL
TRANS, Cab Transmission
22
TRC, Transmission Control
7
25S A Output Sw Power VPS1
LU 0.8 TXL
CAB-T, Cab Transmission
22
SPL D12, Ultrasonic
A
25S B Output Sw Power VPS1
LU 0.8 TXL
SPL D12 Ultrasonic
A
TECM, Trans
12
25S C Output Sw Power VPS1
LU 0.8 TXL
SPL D12 Ultrasonic
A
TECM, Trans
13
LU 0.8 GXL
SPL-NEU, Ultrasonic
A
ECB, Elect Center B
D3
25T A TC Lockup Sol Gnd
W 0.8 TXL
SPL_D19, Ultrasonic
A
Cab T, Cab-Transmission
25
25T B Neutral Signal
LU 0.8 GXL
TS1, Transmission Shifter
D
SPL-NEU, Ultrasonic
A
25T C Neutral Signal
LU 0.8 TXL
SPL-NEU, Ultrasonic
A
TECM, Trans
67
25W
3rd And 4th Gear Signal
LU 0.8 TXL
TS2, Transmission Shifter
B
TECM, Trans
65
25Y
Trans Kick Down Signal
LU 0.8 GXL
TS2, Transmission Shifter
D
SPL D11, Ultrasonic
A
25Y A Trans Kick Down Signal
LU 0.8 TXL
SPL D11, Ultrasonic
A
TECM, Trans
22
25Y B Trans Kick Down Signal
LU 0.8 GXL
197F, Main Cab FNR
6
SPL D11, Ultrasonic
A
25Y C Trans Kick Down Signal
LU 0.8 GXL
20M, Trans Kick Down
2
197M, FNR Main Cab
6
25Y D Trans Kick Down Signal
LU 0.8 GXL
KD_Diode, Diode Assy
C
JSS 197M, FNR Main Cab
6
25Y E Trans Kick Down Signal
LU 0.8 GXL
Cab Fnr, Main Cab Fnr
6
KD Diode, Diode Assy
B
25Y F Trans Kick Down Signal
LU 0.8 GXL
KD Diode, Diode Assy
A
JSS 197F, Main Cab FNR
6
25Y G Trans Kick Down Signal
LU 0.8 GXL
21M, Trans Kick-Down
2
Arm FNR, FNR-Main Cab
6
LU 0.8 TXL
TS2, Transmission Shifter
C
TECM, Trans
63
26E A Trans Enable Signal
LU 0.8 TXL
STE, Trans Enable Switch
3
TECM, Trans
31
26F A FNR Forward Signal
LU 0.8 GXL
197M, FNR Main Cab
2
SFNR, FNR Switch
6
26F B FNR Forward Signal
LU 0.8 TXL
197F, Main Cab FNR
2
TECM, Trans
20
25N
25P
25R
25S
25T
25Z
Reverse Signal
Neutral Signal
1st And 4th Gear Signal
84547255A
Issued 11-11
Printed in E.C.
4002-25
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
26F C FNR Forward Signal
LU 0.8 GXL
FWD Diode, Diode Assy
C
JSS 197M, FNR-Main Cab
2
26F D FNR Forward Signal
LU 0.8 GXL
JSS 197F, Main Cab FNR
2
FWD Diode, Diode Assy
A
26F E FNR Forward Signal
LU 0.8 GXL
Cab FNR, Main Cab FNR
2
FWD Diode, Diode Assy
B
26F F FNR Forward Signal
LU 0.8 GXL
SAJ, FNR Switch
6
Arm FNR, FNR Main Cab
2
26J
FNR Switch Jumper
LU 0.8 GXL
SFNR, FNR Switch
2
SFNR, FNR Switch
4
26K
FNR Switch Jumper
LU 0.8 GXL
SAJ, FNR Switch
2
SAJ, FNR Switch
4
26N A FNR Neutral Signal
LU 0.8 GXL
SFNR, FNR Switch
3
197M, FNR Main Cab
3
26N B FNR Neutral Signal
LU 0.8 TXL
197F, Main Cab FNR
3
TECM, Trans
44
26N C FNR Neutral Signal
LU 0.8 GXL
JSS 197M, FNR-Main Cab
3
Ntrl Diode, Diode Assy
C
26N D FNR Neutral Signal
LU 0.8 GXL
JSS 197F, Main Cab FNR
3
Ntrl Diode, Diode Assy
A
26N E FNR Neutral Signal
LU 0.8 GXL
Ntrl Diode, Diode Assy
B
Cab FNR, Main Cab FNR
3
26N F FNR Neutral Signal
LU 0.8 GXL
SAJ, FNR Switch
3
Arm FNR, FNR-Main Cab
3
26R A FNR Reverse Signal
LU 0.8 GXL
SFNR, FNR Switch
1
197M, FNR Main Cab
4
26R B FNR Reverse Signal
LU 0.8 TXL
197F, Main Cab FNR
4
TECM, Trans
30
26R D FNR Reverse Signal
LU 0.8 GXL
JSS 197F, Main Cab FNR
4
RVS Diode, Diode Assy
A
26R E FNR Reverse Signal
LU 0.8 GXL
Cab FNR, Main Cab FNR
4
RVS Diode, Diode Assy
B
26R F FNR Reverse Signal
LU 0.8 GXL
SAJ, FNR Switch
1
Arm FNR, FNR-Main Cab
4
28F
Fuel Filter Htrs Relay Control
W 0.8 TXL
PRM-D2,PRM Signal
A
EDC7, Engine Controller
36
28G
Grid Heater Source Dr.
W 1.0 GXL
GHC, Grid Htr Relay
1
EDC7, Engine Controller
12
31A
EVGT Relay B+
OR 0.8 GXL
EVGT 4, EVGT
E
SPL EDC4, Ultrasonic
A
31B
Filter Heater Control
OR 0.8 GXL
PRM D2, PRM Signal
B
SPL EDC4, Ultrasonic
A
31F
Air Filter Rest Sw Signal
Y 1.0 SXL
ENG, Engine Cab 1
28
PAF, Air Filter Rest Sw
1
31F A Air Filter Rest Sw Signal
Y 0.8 TXL
CAB-E, Cab Engine
28
SW-PD, Switch Pad
5
31H
Hyd Filter Rest Sw Signal
Y 1.0 SXL
TRANS, Cab Transmission
23
PHF, Hyd Oil Filter Rest Sw
1
31H9
Hyd Filter Rest Sw 9
Y 1.0 SXL
Trans, Transmission Cab
23
PHF9, Hyd Oil Filter Rest Sw
2
Y 0.8 GXL
SW-PD, Switch Pad
4
CAB-T, Cab Transmission
23
31H A Hyd Filter Rest Sw Signal 31L
Pilot Control Switch High
Y 0.8 TXL
SPC, Pilot Control Switch
3
AIC-2, Advance Instr Cluster 2
18
32F
Trans Filter Maint Sw
Y 1.0 SXL
TRANS, Cab Transmission
31
FM, Filter Maint Sw
1
32F A Trans Filter Maint Sw
Y 0.8 TXL
CAB-T, Cab Transmission
31
TECM, Trans
17
32J A Trans Enable Indiction
Y 0.8 GXL
SFNR, FNR Switch
7
197M FNR Main Cab
5
32J C Trans Enable Indiction
Y 0.8 GXL
STE, Trans Enable Switch
9
SPL-D16, Ultrasonic
A
84547255A
Issued 11-11
Printed in E.C.
4002-26
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
32J D Trans Enable Indiction
Y 0.8 TXL
SPL-D16, Ultrasonic
A
TECM, Trans
5
32J E Trans Enable Indiction
Y 0.8 GXL
197F, Main Cab FNR
5
SPL-D16, Ultrasonic
A
32J F
Trans Enable Indiction
Y 0.8 GXL
SPL JSS_21, Ultrasonic
A
JSS 197M, FNR Main Cab
5
32J G Trans Enable Indiction
Y 0.8 GXL
JSS 197F, Main Cab FNR
5
SPL JSS_21, Ultrasonic
A
32J H Trans Enable Indiction
Y 0.8 GXL
Cab FNR, Main Cab FNR
5
SPL JSS_21, Ultrasonic
A
32J J
Trans Enable Indiction
Y 0.8 GXL
SAJ, FNR Switch
7
Arm FNR, FNR Main Cab
5
33P
Brake Warning Press Low
Y 1.0 SXL
BTM_C, Cab Bottom BULKHD
L
PBW, Brake Warning Press Sw
1
33P A Brake Warning Press Low
Y 0.8 TXL
Cab B, Cab BTM BULKHEAD
L
AIC-2, Advance Instr Cluster 2
5
Redundant Brake Accumulator Pressure Low
Y 0.8 TXL
CAB-T, Cab Transmission
1
AIC-2, Advance Instr Cluster 2
4
33R A Redundant Brake Accumulator Pressure Low
Y 1.0 SXL
TRANS, Cab Transmission
1
SPL-RD, Ultrasonic
A
33R B Redundant Brake Accumulator Pressure Low
Y 1.0 SXL
SPL-RD, Ultrasonic
A
PRB2, Redundant Brake Switch
A
33R C Redundant Brake Accumulator Pressure Low
Y 1.0 SXL
SPL-RD, Ultrasonic
A
PRB1, Redundant Brake Switch
A
Y 0.8 TXL
SPB, Parking Brake Switch
3
AIC-2, Advance Instr Cluster 2
6
34A A Diff Lock SW B+
OR 0.8 GXL
SDA, Diff Lock Switch
2
SPL PBS, Ultrasonic
A
34A B Diff Lock SW SIG B+
OR 0.8 GXL
SDM, Diff Lock Switch
2
SPL PBS, Ultrasonic
A
34A C Diff Lock Sol B+
W 0.8 TXL
SPL D19, Ultrasonic
A
Cab T, CAB Transmission
2
34A D Diff Lock Sol B+
OR 1.0 SXL
Trans, Transmission Cab
27
YDL, Diff Lock Solenoid
1
34A E Diff Lock Sol B+
OR 1.0 SXL
YDL 1, Diff Lock Solenoid
1
YDL 2, Diff Lock Solenoid
1
33R
33U
Parking Brake Switch
34B
Diff Lock SW SIG
LU 0.8 TXL
SDA, Diff Lock Switch
3
TECM, Trans
35
34C
Diff Lock Sol GND
LU 0.8 TXL
Cab T, Cab Transmission
27
TECM, Trans
11
34C A Diff Lock Sol GND
LU 1.0 SXL
Trans, Transmission Cab
2
YDL, Diff Lock Solenoid
2
34C D Diff Lock Sol GND
LU 1.0 SXL
YDL 1, Diff Lock Solenoid
2
YDL 2, Diff Lock Solenoid
2
LU 0.8 TXL
TECM, Trans
59
SDM, Diff Lock Switch
1
35A 9 BKUP ALM RLY OUT
BK 1.0 SXL
HD-9, Hood to ENG
7
BU2, Backup Alarm
1
35A A Backup Alarm
Y 0.8 GXL
ECD, Elec Cntr D
AA9
SPL 35A, Ultrasonic
A
35A B Backup Alarm Disable Switch
Y 0.8 GXL
SBU, Backup Alarm Dis Sw
2
SPL 35A, Ultrasonic
A
35A C Backup Alarm Relay Out
Y 0.8 GXL
Cabe2, Cab to ENG2 BULKHD
L
SPL 35A, Ultrasonic
A
34D
Diff Lock SW SIG
84547255A
Issued 11-11
Printed in E.C.
4002-27
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
35A D Backup Alarm Relay Out
Y 0.8 GXL
209M, Backup Alarm Dis Jump
A
SPL 35A, Ultrasonic
A
35A E Backup Alarm Relay Out
Y 0.8 SXL
209F, Backup Alarm Dis Jump
1
SPL-D8-C1, Ultrasonic
A
35A F Backup Alarm Relay Out
Y 0.8 SXL
Cabe2, Cab to ENG2 BULKHD
K
SPL-D8-C1, Ultrasonic
A
35A G Backup Alarm Relay Out
Y 1.0 SXL
ENG2, ENG BULKHD 2
K
E-HD, Trans Hood
B
Backup Alarm Relay Out
Y 1.0 SXL
ENG2, ENG BULKHD 2
K
ENG-H, Engine to Hood
7
35A H Backup Alarm Relay Out
Y 1.0 SXL
HD-E, Hood Trans
B
BU2, Backup Alarm
1
Y 1.0 SXL
HD-N, Hood to Engine
7
BU2, Backup Alarm
1
35A J Revers Light
K 1.0 SXL
ENG2, ENG BULKHD 2
L
SPL-A1A, Ultrasonic
A
35A K Revers Light
K 1.0 SXL
SPL-A1A, Ultrasonic
A
LRR-E, RH rear Comb Light
4
35A L Revers Light
K 1.0 SXL
SPL-A1A, Ultrasonic
A
LLR-E, LH rear Comb Light
4
35A M Reverse Signal
Y 0.8 GXL
MON, Camera/Monitor
3
SPL 35A, Ultrasonic
A
35A N Revers Light
K 1.0 SXL
SPL, REV
A
LLR-9, LH Rear Comb Light
4
35A O Revers Light
K 1.0 SXL
HD-9, Hood to ENG
8
SPL, REV
A
35A P Revers Light
K 1.0 SXL
SPL, REV
A
LRR-9, RH Rear Comb Light
4
35A R Backup Alarm Relay Out
Y 1.0 SXL
ENG2, ENG BULKHD 2
L
ENG-H, Engine to Hood
8
35A GN
35A HN
Backup Alarm Relay Out
35B
AIC Buzzer HSD
W 0.8 TXL
BUZ, AIC Buzzer
1
AIC-1, Advance Instr Cluster 1
13
35C
Backup Alarm Relay Control
Y 0.8 GXL
ECD, Elec Cntr D
A9
TECM, Trans
7
Y 0.8 GXL
SBU, Backup Alarm Dis Sw
1
SPL-D8-C1, Ultrasonic
A
35R C Backup Alarm Sw 35W
Water In Fuel Indicator
W 0.8 TXL
WIF, Water In Fuel Sensor
1
EDC7, Engine Controller
42
35X
Sec. Str Low Press Sig
Y 0.8 TXL
CAB-T, Cab Transmission
6
AIC-2, Advance Instr Cluster 2
11
35X A Sec. Str Low Press Sig
Y 1.0 SXL
SPL-C3, Ultrasonic
A
PSS, Sec. Steering Press Sw
C
35X B Sec. Str Low Press Sig
Y 1.0 SXL
TRANS, Cab Transmission
6
TR-SS, Sec. Steering Mod Option
C
35X C Sec. Str Low Press Sig
Y 1.0 SXL
SPL-C3, Ultrasonic
A
SS-TR, SS Module Trans
C
35X D Sec. Str Low Press Sig
Y 1.0 SXL
SSM, Sec. Steering Module
8
SPL-C3, Ultrasonic
A
Radiator Cool Temp Signal
P 1.0 GXL
ENG, Engine Cab 1
5
RECT, Engine Coolant Temp
A
36C A Radiator Cool Temp Signal
P 0.8 TXL
CAB-E, Cab Engine
5
AIC-1, Advance Instr Cluster 1
11
Fuel Level Analog
P 1.0 SXL
ENG, Engine Cab 1
1
RFL, Fuel Sender
1
36F A Fuel Level Analog
P 0.8 TXL
CAB-E, Cab Engine
1
AIC-1, Advance Instr Cluster 1
2
36C
36F
84547255A
Issued 11-11
Printed in E.C.
4002-28
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
Torque Conv Output Temp Signal
P 1.0 SXL
TRANS, Cab Transmission
13
TCOT, TCO Sender
1
36G A Torque Conv Output Temp Signal
P 0.8 TXL
CAB-T, Cab Transmission
13
TECM, Trans
49
P 1.0 SXL
TRANS, Cab Transmission
30
HOT, Hydraulic Oil Temp Sender
A
P 0.8 TXL
CAB-T, Cab Transmission
30
AIC-1, Advance Instr Cluster 1
9
Fuel Level Analog
P 1.0 SXL
ENG, Engine Cab1
1
RFL 23, Fuel Level Sender
A
36R A Trans Temps/Filter Return
P 1.0 SXL
TRANS, Cab Transmission
12
SPL H1, Ultrasonic
A
36R B Trans Filter Maint Sw Return
P 1.0 SXL
SPL H1, Ultrasonic
A
FM, Filter Maint Switch
2
36R C Valve Body Temp Return
P 0.8 TXL
SPL H1, Ultrasonic
A
TRC, Trans Control
9
36R D TCO Temp Return
P 1.0 SXL
SPL H1, Ultrasonic
A
TCOT, TCO Sender
2
36R E Trans Temps/Filter Return
P 0.8 TXL
CAB-T, Cab Transmission
12
TECM, Trans
46
Valve Body Temp Sig
P 0.8 TXL
TRANS, Cab Transmission
5
TRC, Trans Control
8
36T A Valve Body Temp Sig
P 0.8 TXL
CAB-T, Cab Transmission
5
TECM, Trans
39
37D A Diagnostic Signal
P 0.8 TXL
108F, Diagnostic Connector
2
TECM, Trans
15
36G
36H
Hydraulic Oil Temp Signal
36H A Hydraulic Oil Temp 36J
36T
37E
Diagnostic Signal Switched
P 0.8 TXL
108F, Diagnostic Connector
4
TECM, Trans
18
38A
Doser Valve GND
LU 0.8 GXL
DNOX2, NOX Controller
11
DEFDM, Doser Metering Valve
2
38B
Def Level Sig
Y 0.8 GXL
UBJ, Def Level Temp
1
DNOX2, NOX Controller
18
38B A Def Level Sig
Y 0.8 GXL
UBJM, Def Level Temp
1
DTLTS, Def Tank Level Temp Sensor
1
38C
Tank Heat GND
LU 0.8 TXL
DNOX2, NOX Controller
23
THV, Tank Heater Control Valve
1
38D
Tank Heat B+
OR 0.8 TXL
DNOX2, NOX Controller
1
THV, Tank Heater Control Valve
2
38E
Exht Temp DWN B+
Y 0.8 GXL
DNOX2, NOX Controller
26
DTS, Downstream Temp Sens
1
38F
Exht up Signal
Y 0.8 GXL
UTS, Upstream Temp Sense
1
DNOX2, NOX Controller
28
38G
Def Temp Sig
Y 0.8 GXL
UBJ, Def Level Temp
3
DNOX2, NOX Controller
29
38G A Def Temp Sig
Y 0.8 GXL
UBJM, Def Level Temp
3
DTLTS, Def Tank Level Temp Sensor
3
38H
DNOX2 K-line
W 0.8 TXL
DNOX2, NOX Controller
31
ENG, Engine-Cab1
18
401B
Pedal Pos Signal
Y 0.8 GXL
BTM_C, Cab Bottom BULKHD
F
BPP, Pedal Position
4
41H A High Beam Pwr
Or 1.0 GXL
SRHSTLK, RH Stalk Switch
56a
SPL HB, Ultrasonic
A
41H B High Beam LH Pwr
Or 0.8 GXL
SPL HB, Ultrasonic
A
ECB, Elect Center B
A3
41H C High Beam RH Pwr
Or 0.8 GXL
SPL HB, Ultrasonic
A
ECB, Elect Center B
A4
84547255A
Issued 11-11
Printed in E.C.
4002-29
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
41H D High Beam 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
Or 0.8 TXL
SW-PD, Switch Pad
1
SPL HB, Ultrasonic
A
Or 1.0 GXL
SDR, Driving Lights Switch
6
SRHSTLK, RH Stalk Switch
56
41L A Low Beam Power
Or 1.0 GXL
SRHSTLK, RH Stalk Switch
56b
SPL-LB, Ultrasonic
A
41L B Low Beam RH Power
Or 0.8 GXL
SPL-LB, Ultrasonic
A
ECB, Elect Center B
A6
41L C Low Beam LH Power
Or 0.8 GXL
SPL-LB, Ultrasonic
A
ECB, Elect Center B
A5
K 1.0 GXL
SDR, Driving Lights Switch
3
SPL PR, Ultrasonic
A
41T A Position Lights RH Switched Pwr K 1.0 GXL
SPL PR, Ultrasonic
A
ECB, Elect Center B
A8
41T B Position Lights LH Switched Pwr K 1.0 GXL
SPL PR, Ultrasonic
A
ECB, Elect Center B
A7
41T C Position Lights Switched Pwr
K 1.0 GXL
D-OR, Diode OR
B
SPL-PR, Ultrasonic
A
42C A Front Work Lights Fused Pwr
DU 2.0 GXL
CAB-RF, Cab to Roof Conn.
H
SPL-42C Ultrasonic
A
42C C Front Work Lights Fused Pwr
DU 2.0 GXL
SPL-42C Ultrasonic
A
SWL, Work lights SW
3
42C D Front Work Lights Fused Pwr
DU 1.0 GXL
SPL-42C Ultrasonic
A
D-OR, Diode OR
A
42C F Front Work Lights Fused Pwr
DU 2.0 GXL
ROOF, Roof to Cab Conn.
H
SPL-WRKF, Ultrasonic
A
42C G RH Front Work Lights Fused Pwr DU 1.0 GXL
SPL-WRKF, Ultrasonic
A
LRFW, RH Front Work Light
1
42C H LH Front Work Lights Fused Pwr DU 1.0 GXL
SPL-WRKF, Ultrasonic
A
LLFW, LH Front Work Light
1
42R A RH Front Work LTS Fused Pwr
DU 1.0 GXL
LRFS, Front Wk LT Opt
1
SPL Wrk1, Ultrasonic
A
42R B RH Front Work LTS Fused Pwr
DU 1.0 GXL
SPL Wrk1, Ultrasonic
A
LRFR, Front Wk LT Opt
1
42R C Rear Work Lights Fused Pwr
DU 2.0 GXL
CAB-RF, Cab to Roof Conn.
S
SWL, Work lights SW
6
42R F Rear Work Lights Fused Pwr
DU 2.0 GXL
ROOF, Roof to Cab Conn.
S
SPL-WRKR, Ultrasonic
A
42R G RH Rear Work Lt Fused Pwr
DU 1.0 GXL
SPL-WRKR, Ultrasonic
A
LRRW, RH Rear Work Light
1
42R H LH Rear Work Lt Fused Pwr
DU 1.0 GXL
SPL-WRKR, Ultrasonic
A
LLRW, LH Rear Work Light
1
42R K RH Front Work LTS Fused Pwr
DU 1.0 GXL
SPL WRK1, Ultrasonic
A
LRFO, Front Wk LT Opt
1
41J
41T
Driving Light Power
Position Lights Switched Pwr
42 A
Work Lights Fused Power
R 2.0 GXL
SWL, Work Lights Switch
2
SPL-WL, Ultrasonic
A
42 B
Work Lights Fused Power
R 1.0 GXL
SWL, Work Lights Switch
5
SPL-WL, Ultrasonic
A
43S A Door Open Signal
W 0.8 GXL
CAB-RF, Cab to Roof Conn.
R
AIC 2, ADV Instr Cluster 2
2
43S B Door Open Signal
W 0.8 GXL
ROOF, Roof to Cab Conn.
R
DS, Door Switch
B
43 A
Dome Light Auto Mode
DU 0.8 TXL
CAB-RF, Cab to Roof Conn.
C
AIC-1, Adv Instrument Cluster 1
7
43 B
Dome Light Auto Mode
DU 0.8 GXL
ROOF, Roof to Cab Conn.
C
LDM2, Dome Light Auto
1
44A A Brake Light Relay Out
T 0.8 GXL
Cabe2, Cab to ENG2 BULKHD
S
ECD, Elec Cntr D
AA1
44A D Brake Light Relay Out
T 1.0 SXL
ENG2, ENG BULKHD 2
S
SPL-B8, Ultrasonic
A
84547255A
Issued 11-11
Printed in E.C.
4002-30
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification Wire 44A DN
Circuit
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
Brake Light Relay Out
T 1.0 SXL
ENG2, ENG BULKHD 2
S
ENG-H, Engine to Hood
2
44A E Brake Light Relay Out
T 1.0 SXL
LLR-E, LH Rear Comb Light
1
SPL-B8, Ultrasonic
A
Brake Light Relay Out
T 1.0 SXL
HD-N, Hood to Engine
2
SPL-J2-N, Ultrasonic
A
44A F Brake Light Relay Out
T 1.0 SXL
LRR-E, RH Rear Comb Light
1
SPL-B8, Ultrasonic
A
44A EN
44A FN
Brake Light Relay Out
T 1.0 SXL
LLR, LH Rear Comb Light
2
SPL-J2-N, Ultrasonic
A
44A GN
Brake Light Relay Out
T 1.0 SXL
LRR, RH Rear Comb Light
2
SPL-J2-N, Ultrasonic
A
44A J Brake Light Relay Out
T 1.0 SXL
HD-9, Hood to Engine
2
SPL, L1
A
44A K Brake Light Relay Out
T 1.0 SXL
SPL, L1
A
LRR-9, RH Rear Comb. LT
1
44A L Brake Light Relay Out
T 1.0 SXL
SPL, L1
A
LRR-9, LH Rear Comb. LT
1
44 A
T 0.8 GXL
Cab_B, Cab BTM BULKHEAD
J
ECD, Elec Cntr D
45A A Left Turn Switch Power
N 0.8 GXL
FLSHR, Flasher Module
9
SRHSTLK, RH Stalk Switch
L
45B A Right Turn Switch Power
N 0.8 GXL
FLSHR, Flasher Module
10
SRHSTLK, RH Stalk Switch
R
Brake Light Control Power
AA2
45H
Hazard Switch Power
N 0.8 GXL
FLSHR, Flasher Module
11
SHZ, Hazard Switch
3
45L
Left Turn Signal
N 1.0 SXL
FRONT, Cab Front Chassis
2
LLF, Lights LH
5
45L A Left Turn Signal
N 1.0 SXL
ENG2, ENG BULKHD 2
R
LLR-E, LH Rear Comb Light
2
45L AN Left Turn Signal
N 1.0 SXL
ENG2, ENG BULKHD 2
R
ENG-H, Engine to Hood
3
45L B Left Turn Signal
N 0.8 GXL
Cabe2, Cab to ENG2 BULKHD
R
SPL-PK3, Splice 3-4 Way
D
45L BN Left Turn Signal
N 1.0 SXL
HD-N, Hood to Engine
3
LLR, LH Rear Comb Light
4
45L C Left Turn Signal
N 0.8 GXL
CAB-F, Cab Front Chassis
2
SPL-PK3, Splice 3-4 Way
C
45L D Left Turn Signal
N 0.8 GXL
FLSHR, Flasher Module
8
SPL-PK3, Splice 3-4 Way
B
45L E Left Turn Signal
N 0.8 TXL
SPL-PK3, Splice 3-4 Way
A
AIC-2, Adv Instrument Cluster 2
9
45L N Left Turn Signal
N 1.0 SXL
HD-9, Hood to Engine
3
LLR-9, LH Rear Comb. LT
2
45N A Flasher OPP Side Control
N 0.8 GXL
FLSHR, Flasher Module
2
64F, Flasher Connector
1
45N B Flasher OPP Side Control
N 0.8 GXL
FLSHR, Flasher Module
12
64M, Flasher Connector
A
Right Turn Signal
N 1.0 SXL
FRONT, Cab Front Chassis
3
LRF, Lights RH
5
45R 9 Right Turn Signal
N 1.0 SXL
HD-9, Hood to Engine
4
LRR-9, RH Rear Comb. LT
2
45R A Right Turn Signal
N 1.0 SXL
ENG2, ENG BULKHD 2
P
LRR-E, RH Rear Comb Light
2
45R
84547255A
Issued 11-11
Printed in E.C.
4002-31
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire 45R AN
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
Right Turn Signal
N 1.0 SXL
ENG2, ENG BULKHD 2
P
ENG-H, Engine to Hood
4
45R B Right Turn Signal
N 0.8 GXL
Cabe2, Cab to ENG2 BULKHD
P
SPL-PK3, Splice 3-4 Way
H
Right Turn Signal
N 1.0 SXL
HD-N, Hood to Engine
4
LRR, RH Rear Comb Light
4
45R C Right Turn Signal
N 0.8 TXL
SPL-PK3, Splice 3-4 Way
E
AIC-2, Adv Instrument Cluster 2
10
45R D Right Turn Signal
N 0.8 GXL
CAB-F, Cab Front Chassis
3
SPL-PK3, Splice 3-4 Way
G
45R E Right Turn Signal
N 0.8 GXL
FLSHR, Flasher Module
7
SPL-PK3, Splice 3-4 Way
F
460 A
Y 0.8 TXL
CAB-E, CAB-Engine
16
AIC-2, Adv Instrument Cluster 2
24
45R BN
46 C
Beacon Switched Power
K 1.0 GXL
CAB-RF, Cab to Roof Conn.
E
SBE, Beacon Switch
3
46 D
Beacon Switched Power
K 1.0 GXL
ROOF, Roof to Cab Conn.
E
LBEPWR, Light Beacon power
1
49A
Back Light Power
S 0.8 GXL
HVAC1, HVAC1
3
SPL-BCK-LGT, Spl Back Lgt Pwr
F
49S
Back Light Power
S 0.8 GXL
STA, Trans Auto Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
J
49 A
Back Light Power
S 0.8 GXL
SWL, Work Lights Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
M
49 B
Back Light Power
S 0.8 GXL
SBE, Beacon Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
L
49 C
Back Light Power
S 0.8 GXL
SRWP, Rear Wiper Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
C
49 D
Back Light Power
S 0.8 GXL
SHZ, Hazard SWitch
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
C
49 E
Back Light Power
S 0.8 GXL
SPL-BCK-LGT2, Spl Back Lgt Pwr
A
SPL-BCK-LGT, Spl Back Lgt Pwr
K
49 F
Back Light Power
S 0.8 GXL
SPE, Pin Engage Switch
10
SPL-BCK-LGT2, Spl Back Lgt Pwr
F
49 G
Back Light Power
S 0.8 GXL
SRC, Ride control Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
K
49 H
Back Light Power
S 0.8 GXL
STE, Trans Enable Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
D
49 J
Back Light Power
S 0.8 GXL
SRTD, Detent Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
C
49 K
Back Light Power
S 0.8 GXL
SFL, Return to Travel Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
E
49 L
Back Light Power
S 0.8 GXL
SBU, Back Up Alarm Dis Sw
8
SPL-BCK-LGT, Spl Back Lgt Pwr
E
49 M
Back Light Power
S 0.8 GXL
SHC, Height Control Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
D
49 N
Back Light Power
S 0.8 GXL
SPC, Pilot Control Switch
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
B
84547255A
Issued 11-11
Printed in E.C.
4002-32
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
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 P
Back Light Power
S 0.8 GXL
SDR, Driving Lights Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
G
49 Q
Back Light Power
S 0.8 GXL
SFC, Fan Control Switch
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
G
49 R
Back Light Power
S 0.8 GXL
SDC, Declutch Switch
8
SPL-BCK-LGT, Spl Back Lgt Pwr
H
49 S
Back Light Power
S 0.8 GXL
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
F
SPL-BCK-LGT2, Spl Back Lgt Pwr
M
49Y A Back Light Power
S 0.8 TXL
MH, Heated Mirror
C
SPL-BCK-LGT, Spl Back Lgt Pwr
B
49Y B Back Light Power
S 0.8 GXL
MHS, Trans Enable SW
8
MH-C, Heated Mirror
C
49 T
Back Light Power
S 0.8 GXL
SFWW, Front Wiper/Washer
8
SPL-BCK-LGT2, Spl Back Lgt Pwr
H
49 V
Back Light Power
S 0.8 GXL
SPB, Parking Brake Switch
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
E
49 W
JSS Back Light
S 0.8 GXL
SJS, Joystick Control SW
8
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
A
49 X
Back Light AIC
S 0.8 TXL
SW PD, Switch Pad
3
SPL-PED-BL, Spl Back Lgt Pwr 6 Pck
D
49 Z
Back Light PWR
S 0.8 GXL
SPL-BCK-LGT2, SPL_Back Lgt Pwr
J
SDA, Diff Lock Switch
8
51B A JSS ACT SW
W 0.8 GXL
SPL-JSS 2, Ultrasonic
A
SJS, Joystick Control SW
3
51B B JSS ACT SW
W 0.8 GXL
SJS, Joystick Control SW
6
SPL-JSS 2, Ultrasonic
A
51B C JSS ACT SW
W 0.8 GXL
JSS Cab, JSS Cab
5
SPL-JSS 2, Ultrasonic
A
51B D JSS ACT SW
W 0.8 GXL
Cab Arm FRM, Cab to Arm to FRM
5
SPL-JSS 7, Ultrasonic
A
51B E B+, JSS
W 0.8 GXL
JSS-RLY, Relay K2
86
SPL-JSS 7, Ultrasonic
A
51B G B+, JSS
W 0.8 GXL
SPL-JSS 7, Ultrasonic
A
JSS RLY, Relay K2
87
51B H JSS ACT SW
W 0.8 GXL
SPL-JSS 7, Ultrasonic
A
Cab Arm, Cab to Armrest
6
51B J JSS ACT SW
BK 0.8 TXL
JSS arm, JSS Armrest to Cab
6
CAN MOD_2, JSS CAN MOD
1
51B K JSS Power
W 0.8 GXL
FNR Rly, relay K2
86
SPL JSS_4, Ultrasonic
A
51C A JSS ACT BTN
Y 0.8 GXL
JSS Cab, JSS Cab
10
SJS, Joystick Control SW
5
51C B JSS ACT BTN
Y 0.8 GXL
Cab Arm FRM, Cab to Arm to FRM
10
JSS CNT, JSS Controller
13
51D A GRND, Relay Ctrl
BK 0.8 GXL
JSS Cab, JSS Cab
4
AIC 1, ADV Instr Cluster 1
21
51D B GRND, Relay Ctrl
BK 0.8 GXL
Cab Arm FRM, Cab to Arm to FRM
4
JSS RLY, Relay K2
85
84547255A
Issued 11-11
Printed in E.C.
4002-33
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
51E A Armrest Lower
OR 0.8 GXL
JSS CNT, JSS Controller
6
Cab Arm, Cab to Armrest
3
51E B Armrest Lower
OR 0.8 GXL
JSS Arm, JSS Armrest to Cab
3
Arm Pos, Arm Position
3
51F A LS Press SW SIG
G 1.0 GXL
JSS LS, JSS Load Sense
B
JSS FRM, JSS Frame to Cab
A
51F B LS Press SW
G 0.8 GXL
Cab FRM, Cab to JSS Frame
A
JSS CNT, JSS Controller
16
51F C LS Press SW SIG
G 1.0 GXL
JSS FRM, JSS Frame to Cab
A
JSS LS2, JSS Load Sense
A
51H B Joystick Signal
Y 0.8 GXL
JSS CNT, JSS Controller
4
Cab Arm, Cab to Armrest
10
51H C Joystick Signal
Y 0.8 GXL
JSS Arm, JSS Armrest to Cab
10
PVRES, JSS Joystick
T
51J A Valve Alarm
P 0.8 GXL
SPL JSS_11, Ultrasonic
A
Cab FRM, Cab to JSS frame
B
51J B Valve Alarm
P 0.8 GXL
JSS CNT, JSS Controller
12
SPL JSS 11, Ultrasonic
A
51J C JSS Alarm
P 1.0 GXL
JSS Valve, JSS HYD Valve
2
JSS FRM, JSS Frame to Cab
B
51J D Valve Alarm
P 0.8 GXL
SPL JSS 11, Ultrasonic
A
R1, Resistor
51K B Pilot Press SW
G 0.8 GXL
Cab FRM, Cab to JSS Frame
C
JSS CNT, JSS Controller
8
51K C Pilot Press SW SIG
G 1.0 GXL
JSS PIL PR, JSS Pilot Pressure
B
JSS FRM, JSS Frame to Cab
C
Joystick Signal
Y 1.0 GXL
JSS Valve, JSS HYD Valve
1
JSS FRM, JSS Frame to Cab
D
51L A Joystick Signal
Y 0.8 GXL
JSS CNT, JSS Controller
7
CAB FRM, Cab to JSS Frame
D
51NC
BK 0.8 TXL
PVRES, JSS Joystick
W
CAN MOD 2, JSS CAN MOD
3
51NO NC Neutral SW
Y 0.8 GXL
JSS Arm, JSS Armrest to Cab
11
PVRES, JSS Joystick
U
51NO NC Neutral SW A
P 0.8 GXL
Cab Arm, Cab to Armrest
11
JSS CNT, JSS Controller
14
51PW JSS Power H
W 1.0 SXL
SPL JSS_16, Ultrasonic
A
JSS FRM, JSS Frame to Cab
H
51PW JSS Power J
W 1.0 SXL
JSS LS, JSS Load Sense
A
SPL JSS 16, Ultrasonic
A
51PW JSS Power K
W 1.0 SXL
SPL JSS 16, Ultrasonic
A
JSS Pil Dump, JSS Pilot Dump
1
51 PW JSS Power L
W 1.0 GXL
SPL JSS 16, Ultrasonic
A
JSS LS2, JSS Load Sense
C
51PW JSS Power M
W 0.8 GXL
SPL JSS 6, Ultrasonic
A
Cab Arm FRM, Cab to Arm to FRM
9
51PW JSS Power N
W 0.8 GXL
JSS Cab, JSS Cab
9
SJS, Joystick_Control SW
10
51PW JSS Power P
W 0.8 GXL
JSS Rly, Relay K2
30
SPL JSS 4, Ultrasonic
A
51L
NC Neutral SW
84547255A
Issued 11-11
CS0
Printed in E.C.
4002-34
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
51PW JSS Power Q
W 0.8 GXL
JSS Cnt, JSS Controller
9
SP JSS 4, Ultrasonic
A
51PW JSS Power R
W 0.8 GXL
SPL JSS 6, Ultrasonic
A
Cab Arm, Cab to Armrest
8
51PW JSS Power S
W 0.8 GXL
SPL JSS 13, Ultrasonic
A
JSS Arm, JSS Armrest to Cab
8
51PW JSS Power T
W 0.8 GXL
SPL JSS 6, Ultrasonic
A
Cab Frm, Cab to JSS Frame
H
51PW JSS Power U
BK 0.8 TXL
SPL JSS 13, Ultrasonic
A
Can Mod 2, JSS Can mod
2
51PW JSS Power V
W 0.8 GXL
SPL JSS 13, Ultrasonic
A
PVRES, JSS Joystick
S
51PW JSS Power W
W 0.8 GXL
SPL JSS 6, Ultrasonic
A
SPL JSS 4, Ultrasonic
A
51P A Sec. Str High Press
W 1.0 SXL
SSM, Sec. Steer Module
9
PSS, Sec. Str Pres Switch
A
Armrest Raise
BK 0.8 TXL
Arm Pos, Arm Position
2
CAN MOD 2, JSS CAN MOD
5
51S A JSS Okay Pwr
W 0.8 GXL
JSS Cnt, JSS Controller
5
SPL JSS 5, Ultrasonic
A
51S B JSS Okay Pwr
W 0.8 GXL
Cab Arm, Cab to Armrest
9
SPL JSS 5, Ultrasonic
A
51S C JSS Okay Pwr
W 0.8 GXL
SPL JSS 15, Ultrasonic
A
JSS Arm, JSS Armrest to Cab
9
51S D JSS Okay Pwr
BK 0.8 TXL
CAN MOD_2, JSS CAN MOD
4
SPL JSS 15, Ultrasonic
A
51S E JSS Okay Pwr
W 0.8 GXL
PVRES, JSS Joystick
R
SPL JSS 15, Ultrasonic
A
51S F JSS Okay Pwr
W 0.8 GXL
Cab Frm, Cab to JSS Frame
F
SPL JSS 5, Ultrasonic
A
51S J JSS Okay Pwr
W 1.0 SXL
JSS Valve, JSS HYD Valve
4
JSS Frm, JSS Frame to Cab
F
51 A
Sec. Str Motor Control
W 1.0 SXL
SSM, Sec. Steer Module
2
SPL-SS, Ultrasonic
A
51 B
Sec. Str Motor Control
W 1.0 SXL
SPL-SS, Ultrasonic
A
SSS, SS Mag Switch
1
51 C
Sec. Strg Sol Control
W 1.0 SXL
SPL-SS, Ultrasonic
A
YSS, Sec. Steering Solenoid
1
51 D
Sec. Str Flyback
W 1.0 SXL
SSS, SS MAG Switch
1
SSD, Sec. Steering Diode
C
52AU
Fan Reverse Auto
W 0.8 TXL
SFC, Fan Control Switch
3
AIC-2, Adv Instrument Cluster 2
8
52A A Fan Reverse Relay Out
W 1.0 GXL
CAB-E, Cab Engine
22
ECB, Elect Center B
52A B Fan Reverse Relay Out
W 1.0 SXL
ENG, Engine Cab 1
22
YFR, Fan Rev Solenoid Option
51R
D8 1
52C
Parking Brake Solenoid LSD
W 0.8 TXL
AIC-1, Adv Instrument Cluster 1
14
ECB, Elect Center B
52J
Fan Control Switch Jumper
W 0.8 GXL
SFC, Fan Control Switch
4
SFC, Fan Control Switch
2
52M
Fan Reverse Manual
W 0.8 TXL
SFC, Fan Control Switch
6
AIC-2, Adv Instrument Cluster 2
7
84547255A
Issued 11-11
B10
Printed in E.C.
4002-35
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire 52P
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
Parking Brk Relay Out
W 1.0 SXL
BTM_C, CAB Bottom BULKHD
M
YPB, Park Brake Solenoid
1
52P A Parking Brk Relay Out
W 0.8 GXL
Cab_B, Cab BTM BULKHEAD
M
SPL-PTM, Ultrasonic
A
52P B Parking Brk Relay Out
W 0.8 GXL
SPL-PTM, Ultrasonic
A
ECB, Elect Center B
D10
53A
RTD Switch Power
W 0.8 GXL
SRTD, Detent Switch
3
EM, RTD Height Control RTT
3
53B
RTD ControlSignal
W 1.0 SXL
FRONT, Cab Front Chassis
12
PXF, RTD
A
53B A RTD Control Signal
W 1.0 SXL
PXM, RTD
A
PXT, RTD
A
53B B RTD Control Signal
W 0.8 GXL
EM, RTD Height Control RTT
4
CAB-F, Cab Front Chassis
12
53C A Pilot Control Solenoid LSD
W 0.8 TXL
AIC-1, Adv Instrument Cluster 1
20
ECD, Elect Center D
B6
53P A Pilot Control Relay Out
W 0.8 GXL
SPL-D25, Ultrasonic
A
YPP, Pilot Pressure Solenoid
A
53P B Pilot Control Relay Out
W 0.8 GXL
SFL, Return to Travel Switch
2
SPL-D25, Ultrasonic
A
53P C Pilot Control Relay Out
W 1.0 GXL
SPL-D25, Ultrasonic
A
ECD, Elect Center D
D6
53P D Pilot Control Relay Out
W 0.8 GXL
SHC, Height Control Switch
2
SPL-D25, Ultrasonic
A
53P E Pilot Control Relay Out
W 0.8 GXL
SRTD, Detent Switch
2
SPL-D25, Ultrasonic
A
53P F Pilot Control Relay Out
W 0.8 GXL
CAB-F, Cab Front Chassis
9
SPL-D25, Ultrasonic
A
53P G Pilot Control Relay Out
W 1.0 SXL
FRONT, Cab Front Chassis
9
SPL-A3, Ultrasonic
A
53P H Pilot Control Relay Out
W 1.0 SXL
SPL-A3, Ultrasonic
A
PXF, RTD
C
53P I
Pilot Control Relay Out
W 1.0 SXL
PXM, RTD
C
PXT, RTD
C
53P J Pilot Control Relay Out
W 1.0 SXL
SPL-A3, Ultrasonic
A
PXH, Height Control RTT
C
54A
Height Control Switch Power
W 0.8 GXL
SHC, Height Control Switch
6
EM, RTD Height Control RTT
2
54B
Height RTT Control Signal
W 1.0 SXL
FRONT, Cab Front Chassis
11
PXH, Height Control RTT
A
54B A Height RTT Control Signal
W 0.8 GXL
CAB-F, Cab Front Chassis
11
SPL-D1, Ultrasonic
A
54B B Height RTT Control Signal
W 0.8 GXL
EM, RTD Height Control RTT
5
SPL-D1, Ultrasonic
A
54B C Height RTT Control Signal
W 0.8 GXL
SFL, Return to Travel Switch
6
SPL-D1, Ultrasonic
A
55A A RTT Float Sw Power
W 0.8 GXL
EM, RTD Height Control RTT
1
SPL-RTT, Ultrasonic
A
55A B RTT Float Sw Power
W 0.8 GXL
SFL, Return to Travel Switch
1
SPL-RTT, Ultrasonic
A
55A C RTT Float Sw Power
W 0.8 GXL
SFL, Return to Travel Switch
3
SPL-RTT, Ultrasonic
A
55B
RTT Float Switch Control
W 0.8 GXL
SFL, Return to Travel Switch
5
EM, RTD Height Control RTT
6
56 A
Fan Control PWM
W 1.0 SXL
ENG, Engine Cab 1
23
YFN, Fan PWM Solenoid
A
57 A
Pin Engage Sol Pwr
W 0.8 GXL
CAB-F, Cab Front Chassis
20
SPL-PINE, Ultrasonic
A
57 B
Pin Engage Sol Pwr
W 0.8 GXL
SPE, Pin Engage Switch
1
SPL-PINE, Ultrasonic
A
84547255A
Issued 11-11
Printed in E.C.
4002-36
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
2.0 mm 5.0 mm
DU = Dark Blue W = White Or = Orange
Wire Identification
S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector
Wire
Circuit
Cavity
Connector
Cavity
57 C
Pin Engage Sol Pwr
W 0.8 TXL
SPL-PINE, Ultrasonic
A
AIC-2, Adv Instrument Cluster 2
16
57 D
Pin Engage Sol Pwr
W 1.0 SXL
YPE1, Pin Engage Jumper
A
YPE2, Pin Engage Opt
A
58C
Ride Control Switch Jumper
W 0.8 GXL
SRC, Ride Control Switch
5
SRC, Ride Control Switch
3
58H A Pwr VPS2
W 0.8 TXL
TECM, Trans
8
SPL D19, Ultrasonic
A
58H B Power VPSL
W 0.8 TXL
SPL D19, Ultrasonic
A
TECM, Trans
53
58H C Power
W 0.8 GXL
ECD, Elec Cntr D
D7
SPL D19, Ultrasonic
A
58L
Ride Control Relay LSD
Bk 0.8 TXL
TECM, Trans
57
ECD, Elect Center D
B8
58T
Ride Control Relay Sw Pwr
W 0.8 GXL
SRC, Ride Control Switch
4
ECD, Elect Center D
B7
58 A
Ride Control Sol Pwr
W 1.0 SXL
202M, Rollback Jumper
A
202M, Rollback Jumper
B
58 B
Ride Control Sol Pwr
W 1.0 SXL
FRONT, Cab Front Chassis
18
PRBF, Rollback Pressure Switch
B
58 C
Ride Control Sol Pwr
W 0.8 GXL
CAB-F, Cab Front Chassis
18
SPL-D26, Ultrasonic
A
58 D
Ride Control Sol Pwr
W 0.8 GXL
140M, Diode Module
D
SPL-D26, Ultrasonic
A
58 E
Ride Control Sol Pwr
W 0.8 GXL
SPL-D26, Ultrasonic
A
ECD, Elect Center D
D8
58 F
Ride Control Sol Pwr
W 0.8 GXL
SRC, Ride Control Switch
6
SPL-D26, Ultrasonic
A
58 G
Ride Control Sol Pwr
W 1.0 SXL
YRC, Ride Control Opt
1
Front, Frnt Chas-Cab
18
58 H
Ride Control Signal
W 1.0 SXL
YRC J, Ride Control Jumper
1
YRC J2, Ride Control Opt
1
59D
Hood Relay Control Down
W 1.0 GXL
Cabe2, Cab to ENG2 BULKHD
V
ECC, Elect Cntr C
D3
59D A Hood Relay Control Down
W 1.0 SXL
ENG2, ENG BULKHD 2
V
HD, Hood Switch
A
Hood Relay Control Up
W 1.0 GXL
Cabe2, Cab to ENG2 BULKHD
X
ECC, Elect Cntr C
D1
59U A Hood Relay Control Up
W 1.0 SXL
ENG2, ENG BULKHD 2
X
HD, Hood Switch
C
Hood Down Relay Out
W 1.0 GXL
Cabe2, Cab to ENG2 BULKHD
U
ECC, Elect Cntr C
B3
60D A Hood Down Relay Out
W 1.0 SXL
ENG2, ENG BULKHD 2
U
HDM, Hood Lift Motor
2
Hood Up Relay Out
W 1.0 GXL
Cabe2, Cab to ENG2 BULKHD
W
ECC, Elect Cntr C
B1
60U A Hood Up Relay Out
W 1.0 SXL
ENG2, ENG BULKHD 2
W
HDM, Hood Lift Motor
1
W 1.0 SXL
ENG, Engine Cab 1
30
SPL ACP, Ultrasonic
A
61A B Trinary Press Sw Input
W 0.8 GXL
CAB-E, Cab Engine
30
SPL AC, Ultrasonic
A
61A C AC Switch Input
W 1.0 SXL
SPL ACP, Ultrasonic
A
ENG B, Cab Bottom
8
61A D AC Switch Input
W 1.0 SXL
SPL ACP, Ultrasonic
A
PRH, AC High Press SW
A
61A E AC Switch Input
W 1.0 SXL
PRL, AC Low Press SW
A
BTM E, Cab Bottom
8
61A F Trinary Press SW Input
W 0.8 GXL
HVAC1, HVAC1
1
SPL AC, Ultrasonic
A
61A G Trinary Press SW Input
W 0.8 GXL
SPL AC, Ultrasonic
A
ECD, Elec Cntr D
B9
59U
60D
60U
61A
AC Press Sw Input
84547255A
Issued 11-11
Printed in E.C.
4002-37
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
61B A AC Signal
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
W 0.8 GXL
AIC 2, ADV Instr Cluster 2
12
HVAC1, HVAC1
AC Relay Out
Or 0.8 GXL
CAB-E, Cab Engine
2
ECD, Elect Center D
61C A AC Relay Out
Or 1.0 SXL
ENG, Engine Cab 1
2
ACT, AC Comp Clutch
1
Heat Load Valve Solenoid
Or 0.8 TXL
CAB-E, Cab Engine
8
AIC-1, ADV Instrument Cluster 1
19
61H A Heat Load Valve Solenoid
Or 1.0 SXL
YLV, Heated Valve opt.
1
ENG, Engine Cab 1
8
61H B Heat Load Valve Solenoid
Or 1.0 SXL
YLV2, Heated Valve opt.
1
YLV3, Heated Valve opt.
1
AC Relay Control
W 1.0 SXL
ENG, Engine Cab 1
29
SPL ACS, Ultrasonic
A
61R B AC Relay Control
W 0.8 GXL
CAB-E, Cab Engine
29
ECD, Elect Center D
D9
61R C AC Switch Output
W 1.0 SXL
SPL ACS, Ultrasonic
A
ENG B, Cab Bottom
7
61R D AC Switch Output
W 1.0 SXL
SPL ACS, Ultrasonic
A
PRH, AC High Press SW
B
61R E AC Switch Output
W 1.0 SXL
PRL, AC Low Press SW
B
BTM_E, Cab Bottom
7
61C
61H
61R
4 C10
63C
Front Wiper Park Control
W 0.8 GXL
FWM, Front Wiper Motor
D
ECD, Elect Center D
C4
63C2
Front Wiper Park Control
W 0.8 GXL
ECD, Elect Center D
C2
ECD, Elect Center D
D4
63C3
Front Wiper Park Control
W 0.8 GXL
K-WCO, Wiper Cutout
87a
ECD, Elect Center D
B3
63HC
Front Wiper High Speed Rly Ctrl
W 0.8 GXL
SFWW, Front Wiper/Washer
9
SPL-HC, Ultrasonic
A
63HC A
Wiper Cutout Relay Control
W 0.8 GXL
SPL-HC, Ultrasonic
A
K-WCO, Wiper Cutout
85
63HC B
Front Wiper High Speed Rly Ctrl
W 0.8 GXL
ECD, Elec Cntr D
B2
SPL HC, Ultrasonic
A
63H A Front Wiper High Speed Rly Out
W 0.8 GXL
FMW, Front Wiper Motor
A
SPL-WHS, Ultrasonic
A
63H B Front Wiper High Speed Rly Out
W 0.8 GXL
ECD, Elec Cntr D
D2
SPL WHS, Ultrasonic
A
63H C Front Wiper High Speed Rly Out
W 0.8 GXL
140M, Diode Module
A
SPL-WHS, Ultrasonic
A
63LC
Front Wiper Low Speed Rly Ctrl
W 0.8 GXL
SFWW, Front Wiper/Washer
3
ECD, Elect Center D
B4
63L A Front Wiper Low Speed Rly Out
W 0.8 GXL
FMW, Front Wiper Motor
B
SPL-WLS, Ultrasonic
A
63L B Front Wiper Low Speed Rly Out
W 0.8 GXL
K-WCO, Wiper Cutout
30
SPL-WLS, Ultrasonic
A
63L C Front Wiper Low Speed Rly Out
W 0.8 GXL
140M, Diode Module
B
SPL-WLS, Ultrasonic
A
63W
Front Washer Pump
W 0.8 GXL
CAB-E, Cab Engine
25
SFWW, Front Wiper/Washer
7
63W A Front Washer Pump
W 1.0 SXL
ENG, Engine Cab 1
25
FWW, Front Washer
1
64C
Horn Relay Control
Or 0.8 GXL
SRHSTLK, RH Stalk Switch
31b
ECC, Elect Center C
B8
64 A
Horn Power
Or 0.8 GXL
CAB-F, Cab Front Chassis
13
ECC, Elect Center C
D8
65L
Left Speaker
Or 0.8 GXL
LSPK, Left Speaker
A
SPK, Speaker
84547255A
Issued 11-11
7
Printed in E.C.
4002-38
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
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
65R
Right Speaker
Or 0.8 GXL
RSPK, Right Speaker
A
SPK, Speaker
66A
RR Camera Pwr
OR 0.8 GXL
Mon, Camera/MOnitor
1
ECA, Elect Cntr A
C9
67A
Park Brake Signl
OR 0.8 GXL
TEL, Telematics
E
SPL PTM, Ultrasonic
A
67B
Start Lockout
OR 0.8 GXL
ECC, Elect Cntr C
87
SRP, Work Lights SW
8
68C
Rear Wiper Park Control
Or 1.0 GXL
CAB-RF, Cab to Roof Conn.
K
SRWP, Rear Wiper Switch
1
68C A Rear Wiper Park Control
Or 1.0 GXL
ROOF, Roof to Cab Conn.
K
RWM, Rear Wiper Motor
D
Rear Wiper Switch Power
Or 1.0 GXL
SRWP, Rear Wiper Switch
2
SPL-3, Ultrasonic
A
68L A Rear Wiper Switch Power
Or 1.0 GXL
ROOF, Roof to Cab Conn.
L
RWM, Rear Wiper Motor
B
68L B Rear Wiper Switch Power
Or 1.0 GXL
CAB-RF, Cab to Roof Conn.
L
SPL-3, Ultrasonic
A
68L C Rear Wiper Switch Power
Or 1.0 GXL
140M, Diode Module
F
SPL-3, Ultrasonic
A
68W
Rear Washer Pump
W 0.8 GXL
CAB-E, Cab Engine
24
SRWP, Rear Wiper Switch
6
68W A Rear Washer Pump
W 1.0 SXL
ENG, Engine Cab 1
24
RWW, Rear Washer
1
68L
1
69F
Heated Mirror Signal
W 1.0 GXL
TRLY, Timer Relay
87
MHS, Trans Enable SW
3
69A
Heated Mirror Signal
W 1.0 GXL
SPL3, Ultrasonic
A
TRLY, Timer Relay
86
69B
Heated Mirror Signal
W 1.0 GXL
SPL3, Ultrasonic
A
MHS, Trans Enable SW
10
69D
Heated Mirror Signal
W 1.0 GXL
SPL3, Ultrasonic
A
MH-R, Mirror HTR
1
69E
Heated Mirror Signal
W 1.0 GXL
SPL3, Ultrasonic
A
MH-R, Mirror HTR
1
CAN1 CAN HI H
Y 0.8 TXL TWIST
EDC7, Engine Controller
35
ENG, Engine-Cab1
14
CAN1 CAN LO L
G 0.8 TXL TWIST
EDC7, Engine Controller
34
ENG, Engine-Cab1
13
CANS HA CAN HI, CAN MOD2
Y 0.8 TXL TWIST
JSS Arm, JSS Armrest to Cab
1
CAN MOD 2, JSS CAN MOD
7
CANS HB CAN HI, CAN MOD2
Y 0.8 TXL TWIST
Cab Arm FRM, Cab to Arm to FRM
12
Cab Arm, Cab to Armrest
1
CANS HD CAN HI, CAN MOD3
Y 0.8 TXL TWIST
Cab Arm FRM, Cab to Arm to FRM
7
JSS CNT, JSS Controller
1
CANS CAN LO, CAN MOD2 LA
G 0.8 TXL TWIST
JSS Arm, JSS Armrest to Cab
12
CAN MOD 2, JSS CAN MOD
8
CANS CAN LO, CAN MOD2 LB
G 0.8 TXL TWIST
Cab Arm, Cab to Armrest
12
Cab Arm FRM, Cab to Arm to FRM
1
CANS CAN HI, CAN MOD3 LD
G 0.8 TXL TWIST
Cab Arm FRM, Cab to Arm to FRM
6
JSS CNT, JSS Controller
2
84547255A
Issued 11-11
Printed in E.C.
4002-39
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
CAN H CAN HIGH
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
Y 0.8 TXL TWIST
ENG, ENGINE-CAB1
14
SPL CAN DH, Ultrasonic
A
CAN H2
CAN2 HI, TERM
Y 0.8 GXL TWIST
TERM CAN 2, CAN Bulk Head
B
SPL CAN HV, Ultrasonic
A
CAN H3
CAN2 HI, Nox
Y 0.8 TXL TWIST
SPL-CAN-HT, Ultrasonic
A
EDC7, Engine Controller
53
CAN HA
CAN High
Y 0.8 TXL TWIST
SPL CAN_JS_H1, Ultrasonic
A
SPL CAN GH, Ultrasonic
A
CAN HB
CAN High
Y 0.8 TXL TWIST
SPL-CAN-DIAG, Ultrasonic
A
DIA, Diagnostic
C
CAN HC
CAN High
Y 0.8 TXL TWIST
SPL-CAN-TRANS, Ultrasonic
A
SPL-CAN-DIAG, Ultrasonic
A
CAN HD
CAN High
Y 0.8 TXL TWIST
SPL-CAN-TRANS, Ultrasonic
A
TECM, Trans
25
CAN HE
CAN High
Y 0.8 TXL TWIST
SPL-CAN, Ultrasonic
A
SPL-CAN-TRANS, Ultrasonic
A
CAN HF
CAN High
Y 0.8 TXL TWIST
SW-PD, Switch Pad
7
SPL-CAN, Ultrasonic
A
CAN HG
CAN High
Y 0.8 TXL TWIST
SPL-CAN, Ultrasonic
A
AIC-1, Adv Instrument Cluster 1
3
CAN HH
CAN High
Y 0.8 TXL TWIST
SPL CAN TEL, Ultrasonic
A
TEL, Telematics
L
CAN HJ
CAN High
Y 0.8 TXL TWIST
SPL CAN TEL, Ultrasonic
A
SPL CAN JS H2, Ultrasonic
A
CAN HK
CAN HI, EDC
Y 0.8 TXL TWIST
SPL CAN DH, Ultrasonic
A
EDC7, Engine Controller
35
CAN HL
CAN High
Y 0.8 TXL TWIST
SPL CAN TEL, Ultrasonic
A
SPL CAN DIAG, Ultrasonic
A
CAN HM
CAN2 HI, EDC
Y 0.8 GXL TWIST
Cab E, Cab-Engine
14
SPL-CAN-GH, Ultrasonic
A
CAN HN
CAN High
Y 0.8 TXL TWIST
SPL CAN JS H1, Ultrasonic
A
SPL CAN JS H2, Ultrasonic
A
CAN HO
CAN2 HI, DIAG2
Y 0.8 GXL TWIST
SPL CAN GH, Ultrasonic
A
DIA 2, Diagnostic
C
CAN HP
CAN HI,CAN MOD2
Y 0.8 GXL TWIST
SPL CAN JS H1, Ultrasonic
A
JSS Cab, JSS Cab
12
84547255A
Issued 11-11
Printed in E.C.
4002-40
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
CAN HQ
CAN HI, DNOX2
Y 0.8 GXL TWIST
SPL CAN DH, Ultrasonic
A
DNOX2, NOX Controller
7
CAN HR
CAN HI,CAN MOD3
Y 0.8 GXL TWIST
SPL CAN JS H2, Ultrasonic
A
JSS Cab, JSS Cab
7
CAN HS
CAN2 HI, NOX
Y 0.8 TXL TWIST
SPL CAN HV, Ultrasonic
A
EDC7, Engine Controller
53
CAN HU
CAN2 HI, NOX
Y 0.8 TXL TWIST
SPL CAN HT, Ultrasonic
A
NOXS, NOX Sensor
4
CAN HV
CAN2 HI, TERM
Y 0.8 GXL TWIST
SPL CAN HT, Ultrasonic
A
TERM CAN 2, CAN Bulk Head
B
CAN HW
CAN 2 HI, EVGT
Y 0.8 TXL TWIST
SPL CAN HV, Ultrasonic
A
Turbo, Eng DASH Turbo
7
CAN HZ
CAN 2 HI
Y 0.8 GXL TWIST
SPL CAN HV, Ultrasonic
A
SPL CAN HT, Ultrasonic
A
CAN L CAN Low
G 0.8 TXL TWIST
ENG, Engine-Cab1
13
SPL CAN DL, Ultrasonic
A
CAN L2
CAN 2 LO, Term
Y 0.8 GXL TWIST
Term CAN 2, CAN Bulk Head
13
SPL CAN LV, Ultrasonic
A
CAN L3
CAN L2, Nox
G 0.8 TXL TWIST
SPL-CAN-LT, Ultrasonic
A
EDC7, Engine Controller
52
CAN LA
CAN Low
G 0.8 TXL TWIST
SPL CAN JS_L1, Ultrasonic
A
SPL CAN GL, Ultrasonic
A
CAN LB
CAN Low
G 0.8 TXL TWIST
SPL-CAN-DIAG-L, Ultrasonic
A
DIA, Diagnostic
D
CAN LC
CAN Low
G 0.8 TXL TWIST
SPL-CAN-TRANS-L, Ultrasonic
A
SPL-CAN-DIAG-L, Ultrasonic
A
CAN LD
CAN Low
G 0.8 TXL TWIST
TECM, Trans
26
SPL-CAN-TRANS-L, Ultrasonic
A
CAN LE
CAN Low
G 0.8 TXL TWIST
SPL-CAN-L, Ultrasonic
A
SPL-CAN-TRANS-L, Ultrasonic
A
CAN LF
CAN Low
G 0.8 TXL TWIST
SW-PD, Switch Pad
8
SPL-CAN-L, Ultrasonic
A
CAN LG
CAN Low
G 0.8 TXL TWIST
SPL-CAN-L, Ultrasonic
A
AIC-1, Adv Instrument Cluster 1
4
CAN LH
CAN Low
G 0.8 TXL TWIST
SPL CAN TEL2, Ultrasonic
A
SPL CAN JS L2, Ultrasonic
A
84547255A
Issued 11-11
Printed in E.C.
4002-41
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
CAN LJ
CAN Low, EDC
G 0.8 TXL TWIST
EDC7, Engine Controller
34
SPL CAN DL, Ultrasonic
A
CAN LK
CAN Low, DNOX2
G 0.8 GXL TWIST
SPL CAN DL, Ultrasonic
A
DNOX2, NOX Controller
8
CAN LL
CAN2 LO, EDC
G 0.8 GXL TWIST
Cab E, Cab-Engine
13
SPL CAN GL, Ultrasonic
A
CAN LM
CAN Low
G 0.8 TXL TWIST
SPL CAN TEL2, Ultrasonic
A
TEL, Telematics
M
CAN LP
CAN Low,CAN MOD3
G 0.8 GXL TWIST
SPL CAN JS L1, Ultrasonic
A
JSS Cab, JSS Cab
1
CAN LQ
CAN LOW
G 0.8 TXL TWIST
SPL CAN JS L1, Ultrasonic
A
SPL CAN JS L2, Ultrasonic
A
CAN LR
CAN Low, CAN MOD2
G 0.8 GXL TWIST
SPL CAN JS L2, Ultrasonic
A
JSS Cab, JSS Cab
6
CAN LS
CAN2 LO, NOX
G 0.8 TXL TWIST
SPL CAN LV, Ultrasonic
A
EDC7, Engine Controller
52
CAN LU
CAN2 LO, NOX
G 0.8 TXL TWIST
NOXS, NOX Sensor
3
SPL CAN_LT, Ultrasonic
A
CAN LV
CAN2 LO, Term
G 0.8 GXL TWIST
Term CAN 2, CAN Bulk Head
A
SPL CAN LT, Ultrasonic
A
CAN LW
CAN LO, EVGT
G 0.8 TXL TWIST
SPL CAN LV, Ultrasonic
A
Turbo, ENG DASH Turbo
1
CAN LX
CAN2 LO, DIAG2
G 0.8 GXL TWIST
SPL CAN GL, Ultrasonic
A
DIA 2, Diagnostic
D
CAN LY
CAN Low
G 0.8 TXL TWIST
SP CAN TEL2, Ultrasonic
A
SPL CAN DIAG L, Ultrasonic
A
CAN LZ
CAN 2 LO
G 0.8 GXL TWIST
SPL CAN LV, Ultrasonic
A
SPL CAN LT, Ultrasonic
A
ECC L1
Beacon/Dome Light L1 ECC
BUSS
L1-ECC, ECC Batt Power
1
ECC, Elect Cntr C
J1
Trans ECM Power
ECA-BUSS
ECA-L1, B+ Power
cs01
ECA, Elect Center A
L1
J2
Trans ECM Power
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J3
EMG STR AIC Power
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J4
Emergency Steer AIC Power
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J5
Emergency Steer Pltem Dtnts
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J6
Pltem Dtnts Park Brk Sol
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
84547255A
Issued 11-11
L1-1
Printed in E.C.
4002-42
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
J7
Park Brake Solenoid Horn
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J8
Fan Reverse Turn Signal
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J9
Turn Signal Engine Shut Down
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J10
DNOX SW B+
ECA-BUSS
ECA, Elect Center A
L1
ECA, Elect Center A
L1
J11
Blower Motor Power
ECA-BUSS
PRMB_L1, B+ Power
cs01
ECA, Elect Center A
L2
J12
Blower Motor Front Wiper Washer
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J13
Front Wiper Rear Wiper Washer
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J14
Rear Wiper Washer Backup
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J15
Backup AC
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J16
Heated Mirrors
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J17
Seat Comp EMG Strtr
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J18
Diagnostic Power
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
ECA-BUSS
ECA, Elect Center A
L2
ECA, Elect Center A
L2
J19 J2 ECC
Beacon/Dome Lt Work Lights
ECC-BUSS
ECC, Elect Center C
L1-1
ECC, Elect Center C
L1-2
J3 ECC
Work Lights Driving Lights
ECC-BUSS
ECC, Elect Center C
L1-2
ECC, Elect Center C
L1-3
J4 ECC
Driving Lights Brake Lights
ECC-BUSS
ECC, Elect Center C
L1-3
ECC, Elect Center C
L1-4
J5 ECC
Brake Lights Delay Power
ECC-BUSS
ECC, Elect Center C
L1-4
ECC, Elect Center C
L1-5
J6 ECC
Delay Power Horn
ECC-BUSS
ECC, Elect Center C
L1-5
ECC, Elect Center C
L1-6
J7 ECC
Horn HOD Control
ECC-BUSS
ECC, Elect Center C
L1-6
ECC, Elect Center C
L1-7
J9 ECC
ECC-BUSS
ECC, Elect Center C
L1-8
ECC, Elect Center C
L1-9
J10 ECC
BUSS
ECC, Elect Center C
L1-9
ECC, Elect Center C
L1-10
RAD1 Radio Ground
W 0.8 GXL
RAD-J3, Radio Jumper
5
RAD-J1, Radio Power
8
RAD2 12V Fused Power to Radio
W 0.8 GXL
RAD-J3, Radio Jumper
12
RAD-J1, Radio Power
7
RAD3 12V Fused Power to Radio
W 0.8 GXL
RAD-J3, Radio Jumper
7
RAD-J1, Radio Power
4
RAD4 Left Speaker Ground
W 0.8 GXL
RAD-J3, Radio Jumper
3
RAD-J2, Speaker
8
84547255A
Issued 11-11
Printed in E.C.
4002-43
Wire Identification Codes
21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name
Bk = Black T = Tan LU = Light Blue
DU = Dark Blue W = White Or = Orange
Wire Identification Wire
Circuit
2.0 mm 5.0 mm S = Gray N = Brown R = Red
LG = Light Green G = Green P = Purple
From Connector Color, Size, and Material
Connector
K = Pink U = Blue Y = Yellow
To Connector Cavity
Connector
Cavity
RAD5 Left Speaker
W 0.8 GXL
RAD-J3, Radio Jumper
10
RAD-J2, Speaker
7
RAD6 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
4
RAD-J2, Speaker
6
RAD7 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
11
RAD-J2, Speaker
5
RAD8 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
2
RAD-J2, Speaker
4
RAD9 Not Used
W 0.8 GXL
RAD-J3, Radio Jumper
9
RAD-J2, Speaker
3
RAD10 Right Speaker Ground
W 0.8 GXL
RAD-J3, Radio Jumper
1
RAD-J2, Speaker
2
RAD11 Right Speaker
W 0.8 GXL
RAD-J3, Radio Jumper
8
RAD-J2, Speaker
1
84547255A
Issued 11-11
Printed in E.C.
4002-44
CONNECTORS CONNECTOR AB+, ALTERNATOR B+ CAV 1
WIRE IDENT 1 BA
AIC 1, ADV INSTR CLUSTER 1
CIRCUIT ALTERNATOR B+
CONNECTOR AB5, ALTERNATOR B+ CAV
WIRE IDENT
CIRCUIT
1
1 BF
ALTERNATOR B+
1
30
BATTERY SENSING
CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH
87419488
CAV 1
8602417
CAV 1
WIRE IDENT 61C-A
CIRCUIT AC RELAY OUT
AD, ALTERNATOR D+ CAV 1
WIRE IDENT 14
84547255A
CIRCUIT ALTERNATOR D+
WIRE IDENT 19S-E
CIRCUIT AIC BATT B+
2
36F-A
FUEL LEVEL ANALOG
3
CAN-HG
CAN HIGH
4
CAN-LG
CAN LOW
6
0-DX
AIC SENSOR GND
7
43-A
DOME LT AUTO MODE
9
36H-A
HYDRAULIC OIL TEMP
11
36C-A
RADITAOR COOL TEMP SGNL
12
0-DW
AIC POWER GND
13
35B
AIC BUZZER HSD
14
52C
PARK BRAKE SOL LSD
19
61H
HEAT LOAD VLV SOL
20
53C-A
PILOT CTRL SOL LSD
21
51D-A
GRND, RELAY CTRL
22
0-EZ
POWER RELAY CONTROL
23
52
FAN REVERSER LSD
25
17P-B
SW PAD PWR FR0M AIC PWR
26
56
FAN CONTROL PWM
Issued 11-11
Printed in E.C.
4002-45 ARM FNR, FNR-MAIN CAB
AIC 2, ADV INSTR CLUSTER 2 CAV
WIRE IDENT
CIRCUIT
1
19B-C
FNR SWITCHED PWR
2
26F-F
FNR FORWARD SIGNAL
3
26N-F
FNR NEUTRAL SIGNAL
4
26R-F
FNR REVERSE SIGNAL
5
32J-J
FNR LT SIGNAL
6
25Y-G
TRANS KICKDOWN SIGNAL
ARM POS, ARM POSITION 87410948
CAV 2
WIRE IDENT 43S-A
CIRCUIT DOOR OPEN SGNL
4
33R
RDNT BRK ACCUM PRESS LOW
5
33P-A
BRK WARN PRESS LOW
CAV
WIRE IDENT
CIRCUIT
1
0-SG
COMMON
2
51R
ARMREST RAISE
3
51E-B
ARMREST LOWER
6
33U
PARK BRK SWITCH
7
52M
FAN REVERSE MAN
8
52AU
FAN REVERSE AUTO
CAV
9
45L-E
LEFT TURN SGNL
1
10
45R-C
RIGHT TURN SGNL
11
35X
SEC STR LOW PRESS SGNL
12
61B-A
AC SIGNAL
14
19S-D
AIC DELAY FSD PWR
CAV
15
0-DB
AIC POWER GND RED
1
16
57-C
PIN ENGAGE SOL PWR
17
21K-A
IGN SW START SIGNAL
18
31L
PILOT CTRL SW HIGH
20
19S-C
AIC DELAY FSD PWR
21
19S-F
AIC BATT B+
22
0-DA
AIC CHASSIS GND
B1, STARTER PWR STUD WIRE IDENT 1-NC
CIRCUIT B+ PWR PRMC
B2, STARTER POWER WIRE IDENT 1-BA
CIRCUIT ALTERNATOR B+
B3, STARTER BATTERY CAV 1
WIRE IDENT 0-NB
CIRCUIT MASTER DISCONNECT GND
B4, STARTER POWER ALT5, ALTERNATOR D+
CAV 1
CAV
WIRE IDENT 30
BATTERY SENSING
3
14-5
ALTERNATOR D+
BT1, BATTERY STARTER
1
WIRE IDENT 1-BG
CIRCUIT
CIRCUIT B+ PWR PRMC
B6, STARTER POWER
1
1-NB
BATTERY STARTER
1
1-NG
PWR NON DISCNT
CAV
1
1-NE
BATTERY STARTER
1
84547255A
SSM PWR
B5, STARTER POWER STUD CAV
WIRE IDENT
1-ND
CIRCUIT
CIRCUIT
2
CAV
WIRE IDENT
WIRE IDENT 1-BF
CIRCUIT ALTERNATOR B+
Issued 11-11
Printed in E.C.
4002-46 B7, STARTER BATTERY CAV 1
WIRE IDENT 1-NE
BT4, DISCON-BLCK GRND
CIRCUIT
CAV
BATTERY STARTER
1
B8, STARTER POWER CAV 1
WIRE IDENT 1-NF
WIRE IDENT 0-NC
CIRCUIT BATTERY DISCONNECT
BTM C, CAB BOTTOM BULKHD
CIRCUIT SSM PWR
BPP, PEDAL POSITION
W230R397
CAV A
W230R395
CAV
WIRE IDENT
CIRCUIT
1
22G
PEDAL SENSOR GRND
2
22E
PEDAL SENSOR +5V
3
22F
PEDAL POS SIGNAL
4
401B
PEDAL POS SIGNAL
5
255E
PEDAL SESNOR +5V
6
016B
PEDAL SENSOR GRND
BT2, DISCONECT BATTERY CAV 1
WIRE IDENT 1-NA
CIRCUIT BATTERY CROSSOVER
WIRE IDENT
CIRCUIT
22G
PEDAL SENSOR GRND
B
22E
PEDAL SENSOR +5V
C
22F
PEDAL POS SIGNAL
D
016B
PEDAL SENSOR SIGNAL
E
255E
PEDAL SENSOR +5V
F
401B
PEDAL POS SIGNAL
J
44
BRK LT CTRL PWR
K
1-AA
BRK LT SW PWR
L
33P
BRK WARNING PRESS LOW
M
52P
PARK BRK RLY OUT
A
22D
PEDAL SENSOR GRND
B
22B
PEDAL SENSOR +5V
C
22C
PEDAL POS SIGNAL
J
44-A
BRK LT CTRL PWR
K
1-DR
BRK LT SW PWR
M
52P-A
PARK BRK RLY OUT
BT3, STARTER BATTERY CAV 1
WIRE IDENT 1-NA
84547255A
CIRCUIT BATTERY CROSSOVER
Issued 11-11
Printed in E.C.
4002-47 BTM E, CAB BTTOM
CABE2, CAB TO ENG2 BULKHD
225319C1
CAV
WIRE IDENT
CIRCUIT
W230R398
CAV
WIRE IDENT
CIRCUIT
1
21F-D
EDC7 DIGITAL GND
A
23B-D
NOX RELAY, B+
2
0-AK
PARK BRAKE/WARNING GND
B
18U-C
DCU B+ NON DISCONNECTD
3
24B-A
THROT SIGNAL
C
23B-B
NOX SENSOR B+
4
24R-A
THROT GND
D
1-NM
PWR NON DISCONNECTD
5
24S-A
THROT SUPPLY
E
18U-E
DCU B+ NON DISCONNECTD
6
24L-A
LOW IDLE SWITCH
F
23B-A
NOX SENSOR B+
7
61R-E
AC SWITCH OUTPUT
G
1-NL
PWR NON DISCONNECTD
8
61A-E
AC SWITCH INPUT
H
18T
DNOX SW B+
K
35A-F
BKUP ALM RLY OUT
L
35A-C
BKUP ALM RLY OUT
M
18F-A
LH POSN/TAIL FUSED PWR
N
18G-F
RH POSN/TAIL FUSED PWR
P
45R-B
RIGHT TURN SGNL
R
45L-B
LEFT TURN SGNL
S
44A-A
BRK LT RLY OUT
BU1, BACKUP ALARM GRND CAV 1
WIRE IDENT 0-JB
CIRCUIT BACKUP ALARM GND
BU2, BACKUP ALARM CAV
WIRE IDENT
CIRCUIT
1
35A-H
BKUP ALM RLY OUT
1
35A-HN
BKUP ALM RLY OUT
1
35A-9
BKUP ALM RLY OUT
T
19Y-C
HOOD SWITCH FSD PWR
U
60D
HOOD DOWN RLY OUT
V
59D
HOOD DOWN RLY CTRL
W
60U
HOOD UP RLY OUT
X
59U
HOOD UP RLY CTRL
BUZ, AIC BUZZER CAV
WIRE IDENT
CIRCUIT
1
35B
AIC BUZZER HSD
2
0-B27
BUZZER GND
CAB PW, CAB POWER CAV 1
WIRE IDENT 1CB-A
84547255A
CIRCUIT CAB CB PROTECTED PWR
Issued 11-11
Printed in E.C.
4002-48 CAB ARM, CAB TO ARMREST
CAB B, CAB BTM BULKHEAD
225389C1
CAV
WIRE IDENT
CIRCUIT
W230R396
CAV
WIRE IDENT
CIRCUIT
1
CANS-HB
CAN HI, CAN MOD2
A
22D
PEDAL SENSOR GRND
2
0-SJ
GRND, CAN MOD
B
22B
PEDAL SENSOR +5V
3
51E-A
ARMREST LOWER
C
22C
PEDAL POS SIGNAL
4
17P-D
B+, CAN MOD
J
44-A
BRK LT CTRL PWR
6
51B-H
JSS ACT SW
K
1-DR
BRK LT SW PWR
7
0-SD
GRND, JOYSTICK
L
33P-A
BRK WARN PRESS LOW
8
51PW-R
JSS POWER
M
52P-A
PARK BRK RLY OUT
9
51S-B
JSS OKAY PWR
10
51H-B
JOYSTICK SIGNAL
11
51NO-A
NO NEUTRAL SW
12
CANS-LB
CAN LO, CAN MOD2
CAB ARM FRM, CAB TO ARM TO FRM CAV
WIRE IDENT
CIRCUIT
1
CANS-LB
CAN LO, CAN MOD2
2
17P-G
B+, JOYSTICK
4
51D-B
GRND, RELAY CNTL
5
51B-D
JSS ACT SW
6
CANS-LD
CAN LO, CAN MOD3
7
CANS-HD
CAN HI, CAN MOD3
8
0-SK
GRND, CAN MOD
9
51PW-M
JSS POWER
10
51C-B
JSS ACT BTN
11
18S-D
B+, JSS FUSED
12
CANS-HB
CAN HI, CAN MOD2
84547255A
CAB FNR, MAIN CAB FNR CAV
WIRE IDENT
CIRCUIT
1
19B-B
TRANS ENA SW PWR
2
26F-E
FNR FORWARD SIGNAL
3
26N-E
FNR NEUTRAL SIGNAL
4
26R-E
FNR REVERSE SIGNAL
5
32J-H
TRANS ENABLE LT SIG
6
25Y-E
NONE
Issued 11-11
Printed in E.C.
4002-49 CAB E, CAB-ENGINE CAV
WIRE IDENT
CIRCUIT
1
36F-A
FUEL LEVEL ANALOG
2
61C
AC RELAY OUT
3
21G
EDC7 CRANK CTRL RLY
4
21H
CRANK CTRL RLY LSD
5
36C-A
RADITAOR COOL TEMP SGNL
6
0-DF
CRANK REQUEST RLY CTRL GND
7
0-L
TELEMATICS GRND
8
61H
HEAD LOAD VLV SOL
11
21F
EDC7 DIGITAL GND
13
CAN-LL
CAN2 LO, EDC
14
CAN-HM
CAN2 HI, EDC
15
21D-A
STARTER RLY SIGNAL
16
460-A
17
0-DX
AIC SENSOR GND
18
23J-B
DNOX2 K-LINE
19
0-DW
AIC POWER GND
20
0-DB
AIC POWER GND RED
21
13C-B
FUEL SHUTOFF FUSED PWR
22
52A-A
FAN REVERSE RLY OUT
23
56
FAN CONTROL PWM
24
68W
REAR WSHR PUMP
25
63W
FNT WASHER PUMP
26
14-AB
ALTERNATOR D+
27
21E-B
KEY SWITCH CRANK
28
31F-A
AIR FLTR REST SW SGNL
29
61R-B
AC RELAY CONTROL
30
61A-B
TRINARY PRESS SW INPUT
31
20G-B
EDC7 ISO-K INTERFACE
CAV
WIRE IDENT
CIRCUIT
16
18C-A
RH HIGH BEAM FUSED PWR
17
57-A
PIN ENGAGE SOL PWR
18
58-C
RIDE CTRL SOL PWR
CAB FRM, CAB TO JSS FRAME CAV
WIRE IDENT
CIRCUIT
A
51F-B
LS PRESS SW
B
51J-A
VALVE ALARM
C
51K-B
PILOT PRESS SW
D
51L-A
JOYSTICK SIGNAL
F
51S-F
JSS OKAY PWR
G
0-SF
GRND
H
51PW-T
JSS POWER
J
18S-D
B+, JSS FUSED
CAB RF, CAB TO ROOF CONNECTION
388710A1
CAB F, CAB FRONT CHAS CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
A
0-DZ
WORK LIGHTS GRND
B
0-DY
ROOF SPLICE GNDS
C
43-A
DOME LT AUTO MODE
D
19U-D
DOME LT FSD PWR
E
46-C
BEACON SW PWR
F
0-DR
ROOF SPLICE GNDS
G
0-DS
ROOF SPLICE GNDS FNT WRK LTS FUSE PWR
2
45L-C
LEFT TURN SGNL
H
42C-A
3
45R-D
RIGHT TURN SGNL
J
19K-C
REAR WPR MOTOR FSD PWR
68C
REAR WPR PARK CTRL
5
18G-G
RH POSN/TAIL FUSED PWR
K
6
18B-A
LH HIGH BEAM FUSED PWR
L
68L-B
REAR WPR SW PWR
9
53P-F
PILOT CTRL RLY OUT
M
0-EM
RADIO GND
10
18F-E
LH POSN/TAIL FUSED PWR
N
12V-B
12V FUSED PWR TO RADIO
19U-G
DOOR SW FSD PWR
11
54B-A
HC-RTT CTRL SGNL
P
12
53B-B
RTD CTRL SIGNAL
R
43S-A
DOOR OPEN SGNL
13
64-A
HORN POWER
S
42R-C
REAR WRK LTS FUSE PWR
14
18D-A
LH LOW BEAM FUSED PWR
15
18E-A
RH LOW BEAM FUSED PWR
84547255A
Issued 11-11
Printed in E.C.
4002-50 CAB T, CAB TRANSMISSION
CAN MOD 2, JSS CAN MOD
380839A1
CAV
WIRE IDENT
CIRCUIT
1
33R
RDNT BRK ACCUM PRESS LOW
2
34A-C
DIFF LOCK SOL B+
3
19M
SEC STR ACCESSORY FSD PWR
4
19R-E
SEC STR IGN FSD PWR
5
36T-A
VALVE BODY TEMP SGNL
6
35X
SEC STR LOW PRESS SGNL
7
25A-A
ENG SP SIGNAL
8
25C-A
TURBINE SP SIGNAL
9
25B-A
INT SP SIGNAL
10
25D-A
OUTPUT SP SIGNAL
11
0-DM
SPEED SENSOR GNDS
12
36R-E
TRANS TEMPS/FLTR RETURN
13
36G-A
TCO TEMP SIGNAL
14
25G-A
BRK DECLUTCH SW CTRL
15
25R-A
TC LOCKUP SOL POWER
16
25K-A
TRANS SOL VALVE Y1
17
25L-A
TRANS SOL VALVE Y2
18
25M-A
TRANS SOL VALVE Y3
19
25N-A
TRANS SOL VALVE Y4
20
25P-A
TRANS SOL VALVE Y5
21
25J-A
TRANS SOL VALVE Y6
22
25S-A
OUTPUT SW PWR VPS1
23
31H-A
HYD FLTR REST SW SGNL
24
19A-T
BRK DECLUTCH SW FSD PWR
25
25T-A
TC LOCKUP SOL GND
26
19S2
SEC STR FSD PWR
27
34C
DIFF LOCK SOL GND
28
0-DN
OUTPUT SPEED SENSOR GND
29
19A-M
OUTPUT SP SNSR FUSED PWR
30
36H-A
HYDRAULIC OIL TEMP
31
32F-A
TRANS FLTR MAINT SW
84547255A
87552623
CAV
WIRE IDENT
CIRCUIT
1
51B-J
JSS ACT SW
2
51PW-U
JSS POWER
3
51NC
NC NEUTRAL SW
4
51S-D
JSS OKAY PWR
5
51R
ARMREST RAISE
7
CANS-HA
CAN HI, CAN MOD2
8
CANS-LA
CAN LO, CAN MOD2
9
17P-E
B+, CAN MODULE
10
0-SE
GRND
CBPW, CAB POWER CAV 1
WIRE IDENT 1CB
CIRCUIT CAB CB PROTECTED PWR
CONNECTOR CL - CIGAR LIGHTER
3227856R1
CAV
WIRE IDENT
CIRCUIT
1
19W
CIGAR LIGHTER FUSED POW
2
0-DV
CIGAR LIGHTER GROUND
Issued 11-11
Printed in E.C.
4002-51 CONNECTOR DIA - DIAGNOSTIC
CONNECTOR CNV - 24V TO 12V POWER CONVERTER
310057A1 225351C1
CAV
WIRE IDENT
CAV
WIRE IDENT
CIRCUIT A
CIRCUIT DIAGNOSTICS CONNECTOR GND
0-DH
1
19L-A
POW CONVER. FUSED POW
2
19L-B
POW CONVER. FUSED POW
B
18K-D
DIAGNOSTICS FUSED B+
POW CONVERTER GROUND
C
CAN-HB
CAN HIGH
NOT USED
D
CAN-LB
CAN LOW
E
20G-B
EDC7 ISO-K INTERFACE
3
0-EJ
4 5
12V-C
12V SWITCHED POWER
6
0-ER
POW CONVERTER GROUND
DIA 2, DIAGNOSTIC DC1, DISCONECT BATTERY CAV 1
WIRE IDENT 1-NB
CIRCUIT BATTERY STARTER
DC2, DISCON BLCK GRND CAV 1
WIRE IDENT 0-NB
CIRCUIT MASTER DISCONNECT GND 310057A1
DC3, FUEL SOL DISCONNECT CAV 1
WIRE IDENT 13C
CIRCUIT FUEL SHUTOFF FUSED PWR
DC4, FUEL SOL DISCONNECT CAV 1
WIRE IDENT 13M
CAV
WIRE IDENT
CIRCUIT
A
0D-C
DIAG2 GRND
B
18K-B
DIAG FUSED B+
C
CAN-HO
CAN2 HI, DIAG2
D
CAN-LX
CAN2 LO, DIAG2
E
23J-B
DNOX2 K-LINE
CIRCUIT FUEL SHUTOFF FUSED PWR
DEFDM, DOSER METERING VLV CAV
WIRE IDENT
CIRCUIT
1
38
DOSER VALVE B+
2
38A
DOSER VALVE GND
84547255A
Issued 11-11
Printed in E.C.
4002-52 CONNECTOR DISC - DISCONNECT ENGINE
DNOX2, NOX CONTROLLER CAV
245482C1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
1
38D
TANK HEAT B+
3
18U-D
DCU B+ NON DISCONNECTD
4
18U-B
DCU B+ NON DISCONNECTD
7
CAN-QH
CAN HI, DNOX2
8
CAN-LK
CAN LO, DNOX2
11
38A
DOSER VALVE GND
12
38
DOSER VALVE B+
14
0-LB
DNOX2 MODULE GND
A
13C
FUEL SHUTOFF FUSED POW
15
0-LC
DNOX2 MODULE GND
B
13M
FUEL SHUTOFF FUSED POW
17
0E-A
EXHT TEMP UP GND
18
38B
DEF LEVEL SIG
19
0-T
DEF SENSOR GND
23
38C
TANK HEAT GND
24
18T-A
DNOX2 SW B+
25
0-U
EXHT TEMP DWN GND
26
38E
EXHT TEMP DWN B+
28
38F
EXHT UP SIGNAL
29
38G
DEF TEMP SIG
31
38H
DNOX2 K-LINE
CONNECTOR DM - DIODE OR
245485C1
CAV
WIRE IDENT 19RR
SEC. STEERING IGNITION FUSED PWR
B
NOT USED
C
19R
SEC. STEERING IGNITION FUSED PWR
A
CONNECTOR DS - DOOR SWITCH
CIRCUIT
245482C1
CAV
84547255A
WIRE IDENT
CIRCUIT
A
19U-F
DOOR SWITCH FUSED POWER
B
43S-B
DOOR OPEN SIGNAL
Issued 11-11
Printed in E.C.
4002-53 DTLTS, DEF TANK LEVEL TEMP SENSOR
W230R399
CAV
WIRE IDENT
CIRCUIT
1
38B-A
DEF LEVEL SIG
2
0-TA
DEF SENSOR GND
3
38G-A
DEF TEMP SIG
DTS, DOWNSTREAM TEMP SENS CAV
WIRE IDENT
CIRCUIT
1
38E
EXHT TEMP DWN B+
2
0-U
EXHT TEMP DWN GND
CONNECTOR D-OR - DIODE OR
245485C1
CAV
WIRE IDENT
CIRCUIT
A
42C-D
FRONT WORK LIGHTS FUSED POWER
B
41T-C
POSITION LIGHTS SWITCHED POWER
C
49
BACK LIGHT POWER
84547255A
Issued 11-11
Printed in E.C.
4002-54 EDC7, ENGINE CONTROLLER
CAV
WIRE IDENT
CIRCUIT
35
CAN1-H
CAN HI
35
CAN-HK
CAN HI, EDC
36
28F
FUEL FLTR HTR RLY CTRL
37
21G-A
EDC7 CRANK CTRL RLY
40
13M-A
FUEL SHUTOFF FUSED PWR
42
35W
WIF INDICATOR
48
24L
LOW IDLE SWITCH
51
13A
EVGT RELAY
52
CAN-LS
CAN LO, NOX
52
CAN-L3
CAN2 LO, NOX
53
CAN-HS
CAN2 HI, NOX
53
CAN-H3
CAN2 HI, NOX
68
23K-A
TEMP/HUMD B+
75
0-BV
GRID HEATER CTRL GND
77
24S
THROT SUPPLY
78
24R
THROT GND
79
24B
THROT SIGNAL
89
20G-A
EDC7 ISO-K INTERFACE
ECA L1, B+ POWER CAV cs01
BOSCH-89-POLE
CAV
WIRE IDENT
J1
CIRCUIT TRANS ECM PWR
CONNECTOR EM - HEIGHT CONTROL RTD - RTT
CIRCUIT
2
18J-C
EDC7 FSD PWR
3
18J-B
EDC7 FSD PWR
5
0-BE
EDC7 GND
6
0-BF
EDC7 GND
8
18J-D
EDC7 FSD PWR
9
18J-E
EDC7 FSD PWR
10
0-BD
EDC7 GND
11
0-BC
EDC7 GND
12
28G
GRID HTR SOURCE DR
13
31
EDC RELAY CNTL
17
21H-A
CRANK CTRL RLY LSD
26
23K-B
TEMP/HUMD TEMP
27
23K-C
TEMP/HUMD HUMD
28
23K-E
TEMP/HUMD GND
29
21F-B
EDC7 DIGITAL GND
32
21E-A
KEY SWITCH CRANK
34
CAN-LJ
CAN LO, EDC
34
CAN1-L
CAN LO
84547255A
WIRE IDENT
225351C1
CAV
WIRE IDENT
CIRCUIT
1
55A-A
RTT/FLOAT SWITCHED POW.
2
54A
HEIGHT CONTROL SWITCHED POWER
3
53A
RTD SWITCHED POWER
4
53B-B
RTD CONTROL SIGNAL
5
54B-B
HC-RTT CONTROL SIGNAL
6
55B
RTT FLOAT SWITCH CONTROL
Issued 11-11
Printed in E.C.
4002-55 ENG B, CAB BOTTOM
ENG, ENGINE CAB1 CAV
WIRE IDENT
CIRCUIT
1
36F
FUEL LEVEL ANALOG
1
36J
FUEL LEVEL ANALOG
2
61C-A
AC RELAY OUT
3
21G-A
EDC7 CRANK CTRL RLY
4
21H-A
CRANK CTRL RLY LSD
5
36C
RADIATOR COOL TEMP SGNL
6
0-BAT
CRANK REQUEST GND
7
0-BK
TELE GROUND
8
61H-A
HEAT LOAD VLV SOL
11
21F-A
EDC7 DIGITAL GND
13
CAN-L
CAN LOW
13
CAN1-L
CAN LO
14
CAN-H
CAN HIGH
14
CAN1-H
CAN HI
15
21D
STRTR RLY SIGNAL
16
460
FAN SPEED SENSOR SIGNAL
17
0-BJ
AIC SENSOR GND
225320C1
CAV
WIRE IDENT
CIRCUIT
1
21F-C
EDC7 DIGITAL GND
2
0-BBR
GROUND
3
24B
THROT SIGNAL
4
24R
THROT GND
5
24S
THROT SUPPLY
6
24L
LOW IDLE SWITCH
7
61R-C
AC SWITCH OUTPUT
8
61A-C
AC SWITCH INPUT
84547255A
18
38H
DNOX2 K-LINE
19
0-BG
AIC POWER GND
20
0-BH
AIC POWER GND RED
21
13C-A
FUEL SHUTOFF FUSED PWR
22
52A-B
FAN REVERSE RLY OUT
23
56-A
FAN CONTROL PWM
24
68W-A
REAR WSHR PUMP
25
63W-A
FNT WASHER PUMP
26
14
ALTERNATOR D+
26
14-5
ALTERNATOR D+
27
21E-A
KEY SWITCH CRANK
28
31F
AIR FLTR REST SW SGNL
29
61R
AC RELAY CONTROL
30
61A
AC PRESS SW INPUT
31
20G-A
EDC7 ISO-K INTERFACE
Issued 11-11
Printed in E.C.
4002-56 ECA, ELECT CNTR A
87315248
CAV A1
WIRE IDENT 19A-N
CIRCUIT TRANS FUSE PWR
A2
18S-A
B+, JSS FUSED
A3
19E-A
AIC WAKE UP IGN
A4
19RR
SEC STR IGN FSD PWR
A5
19C-A
PILOT CTRL RLY FSD PWR
A6
19D-A
PARK BRK RLY FSD PWR
A7
19P
PIN ENGAGE/FAN FSD PWR
A8
19B
TURN SIGNAL FSD PWR
A9
13C-B
FUEL SHUTOFF FUSED PWR
A10
18T
DNOX SW B+
C1
18N
BLOWER MOTOR FUSED PWR
C2
19J
FNT WPR FSD PWR
C3
19K
REAR WPR FSD PWR
C4
19H
BACKUP ALARM B+
C6
19N
SEAT CPRSR FSD PWR
C7
19M
SEC STR ACCESSORY FSD PWR
C8
19W
CIGAR LIGHTER FSD PWR
C9
66A
RR CAMERA PWR
L1
J1
TRANS ECM PWR
L1
J2
TRANS ECM PWR
L1
J3
EMG STR AIC PWR
L1
J4
EMG STR AIC PWR
84547255A
CAV
WIRE IDENT
CIRCUIT
L1
J5
EMG STRG PLT EM DTNTS
L1
J6
PLTEM DTNTS PRK BRK SOL
L1
J7
PRK BRK SOL HRN
L1
J8
FAN RVSR TURN SGNL
L1
J9
TURN SGNL ENG SHTDWN.
L1
J10
DNOX SW B+
L2
J11
BLWR MOTOR PWR
L2
J12
BLWR MTR FRNT WIPR WASH
L2
J13
FRNT WIPR RER WIPR WSH
L2
J14
RER WIPR WSH BACKUP
L2
J15
BKUP A/C
L2
J16
HEATED MIRRORS
L2
J17
SEAT COMP EMG STRTR
L2
J18
DIAGNOSTIC PWR
Issued 11-11
Printed in E.C.
4002-57 ECB, ELECT CNTR B
87312843
CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
A1
12V-D
PLUG 1 12V SW PWR
B4
0-DE
NEUT START RLY CTRL GND
A2
12V-E
PLUG 2 12V SW PWR
B5
21F
EDC7 DIGITAL GND
A3
41H-B
HIGH BEAM LH PWR
B6
0-DF
CRANK REQUEST RLY CTRL GND
A4
41H-C
HIGH BEAM RH PWR
A5
41L-C
LOW BEAM RH PWR
A6
41L-B
LOW BEAM LH PWR
A7
41T-B
POSN LIGHTS LH SW PWR
A8
41T-A
POSN LIGHTS RH SW PWR
A9
12V-F
RADIO 12V SW PWR
A10
12V-G
2 WAY RADIO 12V SW PWR
AA1
12V
12V PWR TO OUTLET 1
AA2
12V-A
12V PWR TO OUTLET 2
AA3
18B-A
LH HIGH BEAM FUSED PWR
AA4
18C-A
RH HIGH BEAM FUSED PWR
AA5
18E-A
RH LOW BEAM FUSED PWR
AA6
18D-A
LH LOW BEAM FUSED PWR
AA7
18F-C
LH POSN/TAIL FUSED PWR
AA8
18G
RH POSN/TAIL FUSED PWR
AA9
12V-B
12V FUSED PWR TO RADIO
B1
0-EW
POWER RELAY GND
B2
0-EV
IGN LATCH GND
B3
21K-B
IGN SW START SIGNAL
84547255A
B7
19P-E
FAN REV RLY FSD PWR
B8
52
FAN REVERSER LSD
B9
19D-C
PARK BRK RLY FSD PWR
B10
52C
PARK BRK SOL LSD
C2
0-EA
PWR RELAY GND
D1
13K-B
IGN PWR LATCH B+
D2
0-ET
POWER RELAT GND
D3
25T
NEUTRAL SIGNAL
D4
21C
NEUTR START RLY OUTPUT
D5
21C-A
NEUTR START RLY OUTPUT
D6
21E
KEY SWITCH CRANK
D7
19P-D
FAN REV RLY FSD PWR
D8
52A-A
FAN REVERSE RLY OUT
D9
19D-B
PARK BRAKE RLY FSD PWR
D10
52P-B
PARK BRK RLY OUT
Issued 11-11
Printed in E.C.
4002-58 ECD, ELECT CNTR D
87312843
CAV
WIRE IDENT
CIRCUIT
A1
0-EF
BRK LTS RLY CTRL GND
A2
1-DW
BRAKE LT RLY BAT PWR
A3
0-EZ
POWER RELAY CONTROL
A4
0-EY
POWER RELAY GND
A5
21H
CRANK CTRL RLY LSD
A6
21C-B
NEUT START RLY OUTPUT
A7
23B-C
NOX RELAY GND
A8
23B-A
NOX SENSOR B+
A9
35C
BACK UP ALRM CNTL
A10
19H
BACK ALARM B+
AA1
44A-A
BRK LT RLY OUT
AA2
44A
BRK LT CTRL PWR
AA3
0-KA
IGN PWR CONTROL GND
AA4
13K-A
IGN PWR CONTROL B+
AA5
21D-A
STRTR RLY SIGNAL
AA6
21G
EDC7 CRANK CTRL RLY
AA7
23B-B
NOX SENSOR B+
AA8
23B-D
NOX RELAY B+
AA9
35A-A
BACKUP ALARM
AA10
19A-P
BACKUP ALARM RELAY
B1
19J-E
FNT WPR RLY FSD PWR
B2
63HC-B
FNT WPR RLY HS
84547255A
CAV
WIRE IDENT
CIRCUIT
B3
63C3
FNT WPR PARK CTRL
B4
63LC
FNT WPR LS RLY CTRL
B5
19C-B
PILOT CTRL RLY FSD PWR
B6
53C-A
PILOT CTRL RLY SOL LSD
B7
58T
RIDE CTRL RLY SW PWR
B8
58L
RIDE CTRL RLY LSD
B9
61A-G
TRINARY PRESS SW INPUT
B10
0-DJ
AC RELAY CONTROL GND
C2
63C2
FNT WPR PARK CTRL
C4
63C
FNT WPR PARK CTRL
C10
61C
AC RELAY OUT
D1
19J-D
FNT WPR RLY FSD PWR
D2
63H-B
FNT WPR RLY HS
D3
19J-F
FNT WPR RLY LS CTRL FSD PWR
D4
63-C2
FNT WPR PARK CTRL
D5
19C-C
PILOT CTRL RLY FSD PWR
D6
53P-C
PILOT CTRL RLY OUT
D7
58H-C
POWER
D8
58-E
RIDE CTRL SOL PWR
D9
61R-B
AC RELAY CONTROL
Issued 11-11
Printed in E.C.
4002-59 ECC, ELECT CNTR C
87315249
CAV
WIRE IDENT
CIRCUIT
CAV D2
WIRE IDENT 19Y-A
CIRCUIT HOOD UP RLY FSD PWR
A1
19U-B
BEACON DOME LT FSD PWR
A2
42
WORK LIGHTS SW FSD PWR
D3
59D
HOOD DOWN RLY CTRL
19Y-B
HOOD DOWN RLY FSD PWR
A3
19Z
DRIVING LTS SW FSD PWR
D4
A4
1-DV
BRK LTS/FLASHER BAT PWR
D7
19U-E
HORN RLY FSD PWR
A5
1DM
TIME DELAY/IGN SW FSD PWR
D8
64-A
HORN POWER
A6
19U
HORN RLY FSD PWR
D9
21J
RESTART PREVENT
67B
START LOCKOUT
A7
19Y
HOOD CTRL FSD PWR
D10
A8
19S-B
AIC DELAY FSD PWR
L1-1
ECC-L1
BEACON/DOME LT LI ECC
A9
18K-A
DIAGNOSTIC FUSED PWR
L1-1
J2-ECC
BEACON/DOME LT WORK LTS
A10
19T-C
FUSED BATT PWR
L1-2
J3-ECC
WORK LTS DRIVING LTS
J2-ECC
BEACON/DOME LT WORK LTS
B1
60U
HOOD UP RLY OUT
L1-2
B2
0-B25
HOOD UP CONTROL GND
L1-3
J4-ECC
DRIVING LTS BRK LTS
B3
60D
HOOD DOWN RLY OUT
L1-3
J3-ECC
WORK LTS DRIVING LTS
B4
0-B16
HOOD DOWN CONTROL GND
L1-4
J5-ECC
BRK LTS DLY PWR
J4-ECC
DRIVING LTS BRK LTS
B7
19U-A
HORN RLY FSD PWR
L1-4
B8
64C
HORN RLY CTRL
L1-5
J6-ECC
DLY PWR HRN
B9
21E
KEY SWITCH CRANK
L1-5
J5-ECC
BRK LTS DLY PWR
B10
0-J
START LOCKOUT RLY GND
L1-6
J7-ECC
HRN HOD CTRL
J6-ECC
DLY PWR HRN HRN HOD CTRL
C2
0-B22
HOOD UP RELAY GND
L1-6
C4
0-B12
HOOD DOWN RELAY GND
L1-7
J7-ECC
C10
21E-B
KEY SWITCH CRANK
L1-8
J9-ECC
D1
59U
HOOD UP RLY CTRL
L1-9
J10-ECC
L1-10
J10-ECC
84547255A
Issued 11-11
Printed in E.C.
4002-60 ENG2, ENG BULKHD 2
CONNECTOR ENG-D - DISCONECT HARNESS
245483C1
CAV
WIRE IDENT
CIRCUIT
A
13C-A
FUEL SHUTOFF FUSED POW
B
13M-B
WIF IGN PWR
W230R397
CAV
WIRE IDENT
CIRCUIT
A
23B-F
NOX RELAY B+
B
18U-D
DCU B+ NON DISCONNECTD
C
23A-A
DNOX2 MODULE B+
D
1-NK
PWR NON DISCONNECTD
E
18U-B
DCU B+ NON DISCONNECTD
F
23B-E
NOX SENSOR B+
G
1-NJ
PWR NON DISCONNECTD
H
18T-A
DNOX2 SW B+
K
35A-G
BKUP ALM RLY OUT
K
35A-GN
BKUP ALM RLY OUT
L
35A-J
REVERSE LT
L
35A-R
BKUP ALM RLY OUT
M
18F-AN
LH POSN/TAIL FUSED PWR
M
18F-B
LH POSN/TAIL FUSED PWR
N
18G-H
RH POSN/TAIL FUSED PWR
N
18G-HN
RH POSN/TAIL FUSED PWR
P
45R-A
RIGHT TURN SGNL
P
45R-AN
RIGHT TURN SGNL
R
45L-A
LEFT TURN SGNL
R
45L-AN
LEFT TURN SGNL
S
44A-D
BRK LT RLY OUT
S
44A-DN
T
CONNECTOR ENG-H - ENGINE TO HOOD
225320C1
CAV
WIRE IDENT
CIRCUIT
1
0-BAG-N
HOOD GROUND (NA)
2
44A-DN
BRAKE LIGHT RELAY OUT
3
45L-AN
LEFT TURN SIGNAL
4
45R-AN
RIGHT TURN SIGNAL
5
18G-HN
RH POSITION/TAIL FUSED PWR
6
18F-AN
LH POSITION/TAIL FUSED PWR
BRK LT RLY OUT
7
35A-GN
BACKUP ALARM RELAY OUT
19Y-D
HOOD SWITCH FSD PWR
8
35A-R
BACKUP ALARM RELAY OUT
U
60D-A
HOOD DOWN RLY OUT
V
59D-A
HOOD DOWN RLY CTRL
W
60U-A
HOOD UP RLY OUT
X
59U-A
HOOD UP RLY CTRL
84547255A
Issued 11-11
Printed in E.C.
4002-61 CONNECTOR E-HD - TRANSMISSION HOOD
CONNECTOR FLSHR - FLASHER MODULE
245485C1
CAV
WIRE IDENT
CIRCUIT
225389C1
A
18G-D
LIC PLATE LIGHT FUSED PWR
B
35A-G
BACKUP ALARM RELAY OUT
C
0-BAG
HOOD GROUND (EURO)
CONNECTOR ESS - ENGINE SPEED SENSOR
CAV
1 2
WIRE IDENT
1-DU
FLASHER MODULE POWER
2
45N-A
FLASHER OPT. SIDE CONTR.
3
0-EH
FLASHER MODULE GROUND
4
0-EG
FLASHER MODULE GROUND
5
NOT USED
6
NOT USED
7
45R-E
RIGHT TURN SIGNAL
8
45L-D
LEFT TURN SIGNAL
9
45A-A
LEFT TURN SWITCH POWER
10
45B-A
RIGHT TURN SWITCH POWER
11
45H
HAZARD SWITCH POWER
12
45N-B
FLASHER OPT. SIDE CONT.
CONNECTOR FM - FILTER MAINTENANCE SWITCH
CIRCUIT
25A
ENGINE SPEED SIGNAL
0-HF
ENGINE SPEED SENSOR GROUND
CIRCUIT
1
291718A1
CAV
WIRE IDENT
CONNECTOR FFH - FULE FILTER HEATER
371614A1
CAV
WIRE IDENT
CIRCUIT
1
32F
TRANS FILTER MAINT SW
2
36R-B
TRANS FM SWITCH RETURN
182069A1
CAV
WIRE IDENT
CIRCUIT
A
1-GB
FUEL FILTER HEATER PWR
B
0-BX
FUEL FILTER HEATER GROUND
84547255A
Issued 11-11
Printed in E.C.
4002-62 FNR RLY, RELAY K2 CAV
WIRE IDENT
CONNECTOR FWM - FRONT WIPER MOTOR
CIRCUIT
30
19B-A
FNR SW FUSED PWR
85
0-ST
GRND, JOYSTICK
86
51B-K
JSS POWER
87
19B-B
TRANS ENA SW PWR
87A
0-SS
TRANS ENA SW PWR
FRONT, FRNT CHAS-CAB 245715C1
CAV
WIRE IDENT
CIRCUIT
2
45L
LEFT TURN SGNL
3
45R
RIGHT TURN SGNL
5
18G-A
RH POSN/TAIL FUSED PWR
6
18B
LH HIGH BEAM FUSED PWR
9
53P-G
PILOT CTRL RLY OUT
10
18F
LH POSN/TAIL FUSED PWR
11
54B
HC-RTT CTRL SGNL
12
53B
RTD CTRL SIGNAL
13
64
HORN POWER
14
18D
LH LOW BEAM FUSED PWR
15
18E
RH LOW BEAM FUSED PWR
16
18C
RH HIGH BEAM FUSED PWR
17
57
PIN ENGAGE SOL PWR
18
58-B
RIDE CONTROL SOL PWR
18
58-G
RIDE CONTROL SOL PWR
CAV
WIRE IDENT
CIRCUIT
A
63H-A
FRONT WIPER HIGH SPEED RLY OUT
B
63L-A
FRONT WIPER LOW SPEED RLY OUT
C
19J-A
FRONT WIPER MOTOR FUSED POWER
D
63C
FRONT WIPER PARK CONTROL
CONNECTOR FWMG - FRONT WIPER MOTOR GROUND
FWD DIODE, DIODE ASSY CAV
WIRE IDENT
CIRCUIT
A
26F-D
FNR FORWARD SIGNAL
B
26F-E
FNR FORWARD SIGNAL
C
26F-C
FNR FORWARD SIGNAL
84547255A
245480C1
CAV A
WIRE IDENT 0-B8
CIRCUIT FRONT WIPER MOTOR GROUND
Issued 11-11
Printed in E.C.
4002-63 CONNECTOR FWW - FRONT WASHER
GHF3, GRID HEATER FUSE CAV 1
WIRE IDENT 1-Y
CIRCUIT GRID HTR FSD PWR
GHF4, GRID HEATER CAV 1
WIRE IDENT 1-Y
GND CAB1 , GROUND A
3227856R1
CAV
WIRE IDENT
CIRCUIT CAV
1
63W-A
FRONT WASHER PUMP
2
0-B
FRONT WASHER GROUND
GH, GRID HEATER CAV 1
WIRE IDENT 1-BE
CIRCUIT
0-DD
WORK LIGHTS GRND
1
0-DR
ROOF SPLICE GNDS
1
0-DS
ROOF SPLICE GNDS
CIRCUIT
GND CAB2 , GROUND A
GRID HTR PWR
GH 1, GRID HEATER
1
WIRE IDENT
1
CAV
CAV
CIRCUIT GRID HTR FSD PWR
WIRE IDENT 0-ES
CIRCUIT
WIRE IDENT
CIRCUIT
1
0-B8
FRONT WIPER MOTOR GND
1
0-B10
HOOD GND
1
0-B26
BUZZER/SW PAD GND
GRID HTR GND
GND CAB3 , GROUND C CONNECTOR GHC - GRID HEATER RELAY
CAV
WIRE IDENT
CIRCUIT
1
0-DG
CAB SPLICE GNDS
1
0-DV
CIGAR LIGHTER GND
GND CAB3D , GROUND A CAV
3227856R1
CAV
WIRE IDENT 28G
GRID HTR SOURCE DR
2
0-BV
GRID HTR CONT GND
1
0-DP
DIAG TECM GND
1
0-DQ
DIAG TECM GND
1
0-DAV
TECM DIAGNOSTIC GND
GND CAB4 , GROUND C CAV
GHF1, GRID HEATER FUSE
1
WIRE IDENT 1-E
84547255A
CIRCUIT
CIRCUIT
1
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
1
0-ED
HVAC GNDS
1
0-EJ
POWER CONVERTER GND
1
0-ER
POWER CONVERTER GND
GRID HTR FUSE BAT PWR
Issued 11-11
Printed in E.C.
4002-64 GND CAB5 , GROUND C CAV
WIRE IDENT
GND CAB SPL2, SPL BACK LGHT GD
CIRCUIT
1
0-EK
AUX POWER OUTLET 1 GND
1
0-EL
AUX POWER OUTLET 2 GND
GND CAB6, STRT, FFH, WAT SEP HTR CAV 1
WIRE IDENT
CIRCUIT SPLICE PACK GND CAB SPL2 GND
0-EQ
87324393
EVGT3, EVGT FUSE CAV
WIRE IDENT
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
A
0-J
START LOCKOUT RLY GND
0-KA
IGN PWR CONTROL GND
A
1-T
EVGT 3 PWR
B
B
1-B
EVGT RELAY PWR
C
0-K
CAMERA GND
E
0-EW
POWER RELAY GND
F
0-BBC
JOYSTICK GROUND
G
0-DE
NEUT START RLY CTRL GND
H
0-EQ
SPLICE PACK GND CAB SPL2 GND
K
0-EH
FLASHER MODULE GND
L
0-EG
FLASHER MODULE GND
M
0-EF
BRK LTS RLY CTRL GND
CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE
GND ENG1 , STRT, FFH, WAT SEP HTR CAV
87324393
CAV
WIRE IDENT 0-EE
DIODE SUPPRESSION GROUNDS
B
0-EM
RADIO GROUND
C
0-EP
HORN SWITCH GROUND
D
0D-C
DIAG2 GROUND
E
23B-C
NOX RELAY GROUND
F
0-DG
CAB SPLICE GROUNDS
G
0-DT
FRNT WIP/WASHER SW GND
J
0-DK
SEAT COMPR MOTOR GND
H
0-VA
HEATED MIRRORS GND
K
0-DJ
AC RELAY CONTROL GRND
L
0-DU
PILOT PRESS SOLEN GND
0-DH
DIAGNOSTIC CONNECTOR GROUND
84547255A
CIRCUIT
1
0-BW
WATER SEP HEATER GND
1
0-BX
FUEL FILTER HEATER GND
1
0-GB
STARTER RLY CTRL GND
CIRCUIT
A
M
WIRE IDENT
GND ENG2 , DEDICATED WIF, EDC CAV
WIRE IDENT
CIRCUIT
1
0-BP
WIF SENSOR GND
1
0-BAT
CRANK REQUEST GND
1
0-BAC
EDC7 GND
1
0-BAU
EVGT_2 GND
1
23D-D
NOX SENSOR GND
Issued 11-11
Printed in E.C.
4002-65 GND FC , GROUND A
GND ENG3 , SPLC PK, WSHR MTR CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
1
0-BM
ENGINE SPLICE GNDS
1
0-AG
FRONT CHASSIS GND
1
0-BBR
GROUND
1
0-AB
PROX SW GND
GND GH1, STRT, FFH, WAT SEP HTR
GND ENG4 , REAR LIGHTING CAV
WIRE IDENT
CIRCUIT
1
0-BAG
HOOD GROUNDS (EURO)
1
0-BAG-N
HOOD GROUNDS (NA)
1
0-BT
LH REAR LIGHT GND (EURO)
1
0-BR
RH REAR LIGHT GND (EURO)
CAV 1
CAV
CAV
WIRE IDENT
0-ES
CIRCUIT GRID HTR GND
GND JSS , GROUND A
1
EVGT4, EVGT
WIRE IDENT
WIRE IDENT 0-AV
CIRCUIT
CIRCUIT GRND
GND PDST , GROUND A
A
13B
EVGT RELAY PWR
B
31A
EVGT RELAY B+
CAV
C
13A
EVGT RELAY
1
D
1-B
EVGT RELAY PWR
WIRE IDENT 0-BA
CIRCUIT PEDESTAL GND STRAP
GND PDST1 , GROUND A FSS, FAN SPEED SENS CAV CAV
WIRE IDENT
CIRCUIT
1
460
FAN SPEED SENSOR SIGNAL
2
017A
FAN SPEED SENSOR GND
GND ENG6 , DEDICATED
1
WIRE IDENT
0-DA
CIRCUIT AIC CHASSIS GND
GND PDST2 , GROUND A CAV 1
CAV
WIRE IDENT
WIRE IDENT 0-BA
CIRCUIT PEDESTAL GND STRAP
CIRCUIT
1
0-BG
AIC POWER GND
1
0-BH
AIC POWER GND RED
1
0-BJ
AIC SENSOR GND
1
0-BAR
WIF BODY GRND
GND S1 , GROUND A CAV 1
WIRE IDENT
CIRCUIT FRONT TO REAR CHASSIS GND
0-AP
GND ENG7 , GRND TRANS CLNT GND S2 , GROUND A CAV
WIRE IDENT
CIRCUIT
017A
FAN SPEED SENSOR GND
1
0-BAE
EDC7 SENDER GND
1
0-BBF
DNOX2 MODULE GND
1
0-BK
TELE GROUND
1
0-BU
FUEL LEVEL SENDER GND
1
0-BZ
FUEL LEVEL SENDER GND
84547255A
CAV 1
WIRE IDENT 0-AP
CIRCUIT FRONT TO REAR CHASSIS GND
Issued 11-11
Printed in E.C.
4002-66 GND SSCHAS, SSM GROUND CABLE CAV 1
WIRE IDENT 0-ND
CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS
CIRCUIT SSM GROUND
GND SSMOD, SEC STR CHASIS GND CAV
WIRE IDENT
CIRCUIT
1
0-CE
SEC STEERING CHASSIS GND
1
0-CD
SEC STEERING SPLICE GND
245484C1
CAV
GND WIF, GRND WIF RING TERM CAV 1
WIRE IDENT 0-BAR
CIRCUIT WIF BODY GRND
WIRE IDENT
CIRCUIT
A
18G-E
LICENSE PLATE LIGHT FUSED PWR
B
35A-H
BACKUP ALARM RELAY OUT
C
0-JA
HOOD GROUND (EURO)
HDM, HOOD LIFT MOTOR
GND TRANS, GROUND TRANS CAV
WIRE IDENT
CAV
CIRCUIT
1
0-HW
HOT GROUND
1
1
0-HR
HYD FLTR SW GRND
2
1
0-HL
RED BRAKE SW GND
1
0-HM
RED BRAKE SW GND
WIRE IDENT
CIRCUIT
60U-A
HOOD UP RLY OUT
60D-A
HOOD DOWN RLY OUT
CONNECTOR HD - HOOD SWITCH
245485C1
CAV
WIRE IDENT
CIRCUIT
A
59D-A
HOOD RELAY CONT DOWN
B
19Y-D
HOOD SWITCH FUSED PWR
C
59U-A
HOOD RELAY CONTROL UP
84547255A
Issued 11-11
Printed in E.C.
4002-67 CONNECTOR HD-N - HOOD TO ENGINE
HTS, HMDTY AND AMB TEMP CAV
WIRE IDENT
CIRCUIT
1
23K-A
TEMP/HUMD B+
2
23K-B
TEMP/HUMD TEMP
3
23K-C
TEMP/HUMD HUMD
4
23K-E
TEMP/HUMD GND
HVAC1, HVAC1 CAV 1 225319C1
CAV 1
WIRE IDENT 0-JA-N
WIRE IDENT 61A-F
TRINARY PRESS SW INPUT
2
18N-A
BLOWER MOTOR FUSED PWR
3
49A
BACK LIGHT POWER
4
61B-A
AC SIGNAL
CIRCUIT HOOD GROUNDS (NA)
2
44A-EN
BRAKE LIGHT RELAY OUT
3
45L-BN
LEFT TURN SIGNAL
4
45R-BN
RIGHT TURN SIGNAL
CIRCUIT
CONNECTOR HVAC2 - HVAC2
5
18G-JN
RH POSITION/TAIL FUSED PWR
6
18F-BN
LH POSITION/TAIL FUSED PWR
7
35A-HN
BACKUP ALARM RELAY OUT
HN1, HORN PWR CAV 1
WIRE IDENT 64
CIRCUIT HORN POWER
HN2, HORN GRND CAV 1
WIRE IDENT 0-AF
87552622
CIRCUIT CAV
HORN GND
WIRE IDENT
CIRCUIT
1
18N-B
BLOWER MOTOR FUS PWR
2
0-ED
HVAC GROUNDS
CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER
194788A1
CAV
WIRE IDENT
CIRCUIT
A
36H
HYDR. OIL TEMP SIGNAL
B
0-HW
HYDR. OIL TEMP GROUND
84547255A
Issued 11-11
Printed in E.C.
4002-68 CONNECTOR ISS - INT-SPEED-SENSOR
JSS CAB
225389C1
291718A1
CAV
WIRE IDENT
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
1
25B
INT SPEED SIGNAL
1
CANS-LP
CAN LOW,CAN MOD3
2
0-HG
INT SPEED SENSOR GROUND
2
17P-C
B+, CAN MOD
4
51D-A
GRND, RELAY CTRL
5
51B-C
JSS ACT SW
6
CAN-LR
CAN LOW, CAN MOD2
7
CAN-HR
CAN HI,CAN MOD3
8
0-BBD
JOYSTICK GROUND
9
51PW-N
JSS POWER
10
51C-A
JSS ACT BTN
11
18S-C
B+, JSS FUSED
12
CAN-HP
CAN HI,CAN MOD2
JSS ARM, JSS ARMREST TO CAB
JSS CONTROLLER CAV 1
WIRE IDENT
CANS-HD
CIRCUIT CAN HI, CAN MOD3
2
CANS-LD
CAN LO, CAN MOD3
3
17P-F
B+, JSS CONTROLLER
4
51H-B
JOYSTICK SIGNAL
5
51S-A
JSS OKAY PWR
CIRCUIT
6
51E-A
ARMREST LOWER
51L-A
JOYSTICK SIGNAL
W230R400
CAV
WIRE IDENT
1
CANS-HA
CAN HI, CAN MOD2
7
2
0-SH
GRND, CAN MOD
8
51K-B
PILOT PRESS SW
3
51E-B
ARMREST LOWER
9
51PW-Q
JSS POWER
4
17P-E
B+, CAN MODULE
10
0-SM
GRND, JOYSTICK
0-SN
GRND, JOYSTICK
6
51B-J
JSS ACT SW
11
7
0-SC
GRND, JOYSTICK
12
51J-B
VALVE ALARM
8
51PW-S
JSS POWER
13
51C-B
JSS ACT BTN
9
51S-C
JSS OKAY PWR
14
51NO-A
NO NEUTRAL SW
0-SR
GRND, JOYSTICK
51F-B
LS PRESS SW
10
51H-C
JOYSTICK SIGNAL
15
11
51NO
NO NEUTRAL SW
16
12
CANS-LA
CAN LO, CAN MOD2
84547255A
Issued 11-11
Printed in E.C.
4002-69 JSS PILOT PRESSURE
JSS FRAME TO CAB CAV
WIRE IDENT
CIRCUIT
A
51F-A
LS PRESS SW SIG
A
51F-C
LS PRESS SW SIG
B
51J-C
JSS ALARM
C
51K-C
PILOT PRESS SW SIG
D
51L
JOYSTICK SIGNAL
F
51S-J
JSS OKAY PWR
G
0-AS
GRND, JOYSTICK
H
51PW-H
JSS POWER
CAV
J
18S-E
B+, JSS FUSED
A
18S-E
B+, JSS FUSED
B
51K-C
PILOT PRESS SW SIG
245483C1
WIRE IDENT
CIRCUIT
JSS LOAD SENSE RLY, RELAY K2
245483C1
CAV
WIRE IDENT
CIRCUIT
A
51PW-J
JSS POWER
B
51F-A
LS PRESS SW SIG
245731C1
CAV
JSS PILOT DUMP CAV
WIRE IDENT
CIRCUIT
1
51PW-K
JSS POWER
2
0-AU
GRND, PILOT DUMP
84547255A
WIRE IDENT
CIRCUIT
30
51PW-P
JSS POWER
85
51D-B
GRND, RELAY CNTL
86
51B-E
B+, JSS
87
51B-G
B+, JSS
87A
0-SL
GROUND
Issued 11-11
Printed in E.C.
4002-70 JSS 197F, MAIN CAB FNR
JSS VALVE, JSS HYD VALVE
225350C1
CAV
WIRE IDENT
239451A1
CIRCUIT
1
0-SS
GRND, JOYSTICK
2
26F-D
FNR FORWARD SIGNAL
CAV
3
26N-D
FNR NEUT SIGNAL
4
26R-D
FNR REVERSE SIGNAL
5
32J-G
TRANS ENABLE INDICTION
6
25Y-F
TRANS KICK DOWN SIGNAL
WIRE IDENT
CIRCUIT
1
51L
JOYSTICK SIGNAL
2
51J-C
JSS ALARM
3
0-AT
GRND, JSS VLV
4
51S-J
JSS OKAY PWR
KD DIODE, DIODE ASSY JSS 197M, FNR-MAIN CAB
245485C1
CAV A 225351C1
CAV
WIRE IDENT
CIRCUIT
1
19B-A
FNR SW FUSED PWR
2
26F-C
FNR FORWARD SIGNAL
3
26N-C
FNR NEUT SIGNAL
4
16R-C
FNR REVERSE SIGNAL
5
32J-F
TRANS ENABLE INDICTION
6
25Y-D
TRANS KICK DOWN SIGNAL
84547255A
WIRE IDENT 25Y-F
CIRCUIT TRANS KICK DOWN SIGNAL
B
25Y-E
TRANS KICK DOWN SIGNAL
C
25Y-D
TRANS KICK DOWN SIGNAL
KWCO, WIPER CUT OUT CAV
WIRE IDENT
CIRCUIT
30
63L-B
FNT WPR LS RLY OUT
85
63HC-A
WPR CUT OUT RLY CTRL
86
19J-G
WPR CUT OUT RLY FSD PWR
87A
63C3
FNT WPR PARK CTRL
Issued 11-11
Printed in E.C.
4002-71 LDM3, DOME LIGHT GND
LLR, LH REAR COMB. LT CAV
WIRE IDENT
CIRCUIT
1
0BR-N
LH REAR LIGHT GND (NA)
2
44A-FN
BRK LT RLY OUT
3
18F-BN
LH POSN/TAIL FUSED PWR
4
45L-BN
LEFT TURN SGNL
CAV 1
WIRE IDENT 0-MB
CIRCUIT DOME LIGHT GND
LLF, LIGHTS LH
LLR, RH REAR COMB. LT CAV
WIRE IDENT
CIRCUIT
1
0BT-N
RH REAR LIGHT GND (NA)
2
44A-GN
BRK LT RLY OUT
3
18G-CN
RH POSN/TAIL FUSED PWR
4
45R-BN
RIGHT TURN SGNL 225351C1
L1 ECC, ECC BATT PWR CAV
WIRE IDENT
CIRCUIT
CAV
WIRE IDENT
CIRCUIT
1
0-AJ
LH FRONT LIGHTS GND
2
18D
LH LOW BEAM FUSED PWR
18B
LH HIGH BEAM FUSED PWR
1
1-C
ECC BAT PWR
3
1
ECC-L1
BEACON/DOME LT LI ECC
4
18F
LH POSN/TAIL FUSED PWR
5
45L
LEFT TURN SGNL
LBEGRD, LIGHT BEACON GRND CONNECTOR LLFW - LH FRONT WORK LAMP CAV 1
WIRE IDENT 0-MC
CIRCUIT BEACON LIGHT GND
LBEPWR, LIGHT BEACON PWR CAV 1
WIRE IDENT 46-D
CIRCUIT BEACON SW PWR 245483C1
LDM1, DOME LIGHT B+ CAV 1
WIRE IDENT 19U-C
CIRCUIT DOME LT FSD PWR
CAV
WIRE IDENT
CIRCUIT
1
42C-H
LH FRONT WORK LTS FUSE PWR
2
0-MU
LH FRONT WORK LIGHT GND
LDM2, DOME LIGHT AUTO CAV 1
WIRE IDENT 43-B
84547255A
CIRCUIT DOME LT AUTO MODE
Issued 11-11
Printed in E.C.
4002-72 CONNECTOR LLRW- LH REAR WORK LAMP
CONNECTOR LPL - LICENSE PLATE LAMP
245483C1
CAV
WIRE IDENT
CIRCUIT
245482C1
CAV
1
42R-H
LH REAR WORK LTS FUS PWR
2
0-ME
LH REAR WORK LIGHT GRND
CONNECTOR LLR-E - LH REAR COMBINATION LAMP
WIRE IDENT
CIRCUIT
A
18G-E
LICENSE PLATE LAMP FUSED PWR
A
18G-EN
LICENSE PLATE LAMP FUSED PWR
A
18G-L
LICENSE PLATE LAMP FUSED PWR
B
0-JC
LICENSE PLATE LAMP GRND
CONNECTOR LRF - RH FRONT COMBINATION LAMP
225351C1
CAV
WIRE IDENT
CIRCUIT
1
44A-E
BRAKE LIGHT RELAY OUT
2
45L-A
LEFT TURN SIGNAL
3
18F-B
LEFT POSN/TAIL FUSED POWER
4
35A-L
REVERSE LT
CAV
LH REAR LIGHT GROUND (EURO)
1
0-AH
RH FRONT LIGHTS GROUND
2
18E
RH LOW BEAM FUSED PWR
NOT USED
3
18C
RH HIGH BEAM FUSED PWR
4
18G-A
RH POSIT/TAIL FUSED PWR
5
45R
RIGHT TURN SIGNAL
5
0-BT
6
225351C1
6
84547255A
WIRE IDENT
CIRCUIT
NOT USED
Issued 11-11
Printed in E.C.
4002-73 CONNECTOR LRFO - FRONT WORK LAMP OPT
CONNECTOR LRFW - RH FRONT WORK LAMP
245483C1
CAV
WIRE IDENT
CIRCUIT
245483C1
CAV
1
42R-K
RH FRONT WORK LAMP FUSED PWR
2
0-MP
RH FRNT WORK LAMP GRND
CONNECTOR LRFR - FRONT WORK LAMP OPT
WIRE IDENT
CIRCUIT
1
42C-G
RH FRONT WORK LAMP FUSED PWR
2
0-MJ
RH FRONT WORK LAMP GRND
CONNECTOR LRRW- RH REAR WORK LAMP
245483C1 245483C1
CAV
WIRE IDENT
CIRCUIT
CAV
1
42R-B
RH FRONT WORK LAMP FUSED PWR
2
0-ML
RH FRNT WORK LAMP GRND
WIRE IDENT
CIRCUIT
1
42R-G
RH REAR WORK LAMP FUSED PWR
2
0-MF
RH REAR WORK LAMP GRND
CONNECTOR LRFS- FRONT WORK LAMP OPT
245483C1
CAV
WIRE IDENT
CIRCUIT
1
42R-A
RH FRONT WORK LAMP FUSED PWR
2
0-MG
RH FRONT WORK LAMP GRND
84547255A
Issued 11-11
Printed in E.C.
4002-74 CONNECTOR LRR-E - RH REAR COMBINATION LAMP
NOXS, NOX SENSOR CAV
WIRE IDENT
CIRCUIT
1
23A-A
DNOX2 MODULE B+
2
23D-D
NOX SENSOR GND
3
CAN-LU
CAN2 LO, NOX
4
CAN-HU
CAN2 HI, NOX
NTRL DIODE, DIODE ASSY 225351C1
CAV
WIRE IDENT
CIRCUIT
1
44A-F
2
45R-A
RIGHT TURN SIGNAL
3
18G-J
RIGHT POSITION/TAIL FUSED PWR
4
35A-K
REVERSE LAMP
5
0-BR
RH REAR LIGHT GND (EURO)
6
BRAKE LIGHT RELAY OUT
245485C1
CAV
NOT USED
A
CONNECTOR LSPK - LEFT SPEAKER
WIRE IDENT 26N-D
CIRCUIT FNR NEUT SIGNAL
B
26N-E
FNR NEUT SIGNAL
C
26N-C
FNR NEUT SIGNAL
CONNECTOR OSS - OUTPUT SPEED SENSOR
195552A1
CAV
WIRE IDENT
CIRCUIT
A
65L
LEFT SPEAKER
B
0-PA
LEFT SPEAKER GROUND
MON, CAMERA/MONITOR
291719A1
CAV CAV
WIRE IDENT
CIRCUIT
1
66A
RR CAMERA PWR
2
0-K
CAMERA GND
3
35A-M
REVERSE SIGNAL
84547255A
WIRE IDENT
CIRCUIT
1
0-HE
OUTPUT SPEED GROUND
2
25D
OUTPUT SPEED SIGNAL
3
19A
OUTPUT SPEED SENSOR FUSED PWR
Issued 11-11
Printed in E.C.
4002-75 CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH
CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH
222136A1 291718A1
CAV
WIRE IDENT
CAV
CIRCUIT
1
31F
AIR FILTER RESTRICTION SWITCH SIGNAL
2
0-BY
AIR FILTER RESTRICTION SWITCH GRND
WIRE IDENT
CIRCUIT
1
1-AA
BRAKE LAMP SWITCH PWR
2
44
BRAKE LAMP CONTR PWR
CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH P A1, B+ POWER CAV 1
WIRE IDENT 1-C
CIRCUIT ECC BAT PWR
P A3, B+ POWER CAV 1
WIRE IDENT 1CB-A
CIRCUIT CAB CB PROTECTED PWR
225316C1
CAV
CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH
WIRE IDENT
CIRCUIT
1
33P
LOW BRAKE PRESS WARNING
2
0-AL
BRAKE PRESS WARN SW GROUND
P C1, B+ PWR FRM PRMD CAV
WIRE IDENT
CIRCUIT
1
1-BG
B+ PWR PRMC
1
1-NC
B+ PWR PRMC
245482C1
CAV
WIRE IDENT
CIRCUIT
A
19A-A
BRAKE DECLUTCH SW FUSED PWR
B
25G
BRAKE DECLUTCH SWITCH CONTROL
84547255A
P C2, B+ PWR FRM PRMD CAV 1
WIRE IDENT 1-E
CIRCUIT GRID HTR FUSE BAT PWR
Issued 11-11
Printed in E.C.
4002-76 P C3, B+ PWR FRM PRMD CAV 1
WIRE IDENT 1CB
CONNECTOR PO2 - POWER OUTLET
CIRCUIT CAB CB PROTECTED PWR
P C4, B+ PWR FRM PRMD CAV 1
WIRE IDENT 1-Z
CIRCUIT STRTR RLY BAT PWR
P C6, B+ PWR FRM PRMD CAV 1
WIRE IDENT 1-T
CIRCUIT
12176446
EVGT3 POWER
CAV A
12V-A
B
PHF, HYD OIL FILT RES SW
1
WIRE IDENT 31H
CIRCUIT 12V PWR TO OUTLET 2 NOT USED
C CAV
WIRE IDENT
0-EL
AUX POWER OUTLET 2 GND
CIRCUIT HYD FLTR REST SW SGNL
PRH, AC HIGH PRESS SW
PHF9, HYD FLTR RES SW CAV
WIRE IDENT
CIRCUIT
1
0-HR
HYD FLTR SW GRND
2
31-H9
HYD FLTR RST SW 9
CONNECTOR PO1 - POWER OUTLET
245483C1
CAV
WIRE IDENT
CIRCUIT
A
61A-D
AC SWITCH INPUT
B
61R-D
AC SWITCH OUTPUT
CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH
12176446
CAV A
WIRE IDENT 12V
B C
CIRCUIT 12V PWR TO OUTLET 1 NOT USED
0-EK
245483C1
AUX POWER OUTLET 1 GND CAV
84547255A
WIRE IDENT
CIRCUIT
A
33R-C
RDNT BRAKE ACCUMULATOR PRESS LOW
B
0-HM
RED BRAKE SW GROUND Issued 11-11
Printed in E.C.
4002-77 CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH
PRM A2, PRM SIGNAL CAV
WIRE IDENT
CIRCUIT
A
12ACC-C
PWR CONVERTER PRM CTRL PWR
B
0-EU
PWR CONVERTER RLY CTRL GND
CONNECTOR PRM-B1 - PRM SIGNAL 245483C1
CAV
WIRE IDENT
CIRCUIT
A
33R-B
RDNT BRAKE ACCUMULATOR PRESS LOW
B
0-HL
RED BRAKE SW GROUND
CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH 256340A1
CAV
WIRE IDENT
CIRCUIT
A
12ACC-B
ACC PRM CONTROL POWER
C
0-EC
ACC RELAY CONTROL GND
PRM C1, PRM SIGNAL 245483C1
CAV A B
WIRE IDENT 58 58-B
CAV
CIRCUIT
WIRE IDENT
CIRCUIT
RIDE CONTR SOLENOID PWR
A
13K-C
IGNITION SWITCH POWER
RIDE CONTR SOLENOID PWR
B
0-EB
IGNITION RELAY CTRL GND
PRM D1, PRM OUTPUT
PRM A1, PRM OUTPUT CAV
WIRE IDENT
CIRCUIT
A
18J-F
EDC7 FSD PWR
C
1-GA
FLTR HTR PWR
PRM D2, PRM SIGNAL 409084A1
CAV
WIRE IDENT
CIRCUIT
A
18U-A
DCU B+ NON DISCONNECTD
C
19L
PWR CONVERTER FSD PWR
84547255A
CAV
WIRE IDENT
CIRCUIT
A
28F
FUEL FLTR HTR RLY CTRL
B
31B
FILTER HEATER CONTROL
Issued 11-11
Printed in E.C.
4002-78 PRMB L1, B+ POWER CAV
WIRE IDENT
CS01
J11
CONNECTOR PXF - RTD
CIRCUIT BLWR MOTOR PWR
PRMB L2, B+ POWER CAV 1
WIRE IDENT 19S1
CIRCUIT SEC STRG PWR 245485C1
CAV
PVRES, JSS JOYSTICK CAV
WIRE IDENT
CIRCUIT
R
51S-E
JSS OKAY PWR
S
51PW-V
JSS POWER
T
51H-C
JOYSTICK SIGNAL
U
51NO
NO NEUTRAL SW
V
0-SC
GRND, JOYSTICK
W
51NC
NC NEUTRAL SW
WIRE IDENT
CIRCUIT
A
53B
RTD CTRL SIGNAL
B
0-AC
PROXIMITY SWITCH GROUND
C
53P-H
PILOT CONTROL RELAY OUT
CONNECTOR PXH - HEIGHT CONTROL RTT
CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH
245485C1
CAV A
WIRE IDENT 54B
HC-RTT CTRL SIGNAL
B
0-AA
PROXIMITY SWITCH GROUND
C
53P-J
PILOT CONTROL RELAY OUT
245485C1
CAV
WIRE IDENT
CONNECTOR PXM - RTD
CIRCUIT
A
51P-A
SECONDARY STEER HIGH PRESSURE
B
0-CC
SEC. STEER PRESS SWITCH GROUND
C
35X-A
SECONDARY STEER LOW PRESS SIG
CIRCUIT
245485C1
CAV
84547255A
WIRE IDENT
CIRCUIT
A
53B-A
RTD CONTROL SIGNAL
B
0-AM
RTD GROUND
C
53P-I
PILOT CONTROL RELAY OUT
Issued 11-11
Printed in E.C.
4002-79 CONNECTOR PXT - RTD
CONNECTOR RAD-J1 - RADIO POWER
245485C1
CAV
WIRE IDENT
CIRCUIT
A
53B-A
RTD CONTROL SIGNAL
B
0-AM
RTD GROUND
CAV
C
53P-I
PILOT CONTROL RELAY OUT
1
NOT USED
2
NOT USED
3
NOT USED
292497A1
R1, RESISTOR
4 CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
RAD3
5
CIRCUIT
12V FUSED PWR TO RADIO NOT USED
CS0
0-SP
GRND, JOYSTICK
6
CS0
51J-D
VALVE ALARM
7
RAD2
12V FUSED PWR TO RADIO
8
RAD1
RADIO GROUND
NOT USED
CONNECTOR RAD - RADIO POWER CONNECTOR RAD-J2 - SPEAKER
292495A1
CAV
WIRE IDENT
CIRCUIT
292501A1
1
NOT USED
CAV
2
NOT USED
1
RAD11
RIGHT SPEAKER
NOT USED
2
RAD10
RIGHT SPEAKER GROUND
12V FUSED PWR TO RADIO
3
RAD9
NOT USED
5
NOT USED
4
RAD8
NOT USED
6
NOT USED
5
RAD7
NOT USED
3 4
12V-HB
WIRE IDENT
CIRCUIT
7
12V-HA
12V FUSED PWR TO RADIO
6
RAD6
NOT USED
8
0-EN
RADIO GROUND
7
RAD5
LEFT SPEAKER
8
RAD4
LEFT SPEAKER GROUND
84547255A
Issued 11-11
Printed in E.C.
4002-80 CONNECTOR RAD-J3 - RADIO JUMPER
RFLG, FUEL SEND GRND CAV 1
WIRE IDENT 0-BU
CIRCUIT FUEL LEVEL SENDER GND
RFL.23, FUEL LEVEL SEND 411311A1
CAV
WIRE IDENT
CIRCUIT
1
RAD10
RIGHT SPEAKER GROUND
2
RAD8
NOT USED
3
RAD4
LEFT SPEAKER GROUND
4
RAD6
NOT USED
5
RAD1
RADIO GROUND
6
CAV
WIRE IDENT
CIRCUIT
A
36J
FUEL LEVEL ANALOG
B
0-BZ
FUEL LEVEL SENDER GND
ROOF, ROOF TO CAB CONNECTION
NOT USED
7
RAD3
12V FUSED PWR TO RADIO
8
RAD11
RIGHT SPEAKER
9
RAD9
NOT USED
10
RAD5
LEFT SPEAKER
11
RAD7
NOT USED
12
RAD2
12V FUSED POWER TO RADIO
A
0-MV
RH FRONT WORK LIGHT GND
13
NOT USED
B
0-MH
REAR WORK LIGHT GND
14
NOT USED
C
43-B
DOME LT AUTO MODE
D
19U-C
DOME LT FSD PWR
E
46-D
BEACON SW PWR
F
0-MN
ROOF GROUNDS
G
0-MK
ROOF GROUNDS
H
42C-F
FNT WRK LTS FUSE PWR
J
19K-D
REAR WPR MOTOR FSD PWR
K
68C-A
REAR WPR PARK CTRL
L
68L-A
REAR WPR SW PWR
M
0-EN
RADIO GND
N
12V-H
12V FUSED PWR TO RADIO
P
19U-F
DOOR SW FSD PWR
R
43S-B
DOOR OPEN SGNL
S
42R-F
REAR WRK LTS FUSE PWR
388708A1
CAV
CONNECTOR RECT - ENGINE COOLANT TEMPERATURE
WIRE IDENT
CIRCUIT
194788A1
CAV
WIRE IDENT
CIRCUIT
A
36C
RADIATOR COOLANT TEMP SIGNAL
B
0-BAE
EDC7 SENDER GROUND
RFL, FUEL SENDER CAV 1
WIRE IDENT 36F
84547255A
CIRCUIT FUEL LEVEL ANALOG
Issued 11-11
Printed in E.C.
4002-81 CONNECTOR RWM - REAR WIPER MOTOR
CONNECTOR RSPK - RIGHT SPEAKER
195552A1
CAV
WIRE IDENT
CIRCUIT
A
65R
RIGHT SPEAKER
B
0-PB
RIGHT SPEAKER GROUND
245715C1
CAV
WIRE IDENT
A
CONNECTOR RTHP - THROTTLE PEDAL
CIRCUIT NOT USED
B
68L-A
REAR WIPER SWITCH PWR
C
19K-D
REAR WIPER MOTR FUS PWR
D
68C-A
REAR WIPER PARK CONTROL
CONNECTOR RWMG - REAR WIPER MOTOR GROUND
225351C1
CAV 1
WIRE IDENT 21F-D
CIRCUIT EDC7 DIGITAL GROUND
2
NOT USED
3
NOT USED
3
24B-A
4 4
24R-A
5
THROTTLE SIGNAL
245480C1
NOT USED
CAV
THROTTLE POS. SENS GND
1
WIRE IDENT 0-MA
CIRCUIT REAR WIPER MOTOR GRND
NOT USED
5
24S-A
THROTTLE SUPPLY
6
24L-A
LOW IDLE SWITCH
CONNECTOR RWW - REAR WASHER
RVS DIODE, DIODE ASSY CAV
WIRE IDENT
CIRCUIT
A
26R-D
FNR REVERSE SIGNAL
B
26R-E
FNR REVERSE SIGNAL
C
16R-C
FNR REVERSE SIGNAL
3227856R1
CAV
84547255A
WIRE IDENT
CIRCUIT
1
68W-A
REAR WASHER PUMP
2
0-BL
REAR WASHER GROUND Issued 11-11
Printed in E.C.
4002-82 SAJ, FNR SWITCH CAV
WIRE IDENT
CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH
CIRCUIT
1
26R-F
FNR REVERSE SIGNAL
2
26K
FNR SWITCH JUMPER
3
26N-F
FNR NEUT SIGNAL
5
19B-E
FNR SW FUSED PWR
6
26F-F
FNR FORWARD SIGNAL
7
32J-J
TRANS ENABLE INDICTION
8
19B-F
FNR SW FUSED PWR
A
25Y-F 382391A1
CAV
CONNECTOR SBE - BEACON SWITCH
382391A1
CAV
WIRE IDENT
1
CIRCUIT
35R-C
BACKUP ALARM SWITCH
2
35A-B
BACKUP ALARM DISABLE SW
3
NOT USED
4
NOT USED
5
NOT USED
6
NOT USED
7
0-B21
BACK LIGHT GROUND
8
49-L
BACK LIGHT POWER
9
NOT USED
10
NOT USED
CIRCUIT NOT USED
2
19U-H
BEACON SWITCH FUS PWR
3
46-C
BEACON SWITCHED POWER
4
NOT USED
5
NOT USED
6
WIRE IDENT
1
CONNECTOR SC - SEAT COMPRESSOR MOTOR
NOT USED
7
0-B15
BACK LIGHT GROUND
8
49-B
BACK LIGHT POWER
9
NOT USED
10
NOT USED
245482C1
CAV
WIRE IDENT
CIRCUIT
A
19N
SEAT COMPRESSOR FUSED PWR
B
0-DK
SEAT COMPRESSOR MOTOR GROUND
SDA, DIFF LOCK SWITCH CAV 2
84547255A
WIRE IDENT
CIRCUIT
34A-A
DIFF LOCK SW B+
3
34B
DIFF LOCK SW SIG
7
0-B31
SDA GND
8
49-Z
BACK LIGHT PWR Issued 11-11
Printed in E.C.
4002-83 CONNECTOR SDC - DECLUTCH SWITCH
CONNECTOR SDR - DRIVING LIGHTS SWITCH
382391A1
CAV
WIRE IDENT
CIRCUIT
382391A1
CAV
WIRE IDENT
CIRCUIT
1
25G-B
BRAKE DECLUTCH SWITCH CONTROL
1
2
19A-R
DECLUTCH SW FUSED PWR
2
19Z-A
DRIVING LIGHTS SW FUSED PWR
3
22A
41T
POSITION LIGHTS SW PWR
DECLUTCH SW
3
4
NOT USED
4
5
NOT USED
6
NOT USED
NOT USED
NOT USED
5
19Z-B
DRIVING LIGHTS SWITCH FUSED POWER DRIVING LIGHTS POWER
7
0-B18
BACK LIGHT GROUND
6
41J
8
49-R
BACK LIGHT POWER
7
0-B19
BACK LIGHT GROUND
9
NOT USED
8
49-P
BACK LIGHT POWER
10
NOT USED
9
NOT USED
10
NOT USED
SDM, DIFF LOCK SWITCH CAV
WIRE IDENT
CIRCUIT
1
34D
DIFF LOCK SW SIG
2
34A-B
DIFF LOCK SW SIG B+
84547255A
Issued 11-11
Printed in E.C.
4002-84 CONNECTOR SFC - FAN CONTROL SWITCH
CONNECTOR SFNR - FNR SWITCH
382391A1
CAV
WIRE IDENT
1
CIRCUIT
382391A1
CAV
WIRE IDENT
CIRCUIT
NOT USED
1
26R-A
FNR REVERSE SIGNAL
2
52J
FAN CONTROL SW JUMPER
2
26J
FNR SWITCH JUMPER
3
52-AU
FAN REVERSE AUTO
3
26N-A
FNR NEUTRAL SIGNAL
4
52J
FAN CONTROL SW JUMPER
4
26J
FNR SWITCH JUMPER
5
19P-C
FAN REVERSE SWITCH FUSED PWR
5
19A-V
FNR SWITCH FUSED POWER
6
26F-A
FNR FORWARD SIGNAL
6
52M
FAN REVERSE MANUAL
7
32J-A
TRANS ENABLE INDICATION
7
0-B7
BACK LIGHT GROUND
8
19A-G
8
49-Q
BACK LIGHT POWER
9
NOT USED
10
NOT USED
FNR SWITCH FUSED POWER
9
NOT USED
10
NOT USED
CONNECTOR SFWW - FRONT WIPER AND WASHER SWITCH
CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH
87345132
382391A1
CAV
WIRE IDENT
CIRCUIT
1
55A-B
RTT/FLOAT SWITCH POWER
2
53P-B
PILOT CONTROL RELAY OUT
3
55A-C
RTT/FLOAT SWITCH POWER
4
0-29
RTT/FLOAT GROUND
5
55B
RTT FLOAT SW CONTROL
6
54B-C
HC-RTT CONTROL SIGNAL
7
0-B2
BACK LIGHT GROUND
8
49-K
BACK LIGHT POWER
9
NOT USED
10
NOT USED
84547255A
CAV
WIRE IDENT
1
CIRCUIT NOT USED
2
0-DT
FRONT WIPER/WASHER SW GND
3
63LC
FRNT WIP LS RELAY CONTR
19J-B
INT WIP/WAS SW FUSED PWR
4 5
NOT USED
6
NOT USED
7
63W
FRONT WASHER PUMP
8
49-T
BACK LIGHT POWER
9
63HC
FRONT WIPER HS RELAY CONTROL
10
NOT USED Issued 11-11
Printed in E.C.
4002-85 CONNECTOR SHC - HEIGHT CONTROL SWITCH
SJS, JOYSTICK CONTROL SW CAV
382391A1
CAV
WIRE IDENT
1 2
CIRCUIT
CIRCUIT
2
18S-B
B+, JSS FUSED
3
51B-A
JSS ACT SW
4
0-BBA
JOYSTICK GROUND
5
51C-A
JSS ACT BTN
6
51B-B
JSS ACT SW
7
0-BBB
JOYSTICK GROUND
8
49-W
JSS BACKLIGHT
9
0-BBE
JOYSTICK GROUND
10
51PW-N
JSS POWER
NOT USED 53P-D
PILOT CONTROL RELAY OUT
3
NOT USED
4
NOT USED
5
NOT USED
S KEY, IGNITION SWITCH CAV
CIRCUIT TIME DELAY/IGN SW FSD PWR
1DM
BACK LIGHT GROUND
2
21K
IGN SW START SIGNAL
13K
IGNITION SWITCH POWER
12ACC
IGNITION SW ACC POWER
54A
HC CONTROL SW PWR
7
0-B3
BACK LIGHT POWER
3
9
NOT USED
4
10
NOT USED
49-M
WIRE IDENT
1
6
8
WIRE IDENT
CONNECTOR SPB - PARKING BRAKE SWITCH CONNECTOR SHZ - HAZARD SWITCH
382391A1 382391A1
CAV
WIRE IDENT
1
CIRCUIT
CAV
WIRE IDENT
1
CIRCUIT NOT USED
NOT USED
2
19A-L
PARK BRK SW FUSED PWR
33U
PARK BRAKE SWITCH
2
1-KA
HAZARD SWITCH POWER
3
3
45H
HAZARD SWITCH POWER
4
NOT USED
4
NOT USED
5
NOT USED
5
NOT USED
6
NOT USED
6
NOT USED
7
0-B29
RTT/FLOAT GROUND
BACK LIGHT GROUND
8
49-V
BACK LIGHT POWER
BACK LIGHT POWER
9
NOT USED
9
NOT USED
10
NOT USED
10
NOT USED
7 8
0-B24 49-D
84547255A
Issued 11-11
Printed in E.C.
4002-86 CONNECTOR SPC - PILOT CONTROL SWITCH
CONNECTOR SPK - SPEAKER
382391A1
CAV
WIRE IDENT
1
292494A1
CIRCUIT NOT USED
CAV
65R
WIRE IDENT
RIGHT SPEAKER
CIRCUIT
2
0-PB
RIGHT SPEAKER GROUND
2
19C-F
PILOT CONTROL SW FUSED PWR
1
3
31L
PILOT CONTROL SW HIGH
3
NOT USED
4
NOT USED
4
NOT USED
5
NOT USED
5
NOT USED NOT USED
6
NOT USED
6
7
0-B1
BACK LIGHT GROUND
7
65L
LEFT SPEAKER
8
49-N
BACK LIGHT POWER
8
0-PA
LEFT SPEAKER GROUND
9
NOT USED
10
NOT USED
SPL ACP, ULTRASONIC
CONNECTOR SPE - PIN ENGAGE SWITCH
CAV
WIRE IDENT
CIRCUIT
A
61A-C
AC SWITCH INPUT
A
61A-D
AC SWITCH INPUT
A
61A
AC PRESS SW INPUT
SPL ACS, ULTRASONIC CAV
382391A1
CAV
WIRE IDENT
CIRCUIT
A
61R-C
AC SWITCH OUTPUT
A
61R-D
AC SWITCH OUTPUT
A
61R
AC RELAY CONTROL
CIRCUIT
1
57-B
PIN ENGAGE SOL PWR
2
19P-A
PIN ENGAGE SW FUS PWR
3
NOT USED
4
NOT USED
5
NOT USED
6
NOT USED
7
NOT USED
8
NOT USED
9
0-B5
BACK LIGHT GROUND
10
49-F
BACK LIGHT POWER
84547255A
WIRE IDENT
SPL AJ, ULTRASONIC CAV
WIRE IDENT
CIRCUIT
A
19B-C
FNR SW FUSED PWR
A
19B-D
FNR SW FUSED PWR
A
19B-E
FNR SW FUSED PWR
A
19B-F
FNR SW FUSED PWR
Issued 11-11
Printed in E.C.
4002-87 CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT GRND
CAV
WIRE IDENT
CIRCUIT
D
0-B4
BACK LIGHT GND
E
0-B5
BACK LIGHT GND
F
0-B6
CAB 2 GND
G
NOT USED
H
NOT USED
J
0-B20
BACK LIGHT GND
K
0-B29
RTT/FLOAT GND
L
0-B11
BACK LIGHT GND
M
0-B7
BACK LIGHT GND
SPL BCK LGT, SPLICE BACK LGHT PWR 87324393
CAV
WIRE IDENT
CIRCUIT
A
0-B13
BACK LIGHT GND
B
0-B14
BACK LIGHT GND
C
0-B15
BACK LIGHT GND
D
0-B6
CAB 2 GND
E
0-B17
BACK LIGHT GND
F
0-B18
BACK LIGHT GND
G
0-B19
H
BACK LIGHT GND NOT USED
J
0-B21
BACK LIGHT GND
K
0-DAP
BACK LIGHT GND
L
0-B23
BACK LIGHT GND
CAV
M
0-B32
BACK LIGHT GND
A
49
BACK LIGHT POWER
C
49-C
BACK LIGHT POWER
D
49-H
BACK LIGHT POWER
E
49-L
BACK LIGHT POWER
F
49A
BACK LIGHT POWER
G
49-P
BACK LIGHT POWER
H
49-R
BACK LIGHT POWER
J
49S
BACK LIGHT POWER
87324393
CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT GRND
WIRE IDENT
CIRCUIT
K
49-E
BACK LIGHT POWER
L
49-B
BACK LIGHT POWER
M
49-A
BACK LIGHT POWER
87324393
CAV
WIRE IDENT
CIRCUIT
A
0-B31
SDA GROUND
B
0-B2
BACK LIGHT GND
C
0-B3
BACK LIGHT GND
84547255A
Issued 11-11
Printed in E.C.
4002-88 SPL PED BL, SPL BACK LGT PWR 6 PCK
CONNECTOR SPL-PED-BL-GD - SPL BACK LIGHT POWER 6 PACK
87324391
CAV A
WIRE IDENT 49-W
87324391
CIRCUIT JSS BACKLIGHT
CAV
0-B9
WIRE IDENT NOT USED
CIRCUIT
B
49-N
BACK LIGHT POWER
A
C
49-D
BACK LIGHT POWER
B
0-B1
BACK LIGHT GROUND
D
49-X
BACK LIGHT AIC
C
0-B24
BACK LIGHT GROUND
E
49-V
BACK LIGHT POWER
D
0-B30
NOT USED
BACK LIGHT POWER
E
0-B29
RTT/FLOAT GROUND
F
0-B11
BACK LIGHT GROUND
F
49-S
CONNECTOR SPL-HOOD-GND - HOOD GROUND 6 PACK
CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK
87324391
CAV
WIRE IDENT
87324391
CIRCUIT
A
0-B12
HOOD DOWN RELAY GRND
CAV
WIRE IDENT
CIRCUIT
B
0-B16
HOOD DOWN CONTR GRND
A
19P-A
PIN ENGAGE SW FUSED PWR
19P
PIN ENGAGE/FAN FUS PWR
19P-C
RAN REVERSE SW FUS PWR
C
0-B22
HOOD UP RELAY GROUND
B
D
0-B25
HOOD UP CONTR GRND
C
E
0-B10
HOOD GROUND
D
NOT USED
E
19P-D
FAN REV RELAY FUS PWR
F
19P-E
FAN REV RELAY FUS PWR
F
84547255A
NOT USED
Issued 11-11
Printed in E.C.
4002-89 SPL PK1, SPLICE 3-4 WAY
CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY
87324462
CAV
WIRE IDENT
CIRCUIT
87324462
CAV
WIRE IDENT
CIRCUIT
J
18K-D
DIAG FUSED B+
A
45L-E
LEFT TURN SIGNAL
K
18K-A
DIAGNOSTIC FUSED PWR
B
45L-D
LEFT TURN SIGNAL
L
18K-B
DIAG FUSED B+
C
45L-C
LEFT TURN SIGNAL
D
45L-B
LEFT TURN SIGNAL
E
45R-C
RIGHT TURN SIGNAL
F
45R-E
RIGHT TURN SIGNAL
G
45R-D
RIGHT TURN SIGNAL
H
45R-B
RIGHT TURN SIGNAL
J
19J-B
FRONT WIPER/WASHER SW FUSED PWR
K
19J-C
FRONT WIPER RLY FUSED POWER
L
19J-D
FRONT WIPER RELAY FUSED POWER
M
19J-F
FRONT WIPER RLY LS CTRL FUSED POWER
SPL BCK LGT2, SPL BACK LGT PWR
87324462
CAV A
WIRE IDENT
SPL ROOF, SPLICE ROOF GROUND
CIRCUIT
49-E
BACK LIGHT POWER
CAV
B
49Y-A
BACK LIGHT POWER
A
C
49-J
BACK LIGHT POWER
B
0-MB
DOME LIGHT GND
D
49-M
BACK LIGHT POWER
C
0-MA
REAR WIPER MOTOR GND
E
49-K
BACK LIGHT POWER
D
0-MN
ROOF GROUNDS
F
49-F
BACK LIGHT POWER
E
0-MK
ROOF GROUNDS
G
49-Q
BACK LIGHT POWER
J
49-Z
BACK LIGHT POWER
H
49-T
BACK LIGHT POWER
K
49-G
BACK LIGHT POWER
M
49-S
BACK LIGHT POWER
84547255A
WIRE IDENT 0-MC
CIRCUIT BEACON LIGHT GND
Issued 11-11
Printed in E.C.
4002-90 CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER
CONNECTOR SRC - RIDE CONTROL SWITCH
382391A1
CAV
WIRE IDENT
1 87324393
CAV
WIRE IDENT
CIRCUIT
A
19A-N
TRANS FUSED POWER
B
19A-F
TRANS ENABLE SWITCH FUSED PWR
CIRCUIT NOT USED
2
19C-D
RIDE CTRL SW FUSED PWR
3
58C
RIDE CTRL SWITCH JUMPER
4
58T
RIDE CTRL RELAY SW PWR
5
58C
RIDE CTRL SWITCH JUMPER
58-F
RIDE CTRL SOLENOID PWR
C
19A-Q
TRANS/AUTO SWITCH FUSED PWR
6 7
0-B20
BACK LIGHT GROUND
D
19A-T
BRAKE DECLUTCH SW FUSED PWR
8
49-G
BACK LIGHT POWER
E
19A-W
DIAGN CONN. FUSED PWR
F
19A-C
FNR SWITCH FUSED PWR
G
19A-P
BACKUP ALARM RLY
H
19A-R
DECLUTCH SW FUSED PWR
J
19A-K
TECM FUSED PWR
K
19A-M
OUTPUT SPEED SENSOR FUSED PWR
L M
9
NOT USED
10
NOT USED
CONNECTOR SRC-1 - STARTER RELAY
NOT USED 19A-H
TRANS SHIFTER FUSED PWR
225316C1
CAV
84547255A
WIRE IDENT
CIRCUIT
1
21D
STARTER RELAY SIGNAL
2
0-GB
STARTER RELAY CONTROL GROUND
Issued 11-11
Printed in E.C.
4002-91 CONNECTOR SRHSTLK - RH STALK SWITCH
CONNECTOR SRWP - REAR WIPER SWITCH
382391A1
CAV
WIRE IDENT
CIRCUIT
1
68C
REAR WIPER PARK CONTROL
2
68L
REAR WIPER SW PWR
3
19K-A
REAR WIPER SW FUSED PWR
87318288
CAV
WIRE IDENT
CIRCUIT
31b
64C
HORN RELAY CONTROL
49a
19B
TURN SIGNAL FUSED POWER
56a
41H-A
HIGH BEAM POWER
56b
41L-A
LOW BEAM POWER
56d
19Z-C
HIGH BEAM FLASH FUS PWR
31
0-EP
HORN SWITCH GROUND
56
41J
DRIVE LIGHTS POWER
L
45A-A
LEFT TURN SWITCH POWER
R
45B-A
RIGHT TURN SWITCH POWER
4
NOT USED
5
19K-B
REAR WIPER SW FUSED PWR
6
68W
REAR WASHER PUMP
7
0-B23
BACK LIGHT GROUND
8
49-C
BACK LIGHT POWER
9
NOT USED
10
NOT USED
SSD, SEC STR DIODE CONNECTOR SRTD - DETENT SWITCH
245485C1
CAV 382391A1
CAV
WIRE IDENT
1
CIRCUIT
WIRE IDENT
CIRCUIT
A
0-CH
SEC STR FLYBACK GND
B
0-CG
SEC STR FLYBACK GND
C
51-D
SEC STR FLYBACK
NOT USED
2
53P-E
PILOT CONTROL RELAY OUT
3
53A
RTD SWITCHED POWER
4
NOT USED
5
NOT USED
6
NOT USED
7
0-B4
8
49-J
BACK LIGHT GROUND BACK LIGHT POWER
9
NOT USED
10
NOT USED
84547255A
Issued 11-11
Printed in E.C.
4002-92 CONNECTOR SS-TR - SS-MOD-TRANS
CONNECTOR SSM - SECONDARY STEERING MODULE
245489C1
CAV
225389C1
CAV
WIRE IDENT
CIRCUIT
1
19R-C
SEC. STEERING IGNITION FUSED PWR
2
51-A
SECOND STEER MOTOR CONTR
3
19S1-X
SECONDY STEER FUS PWR
4
0-CE
SECONDY STEER CHASSIS GRND
5
NOT USED
6
NOT USED
7
19M-C
SECONDARY STEER ACC FUSED PWR
8
35X-D
SECOND STEER LOW PRESS SIG
9
51P-A
SECONDARY STEER HIGH PRESS
10
WIRE IDENT
CIRCUIT
A
19M-C
B
19R-C
SEC. STR IGNIT FUS PWR
35X-C
SEC. STR LOW PRESS SIGNAL
C D
SEC. STR ACCESS FUS PWR
NOT USED
E
19S1-X
F
SEC. STR FUSED POWER NOT USED
CONNECTOR STA - TRANSMISSION AUTO SWITCH
NOT USED
11
0-CA
SECONDARY STEER SIGNAL GRND
12
0-CB
SECONDARY STEER SIGNAL GRND
SSS, SS MAG SWITCH CAV
WIRE IDENT
382391A1
CAV
WIRE IDENT
1
CIRCUIT NOT USED
2
19A-Q
TRANS AUTO SW FUS PWR
3
25H
TRANS AUTO SIGNAL
4
NOT USED
CIRCUIT
5
NOT USED NOT USED
1
51-D
SEC STR FLYBACK
6
1
51-B
SEC STR MOTOR CTRL
7
0-B17
BACK LIGHT GROUND
8
49S
BACK LIGHT POWER
84547255A
9
NOT USED
10
NOT USED
Issued 11-11
Printed in E.C.
4002-93 CONNECTOR STE - TRANSMISSION ENABLE SWITCH
CONNECTOR SWL - WORK LIGHTS SWITCH
382391A1 382391A1
CAV
WIRE IDENT
1
CIRCUIT
CAV
WIRE IDENT
1
CIRCUIT NOT USED
NOT USED
2
42-A
WORK LIGHTS FUSED PWR
3
42C-C
FR WORK LIGHTS FUSE PWR
2
19A-D
TRANS ENABLE SW FUSED POWER
3
26E-A
TRANS ENABLE SIGNAL
4
NOT USED
5
NOT USED
6
NOT USED
7
0-DAP
BACK LIGHT GROUND
8
49-H
BACK LIGHT POWER
9
32J-C
TRANS ENABLE INDICTION
10
19A-E
AIC FUSED PWR
4
NOT USED
5
42-B
WORK LIGHTS FUS PWR
6
42RC
RE WORK LIGHTS FUSE PWR
7
0-B14
BACK LIGHT GROUND
8
49-A
BACK LIGHT POWER
9
NOT USED
10
NOT USED
STTR GRN, GRID HTR FUSE CAV 1
WIRE IDENT 0-NC
84547255A
CIRCUIT BATTERY DISCONNECT
Issued 11-11
Printed in E.C.
4002-94 CONNECTOR SW-PD - SWITCH PAD
CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER
291718A1 87552623
CAV 1
WIRE IDENT 41H-D
2 3
CIRCUIT HIGH BEAM POWER NOT USED
49-X
BACK LIGHT AIC
4
31H-A
HYDRAULIC FILTER REST SW SIGNAL
5
31F-A
AIR FILTER REST SWITCH SIGNAL
6
CAV
WIRE IDENT
CIRCUIT
1
36G
TCO TEMPERATURE SIGNAL
2
36R-D
TCO TEMPERATURE RETURN
NOT USED
7
CAN-HF
CAN HIGH
8
CAN-LF
CAN LOW
9
17P-A
SWITCH PAD PWR FROM AIC PWR
10
0-B28
SWITCH PAD GROUND
84547255A
Issued 11-11
Printed in E.C.
4002-95 TECM, TRANS
CAV
411398A1
CAV 1
WIRE IDENT 0-DP
CIRCUIT DIAG TECM GND
WIRE IDENT
CIRCUIT
20
26F-B
FNR FORWARD SIGNAL
21
22A
DECLUTCH SW
22
25Y-A
TRANS KICK DOWN SIGNAL
23
19T-A
FUSED BATT PWR
24
22D
PEDAL SENSOR GRND
25
CAN-HD
CAN HIGH
26
CAN-LD
CAN LOW
29
25H
TRANS AUTO SIGNAL
30
26R-B
FNR REVERSE SIGNAL
31
26E-A
TRANS ENABLE SIGNAL
32
25M-A
TRANS SOL VALVE Y3
35
34B
DIFF LOCK SW SIG
37
22B
PEDAL SENSOR +5V
38
22C
PEDAL POS SIGNAL
39
36T-A
VALVE BODY TEMP SGNL
41
25C-A
TURBINE SP SIGNAL
42
25B-A
INT SP SIGNAL
43
25F
FORWARD SIGNAL
44
26N-B
FNR NEUT SIGNAL
45
19A-K
TECM FUSED PWR
46
36R-E
TRANS TEMPS/FLTR RETURN
49
36G-A
TCO TEMP SIGNAL
50
25R-A
TC LOCKUP SOL POWER
51
25J-A
TRANS SOL VALVE Y6
53
58H-B
POWER VPSL
55
25N-A
TRANS SOL VALVE Y4
56
25K-A
TRANS SOL VALVE Y1
57
58L
RIDE CTRL RLY LSD
59
34D
DIFF LOCK SW SIG
62
25D-A
OUTPUT SP SIGNAL
63
25Z
1ST AND 4TH GEAR SIGNAL
2
0-DQ
DIAG TECM GND
3
0-DM
SPEED SENSOR GNDS
4
0-DN
OUTPUT SPEED SENSOR GND
64
25R
REVERSE SIGNAL
5
32J-D
TRANS ENABLE INDICTION
65
25W
3RD AND 4TH GEAR SIGNAL
7
35C
BACK UP ALRM CNTL
66
25G-C
BRK DECLUTCH SW CTRL
8
58H-A
POWER VPS2
67
25T-C
NEUTRAL SIGNAL
68
19T-B
FUSED BATT PWR
9
25P-A
TRANS SOL VALVE Y5
10
25L-A
TRANS SOL VALVE Y2
11
34C
DIFF LOCK SOL GND
12
25S-B
OUTPUT SW PWR VPS1
13
25S-C
OUTPUT SW PWR VPS1
15
37D-A
DIAGNOSTIC SGNL
17
32F-A
TRANS FLTR MAINT SW
18
37E
DIAGN SGNL SWITCHED
19
25A-A
ENG SP SIGNAL
84547255A
Issued 11-11
Printed in E.C.
4002-96 TERM CAN 2, CAN BULK HEAD
TRANS, TRANSMISSION-CAB
380838A1
CAV
87315267
CAV
WIRE IDENT
CIRCUIT
WIRE IDENT
CIRCUIT
1
33R-A
RDNT BRK ACC PRESS LOW
2
34C-A
DIFF LOCK SOL GND
3
19M-A
SEC STR ACCESS FSD PWR
4
19R-A
SEC STR IGN FSD PWR
5
36T
VALVE BODY TEMP SGNL
A
CAN-L2
CAN 2 LO, TERM
6
35X-B
SEC STR LOW PRESS SGNL
A
CAN-LV
CAN2 LO, TERM
7
25A
ENG SP SIGNAL
B
CAN-H2
CAN2 HI, TERM
8
25C
TURBINE SP SIGNAL
B
CAN-HV
CAN2 HI, TERM
9
25B
INT SP SIGNAL
10
25D
OUTPUT SP SIGNAL
11
0-HD
SPEED SENSOR GNDS
12
36R-A
TRANS TEMPS/FLTR RETURN
13
36G
TCO TEMP SIGNAL
14
25G
BRK DECLUTCH SW CTRL
15
25R-B
TC LOCKUP SOL POWER
16
25K
TRANS SOL VALVE Y1
16
25K-9
TRANS SOL VALVE Y2
17
25L-9
TRANS SOL VALVE Y1
17
25L
TRANS SOL VALVE Y2
18
25M
TRANS SOL VALVE Y3
19
25N
TRANS SOL VALVE Y4
20
25P
TRANS SOL VALVE Y5
THV, TANK HEATER CONTROL VALVE
371614A1
CAV
WIRE IDENT
CIRCUIT
1
38C
TANK HEAT GND
2
38D
TANK HEAT B+
84547255A
21
25J
TRANS SOL VALVE Y6
22
25S
OUTPUT SW PWR VPS1
23
31H
HYD FLTR REST SW SGNL
23
31H9
HYD FLTR REST SW9
24
19A-A
BRAKE DECLUTCH SW FSD PWR
25
24T-B
TC LOCKUP SOL GND
26
19S1-E
SEC STR FSD PWR
27
34A-D
DIFF LOCK SOL B+
28
0-HE
OUTPUT SPEED SENS GND
29
19A
OUTPUT SP SENS FSD PWR
30
36H
HYDRAULIC OIL TEMP
31
32F
TRANS FLTR MAINT SW
Issued 11-11
Printed in E.C.
4002-97 CONNECTOR TRC - TRANSMISSION CONTROL
CONNECTOR TR-SS - SEC-STR-MOD-OPT
245488C1 371566A1
CAV
WIRE IDENT
CIRCUIT
CAV
SEC. STEER ACC FUS PWR
B
19R-A
SEC. STEERING IGNITION FUSED PWR
TRANS SOLENOID VALVE Y2
C
35X-B
25K
TRANS SOLENOID VALVE Y1
1
25L-9
TRANS SOLENOID VALVE Y1
2
25K-9
2
25L
TRANS SOLENOID VALVE Y2
D
3
25M
TRANS SOLENOID VALVE Y3
E
4
25N
TRANS SOLENOID VALVE Y4
F
5
25P
TRANS SOLENOID VALVE Y5
6
25J
TRANS SOLENOID VALVE Y6
7
25S
OUTPUT SW POWER VPS1
8
36T
VALVE BODY TEMP SIGNAL
9
36R-C
VALVE BODY TEMP RETURN
10
NOT USED
11
NOT USED
12
NOT USED
13
NOT USED
14
NOT USED
15
NOT USED
16
NOT USED
SEC STR LOW PRESS SGNL NOT USED
19S1-E
SEC. STEER FUSED PWR NOT USED
CONNECTOR TS1 - TRANSMISSION SHIFTER
245486C1
CAV
84547255A
CIRCUIT
19M-A
1
A
WIRE IDENT
WIRE IDENT
CIRCUIT
A
19A-H
TRANS SHIFTER FUSED PWR
B
25F
FORWARD SIGNAL
C
25R
REVERSE SIGNAL
D
25T-B
NEUTRAL SIGNAL
Issued 11-11
Printed in E.C.
4002-98 CONNECTOR TS2 - TRANSMISSION SHIFTER
UBJ, DEF LEVEL TEMP
245487C1
CAV
WIRE IDENT
A
CIRCUIT
W230R399
CAV
WIRE IDENT
CIRCUIT
NOT USED
1
38B
DEF LEVEL SIG
B
25W
3RD AND 4TH GEAR SIGNAL
2
0-T
DEF SENSOR GND
C
25Z
1ST AND 4TH GEAR SIGNAL
3
38G
DEF TEMP SIG
D
25Y
TRANSMISSION KICK DOWN SIGNAL
UBJM, DEF LEVEL TEMP CONNECTOR TSS - TURBINE SPEED SENSOR
CAV
WIRE IDENT
CIRCUIT
1
38B-A
DEF LEVEL SIG
2
0-TA
DEF SENSOR GND
3
38G-A
DEF TEMP SIG
UTS, UPSTREAM TEMP SENSE CAV
WIRE IDENT
CIRCUIT
1
38F
EXHT UP SIGNAL
2
0E-A
EXHT TEMP UP GND
291718A1
CAV
WIRE IDENT
CIRCUIT
1
25C
TURBINE SPEED SIGNAL
2
0-HH
TURBINE SPEED SENS GRND
CONNECTOR WIF - WATER IN FUEL SENSOR
8602416
CAV 1
84547255A
WIRE IDENT 35W
CIRCUIT WIF INDICATOR
2
0-BP
WIF SENSOR GROUND
3
13M-C
WIF SENSOR FUSED PWR
Issued 11-11
Printed in E.C.
4002-99 CONNECTOR WSH - WATER SEPARATOR HEATER
CONNECTOR YFN - FNA PWM SOLENOID
256340A1
182069A1
CAV
WIRE IDENT
CAV
CIRCUIT
A
0-BW
WATER SEPARATOR HEATER GROUND
B
1-GC
WATER SEPARATOR HEATER POWER
WIRE IDENT
CIRCUIT
A
56-A
FAN CONTROL PWM
B
0-BQ
FAN SPEED PWM SOLEN GND
CONNECTOR YFR - FAN REVERSING SOLENOID OPT YDL, DIFF LOCK SOLENOID CAV
WIRE IDENT
CIRCUIT
1
34A-D
DIFF LOCK SOL B+
2
34C-A
DIFF LOCK SOL GND
YDL 1, DIFF LOCK SOLENOID 225316C1
CAV
WIRE IDENT
CIRCUIT
1
52A-B
FAN REVERSING RELAY OUT
2
0-BB
FAN REVERSING SOLEN GND
YLS, TC LOCKUP VALVE 225315C1
CAV
WIRE IDENT
CIRCUIT
1
34A-E
DIFF LOCK SOL B+
2
34C-D
DIFF LOCK SOL GND
CAV
WIRE IDENT
CIRCUIT
1
25R-B
TC LOCKUP SOL POWER
2
24T-B
TC LOCKUP SOL GND
YDL 2, DIFF LOCK SOLENOID CAV
WIRE IDENT
CIRCUIT
1
34A-E
DIFF LOCK SOL B+
2
34C-D
DIFF LOCK SOL GND
84547255A
Issued 11-11
Printed in E.C.
4002-100 YPE2, PIN ENGAGE OPT
CONNECTOR YPB - PARKING BRAKE SOLENOID
245482C1
CAV 291718A1
CAV
WIRE IDENT
CIRCUIT
1
52P
PARKING BRAKE RELAY OUT
2
0-AN
PARK BRAKE SOLEN GND
WIRE IDENT
CIRCUIT
A
57-D
PIN ENGAGE SOL PWR
B
0-AW
PIN ENGAGE GND
CONNECTOR YPP - PILOT PRESSURE SOLENOID
CONNECTOR YPE - PIN ENGAGE OPT
245482C1
CAV 245482C1
CAV
WIRE IDENT
CIRCUIT
A
57
PIN ENGAGE SOLENOID PWR
B
0-AE
PIN ENGAGE GROUND
WIRE IDENT
CIRCUIT
A
53P-A
PILOT CONTROL RELAY OUT
B
0-DU
PILOT PRESS SOLEN GND
CONNECTOR YRC - RIDE CONTROL OPT YPE1, PIN ENGAGE JUMPER CAV
WIRE IDENT
CIRCUIT
A
57-D
PIN ENGAGE SOLENOID PWR
B
0-AW
PIN ENGAGE GROUND
291718A1
CAV
84547255A
WIRE IDENT
CIRCUIT
1
58-G
RIDE CONTR SOLEN PWR
1
58
RIDE CONTR SOLEN PWR
2
0-AD
RIDE CONTROL GROUND
Issued 11-11
Printed in E.C.
4002-101 YRC J, RIDE CNTRL JUMPER CAV
WIRE IDENT
21M, TRANS KICK-DOWN
CIRCUIT
1
58-H
RIDE CONTROL SIGNAL
2
0-RD
RIDE CONTROL GND
YRC J2, RIDE CONTROL OPT CAV
WIRE IDENT
CIRCUIT
1
58-H
RIDE CONTROL SIGNAL
2
0-RD
RIDE CONTROL GND
225316C1
CAV
CONNECTOR YSS - SECONDARY STEERING SOLENOID
WIRE IDENT
CIRCUIT
1
19B-D
FNR SW FUSED PWR
2
25Y-G
TRANS KICK DOWN SIGNAL
CONNECTOR 64F - FLASHER CONNECTOR
225316C1
CAV 1 2
WIRE IDENT 51-C 0-CF
CIRCUIT
245481C1
SEC. STEERING SOLENOID CONTROL SEC. STEERING SOLENOID GROUND
CAV 1
WIRE IDENT 45N-A
CIRCUIT FLASHER OPT SIDE CONTR
CONNECTOR 64M - FLASHER CONNECTOR CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH
245480C1
225316C1
CAV
WIRE IDENT
CIRCUIT
1
19A-U
TRANS KICK DOWN SW FSD PWR
2
25Y-C
TRANS KICK DOWN SIGNAL
84547255A
CAV A
WIRE IDENT 45N-B
CIRCUIT FLASHER OPT SIDE CONTR
Issued 11-11
Printed in E.C.
4002-102 CONNECTOR 108F - DIAGNOSTIC CONNECTOR
193, STARTER RELAY CAV 1
WIRE IDENT 1-BB
CIRCUIT STRTR SOL PWR
194, STARTER SIGNAL CAV 1
291663A1
CAV
WIRE IDENT
1
19A-W
2 3 4
WIRE IDENT 1-BB
CIRCUIT STRTR SOL PWR
195, STARTER RELAY POWER
CIRCUIT DIAGN CONN. FUSED PWR
CAV
37D-A
DIAGNOSTIC SIGNAL
1
0-DAV
DIAGNOSTIC TECM GROUND
37E
DIAGNOSTIC SIGNAL SWITCHED
5
NOT USED
6
NOT USED
WIRE IDENT 1-Z
CIRCUIT STRTR RLY BAT PWR
CONNECTOR 197F - MAIN CAB FNR
115, GRID HTR PWR CAV 1
WIRE IDENT 1-BE
CIRCUIT GRID HTR PWR
CONNECTOR 140M - DIODE MODULE
225350C1
CAV
WIRE IDENT
CIRCUIT
1
19A-C
FNR SWITCH FUSED POWER
2
26F-B
FNR FORWARD SIGNAL
3
26N-B
FNR NEUTRAL SIGNAL
4
26R-B
FNR REVERSE SIGNAL
5
32J-E
TRANS ENABLE INDIC LAMP
6
25Y-B
TRANS KICK DOWN SIGNAL
245488C1
CAV
WIRE IDENT
CIRCUIT
A
63H-C
FRONT WIPER HIGH RYL OUT
B
63L-C
FRONT WIPER LOW RYL OUT
C
0-EE
DIODE SUPPRESSION GNDS
58-D
RIDE CONTROL SOLENOID PWR
D E F
NOT USED 68L-C
84547255A
REAR WIPER SWITCH PWR
Issued 11-11
Printed in E.C.
4002-103 CONNECTOR 197M - FNR MAIN CAB
CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER
225351C1
CAV
WIRE IDENT
245481C1
CIRCUIT CAV
1
19A-B
FNR SWITCHED FUSED POWER
2
26F-A
FNR FORWARD SIGNAL
3
26N-A
FNR NEUTRAL SIGNAL
4
26R-A
FNR REVERSE SIGNAL
5
32J-A
TRANS ENABLE INDIC LAMP
6
25Y-C
TRANS KICK DOWN SIGNAL
1
WIRE IDENT 35A-E
CIRCUIT BACKUP ALARM RELAY OUT
CONNECTOR 209M - BACKUP ALARM DISABLE JUMPER
CONNECTOR 202M - ROLLBACK JUMPER
245480C1
CAV A
WIRE IDENT 35A-D
B
CIRCUIT BACKUP ALARM RELAY OUT NOT USED
245482C1
CAV
WIRE IDENT
CIRCUIT
A
58-A
RIDE CONTR SOLENOID PWR
B
58-A
RIDE CONTR SOLENOID PWR
CONNECTOR 215F - ALTERNATOR RESISTOR
199436A1
CAV 1
84547255A
WIRE IDENT 14-A
CIRCUIT ALTERNATOR D+
Issued 11-11
Printed in E.C.
4002-104 CONNECTOR 216F - ALTERNATOR RESISTOR
199436A1
CAV 1
WIRE IDENT 19R-D
CIRCUIT ALTERNATOR RESISTOR FUSED PWR
242F, CHAS GRD SEC STRG MTR CAV 1
WIRE IDENT 0-ND
CIRCUIT SSM GROUND
244F STARTER SEC STRG MTR CAV
WIRE IDENT
CIRCUIT
1
1-ND
SSM PWR
1
1-NF
SSM PWR
245F, SEC STR FLYBACK CAV
WIRE IDENT
CIRCUIT
1
0-CG
SEC STR FLYBACK GND
1
0-CH
SEC STR FLYBACK GND
84547255A
Issued 11-11
Printed in E.C.
4003
Section 4003 BATTERIES
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 4 4 5 5 5 6 7 7 8 8
Printed in E.C.
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.
WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in enclosed area. Always shield eyes when working near batteries. Keep out of reach of children. D-47-53A
48-57B
SPECIAL TOOLS
B795328
The CAS10147 tester is used to do the Capacity (Load) Test. This tool is first used on Page 6.
84547255A
Issued 11-11
Printed in E.C.
4003-4
MAINTENANCE Electrolyte Level
Inspecting and Cleaning a Battery
If the battery is a maintenance free battery, check the level of the electrolyte every 1000 hours of operation or six months, whichever occurs first. For all other batteries, check the level of the electrolyte every 250 hours of operation.
If damage causes an electrolyte leak, replace the battery.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed for access to the battery caps, it is possible that the words Maintenance Free have been removed from the decal. Check the level of the electrolyte more often during hot weather. The use of a large amount of water by the battery can be caused by high battery temperature or a voltage regulator setting that is too high. Keep the electrolyte level above the top of the plates in the battery at all times to prevent damage to the battery. NOTE: On maintenance free batteries it is necessary to remove the center part of the decal for access to the battery caps. Do not discard the center part of the decal. Install the center part of the decal after the battery caps have been installed.
Inspect the battery at regular intervals for dirt, corrosion, and damage. Electrolyte and dirt on the top of the battery can cause the battery to discharge by making a passage for the current to flow. If the battery must be cleaned, remove the battery from the battery carrier and clean the battery, cable terminals, and the battery carrier. When available, use New Holland Battery Saver and Cleaner according to the instructions on the container. New Holland Battery Saver and Cleaner also helps prevent corrosion. If New Holland Battery Saver and Cleaner is not available, use baking soda and water as a cleaner. DO NOT permit any type of cleaner to enter the cells of the battery. Install the battery in the machine and make sure the fasteners are tight. Apply New Holland Battery Saver and Cleaner or Urethane Seal Coat to the cable terminals to prevent corrosion. See the Parts Counter Catalog. DO NOT apply grease.
If the level of the electrolyte is low, add distilled water or other clean water until the electrolyte is just below the cell opening. Do not add more water than is needed. Too much water can cause bad performance, a short service life, and corrosion around the battery. NOTE: Add water only. DO NOT add electrolyte.
84547255A
Issued 11-11
Printed in E.C.
4003-5
BATTERY TEST NOTE: To correctly test a battery, do each part of the battery test until you know the condition of the battery.
1
2
Visual Checks 1. Make sure the cable connections are clean and tight. Clean foreign material from the top of the battery. 2. Inspect the battery case, battery posts, and cables for damage. 3. Check the electrolyte level. See Page 4. 4. If you added water to the battery, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte.
Specific Gravity Check A hydrometer is used to check the specific gravity (weight) of the electrolyte. The specific gravity is an indication of the level of charge for each cell. Hydrometers are made to show the correct specific gravity when the temperature of the electrolyte is 26.7°C (80°F). When you check the specific gravity, you must know the temperature of the electrolyte. If your hydrometer does not have a thermometer, get a thermometer to check the temperature of the electrolyte. The thermometer must indicate a high temperature of at least 52°C (120°F). 1. Remove enough electrolyte from a cell so that the float is free in the tube. NOTE: If the specific gravity cannot be checked without first adding water to the cell, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte. Then check the specific gravity. 2. Read the float. 3. Read the thermometer. If the reading is above 26.7°C (80°F) add specific gravity points to the reading for specific gravity. If the reading is below 26.5°C (80°F) subtract specific gravity points from the reading for specific gravity. See the following illustration and add or subtract specific gravity points as needed.
B790863
1. TEMPERATURE IN F
2. TEMPERATURE IN C
SPECIFIC GRAVITY CHART
4. Make a record of the corrected specific gravity reading for each cell. 5. If the difference between the high reading and the low reading is 0.050 or more, charge the battery and check the specific gravity again. If after charging, the difference is still 0.050 or more, install a new battery. 6. The corrected specific gravity reading shows the level of charge for the cell. The level of charge must be at least 75% in each of the cells. ln maintenance free batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.240 or higher. In all other batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.230 or higher. 7. If the difference between the high reading and the low reading is less than 0.050, and the level of charge is at least 75% in all of the cells, do the Capacity (Load) Test. 8. If the difference between the high reading and the low reading is less than 0.050, but the level of charge is less than 75% in any of the cells, charge the battery and check the specific gravity again. If after charging: A. The level of charge is less than 75% in any of the cells, discard the battery. B. The level of charge is at least 75% in all of the cells, do the Capacity (Load) Test.
84547255A
Issued 11-11
Printed in E.C.
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.
2
1
NOTE: Never apply a load for longer than 15 seconds. After each 15 seconds, turn the load control knob to OFF for at least one minute. 4. Apply a 15 ampere load to the battery for 15 seconds. Wait at least three minutes before applying the load again. 5. Check and make a record of the temperature of the electrolyte. 6. Find the correct load for this test in Specifications in Section 4001. NOTE: The correct load is half of the cold cranking amperes at -17°C (0°F). 7. Turn the load control knob until the ammeter indicates the specified load. Keep the load for 15 seconds and read the voltmeter. Turn the load control knob to OFF. 8. Compare the test reading and the temperature of the electrolyte to the chart below. Temperature of . . . . . . . . . . . . . . . Minimum Voltage electrolyte 21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6 16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9.3 -1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 -12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 A. If the test result is equal to or more than the 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
84547255A
2. AMMETER CLAMP (TIP OF ARROW AWAY FROM BATTERY)
Issued 11-11
Printed in E.C.
4003-7
CHARGING A BATTERY WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83
See Specifications in Section 4001 for the reserve capacity of the battery in this machine. The charging rate must be decreased if:
Before you charge the battery, check the level of the electrolyte.
1. Too much gas causes the electrolyte to flow from the cells.
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.
2. The temperature of the electrolyte rises above 52°C (125°F). NOTE: For the best charge, use the slow charging rates. The battery is fully charged when, over a three hour
Charging Guide For Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery Battery Capacity - See Reserve Capacity under Specifications
Slow Charge
Fast Charge
10 Hours at 5 Amperes 5 Hours at 10 Amperes
2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes
Above 80 to 125 Minutes
15 Hours at 5 Amperes 7.5 Hours at 10 Amperes
3.75 Hours at 20 Amperes 1.5 Hours at 50 Amperes
Above 125 to 170 Minutes
20 Hours at 5 Amperes 10 Hours at 10 Amperes
5 Hours at 20 Amperes 2 Hours at 50 Amperes
Above 170 to 250 Minutes
30 Hours at 5 Amperes 15 Hours at 10 Amperes
7.5 Hours at 20 Amperes 3 Hours at 50 Amperes
80 Minutes or Less
*initial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been removed from the decal. Continued on next page
84547255A
Issued 11-11
Printed in E.C.
4003-8
Charging Guide For Batteries Other Than Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve Capacity under Specifications
Slow Charge
Fast Charge
10 Hours at 5 Amperes 5 Hours at 10 Amperes
2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes
Above 80 to 125 Minutes
15 Hours at 5 Amperes 7.5 Hours at 10 Amperes
3.75 Hours at 20 Amperes 1.5 Hours at 50 Amperes
Above 125 to 170 Minutes
20 Hours at 5 Amperes 10 Hours at 10 Amperes
5 Hours at 20 Amperes 2 Hours at 50 Amperes
Above 170 to 250 Minutes
30 Hours at 5 Amperes 15 Hours at 10 Amperes
7.5 Hours at 20 Amperes 3 Hours at 50 Amperes
Above 250 Minutes
24 Hours at 10 Amperes
6 Hours at 40 Amperes 4 Hours at 60 Amperes
80 Minutes or Less
*initial rate for standard taper charger.
PREPARING A DRY CHARGED BATTERY FOR USE 1. Remove the caps from the battery. 2. Fill each cell to the top of the separators with electrolyte. This will permit the volume of electrolyte to increase when heated by charging the battery. 3. Install the caps on the battery.
5. Charge the battery at 30 amperes until the specific gravity is 1.250 or more an d the temperature of the electrolyte is at least 15.5°C (60°F). 6. If necessary, fill each cell with electrolyte until the electrolyte is just below split ring at the bottom of the cell opening.
4. Connect a battery charger to the battery.
84547255A
Issued 11-11
Printed in E.C.
4003a
Section 4003a JUMP POST OPTION
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
4003-2
TABLE OF CONTENTS Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84547255A
Issued 11-11
Printed in E.C.
4003-3
JUMP POST OPTION STEP 1
5. Connect the other end of the negative (-) cable to the negative (-) terminal of the jump post (black). Do not connect it to sheet metal or any rotating part, as damage can result. Do not connect to the negative (-) terminal on the battery. 6. Start the engine. 7. Remove the booster battery negative (-) cable from the jump post and then from the machine being used for starting. Remove the positive (+) cable from the jump post terminal and then from the booster battery. 8. Install the terminal covers.
W270R458
The Jump Post option can be used to provide power to star t the machine if i ts batter ies become discharged. The option can be used to provide power to the machine for the purpose of raising the hood if its batteries have become discharged. The option can be used to start other disabled equipment without accessing the main battery terminals. NOTE: Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts). The jump post is located on the left hand side of the machine inside the main electrical disconnect compartment. 1. Turn off the ignition and all accessories on the machine(s). Use the jump post to connect the auxiliary battery. 2. Remove the terminal covers and connect one end of the positive (+) cable to the positive (+) terminal on the booster battery. 3. Connect the other end of the positive (+) cable to the positive (+) terminal of the jump post (red). 4. Connect the negative (-) cable to the negative (-) terminal on the booster battery.
84547255A
Issued 11-11
Printed in E.C.
4003-4
NOTES
84547255A
Issued 11-11
Printed in E.C.
Section 4005
4005
INSTRUMENT CLUSTER
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
4005-2
TABLE OF CONTENTS INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 4 5 6 9 11 12 13 16 16 16 16 17
Printed in E.C.
4005-3
INSTRUMENT CLUSTER 1
2
15
3
4
5
14
6
7
8
12
13
9
10
11
BS06H240
1. 2. 3. 4. 5. 6. 7. 8.
LOW BRAKE PRESSURE INDICATOR HIGH BEAM INDICATOR TRANSMISSION OIL TEMPERATURE GAUGE CAUTION MASTER INDICATOR MULTI FUNCTION LCD DISPLAY STOP MASTER INDICATOR HYDRAULIC OIL TEMPERATURE GAUGE WAIT TO START ENGINE PREHEAT
9. 10. 11. 12. 13. 14. 15.
LACK OF AUX STEER PRESSURE (OPTIONAL) PARKING BRAKE INDICATOR RIGHT TURN INDICATOR FUEL LEVEL GAUGE FUEL LEVEL AT MINIMUM ENGINE COOLANT TEMPERATURE GAUGE LEFT TURN INDICATOR
The instrument cluster monitors a number of functions and can be tailored to fit the 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:
84547255A
Issued 11-11
Printed in E.C.
4005-4
Self-Test 1. Turn the ignition (key) switch to the ON position. 2. The instrument cluster will automatically check each monitored system. 3. All LED’s (Light Emitting Diodes) will illuminate for 2 - 3 seconds. 4. Four gauges will energize for 2 - 3 seconds. 5. The warning alarm will sound for 2 - 3 seconds.
Power Circuit Test A. Check fuse ECA-F3. If the fuse is bad, replace the fuse and repeat Self-Test. If the fuse is good, go to next step. B. Check wire 19EA for continuity. Repair/replace the wire as required. If continuity is found go to next step. C. Check power relay module A for proper operation, see Section 4002. If the power relay module checks good, go to next step.
6. If there is an open circuit between a sensor and the instrument cluster, the LED will flash and the warning alarm will sound for 5 seconds.
D. Check the ignition switch for proper operation, see Section 4002. If the ignition switch checks good, go to next step.
7. If there were no faults detected during the check, all monitored systems will return to normal operation.
E. Check fuse ECC-F5. If the fuse is bad, replace the fuse.
8. If only some of the LEDs illuminate, replace the instrument cluster. 9. If the LEDs illuminate, but the warning alarm does not sound, see section 4002 and test the alarm circuit. 10. If the warning alarm sounds but the LEDs do not illuminate, if no power is present at buzzer, replace the instrument cluster, if power is present at the buzzer, replace the buzzer. 11. If the warning alarm does not sound and the LEDs do not illuminate on the instrument cluster, do the following steps to test the power circuit:
84547255A
Issued 11-11
Printed in E.C.
4005-5
LCD Multi-function Display
Information will be displayed in different zones on the LCD, as directed by the operator or machine. In most situations the operator or technician will be given specific information to follow if conditions are not correct. 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.
W230M139
The LCD Multi-Function Display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps.
2. This example, shows that the Transmission Control Lever is in Neutral. The display will show Forward, Neutral, or Reverse, depending on where the Directional Control Lever is positioned. NOTE: Forward and Reverse will blink if the transmission clutches are disconnected. 3. This zone shows the gear numerically (3th).
F
R
12 3 4
4. This example shows the current transmission mode that has been selected. A. If the Transmission is operating normally it will display either
N
2
3
1
7.0 H
A A 11 22
5 4 6
W230R477
LCD MULTI-FUNCTION DISPLAY 4 SPEED
●
A - Automatic
●
M - Manual operation.
B. If the Transmission is not operating normally the display will show ●
C - Substitute Clutch.
●
L - Limp Home.
●
S - Transmission Shutdown.
●
U - TCU Shutdown.
5. This example shows the Power Boost Status.
F N
2
R 3
1
7.0 H
12 3 D
A A 11 22
5
●
MAX - Maximum Power.
●
STD - Normal/Standard mode of Operation.
●
AUTO - Switches automatically Maximum and Standard Power.
●
ECO - Limited Power for fuel efficiency.
between
6. This example will show the Time in either 12 hour or 24 hour.
4 6
W230R476
LCD MULTI-FUNCTION DISPLAY 5 SPEED
84547255A
Issued 11-11
Printed in E.C.
4005-6
Navigating Through The LCD Multi-function Display Screens
A
Using The Arrow Keys At any time, during operation or with the key switch on, the operator may scroll through three information screens and two trip screens by using the arrow keys. These five screens are in a circular loop and may be reached by pressing the up or down key. The following sequence is using the down key only.
C
NOTE: Pressing the escape key will return the LCD back to the normal driving screen.
B
D BD06F186
Located on the steering column, just to the left of the Park Switch, is the key pad. Use this key pad to move 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.
BD06F188
From the driving screen push the down arrow, as shown.
B. Enter key: Use this key to confirm, yes, this is the desired function. C. Up arrow key: Use this key to scroll up to selections. D. Down arrow key: Use this key to scroll down to selections. NOTE: Arrows on the screen will indicate if selections are up or down from the current selection. NOTE: Display units can be changed by the operator.
W230R435
Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPM’s, speed, fuel level, and the Urea level.
84547255A
Issued 11-11
Printed in E.C.
4005-7
W230R436
W230R438
Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Fahrenheit or Celsius, and the Urea level.
Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.
W230R437
Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and the Urea level.
Info Voltage Air Turbo DefTemp DefLvl
W230R439
By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.
4 V 24.2 °C 42 °C 32 % 24 W230M171
Push the down key again to display the info 4 screen. This screen display the voltage level, turbocharger air temperature, Urea temperature and Urea level.
84547255A
Issued 11-11
Printed in E.C.
4005-8
Reset The Trip Information
Trip 04May2008,
2 17:42
Time Fuel
Hrs 102.9 L 1000.6
Fuel/hr
L/h
9.1 BD06F172 W230M137
Highlight the trip screen you wish to set.
The trip screen will indicate a reset message. At this screen, press confirm to clear the numbers and reset the trip information. The current date and time will display automatically. The hours, fuel consumption, and fuel used per hour will reset and revert to zero.
Trip 04May2008,
BD06F187
2 17:42
Time Fuel
Hrs 102.9 L 1000.6
Fuel/hr
L/h
9.1
Press the confirm button to reset the trip selection to zero. W230M137
Press the escape key to return to the main driving screen and lock settings into memory. The screen will begin to record time and fuel usage immediately.
84547255A
Issued 11-11
Printed in E.C.
4005-9
Entering The Service Screens After the machine has been started or the key switch has been turned to on the operator or service technican may use this service menu to adjust machine configurations to working conditions, test components, view faults that may have occurred, or select preferences. NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.
W230M141 / BD06F188
Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to scroll through the menu’s. Items and selections in this menu are: 1. Setting Menu ●
Engine (Auto Idle, Power Mode, Eng Options, Factory Set, Auto Shutdown, Fan Gain)
●
Transmission (Max Gear, Min Gear, ICCO ENABLE)
●
Joystick Steering (Option)
2. Display Menu ●
Options (Engine Snd, Ground Snd)
●
Language (English, Deutsch, Francais, Italiano, Espagnol, Portuguese)
●
Units (Metric, English, Imperial)
●
Clock (24 or 12 Hour Increments)
●
Backlight (Day Disp., Day Led, Night Disp., Night Led)
●
Factory Set (Reset, Display Setting, Confirm Please)
4. Service ●
Calibration (Clutch Calib, Pedal Calib, Park Brake, Fan Test)
●
Change Model
●
Slot Tires
For other submenu see next page. * The tests in the configuration menu should be performed only by a qualified operator or technician, as some tests require the engine to be running at high RPM’s.
3. Diagnostics ●
Show Errors (Red, Yellow, White, Memory) Memory 1/2
●
Reset Errors (Reset, Confirm Please)
●
Cluster S/W (Software Part Number, Software Serial Number, Software ID, Software Version)
●
Transmission (SW, HW, VER, SER)
84547255A
Issued 11-11
Printed in E.C.
84547255A
Transm.
1
5
Deflt
WorkIdle
STANDARD AUTO ECO
Low
Accelerated
ON
EngOptions
(Option)
2
Joyst Steer
JSS_Spd
Fan Auto
Power Mode
(5 Speed)
POWERINCH ON
Min Gear
Max Gear
MAX
Auto Idle
(4 Speed)
1
4
Transm.
Joyst. Steer
Off
Factory Set
EngOptions
Min Gear
Power Mode
Transm.
Max Gear
Engine
Auto Idle
Settings
Engine
ON
Ground Spd
Confirm Please
Engine Settings
Reset
Factory Set
ON
Engine Spd
OPT Options
Language
English Imperial
Deutsch Francais Italiano Espagnol Portugue
OFF
(Option)
30 min Protection OFF Interval
Units Metric
English
Language
Factory Set
Backlight
Clock
Units
Auto Shtdwn Economy
Display OPT Options
2
17NOV10,Hr 1
1067 0.00
SCR Control CAN Msg Engine Timeout
MEMORY 1/2 19605 Warning
0
WHITE MEMORY
0 0
Show Errors
Ver
Ldr
Backlight Day Disp. Day LED Night Disp. Night LED
1.8.0.0 3.0.2.8
87372814 84340740
Cluster HW P/N SW P/N
12 Hr 12 30 1 1 2011
Clock
RED YELLOW
!
Format Hour Minute Day Month Year
Settings Display Diagnostics Service
Main Menu
6057 018 121 6009 365 007
Transm.
Confirm Please
Display Settings
Reset
Factory Set
VER 932___tdz_Luc SER 4506JCWFw
SW HW
20 20 5 5
!
Confirm Please
ClutchCalib
Transm.
Cluster
Show Errors
Diagnostics
Calibration
Issued 11-11
Press Esc To Exit
Press Esc To Exit
..
Turn Key OFF
Now,
Change OK
420
Reset Actual PWM
735 *****
70% Speed
AdjustSpeed
Fan Speed
Engage 3rdManual
PedalCalib
Test at fixed
ParkBrake Test Park Brake
Fixed 70%
Confirm Please
Fan Speed Mode
Switch to Fixed
Fan Test
20.5 Rad
Select Tires TireSize
PedalCalib
Confirm Please
Test Park Brake
ParkBrake
Slct_Tires
Push Pedal Full
Confirm Please
PedalCalib
Fan Test
ParkBrake
PedalCalib
ClutchCalib
Service Calibration
4005-10
W230R478
Printed in E.C.
4005-11 SELECT SCREEN The "Display" selection screen allows time settings to be entered. Highlight "clock" and press the select button. This will allow the time settings to be changed.
W230M142
W230M143
W230M144
The "Diagnostic" selection screen allows the software screens which cannot be modified to be viewed by highlighting "cluster S/W" and pressing the confirmation button.
W230M145
Figure 4
W230M146
Figure 5
W230M147
Figure 6
Figure 1
Figure 2
Figure 3
NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to page back to the main screen. Turning the machine off will also lock the settings into memory.
84547255A
Issued 11-11
Printed in E.C.
4005-12 SELECTING POWER MODES The power mode allows the operator to choose the most effective machine power for the current job conditions. Idling can be changed from automatic to a fixed rate. Most commonly Auto is chosen, as the power will automatically increase or decrease between maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency. Press and hold the confirm key for two seconds to arrive at the service screen.
W230M141
Figure 9
W230M149
At the screen shown above, highlight the power mode, and press the confirm key to move to the Power Mode Selection Menu.
Figure 7 Figure 10
W230M150
At the Power Mode Menu press the confirm key again to activate the selections. The highlighted section will flash to indicate a new selection can be made. Press the up or down key to select the Power Mode, and then press the confirm key. Use the escape key to return to the main driving screen and to lock the mode selection into memory. Confirming the Selected Mode
W230M148
84547255A
Figure 8
The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected.
Issued 11-11
Printed in E.C.
4005-13 OPTIONS AND PREFERENCE SCREENS LANGUAGE SCREEN, MEASUREMENT UNITS, AND CLOCK The LCD screen can be set with language, measurements, and/or clock preferences. Use the arrow keys to scroll to the display menu. Press the confirm key on the correct selection. Press the escape key to return to the main driving screen and lock the selection into memory. Choose the preferences desired: language in English, Spanish, Portuguese, Italian, German, French; measurement units in metric, English, or Imperial; and clock units in 12 or 24 hour cycles. Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, press the confirm key, then use the escape key to return to the main driving screen in order to lock the preference into memory.
W230M142
W230M155
84547255A
W230M156
Figure 13
W230M157
Figure 14
W230M158
Figure 15
Figure 11
Figure 12
Issued 11-11
Printed in E.C.
4005-14 CLOCK
DISPLAY MENU
Setting The Hour and Date
The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key until the screen reverts to the main driving screen to lock the selection into memory. The screen display can be changed to suit working conditions. The screen will change to night function illumination when the head lamps are turned on.
From the display screen, choose the clock designation and press the confirm key. Use the arrow keys to show field for time and date by pressing the arrow key. When the correct time and date have been entered by using the up and down arrow keys (up increases the numbers - down decreases the numbers), press the confirm key to lock in correct time. Press the escape key to return to the main driving screen and lock selections into memory.
W230M142
Figure 19
W230M160
Figure 20
Figure 16
W230M143
Figure 17
W230M144
Figure 18
84547255A
W230M159
Issued 11-11
Printed in E.C.
4005-15
Clutch Calibration After warming the oil temperature: 1. Park the machine on a firm level surface. 2. Place the NEUTRAL.
Transmission
Control
Lever
in
3. Set the Park Brake. 4. With the engine running, at idle, enter the Service Screen Menu and scroll to Service.
W230M175
If, conditions are not correct, an error message will appear and guide the operator or technican. There are six, if conditions not met, screens:
W230M173
Use the confirm and arrow button to scroll to the screen shown above. At this screen push the confirm button again.
●
Not in neutral
●
Park Brake OFF
●
Machine moving
●
Oil temp too low
●
Oil temp too high
●
Engine RPM low
●
Engine RPM high
If conditions are correct the operator or technican will see six calibration screens pass. They will display in this order: ●
Adjust K1
●
Adjust K2
●
Adjust K3
●
Adjust K4
●
Adjust KV
●
Adjust KR
Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start. W230M174
This screen will prompt the operator or technican to confirm or escape.
84547255A
If the process is not completed the operator or technican will be prompted to escape.
Issued 11-11
Printed in E.C.
4005-16
Auto Idle Idling can be changed from automatic to a fixed rate. The fixed idle rate is defined as Standard Idle at 900 RPM. Highlight the auto idle selection by using the arrow keys, then press confirm. When you have chosen the selection, lock the selection into memory by pressing the confirm key.
RPM Engine speed in RPM will show on the display if the engine speed is running up to 550 RPM’s, and will disappear if the engine speed is lower than 300 RPM. W230M141
Options Menu
MPH/KPH
Use the arrow keys to choose the menu. Press the confirm key, and the options sub-menu will appear. The options menu will allow the operator to choose options for the fan, idle.
Vehicle speed will show on the display if it is up to 1.0 MPH / 1.5 KPH and will disappear if the vehicle speed is less than 0.6 MPH / 1.0 KPH.
Fan Auto The fan can be set to run at automatic or the fan will run at maximum speed. Automatic is the more common or preferred setting. It will switch between high speed, low speed, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil. The operator can choose fan speed or reversing capabilities. Highlight the fan auto selection by using the arrow keys, then press confirm. When you have chosen the selection, lock the selection into memory by pressing the confirm key.
84547255A
Issued 11-11
Printed in E.C.
4005-17
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Section 4006
4006
REAR VIEW CAMERA AND MONITOR
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
4006-2
TABLE OF CONTENTS REAR VIEW CAMERA AND MONITOR (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Components of the rear view camera and monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation the rear view camera and monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84547255A
Issued 11-11
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4006-3 REAR VIEW CAMERA AND MONITOR (OPTIONAL) The rear view back-up camera reduces vehicle blind spots during reversing operations. It assists operators when backing for loading operations and offers a view of other equipment, obstacles, and/or personnel in the work area. Refer to the camera manufacture's instructions for correct operation of the camera monitor. The camera monitor is mounted in the operator's compartment and the camera eye is located behind the rear grille. The camera eye has built in moisture resistance for equipment that operates in harsh environments. The camera is available for yourauthorized dealer. W230M181
W230M182
84547255A
Issued 11-11
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4006-4
COMPONENTS OF THE REAR VIEW CAMERA AND MONITOR 1. Bar mounting 2. Monitor arm mount 3. Plate access monitor adaptor 4. Monitor 5. Mounting bracket rear camera 6. Rear camera 7. Washer 8. Bolt 9. Washer 10. Nut 11. Washer 12. Screw 13. Washer 14. Screw 15. Nut 16. Cab right hand console 17. Washer 18. Screw 19. Latch 20. Rivet 21. Nut 22. Grommet 23. Strap cable
84547255A
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Printed in E.C.
4006-5
5
7
7 10
8
15 6 13 14
13
9
2
4 12 11 17
18
1
21
22
20
19
23 3
16 W230R490
INSTALLATION THE REAR VIEW CAMERA AND MONITOR Printed in E.C.
Issued 11-11
84547255A
4006-6
84547255A
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INDEX OF FUNCTIONS FUNCTIONS
DIAGRAM SYMBOL DESCRIPTIONS
SHT
AIR SEAT
12
CAN COMMUNICATION
12
COLD START
4
ENGINE CONTROL
5
HOOD LIFT
11
HVAC
12
IGNITION SWITCH
4
INSTRUMENT CLUSTER
9
HOOD LIFT
SPLICE SYMBOL SPLICE NAME WIRE NAME WIRE COLOR WIRE SIZE (mm 2) MALE CONNECTOR FEMALE CONNECTOR
11
LIGHTING 1 (combos...)
6
LIGHTING 2 (work lights)
7
MACHINE CONTROLS
10
RADIO/POWER CONVERTER
12
POWER DISTRIBUTION
4
TRANSMISSION CONTROL
8
SCR EXHAUST TREATMENT
6
SECONDARY STEERING
11
WIPER/WASHER SYSTEM
11
JOYSTICK STEERING
13
CONNECTOR REFERENCE DESIGNATOR
CONNECTOR INTERFACE (ONE HARNESS CONNECTS TO ANOTHER HARNESS) INDICATES WIRES CROSSING (NOT CONNECTED)
INDICATES PARTIAL CONNECTOR (NOT ALL ENTRY PORTS SHOWN)
REF DES NAMING CONVENTION S... ROCKER SWITCHES L... LIGHTS P... PRESSURE SENSOR/SWITCHES Y... SOLENOIDS R... RESISTANCE MEASURE ABOVE LETTER FOLLOWED BY THE FIRST LETTER OF THE FIRST TWO WORDS OF THE SYMBOL LABEL. SPL... SPLICE
INDICATES THAT THE WIRE CONNECTS TO CONNECTOR TECM (TRANSMISSION ELECTRONIC CONTROL MODULE) ON SHEET 6. TECM CAN BE LOCATED ON SHEET 6 USING ZONE (GRID) LOCATIONS GIVEN IN TABLES ON SHEET 2.
INDICATES INTERNALLY GROUNDED COMPONENT
LARGE CONNECTOR LIST NAME
DESCRIPTION
SHT
INDEX / WIRE INFORMATION
COLOR ABBREVIATIONS ABBREVIATION
COLOR
Bk
BLACK
DU
DARK BLUE
G
GREEN
K
PINK
LG
LIGHT GREEN
LU
LIGHT BLUE
N
BROWN
Or
ORANGE
P
PURPLE OR VIOLET
R
RED
S
GREY
T
TAN
U
BLUE
W
WHITE
Y
YELLOW
1
CONNECTOR LIST NAME
DESCRIPTION
SHT
CONNECTOR LIST NAME
DESCRIPTION
SHT
CONNECTOR LIST NAME
DESCRIPTION
CONNECTOR LIST
SHT
CONNECTOR LIST NAME
DESCRIPTION
SHT
2
DESCRIPTION
SHT
CONNECTOR LIST
CONNECTOR LIST
CONNECTOR LIST NAME
NAME
DESCRIPTION
SHT
NAME
DESCRIPTION
PIN
NAME
PIN
PIN
PIN
LOCATION
CONNECTOR LIST
PIN
LOCATION
PIN
NAME
LOCATION
PIN
NAME
LOCATION
PIN
NAME
LOCATION
SHT
LOCATION
PIN
LOCATION
PIN
LOCATION
LOCATION
PIN
LOCATION
LOCATION
3
3
18 15
21
13
14
20 5 9
2
8
11 10
1
4 158
16 6
17
COLD START
159
160
POWER DISTRIBUTION
IGNITION SWITCH
4
22 24
162 161
163 23 PL23 ONLY
169 164
168
165 166 167
ENGINE CONTROL
5
92
95
90
78
93
91
94
79 101
101
100
100
103
96
97
102
LIGHTING 1
BACKUP ALARM
6
89
81
88
87 80
86
84
85
170 83 82
LIGHTING 2
7
172
54 173 171
JOYSTICK ONLY
57
55
SINGLE AXIS CONTROLLER ONLY
59 56
174
46
47 45
61
48
58
49
50 51 52
53
TRANSMISSION CONTROLS
60
8
64
74 68 72
65
67
75
69 73
76
66
INSTRUMENT CLUSTER
9
25 35 36
26 32 29 33
31 37
98
27
39 99
28
40 34
38 44
41
30
42 43
MACHINE CONTROLS
10
113 155 154
105
104
108 114
106
107
109
156 115 117
111
112 113 116 157
110
118
SECONDARY STEERING
HOOD LIFT
WIPER/WASHER SYSTEM
11
121
127 122 126
129 128
130
125 123 124
119
CAN COMMUNICATION
HVAC
AIR SEAT
RADIO POWER/CONVERTER
12
184
177 175
185 176 179
178 181
182 180
183
186
JOYSTICK STEERING
13
145 144
146 143
147
148
149
150
153 151 152
STANDARD HVAC
14
COMPONENT NUMBERS COMPONENT STARTING RELAY RESISTOR - 75 OHM ALTERNATOR CRANK CONTROL RELAY BATTERIES CRANK REQUEST RELAY MASTER DISCONNECT SWITCH STARTER IGNITION SWITCH NEUTRAL START RELAY POWER RELAY MODULE A POWER RELAY MODULE B POWER RELAY MODULE C GRID HEATER RELAY GRID HEATER POWER RELAY MODULE D WATER SEPARATOR HEATER FUEL FILTER HEATER WATER IN FUEL SENSOR THROTTLE POTENTIOMETER ENGINE CONTROLLER RETURN TO TRAVEL FLOAT SWITCH HEIGHT CONTROL SWITCH ELECTROMAGNETIC DETENTS RETURN TO DIG PROXIMITY SWITCH PILOT CONTROL RELAY ECD-K3 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW RETURN TO DIG SWITCH PIN ENGAGE SWITCH (OPTION) PILOT PRESSURE SOLENOID PIN ENGAGE SOLENOID (OPTION) RIDE CONTROL SWITCH (OPTION) RIDE CONTROL RELAY (OPTION) FAN CONTROL SWITCH (OPTION) FAN REVERSE RELAY (OPTION) PILOT CONTROL SWITCH RIDE CONTROL SOLENOID (OPTION) ROLLBACK PRESSURE SW (XT WITH RIDE CONTROL ONLY) ROLLBACK JUMPER FAN PWM SOLENOID FAN REVERSE SOLENOID (OPTION) OUTPUT SPEED SENSOR TRANSMISSION SOLENOID VALVE AND TEMP SENDER FILTER MAINTENANCE SWITCH
COMPONENT # SHT 61 8 DIAGNOSTIC CONNECTOR 62 1 INSTRUMENT CLUSTER CONNECTOR 1 63 9 WARNING BUZZER 64 9 PARKING BRAKE RELAY 65 9 FUEL LEVEL SENDER 66 9 AIR FILTER RESTRICTION SWITCH 67 9 PARKING BRAKE SOLENOID 68 9 RADIATOR COOLANT TEMPERATURE SENDER 69 9 BRAKE PRESSURE WARNING SWITCH 70 1 SWITCH PAD 71 1 INSTRUMENT CLUSTER CONNECTOR 2 72 9 HYDRAULIC FILTER RESTRICTION SWITCH 73 9 HYDRAULIC OIL TEMPERATURE SENDER 74 9 PARK BRAKE SWITCH 75 9 REDUNDANT BRAKE PRESSURE SWITCH 1 76 9 REDUNDANT BRAKE PRESSURE SWITCH 2 78 6 BACKUP ALARM RELAY 79 6 BACKUP ALARM DISABLE SWITCH 80 7 WORK LAMPS SWITCH 81 7 DOOR SWITCH 82 7 ROTATING BEACON (OPTIONAL) 83 7 DOME LAMP 84 7 ROTATING BEACON SWITCH (OPTIONAL) 7 LEFT HAND FRONT WORK LAMP 85 86 7 RIGHT HAND FRONT WORK LAMP 87 7 LEFT HAND REAR WORK LAMP 88 7 RIGHT HAND REAR WORK LAMP 89 7 DIODES 90 6 BRAKE LAMP SWITCH 91 6 BRAKE LAMP RELAY 92 6 FLASHER MODULE 93 6 HAZARD SWITCH 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 95 6 DRIVING LAMPS SWITCH 96 6 LEFT HAND FRONT COMBINATION LAMPS 97 6 RIGHT HAND FRONT COMBINATION LAMPS 98 10 HORN RELAY 99 10 HORN RELAY 100 6 RIGHT HAND REAR COMBINATION LAMPS 101 6 LEFT HAND REAR COMBINATION LAMPS 102 6 LICENSE PLATE LAMP 103 6 BACKUP ALARM 104 11 FRONT WIPER HIGH SPEED RELAY 105 11 WIPER CUTOUT RELAY
# 119 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163
SHT 12 12 12 12 12 12 12 12 12 12 12 NA NA NA NA NA NA NA NA NA NA NA NA 14 14 14 14 14 14 14 14 14 14 14 11 11 11 11 4 4 4 5 5 5
8 8 8 8 8
TORQUE CONVERTER OUTPUT TEMPERATURE SENDER ENGINE SPEED SENSOR INTERMEDIATE SPEED SENSOR TURBINE SPEED SENSOR TRANSMISSION SHIFTER
106 107 108 109 110
11 11 11 11 11
FRONT WIPER LOW SPEED RELAY REAR WIPER AND WASHER SWITCH FRONT WIPER AND WASHER SWITCH FRONT WIPER MOTOR REAR WIPER MOTOR
164 165 166 167 168
5 5 5 5 5
TANK HEATER CONTROL VALVE DEF LEVEL AND TANK TEMPERATURE UPSTREAM TEMPERATURE SENSOR DOWNSTREAM TEMPERATURE SENSOR DOSER METERING VALVE
8 8 8 8 8 8 8 8
TRANSMISSION ELECTRONIC CONTROL MODULE TRANSMISSION ENABLE SWITCH FNR SWITCH FOR JOYSTICK CONTROLS TRANSMISSION KICK DOWN SWITCH FNR SWITCH FOR SINGLE AXIS CONTROLS TRANSMISSION AUTO SWITCH BRAKE DECLUTCH PRESSURE SWITCH DECLUTCH SWITCH
111 112 113 114 115 116 117 118
11 11 11 11 11 11 11 11
REAR WASHER MOTOR FRONT WASHER MOTOR DIODES SECONDARY STEERING DIODES SECONDARY STEERING SOLENOID SECONDARY STEERING MODULE SECONDARY STEERING MOTOR SECONDARY STEERING PRESSURE SWITCH
169 170 171 172 173 174 175 176
5 7 8 8 8 8 13 13
DNOX CONTROLLER REAR VIEW CAMERA/MONITOR DIFFERENTIAL LOCK SWITCH (MANUAL) DIFFERENTIAL LOCK SWITCH DIFFERENTIAL LOCK SOLENOID LOCKUP SOLENOID JOYSTICK PVRES TRANSMISSION KICK DOWN SWITCH
# 1 2 3 4 5 6 8 9 10 11 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
SHT 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 8 8 8
48 49 50 51 52 53 54 55 56 57 58 59 60
COMPONENT DIAGNOSTIC CONNECTOR POWER CONVERTER - 24 TO 12 VOLT 12 VOLT POWER OUTLETS (OPTION) RADIO RIGHT SPEAKER LEFT SPEAKER AIR SEAT CIGAR LIGHTER AIR CONDITIONING CLUTCH RELAY AIR CONDITIONING HIGH-LOW PRESSURE SWITCH AIR CONDITIONING COMPRESSOR CLUTCH ELECTRONIC PANEL EXTERNAL AIR TEMPERATURE SENSOR INTERNAL AIR TEMPERATURE SENSOR SUN SENSOR BLOWER FAN RESISTOR BLOWER MOTORS THERMOCOUPLE SENSOR MIXED AIR SENSOR COMPRESSOR RELAY RECYCLING MOTOR ELECTRONIC WATER VALVE 24 TO 12 VOLT CONVERTER ACTUATOR DRIVER ELECTRONIC WATER VALVE BLOWER FAN RESISTOR BLOWER MOTOR THERMOSTAT FAN SPEED SWITCH AIR CONDITIONING SWITCH CONTROL PANEL LAMPS WATER VALVE POTENTIOMETER AIR RECIRCULATING SWITCH HOOD UP RELAY HOOD DOWN RELAY HOOD SWITCH HOOD MOTOR IGNITION POWER LATCH IGNITION POWER CONTROL START LOCKOUT NOX SENSOR HUMIDITY AND AMBIENT TEMPERATURE SENSOR NOX SENSOR (NOXS)
#/-0/.%.4 .5-"%2).' ).&/2-!4)/.
# 177 178 179 180 181 182 183 184 185 186
SHT 13 13 13 13 13 13 13 13 13 13
COMPONENT ARM POS FNR SWITCH (OPTION) FNR RELAY PILOT DUMP VALVE JSS VALVE LOAD SENSE PRESSURE SENSOR PILOT PRESSURE SWITCH JSS RELAY JOYSTICK STR SWITCH (OPTION) JSS CONTROLLER
5
SECTION INDEX
STEERING Section Title
Section Number
Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001 Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005 Center Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006 Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5008 Joystick Steering System (JSS) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5009
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
5001 Section 5001 REMOVAL AND INSTALLATION OF STEERING COMPONENTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
5001-2
TABLE OF CONTENTS STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 5 8 8 8 10 10 10 12 12 12 14 14 14 16 16 16
Printed in E.C.
5001-3
STEERING CONTROL VALVE Removal
STEP 7
STEP 1 Remove the cab skirts from the cab or canopy.
STEP 2 Remove all dirt and grease from steering control valve.
STEP 3 Remove hydraulic reservoir fill cap, attach a vacuum pump to the reservoir, start the pump. W230R595
STEP 4 Tag hoses connected to steering control valve.
Remove the mounting nut and washers from the steering shaft.
STEP 5
STEP 8
BD06G262
Disconnect hoses from steering control valve, cap or plug the fittings and hoses, turn off the vacuum pump.
W230R596
Remove the steering wheel from the shaft.
STEP 9
STEP 6
W230R597 W230R594
Remove the center cap from the steering wheel.
84547255A
Remove the six mounting screws from the instrument cover.
Issued 11-11
Printed in E.C.
5001-4
STEP 10
STEP 13
BD06G248
BD06G258
Remove the five mounting screws for the left and right hand trim.
Remove the two mounting screws from the lower trim.
STEP 11
STEP 14
BD06G249
BD06G259
Disconnect the ignition switch, remove the right and left hand trim pieces from the column.
Pull floor mat away from the column and remove the lower trim from the column.
STEP 12
STEP 15
BD06G257
Remove the screw from the brace.
84547255A
BD06G260
Remove the two lower mounting screws from the front vent.
Issued 11-11
Printed in E.C.
5001-5
Installation
STEP 16
STEP 18
BD06G261
Remove the three vents from the front trim, remove the three mounting bolts inside of the vent holes, remove the vent.
STEP 17
BD06G264
Put the rubber bushing on the spacer with the tapered end towards the steering valve.
STEP 19 Have an assistant push the valve into place while turning the steering shaft, this will engage the splines.
STEP 20
BD06G263
Remove the four mounting bolts for the steering control valve. IMPORTANT: Have an assistant support and remove the valve while removing the mounting bolts. BD06G263
Install and tighten the four mounting bolts for the steering control valve.
84547255A
Issued 11-11
Printed in E.C.
5001-6
STEP 21
STEP 24
BD06G261
Install the front trim, install and tighten the three mounting bolts inside of the vent holes, install three vents into the front trim.
BD06G257
Install the screw into the brace.
STEP 25
STEP 22
BD06G249
BD06G260
Install the two lower mounting screws that mount the front vent to the cab.
Connect the ignition switch, install the right and left hand trim pieces onto the column.
STEP 26
STEP 23
BD06G248
BD06G258
Install and tighten the five mounting screws for the left and right hand trim.
Install the lower trim onto the column, instal and tighten the two mounting screws mounting the lower trim, place the floor mat into position.
84547255A
Issued 11-11
Printed in E.C.
5001-7
STEP 27
STEP 30
W230R597
BD06G262
Install and tighten the six mounting screws for the instrument cover.
Start the vacuum pump, remove the caps and plugs the fittings and hoses. Connect hoses to steering control valve according to the tags installed during removal, remove and discard the tags.
STEP 28
STEP 31 Remove the vacuum pump from the reservoir, install and tighten the reservoir fill cap.
STEP 32 Start and run the machine at low idle, turn the wheel to full left and then to full right, stop the machine and check for leaks.
STEP 33 W230R595
Install the steering wheel, install and tighten the mounting nut and washers, tighten the nut to 50 Nm (37 lbf-ft).
STEP 29
Install the skirts onto the cab or canopy.
STEP 34 Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
W230R594
Install the center cap on the steering wheel.
84547255A
Issued 11-11
Printed in E.C.
5001-8
AUXILIARY STEERING PRIORITY VALVE Removal
Installation
1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine,
1. Connect and hand tighten tube reliefe return (5) to the elbow in the steering priority valve.
2. Put master disconnect switch in OFF position.
3. Tighten pressure tube reliefe return (5).
3. Remove all dirt and grease from auxiliary steering priority valve and adjacent area. See illustration on page 9.
4. Tighten the bolts (6).
4. Remove hydraulic reservoir fill cap.
2. Install washers and bolts (6).
5. Connect and tighten the hose orbitrol (7). 6. Connect and tighten steering pressure hose (9).
5. Connect a vacuum pump to hydraulic reservoir.
7. Connect and tighten accumulator (1).
6. Start vacuum pump.
8. Connect and tighten the hose orbitrol (2).
7. Tag and disconnect the hose hydraulic tank from the suction port (4) from auxiliary steering pump and motor. Install a cap on the fitting and a plug in the hose.
9. Connect electrical connector to the pressure switch (3).
8. Tag and disconnect tank return tube (10) from the priority valve. Install a cap on the elbow and a plug in the tube. 9. Stop the vacuum pump. 10. Tag and disconnect the wiring from the steering solenoid (8). 11. Tag and disconnect the wiring from the pressure switch (3).
steering
the
hose
10. Connect electrical connector to the steering solenoid (8). 11. Start vacuum pump. 12. Connect and tighten tank return tube (10). 13. Connect and tighten hose to auxiliary steering pump port (4). 14. Stop vacuum pump. Disconnect vacuum pump from hydraulic reservoir. 15. Install fill cap on hydraulic reservoir.
12. Tag and disconnect the hose orbitrol (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 the hose hydraulic accumulator (1) from the priority valve. Install a cap on the elbow and a plug in the hose.
17. Check to make sure priority valve operates correctly. See Section 5002.
14. Tag and disconnect steering pressure hose (9) from priority valve. Install a cap on the fitting and a plug in the hose.
18. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
15. Tag and disconnect the hose orbitrol (7) from priority valve. Install a cap on the fitting and a plug in the hose. 16. Loosen tube reliefe return (5) connected to elbow installed in steering priority valve. 17. Support auxiliary steering priority valve. Remove four bolts (6) and washers. 18. Remove auxiliary steering priority valve.
84547255A
Issued 11-11
Printed in E.C.
5001-9
11
1
10
6 12 8
7
4
3
2
9
13
5
W270R012
1. 2. 3. 4. 5. 6. 7.
HOSE HYDRAULIC ACCUMULATOR HOSE ORBITROL PRESSURE SWITCH HOSE HYDRAULIC TANK TUBE RELIEF RETURN BOLT + WASHER HOSE ORBITROL
8. 9. 10. 11. 12. 13.
STEERING SOLENOID HOSE STEERING VALVE HOSE TANK RETURN REAR CHASSIS AUXILIARY STEERING PRIORITY VALVE AUXILIARY STEERING PUMP
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5001-10
STEERING PRIORITY VALVE Removal 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine, 2. Put master disconnect switch in OFF position. 3. Remove all dirt and grease from steering priority valve (7) and adjacent area. See illustration on page 11. 4. Remove hydraulic reservoir fill cap. 5. Connect a vacuum pump to hydraulic reservoir. 6. Start vacuum pump. 7. Tag and disconnect all hoses connected to the steering priority valve (7). 8. Loosen and remove eight bolts (4) and two spit flanges (3). 9. Remove the high pressure pump discharge tube (5), discard O-rings (6). 10. Support the steering priority valve (7), remove mounting bolts (8). 11. Remove steering priority valve (7). 12. Discard O-ring (9).
Installation 1. Install bolts with washers (8) through priority valve. Install new O-ring (9) on top of priority valve. Install priority valve (7) onto low pressure pump, tighten bolts to 84.7 to 101.7 Nm (750 to 900 lbf-in). 2. Install new O-rings (6) onto high pressure pump discharge tube (5). 3. Place tube into position and intsall two split flanges (3) and eight bolts (4) with washers, tighten bolts to 84.7 to 101.7 Nm (750 to 900 lbf-in). 4. Connect all hoses as tagged to the steering priority valve (7). 5. Stop vacuum pump. 6. Disconnect reservoir.
vacuum
pump
from
hydraulic
7. Install fill cap on hydraulic reservoir. 8. Put battery disconnect switch in ON position. Start engine and run at low idle for 30 seconds. Stop engine and check for leaks. 9. Check to make sure steering priority valve operates correctly. See Section 5002. 10. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
84547255A
Issued 11-11
Printed in E.C.
5001-11
2
1
9
6 5
6
4
7
3
8
W270R017
1. 2. 3. 4. 5.
LOW PRESSURE PUMP (LOADER PUMP) HIGH PRESSURE PUMP (STEERING PUMP) SPLIT FLANGE BOLT STEERING PUMP OUTPUT LINE
6. 7. 8. 9.
O-RINGS STEERING PRIORITY VALVE BOLT O-RING
STEERING PRIORITY VALVE ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5001-12
AUXILIARY STEERING PUMP AND MOTOR Removal 1. Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine,
7. Connect ground cable (1) to ground stud of auxiliary steering pump and motor (7) following tag installed during removal.
2. Put master disconnect switch in OFF position.
8. Connect positive cable (2) to B+ stud of auxiliary steering pump and motor (7) following tag installed during removal.
3. Tag and disconnect two wiring harness (8) from auxiliary steering pump and motor (7) solenoid. See illustration on page 13.
9. Connect wiring harness wires (8) to auxiliary steering pump and motor (7) following tags installed during removal.
4. Tag and disconnect positive cable (2) from B+ stud of auxiliary steering pump and motor (7). 5. Tag and disconnect ground cable (1) from ground stud of auxiliary steering pump and motor (7). 6. Remove hydraulic reservoir fill cap. 7. Connect a vacuum pump to hydraulic reservoir. 8. Start vacuum pump. 9. Disconnect suction hose (4) from auxiliary steering pump and motor (7). Install a plug in suction hose and cap on fitting. 10. Stop vacuum pump. 11. Loosen fittings on pressure tube (5). 12. Support auxiliary steering pump and motor (7). Remove nuts (3), cap screws, and washers securing auxiliary steering pump and motor (7). 13. Remove pressure tube (5) and auxiliary steering pump and motor (7).
Installation 1. Position auxiliary steering pump and motor (7) on its mounting plate while connecting and hand tightening pressure tube (5) to auxiliary steering priority valve (6). See illustration on page 13.
10. Put master disconnect switch in ON position. 11. Start and run engine at low idle and raise bucket 500 mm (20 inches) above ground. Check that auxiliary steering light on information center is OFF. IMPORTANT: In following Step, do not run auxiliary steering pump and motor continuously for more than 20 seconds at a time without a two minute cool down. 12. With engine at low idle and machine steering straight ahead, turn key switch to OFF position to stop engine and then immediately back to ON position (not START position). Auxiliary steering pump and motor should start operating immediately. Check that auxiliary steering light on information center is ON and auxiliary steering pump and motor is operating. 13. Turn steering wheel all the way to left and right to make sure that auxiliary steering pump and motor operates correctly. 14. Restart engine. Check that auxiliary steering light on information center stays ON and auxiliary steering pump and motor is operating. After about three seconds motor should stop operating and auxiliary steering light should go out. 15. Let engine run and allow batteries to recharge for a minimum of 10 minutes.
2. While supporting auxiliary steering pump and motor (7) have an assistant install cap screws, washers, and nuts (3) to secure auxiliary steering pump and motor (7), tighten the nuts. 3. Tighten pressure tube (5) fittings securely. 4. Start vacuum pump. 5. Remove plug from suction hose (4) and cap from elbow. Connect suction hose to elbow installed in auxiliary steering pump and motor (7). 6. Stop and disconnect vacuum pump. Install fill cap in hydraulic reservoir. 84547255A
Issued 11-11
Printed in E.C.
5001-13
10
8 9
10 3 4 5
2
7 1
9
6
5 7
4
W270R018
1. 2. 3. 4. 5.
GROUND CABLE POSITIVE CABLE NUT (4) SUCTION HOSE PRESSURE TUBE
6. 7. 8. 9. 10.
AUXILIARY STEERING PRIORITY VALVE AUXILIARY STEERING PUMP AND MOTOR WIRING HARNESS REAR CHASSIS HYDRAULIC ACCUMULATOR
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5001-14
STEERING CYLINDER Removal 1. Loosen the fill cap for the hydraulic reservoir to release pressure in the reservoir, then tighten the fill cap. 2. Disconnect grease hoses (1) from steering cylinders (4-11). See illustration on page 15. 3. Disconnect hydraulic hoses (2, 3, 9, 10, 16 and 17) from steering cylinders (4-11). 4. Install a plug in each hose (2, 3, 9, and 10) to prevent entry of foreign matter. 5. Remove cap screw (13). 6. Remove pin (12). 7. Remove washers (14). 8. Remove cap screw (8), washer (7), and spacer (6) securing pivot pin (5) at rear of steering cylinders (4-11). 9. Use a suitable driver and drive pivot pin (5) out of steering cylinder (11). 10. Remove steering cylinders (4-11).
Installation 1. Put steering cylinders (4-11) in position in machine. 2. Make sure washers (14) are installed between steering cylinders (4-11) and front frame of machine. 3. Install the pivot pin (5) to secure rear of steering cylinders (4-11) to machine frame (15). Install spacer (6), washer (7), and cap screw (8) to secure pivot pin (5). 4. Tighten cap screw (8). 5. Install pin (12) in front of steering cylinders (4-11). Make sure that washers (14) are installed in correct position. 6. Install cap screw (13) in steering cylinders (4-11) rod end and pin (12). Tighten cap screw (13). 7. Connect hose assemblies 2, 3, 9, 10, 16 and 17) to steering cylinders (4-11). 8. Connect grease hoses (1) to steering cylinders (4-11). 9. Tighten hydraulic reservoir fill cap. 10. Start engine. 11. Turn steering wheel all the way to right and then to the left several times. 12. Stop the engine. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
84547255A
Issued 11-11
Printed in E.C.
5001-15
8 7
6
5
15
2
9 3
11
16
4 10 17
12
13
1
14
W270R023
1. 2. 3. 4. 5.
GREASE HOSE 6. HOSE ASSEMBLY 7. HOSE ASSEMBLY 8. STEERING CYLINDER 9. PIVOT PIN 10.
SPACER 11. WASHER 12. CAP SCREW 13. HOSE ASSEMBLY 14. HOSE ASSEMBLY 15.
STEERING CYLINDER PIN CAP SCREW WASHER REAR CHASSIS
16. HOSE ASSEMBLY 17. HOSE ASSEMBLY
STEERING CYLINDER ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5001-16
STEERING BACK PRESSURE VALVE Removal 1. Remove the fill cap for the hydraulic reservoir to release pressure in the reservoir, attach a vacuum pump to the reservoir, start the pump. 2. Disconnect hoses 2 and 5 from the pressure valve (4). 3. Remove the nuts (10), bolts (11) and washer (12) from the pressure valve, remove the valve from the machine.
Installation 1. Install the valve (4), bolts (11), washer (12) and nuts (10) onto the machine, tighten the bolts. 2. Install new O-rings (8) onto the fittings of the hoses, install and tighten the hoses. 3. Stop the vacuum pump, install and tighten the reservoir filler cap. 4. Start and run the machine at low idle, turn the steering wheel from full left lock to full right lock holding the steering over relief. 5. Stop the machine and check for leaks. 6. Check fluid level in hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
84547255A
Issued 11-11
Printed in E.C.
5001-17
1
A 2
3 10
A
12
11 9
12
7
4
8
13 6
5
W270R022
1. 2. 3. 4. 5. 6. 7.
STEERING CONTROL VALVE RETURN HOSE CONNECTOR RELIEF VALVE RETURN HOSE TO FILTERS RETURN MANIFOLD REAR CHASSIS
8. 9. 10. 11. 12. 13.
O-RING CONNECTOR NUTS BOLTS WASHER CONNECTOR
STEERING BACK PRESSURE VALVE ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5001-18
NOTES
84547255A
Issued 11-11
Printed in E.C.
5002
Section 5002 STEERING SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
5002-2
TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding The Results Of The Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 4 4 5 5 5 5 6 6 7 8 9 10
Printed in E.C.
5002-3
SPECIAL TOOLS
B785789
380001731 FLOWMETER
B009638
380001739 PRESSURE TEST FITTING KIT
B797157
380001740 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM NOTE: The steering hydraulic schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual.
4. Do the main hydraulic pump test. See Section 8002. If the main pump is bad, repair or replace the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir is correct. Visually inspect the steering system for leakage and damage.
5. Test the steering cylinders for leakage, refer to instructions on page 8. If a steering cylinder is leaking, repair or replace the steering cylinder.
2. The loader/steering pump differential pressure must be properly adjusted. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump differential Pressure.
6. If the steering system is noisy test the back pressure relief valve, refer to instructions on page 9.
3. Do the steering limit valve pressure test. Refer to page 6. If the pressure is above or below specifications, adjust the steering limit valve.
84547255A
Issued 11-11
Printed in E.C.
5002-4
AUXILIARY STEERING SYSTEM PUMP TEST Equipment Required
6. Connect the ammeter clamp (1) to the cable as in illustration.
1. 380001731 Flowmeter 2. 380001740 Flowmeter fitting kit
Test Procedure 1. Install articulation lock.
1
BB830300
1. AMMETER CLAMP
1
7. Make sure that the parking brake is applied and the bucket is on the floor. W230R407
1. ARTICULATION LOCK
NOTE: When performing this pressure check, always be sure the articulation lock is in place, especially when working in the articulation joint areas. 2. Loosen and remove the outlet hose to the Auxiliary Steering Pump from the Auxiliary Steering Priority Valve. 3. Install a plug into the Auxiliary Steering Priority Valve. 4. Connect the inlet of the flowmeter to the outlet line of the Auxiliary Steering Pump. 5. Install the outlet hose of the flowmeter in the hydraulic reservoir and hold in place with wire.
8. Make sure that temperature.
the
oil
is
at
operating
9. Make sure that the load valve for the flowmeter is open (zero pressure). 10. Start and run the engine. 11. Stop the engine and turn the key back to the On position. 12. Turn the steering wheel, this will activate the auxiliary steering pump. 13. Turn the load valve on the flowmeter towards CLOSED until the pressure is 104 bar (1500 psi). 14. Read the flowmeter and ammeter gauges and record the readings. 15. The flowmeter reading must not be less than 24.6 L/min, (6.5 U.S. gpm). The ammeter reading must be 315 amps. 16. Turn the key switch to the OFF position. If the flow was less than the specification, or if the amperage was more than 315 amperes, remove the auxiliary steering motor and pump. Test the auxiliary steering motor. If the motor is good, make repairs to the pump.
84547255A
Issued 11-11
Printed in E.C.
5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST Test Equipment
5. Push the button on the remote starter switch (1) and look at the voltmeter in the tester.
1. A 24 volt battery that is fully charged. NOTE: A 24 volt battery system (two 12 volt batteries in a series) is used for this test. A 12 volt battery system will cause damage to the auxiliary steering motor. 2. A remote starter switch.
6. Turn the load control (8) until the voltmeter (7) indicates 24 volts. Look at the ammeter (6) in the tester. Make a record of the ammeter indication.
6
3. A tachometer to check the armature speed.
7
4. A Sun Electric VAT-33 Starting and Charging System Tester.
Test Procedure
8
1. Remove the connector that is between the terminals on the magnetic switch and the auxiliary steering motor. 2. Remove the auxiliary steering motor from the auxiliary steering pump. 3. Remove the drive coupling from the auxiliary steering motor (3). 4. Connect the auxiliary steering motor (3), remote starter switch (1) and tester (2) to the 24 volt battery system (5) as illustrated.
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.
5 B790852
1. 2. 3. 4. 5.
84547255A
7. Hold the tachometer against the armature shaft. Look at the tachometer. Make a record of the indication.
Understanding The Results Of The Test
4
3
6. AMMETER 7. VOLTMETER 8. LOAD CONTROL
8. Release the button on the remote starter switch (1).
2
1
B795328
2. If the armature speed was less than 6950 r/min (rpm) and the ammeter indication was higher than 30 amperes, replace the motor.
REMOTE STARTER SWITCH TESTER AUXILIARY STEERING MOTOR AMMETER CLAMP 24 VOLT BATTERY SYSTEM
Issued 11-11
Printed in E.C.
5002-6
STEERING PRIORITY VALVE NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and Adjusting the Loader/Steering Pump Differential Pressure.
Pressure Setting Test
4. Make sure that the temperature of the hydraulic oil is at least 54° C (129° F).
1. Install articulation lock (1).
5. To measure the temperature of the oil using the instrument panel: A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored. 6. Apply the parking brake. 7. Start and run the engine at full throttle. 8. Lower the lift arms and hold the control lever in the FLOAT position.
1
9. Hold the bucket control lever in the rollback position. W230R407
1. ARTICULATION LOCK
IMPORTANT: When performing the following pressure check and adjustment, the articulation lock must be installed. Use caution when working in or near the articulation area. 2. Remove the dust cap from the test port (1-2).
10. Continue holding until the specified temperature of the oil is reached. 11. Stop the engine. 12. Start the engine and operate the machine at full throttle. 13. With the articulation lock still in place, turn and hold the steering wheel for a hard right turn. 14. Continue holding the steering wheel, and read the pressure gauge. 15. The pressure gauge must indicate 239 to 243 bar (3465 to 3525 psi). If the pressure is not correct, adjust the steering relief valve.
2 1 W270R019
1. G1 TEST PORT 2. G2 TEST PORT
3. Connect a 345 bar (5000 psi) pressure gauge to the test port (2). NOTE: Make sure when you connect the pressure gauge that you do so in a manner that you can read the pressure gauge while sitting in the operators seat.
84547255A
Issued 11-11
Printed in E.C.
5002-7
Pressure Setting Adjustment 1. Turn the adjusting screw clockwise to increase the pressure setting. Turn the adjusting screw counterclockwise to decrease the pressure setting.
1
2. Repeat pressure test procedure. 3. If necessary, adjust the limit valve again until within the specified range. 4. Stop the engine before removing the pressure gauge.
2 W270R020
1. STEERING PRIORITY VALVE 2. LIMIT VALVE
84547255A
Issued 11-11
Printed in E.C.
5002-8
STEERING CYLINDER LEAK TEST NOTE: Make sure all persons are clear of the area of the center pivot. Make sure the center pivot is free of any obstructions. 1. Park the machine on a level surface. 2. Turn the machine all the way to the right. 3. Stop the engine and apply the parking brake. 4. Find the tube that is connected to the rod end of the left-hand steering cylinder. Disconnect the tube from the left-hand cylinder. 5. Install a plug in the tube. 6. Start and run the engine at full throttle. 7. Turn the steering wheel to the right. Hold the steering wheel for a full right turn. Have another person check for leakage from the opening of the rod end of the left-hand steering cylinder. 8. If there is constant leakage from the rod end, the piston packing in the left-hand steering cylinder is damaged. Repairs must be made. See Section 5005.
84547255A
9. Connect the tube to the rod end of the left-hand steering cylinder. 10. Turn the machine all the way to the left. 11. Stop the engine. 12. Find the tube that is connected to the rod end of the right-hand steering cylinder. Disconnect the tube from the right-hand steering cylinder. 13. Install a plug in the tube. 14. Start and run the engine at full throttle. 15. Turn the steering wheel to the left. Hold the steering wheel for a full left turn. Have another person check for leakage at the opening of the rod end of the right-hand steering cylinder. 16. If there is constant leakage from the rod end, the piston packing in the right-hand steering cylinder is damaged. Repairs must be made. See Section 5005. 17. Connect the tube to the rod end of the right-hand steering cylinder.
Issued 11-11
Printed in E.C.
5002-9
STEERING BACK PRESSURE VALVE
2
1
4
3
W270R021
1. STEERING CONTROL VALVE 2. RETURN HOSE
84547255A
3. CONNECTOR M27 ORB 4. RELIEF VALVE
Issued 11-11
Printed in E.C.
5002-10
Pressure Test 1. Disconnect the return hose (2) from the connector (3). 2. Install a â&#x20AC;&#x153;Tâ&#x20AC;? fitting and connect a pressure gauge capable of reading 35 bar (500 psi). 3. Start and run the machine at high idle.
4. Turn the steering wheel and observe the pressure. 5. The pressure should be 8 to 10 bar (115 to 145 psi). 6. If pressure is not as specified, replace the relief valve. NOTE: The relief valve is not adjustable.
84547255A
Issued 11-11
Printed in E.C.
Section 5005
5005
STEERING CYLINDERS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
5005-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 3 5
Printed in E.C.
5005-3
SPECIFICATIONS Torque for piston cap screw ...............................................................1600 to 1830 Nm (1180 to 1349.7 pound feet) Torque for gland ..................................................................................................407 Âą 68 Nm (300 Âą 50 pound feet)
STEERING CYLINDER Disassembly 1. Fasten tube (18) in a vise. Be careful not to damage the tube. See illustration on page 4. 2. Remove gland (1) from tube (18). 3. Pull piston rod (14) and piston (9) straight out of tube (18). 4. Fasten piston rod (14) yoke in vise and put a support below piston rod near piston (9). Put a shop cloth between support and piston rod to prevent damage to piston rod. 5. Loosen and remove bolt and washer (8) that hold piston (9). 6. Remove piston (9) from piston rod (14).
Inspection 1. Clean all parts in cleaning solvent. 2. Check to be sure that piston rod (14) is straight. If piston rod is bent, install a new piston rod. 3. Inspect inside of tube (18) for deep grooves and other damage. If there is any damage to tube, a new tube must be used. 4. Remove small scratches on piston rod (14) or inside tube (18) with emery cloth of medium grit. Use emery cloth with a rotary motion. 5. Inspect bushing (17). If bushing requires replacement, remove grease fitting (15) and retaining rings (16) then press bushing from tube end.
7. Remove and discard seal (13), loader ring (12), wear ring (11), cast iron ring (10) and seal (20) from piston (9). 8. Remove gland (1) from piston rod (14). 9. Remove and discard O-ring (7), backup ring (6), rod wiper (2), rod seal (3), buffer seal (4), and bearing (5) from gland (1).
84547255A
Issued 11-11
Printed in E.C.
5005-4
16 17
15
16 18
8 9 11 19
4 5
6
7
10
20
12
13
3 14
1 2
W270R024
1. 2. 3. 4. 5.
GLAND ROD WIPER ROD SEAL BUFFER SEAL BEARING
6. 7. 8. 9. 10.
BACKUP RING O-RING BOLT AND WASHER PISTON RING CAST IRON
11. 12. 13. 14. 15.
WEAR RING RING LOADER SEAL PISTON ROD GREASE FITTING
16. 17. 18. 19. 20.
RETAINING RING BUSHING TUBE SCREW SEAL
STEERING CYLINDER ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5005-5
Assembly 1. Install bearing (5) in gland (1). 2. Install buffer seal (4) in gland (1) so that lips of seal are toward small end of gland. 3. Install rod seal (3) in gland (1). Rod seal must be installed so that lips of seal are toward small end of gland. Seal can be difficult to install. Use tools that will not damage seal. See illustration on page 4. 4. Install rod wiper (2) in gland (1) with wiper lips toward large end of gland. 5. Install O-ring (7) on gland (1). 6. Install backup ring (6) on gland (1). The backup ring must be toward large end of gland. If backup ring is not flat on both sides, the side that is not flat must be toward O-ring (7). 7. Fasten piston rod (14) yoke in vise. 8. Lubricate piston rod (15) and bore in gland (1) with clean hydraulic oil. NOTE: If a new gland (1) is being installed, write part number of cylinder on gland. 9. Push gland (1) onto piston rod (14) large end first. If necessary, use a soft hammer to drive the gland onto piston rod. 10. Put a support below and near the end of piston rod (14). Put a cloth between support and piston rod to prevent damaging piston rod. 11. Install new cast iron ring (10) on piston (9). 12. Install new wear ring (11) on piston (9). 13. Install a new loader ring (12) on piston (9). 14. Install a new seal (13-20) over loader ring (12). 15. Clean the threads on the end of piston rod (14) and threads of bolt (8) using Loctite cleaning solvent. Allow to dry. Apply Loctite 243 to piston rod threads 6.4 mm (1/4 inch) from open end of piston rod so that there is 12.7 mm (1/2 inch) of Loctite 243 on piston rod threads. DO NOT apply Loctite to first 6.4 mm (1/4/inch) of piston rod threads.
84547255A
16. Install bolt and hardened washer (8) in piston (9). 17. Install piston (9) on piston rod (14) and start bolt (8) into piston rod. 18. Tighten bolt (8) to a torque of 1600 to 1830 Nm (1180 to 1349.7 pound feet). 19. Fasten tube (18) in vise. Be careful not to damage tube. 20. Apply petroleum jelly to O-rings (7) and backup ring (6) on gland (1) and to sealing surface in tube (18). 21. Lubricate piston (9) and inside of tube (18) with clean hydraulic oil. 22. Push the piston (9) straight into tube (18). Be careful not to damage cast iron ring (10), wear ring (11), and seal (13) on piston (9). 23. When piston (9) is in smooth part of tube (18), start gland (1) into tube (18). 24. If the original parts are being assembled: A. Tighten gland to a torque of 407 ± 68 Nm (300 ± 50 pound-feet). B. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds). C. If, after tightening gland, the self-tapping screw (19) holes are not aligned, a new hole for self-tapping screw must be drilled. See Step 25. 25. If a new gland (1) or a new tube (18) are being assembled: A. Tighten gland (1) to a torque of 407 ± 68 Nm (300 ± 50 pound-feet). B. Use a No. 27 drill bit and drill a hole half in gland (1) and half in tube (18). Drill to a depth of 11 mm (7/16 inch). Do not drill within 13 mm (1/2 inch) of a hole for gland wrench. C. Install and tighten self-tapping screw (19) to a torque of 2.3 Nm (20 inch-pounds). 26. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.
Issued 11-11
Printed in E.C.
5005-6
NOTES
84547255A
Issued 11-11
Printed in E.C.
Section 5006
5006
CENTER PIVOT
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
5006-2
TABLE OF CONTENTS SPECIFICATIONs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 4 6 9
Printed in E.C.
5006-3
SPECIFICATIONS SPECIAL TORQUES M16 bolt for upper pivot pin.......................................................................404 to 448 Nm (298 to 331 pound-feet) M12 bolts for bearing retainers and lower pivot pin ..................................603 to 752 Nm (445 to 555 pound-feet) M12 bolts for lower pin plate .....................................................................404 to 448 Nm (298 to 331 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) 380001744................................................................................ *Top bearing driver, bottom bearing driver and plate * (Requires screw, two nuts, and two washers from 380001735)
BC06A173
380001744 DRIVER SET
BC06A174
CAS2029 DRIVER SET
NOTE: The upper bearing can be installed using 380001744 Driver Set and the lower bearing can be installed using CAS2029 Driver Set.
84547255A
Issued 11-11
Printed in E.C.
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.
84547255A
19. Disconnect the supply hose. 20. Install a cap on the hose and a plug in the fitting. 21. Stop the vacuum pump. 22. Loosen and remove the self-locking nut and bolt that hold the pivot pin for the steering cylinder rod eye. 23. Remove the pivot pin from the rear frame and the steering cylinder rod eye. 24. Remove the washer from the rear frame. Move the steering cylinder out of the way. 25. Repeat steps 22, 23 and 24 for the other steering cylinder. 26. Loosen and remove the Ferry head screws and retainers that fasten the drive shaft to the front yoke. Move the drive shaft out of the way. 27. Place two stands below and in contact with the front frame. 28. Install blocks between the rear axle and the rear frame on both sides of the machine to prevent the rear frame from tipping. 29. Put a jack in contact with both sides of the rear frame near the center pivot area. Use another jack at the rear of the machine to prevent the rear frame from tipping. 30. Loosen and remove the bolt (1), washer (2), and spacer (3) that fasten the upper pivot pin (4) to the rear chassis (5). 31. Use a prybar to remove the upper pivot pin (4). 32. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10). 33. Loosen and remove the bolts (1) and washers (2) that fasten the lower pin plate (15) to the bottom of the rear chassis (5). 34. Use the ram and hand pump to remove the lower pivot pin (10). 35. Install the puller on the bottom spacer (14), see Special Tools in this section.
Issued 11-11
Printed in E.C.
5006-5
1
2 3
4
16
1
6
2
7 8 9 6
16
5
10 16 11 6
12
A
16
8 13 6
8
2
14
1
2 1
15 2 1
A
W270R002
1. 2. 3. 4.
BOLT WASHER SPACER UPPER PIVOT PIN
5. 6. 7. 8.
REAR CHASSIS SEAL BEARING RETAINER SHIM
9. 10. 11. 12.
UPPER PIVOT BEARING LOWER PIVOT PIN LOWER BEARING SPACER LOWER PIVOT BEARING
13. 14. 15. 16.
BEARING RETAINER BOTTOM SPACER LOWER PIN PLATE FRONT CHASSIS
CENTER PIVOT ASSEMBLY
84547255A
Issued 11-11
Printed in E.C.
5006-6 36. Remove the bottom spacer (14). 37. Release the parking brake. 38. Use prybars to turn the left rear wheel backwards and the right rear wheel forward to move the front of the rear frame to the left for access to the bearings. Install blocks under the wheels to prevent the rear frame from moving.
Assembly 1. Pack the bearing cones with grease. Be careful not to mix the bearing cones. 2. Lubricate the bore in the top pivot with grease. 3. Install a bearing cup (20) in the top pivot (22). 4. Install the bearing driver (17) and plate (21).
39. Apply the parking brake.
17 18
40. Hold the bearing retainer (13) in place and loosen and remove the bolts (1) and washers (2) that fasten the bearing retainer (13) and shims (8) to the bottom of the rear pivot.
19
41. Remove the bearing retainer (13) and shims (8). 42. Remove the lower bearing spacer (11) from the top of the lower pivot. 43. Loosen and remove the bolts (1) and washers (2) that fasten the bearing retainer (7) and shims (8) to the top of the top pivot. 44. Remove the bearing retainer (7) and shims (8). 45. Use the puller to remove the seal (6) from the top of the bottom pivot. 46. Use the puller to remove the seal (6) from the bottom of the top pivot. 47. Use an acceptable driver, the hydraulic ram, and the hand pump to remove the upper pivot bearing (9) from the top pivot. See Special Tools in this section. NOTE: The spacers are matched to the bearing sets. Do not mix the spacers. Do not use the old spacers if new bearing sets are being installed. 48. Use an acceptable driver, the hydraulic ram, and the hand pump to remove the lower pivot bearing (12) from the bottom pivot. See Special Tools in this section. NOTE: The spacers are matched to the bearing sets. Do not mix the spacers. Do not use the old spacers if new bearing sets are being installed.
20 21
22 BC06A118
17. BEARING DRIVER 18. NUT 19. SREW
20. BEARING CUP 21. PLATE 22. TOP PIVOT
5. Tighten a nut (18) on the screw (19) until the bearing cup (20) is seated in the bore of the top pivot (22). Remove the bearing driver (17) and plate (21) from the top pivot (22). 6. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the top pivot (22). 7. Install the bearing driver (17) and plate (21). 8. Tighten a nut (18) on the screw (19) until the bearing cup (26) is seated against the spacer (24). Remove the bearing driver (17) and plate (21) from the top pivot (22).
23
17
18
19 26
24
49. Use an acceptable driver to press the seal (6) out of each bearing retainer (7 and 13).
25
21
22 BC06A119
23. BEARING CONE 24. SPCAER
84547255A
25. BEARING CONE 26. BEARING CUP
Issued 11-11
Printed in E.C.
5006-7 9. Put the bearing retainer (7) in place on the upper pivot bearing assembly (9). 10. Install the bearing driver (17) and plate (21). 11. Tighten a nut (18) on the screw (19) until the bearing retainer (7) is tight against the upper pivot bearing assembly (9).
7
17
18
19
18. Use an acceptable driver to install the seal (6) in the bottom of the top pivot. 19. The bottom of the seal (6) must be even with the bottom of the top pivot.
27
9
BC06A125.
21
22
20. Apply grease to the upper pivot pin (4). BC06A120
12. Measure the gap (27) between the bearing retainer (7) and the top pivot (22). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 13. Remove the bearing driver (17), plate (21), and bearing retainer (7) from the top pivot. 14. Install the shims (8) and the bearing retainer (7). 15. Install the washers (2) and bolts (1). Tighten the bolts (1) to 124 Nm (91 pound-feet).
21. Install the upper pivot pin (4) in the top pivot. 22. Lubricate the top pivot until grease is forced out of the seal (6). 23. Rotate the upper pivot pin (4) to check the bearing assembly. The upper pivot pin (4) must rotate smoothly, but not easily. Leave the upper pivot pin (4) in place to keep dirt out of the upper pivot bearing (9). 24. Lubricate the bore for the bottom pivot with grease. Install a bearing cup in the bottom pivot. 25. Install the bearing driver (17) and plate (21).
16. Install the seal (6) in the bearing retainer (7). The top of the seal (6) must be even with the top of the bearing retainer (7).
19
21
18 28 29
17 BC06A123
BC06A121
17. Fill the other seal (6) for the top pivot with grease.
26. Tighten a nut (18) on the screw (19) until the bearing cup (28) is seated in the bore in the bottom pivot (29). 27. Remove the bearing driver (17) and plate (21) from the bottom pivot (29). 28. Install a bearing cone (25), spacer (24), the other bearing cone (23), and the remaining bearing cup (26) in the bottom pivot (29). 29. Install the bearing driver (17) and plate (21).
84547255A
Issued 11-11
Printed in E.C.
5006-8
25
21
18
40. Install the seal (6) in the bearing retainer (13). The bottom of the seal (6) must be even with the bearing retainer (13).
19
24 29 23
26
17
BC06A124
30. Tighten a nut (18) on the screw (19) until the bottom bearing cup (26) is seated against the spacer (24). 31. Remove the bearing driver (17) and plate (21) from the bottom pivot (29).
BC06A126
41. Install the other seal (6) in the bottom pivot. The top of the seal (6) must be even with the top of the bottom pivot.
32. Put the bearing retainer (13) in place on the lower pivot bearing (12). 33. Install the bearing driver and plate.
21
18
19 29 30
12
BC06A121
17
13
42. Install the lower bearing spacer (11) and the bottom spacer (14). BC06A125
34. Tighten a nut (18) on the screw (19) until the bearing retainer (13) is tight against the lower pivot bearing assembly (12). 35. Measure the gap (30) between the bearing retainer (13) and the bottom pivot (29). Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims (8) equal to that value. 36. Remove the bearing driver (17), plate (21) and bearing retainer (13) from the bottom pivot.
43. Apply grease to the lower pivot pin (10). 44. Install the lower pivot pin (10) in the bottom pivot. 45. Hold the bottom spacer (14) in place and lubricate the bottom pivot until grease is forced out of the seal (6). 46. Rotate the lower pivot pin (10) to check the bearing assembly. The lower pivot pin (10) must rotate smoothly, but not easily. 47. Remove the lower pivot pin (10) and the upper pivot pin (4). 48. Remove the bottom spacer (14).
37. Install the shims (8), the bearing retainer (13), washers (2) and bolts (1). 38. Tighten the bolts (1) to 124 Nm (91 pound-feet). 39. Fill the seal (6) for the bearing retainer (13) with grease.
84547255A
Issued 11-11
Printed in E.C.
5006-9
CONNECTING THE FRONT FRAME TO THE REAR FRAME 1. Release the parking brake. 2. Move the rear frame into alignment with the front frame. 3. Move the steering cylinders as required to move the rear frame into alignment with the front frame.
26. Align the hole in the pivot pin with the holes in the steering cylinder rod eye, and install the pivot pin. 27. Install the bolt and self-locking nut that hold the pivot pin.
4. Apply the parking brake.
28. Repeat steps 25, 26 and 27 for the other steering cylinder.
5. Apply grease to the upper pivot pin (4).
29. Start the vacuum pump.
6. Install the upper pivot pin (4), spacer (3), washer (2) and bolt (1). Be careful not to damage the seal (6).
30. Connect the return hose. 31. Connect the supply hose.
8. Apply grease to the lower pivot pin (10).
32. Put the bracket for the hoses in position on the rear frame. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the rear frame.
9. Install the lower pivot pin (10) in the frames. Be careful not to damage the seal (6).
33. Put the bracket for the hoses in position on the front frame.
10. Use the ram and hand pump to install the bottom spacer (14). See Special Tools in this section.
34. Install the bolts, flat washers, and self-locking nuts that fasten the bracket to the front frame.
11. Install the lower pin plate (15), three inner bolts (1), and washers (2) that fasten the lower pin plate (15) to the lower pivot pin (10).
35. Connect the hoses for the steering cylinders.
12. Tighten the bolts (1) to 69 Nm (51 pound-feet).
37. Stop the vacuum pump.
13. Measure the gap between the lower pin plate (15) and the bottom pivot. Make a record of the measurement. Subtract 0.0762 to 0.1016 mm (0.003 to 0.004 inch) from the measurement. Select shims equal to that value.
38. Connect the front wiring harness to the rear wiring harness.
7. Tighten the bolt (1) to 404 to 448 Nm (298 to 331 pound-feet).
14. Loosen the bolts (1) that fasten the lower pin plate (15) to the lower pivot pin (10). 15. Start the six outer bolts (1) into the lower pin plate (15) and the bottom pivot. 16. Install the shims (8). 17. Tighten the six outer bolts (1) to 404 to 448 Nm (298 to 331 pound-feet). 18. Tighten the three inner bolts (1) to 603 to 752 Nm (445 to 555 pound-feet).
36. Connect the brake hose for the front brakes at the front bracket.
39. Put the clamp on the wiring harness in position on the bracket. Install the bolt, lock washer, and nut that fasten the clamp on the wiring harness to the bracket. 40. Put the ground wire in position on the stud. Install the washer and nut that fasten the ground wire to the stud. 41. Install a tie strap to fasten the wiring harness to the tube. 42. Disconnect the vacuum pump from the hydraulic reservoir.
19. Remove the jacks from the rear frame.
43. Check the fluid level in the hydraulic reservoir. Add oil as required.
20. Remove the blocks from the rear axle.
44. Install the fill cap in the hydraulic reservoir.
21. Remove the stands from the front frame. 22. Put the drive shaft in position on the front yoke.
45. Bleed air from the front axle bleed screws. Refer to Section 7002 for complete brake bleeding instructions.
23. Install new Ferry head screws that fasten the drive shaft to the front yoke.
46. Lubricate the pivot pins for the steering cylinder rod eyes.
24. Tighten the Ferry head screws to 53 to 62 Nm (39 to 46 pound-feet).
47. Install the covers on both sides of the machine.
25. Put the steering cylinder rod eye in position in the frame. Install the washer between the steering cylinder rod eye and the rear frame. 84547255A
Issued 11-11
Printed in E.C.
5006-10
NOTES
84547255A
Issued 11-11
Printed in E.C.
Section 5008
5008
AUXILIARY STEERING MOTOR AND PUMP
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
5008-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 4 4 4
Printed in E.C.
5008-3
SPECIFICATIONS Auxiliary steering motor Maximum amperes...............................................................................................................................30 amperes Minimum armature speed ............................................................................................................ 6950 r/min (rpm) Motor .......................................................................................................................................................... 24 volts Auxiliary steering pump Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes (6.5 U.S. gpm at 1500 psi at 315 amperes)
84547255A
Issued 11-11
Printed in E.C.
5008-4
AUXILIARY STEERING MOTOR AND PUMP Disassembly
Assembly
NOTE: Refer to Section 5001 for removal and installation of the auxiliary steering motor and pump.
1. Lubricate all parts with clean hydraulic oil before assembly.
NOTE: The pump is the only component that is disassembled. The switch (8) and motor (1) are replaced as units and are not serviced. Refer to the illustration on page 5.
2. Lubricate and install a new seal (4) and retaining ring (3) on the plate (17). Refer to the illustration on page 5.
1. Make an alignment mark on the pump assembly and motor (1). 2. Loosen and remove the two screws (15) and lock washers (14) that hold the pump assembly to the motor (1). 3. Remove and discard the mounting gasket (13), retaining ring (3) and seal (4) from the pump assembly. 4. Loosen and remove the four bolts (2) that hold the pump assembly together. 5. Remove the end plate (21) from the body (18). 6. Remove and discard the seal (6) and backup ring (5) from the end plate (21). 7. Remove the wear plate (23), drive gear (20) and driven gear (19) from the body (18). 8. Remove the body (18) from the plate (17). 9. Remove and discard the O-rings (7) from the body (18).
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.
84547255A
Issued 11-11
Printed in E.C.
5008-5
8
10
9
11 16
12
1 13 3
17
4
14
15
5 6 23
19 7 22 18 22 7 20 23 6 5 21 2 BS01C121
1. 2. 3. 4. 5. 6.
MOTOR BOLT RETAINING RING SEAL BACKUP RING SEAL
7. 8. 9. 10. 11. 12.
O-RING SWITCH CABLE SCREW LOCK WASHER WASHER
13. 14. 15. 16. 17. 18.
GASKET LOCK WASHER SCREW WIRE PLATE BODY
19. 20. 21. 22. 23.
DRIVEN GEAR DRIVE GEAR END PLATE PINS WEAR PLATE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
5008-6
NOTES
84547255A
Issued 11-11
Printed in E.C.
5009 Section 5009 JOYSTICK STEERING SYSTEM (JSS) (optional)
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italy
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed at E.C. Issued November, 2011
5009-2
TABLE OF CONTENTS SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 JOYSTICK STEERING SYSTEM (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Activation logic of the software and joystick steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Preliminary check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 System efficiency check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3rd F-N-R SWITCH ON THE ARMREST (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PROCEDURES FOR TURNING ON / OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Main F-N-R lever activation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Activation procedure for auxiliary JSS F-N-R (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turning JSS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turning JSS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turning on auxiliary F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turning off auxiliary F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 KICK-DOWN BUTTON TO SELECT A LOWER GEAR (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 JSS Related Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WORKING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 JSS HYDRAULIC PRESSURE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 STEERING CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
84547255A
Issued 11-11
Printed in E.C.
5009-3
SAFETY STANDARDS For all the safety measures, refer to the use and maintenance book supplied together with this manual. WARNING: this symbol is used to draw attention to the safety instructions given in the manual. When found in the text, carefully read the accompanying message and pay attention to the risk of serious or deadly accidents. M171C
WARNING: when the machine is running and the Joystick Steering control has been activated, to avoid serious or deadly accidents pay particular attention to sudden movements in the cab.
WARNING: make sure that the Joystick Steering control has been turned off during the operations of raising and lowering the machine from the trailer loading deck. The machine could fall off the ramp or off the trailer and cause serious or deadly accidents. It is absolutely forbidden to use the Joystick Steering control for these operations.
WARNING: when the Joystick Steering system is active and the operator presses the implement locking switch, the Joystick Steering function will be active.
WARNING: the function of the Joystick steering control is forbidden when driving on roads.
WARNING: the emergency steering system always comes into operation via the main steering system.
WARNING: the main steering system is always active and is considered the normal steering system. Regular use of the Joystick Steering is allowed within 20 km/h and this limit depends on the actual conditions of the ground being worked on.
WARNING: before starting to drive on the public highway, lock the LH arm in the vertical position with the special pin.
84547255A
Issued 11-11
Printed in E.C.
5009-4
JOYSTICK STEERING SYSTEM (JSS) Description of the JSS The JSS is mounted in parallel with the standard steering system, that always has priority, increasing the comfort and the functionality of the machine. The main components of the JSS are: - proportional valve PVG32 with pilot solenoid valve incorporated;
The JSS must be disconnected for driving on roads For safely turning on and off, there is a specific procedure to avoid accidental turning on/off and steering (as indicated in the Use and Maintenance Manual).
3
- compensation valve PVFC for the pressures from the proportional valve PVG32 and from the power steering valve; - pressure switch LS connected to the line from the power steering to detect use of the standard steering: normally closed (N/C) switch, it opens at 60 bar; - pilot pressure switch connected to the proportional valve PVG32 to detect whether the pilot solenoid valve is working/defective: normally closed (N/C) switch, it opens at 8 bar; - joystick (1) controlling the proportional valve incorporated in the left armrest (2); - position switch incorporated in the left armrest with double contact: 1. at the top N/C (normally closed); 2. at the bottom N/O (normally open); - three-position switch (3) to control the JSS: 1. Off - retained with mechanical lock; 2. On - retained; 3. activation - transitory position (clicks);
4
1
5
2
- relay K2 for JSS power supply; - set of diodes to combine the JSS control button and the AUX F-N-R enabling button in safety;
521E-4R001
- Can Module that incorporates the JSS activation procedure and the software for monitoring the system; - modulation controller of the electric signal between the joystick and proportional valve; - left-hand F-N-R switch (4) on the armrest (2); - Kick-Down left-hand button (5) on the armrest (2). The joystick steering gear is available only on request. The speed with which it is possible to work with this system depends on the type of terrain.
84547255A
Issued 11-11
Printed in E.C.
5009-5
Activation logic of the software and joystick steering
Joystick steering is turned off as soon as:
To enable the joystick steering system it is necessary first of all to put the machine in a safe condition and then activate the JSS with the control button. On sending the JSS activation signal the software runs a preliminary test to verify whether the machine is in a condition of safety. Secondarily it checks the efficiency of the system.
- the gearbox / main lever control is moved from neutral to forward or reverse drive;
Preliminary check The condition of the machine being made safe is given by: - left armrest completely lowered; - gear lever in neutral; - implement locking switch disenabled; - pilot pressure switch on;
- the left armrest is raised;
- the steering wheel is operated; - the proportional valve suffers trouble; - system errors occur; - the JSS switch is disconnected; - ignition turned off. A slight audible warning and a message on the display warn that the JSS has been disconnected. To switch the JSS back on after disconnection, follow the system activation procedure. The errors related to the JSS are only displayed with the JSS switch in the ON position and they can be reset by moving the JSS switch onto OFF.
- joystick steering switch in neutral; - machine stationary.
System efficiency check - with the JSS off, the pilot pressure must be less than or equal to 8 bar; - the software monitors the armrest position switch. When the JSS is turned on and during the whole time it stays on, the switching of the N/O-N/C switch is checked. Any trouble is detected with an error message and the system is switched off; When all the prerequisites have been satisfied the JSS will be powered via closure of PIN 1:21 of the output AIC LSD1 that switches over the relay K2 enabling the electric supply of the JSS with consequent activation of the system under safety conditions. Once the supply is made, the system verifies that the alarm signal of the valve of the JSS is = 0 and that on the joystick supply PIN the signal is = 1. After activation the system stays in operation for the whole time in which: - the left armrest stays lowered; - the main gear lever stays in neutral; - the steering wheel stays inactive; - the control switch stays ON; - no system errors occur;
84547255A
Issued 11-11
Printed in E.C.
5009-6
3rd F-N-R SWITCH ON THE ARMREST (left-hand side) For the joystick steering system it is necessary to integrate a third F-N-R switch in the current operating logic of the gearbox. For this purpose the software of the control unit of the transmission (TCU) is able to turn the F-N-R switch on the armrest on/off when the JSS is activated. It is therefore necessary for the TCU control unit to generate a new CAN message stating JSS F-N-R enabled/disenabled. The software in the transmission control unit (TCU) has to be compatible with systems with and without the joystick steering system. This means that all the current TCU functions will remain unchanged.
Position of the F-N-R switches in the cab 1. F-N-R (current) main located on the gear lever of the steering column; 2. F-N-R (current) AUX incorporated on the implement control joystick (or console on right-hand side); 3. JSS F-N-R (new) AUX incorporated on the armrest on the left-hand side.
PROCEDURES FOR TURNING ON / OFF Among the three F-N-R activation devices, the one on the gear lever of the steering column has priority over the other two auxiliary ones, which must be enabled, each one with a specific enabling signal and according to a specific activation procedure. If enabled, the JSS F-N-R auxiliary switch located on the left-hand side armrest has priority over the F-N-R auxiliary switch on the right. Main F-N-R lever activation procedure
- in order to enable the auxiliary JSS switch, it is necessary to check the position of the switch; - if the auxiliary JSS F-N-R switch is in neutral, enabling will take place directly; - if the auxiliary JSS F-N-R switch is not in neutral, enabling will not take place directly, the software will check the status of the JSS F-N-R switch; Indeed, only at the moment when the JSS F-N-R switch is in the neutral position will its enabling be confirmed (without pressing the JSS activation switch again); - during activation of the JSS a message is sent via CAN stating "JSS ON"; - the auxiliary JSS F-N-R switch is disenabled when the JSS is disenabled; - when turning off the JSS a message is sent via CAN stating "JSS OFF". Turning JSS ON - Press the JSS ON button: a. armrest on left-hand side lowered; b. implement locking switch disenabled; c. low JSS piloting pressure; d. JSS joystick in neutral; e. no error in the JSS; f. main F-N-R gear control lever in neutral; g. vehicle stationary (speed less than or equal to 1.5 km/h). Turning JSS OFF 1. Using the steering wheel; 2. gear lever on the steering column / main F-N-R switch not in neutral; 3. armrest on left-hand side raised; 4. JSS enabling button OFF; 5. errors in the JSS; 6. engine OFF.
- The main F-N-R lever on the steering column is always active; - the main F-N-R switch has priority over all the other auxiliary F-N-R switches; - one of the auxiliary F-N-R switches can be enabled only if the main switch is in neutral. Activation procedure for auxiliary JSS F-N-R (left-hand side) The auxiliary JSS F-N-R switch is incorporated in the armrest on the left-hand side that is an integral part of the JSS: - the auxiliary JSS F-N-R switch will be enabled with the activation of the JSS; - when the JSS is activated, a message is sent via CAN to the gearbox control unit; - this will cause activation of the auxiliary JSS switch as well as starting the JSS F-N-R enabling procedure; 84547255A
Issued 11-11
Printed in E.C.
5009-7 Turning on auxiliary F-N-R The auxiliary F-N-R switch is on the console on the right-hand side. If the machine is provided with an implement control joystick, the auxiliary F-N-R switch is incorporated on the joystick: - if the JSS is ON, JSS F-N-R is enabled and auxiliary F-N-R cannot be enabled; - if the JSS is OFF, the activation procedure remains unchanged, and that is: â&#x2014;? press the auxiliary F-N-R momentary enabling switch; a. main F-N-R on the steering column in neutral; b. auxiliary F-N-R switch in neutral; c. machine stationary; d. engine ON; â&#x2014;? auxiliary F-N-R provides enabling signal for 8 seconds; a. within 8 seconds: 1. press the parking brake release button; 2. engage forward or reverse drive; 3. permanent enabling signal for auxiliary F-N-R; b. after 8 seconds: 1. auxiliary F-N-R is disenabled. Turning off auxiliary F-N-R - gear lever on the steering column / main F-N-R switch not in neutral; - parking brake engaged; - engine off.
KICK-DOWN BUTTON TO SELECT A LOWER GEAR (left-hand side) Besides the current button to select a lower gear on the implement control joystick (or on the console on the right-hand side according to the option), a second button will be available to select a lower gear incorporated in the left armrest with the joystick steering system. This button will be activated together with the JSS and it will disenable the button on the right-hand side to select a lower gear.
84547255A
Issued 11-11
Printed in E.C.
5009-8
Summary table of the ON/OFF statuses The following table illustrates the states of activation of the JSS, JSS F-N-R and auxiliary F-N-R: Starting status
JSS Off
JSS Off
JSS Off
JSS On
JSS / AUX F-N-R disenabled
(JSS) AUX F-N-R enabled
JSS / AUX F-N-R disenabled
JSS (AUX) F-N-R enabled
Activation signal
JSS activation signal
JSS activation signal
Auxiliary F-N-R enabling signal
F-N-R enabling signal or JSS enabling signal
JSS safety conditions to be respected
Implement locking switch disenabled; Armrest on left-hand side lowered; Vehicle stationary; Main F-N-R gear lever = neutral; JSS pilot pressure less than 8 bar; JSS Joystick = neutral; No error JSS system.
Implement locking switch disenabled; Armrest on left-hand side lowered; Vehicle stationary; Main F-N-R gear lever = neutral; JSS pilot pressure less than 8 bar; JSS Joystick = neutral; No error JSS system.
Resulting JSS status
JSS On
JSS On
JSS Off
JSS On
F-N-R conditions
JSS On JSS F-N-R = neutral.
JSS On JSS F-N-R = neutral.
Vehicle stationary; Main F-N-R gear lever = neutral; AUX F-N-R = neutral.
Vehicle stationary Main F-N-R gear lever = neutral; AUX F-N-R = neutral.
Resulting F-N-R status
JSS F-N-R Enabled Stays enabled.
JSS F-N-R Enabled Stays enabled.
AUX F-N-R Enabled within 8 seconds release parking brake and engage F or R to maintain enabling.
JSS F-N-R Enabled
F-N-R conditions not respected
If JSS F-N-R not in neutral.
If JSS F-N-R not in neutral.
If AUX F-N-R not in neutral.
Alternative F-N-R status
JSS / AUX F-N-R disenabled.
JSS / AUX F-N-R disenabled.
JSS / AUX F-N-R disenabled.
84547255A
Issued 11-11
Printed in E.C.
5009-9
JSS Related Error Handling All JSS related errors will be displayed only while the JSS activation switch is in ON position except for the red error “Short to power on power supply” and the failure of the activation switch which will be always displayed when present. All JSS related errors will be reset by switching the JSS activation switch to the OFF position. While ignition is ON and JSS is deactivated the software will check if the JSS Power Supply is off. Check JSS Output Control is low/open if not a red error will be displayed “Short on JSS power supply JSS active”
Table of error codes Error Item
Location of Error Detection
1812y
JSC
Open Circuit, Short to Battery or Short to Ground at JSS armrest switch.
1816y
JSC
Open Circuit / JSS activation switch mechanical defect.
1820y
JSC
Check JSS Relay, JSS Valve, JSS Joystick power supply connections.
1821r
JSC
Short to ground on JSS Relay 85/AIC1.21 or short to Power on Relay 86/87a. Or Activation Switch failure.
1823y
JSC
JSS RELAY, GROUND CONNECT., BAD ELEC. CONNCT. Permanent ground at JSS Relay (87) open circuit or short to power.
1824y
JSC
Short to battery at activation button. Aactivation switch failure.
1829y
JSC
Joystiok Steering is not calibrated.
1830y
JSC
Open circuit between activation switch Pin 3 and C5.E Pin 1.
1831y
JSC
JSC CONTROLLER, WRONG OPERATION. JSC controller internal fault.
1832y
JSC
JSC CONTROLLER, JSC SIGNAL IN, OUT OF LIMITS. Input signal from JSS joystick to JSC controller out of limits. (Joystick Neutral: USignal>40%UBat + <60%Ubat; Joystick Actuated: USignal>20%UBat + <80%UBat)
1833y
JSC
Output signal from JSC controller to valve out of limits. Check connector of JSS valve and JSC controller.
1834y
JSC
JSS CONTROLLER, JSC OUTPUT, SC to BAT Power is applied to one of the JSC controller outputs. Check electrical connection for short to power. Or JSC internal Relay is defect.
1835y
AIC
JSS-valve/Pin4 JSC/Pin5 short to power, short to ground or open circuit.
1836y
JSC
JSS CONTROLLER, BOARD TEMPERATURE, OUT OF LIMITS Temperature on the JSC board is <-40°C or >+85°C; Check ambient temperature or short circuit at JSC power outputs.
1837y
JSC
JSS CONTROLLER, SWITCHED POWER, OUT OF LIMITS Switched power supply at JSC Pin3 is out of limit; Check elect connection for electrical transients, burst or drifts.
1838y
JSC
Neutral Sw out of range.
Message
1841y
JSC
JSS valve internal error, spool position not accurate or signal voltage out of range.
1842y
JSC
JSS valve Pin2 (alarm signal) open circuit.
1843y
JSC
Pilot pressure switch open when JSS is deactivated. High pilot pressure on JSS valve even when JSS is not active. Pilot Dump valve stuck close or short to power on valve power supply. Or open circuit on JSS pilot pressure switch lines or JSC/Pin8.
1844y
JSC
Pilot pressure switch short to ground.
JSC
Pilot pressure switch stays closed (Input JSC8 =1) allthough JSS is activated. With low pilot pressure on JSS valve no steering with JSS possible. Error is displayed when JSS active and Pilot pressure stays low. Pilot Dump valve stuck open or open circuit or short to ground on JSS valve power supply (Valve Connector Pin4). Or short to power on JSS pilot pressure switch lines or input JSC/Pin8.
1845y
84547255A
Issued 11-11
Printed in E.C.
5009-10 Error Item
Location of Error Detection
1846y
JSC
Standard steering orbitro tank pressure transducer switch short to power or short to ground.
1847y
JSC
JSC Model type not available, no model type information available in JSC, probably missing information from AIC.
1850y
JSC
JSS joystick Pins2, 4 or 6 short to ground, short to battery or open circuit. Or JSS joystick internal failure.
Message
1852y
JSC
JSS joystick Pins5 open circuit. Or JSS joystick internal failure.
1860y
JSC
CAN timeout of C5.E detected by JSC.
1861y
JSC
CAN timeout of AIC detected by JSC Controller.
1863y
AIC
Internal malfunction transmission controller. TCU message JSS F-N-R dissabled or JSS F-N-R not activated.
9128y
AIC
CAN timed out during operation
9134y
AIC
CAN timed out during operation C5.E detected by AIC
9135y
AIC
CAN timed out during operation JSC detected by AIC
84547255A
Issued 11-11
Printed in E.C.
5009-11
WORKING PRINCIPLE The main components of the JOYSTICK STEERING SYSTEM are: - hydraulic valves â&#x2014;? proportional steering valve PVG32 (1) for activating the steering cylinders with an incorporated pilot solenoid valve (2); â&#x2014;? valve PVFC (3) that controls the LS signals from the proportional valve PVG32 (1) and from the power steering valve (4) and transmits them to the pump (5) to allow correct operation; - two-way PVRES control joystick that sends the signal to the pilot solenoid valve (2) located inside the proportional valve PVG32 (1); - modulation controller (7) of the electric signal between the joystick (10) and proportional valve (1); - F-N-R switch (12) on the armrest on the left-hand side; - Kick-Down button (13) on the left-hand armrest; - F-N-R switch (14) on console on right-hand side; - Kick-Down button (15) on implement control Joystick on right-hand side.
If, when using the JSS, a manoeuvre is made with the steering wheel, the pressure switch LS (11), located on the LS line of the power steering valve (4) receives enough pressure to switch over and therefore to turn off the JSS. IT IS IMPORTANT to remember that, for reasons of safety, the joystick (10) must be turned off for driving on roads. Use of the joystick can be disenabled at any time by the operator with the steering wheel, which has priority over the joystick. In addition, it is absolutely prohibited to use the JSS during the operations of loading and unloading the machine on and off a truck for transport. For signalling any JSS malfunctioning, there are some warning lights on the control panel accompanied by audible warnings of two different lengths depending on the trouble that has occurred.
The JSS is controlled by a switch (8) located on the control panel, which, via software loaded on a component (9) installed inside the armrest, checks that there are all the necessary safety conditions for correct operation of the system. These conditions must be: a. left armrest completely lowered; b. gear lever in neutral; c. implement locking switch disenabled; d. pilot pressure sensor closed; e. JSS switch (8) in neutral; f. machine stationary. If not even one of these conditions occurs, the software will not allow activation of the system. Only after the software receives all the information and confirms that the general situation is correct will it allow operation of the joystick that, via an electric signal, activates the pilot solenoid valve (2) located inside the proportional valve PVG32 (1). The actuator inside the electric module (6) of the proportional valve of the steering gear (1) sets the directional shuttle in operation that allows the oil to flow to the line of the steering cylinder. Through the pilot pressure switch of the valve PVG32 (1), the software verifies that the oil pressure is correct for the operation of the joystick (10).
84547255A
Issued 11-11
Printed in E.C.
2 212 bar
1 212 bar
3 212 bar
5009-12
W230R057
Connections port 1. to the steering priority valve port 2. to the auxiliary steering valve port 3. to the LS port of the valve PVG32 Illustration of the valve PVFC 84547255A
Issued 11-11
Printed in E.C.
T2
B
LS
A
P
T2
LX
PP
TO
T
T LS
M
P
A
B
PP
TO
LX
5009-13
W190-4R092
Connections ports A and B. to the steering cylinder on the stem side and bottom side 350 bar, 100 l/min LS port. to port 3 of the valve PVFC port P. to the steering priority valve 350 bar, 150-230 l/min
port PP. port T. port T2. port TO, LX.
pilot pressure switch 8 bar outlet 25/40 bar not used not used
Illustration of the valve PVG32 84547255A
Issued 11-11
Printed in E.C.
5
1
7
10
8
3
4
11
9
6
2
5009-14
W190-4R099
1. 2. 3. 4. 5. 6.
Valve PVPV Valve PVM Valve PVB Shuttle PVBS Valve PVES Valve PVSI
7. 8. 9. 10. 11.
Screws Seal Seal Seal Seal
Exploded view of the valve PVG32 84547255A
Issued 11-11
Printed in E.C.
5009-15
10
10
20
5.7 Nm
1.7 Nm
1.7 Nm
5.7 Nm
+/Vbat Signal SW1 +/SW2
20
2
1 3
PVE E
-
+
W190-4R093
Illustration of the Joystick Steering PVRES
84547255A
Issued 11-11
Printed in E.C.
5009-16
ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM Removal
STEP 2 1
STEP 1 Park loader on level ground and lower bucket to ground. Put transmission in NEUTRAL, apply parking brake, and shut down engine. Put the master disconnect switch in the OFF position. Remove all dirt and grease from the steering system valves and adjacent area.
8
3
2
5
IMPORTANT: MARK and LABEL all the various parts (electric connections, hydraulic connections, etc..) so as to facilitate all the various operations of INSTALLATION.
4
6 7 W270R050
Disconnect the chassis frame cable (1) from the valve PVG32 (2), the connection (3) from the pilot pressure switch at 8 bar, the four-way "DEUTSCH" connection (4) of the electric actuator of the proportional valve, the two-way "DEUTSCH" connection (5) of the solenoid valve. From the valve PVFC (6) disconnect the connection (7) from the 60 bar pressure switch and release the connection by removing the strap (8).
84547255A
Issued 11-11
Printed in E.C.
5009-17
STEP 3
STEP 4
1
11
2
9 10
1 W190-4R072
Release the chassis frame cable (1) from the stud pin (9) positioned on the rear chassis frame (10) of the machine by removing the nut (11).
W190-4R073
From the right-hand side of the machine, under the cab, open the door to access the fuse and relay compartment and disconnect the ten-position "PACKARD" interface connector of the chassis frame cable (1) with the connector of the cab/joystick cable (2). Remove the chassis frame cable (1).
84547255A
Issued 11-11
Printed in E.C.
5009-18
STEP 5
STEP 6
3
1
4 4
3
2
2
W190-4R075
W190-4R074
Disconnect the twelve-position "DEUTSCH" interface connector (1) of the cab/joystick cable (2) with the armrest cable (3) and the six-position connector (4).
Disconnect the cab/joystick cable (2) from the cab wiring (3) by disconnecting the twelve-position "DEUTSCH" connector (4).
84547255A
Issued 11-11
Printed in E.C.
5009-19
STEP 7
STEP 8 5
2
6
7
10 9
8
5 12 11 W190-4R076
Disconnect the cab/joystick cable (2) from the steering control device (5) by detaching the sixteen-position connector (6), the six-position "DEUTSCH" connector (7) of the transmission switch and the cab cable connector (8).
W190-4R077
Remove the steering control device (5) from the supporting plate (9) by removing the nut (10, qty. 3), and the screw (11) complete with washer (12).
STEP 9 6
2
3
4
1 5
W190-4R078
Staccare il cavo cabina/joystick (1) dai punti di fissaggio situati sul pannello fusibili e relè (2) mediante la rimozione dei due connettori a cinque posizioni (3), svitando i dadi (4, q.tà totale 2), le rondelle (5) e le viti (6). Remove the cab / joystick cable (1). 84547255A
Issued 11-11
Printed in E.C.
5009-20
STEP 10
ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM 7
8
7
8
1 W190-4R079
Disconnect the two 24-volt relays (7) and the four diodes (8) from the respective connectors of the cab / joystick cable (1).
STEP 11
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Plate Steering control device Cab/joystick cable Chassis frame cable Washer Screw Nut Joystick Steering System switch Nylon strap Screw Washer Nut 10A fuse in position ECA-F2 Cab Stud pin on rear chassis frame Cable terminal with eyelet Metal cable clamp Armrest cable Control joystick CAN module Relay Diode Pressure switch 8 bar Pressure switch 60 bar Steering valve PVFC Steering valve PVG32 Armrest position switch F-N-R switch Kick-Down switch Solenoid Valve
9
W190-4R080
To remove the armrest cable (9), refer to the chapter titled "JOYSTICK STEERING ARMREST."
84547255A
Issued 11-11
Printed in E.C.
5009-21
8
14 C
20 19
12 11 10
15
28
27 29
E C
13
E
16
18
1 21
2
22 3
9 23
7 6 5
A 17
26 30
A
4 25
24
721E-4R001
ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM Printed in E.C.
Issued 11-11
84547255A
5009-22
20
21 27
19
22
22
29 8
22
22 28
21
26 13
24 25 16 23
2
W190-4R097
WIRING DIAGRAM OF THE JOYSTICK STEERING SYSTEM 84547255A
Issued 11-11
Printed in E.C.
5009-23
Installation
STEP 13
STEP 12 1
1 3
8 11
2
5
9 10 W190-4R088
4
Fasten the chassis frame cable (1) to the stud pin (9) positioned on the rear chassis frame (10) of the machine by installing the nut (11).
6
STEP 14
7 W270R050
Connect the chassis frame cable (1) to the valve PVG32 (2), the connection (3) of the pilot pressure switch at 8 bar, the four-way “DEUTSCH” connection (4) of the electric actuator of the proportional valve, the two-way “DEUTSCH” connection (5) of the solenoid valve. Connect the connection (7) of the 60 bar pressure switch to the valve PVFC (6) and secure the connection by inserting the strap (8) on one of the two fixing screws of the valve.
12
14 13 16 15
W190-4R083
On the right-hand side of the machine, under the cab, open the door providing access to the fuse and relay compartment and fit the steering control device (12) on the supporting plate (13) by installing the nut (14, qty. 3), and the screw (15) complete with washer (16).
84547255A
Issued 11-11
Printed in E.C.
5009-24
STEP 15
STEP 17 2
12
9 10
8 1 3
2
11
3
1
W190-4R085
W190-4R100
Connect the two 24-volt relays (2) and the four diodes (3) to the respective connectors of the cab / joystick cable (1).
Fasten the cab/joystick cable (1) via the connectors (8) to the fixing points on the fuse and relay panel (9) by installing the nuts (10, qty. 2), washers (11) and screws (12).
STEP 18
STEP 16 4
1
5
14
6
13 1
7
W190-4R086
Connect the cab/joystick cable (1) to the cab cable (13) via the twelve-position “DEUTSCH” connector (14). W190-4R084
Connect the cab/joystick cable (1) to the steering control device (4) via the sixteen-position connector (5). Connect the six-position “DEUTSCH” connector (6) of the transmission button and the cab cable connector (7). 84547255A
Issued 11-11
Printed in E.C.
5009-25
STEP 19
STEP 21
3
4
2
5
1
2 W190-4R073
W190-4R087
Connect the ten-position “PACKARD” interface connector of the chassis frame cable (1) with the connector of the cab/joystick cable (2).
Connect the twelve-position “DEUTSCH” interface connector (4) of the cab/joystick cable (2) with the armrest cable (3) and the six-position connector (5).
STEP 20
3
W190-4R082
To install the armrest cable (3), refer to the chapter titled “JOYSTICK STEERING ARMREST.”
84547255A
Issued 11-11
Printed in E.C.
5009-26
STEERING VALVES PVG32 AND PVFC Removal
STEP 3
STEP 1 Remove all dirt and grease from the steering valves and adjacent area.
5
STEP 2
2
6 1 4 2
3
W270R053
W270R052
Detach the rigid steering pipe LS (3) from the valve PVG32 (1) and from the valve PVFC (2). Disconnect hose (4) from the accumulator hydraulic.
Disconnect the connection hose (5) from the valve PVFC (2), with the auxiliary steering valve and the hose (6) coming from the steering priority valve. Plug the hoses in order to avoid oil spillage and the fittings to prevent debris getting inside.
STEP 4
7 W270R054
Disconnect the suction hose (7) of the auxiliary steering valve from the valve PVG32.
84547255A
Issued 11-11
Printed in E.C.
5009-27
STEP 5
STEP 7
3
1 W270R057
W270R055
Disconnect the hose to return manifold (1).
Disconnect the stem side steering cylinder line supply hose (3).
STEP 8
STEP 6
5 2
4
7
6 W270R056
Disconnect the bottom side steering cylinder line supply hose (2). W270R058
Remove the steering valve PVG32 (4) from the support (5) by taking out the fixing screws (6, qty. 4) complete with washers (7).
84547255A
Issued 11-11
Printed in E.C.
5009-28
STEP 9
STEP 12
1
11
11
6
3 2
4 5
11 W270R059
Remove the support (1) from the rear chassis frame by removing the nuts (2, qty. 4) complete with washers (3) that lock the screws (4) and spacers (5).
Unscrew the couplings (11) for connection to the hydraulic pipes from the steering valve PVFC (6).
STEP 10
STEP 13
W270R062
1 1
6 2
W270R060
Remove the support (1) with valve PVFC (6).
W190-4R014
Remove the 15 bar pilot pressure switch (1) complete with seal (2) from the steering valve PVG32.
STEP 11
STEP 14 1
8
6
9
7 3
10 W270R061
Remove the steering valve PVFC (6) from the support (1) by removing the nuts (7, qty. 2) and the washers (8) that secure the screws (9) complete with washers (10).
84547255A
W190-4R015
Remove the reduction unit (3).
Issued 11-11
Printed in E.C.
5009-29
STEP 15
STEP 17
3 1 W190-4R016
Unscrew the coupling (1) from the “LS” port of the steering valve PVG32.
STEP 16
W270R063
Unscrew the coupling (3) from the port “P”.
STEP 18
2 4
W190-4R017
Remove the two couplings (2) from the ports “A” and “B” supplying the steering cylinder line.
W270R064
Remove the coupling (4) from the port “T”.
84547255A
Issued 11-11
Printed in E.C.
5009-30
LEGEND OF JSS HYDRAULIC COMPONENTS WITH AUXILIARY STEERING SYSTEM 1. Bracket valve steering 2. Spacer 3. Bracket accumulator 4. Proportional valve PVG32 5. Valve PVFC 6. Clamp 7. Hydraulic accumulator 9. Connector 10. Connector 11. Elbow 12. Elbow 13. Tee with orifice 14. Elbow 15. Hose accumulator to PVFC valve 16. Connector 17. Tube steering LS 18. Connector 19. Hose PVFC valve to Auxiliary steering valve 20. Clamp 23. Hose auxiliary valve to Joystick Steering valve PVG32 25. Hose Joystick to priority valve 26. Hose to return manifold 27. Connector 28. Pressure trasmitter 29. Connector 31. Elbow 32. Connector 33. Hose orbitrol to reliefe valve 34. Hose reliefe valve to tank 35. Reduction 36. Switch pilot pressure 37. Washer 38. Bolt 39. Nut 40. Washer 41. Nut 42. Tube Joystick Steering left 43. Tube Joystick Steering right 44. Washer 45. Bolt 46. Elbow 47. Washer 48. Nut 49. Plate 50. Bolt 51. Washer 52. O-ring 53. Elbow 54. Block tube mounting 55. Connector 56. Connector 57. Seal 58. Priority valve 59. Chassis rear 60. Standard orbitrol 84547255A
61. Hydraulic tank 62. Auxiliary steering valve 63. Return manifold 64. Reliefe valve steering
Issued 11-11
Printed in E.C.
5009-31
D
36
53
F
B
43
59
2
46
20
C
10
46
19 M
9
55
26
B
4
35
42
D
33
M
57
10
4
41 40
B
1
23
K 58
E
12 19
25
C A
E
J
F
H
45
12
44
L C
11
25 60
34
H
L
39 37
16
38 15
37
5
17
32 J 13
33 G
A
D
W270R065
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM- Table 1 Printed in E.C.
Issued 11-11
84547255A
5009-32
F
E
G
64
28
59 47
43
53 41
27
3 48
7
31
6
58
45
44 17
14 L K
63 52
25 26
61 M
62 18
49
56
50
H
29 34
23
54
19 J
41
51
W270R066
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM - Table 2 84547255A
Issued 11-11
Printed in E.C.
5009-33
NOTES
84547255A
Issued 11-11
Printed in E.C.
5009-34
LEGEND OF JSS HYDRAULIC COMPONENTS WITHOUT AUXILIARY STEERING SYSTEM 1. Bracket valve steering 2. Spacer 3. Bracket accumulator 4. Proportional valve PVG32 5. Valve PVFC 6. Clamp 7. Hydraulic accumulator 8. Elbow 9. Connector 10. Connector 11. Elbow 12. Elbow 13. Tee with orifice 14. Elbow 15. Hose accumulator to PVFC valve 16. Connector 17. Tube steering LS 18. Connector 19. Hose PVFC valve to standard orbitrol 20. Clamp 23. Hose priority valve to Joystick Steering valve PVG32 25. Hose Joystick steering valve PVFC to priority valve 26. Hose to return manifold 27. Connector 28. Pressure trasmitter 29. Connector 31. Elbow 32. Connector 33. Hose orbitrol to reliefe valve 34. Hose reliefe valve to tank 35. Reduction 36. Switch pilot pressure 37. Washer 38. Bolt 39. Nut 40. Washer 41. Nut 42. Tube Joystick Steering left 43. Tube Joystick Steering right 44. Washer 45. Bolt 46. Elbow 47. Washer 48. Nut 49. Plate 50. Bolt 51. Washer 52. O-ring 53. Elbow 54. Block tube mounting 55. Connector 56. Connector 57. Seal 58. Priority valve 59. Chassis rear 84547255A
60. Standard orbitrol 61. Hydraulic tank 63. Return manifold 64. Reliefe valve steering
Issued 11-11
Printed in E.C.
5009-35
D 57
33 53
35
36 42
M
43
19
M F
59
2
46
B
9
C
26 B
G
10
46
D
K
10
4 41
55
40
23
58
12
19 C
A
E
H
25
20
J 45
L
F
C
J
12
44
11
25 39
34
H
B
1
5
L
60
37
16
38 15
17
37 13
A
32
G 33
19
D
W270R067
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERING SYSTEM- Table 1 Printed in E.C.
Issued 11-11
84547255A
5009-36
F
E
G
64
28
59 47
43
53 41
27
3 48
7
58
6
45
31
44 17
14 L
K
63
25
52 26 61
58 M
49
50
H
29 34
23
54 41
51
W270R068
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERING SYSTEM - Table 2 84547255A
Issued 11-11
Printed in E.C.
5009-37
Installation
STEP 20
Before refitting the steering valves, clean all the disassembled parts thoroughly using a specific wash solvent and dry them using a jet of air. Carry out the procedure for installation following the phases described here: 1. Check each part to verify that they there are no dents, scoring or other defects. 2. Replace all damaged or deformed parts with new ones.
2
STEP 19 W270R070
Fit the coupling (2) for connection with the suction hose of the steering priority valve on the port “P”. Tighten the coupling to a torque of 170 Nm.
STEP 21 1 3
W270R069
Fit the coupling (1) for connection with the hydraulic outlet hose on the port “T” of the steering valve PVG32. Tighten the couplings to a torque of 310 Nm.
W190-4R022
Fit the two couplings (3) for connection with the steering cylinder line supply hoses on the ports “A” and “B”. Tighten the couplings to a torque of 100 Nm.
84547255A
Issued 11-11
Printed in E.C.
5009-38
STEP 22
STEP 25
6
8
5 7 1 W190-4R023
Fit the coupling (1) on the port “LS”. Tighten the coupling to a torque of 45 Nm.
STEP 23
W270R071
Fit the coupling (6) on the port “1” of the steering valve PVFC (5), the “T” coupling (7) on the port “2” and the coupling (8) on the port “3”. Tighten all the couplings to a torque of 45 Nm.
2
W190-4R024
Fit the reduction unit (2) of the pilot pressure switch on the port “Pp”. Tighten the reduction unit to a torque of 45 Nm.
STEP 24
3
4
2 W190-4R025
Install the pilot pressure switch (3) complete with seal (4) on the reduction unit (2).
84547255A
Issued 11-11
Printed in E.C.
5009-39
STEP 26
STEP 28
1
1 2
6
3
5
10 9
7 8
4 W270R072
W270R074
Fit the steering valve PVFC (2) on the support (1) by inserting the screws (3, qty. 2) complete with washers (4), the nuts (5) and washers (6).
Install the screws (7, qty. 3) and the washers (8) for assembling the support (1) complete with valve PVFC and lock them with the nuts (9) and the washers (10). Tighten the nuts to a torque of 110 Nm.
STEP 27
STEP 29
1
1
11
2 13 W270R073
Position the support (1) with valve PVFC (2) on the LH side wall of the rear chassis frame of the machine.
12
W270R075
Fit the steering valve PVG32 (11) on the support (1) using the screws (12, qty. 4) and washers (13). Tighten the screws to a torque of 30 Nm.
84547255A
Issued 11-11
Printed in E.C.
5009-40
STEP 30
STEP 32
1
3 W270R076
Connect the stem side steering cylinder line supply hose (1) on the coupling fitted on the valve PVG32. Tighten the pipe to a torque of 60 Nm.
W270R077
Connect and tighten the hose to return manifold (3) to a torque of 125 Nm.
STEP 31 STEP 33
2
4 W270R078
W270R056
Connect the bottom side steering cylinder line supply hose (2). Tighten to a torque of 60 Nm.
84547255A
Connect the suction hose (4) of the auxiliary steering valve. Tighten the pipe to a torque of 60 Nm.
Issued 11-11
Printed in E.C.
5009-41
STEP 34
STEP 35
2
1 4 6 3
5 1 W270R080
W270R079
Connect the connection hose (2) on the valve PVFC (1), with the auxiliary steering valve and the hose (3) coming from the steering priority valve. Tighten the pipes to a torque of 14 Nm.
84547255A
Connect the rigid pipe of the device â&#x20AC;&#x153;LSâ&#x20AC;? (5) on the valve PVG32 (4) and on the valve PVFC (1). Tighten the pipe to a torque of 14 Nm. Connect and tighten the hose (6) from the accumulator hydraulic.
Issued 11-11
Printed in E.C.
5009-42
JOYSTICK STEERING SYSTEM ARMREST REMOVAL
STEP 3
STEP 1 3 2
1
6 4 W190-4R037
W190-4R036
Unscrew and remove the knob (1) and the washer (2) for longitudinal armrest adjustment.
Remove the locking screws (6, qty. 4) of the cover of the armrest (3) from the support (4). Remove the cover (3).
STEP 4
STEP 2 8 3
4
7 9 5
W190-4R035
Remove the cover (3) complete with support (4) from the armrest adjustment device (5).
84547255A
W190-4R101
Disconnect the two-position “DEUTSCH” connector (7) of the “Kick-Down” button (8) with the armrest cable connector (9).
Issued 11-11
Printed in E.C.
5009-43
STEP 5
STEP 7
3 8
7
12
1
10
9 2 W190-4R102
From the inside and bottom of the armrest cover (1) unscrew the threaded washer (2) and extract the “Kick-Down” button (3) complete with cable and connector from the top of the armrest cover.
STEP 6
11 W190-4R038
Remove the nuts (8, qty. 2), washers (9), screws (10) and washers (11) from the valve PVRES (7) of the Joystick. Disconnect the six-position connector (12) from the valve (7).
5
1
6
4
W190-4R103
Disconnect the ten-position connector (4) of the “F-N-R” switch (5) with the armrest cable (6). Remove the switch (5) from the armrest cover (1).
84547255A
Issued 11-11
Printed in E.C.
5009-44
STEP 8
STEP 11 1 7
5 2
W230R049
Disconnect the ten-position connector (2) from the CAN module (1).
8 6
STEP 9
W230R052
Unscrew and remove the knob (5) for height adjustment of the armrest and spacer (6). Raise and extract the armrest device (7) from the support fixed to the seat (8).
1
3 W230R050
Detach the CAN module (1) from the support (3).
STEP 10
4
W230R051
Disconnect the three-position â&#x20AC;&#x153;DEUTSCHâ&#x20AC;? connector (4) from the armrest positioning switch. Remove the armrest cable.
84547255A
Issued 11-11
Printed in E.C.
5009-45
STEP 12
STEP 13 10
1 7 3
8
11
5
4
4 2
6 W190-4R043
With the armrest lowered remove the armrest height / angle adjustment device (2) from the support assembly (1) by removing the nut (3) and the washers (4), screws (5) and nylon bushings (6, qty. 2).
9 2
W190-4R104
Remove the locking bracket (7) of the pin (8) from the armrest height/angle adjustment device (2) by unscrewing the nuts (9, qty. 2), removing the screws (10) and the washers (11). Remove the pin (8) from inside the seat of the bracket (7).
84547255A
Issued 11-11
Printed in E.C.
5009-46
STEP 14
STEP 16 2
13 12 3
10 11
1
W190-4R046
Remove the support for fastening the safety belt by removing the nut (10) complete with washer (11), the screw (12) and washer (13).
4
STEP 17 7
5
6 W190-4R044
Unscrew the knob (2) from the support (1) and extract the armrest height/angle adjustment pin (3). Remove the closing plate (4) from the support (1) by removing the screws (5, qty. 4) complete with washers. Remove the armrest position switch (6) from the inside of the support (1) by removing the screws (7, qty. 2) and the washers.
14
W190-4R047
Remove the four fixing screws (14, qty. 4) complete with washers from the seat cushion.
STEP 15
8
9
W190-4R045
Disconnect the wiring harness from the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option). Remove the screws (8, qty. 4) and washers (9) from the base of the seat. Remove the seat inside the cab by using a hoist provided with straps. Pay particular attention when carrying out this operation so as not to cause any damage to the inside or outside of the machine. 84547255A
Issued 11-11
Printed in E.C.
5009-47
STEP 18
STEP 20 4 1
1
3
2 W190-4R048
W190-4R050
Pressing down on the seat cushion support plate (1), slightly tilt the aluminium tongue (2) to allow release of the support (1) and allow raising/rotating the front. In this phase, take great care since the aluminium tongue (2) has greatly reduced thickness and so therefore avoid breaking it.
Unhook the metal rod (4) from the locking support (3) and remove the seat cushion support plate (1).
STEP 21 3
STEP 19
5 7 6 W190-4R051
1 W190-4R049
Raise, slowly rotating, the seat cushion support plate (1).
84547255A
Turn the knob of the locking support (3) clockwise and move the plate (5) forward in such a way as to allow the sliding blocks (6, qty. 4) to slide inside the guides and get positioned in their respective seats (7). Remove the plate (5).
Issued 11-11
Printed in E.C.
5009-48
STEP 22
STEP 23
7
1 2
3
4
8
5
6
W190-4R052
Remove the plate (1) of the seat by removing the retaining bolts (2, qty. 4) and washers (3). To perform this operation it is necessary to slide the plate (1) forwards to have access to the two front nuts (4) complete with washers (5) positioned inside the guides (6, qty. 2) underlying the plate (1) of the seat. Repeat the disassembly operation of the two rear screws (7) making the plate (1) slide back.
W190-4R053
Remove the armrest support plate (8).
INSTALLATION STEP 24 6
8 W190-4R054
Position the armrest support plate (8) on the seat runners (6).
84547255A
Issued 11-11
Printed in E.C.
5009-49
STEP 25
STEP 27
10
9
2
1
W190-4R055
W190-4R057
Position the previously removed seat plate (1) on the seat support plate (2).
Install the seat plate (9). Turn the locking support (10) clockwise and at the same time push the plate (9) toward the rear of the seat to allow locking it.
STEP 26
STEP 28 13
8
11
9 1 3
4
12 W190-4R058
5
Insert the two lugs for positioning the seat cushion support plate (11) inside the two special openings shown in the figure on the seat plate (9) and hook the metal rod (13) to the catch (12). Slowly lower the seat cushion support plate (11).
6
7
W190-4R056
Push the seat plate (1) forwards. From the top, insert the two front screws (3) complete with washers (4) and lock them at the bottom, from the seat runners (7), using the nuts (5) and the washers (6). Tighten the nuts to a torque of 32 Nm. Repeat the assembly operation of the two rear screws (8) making the seat plate (1) slide back.
84547255A
Issued 11-11
Printed in E.C.
5009-50
STEP 29
STEP 31
6
5
1
7
8
2 W190-4R048
W190-4R060
Lock the seat cushion support plate (1) by restoring the correct bend in the aluminium tongue (2). In this phase, take great care since the aluminium tongue (2) has greatly reduced thickness and so therefore avoid breaking it so as not to jeopardize seat operation.
Fit the support for fastening to the safety belt by inserting the screw (5) and the washer (6), the nut (7) and the washer (8). Tighten the nut to a torque of between 47 and 68 Nm. Carefully check that the seat belt mounting hardware is tight and the seat belt is not cut or frayed.
STEP 30
STEP 32
4 3 1 9 10
W190-4R059
W190-4R061
Install the seat cushion (3) on the support plate (1) and secure it with the screws (4, qty. 4) complete with washers.
Using a hoist equipped with lifting straps, sling the seat and position it inside the cab. Connect the wiring harness to the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option). Install the seat on the base and secure it with the four screws (9) complete with washers (10). Tighten the screws to a torque of between 73 and 87 Nm. Carefully check that the tightening torque of the screws fastening the operatorâ&#x20AC;&#x2122;s seat is as prescribed and that the parts are not worn or damaged.
84547255A
Issued 11-11
Printed in E.C.
5009-51
STEP 33
STEP 34 11
5 9
8
12
4
1
6 13 10
3 7
2 W190-4R062
Fit the armrest position switch (2) on the support (1) using the screws (3, qty. 2) complete with washers. Insert the adjuster pin (4) inside the support (1) and screw the knob (5) on it. Install the closing plate (6) on the support (1) and secure it with the screws (7, qty. 4) complete with washers.
W190-4R105
Insert the armrest locking pin (8) inside the seat of the bracket (9) and fit it all on the armrest height/angle adjustment device (10) using the screws (11, qty. 2), washers (12) and nuts (13). Tighten the nuts to a torque of 7 Nm.
STEP 35
8 W190-4R106
Insert, rotate and secure the armrest locking pin (8) as shown in the figure.
84547255A
Issued 11-11
Printed in E.C.
5009-52
STEP 36
STEP 38 1 11
6
4
5
5 2
3
W190-4R065
W190-4R063
Fit the armrest height / angle adjustment device (2) on the support assembly (1) by inserting the nylon bushings (3, qty. 2), screw (4) with the washers (5) and nut (6).
Install the armrest cable connecting it to the positioning switch via the three-position â&#x20AC;&#x153;DEUTSCHâ&#x20AC;? connector (11).
STEP 37
7
9
8 10
W190-4R064
Insert the armrest device (7) inside the support (8) fixed to the seat and screw on the knob (9) for armrest height adjustment complete with spacer (10).
84547255A
Issued 11-11
Printed in E.C.
5009-53
STEP 39
STEP 41
9
5
4
1 7 2 6
W190-4R066
Install the CAN module (1) inside the special seat (2) situated on the armrest device.
8
STEP 40
W230R054
Connect the “PHOENIX” connector (5) to the valve PVRES (4) of the Joystick and fit the valve on the support (6) by inserting the screws (7, qty. 2) with the washers (8, qty. 4) and the nuts (9, qty. 2). Pay attention to the correct positioning of the valve (4) so that the letter “A” stamped on it is on the left-hand side in relation to the direction of travel of the machine.
1
STEP 42
3 W230R053
11
Connect the ten-position connector (3) to the CAN module (1).
10
12 W230R055
Insert the “Kick-Down” button (11) on the armrest cover (10) and lock it from the bottom with the threaded washer (12).
84547255A
Issued 11-11
Printed in E.C.
5009-54
STEP 43
STEP 44 2
5
4 1 7
3
6
W190-4R108
W190-4R109
Connect the two-position “DEUTSCH” connector (1) of the “Kick-Down” button (2) with the armrest cable connector (3).
Insert the “F-N-R” switch (5) in the related assembly seat of the armrest cover (4) and connect it to the ten-position connector (6) of the armrest cable (7).
STEP 45
4
9 8 W190-4R069
Put the armrest cover (4) on the support (8) and secure it with the screws (9, qty. 4).
84547255A
Issued 11-11
Printed in E.C.
5009-55
STEP 46
1 5
2 4 3
W190-4R070
Position the cover (1) complete with support (2) on the armrest adjustment device (3) and screw on the knob (4) complete with washer (5).
STEP 47 Put the battery disconnecting switch in the ON position and start the engine. Turn the steering wheel all the way to the left and then to the right several times. Switch off the engine. Check the hydraulic oil level. See the specific section for the specifications.
84547255A
Issued 11-11
Printed in E.C.
5009-56
JSS HYDRAULIC PRESSURE ADJUSTMENTS IMPORTANT: in making the following checks and pressure adjustments, the machine articulation must be locked. Great attention must be paid to following all the procedures for making the machine safe, particularly when operating on the articulation joint and near the arm of the loader.
A. Main hydraulic pressure setting of the pump This setting is given by the difference between the pressure of the hydraulic pump and the LS signal, which must be between 26±1 bar (377±14.5 psi):
1. with the engine OFF and bucket on the ground, connect a quick coupling pressure gauge to the pressure point G1 (1) of the priority valve (2, figure 1), to the LS pressure point (3) of the hydraulic pump 1 (5, figure 2) and to the LS pressure point (4) of the hydraulic pump 2 (6, figure 2); 2. with the engine at idle speed, with all the controls in neutral, JSS NOT active, the difference between the pressure P and LS must be equal to that specified 26±1 bar (377±14.5 psi); 3. with the engine at idle speed, with all the controls in neutral, JSS ON and joystick in neutral, the difference between the pressure P and LS must be equal to that specified 26±1 bar (377±14.5 psi);
2 1
W270R081
Figure 1 1. Pressure point G1 2. Priority valve
84547255A
Issued 11-11
Printed in E.C.
5009-57 4. with the engine at idle speed, with all the controls in neutral, JSS ON and joystick NOT in neutral, the difference between the pressure P and LS must be equal to that specified 26 Âą1 bar (377Âą14.5 psi);
5. if the setting is not correct, verify that all the hydraulic connections are exact, particularly the connections on the hydraulic steering valve PVFC that manages the LS signals.
5
6
7
3
4
8 W270R082
Figure 2 3. Pressure point LS hydraulic pump 1 4. Pressure point LS hydraulic pump 2 5. Hydraulic pump 1 6. Hydraulic pump 2 7. Pressure regulator hydraulic pump 1 8. Pressure regulator hydraulic pump 2
84547255A
Issued 11-11
Printed in E.C.
5009-58
B. Steering pressure limit setting With the engine at high revs, the pressure of the port G1 must be between 239 and 243 bar (3465-3525 psi): - make sure that the pressure value stated in paragraph A is as specified 26Âą1 bar (377Âą14.5 psi); - with the engine OFF and bucket on the ground, connect a quick coupling pressure gauge on the pressure point G1 of the front and bottom of the priority valve (figure 1); - with the articulation locked, engine at high revs and JSS ON begin steering with the joystick in both directions to its limit stop. Keep this condition and read the pressure value on the pressure gauge, which must be equal to that specified above 239 and 243 bar (3465-3525 psi); - if the pressure gauge records a pressure above or below the specified one, check that all the hydraulic connections have been made correctly.
3. move the joystick completely to the right and at the same tim e, with a chronometer, start measuring the time. Stop the chronometer when the machine is completely steered on the right-hand side. Take the time to compare it with the time specified in the table of speed levels. 4. move the joystick completely to the left and at the same time, with a chronometer, start measuring the time. Stop the ch ronometer when the machine is completely steered on the left-hand side. Take the time to compare it with the time specified in the table of speed levels. If the value is not in the range shown in the table, follow the system calibration procedure; 5. repeat what is specified in point 1, 2, 3 and 4 with the difference that the engine has to have high revs; 6. if the adjustments are not exact, verify the specifications given in paragraphs A and B.
C. Steering times IMPORTANT: when carrying out the following procedure check that the articulation of the machine is NOT locked. Great attention must be paid to following all the procedures for making the machine safe, particularly when operating on the articulation joint and near the arm of the loader. The speed of steering is not constant but depends on the speed reached by the vehicle. On reaching 20 km/h the steering sensitivity is reduced by 80% compared to the normal speed of steering. The JSS can be set on three different levels of steering speed. The three speed levels are: 1. from 4.5 to 5.5 sec.* 2. from 3.2 to 4.5 sec.* 3. from 2.8 to 3.2 sec.* *(time to take the machine from all right to all left). The purpose of this setting is to make steering the machine equipped with the JSS similar to the standard steering system: 1. with the engine at idle speed, with all the controls in neutral and JSS ON, steer the machine completely to the left; 2. set a speed level (e.g. 1, 2 or 3);
84547255A
Issued 11-11
Printed in E.C.
5009-59
STEERING CALIBRATION PROCEDURE ATTENTION: The views in the following steps may be different than the machine.
STEP 4
STEP 1 Before running the machine calibration procedure, the operator must carry out the following operations: - Start the engine; - Set the machine in a straight position; - Activate the Joystick Steering System; - Slightly lift the bucket off the ground; - Release the parking brake.
STEP 2 W190-4R112
Press the confirm/send button (2) within two seconds to confirm access to the calibration procedure. If you do not press any buttons after two seconds the screen will show "Calibration", "Timeout" "Cancelled". In this case to be able to re-access the calibration procedure repeat Step 2.
1
STEP 5 2 W230R605
At the same time press the Joystick Steering activation switch (1) and the confirm/send button (2).
STEP 3
W190-4R113
If it is kept pressed longer than expected, the main menu screen appears.
W190-4R111
Keep pressed until the screen shows "Calibration?".
84547255A
Issued 11-11
Printed in E.C.
5009-60
STEP 6
STEP 8
W190-4R114
W190-4R116
If you want to run calibration, press (within two seconds) the confirm/send button (2, see figure on preceding page). The display will show a screen with the wording "Steer Straight?" that asks the operator whether the machine is positioned straight. Press the confirm / send button (2, see figure on preceding page) to confirm the operation.
After this operation the display will show a screen with the wording "O. K." The display will automatically show the screen with the wording "Joyst Full Left" "Release when WL starts moving", the operator must then repeat Step 7 twice.
STEP 9
STEP 7
W190-4R117
W190-4R115
The display will show a screen with the wording "Joyst Full Left" "Release when WL starts moving". At this moment the operator must move the Joystick lever completely to the left. As soon as he perceives a small movement of the machine he must release the lever.
84547255A
Afterwards the display will automatically show the screen with the wording "Joyst Full Right" "Release when WL starts moving". At this moment the operator must move the Joystick lever c ompletely to the right. As soon as he perceives a small movement of the machine he must release the lever.
Issued 11-11
Printed in E.C.
5009-61
STEP 10
W190-4R116
After this operation the display will show a screen with the wording "O. K.". The display will automatically show the screen with the wording "Joyst Full Right" "Release when WL starts moving", the operator must then repeat Step 9 twice.
STEP 11
W190-4R118
The display will show a screen with the wording "Calibration Successful" indicating the success of the calibration procedure.
84547255A
Issued 11-11
Printed in E.C.
5009-62
NOTES
84547255A
Issued 11-11
Printed in E.C.
SECTION INDEX
POWER TRAIN Section Title
Section Number
Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001 Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004 Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004 Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006 Transmission Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6001 Section 6001 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6001-2
TABLE OF CONTENTS TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 14 15 26 26 28 29 31 31 33 35
Printed in E.C.
6001-3
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. 1. Remove the filler cap for the hydraulic reservoir. 2. Drain the hydraulic reservoir. 3. Tag and disconnect all hydraulic hoses and electrical connections from the hydraulic tank and from the radiator fluid tank. 4. Fasten acceptable lifting equipment to the hydraulic reservoir. 5. Remove the nuts, hardened washers, and bolts that mount the hydraulic reservoir to the frame. 6. Carefully raise the reservoir and remove the reservoir. 7. Remove the cap screws (1) from the center drive shaft (2) at the transmission, refer to illustration on page 4. 8. Remove the cap screws (3) from the rear drive shaft (4) at the transmission.
84547255A
Issued 11-11
Printed in E.C.
6001-4
1
2
3
4 W270R580
1. CAP SCREW 2. CENTER DRIVE SHAFT
3. CAP SCREW 4. REAR DRIVE SHAFT DRIVE SHAFTS
84547255A
Issued 11-11
Printed in E.C.
6001-5 9. Loosen the clamp and remove the sight gauge upper hose (1), refer to illustration on page 6. 10. Loosen the clamp and remove the sight gauge lower hose (2) from the fill tube (3). 11. Remove the filler tube (3) from the transmission. 12. Tag and remove the filters bypass hose (1), refer to illustration on page 7. 13. Tag and remove the filters inlet hose (2).
15. Tag and disconnect the hose transmission to thermal valve by pass (1) “INLET” port. Refer to illustration on page 8. 16. Tag and disconnect the hose transmission to thermal valve by pass (2) “TANK” port. 17. Tag and disconnect the parking brake hose (1), refer to illustration on page 9. 18. Tag and disconnect the differential lock axle pressure hose (2).
14. Tag and remove the filters return hose (3).
84547255A
Issued 11-11
Printed in E.C.
6001-6
3
1
2
4 W270R581
1. SIGHT GAUGE UPPER HOSE 2. SIGHT GAUGE LOWER HOSE
3. FILLER TUBE 4. SIGHT GAUGE BRACKET
TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-7
2
1
3
4
W270R582
1. FILTER BYPASS HOSE 2. FILTER INLET HOSE
3. FILTER RETURN HOSE 4. FILTERS
TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-8
1
2
W270R583
1. HOSE TRANSMISSION TO THERMAL VALVE BYPASS “INLET” PORT
2. HOSE TRANSMISSION TO THERMAL VALVE BYPASS “TANK” PORT
TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-9
2
1 W270R584
1. PARKING BRAKE HOSE
2. DIFFERENTIAL LOCK AXLE PRESSURE HOSE TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-10 19. Tag and disconnect hydraulic oil temperature sender (1), refer to illustration on page 11 and 12. 20. Tag and disconnect the transmission filter clogged switch (2). 21. Tag and disconnect the hydraulic filter clogged switch (3).
29. Tag and disconnect the turbine speed sensor (11). 30. Tag and disconnect the engine speed sensor (12). 31. Tag and disconnect the PRB2 redundant brake switch (13).
22. Remove the harness retaining clamp (4).
32. Tag and disconnect the PRB1 redundant brake switch (14).
23. Tag and disconnect the transmission controller (5).
33. Tag and disconnect the output speed sensor (15).
24. Tag and disconnect the torque converter output sender (6).
34. Tag and disconnect the transmission to cab connector (16).
25. If equipped, tag and disconnect the secondary steering harness (7).
35. Tag and disconnect the parking brake declutch pressure switch (17).
26. Tag and disconnect the transmission ground (8).
36. Tag and disconnect the differential lock solenoid (18).
27. Remove the harness retaining clamp (9). 28. Tag and disconnect the intermediate speed sensor (10).
84547255A
37. Move the wiring harness out and away from the transmission.
Issued 11-11
Printed in E.C.
6001-11
4 7 8 14 17
2 13 A
A 12
18 11
10 W270R585
2. 4. 7. 8. 10. 11.
TRANSMISSION FILTER CLOGGED SWITCH CLAMP SECONDARY STEERING (OPT) TRANSMISSION GROUND INTERMEDIATE SPEED SENSOR TURBINE SPEED SENSOR
12. 13. 14. 17. 18.
ENGINE SPEED SENSOR PRB2 BRAKE SWITCH PRB1 BRAKE SWITCH PARKING BRAKE DECLUTCH PRESSURE SWITCH DIFFERENTIAL LOCK SOLENOID
TRANSMISSION WIRING HARNESS
84547255A
Issued 11-11
Printed in E.C.
6001-12
9
5 6
16
B
3
15
1 B W270R586
1. 3. 5. 6.
HYDRAULIC OIL TEMPERATURE SENDER HYDRAULIC FILTER CLOGGED SWITCH TRANSMISSION CONTROLLER TORQUE CONVERTER OUTPUT SENDER
9. CLAMP 15. OUTPUT SPEED SENSOR 16. TRANSMISSION TO CAB CONNECTOR
TRANSMISSION WIRING HARNESS
84547255A
Issued 11-11
Printed in E.C.
6001-13 38. Remove the self-locking nuts (4), hardened washers (5), bolts (2), and washers (3), refer to illustration on page 14.
42. Remove the engine and transmission from the machine. Put the engine and transmission on an acceptable support.
39. Loosen the nuts on the front ROPS cab or canopy mounting bolts and remove the rear mounting bolts. Raise the rear of the ROPS cab or canopy approximately 152 MM. (6 inches).
43. Remove the starter from the engine.
40. Install a block on each side. 41. 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.
44. Fasten acceptable lifting equipment to the transmission. 45. Using the engine turning tool, turn the flywheel for access to the flex plate bolts (10). 46. Remove the twelve hardened washers (11) and bolts (10) from the flex plate. 47. Remove the cap screws (13) that hold the transmission to the flywheel housing. 48. Remove the transmission.
84547255A
Issued 11-11
Printed in E.C.
6001-14
Transmission Mounting Bracket
11
12
13 10
2
9
3 6
1
7
8
5 4 W270R572
1. 2. 3. 4. 5. 6. 7.
ISOLATOR BOLT WASHER NUT - Torque 929 to 1044 Nm (685 to 770 lbf-ft) WASHER BRACKET BOLT - Torque 1125 to 1274 Nm (830 to 940 lbf-ft)
84547255A
8. 9. 10. 11. 12. 13.
WASHER TRANSMISSION 4 SPEED BOLT - Torque 33 to 41 Nm (24 to 30 lbf-ft) WASHER BOLT - Torque 54 to 60 Nm (40 to 44 lbf-ft) WASHER
Issued 11-11
Printed in E.C.
6001-15
Installation NOTE: The transmission must be installed with the engine. See Section 2000 for engine installation. 1. Fasten acceptable lifting equipment to the transmission. 2. Install bracket (6), bolts (7) and washer (8), torque bolts to 1125 to 1274 Nm (830 to 940 pound-feet), refer to illustration on page 14. 3. Replace the cap screws (13) that hold the transmission to the flywheel housing. Tighten the cap screws to 54 to 60 Nm (40 to 44 pound-feet). 4. Turn the flywheel to access, install and tighten the twelve bolts (10) and hardened washers (11) for the flex plate to 33 to 41 Nm (24 to 30 pound-feet). 5. Place the engine and transmission in the machine. 6. Install the self-locking nuts (4), hardened washers (5), isolators (1), washers (3), and bolts (2) that hold the transmission mounting brackets (6) to the machine. Tighten the self-locking bolts to 929 to 1044 Nm (685 to 770 pound-feet). 7. Lower the ROPS cab or canopy and tighten the front mounting bolt nuts to 773 to 854 Nm (570 to 630 pound-feet). 8. Place the wiring harness into position over the transmission, refer to illustration on page 11 and 12.
84547255A
9. Connect the differential lock solenoid (18). 10. Connect the parking brake declutch pressure switch (17). 11. Connect the transmission to cab connector (16). 12. Connect the output speed sensor (15). 13. Connect the PRB1 redundant brake switch (14). 14. Connect the PRB2 redundant brake switch (13). 15. Connect the engine speed sensor (12). 16. Connect the turbine speed sensor (11). 17. Connect the intermediate speed sensor (10). 18. Install the harness retaining clamp (9). 19. Connect the transmission ground (8). 20. If equipped, connect the secondary steering harness (7). 21. Connect the torque converter output sender (6). 22. Connect the transmission controller (5). 23. Install the harness retaining clamp (4). 24. Connect the hydraulic filter clogged switch (3). 25. Connect the transmission filter clogged switch (2). 26. Connect hydraulic oil temperature sender (1).
Issued 11-11
Printed in E.C.
6001-16
4 7 8 14 17
2 13 A
A 12
18 11
10 W270R585
2. 4. 7. 8. 10. 11.
TRANSMISSION FILTER CLOGGED SWITCH CLAMP SECONDARY STEERING (OPT) TRANSMISSION GROUND INTERMEDIATE SPEED SENSOR TURBINE SPEED SENSOR
12. 13. 14. 17. 18.
ENGINE SPEED SENSOR PRB2 BRAKE SWITCH PRB1 BRAKE SWITCH PARKING BRAKE DECLUTCH PRESSURE SWITCH DIFFERENTIAL LOCK SOLENOID
TRANSMISSION WIRING HARNESS
84547255A
Issued 11-11
Printed in E.C.
6001-17
9
5 6
16
B
3
15
1 B W270R586
1. 3. 5. 6.
HYDRAULIC OIL TEMPERATURE SENDER HYDRAULIC FILTER CLOGGED SWITCH TRANSMISSION CONTROLLER TORQUE CONVERTER OUTPUT SENDER
9. CLAMP 15. OUTPUT SPEED SENSOR 16. TRANSMISSION TO CAB CONNECTOR
TRANSMISSION WIRING HARNESS
84547255A
Issued 11-11
Printed in E.C.
6001-18 27. Install the differential lock axle pressure hose (2), refer to illustration on page 22.
32. Install the filters bypass hose (1), refer to illustration on page 20.
28. Install the parking brake hose (1).
33. Install the filters inlet hose (2).
29. Install the sight gauge upper hose (1) and tighten th clamp., rfer to illustration on page 19.
34. Install the filters return hose (3).
30. Install the filler tube (3) on the transmission. 31. Install the sight gauge lower hose (2) to the fill tube (3) and tighten the clamp.
84547255A
35. Install the transmission to thermal valve bypass hose (1) “INLET” port, refer to illustration on page 21. 36. Install the transmission to thermal valve bypass (2) “TANK” port.
Issued 11-11
Printed in E.C.
6001-19
3
1
2
4 W270R581
1. SIGHT GAUGE UPPER HOSE 2. SIGHT GAUGE LOWER HOSE
3. FILLER TUBE 4. SIGHT GAUGE BRACKET
TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-20
2
1
3
4
W270R582
1. FILTER BYPASS HOSE 2. FILTER INLET HOSE
3. FILTER RETURN HOSE 4. FILTERS
TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-21
1
2
W270R583
1. HOSE TRANSMISSION TO THERMAL VALVE BYPASS “INLET” PORT
2. HOSE TRANSMISSION TO THERMAL VALVE BYPASS “TANK” PORT
TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-22
2
1 W270R584
1. PARKING BRAKE HOSE
2. DIFFERENTIAL LOCK AXLE PRESSURE HOSE TRANSMISSION LINES
84547255A
Issued 11-11
Printed in E.C.
6001-23 37. Install the cap screws (1) to fasten the center drive shaft (2) to the transmission. Tighten the cap screws to 136 to 149 Nm (100 to 110 pound-feet). refer to illustration on page 24. 38. Put the rear drive shaft (4) into position on the machine.
84547255A
39. Replace the cap screws to the rear drive shaft (4) at the rear axle. Tighten the cap screws to 136 to 149 Nm (100 to 110 pound-feet). 40. Install the cap screws (3) to the rear drive shaft (4) to the transmission. Tighten the cap screws to 136 to 149 Nm (100 to 110 pound-feet).
Issued 11-11
Printed in E.C.
6001-24
1
2
3
4 W270R580
1. CAP SCREW 2. CENTER DRIVE SHAFT
3. CAP SCREW 4. REAR DRIVE SHAFT DRIVE SHAFTS
84547255A
Issued 11-11
Printed in E.C.
6001-25 41. Carefully place the reservoir into position onto the machine. 42. Install the nuts, hardened washers, and bolts that mount the hydraulic reservoir to the frame, tighten the bolts. 43. Connect to the hydraulic tank and fluid reservoir all the hydraulic hoses and electrical connections.
45. Replace the filler cap for the hydraulic reservoir. 46. Fill the transmission with proper lubricant, refer to section 1002. 47. Refer to section 2000 and complete the engine installation procedures. 48. Start and run the machine until all systems are at operating temperature, check for leaks and repair as needed.
44. Fill the hydraulic reservoir.
84547255A
Issued 11-11
Printed in E.C.
6001-26
FRONT AXLE Removal
STEP 4
STEP 1
W270R573
W230R406
Park machine on level surface. Have assistant put articulation lock in LOCKED position.
Remove eight bolts securing front drive shaft to front axle.
STEP 5
IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.
3
2
2
STEP 2
1 W270R574
BD03A092
Raise bucket and have assistant install safety link. Lower loade r arm s slowly until sa fe ty link is supporting loader arms.
Remove clamp securing lubrication hose (1) to machine and nut securing opposite end of hose. Remove eight bolts (2) securing center drive shaft to front drive shaft. Use a pry bar to separate drive shafts. While supporting center bearing and front drive shaft, remove four nuts (3) and bolts and washers. Lower center bearing and front drive shaft from mounting plate and remove from machine.
STEP 3 Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit. Put key switch in OFF position.
84547255A
Issued 11-11
Printed in E.C.
6001-27
STEP 6
STEP 9 3
2
1 W270R575
Disconnect brake hose (1), differential lock axle pressure hose (2) and accumulator brake damping (3). Remove and discard O-ring face seal from elbow.
BD01F297
Use an acceptable jack to hold front axle.
STEP 10
STEP 7
BD01F295
BD01F298
Remove bolts and washers from front wheels. Remove both wheels from front axle.
STEP 11
BD01D392
Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine.
STEP 8 Repeat Step 7 to raise other front axle tire from ground.
84547255A
BD01F296
Remove eight nuts bolts, and washers securing front axle to machine.
STEP 12 Carefully lower front axle and remove from under machine.
Issued 11-11
Printed in E.C.
6001-28
Front Axle Mounting
1
2
5
3 4
W230R008
1. BOLT 2. WASHER 3. WASHER
84547255A
4. NUT 5. FRONT AXLE
Issued 11-11
Printed in E.C.
6001-29
Installation
STEP 15
STEP 13 Carefully move front axle under machine and raise against mounting pads on machine.
STEP 14
BD01F295
8
16
1
9 17
20 12 4
BD01F296
Apply one drop of engine oil to threads prior to assembly. Install eight washers, bolts, washers, and nuts to secure front axle to machine. Tighten bolts to a torque of 1520 to 1712 Nm (1121 to 1263 pound feet).
5 13
22
21
14
3
6
11 18
19 10
2 23 15
7
W270R576
Install both wheels on front axle and secure. Tighten bolts to a preliminary torque of 298 Nm (230 pound feet) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence.
STEP 16
BD01F297
Remove jack from front axle.
84547255A
Issued 11-11
Printed in E.C.
6001-30
STEP 17
STEP 20 3
2
2
1 BD01F298
W270R574
Position and support center bearing and front drive shaft and install washers and four bolts and nuts (3). Tighten bolts to a torque of 150 to 164 Nm (110 to 120 pound feet). Install eight bolts (2). Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet). Secure lubrication hose (1) to machine using clamp; secure opposite end of hose using nut.
STEP 21
BD01D392
Using an acceptable hydraulic jack, raise axle and remove jack stand from under machine.
STEP 18 Repeat Step 17 to remove other jack stand from under machine.
STEP 19 W270R573
3
Secure drive shaft to front axle using eight bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).
2
STEP 22 If necessary, fill axle with gear lubricant specified in Section 1002.
1
STEP 23 Refer to Section 7002 and bleed brakes. W270R575
Install a new O-ring face seal and connect accumulator brake damping (3), brake hose (1) and differential lock axle pressure hose (2).
STEP 24 Start engine and raise bucket. Have assistant remove safety link. Lower bucket to ground and stop engine.
STEP 25 Put articulation lock in OPERATING position.
84547255A
Issued 11-11
Printed in E.C.
6001-31
REAR AXLE Removal
STEP 5
STEP 1 Park machine on a level surface; be sure to allow adequate space at side of machine for removal of rear axle. Stop engine. Actuate brake pedal several times to discharge brake accumulators. Put key switch in ON position and move loader control lever back and forth at least 30 times to release any pressure from hydraulic circuit.
STEP 2 W270R578
Disconnect brake hose. Remove and discard O-ring face seal from elbow.
STEP 6
W230R406
Put articulation lock in LOCKED position.
STEP 3 Install wood blocks between rear axle and chassis to prevent rear axle from pivoting.
BD01F299
Using an acceptable hydraulic jack, raise one tire from ground and install an acceptable jack stand under machine. Repeat this step for other tire.
STEP 4
STEP 7
W270R577
Remove eight bolts. Use a pry bar to disconnect rear drive shaft from rear axle. BD01F302
Use an acceptable jack to hold rear axle, front and rear of trunnion.
84547255A
Issued 11-11
Printed in E.C.
6001-32
STEP 8
STEP 18 Only W300C, refer to illustration on page 34, remove the screw (13) and washer (14). Remove the bearing trunnion (15) rear axle.
STEP 19 Remove the rear trunnion (3) from the rear axle (1). NOTE: Replace the seals and bushings in the trunnions as required.
BD01F295
Remove bolts and washers from rear wheels. Remove both wheels from rear axle.
STEP 9 Remove the grease hoses (12) from the rear axle trunnions (2 and 3), refer to illustration on page 33.
STEP 10 Remove the self-locking nuts (11) from the bolts (10).
STEP 11 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.
STEP 12 Remove the front trunnion (2) from the rear axle (1).
STEP 13 Remove the cap screws (8) and washers (9) from the rear cover (7) on the rear trunnion (3).
STEP 14 Remove the rear cover (7) from the rear trunnion (3).
STEP 15 Remove the thrust washer (5).
STEP 16 Remove the cap screws (8) and washers (9) that fasten the spacer (6) to the rear axle (1).
STEP 17 Remove the spacer (6) and thrust washer (5).
84547255A
Issued 11-11
Printed in E.C.
6001-33
Rear Axle Mounting W270C 8 12
9
5
8
9
10
6
1
5
7 9 10 9 11
3
9
4 12
9 11
4 2
4 W270R579
1. 2. 3. 4.
84547255A
REAR AXLE FRONT TRUNNION REAR TRUNNION OIL SEAL
5. 6. 7. 8.
THRUST WASHER TRUNNION SPACER COVER CAP SCREW
9. 10. 11. 12.
WASHER BOLT SELF-LOCKING NUT GREASE HOSES
Issued 11-11
Printed in E.C.
6001-34
Rear Axle Mounting W300C 8
9
8
12
9
5
13 5
10 14
9
10 1
7 6 4 9
3
11
12
15
4
2
9 11
4 W300R002
1. 2. 3. 4. 5.
84547255A
REAR AXLE FRONT TRUNNION REAR TRUNNION OIL SEAL THRUST WASHER
6. 7. 8. 9. 10.
TRUNNION SPACER COVER CAP SCREW WASHER BOLT
11. 12. 13. 14. 15.
SELF-LOCKING NUT GREASE HOSES SCREW WASHER BEARING TRUNNION
Issued 11-11
Printed in E.C.
6001-35
Installation STEP 20 Put the rear axle (1) on blocks.
STEP 21 Install the rear trunnion (3) to the rear axle (1). Ensure bushing is properly positioned.
STEP 22 Only W300C, refer to illustration on page 34, install the bearing trunnion (15) rear axle, the washers (14) and screws (13). Tighten the screws to a torque of 575 to 600 Nm (420 to 440 pound-feet).
STEP 23 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).
STEP 24 Tighten the cap screws (8) to a torque of 285 to 320 Nm (210 to 235 pound-feet).
STEP 25 Install the other thrust washer (5). Fasten the rear cover (7) to the rear trunnion (3) using six washers (9) and cap screws (8).
STEP 26 Tighten the cap screws (8) to a torque of 105 to 115 Nm (75 to 85 pound-feet).
STEP 27 Install the front trunnion (2) to the rear axle (1). Ensure trunnion is properly positioned, see illustration on page 33.
STEP 28 Using acceptable lifting equipment, slowly move the rear axle (1) and trunnions (2 and 3) into position under the rear chassis.
STEP 29 Install the bolts (10), hardened washers (9), and nuts (11) to fasten the trunnions (2 and 3) to the rear chassis.
STEP 30 Tighten the nuts (11) to a torque of 651 to 732 Nm (480 to 540 pound-feet).
84547255A
Issued 11-11
Printed in E.C.
6001-36
STEP 31
STEP 33
BD01F295
W270R578
Install a new O-ring face seal. Connect brake hose.
8
16
1
STEP 34 9 17
20 12 4
5 13
22
21
14
3
6
11 18
19 10
2 23 15
7 W270R577 W270R576
Install both wheels on front axle and secure. Tighten bolts to a preliminary torque of 298 Nm (220 pound feet) in sequence indicated; then tighten to a torque of 640 to 720 Nm (475 to 530 pound feet) in same sequence.
Connect rear drive shaft to rear axle. Install eight bolts. Tighten bolts to a torque of 136 to 149 Nm (100 to 110 pound feet).
STEP 35 If necessary, fill axle with gear lubricant specified in Section 1002.
STEP 32 Remove hydraulic jack supporting rear axle and jack stands supporting loader.
STEP 36 Refer to Section 7002 and bleed brakes.
STEP 37 Put articulation lock in OPERATING position.
84547255A
Issued 11-11
Printed in E.C.
6002
Section 6002 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, AND TROUBLESHOOTING
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6002-2
TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 8 8 8 8 8 9 9 9 9 9 10 11 11 11 11 11 12 12 12 12 12 12 13 14 15 15 15 15 15 16 16 16 16 16 16 16 16 16 16 17 18 18 18
Printed in E.C.
6002-3
SPECIAL TOOLS 380001740 Flowmeter kit
380001743 Transmission supplemental fitting kit. Includes: 380000509 special 90 degree adapter and 380001749 plug and cap set.
380001750 Flowmeter adapter 380001745 Flow test kit
380001739 Master pressure test kit
SPECIFICATIONS Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi) Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi) Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi) Converter out pressure.....................................................................................................3.5 to 6.5 bar (51 to 96 psi) Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi) Minimum pump output (at 2000 rpm) .....................................................................................80 L/min (21 U.S. gpm) Transmission oil operating temperature .........................................................................80 to 120 °C (176 to 248 °F) Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K2 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K3 ........................................................................................................................16 to 18 bar (232 to 261 psi) Clutch K4 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Ratio W270C
1st
2nd
3rd
4th
Forward
3.731
2.207
1.421
0.625
Reverse
3.731
2.207
1.421
-
1st
2nd
3rd
4th
Forward
3.731
2.207
1.421
0.625
Reverse
3.731
2.207
0.970
-
Ratio W300C
84547255A
Issued 11-11
Printed in E.C.
6002-4
4 1 7
2
2
2
2
8
3 5
6
W270R592
1. 2. 3. 4.
TRANSPORATION EYE GEARBOX MOUNTING PADS COARSE FILTER PLUG CONNECTION
5. 6. 7. 8.
OIL FILLER MOUNTING PROVISION OIL DRAIN PLUG CONNECTION TO HEAT EXCHANGER OUTPUT FLANGE
COMPONENT LOCATIONS 4 SPEED FRONT VIEW
84547255A
Issued 11-11
Printed in E.C.
6002-5
12 1 2
9
11 3 6
10
5
7
4
8
13
8
W270R593
1. 2. 3. 4. 5. 6. 7.
CONNECTION TO ENGINE BREATHER PTO, COAXIAL, ENGINE DEPENDENT PARKING BRAKE (DISC BRAKE) INDUCTIVE SENSOR FOR TURBINE SPEED ASSEMBLY APERTURE CONNECTION RETURN PIPE FROM DIFFERENTIAL LOCK
8. 9. 10. 11. 12. 13.
GEARBOX MOUNTING PADS CONNECTION SYSTEM PRESSURE INDUCTIVE SENSOR FOR INTERMEDIATE GEAR TRAIN SPEED INDUCTIVE SENSOR FOR ENGINE SPEED TRANSPORTATION EYE OUTPUT FLANGE REAR SIDE
COMPONENT LOCATIONS 4 SPEED SIDE VIEW
84547255A
Issued 11-11
Printed in E.C.
6002-6
11
1
1
9 8 7
3 2
6 10
5
4
W270R594
1. 2. 3. 4. 5. 6.
TRANSPORTATION EYE HALL-SENSOR OUTPUT SPEED CONNECTION FROM HEAT EXCHANGER OIL FILLER MOUNTING PROVISION TYPE PLATE BREATHER
7. 8. 9. 10. 11.
INDUCTIVE SENSOR FOR ENGINE SPEED CONNECTION TO FILTER CONNECTION FROM FILTER PRESSURE CONNECTION ELECTRICAL HYDRAULIC TRANSMISSION CONTROL
COMPONENT LOCATIONS 4 SPEED REAR VIEW
84547255A
Issued 11-11
Printed in E.C.
6002-7
4
3 9
11
12
7
8
10
5
13
2 6
1
W270R595
1. 2. 3. 4. 5. 6. 7.
OIL FILLER PLUG CONNECTION FROM FILTER BYPASS BREATHER TRANSPORTATION EYE PLUG CONNECTION MEASURING POINT FOR PRESSURE BEFORE CONVERTER MEASURING POINT FOR PRESSURE OIL CLUTCH KV
8. 9. 10. 11. 12. 13.
MEASURING POINT FOR PRESSURE OIL CLUTCH KR MEASURING POINT FOR PRESSURE OIL CLUTCH K1 MEASURING POINT FOR PRESSURE OIL CLUTCH K2 MEASURING POINT FOR PRESSURE OIL CLUTCH K3 MEASURING POINT FOR PRESSURE OIL CLUTCH K4 MEASURING POINT FOR SYSTEM PRESSURE
COMPONENT LOCATIONS 4 SPEED TOP VIEW
84547255A
Issued 11-11
Printed in E.C.
6002-8
TRANSMISSION OPERATION General
Transmission ECM Tasks
The transmission is equipped with a Transmission ECM (Electronic Control Module). This module controls modulation and shifting that were normally associated with hydraulically modulated transmissions, providing smoother shifts and enhanced clutch life.
The Transmission ECM performs a variety of tasks in the overall system. The Transmission ECM:
The Transmission ECM relies on signals from several sensors that are incorporated into the design. These sensors measure the speed of several components, as well as other sensors that measure temperature. These solenoids and sensors are further defined in the following paragraphs. I n ad d i t i on , t h e t ra n s m i s s i o n i n c o rp o r a t es a two-piece transmission case for ease of transmission maintenance, helical cut gears that help reduce noise, and all external hoses have been eliminated (all oil passages are internal).
A. Determines which clutches to engage in the transmission. B. Protects the engine and transmission turbine from overspeed conditions during downloading. C. Receives speed information from the engine speed sensor, the turbine speed sensor, the intermediate shaft speed sensor and the transmission output shaft speed sensor. These speed sensors are checked to determine if normal sensor operation is present. The data is also used to control modulation during shifting and to determine the appropriate shift patterns. D. Detects system failures and determines the appropriate alternative actions.
Transmission ECM Modulation and shifting are controlled by the Transmission Electronic Control Module (Transmission ECM). This module replaces the oil and springs that are found in hydraulically modulated transmissions. The Transmission ECM controls the clutch engagement, providing smoother shifts and enhanced clutch life, whether the transmission is set to the automatic or manual shift mode. The Transmission ECM also informs the Information Center, by the use of diagnostic codes, of any transmission error and the hours of operation that the error occurred.
E. Provides various diagnostic messages to the Information Center. F. Provides other information to the information center, which in turn displays engine speed, wheel speed, gear shift selection, and actual gear selection. G. Provides a method to transmission clutch control.
calibrate
the
H. Establishes clutch modulation pressure during transmission shifts.
Electrical Shift Solenoids Electrical Shift Solenoids control the modulation of the clutches, eliminating the need for a modulation valve, and providing a smooth shift while maintaining constant control over clutch engagement as follows: A. A temperature sensor relays the temperature to the Transmission ECM.
oil
B. The Transmission ECM times the rate the solenoid energizes and de-energizes. C. As the transmission changes gears, there is reduced hesitation from one gear to the next.
84547255A
Issued 11-11
Printed in E.C.
6002-9
Transmission Sensor Data Collection The Transmission ECM collects and uses information from four sensors to accurately shift the transmission and determine if any clutches are slipping. These sensors are: Engine (Speed) Sensor - monitors engine speed to determine the load on the engine for shift points and sends the engine rpm to the Transmission ECM, which sends the information to the tachometer in the Information Center. Turbine (Speed) Sensor - assists the engine speed sensor in determining the load going into the transmission and helps determine shift points. Intermediate (Shaft Speed) Sensor - determines differential gear speed in the transmission to check for clutch slippage. Output (Speed) Sensor - monitors transmission output shaft speed to help determine the load on the transmission and to assist in determining shift points. Sends output shaft speed to Transmission ECM which sends the information to the speedometer in the Information Center. The transmission E CM 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 ll s t i l l b e a predetermined amount of time. If the transmission is shifted from neutral into a direction in the Clutch Modulation Substitute Mode in automatic, the transmission will shift into 4th gear and shift down until it gets the correct output speed from the turbine.
Limp-Home Mode In this mode, the transmission will go into second gear, forward or reverse, no matter what gear is selected. If second gear is not obtainable, the Transmission ECM selects a series of prioritized gears until an operable gear is found. The transmission will go into the Limp Home Mode if there is a fault on one clutch, a fault on one clutch valve, or a fault on more than one speed sensor.
Transmission/Transmission ECM Shutdown Mode In this mode, the Transmission ECM has detected a severe failure that disables control of the transmission. The transmission will go into Shutdown Mode if there is a fault on more than one clutch, a fault on the solenoid power supply, or invalid voltage. In this mode, the Transmission ECM will shut off all solenoid valves and the power supply and the transmission shifts into and stays in neutral. If the Transmission ECM generates a code, the wrench over the service manual icon will be displayed on the Information Center.
84547255A
Issued 11-11
Printed in E.C.
6002-10
Transmission Clutch Calibration The Transmission ECM has the capability to find the optimal adjustment of the clutch filling parameters for each individual transmission, providing the ability to individually adjust the optimum fill time for the individual transmission in the machine. Clutch Filling Parameter Calibration is performed on each machine at the plant and should be repeated at the first 250 hours of use and every 1000 hours thereafter. Before doing the following transmission clutch calibration procedures make sure of the following: 1. The machine is running and the transmission oil is warm. 2. Engine low idle speed is correct. 3. The transmission is in neutral.
W230M173
Highlight Calibration, and press the confirm key. Always follow the prompts on the screen. Should an error occur, use the escape key to start over again.
4. The park brake is applied. 5. If steps 1 through 4 have been accomplished, calibrate the transmission clutches as follows: With the engine running at idle, enter the service screen menu and scroll to Service screen. Press the confirm key.
W230M174
W230M139
W230M175
The screen will show a confirm prompt. If you doubt your ability to perform this operation, press the escape key and call your dealer.
W230M172
84547255A
Issued 11-11
Printed in E.C.
6002-11 If machine conditions are incorrect, an error message will appear. The calibration procedure will not complete. Follow the prompts to aid in correcting any machine conditions. The screen may display the following prompts to guide the user to correct machine conditions: ❷ ❷ ❷ ❷ ❷ ❷ ❷
Not in neutral Parking Brake OFF Machine moving Oil temp too low Oil temp too high Engine RPM low Engine RPM high
If conditions are correct, the user will see six calibration screens displayed. They will appear in the following order: ❷ Adjust K1 ❷ Adjust K2 ❷ Adjust K3 ❷ Adjust K4 ❷ Adjust KV ❷ Adjust KR Once the calibration process is complete, the user will be prompted to turn the engine Off and restart the machine. If the process is not completed, the screen will prompt the user to escape.
Gear Selections The transmission provides 4 forward and 3 reverse gear selections. The transmission ratios were designed to give optimized speed and torque for each gear selection. The torque converter is a single stage torque converter (one locking unit in the torque converter).
Automatic/Manual Modes The automatic/manual switch is located on the right control panel. The transmission is in automatic mode when the top of the automatic/manual switch is depressed. The Transmission Display Center indicates when the machine is in the automatic mode.
Upshifting in Automatic Mode Upshifting is determined by machine speed and the torque on the transmission. The transmission will shift from first or second gear up to the highest gear selected as the accelerator is depressed, machine speed increases, and required torque is reduced. If the machine speed is increasing, but the operator is not depressing the accelerator (such as when going down a hill), the transmission will not upshift. As the operator depresses the accelerator and the torque on the transmission is lowered, the transmission will upshift.
Downshifting in Automatic Mode Downshifting is determined directly by machine speed and transmission torque. The transmission will downshift to first or second gear as machine speed decreases and transmission torque increases. For example, if the unit begins to climb a hill in forth gear and the machine speed decreases, as the torque requirement increases, the transmission will downshift into third, then second, and down to first gear, if necessary.
Upshifting in Manual Mode In the manual mode, the transmission starts out in the selected gear and stays in that gear until the operator selects another gear or direction. The transmission can be upshifted without reducing engine speed or machine speed. If the gear selected is two or more gears higher than the present gear, the transmission will shift up through the gears at 2.5 second intervals until the selected gear has been reached. 84547255A
Issued 11-11
Printed in E.C.
6002-12
Downshifting in Manual Mode
Manual Mode
The transmission can be downshifted in the manual mode without reducing engine speed or machine speed.
In the manual mode, the downshift button toggles between 1st and 2nd gear. The manual mode is useful in short haul operations. In this mode, the downshift button functions in two ways in 1st and 2nd gear.
If 1st gear is selected from 3rd or 4th gear, the transmission will downshift into 2nd gear for 1.2 seconds and then will shift into 1st gear.
Downshift Button The downshift button is located on front of the joystick control lever in machines with a single lever configuration, and on top of the control tower in machines with a three lever configuration.
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.
With the number of different ways the downshift button functions, the operator can tailor the use of the machine to the application at hand.
Cold Start Protection System
Automatic Mode
The transmission has a cold start protection system. When the transmission sump temperature is minus 10째 C (14째 F), the Transmission ECM will keep the transmission in neutral.
In the Automatic Mode, the downshift button only shifts down. The downshift button allows the operator to downshift through the entire range of gears. This is useful in long haul applications or roading. Each time the button is pushed the transmission will instantly downshift one gear from 4th to 3rd, then from 3rd to 2nd, and then from 2nd to 1st. The transmission will automatically downshift and then upshift, as needed, to the last gear that was selected with the downshift button. Example: If the downshift button was used to shift from 4th to 3rd gear, the transmission will automatically shift from 3rd down and then back up to 3rd again. It will not shift into 4th until the transmission has been returned to the full range automatic mode. The transmission will return to the full range automatic mode when: A. Another gear is selected. B. The shifter is moved into neutral and then into forward or reverse. C. The autoshift switch is recycled.
When the transmission sump temperature warms up to minus 10째 C (14째F) (within approximately one minute), the machine will operate in all gears.
Brake Pedal Transmission Declutch A transmission declutch feature concentrates more engine power on the loader when digging in heavy or tough conditions, providing smoother stops and starts. Total disconnection of the transmission from the engine is prevented. This feature will function in 1st, 2nd, or 3rd gear only. It will not function in 4th gear. When the transmission declutch switch is in the on position and the brake pedal is pushed, the Transmission ECM reduces the pressure to the transmission forward or reverse clutch. The Transmission ECM will not completely disconnect the clutch from the engine, but gradually reduces the forward or reverse clutch pressure down to a lower level. When the brake pedal is released, the Transmission ECM gradually increases the forward or reverse clutch back up to system clutch pressure. If the direction is changed while the transmission is declutched, the selected forward or reverse clutch will be filled and maintain a low pressure until the brake pedal is released. Then the selected forward or reverse clutch pressure will gradually increase up to system clutch pressure.
84547255A
Issued 11-11
Printed in E.C.
6002-13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM No.
IDENTIFICATION/LOCATION
CONNECTION
DESIGNATION ON VALVE BLOCK H
Measuring Points for Pressure Oil and Temperature 1
Before the Converter - Opening Pressure 11+2 bar (159.5 + 29 psi)
M10x1
2
Behind the Converter - Opening Pressure 4.3+3 bar (62 + 43.5 psi)
M10x1
3
Clutch Forward 16+2 bar (232 + 29 psi)
KV M10x1
4
B
Clutch Reverse 16+2 bar (232 + 29 psi)
KR M10x1
E
5
Clutch 16+2 bar (232 + 29 psi)
K1 M10x1
D
6
Clutch 16+2 bar (232 + 29 psi)
K2 M10x1
A
7
Clutch 16+2 bar (232 + 29 psi)
K3 M10x1
C
8
Clutch 16+2 bar (232 + 29 psi)
K4 M10x1
F
M10x1
K
9
System Pressure 16+2 bar (232 + 29 psi)
3
8
6
9 1
7
4
5
2
W270R596
84547255A
Issued 11-11
Printed in E.C.
6002-14
CHART FOR RECORDING PRESSURE READINGS Use this chart to record the pressure readings. P.I.N. Number:
Date: TEST POINTS
Shift Speed
P 9
V 3
R 4
1 5
2 6
3 7
4 8
5 1
6 2
LP
1st F 2nd F 3rd F 4th F 1st R 2nd R 3rd R Neut P= MAIN PRESSURE
1= FIRST GEAR CLUTCH
4= FOURTH GEAR CLUTCH
V= FORWARD CLUTCH
2= SECOND GEAR CLUTCH
5= CONVERTER IN
R= REVERSE CLUTCH
3= THIRD GEAR CLUTCH
6= CONVERTER OUT
84547255A
LP= LUBE PRESSURE
Issued 11-11
Printed in E.C.
6002-15
PRESSURE TEST RESULTS All or Most Pressures Low and/or Flow Test Low Possible causes include: 1. Oil level not correct. 2. Oil type and grade not correct. 3. Oil operating temperature high. 4. Screen for suction tube plugged. 5. Suction tube or gaskets leak. 6. Main pressure valve, springs, or valve bore. 7. Reduction valve, springs, or valve bore.
Not Enough Power Possible causes include: 1. Check Electrical Troubleshooting in this Section to verify actual gear selected. 2. Engine RPM below Stall Test specified RPM. (Refer to Section 2002 for specifications.) A. Check engine and fuel system for problem. B. Check that torque converter installation is correct. 3. Engine RPM above Stall Test specified RPM. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak.
A. Check converter pressures and flow.
9. Charge pump worn.
B. Check that torque converter installation is correct.
10. Oil supply flange not sealing correctly.
Some Pressures Low Possible causes include: 1. Circuit isolation does not correct low pressure. A. Control valve or gasket. B. Channel plate or gasket. 2. Circuit isolation corrects low pressure. A. Clutch shaft or seals. B. Clutch drum or piston.
84547255A
Machine Stops or Hesitates While Shifting - Intermittent Possible causes include: 1. Check orifice and O-ring. (See Section 6007 for replacing.) 2. Check for foreign material plugging orifices or sticking valves. 3. Check for reduced pressure at test pressure points. 4. See Electrical Troubleshooting in this Section for electrical system problem.
Issued 11-11
Printed in E.C.
6002-16
CONVERTER OUT PRESSURE CHECK Test Equipment Required
3. Install the pressure gauge.
0 to 28 bar (400 psi) gauge with hose long enough to take readings in the cab and 380000509 Special Adapter.
4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F).
Test Procedure 1. Block the machine tires.
5. While in the cab, put the transmission in NEUTRAL. Run the engine at full throttle. Record the reading in the chart on page 16. Pressure must be a minimum of 3.5 to 6.5 bar (51 to 96 psi).
2. Apply the parking brakes.
LUBRICATION PRESSURE CHECK Test Equipment Required
3. Install the pressure gauge in the cooler return line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle. Put the transmission in each gear and record the reading in the chart on page 16. Pressure must be 0.2 to 1.2 bar (3 to 18 psi).
1. Block the machine tires. 2. Apply the parking brakes.
FLOWMETER TEST Test Equipment Required 380001740 Flowmeter Kit; 380001750 Flowmeter Adapter.
Flowmeter Test Procedure 1. Block the machine tires.
3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212° F). 4. Remove the filter and install the 380001750 adapter. 5. Install the flowmeter between the adapter and the filter. 6. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The correct flow is 80 L/min (21 U.S. gpm) at 2000 rpm.
2. Apply the parking brakes.
CONSUMPTION TEST PROCEDURE 1. Block the machine tires. 2. Apply the parking brakes. 3. Heat the oil to an operating temperature of 80 to 100° C (176 to 212 ° F). 4. Install the flowmeter to converter outlet line (line to cooler) in series.
6. Repeat the procedure with the transmission in FORWARD in third gear. The flow must be 9.1 L/min (2 U.S. gpm). 7. Repeat the procedure with the transmission in REVERSE in third gear. The flow must be 9.1 L/min (2 U.S. gpm).
5. While in the cab, run the engine at full throttle. Put the transmission in NEUTRAL and record the flow measurement. The flow must be 9.1 L/min (2 U.S. gpm).
84547255A
Issued 11-11
Printed in E.C.
6002-17
TRANSMISSION OVERHEATING 1. Operate machine in normal operating conditions and observe: A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the ambient temperatures. B. Use a stop watch to establish the exact length of time required to reach the overheating condition. C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission? 2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle (1250 to 1450 RPM). A. Oil temperature returns to Normal - establish length of time. 1. Check oil level, type and grade is correct (See Section 1002). 2. Check operator’s gear selection is correct for conditions. 3. Make sure brakes are fully released. 4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002). B. Oil temperature remains overheated. 1. Check for dirty radiator - airflow restricted. 2. Check for engine overheating problem. 3. Check for faulty oil temperature gauge and sender or switch (See Section 4002). 3. Perform all the pressure and flow tests. 4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are not within specifications. 5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.
84547255A
Issued 11-11
Printed in E.C.
6002-18
ERROR CODES In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with a recorded error number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION Function
Shifter
Shifter Wire Color
Shifter Tower Connector
Shifter Shroud Connector
Harness Wire #
Harness ped/cab #
Trans. ECM #
power
B+
black/red
A
A
19A_H
43
45
forward
V
yellow
-
B
25F
44
43
reverse
R
pink
-
C
25R
45
64
neutral
N
gray
-
D
25T_B
46
67
gear2(3-4)
B2
green
B
-
25W
48
65
gear1(1-2)
B1
blue
C
-
25Z
49
63
downshift
DS
purple
D
-
25Y
50
22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral N is high. In first gear, B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low and B2 is high. In fourth gear, B1 and B2 are high. Downshift, DS, is activated when the end of the shifter is engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES Transmission ECM Function
Transmission ECM Pin #
Transmission Valve
Clutch #
Transmission Valve Pin #
Wire #
Trans/Cab Pin #
A1P1
56
Y1
K4
1
25K
16
A1P2
10
Y2
KR
2
25L
17
A1P3
32
Y3
K1
3
25M
18
A1P4
55
Y4
K3
4
25N
19
A1P5
9
Y5
KV
5
25P
20
A1P6
51
Y6
K2
6
25J
21
VPSI
12,13
all Y
all K
7
25S
22
TEMP
39
TEMP
none
8
36T
5
TEMP
46
TEMP
none
9
36R
12
84547255A
Issued 11-11
Printed in E.C.
6003
Section 6003 TRANSMISSION
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6003-2
TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
84547255A
Issued 11-11
Printed in E.C.
6003-3
SPECIAL TOOLS
Adjusting screws M6 1
380001558
Handle 2
380001557
Rolling tool 3
380001285
Assembly 4 380001556
Rolling tool 5 380001286
Rolling tool 6
84547255A
380001287
Issued 11-11
Printed in E.C.
6003-4
Driver tool 7 380001560
Assembly fixture (Inner installer and driver) 8
84547255A
380001559
Issued 11-11
Printed in E.C.
6003-5
TRANSMISSION DISASSEMBLY
STEP 3
STEP 1
W270R139
W270R137
Remove all oil pipes, the complete gear shift system and the duct plate.
Fasten the complete transmission to the assembly truck.
Converter Drive
STEP 2
STEP 4
W270R138
Remove the plug (arrow) and drain the oil. Then remove the oil cylinder.
84547255A
W270R140
By means of the lifting tackle separate the torque converter from the transmission.
Issued 11-11
Printed in E.C.
6003-6
STEP 5
STEP 8
W270R141
W270R144
Loosen the bolt connection and by means of the forcing screws (3x) separate the cover from the converter bell.
Loosen the bolt connection and by means of lifting tackle and pry bar set separate the converter bell from the transmission housing.
STEP 6
STEP 9
W270R142
By means of the extractor pull the oil supply flange out of the converter bell.
W270R145
Remove the rectangular ring (arrow).
STEP 10
STEP 7
W270R146 W270R143
Remove the converter safety valve (arrow 1), if required.
Press the input shaft out of the spur gear bearing. Remove the released bearing inner ring and the spur gear.
NOTE: Converter safety valve is fixed by means of slotted pin (arrow 2). 84547255A
Issued 11-11
Printed in E.C.
6003-7
STEP 11
W270R147
Press off the bearing inner ring from the spur gear.
STEP 12
W270R148
Remove the converter pressure back-up valve.
STEP 13
9
W270R149
Remove the inductive transmitter (9).
84547255A
Issued 11-11
Printed in E.C.
6003-8
Input Shaft
STEP 17
STEP 14
W270R153
W270R150
Loosen the cap screw.
S n a p o ut t he r e c t an g u l ar r i n g ( ar ro w 1 ) an d remove both shims (arrow 2).
Transmission Pump
STEP 15
STEP 18
W270R151
Remove the cap screw and clamping plate.
W270R154
Loosen the cap and hexagon screws (depending on the version) respectively and separate the pump flange from the housing.
STEP 16
W270R152
Press the input shaft out of the bearing. NOTE: Pay attention to released input shaft as well as shims.
84547255A
Issued 11-11
Printed in E.C.
6003-9
STEP 19
STEP 21
W270R155
W270R157
Loosen the cap screws. Position the extractor on the transmission pump and fasten it by means of screws to the transmission pump. Then pull out the pump from the housing bore.
Press out the driver with ball bearing from the bearing bore. Then separate the ball bearing from the driver.
NOTE: Extracting is supported by slightly tapping onto the transmission housing.
STEP 22
Remove the ball bearing and the driver (Step 20 ... 21) STEP 20
W270R158
Loosen the cap screws, take off the pump cover and remove the rotor set. NOTE: If marks due to running-in are found on the pump housing or housing cover, the complete pump is to be replaced. W270R156
Snap out the retaining ring.
84547255A
Then assemble the rotor set with the chamfer on the tooth tip showing downwards and install the housing cover again.
Issued 11-11
Printed in E.C.
6003-10
Layshaft
Removal of Inductive and Speed transmitter
STEP 23
STEP 25
W270R159
Remove the sealing cover and loosen the hexagon screw.
STEP 24
W270R161
14 = n – Turbine 5 = n – internal speed input 13 = n – Output (Speed transmitter) W270R160
Expel the idler shaft by means of the striker from the housing bore and layshaft bearing respectively.
84547255A
Issued 11-11
Printed in E.C.
6003-11
Output
STEP 28
Version with Parking Brake STEP 26
W270R164
W270R162
Transmission rearside: ATTENTION: For working on the brake system observe the instructions and specifications of the brake manufacturer. Unscrew the screw cap.
Loosen the cap screws and separate the complete brake from the transmission housing. Remove the lock p late. Loosen th e hexagon screws and separate the output flange/brake disc from the output shaft.
Removal of the Clutches and Layshaft STEP 29
STEP 27
W270R165
W270R163
Loosen the counternut and unscrew the adjusting screw in counterclockwise direction until the brake disc is released.
84547255A
Loosen the hexagon screws and expel the bearing cover KV/K1 by means of the striker from the housing bore. Remove the bearing cover KR/K2 (arrow) analogously. NOTE: Mark the installation location of the bearing cover.
Issued 11-11
Printed in E.C.
6003-12
STEP 30
STEP 33
W270R166
Pull out the bearing cover K4/K3 by means of the forcing screws from the housing bore.
W270R169
Expel the output shaft from the output gear.
STEP 34
STEP 31
W270R170
Separate the bearing inner ring from bearing cover K4/K3.
Loosen the hexagon screws and remove the oil baffle. Lift the output gear out of the transmission housing.
STEP 32
STEP 35
W270R167
2
3
1
W270R168
W270R171
Loosen the bolt connection. Separate the housing cover from the housing by equally tightening both forcing screws (arrow 1 and 2) as well as the threaded spindle (arrow 3).
Remove the bearing inner ring from the output gear.
84547255A
Issued 11-11
Printed in E.C.
6003-13
STEP 36
STEP 38
W270R172
W270R174
Take the roller bearing out of the housing bore and remove the oil baffle (arrow).
Opposite figure shows the clutches when removed.
STEP 39
Remove the multi-disc clutches STEP 37
W270R175
Remove the layshaft gear. W270R173
NOTE: For removal of the single clutches observe the following sequence: K4/K3 --> KR/K2 --> KV/K1. For removal of clutch K4/K3, lift the clutch KR/K2 slightly and move it in direction of the arrow, see figure.
84547255A
Issued 11-11
Printed in E.C.
6003-14
Removal of the 2nd Power Take-Off
STEP 43
STEP 40
W270R179
W270R176
Snap out the retaining ring and remove the shims.
Pull the bearing outer ring out of the housing bore.
STEP 44
STEP 41
W270R180
W270R177
Lift the output shaft by means of the pry bar set until the bearing outer ring is released.
Pull off the bearing inner ring from the shaft. Press off the opposite bearing inner ring from the shaft. NOTE: Shaft and gear cannot be separated (shrink fit).
STEP 42
W270R178
Take the output shaft out of the housing.
84547255A
Issued 11-11
Printed in E.C.
6003-15
Dismantling of the Multi-Disc Clutch K3/K4
STEP 48
STEP 45
W270R184
Pull off the bearing inner ring from the disc carrier. W270R181
STEP 49
By means of clamping ring fasten the clutch to the assembly truck.
STEP 46
W270R185
Squeeze out the snap ring. Remove the end shim and disc set K3. W270R182
STEP 50
Pull off the roller bearing from the disc carrier.
STEP 47
W270R186
Rotate disc carrier by 90°. Loosen the slotted nut. W270R183
Separate spur gear K3 from the disc carrier.
84547255A
Issued 11-11
Printed in E.C.
6003-16
STEP 51
STEP 54
W270R187
Rotate disc carrier by 90°. Pull off the taper roller bearing.
W270R190
Pull off the taper roller bearing.
STEP 55
STEP 52
W270R191
Pull off the spur gear K4 from the disc carrier.
Squeeze out the snap ring. Remove the end shim and the disc set K4.
STEP 53
STEP 56
W270R188
W270R189
Remove the ring.
84547255A
W270R192
Preload the compression spring by means of fixture. Squeeze out the snap ring and the released single components. Remove the opposite single components (K3 side) analogously.
Issued 11-11
Printed in E.C.
6003-17
STEP 57
STEP 60
W270R193
W270R196
Separate both pistons by means of compressed air from the disc carrier.
Pull off the taper roller bearing from the disc carrier.
Dismantling of the Multi-Disc Clutch KR/K2
STEP 61
STEP 58
W270R197
Press off the spur gear K2 from the disc carrier. W270R194
Fasten the clutch by means of clamping ring (arrow) on the assembly truck.
ATTENTION: Pay attention to released disc carrier.
STEP 62
STEP 59
W270R198
W270R195
Rotate disc carrier by 90°. Loosen the slotted nut. 84547255A
Fasten the disc carrier by means of clamping ring. Pull off the taper roller bearing from the disc carrier.
Issued 11-11
Printed in E.C.
6003-18
STEP 63
STEP 66
W270R199
W270R202
Squeeze out the snap ring. Remove the end shim and disc set K2.
Fasten spur gear KR by means of clamping ring (arrow) and pull it from the disc carrier.
STEP 64
NOTE: Collar of the clamping ring must show upwards (to the spur gear).
STEP 67
W270R200
Rotate disc carrier by 90°. Loosen the slotted nut.
W270R203
Remove the ring.
STEP 65
STEP 68
W270R201
Pull off the taper roller bearing from the disc carrier.
84547255A
W270R204
Squeeze out the snap ring. Remove end shim and disc set KR.
Issued 11-11
Printed in E.C.
6003-19
STEP 69
STEP 71
W270R205
W270R207
Pull off the taper roller bearing from the disc carrier. Remove both pistons (like described in Step 56 and 57).
Pull off the taper roller bearing from the disc carrier.
STEP 72
Dismantling of the Multi-Disc Clutch KV/K1 STEP 70
W270R208
Remove the shim.
STEP 73 W270R206
Fasten clutch by means of clamping ring to the assembly truck. Loosen the slotted nut.
W270R209
Pull off spur gear K1 from the disc carrier.
84547255A
Issued 11-11
Printed in E.C.
6003-20
STEP 74
STEP 76
W270R210
Opposite figure shows the spur gear bearing K1. Bearing (1) can only be obtained as complete part. ATTENTION: If it is necessary to remove the clutch-pack-sided ball bearing (arrow or Step 76), the complete bearing (1) has to be removed.
STEP 75
W270R212
Pull off the ball bearing from the disc carrier. NOTE: Pay attention to released balls.
STEP 77
W270R211
Take off the bush.
W270R213
Squeeze out the snap ring. Remove end shim and disc set K1.
84547255A
Issued 11-11
Printed in E.C.
6003-21
STEP 78
STEP 81
W270R214
Rotate disc carrier by 90°. Loosen the slotted nut.
W270R217
Remove the ring.
STEP 82
STEP 79
W270R218 W270R215
Pull off the taper roller bearing from the disc carrier.
STEP 80
Pull off the taper roller bearing from the disc carrier. Squeeze out the snap ring. Remove end shim and disc set KV. Remove both pistons (like described in Step. 56 and 57).
W270R216
Pull off spur gear KV from the disc carrier.
84547255A
Issued 11-11
Printed in E.C.
6003-22
REASSEMBLY
STEP 4
2nd Power Take-Off STEP 1
W270R222
Position the preassembled power take-off shaft in the housing and insert the bearing outer ring until contact. W270R219
Undercool the shaft (ca. - 80° C), heat the gear (approx. + 120° C) and install or press it until contact.
STEP 5
STEP 2
W270R223
W270R220
Axial play – power take-off bearing max. 0.0039 in (0.10 mm), to be adjusted by means of shim(s) and retaining ring.
Press the bearing inner ring until contact. Press the opposite bearing inner ring until contact.
STEP 3
W270R221
Insert the bearing outer ring (arrow) into the housing bore until contact. 84547255A
Issued 11-11
Printed in E.C.
6003-23
STEP 6
W270R224
Rotate the transmission housing by 180°. Insert the sealing disc (arrow) with the concave side showing downwards into the housing bore until contact. NOTE: Wet contact face with Loctite (Type No. 262). ATTENTION: Do not damage the centric orifice bore 0.031 in (0.80 mm) when installing the sealing disc.
84547255A
ø
Issued 11-11
Printed in E.C.
6003-24
Assembly of the Multi-Disc Clutch K4/K3 The following sketch shows the clutch sectioning
1 3 2 K4
K3
7
6
5
4
4
5 W270R225
1 2 3 K4 K3 4 5 6 7
= Disc carrier (assy) = Spur gear K4 = Spur gear K3 = Multi-disc clutch K4 = Multi-disc clutch K3 = Piston = Compression spring = Plug 2x = Plug 1x
NOTE: Observe the installation position of the single components for the following assembly.
84547255A
Issued 11-11
Printed in E.C.
6003-25
STEP 7
STEP 9
W270R228
Put both O-Rings scroll-free into the annular grooves of the piston, see arrows.
STEP 10
W270R226
Lift the disc carrier with the K4-side showing downwards into the clamping ring and fasten it. Rotate disc carrier by 180°. ATTENTION: To install new disc carriers the finished bores have to be sealed with plugs. Installation position, see arrow.
STEP 8
W270R229
Oil the O-Rings and the piston contact surface. Install K3 piston equally until contact. NOTE: Observe the installation position of the piston.
STEP 11
W270R227
Flush-mount the drain valve (arrow) with the chamfer showing downwards.
W270R230
Install spacer and compression spring.
84547255A
Issued 11-11
Printed in E.C.
6003-26
STEP 12
W270R231
Place guide ring, with the chamfer (arrow) showing upwards, over the compression spring and install the snap ring.
STEP 13
W270R232
Lift the disc carrier out of the clamping ring. Preload the compression spring by means of fixture and engage the snap ring into the annular groove of the disc carrier (arrow). Install the drain valve, piston and compression spring on the opposite side (Clutch K4) analogously ( Step 8...13). Then lift the disc carrier with the K4-side showing downwards into the clamping ring and fasten it. Rotate disc carrier by 180°.
84547255A
Issued 11-11
Printed in E.C.
6003-27
Disc Components K4
K4 3
K3
4
3
2
1
8
9 6
6 7
5
7
W270R233
Pos.
Description
Quantity
1= Disc carrier 2= Piston 3= Outer clutch disc 4= Outer clutch disc 5= Inner clutch disc 6= Inner clutch disc 7= Inner clutch disc 8= Snap ring 9= End shim Number of friction surfaces: 10 Disc clearance: 0.086 ... 0.094 in (2.2
1 1 2 4 2 4 2 1 1
s (mm)
Remarks
0.072 in (1.85 mm) 0.098 in (2.5 mm) 0.15 in (4.0 mm) 0.098 in (2.5 mm) 0.098 ... 0.15 in (2.5 ... 4.0 mm) 0.082 ... 0.12 in (2.10 ... 3.10 mm)
Coated on one side Coated on both sides
Optional Optional
... 2.4 mm)
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively. The respective clutch side can be seen on the length of the disc carrier, see sketch. K4 = Dimension X (short disc carrier side) K3 = Dimension Y (long disc carrier side).
84547255A
Issued 11-11
Printed in E.C.
6003-28
Check disc clearance K4 = 0.086 ... 0.094 in (2.2 ... 2.4 mm) (Step 14 ... 16)
STEP 16
STEP 14
W270R236
W270R234
NOTE: In order to ensure a perfect measuring result, the disc set is first of all to be installed without oil. Install disc set according to sketch or table (Page 27).
STEP 15
Press on end shim with approx. 100 N (10 kg) and set dial indicator to â&#x20AC;&#x17E;Zeroâ&#x20AC;&#x153;. Then press end shim against snap ring (upwards) and read disc clearance on the dial indicator. NOTE: If the required disc clearance differs, it has to be corrected with the adequate inner clutch disc or/and snap ring, see table / Pos. 7 and Pos. 8. (Page 27).
Preassemble and install spur gear K4 (Step 17 ... 21) STEP 17
W270R235
Install the end shim and fasten it by means of the snap ring. W270R237
Opposite figure shows the single components of spur gear K4. 1 = Bearing inner ring 2 = Bearing outer ring 3 = Ring 4 = Spur gear Locate both bearing outer rings (2) until contact.
84547255A
Issued 11-11
Printed in E.C.
6003-29
STEP 18
STEP 21
W270R238
W270R241
Heat the bearing inner ring and install it until contact.
Heat the bearing inner ring (spur gear bearing) and locate it until contact.
STEP 19
ATTENTION: Use safety gloves.
STEP 22
W270R239
Install the ring (3). W270R242
STEP 20
Heat the bearing inner ring (clutch bearing) and install it until contact. ATTENTION: Use safety gloves.
W270R240
Assemble the spur gear until all inner clutch discs are located.
84547255A
Issued 11-11
Printed in E.C.
6003-30
Clutch Components K3
K4
K3
X
Y 1
2
3
4
3
8 9
5
6
6 7
7
W270R243
Pos.
Description
Quantity
s (mm)
Remarks
1= Disc carrier 1 2= Piston 1 3= Outer clutch disc 2 0.072 in (1.85 mm) 4= Outer clutch disc 4 0.098 in (2.5 mm) 5= Inner clutch disc 2 0.15 in (4.0 mm) 6= Inner clutch disc 4 0.098 in (2.5 mm) 7= Inner clutch disc 2 0.098 ... 0.15 in (2.5 ... 4.0 mm) 8= Snap ring 1 0.082 ... 0.12 in (2.10 ... 3.10 mm) 9= End shim 1 Number of friction surfaces: 10 Disc clearance: 0.086 ... 0.094 in (2.2 ... 2.4 mm)
Coated on one side Coated on both sides
Optional Optional
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively. The respective clutch side can be seen on the length of the disc carrier, see sketch. K3 = Dimension Y (long disc carrier side) K4 = Dimension X (short disc carrier side).
84547255A
Issued 11-11
Printed in E.C.
6003-31
Check disc clearance K3 = 0.086 ... 0.094 in (2.2 ... 2.4 mm) (Step 23 ... 25)
STEP 25
STEP 23
W270R246
W270R244
NOTE: In order to ensure a perfect measuring result, the disc set is first of all to be installed without oil.
Press on end shim with approx. 100 N (10 kg) and set dial indicator to â&#x20AC;&#x17E;Zeroâ&#x20AC;&#x153;. Then press end shim against snap ring (upwards) and read disc clearance on the dial indicator.
Install disc set according to sketch or table (Page 30).
NOTE: If the required disc clearance differs, it has to be corrected with the adequate inner clutch disc or/and snap ring, see table / Pos. 7 and Pos. 8. (Page 30).
STEP 24
STEP 26
W270R245
W270R247
Install the end shim and fasten it by means of the snap ring.
Heat the bearing inner ring and install it until contact.
84547255A
ATTENTION: Use safety gloves.
Issued 11-11
Printed in E.C.
6003-32
STEP 27
STEP 29
W270R248
W270R250
Lift the disc carrier out of the clamping ring. To ensure the exact locating of the single components, preload the bearing with 100 000 N (10 t).
Install the bearing outer ring into spur gear K3 until contact.
ATTENTION: Support on the lower as well as upper bearing inner ring. Use pressure pieces.
STEP 30
STEP 28
W270R251
Assemble the spur gear until all inner clutch discs are located. W270R249
Lift the disc carrier with the K4-side showing downwards into the clamping ring and fasten it. Rotate disc carrier by 90°. Install the slotted nut.
STEP 31
NOTE: Observe installation position of the slotted nut! Collar ø 2.36 in (ø 60 mm) must show to the bearing inner ring, also see sketch/page 24. Oil the thread. Tightening torque .......= 550 Nm (4867.9 pound in)
W270R252
Heat the roller bearing and locate it until contact. ATTENTION: Use safety gloves.
84547255A
Issued 11-11
Printed in E.C.
6003-33
STEP 32
W270R253
Install the bearing inner ring.
STEP 33
W270R254
Check function of the clutches K3 and K4 by means of compressed air. NOTE: Closing or opening of the clutches is clearly audible when the single parts have been installed adequately.
STEP 34
W270R255
Snap-in and lock the rectangular rings (3, see arrows).
84547255A
Issued 11-11
Printed in E.C.
6003-34
Assembly of the Multi-Disc Clutch KR/K2 The following sketch shows the clutch sectioning.
2
1
3
K2
KR 7
6
5
4
4
5 W270R256
1 2 3 K4 K3 4 5 6 7
= Disc carrier = Spur gear KR = Spur gear K2 = Multi-disc clutch KR = Multi-disc clutch K2 = Piston = Compression spring = Plug = Plug
NOTE: Observe the installation position of the single components for the following assembly.
84547255A
Issued 11-11
Printed in E.C.
6003-35
STEP 35
STEP 37
W270R259
Put both O-Rings scroll-free into the annular grooves of the piston, see arrows.
STEP 38
W270R257
Lift the disc carrier with the KR-side showing downwards into the clamping ring and fasten it. Then rotate disc carrier by 180°. ATTENTION: To install new disc carriers the finished bores have to be sealed with plugs. Installation position, see arrow, Step 35... 36.
STEP 36
W270R260
Oil the O-Rings and the piston contact surfaces. Install K2 piston equally until contact. NOTE: Observe the installation position of the piston, see figure.
STEP 39
W270R258
Flush-mount the drain valve (arrow) with the chamfer showing downwards. W270R261
Install spacer and compression spring.
84547255A
Issued 11-11
Printed in E.C.
6003-36
STEP 40
W270R262
Place guide ring, with the chamfer (arrow) showing upwards, over the compression spring and install the snap ring.
STEP 41
W270R263
Lift the disc carrier out of the clamping ring. Preload the compression spring by means of fixture and engage the snap ring into the annular groove of the disc carrier (arrow). Install the drain valve, piston and compression spring on the opposite side (Clutch KR) analogously (like Step 36 ... 41). Then lift the disc carrier with the KR-side showing downwards into the clamping ring and fasten it. Rotate disc carrier by 180°.
84547255A
Issued 11-11
Printed in E.C.
6003-37
Disc Components KR
KR
K2
.
W270R264
Pos.
Description
Quantity
s (mm)
Remarks
1= Disc carrier 1 2= Piston 1 3= Outer clutch disc 2 0.072 in (1.85 mm) 4= Outer clutch disc 4 0.13 in (3.35 mm) 5= Inner clutch disc 2 0.098 in (2.5 mm) 6= Inner clutch disc 4 0.11 in (3.0 mm) 7= Inner clutch disc 2 0.098 ... 0.15 in (2.5 ... 4.0 mm) 8= Snap ring 1 0.082 ... 0.12 in (2.10 ... 3.10 mm) 9= End shim 1 Number of friction surfaces: 24 Disc clearance: 0.110 ... 0.118 in (2.8 ... 3.0 mm)
Coated on one side Coated on both sides
Optional Optional
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively. The respective clutch side can be seen on the length of the disc carrier, see sketch. KR = Dimension Y (long disc carrier side) K2 = Dimension X (short disc carrier side).
84547255A
Issued 11-11
Printed in E.C.
6003-38
Check disc clearance KR = 0.110 ... 0.118 in (2.8 ... 3.0 mm) (Step 42 ... 44)
STEP 44
STEP 42
W270R267
W270R265
NOTE: In order to ensure a perfect measuring result, the disc set is first of all to be installed without oil. Install disc set according to sketch or table (Page 37).
Press on end shim with approx. 100 N (10 kg) and set dial indicator to â&#x20AC;&#x17E;Zeroâ&#x20AC;&#x153;. Then press end shim against snap ring (upwards) and read disc clearance on the dial indicator. NOTE: If the required disc clearance differs, it has to be corrected with the adequate inner clutch disc or/and snap ring, see table / Pos. 7 and Pos. 8. (Page 37).
Preassemble and install spur gear KR (Step 45... 49)
STEP 43
STEP 45
W270R266
Install the end shim and fasten it by means of the snap ring. W270R268
Opposite figure shows the single components of spur gear KR. 1 = Bearing inner ring 2.9 x 1.4 in (75 x 37 mm) 2 = Ring 3 = Spur gear 4 = Bearing inner ring 2.9 x 1.6 in (75 x 41 mm)
84547255A
Issued 11-11
Printed in E.C.
6003-39
STEP 46
STEP 49
W270R269
W270R272
Heat the bearing inner ring 2.9 x 1.4 in (75 x 37 mm) and install it until contact.
Heat the bearing inner ring 2.9 x 1.6 in (75 x 41 mm) and locate it until contact.
ATTENTION: Use safety gloves.
ATTENTION: Use safety gloves.
STEP 47
STEP 50
W270R270
W270R273
Assemble the spur gear until all inner clutch discs are located.
Heat the bearing inner ring (clutch bearing) and locate it until contact. ATTENTION: Use safety gloves.
STEP 48
W270R271
Install the ring.
84547255A
Issued 11-11
Printed in E.C.
6003-40
Disc Components K2
K2
KR
W270R274
Pos.
Description
Quantity
s (mm)
Remarks
1= Disc carrier 1 2= Piston 1 3= Outer clutch disc 2 0.072 in (1.85 mm) 4= Outer clutch disc 4 0.098 in (2.5 mm) 5= Inner clutch disc 2 0.15 in (4.0 mm) 6= Inner clutch disc 4 0.098 in (2.5 mm) 7= Inner clutch disc 2 0.098 ... 0.15 in (2.5 ... 4.0 mm) 8= Snap ring 1 0.082 ... 0.12 in (2.10 ... 3.10 mm) 9= End shim 1 Number of friction surfaces: 24 Disc clearance: 0.086 ... 0.094 in (2.2 ... 2.4 mm)
Coated on one side Coated on both sides
Optional Optional
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively. The respective clutch side can be seen on the length of the disc carrier, see sketch. K2 = Dimension X (short disc carrier side) KR = Dimension Y (long disc carrier side).
84547255A
Issued 11-11
Printed in E.C.
6003-41
Check disc clearance K2 = 0.086 ... 0.094 in (2.2 ... 2.4 mm) (Step 51 ... 53)
STEP 53
STEP 51
W270R277
W270R275
NOTE: In order to ensure a perfect measuring result, the disc set is first of all to be installed without oil. Install disc set according to sketch or table (Page 40).
Press on end shim with approx. 100 N (10 kg) and set dial indicator to â&#x20AC;&#x17E;Zeroâ&#x20AC;&#x153;. Then press end shim against snap ring (upwards) and read disc clearance on the dial indicator. NOTE: If the required disc clearance differs, it has to be corrected with the adequate inner clutch disc or/and snap ring, see table / Pos. 7 and Pos. 8. (Page 40),
STEP 52
W270R276
Install the end shim and fasten it by means of the snap ring.
84547255A
Issued 11-11
Printed in E.C.
6003-42
Preassemble and install spur gear K2 (Step 54 ... 58)
STEP 56
STEP 54
W270R280
Heat the bearing inner ring and install it until contact. W270R278
Undercool gear 1 (approx. – 80° C) and heat gear 2 (approx. 120° C). Engage the snap ring (arrow), preload it and join both components by means of hydr. press until the snap ring engages into the annular groove of gear 2.
ATTENTION: Use safety gloves.
STEP 57
STEP 55
W270R281
Assemble the spur gear until all inner clutch discs are located.
STEP 58 W270R279
Opposite figure shows the single components of the spur gear bearing. 1 = Bearing inner ring 2 = Spur gear assy 3 = Bearing inner ring
W270R282
Heat the bearing inner ring (spur gear bearing) and install it until contact. ATTENTION: Use safety gloves.
84547255A
Issued 11-11
Printed in E.C.
6003-43
STEP 59
STEP 61
W270R283
W270R285
Heat the bearing inner ring (clutch bearing) and locate it until contact.
Lift the disc carrier into the clamping ring and fasten it. Rotate disc carrier by 90°. K2-side: Install the slotted nut.
ATTENTION: Use safety gloves.
NOTE: Observe installation position of the slotted nut! Chamfer must show to the bearing inner ring, also see sketch/page 34. Oil the thread.
STEP 60
STEP 62
W270R284
Lift the disc carrier out of the clamping ring. To ensure the exact locating of the single components, preload the bearing with 100 000 N (10 t). ATTENTION: Support on the lower as well as upper bearing inner ring. Use pressure pieces.
W270R286
KR-side: Install the slotted nut. NOTE: Observe installation position of the slotted nut! Collar ø 2.9 in (ø 76 mm) must show to the bearing inner ring, also see sketch/page 34. Oil the thread. Tightening torque ...= 800 Nm (7080.6 pound inch)
84547255A
Issued 11-11
Printed in E.C.
6003-44
STEP 63
W270R287
Check function of the clutches K3 and K4 by means of compressed air. NOTE: Closing or opening of the clutches is clearly audible when the single parts have been installed adequately. Snap-in and lock the rectangular rings (see arrows).
84547255A
Issued 11-11
Printed in E.C.
6003-45
Assembly of the Multi-Disc Clutch KV/K1 The following sketch shows the clutch sectioning
2
1 3
KV
K1
7
6
5
4
4
5 W270R288
1 2 3 K4 K3 4 5 6 7
= Disc carrier = Spur gear KV = Spur gear K1 = Multi-disc clutch KV = Multi-disc clutch K1 = Piston = Compression spring = Plug 2x = Plug 1x
NOTE: Observe the installation position of the single components for the following assembly.
84547255A
Issued 11-11
Printed in E.C.
6003-46
STEP 64
STEP 66
W270R290
Put both O-Rings scroll-free into the annular grooves of the piston, see arrows.
STEP 67
W270R289
Lift the disc carrier with the KV-side showing downwards into the clamping ring and fasten it. Then rotate disc carrier by 180°. ATTENTION: To install new disc carriers the finished bores have to be sealed with plugs . Installation position, see arrow.
STEP 65
W270R291
Oil the O-Rings and the piston contact surfaces. Install K1 piston equally until contact. NOTE: Observe the installation position of the piston, see figure.
STEP 68
W270R258
Flush-mount the drain valve (arrow) with the chamfer showing downwards. W270R292
Install spacer and compression spring.
84547255A
Issued 11-11
Printed in E.C.
6003-47
STEP 69
W270R293
Place guide ring, with the chamfer (arrow) showing upwards, over the compression spring and install the snap ring.
STEP 70
W270R294
Lift the disc carrier out of the clamping ring. Preload the compression spring by means of fixture and engage the snap ring into the annular groove of the disc carrier (arrow). Install the drain valve, piston and compression spring on the opposite side (Clutch KV) analogously. Then lift the disc carrier with the KV-side showing downwards into the clamping ring and fasten it. Rotate disc carrier by 180°.
84547255A
Issued 11-11
Printed in E.C.
6003-48
Disc Components KV
KV
K1
Y
X
4
3
3
2
1
8 9
7
5
6
5
W270R295
Pos.
Description
Quantity
s (mm)
Remarks
1= Disc carrier 1 2= Piston 1 3= Outer clutch disc 2 0.072 in (1.85 mm) 4= Outer clutch disc 4 0.098 in (2.5 mm) 5= Inner clutch disc 2 0.13 in (3.5 mm) 6= Inner clutch disc 4 0.15 in (4.0 mm) 7= Inner clutch disc 2 0.098 ... 0.15 in (2.5 ... 4.0 mm) 8= Snap ring 1 0.082 ... 0.12 in (2.10 ... 3.10 mm) 9= End shim 1 Number of friction surfaces: 24 Disc clearance: 0.110 ... 0.118 in (2.8 ... 3.0 mm)
Coated on one side Coated on both sides
Optional Optional
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively. The respective clutch side can be seen on the length and ø of the disc carrier respectively, see sketch. KV = Dimension Y (short disc carrier side and large ø respectively) K1 = Dimension X (short disc carrier side and small ø respectively).
84547255A
Issued 11-11
Printed in E.C.
6003-49
Check disc clearance KV = 0.110 ... 0.118 in (2.8 ... 3.0 mm) (Step 71 ... 73)
STEP 73
STEP 71
W270R298
W270R296
NOTE: In order to ensure a perfect measuring result, the disc set is first of all to be installed without oil. Install disc set according to sketch or table (Page 48).
Press on end shim with approx. 100 N (10 kg) and set dial indicator to â&#x20AC;&#x17E;Zeroâ&#x20AC;&#x153;. Then press end shim against snap ring (upwards) and read disc clearance on the dial indicator. NOTE: If the required disc clearance differs, it has to be corrected with the adequate inner clutch disc or/and snap ring, see table / Pos. 7 and Pos. 8. (Page 48).
Preassemble and install spur gear KV (Step 74 ... 78)
STEP 72
STEP 74
W270R297
Install the end shim and fasten it by means of the snap ring. W270R299
Opposite figure shows the single components of spur gear KV. 1 = Bearing inner ring 2 = Bearing outer ring 3 = Ring 4 = Spur gear Install both bearing outer rings (2) until contact.
84547255A
Issued 11-11
Printed in E.C.
6003-50
STEP 75
STEP 78
W270R300
W270R303
Heat the bearing inner ring and install it until contact.
Heat the bearing inner ring (spur gear bearing) and locate it until contact.
ATTENTION: Use safety gloves.
ATTENTION: Use safety gloves.
STEP 76 STEP 79
W270R301
Install the ring.
W270R304
Heat the bearing inner ring (clutch bearing) and locate it until contact.
STEP 77
ATTENTION: Use safety gloves. Rotate disc carrier by 180°.
W270R302
Assemble the spur gear until all inner clutch discs are located.
84547255A
Issued 11-11
Printed in E.C.
6003-51
Disc Components K1
KV
K1
Y
X 1
2
4
3
3
8 9 5
6 5
7
W270R305
Pos.
Description
Quantity
s (mm)
Remarks
1= Disc carrier 1 2= Piston 1 3= Outer clutch disc 2 0.072 in (1.85 mm) 4= Outer clutch disc 4 0.098 in (2.5 mm) 5= Inner clutch disc 2 0.15 in (4.0 mm) 6= Inner clutch disc 4 0.098 in (2.5 mm) 7= Inner clutch disc 2 0.098 ... 0.15 in (2.5 ... 4.0 mm) 8= Snap ring 1 0.082 ... 0.098 in (2.1 ... 2.5 mm) 9= End shim 1 Number of friction surfaces: 14 Disc clearance: 0.086 ... 0.094 in (2.2 ... 2.4 mm)
Coated on one side Coated on both sides
Optional Optional
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively. The respective clutch side can be seen on the length and ø of the disc carrier respectively, see sketch. K1 = Dimension X (short disc carrier side and small ø respectively) KV = Dimension Y (short disc carrier side and large ø respectively).
84547255A
Issued 11-11
Printed in E.C.
6003-52
Check disc clearance K1 = 0.086 ... 0.094 in (2.2 ... 2.4 mm) (Step 80 ... 82)
STEP 82
STEP 80
W270R308
W270R306
NOTE: In order to ensure a perfect measuring result, the disc set is first of all to be installed without oil. Install disc set according to sketch or table (Page 51).
Press on end shim with approx. 100 N (10 kg) and set dial indicator to â&#x20AC;&#x17E;Zeroâ&#x20AC;&#x153;. Then press end shim against snap ring (upwards) and read disc clearance on the dial indicator. NOTE: If the required disc clearance differs, it has to be corrected with the adequate inner clutch disc or/and snap ring, see table / Pos. 7 and Pos. 8. (Page 51).
STEP 81
W270R307
Install the end shim and fasten it by means of the snap ring.
84547255A
Issued 11-11
Printed in E.C.
6003-53
Preassemble and install spur gear K1 (Step 83 ... 89)
STEP 85
STEP 83
W270R311
Install the bush with collar (arrow) on face end showing to the snap ring.
STEP 86
W270R309
Opposite figure shows the single components of spur gear K1.
W270R312
Press in the ball bearing until contact.
1 = Ball bearing (assy) 2 = Snap ring 3 = Spur gear NOTE: Prior to installation of the single components, align the disc set by means of the spur gear radially and center it.
NOTE: Install the ball bearing with the lubricating groove (arrow) showing downwards. Put the press-in tool only to the bearing outer ring.
STEP 84
W270R310
Install the snap ring. 84547255A
Issued 11-11
Printed in E.C.
6003-54
STEP 87
STEP 90
W270R313
Heat the second ball bearing and install it until contact. NOTE: Lubricating groove (arrow), must show upwards.
W270R316
Install shim s = 0.04 in (1.20 mm).
STEP 91
ATTENTION: Use safety gloves.
STEP 88
W270R317
Heat the bearing inner ring and install it until contact. ATTENTION: Use safety gloves. W270R314
Assemble the bush.
STEP 89
W270R315
Heat the spur gear to approx. 120° C and assemble it until all inner clutch discs are located. ATTENTION: Use safety gloves. 84547255A
Issued 11-11
Printed in E.C.
6003-55
STEP 92
STEP 94
W270R318
W270R320
Lift the disc carrier out of the clamping ring. To ensure the exact locating of the single components, preload the bearing with 100 000 N (10 t).
Check function of the clutches KV and K1 by means of compressed air.
ATTENTION: Support on the lower as well as upper bearing inner ring. Use pressure pieces.
NOTE: Closing or opening of the clutches is clearly audible when the single parts have been installed adequately.
STEP 93
STEP 95
W270R319
Lift the disc carrier into the clamping ring. Rotate disc carrier by 90°. Install the slotted nut.
W270R321
Snap-in and lock the rectangular rings (see arrows).
NOTE: Observe installation position of the slotted nut. Collar ø 2.3 in (ø 60 mm) must show to the taper roller bearing, also see sketch/page 45. Oil the thread. Tightening torque ... = 550 Nm (4867.9 pound inch)
84547255A
Issued 11-11
Printed in E.C.
6003-56
Installation of Layshaft Gear, Multi-Disc Clutches and Output Gear
STEP 98
STEP 96
W270R324
Insert the bearing outer rings KV/K1, KR/K2 and K3/K4 into the housing bores until contact, see arrows. W270R322
Opposite figure shows the single components of the layshaft gear bearing.
STEP 99
1 = Bearing inner ring 2 = Ring 3 = Layshaft gear
STEP 97
W270R325
Position clutch KV/K1 by means of lifting tackle.
STEP 100
W270R323
Position layshaft gear (assy) in the housing. NOTE: Only when the clutches are installed, the idler shaft can be mounted.
W270R326
Position clutch KR/K2.
84547255A
Issued 11-11
Printed in E.C.
6003-57
STEP 101
STEP 104
W270R327
W270R330
Check the installation position of the layshaft gear (arrow) once again and correct it, if required.
Insert the bearing outer ring into the housing bore until contact.
STEP 102
STEP 105
W270R328
Fasten the spur gear K3 by means of fixture and eyebolt (arrow) axially. NOTE: Spur gear fixing prevents the clutch discs from dislocating when the clutch is lifted in.
STEP 103
W270R331
Heat the bearing inner ring and install it until contact. ATTENTION: Use safety gloves. NOTE: Observe installation position â&#x20AC;&#x201C; collar (arrow) shows to the spur gear. Install the bearing inner ring after cooling down subsequently (press).
STEP 106
W270R329
Lift the clutch KR/K2 slightly, move it in direction of the arrow and position clutch K3/K4. Then remove the fixture (Step 102) again. 84547255A
W270R332
Position the oil baffle. Issued 11-11
Printed in E.C.
6003-58
STEP 107
W270R333
Install the output gear by means of lifting tackle.
STEP 108
W270R334
Position upper oil baffle and fasten both plates by means of hexagon screws. NOTE: Install washers. Secure hexagon screws with Loctite (Type No. 243). Tightening torque .......= 23 Nm (203.5 pound inch)
84547255A
Issued 11-11
Printed in E.C.
6003-59
Preassembly and Mounting of the Housing Cover
STEP 111
STEP 109
W270R337
W270R335
Note to Step 109 and 110: Depending on the transmission version, differences as regards the single components and their installation position are possible. Obligatory is the respective spare parts list.
Wet the mounting face with sealing compound (Loctite, Type No. 574). By means of the lifting tackle place the housing cover on the transmission housing until contact.
STEP 112 2
NOTE: Install the sealing cover (arrow). Wet the sealing surface with Loctite (Type No. 262).
STEP 110 3
1
W270R338
Install both cylindrical pins (arrow 1 and 2) and the slotted pin (arrow 3). Then fasten the housing cover by means of hexagon and cap screws. Tightening torque ......... = 46 Nm (407 pound inch) W270R336
Insert the O-Ring into the annular groove of the cover and fasten the cover by means of hexagon screws. NOTE: Wet the thread of the hexagon screws with Loctite (Type No. 574). Observe the installation position of the cover, see Figure. Tightening torque ....... = 23 Nm (203.5 pound inch)
84547255A
Issued 11-11
Printed in E.C.
6003-60
Adjust the bearing preload of clutch K4/K3 = 0.0 ... 0.0019 in (0.0 ... 0.05 mm) (Step 114 ... 116)
STEP 114
STEP 113 1
2 W270R340
Housing dimension: P re ss o n e q u a l l y t h e b e a r i n g i n n e r r i n g a n d determine Dim. I, from the mounting face to the bearing inner ring.
1
Dim. I e.g.............................. = 1.71 in (43.65 mm) NOTE: Take several measuring points and determine the mean value. Then remove the bearing inner ring again.
2
STEP 115
W270R339
NOTE: For installation of a new bearing cover, both finished bores have to be sealed by means of a plug. Finished bores are located opposite (180°) to each other, also see arrow. 1 = Bearing cover-K4/K3 2 = Plug W270R341
Cover dimension: Determine Dim. II, from the mounting face until contact/bearing inner ring. Dim. I e.g.............................. = 1.65 in (42.12 mm)
84547255A
Issued 11-11
Printed in E.C.
6003-61
STEP 116
STEP 118
W270R342
Example: Dim. I ................................... = 1.71 in (43.65 mm) Dim. II ................................... = 1.65 in (42.12 mm) Difference ............................. = 0.060 in (1.53 mm) Bearing preload................... = 0.0007 in (0.02 mm) Resulting shim(s) ............... = 0.061 in (1.55 mm)
W270R344
Grease the rectangular rings (arrows) and centrally align them.
STEP 119
Put on the shim.
STEP 117
W270R345
Install the O-Ring (arrow) and grease it. Heat the inner diameter of the bearing cover (bearing seat).
W270R343
Heat the bearing inner ring and place it until contact. ATTENTION: Use safety gloves. NOTE: Install the bearing inner ring after cooling down subsequently (press).
84547255A
Issued 11-11
Printed in E.C.
6003-62
STEP 120
W270R346
Install two adjusting screws. Assemble the bearing cover and tighten it equally until contact by means of hexagon screws. Tightening torque ............= 46 Nm (47 pound inch) NOTE: Observe the radial installation position.
STEP 121
W270R347
Check the function of both clutches by means of compressed air. NOTE: In case of a decisive pressure loss, the possible cause might be the breakage of one or several rectangular rings (see arrow, Step 118). Replace the rectangular rings, if required.
84547255A
Issued 11-11
Printed in E.C.
6003-63
Adjust the bearing preload of clutch KR/K2 = 0.0 ... 0.0019 in (0.0 ... 0.05 mm) (Step 123 ... 127)
STEP 123
STEP 122 1
2 W270R349
Install both studs (arrows). NOTE: Wet the thread with Loctite (Type No. 243). Tightening torque ......... = 13 Nm (115 pound inch)
1
STEP 124
2
W270R348
NOTE: For installation of a new bearing cover, both finished bores have to be sealed by means of a plug. Finished bores are located opposite (180°) to each other, also see arrow. 1 = Bearing cover-KR/K2 2 = Plug
84547255A
W270R350
Install the bearing outer ring until contact. NOTE: Pay attention to exact contact.
Issued 11-11
Printed in E.C.
6003-64
STEP 125
STEP 127
W270R351
Housing dimension: Determine Dim. I, from the bearing outer ring to the mounting face. Dim. I e.g. .............................= 0.63 in (16.13 mm)
STEP 126
W270R353
Example: Dim. I ................................... = 0.69 in (17.75 mm) Dim. II................................... = 0.63 in (16.13 mm) Difference ............................. = 0.063 in (1.62 mm) Bearing preload ............e.g. + 0.0011 in (0.03 mm) Resulting shim(s) ...............= 0.065 in (1.65 mm) Fix the shim with assembly grease into the cover. Install the O-Ring (arrow).
STEP 128
W270R352
Cover dimension: Determine Dim. II, from the contact/bearing outer ring to the mounting face. Dim. II e.g. ............................= 0.69 in (17.75 mm)
84547255A
W270R354
Grease the rectangular rings (arrows) and centrally align them.
Issued 11-11
Printed in E.C.
6003-65
STEP 129
Adjust the bearing preload of clutch KV/K1 = 0.0 ... 0.0019 in (0.0 ... 0.05 mm) (Step 132 ... 135) STEP 131 1
2 W270R355
Pull the bearing cover equally until contact. Tightening torque ..........= 46 Nm (407 pound inch) W270R357
STEP 130
NOTE: For installation of a new bearing cover, both finished bores have to be sealed by means of a plug. Installation position, see arrows. 1 = Bearing cover-KV/K1 2 = Plug
STEP 132
W270R356
Check the function of both clutches by means of compressed air. NOTE: In case of a decisive pressure loss, the possible cause might be the breakage of one or several rectangular rings (see STEP 128). Replace the rectangular rings, if required. W270R358
Put the bearing outer ring over the bearing inner ring. Housing dimension: Press on equally the bearing outer ring and determine Dim. I, from the mounting face to the bearing outer ring. Dim. I e.g.............................. = 2.07 in (52.67 mm) NOTE: Take several measuring points and determine the mean value.
84547255A
Issued 11-11
Printed in E.C.
6003-66
STEP 133
STEP 135
W270R359
Put the ring with the chamfer showing downwards into the bearing cover.
STEP 134
W270R361
Example: Dim. I ................................... = 2.07 in (52.67 mm) Dim. II................................... = 1.99 in (50.75 mm) Difference ..........................e.g. 0.075 in (1.92 mm) Bearing preload .................... = 0.001 in (0.03 mm) Resulting shim(s) ...............= 0.076 in (1.95 mm) Put in the shim.
STEP 136
W270R360
Cover dimension: Determine Dim. II, from the mounting face to the ring. Dim. II e.g. ............................= 1.99 in (50.75 mm) W270R362
Install the bearing outer ring until contact. Assemble the O-Ring (arrow).
84547255A
Issued 11-11
Printed in E.C.
6003-67
STEP 137
STEP 140
W270R363
W270R366
Grease the rectangular rings (arrows) and centrally align them.
Check the function of both clutches by means of compressed air. NOTE: In case of a decisive pressure loss, the possible cause might be the breakage of one or several rectangular rings (see arrow, STEP 137). Replace the rectangular ring, if required.
STEP 138
W270R364
Heat the bearing bore.
STEP 139
W270R365
Install two adjusting screws. Place the bearing cover until contact and fasten it by means of hexagon screws. NOTE: Observe the radial installation position, see figure.
84547255A
Issued 11-11
Printed in E.C.
6003-68
Output
STEP 143
Installation of the Output Shaft STEP 141
W270R367
Heat the inner diameter of the output gear.
STEP 142
W270R369
Rotate the transmission housing into the vertical position (90°). By means of the mounting tool the output shaft has preliminarily to be fixed axially at the converter side. Then rotate the transmission housing back again (90°).
W270R368
Assemble the output shaft with the long gearing showing downwards until contact.
84547255A
Issued 11-11
Printed in E.C.
6003-69
Adjust the axial play of the output bearing = 0.011 ... 0.019 in (0.3 ... 0.5 mm) (Step 144 ... 146)
STEP 146
STEP 144
W270R372
Install the shim.
STEP 147 W270R370
Determine Dim. I, from plane face/housing to end face/output shaft. Dim. I e.g. ...............................= 2.6 in (66.90 mm)
STEP 145
W270R371
Measure Dim. II, from plane face/housing to contact face/ball bearing. Dim. II e.g. .............................. = 2.5 in (64.20 mm) Example: Dim. I ........................................ 2.6 in (66.90 mm) Dim. II ......................................- 2.5 in (64.20 mm) Difference ...............................= 0.10 in (2.70 mm) required axial play 0.011 ... 0.019 in (0.3 ... 0.5 mm) e.g.................- 0.015 in (0.40 mm) Resulting shim e.g. ........... s = 0.09 in (2.30 mm)
84547255A
W270R373
Install the ball bearing and pull it until contact by means of the output flange. Then remove the output flange again.
Issued 11-11
Printed in E.C.
6003-70
STEP 148
Output Flange – Version with Parking Brake STEP 150
W270R374
Fasten the ball bearing by means of retaining ring.
STEP 149
W270R376
Press on the screen sheet (arrow) until contact.
STEP 151
W270R375
Remove the converter-side mounting tool again. Install the shaft seal, (arrow) with the sealing lip showing to the oil sump. NOTE: Using of the specified mounting tool, results in the exact installation position (without retaining ring = 0.78 in (20 mm)). Grease the sealing lip.
W270R377
Install the output flange-brake disk until contact.
ATTENTION: Depending on the version different shaft seals can be used: Outer diameter rubber-coated – wet it with spirit. Outer diameter metallic – wet it with sealing compound (Loctite, Type No. 574).
84547255A
Issued 11-11
Printed in E.C.
6003-71
Adjust gap size X = 0.011 ... 0.031 in (0.3 ... 0.8 mm) (Step 152 ... 155)
STEP 154
STEP 152 2
1
W270R380
Measure Dim. II, from the plane face to the collar of the output flange. Dim. II z.B. ........................... = 1.41 in (36.00 mm) Example:
X W270R378
X = Gap size 1 = Shim 2 = O-Ring
Dim. I .................................... 1.45 in (37.00 mm) Dim. II ..................................... 1.41 in (36.00 mm) Difference............................. = 0.039 in (1.00 mm) Gap size X 0.011 ... 0.031 in (0.3 ... 0.8 mm) e.g. ........................................ - 0.019 in (0.50 mm) Resulting shim................. s = 0.019 in (0.50 mm)
STEP 155
STEP 153
W270R381 W270R379
Install the output flange until contact. Measure Dim. I, from the plane face of the output flange to the end face of the output shaft.
Place the O-Ring (arrow) into the space between output flange and shaft (see also Step. 152) and put on the shim.
Dim. I e.g. ............................. = 1.45 in (37.00 mm)
84547255A
Issued 11-11
Printed in E.C.
6003-72
STEP 156
Mount the brake (Step 158 ... 162) STEP 158
>13 W270R382
Put on the washer and fasten the output flange by means of hexagon screws. Tightening torque ..........= 46 Nm (407 pound inch)
STEP 157
W270R384
ATTENTION: For working on the brake system, the instructions and specifications of the brake manufacturer are mandatory. Remove the screw cap and loosen the locking nut. Unscrew the adjusting screw in counterclockwise direction until a Dim. > 0.51 in (13.0 mm) (brake disc shim) results.
STEP 159
W270R383
Fasten the hexagon screws by means of the lock plate.
W270R385
Position the brake and fasten it with cap screws. Tightening torque ..... = 125 Nm (1106 pound inch)
84547255A
Issued 11-11
Printed in E.C.
6003-73
Adjust the nominal clearance = 0.078 in (2.0 mm) (Step 160 ... 162)
STEP 162
STEP 160
W270R388
Put new O-Ring into the screw cap and grease it. Install the screw cap. W270R386
Make the pressure connection and apply the required release pressure = 2175.5 psi (150 bar) to the brake (cup spring set preloaded). Fasten the adjusting screw in clockwise direction until both brake lining carriers contact the brake disc (turning of the adjusting screw is then not possible or admissible any more without a higher application of force). Then turn back the adjusting screw by 4/5 turns in counterclockwise direction. 4/5 turns is equal to a nominal clearance of 0.078 in (2.0 mm).
STEP 161
W270R387
Keep the adjusting screw positioned and fix it by means of a lock nut.
84547255A
Issued 11-11
Printed in E.C.
6003-74
Output Flange (Converter Side)
STEP 165
STEP 163
1
2
W270R391
W270R389
Install the shaft seal (arrow) with the sealing lip showing to the oil sump.
1 = Screen sheet 2 = Output flange
STEP 166
NOTE: Using of the specified mounting tool, results in the exact installation position (with retaining ring = 0.27 in (7.0 mm)). Grease the sealing lip. ATTENTION: Depending on the version different shaft seals can be used: Outer diameter rubber-coated â&#x20AC;&#x201C; wet it with spirit. Outer diameter metallic â&#x20AC;&#x201C; wet it with sealing compound (Loctite, Type No. 574).
STEP 164
W270R392
Install the output flange until contact. NOTE: Setting of the gap size as well as fixing of the output flange is identical with the installation of the output flange at the transmission rearside.
W270R390
Press the screen sheet (arrow) over the collar of the output flange until contact. NOTE: Observe the installation position, see Step 165.
84547255A
Issued 11-11
Printed in E.C.
6003-75
Installation of the Idler shaft
STEP 170
STEP 167
W270R396
W270R393
Align the layshaft gear and the single components centrically. Heat the layshaft gearing.
Remove the adjusting screw and fasten the axle by means of hexagon screw. NOTE: Wet the thread of the hexagon screw with Loctite (Type No. 243). Tightening torque ......... = 46 Nm (407 pound inch)
STEP 168
STEP 171
W270R394 W270R397
Install the adjusting screw.
Insert the sealing covers (arrow), with the concave side showing downwards, flush to the housing surface.
STEP 169
NOTE: Wet contact face with Loctite (Type No. 262).
W270R395
Install the idler shaft until contact.
84547255A
Issued 11-11
Printed in E.C.
6003-76
Transmission Pump
STEP 175
STEP 172
W270R401
W270R398
Press the needle sleeve (arrow), with the reinforced coating towards the press-in tool until contact.
Install the ball bearing and driver respectively and press it until contact. NOTE: Pay attention to align the key to the keyway.
STEP 176
STEP 173
W270R402 W270R399
Snap the V-Rings into the recess of the driver (internal gearing). Install the key (arrow).
Fasten the ball bearing by means of retaining ring.
STEP 177
STEP 174
W270R403 W270R400
Install the O-Ring (arrow) and grease it.
Press the ball bearing over the collar of the driver until contact.
84547255A
Issued 11-11
Printed in E.C.
6003-77
STEP 178
STEP 180
W270R404
Heat the housing bore.
W270R406
Put the O-Ring (arrow) into the annular groove of the pump flange.
STEP 179
NOTE: Depending on the transmission version, differences as regards the version and fastening of the pump flange are possible. Obligatory is the respective spare parts list.
STEP 181
W270R405
Install two adjusting screws and assemble the pump until contact. NOTE: Observe the radial installation position. W270R407
Fasten the pump flange and the pump respectively by means of hexagon screws. NOTE: Wet thread of both hexagon screws (position, see arrows) with Loctite, Type No. 574 (through holes). Tightening torque ......... = 79 Nm (699 pound inch) Then rotate the transmission housing by 90°.
84547255A
Issued 11-11
Printed in E.C.
6003-78
STEP 182
STEP 185
W270R408
W270R411
Snap-in and lock the rectangular ring (arrow).
Install the input shaft until contact.
STEP 183
STEP 186
W270R409
Install both shims (each 0.078 in (2.0 mm) thick). NOTE: Use assembly grease.
W270R412
Fasten the input shaft by means of clamping plate and cap screw (arrow). Tightening torque ......... = 32 Nm (283 pound inch)
STEP 184
NOTE: Wet thread of the cap screw with Loctite (Type No. 243).
W270R410
Heat the bevel bearing inner ring.
84547255A
Issued 11-11
Printed in E.C.
6003-79
Input â&#x20AC;&#x201C; Converter Bell
STEP 190
STEP 187
W270R416
Heat the spur gear bore (arrow). W270R413
ATTENTION: To install a new converter bell the finished bores have to be sealed with plugs. Installation position, see arrow.
STEP 191
STEP 188
W270R417
Install the input shaft until contact.
STEP 192 W270R414
Locate the bearing outer ring into the housing bore until contact and install the bearing inner ring, see arrow.
STEP 189
W270R418
Heat the bearing inner ring and install it until contact. ATTENTION: Use safety gloves. W270R415
Install the spur gear (arrow) with the long collar showing upwards and position it. 84547255A
Issued 11-11
Printed in E.C.
6003-80
STEP 193
STEP 196
W270R419
Install the bearing outer ring until contact.
W270R422
Press the needle bearing (arrow), with the reinforced coating towards the press-in tool into the bore of the bearing cover until contact.
STEP 194
STEP 197
W270R420
Snap in the rectangular ring (arrow) into the annular groove of the input shaft and lock it. Then grease the rectangular ring and centrally align it.
STEP 195
W270R423
Flush-mount the shaft seal (arrow) with the sealing lip showing (downwards) to the oil sump. NOTE: Wet the outer diameter with spirit. Grease the sealing lip.
1
3
2 W270R421
Install the converter safety valve (arrow 1) and fasten it by means of slotted pin (arrow 2). NOTE: Flush-mount slotted pin to recess. Put the O-Ring (arrow 3) into the annular groove. 84547255A
Issued 11-11
Printed in E.C.
6003-81
STEP 198
STEP 201
W270R424
W270R427
NOTE: Make the following steps (Step 198...201) in direct time sequence to secure the precise contact of the oil supply flange.
Put on the bearing cover and fasten it by means of hexagon screws. Tightening torque ......... = 46 Nm (407 pound inch)
Heat the housing bore.
STEP 202 STEP 199
1
2
3 W270R428 W270R425
Install two adjusting screws and put in the oil supply flange until contact. NOTE: Observe the radial installation position.
Install the single components according to the opposite figure. 1 = Screw plug ......... = 150 Nm (1327.6 pound inches) 2 = Screw plug .............. = 25 Nm (221.2 pound inches)
STEP 200
3 = Temperature sensor = 25 Nm (221.2 pound inches) and screw plug respectively (depending on the version) ....... = 35 Nm (309.7 pound inches) NOTE: Always install new O-Rings.
W270R426
Place the O-Ring (arrow) with assembly grease into the annular groove of the bearing cover. 84547255A
Issued 11-11
Printed in E.C.
6003-82
Converter pressure back-up valve (Step 203 ... 204)
STEP 205
STEP 203
W270R431
Fasten the gasket and cover plate by means of hexagon screws (install the washers). W270R429
Install the slotted pin 0.23 x 1.96 in (6 x 50 mm) until contact.
Tightening torque .......... = 9.5 Nm (84 pound inch)
STEP 206
STEP 204 1
2 W270R432 W270R430
Assemble piston and compression spring. Provide screw plug with a new O-Ring and install it.
Install two adjusting screws and put on the gasket (arrow 1). Put the O-Ring (arrow 2) into the annular groove.
Tightening torque ... = 130 Nm (1150.5 pound inch)
84547255A
Issued 11-11
Printed in E.C.
6003-83
STEP 207
STEP 209
W270R433
W270R435
Install the converter bell by means of lifting tackle until contact.
Fasten flexible plates by means of hexagon screws (install the washers).
NOTE: Slight rotary motions of the input shaft facilitate the installation (protect teeth from damage). Observe the radial installation position.
NOTE: Wet thread of the hexagon screws with Loctite (Type No. 243).
STEP 208
Tightening torque ......... = 46 Nm (407 pound inch)
STEP 210
W270R434 W270R436
Fasten the converter bell by means of hexagon screws. Tightening torque (M8/10.9) ..................... = 34 Nm ................................................ (300.9 pound inch) Tightening torque (M12/10.9) ................. = 115 Nm .............................................. (1017.8 pound inch)
84547255A
Install the rectangular ring (arrow) into the annular groove and lock it. Then grease the rectangular ring and centrally align it.
Issued 11-11
Printed in E.C.
6003-84
STEP 211
Coarse Filter STEP 213
W270R439
Install filter (assy) into the housing bore. ATTENTION: Oil the sealing (arrow).
STEP 214
W270R437
Assemble converter by means of lifting tackle until contact. NOTE: At a control dimension < 1.69 in (43 mm), the exact installation position of the converter is ensured.
STEP 212 W270R440
Fasten the cover by means of hexagon screws (install the washers). NOTE: Install the new O-Ring (arrow). Tightening torque ...... = 23 Nm (203.5 pound inch)
W270R438
ATTENTION: Until installation of the transmission, fix the converter axially.
84547255A
Issued 11-11
Printed in E.C.
6003-85
Inductive and Speed Transmitters
STEP 216
STEP 215
9
5
13
14
W270R442
13 = Speed transmitter n – Output W270R441
Following sketches show the installation position of the single inductive and speed transmitters.
STEP 217
"S"
"A"
X
I
14 = Inductive transmitter n – Turbine 9 = Inductive transmitter n – Engine 5 = Inductive transmitter n – int. speed input
W270R443
NOTE: The following figures describe the installation and setting respectively of the inductive transmitter n – Engine (9). Installation of the inductive transmitter n – Turbine (14) and n – internal speed input (5) is to be made analogously. Observe the different setting dimensions “X”: ATTENTION: Inductive transmitter n – Engine (9) X = 0.019 + 0.011 in (0.5 + 0.3 mm) Inductive transmitter n – Turbine (14) X = 0.019 + 0.011 in (0.5 + 0.3 mm) Induct. transmitter n – int. speed input (5) X = 0.011 ± 0.0039 in (0.3 ± 0.1 mm).
84547255A
Issued 11-11
Printed in E.C.
6003-86
Adjust Dim. „X" by means of shim ring (Step 218 ... 222)
STEP 220
STEP 218
W270R447
Turn out the plug gauge and determine Dim. II (also see Step 219). W270R444
Measure Dim. I on the inductive transmitter, from contact face to screw-in face. Dim. I e.g. .............................= 1.18 in (30.00 mm)
STEP 219
Dim. II e.g........................... = 1.185 in (30.10 mm) Example “A1”: Dim. II.................................... 1.185 in (30.10 mm) Dim. X 0.019 + 0.011 in (0.5 + 0.3 mm) ....................... - 0.023 in (0.60 mm) results in installation dimension A ......................... = 1.16 in (29.50 mm) Example “A2”: Dim. I.................................... 1.181 in (30.00 mm) Installation dimension A......... - 1.16 in (29.50 mm) results in shim ring .........s = 0.019 in (0.50 mm)
II
STEP 221
W270R448
Install the adequate shim ring and wet the thread (arrow) with Loctite (Type No. 574). W270R445
Turn in the counting disc radially until one tooth tip is centrally to the inductive transmitter bore. Turn the plug gauge until contact. Locate anvil at the tooth tip and lock it by means of threaded pin.
84547255A
Issued 11-11
Printed in E.C.
6003-87
STEP 222
STEP 224
W270R449
W270R451
Install the inductive transmitter n – Engine (9), see arrow.
Opposite figure shows the speed transmitter (Hall sensor).
Tightening torque ....... = 30 Nm (265.5 pound inch)
STEP 225
Set and install the inductive transmitter n – Turbine (14) and n-internal speed input (5) analogously. NOTE: Observe the different setting dimensions. Installation position of the single inductive transmitters, also see Step 215 and 216.
Install speed transmitter n – Output/Speedo (13) (Step 223... 228) STEP 223
X W270R452
2
Determine Dim. I, from the housing face to spur gear K3.
13 1
Dim. I e.g.............................. = 1.56 in (39.70 mm)
3
STEP 226
W270R450
1 = Housing 2 = Spur gear K3 3 = Disc carrier 13 = Speed transmitter (Hall sensor) X = Setting dimension “X” = 0.039 + 0.019 in (1.0 + 0.5 mm)
W270R453
Measure Dim. II, from the contact face to the mounting face. Dim. II e.g............................. = 1.57 in (40.00 mm) 84547255A
Issued 11-11
Printed in E.C.
6003-88
STEP 227
STEP 229
W270R454
Example “B1”: Dim. I ....................................... 1.56 in (39.70 mm) Dim. X 0.039 + 0.019 in (1.0 + 0.5 mm) ........................ - 0.04 in (1.20 mm) results in installation dimension.. = 1.51 in (38.50 mm) Example “B2”: Dim. II ..................................... 1.57 in (40.00 mm) Installation dimension A .........- 1.51 in (38.50 mm) results in shim................. s = 0.059 in (1.50 mm)
W270R456
Flush-mount cup (arrow) to the housing face and install the breather. Tightening torque (breather) .................. = 12 Nm (106.2 pound inch) NOTE: Wet the sealing surface of the cup with Loctite (Type No. 262).
STEP 230 1
Install shims (3x, s = 0.019 in (0.50 mm)) and grease the O-Ring (arrow).
STEP 228
2 3
W270R457
Provide both screw plugs (arrow 1 and 2) with a new O-Ring and install them. Tightening torque ....... = 100 Nm (885 pound inch) Tightening torque ..... = 145 Nm (1283 pound inch) W270R455
Fasten the speed transmitter by means of cap screw.
Provide the adapter (arrow 3) with a new O-Ring and install it.
Tightening torque .......= 23 Nm (203.5 pound inch) NOTE: Installation position of the speed transmitter, also see Step 215 and 216.
84547255A
Issued 11-11
Printed in E.C.
6004
Section 6004 FRONT AXLE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6004-2
TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 5 7 7 8 20 42 42 42
Printed in E.C.
6004-3
SPECIAL TOOLS Planetary bearing puller collet set .............................................................................................................380001757 Brake housing seal installer.......................................................................................................................380001574 Differential bearing cone puller collet set...................................................................................................380001569 Differential bearing preload wrench...........................................................................................................380001565 Brake housing inner bearing cup installer .................................................................................................380001572 Brake housing outer bearing cup installer .................................................................................................380001573 Brake housing inner bearing cup installer .................................................................................................380001556 Wear ring installer adapter ........................................................................................................................380001754 Wear ring installer adapter .......................................................................................................................380001755 Pinion depth gauge set..............................................................................................................................380001570 Pinion depth gauge block ..........................................................................................................................380001753 Puller body and screw ...............................................................................................................................380001575 Support bracket .........................................................................................................................................380001576 Slide hammer puller adapter .....................................................................................................................380001545 Slide hammer ............................................................................................................................................380001582 Replacer ....................................................................................................................................................380001552 Magnetic base with indicator .....................................................................................................................380001725 Heat gun ....................................................................................................................................................380001544 Lifting sling.................................................................................................................................................380001579 Engine stand..............................................................................................................................................380001580 Snap ring pliers..........................................................................................................................................380001584 Snap ring pliers..........................................................................................................................................380001583 Snap ring pliers..........................................................................................................................................380001585 Step plate set (includes 380001539, 380001541, and 380001542) ............................................................OEM4288 Step plate ..................................................................................................................................................380001539 Step plate ..................................................................................................................................................380001541 Step plate ..................................................................................................................................................380001542 Hexagonal wrench 4.1 in (105 mm)...........................................................................................................380003004 Lifting devise..............................................................................................................................................380002303 Clamping devise ........................................................................................................................................380001564 Assembly fixture ........................................................................................................................................380100001
84547255A
Issued 11-11
Printed in E.C.
6004-4
SPECIFICATIONS Axle supplied with hydraulic avtivated locking differentials Overall width ................................................................................................................................. 2493 mm (98 inch) Track........................................................................................................................................... 2550 mm (88.5 inch) Distance flange to flange ............................................................................................................... 2314 mm (91 inch) Mounting pad center to center.................................................................................................... 1041 mm (40.9 inch) Mounting pad height .......................................................................................................................112 mm (4.4 inch) Wheel mounting bolt circle Dia. .................................................................................................... 500 mm (19.6 inch) Wheel mounting studs 23 Hub pilot Dia. ................................................................................................................................ 448 mm (17.6 inch) Input flange joint centerline to be.................................................................................................. 399 mm (15.7 inch) Axle filled with 20W-40 Oil
SPECIAL TORQUES Bolts Securing Wheel End to Axle Housing......................................................................... 560 Nm (413 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads)................................................1200 Nm (885 pound feet) Bolts Securing Differential Ring Gear.................................................................................. 560 Nm (413 pound feet) Bolts Securing Axle Housing to Center Section .................................................................. 560 Nm (413 pound feet) Locknut Securing Planetary Carrier.................................................................................. 500 Nm (368.7 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-5
GEAR TOOTH CONTACT PATTERNS Ideal Tooth Contact Pattern
Pinion Distance Must Be Increased
BS01D011
BS01D009
COAST SIDE (CONCAVE)
BS01D013 BS01D012
COAST SIDE (CONCAVE)
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
84547255A
Issued 11-11
Printed in E.C.
6004-6
Pinion Distance Must Be Decreased
BS01D016 BS01D010
DRIVE SIDE (CONVEX)
BS01D015
COAST SIDE (CONCAVE)
84547255A
Issued 11-11
Printed in E.C.
6004-7
LUBRICATION 4
3 5 2
4
1
1
2 W230R550
1. OIL DRAIN HOLE (AXLE HOUSING) 2. OIL DRAIN HOLE (OUTPUTS)
3. OIL FILL HOLE 4. BRAKE BLEEDER
5. BLEEDER
WEAR MEASUREMENT ON MULTI-DISC BRAKE X
BS00M071
BD00M234
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a changed braking behavior. A wear measurement has to be made on both wheels ends. Remove crew plug, actuate brake and determine dimension “X” using a feeler guage. If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced. Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pond-feet).
84547255A
Issued 11-11
Printed in E.C.
6004-8
DISASSEMBLY Output and brake
STEP 3
STEP 1
W230R445
Remove the breather valve (see arrow). W230R551
STEP 4
Fix axle to assembly truck. ATTENTION: Before clamping the axle fully turn in the support. Position axle first onto the two fixtures, secure with clamping brackets and then unbolt the support until contact with the axle is obtained.
STEP 2
W230R553
Secure the output with the lifting device 380002303 and loosen hexagon screws. Then separate the output assy from the axle housing.
STEP 5
W230R447 W230R552
Loosen screw plugs and drain oil from the axle.
Pull stub shaft and sun gear shaft. NOTE: Pay attention to potentially releasing shim.
84547255A
Issued 11-11
Printed in E.C.
6004-9
STEP 6
STEP 9
W230R448
Fix output to assembly truck.
W230R451
Press planetary carrier with a two-armed puller out of the profile of the output shaft.
STEP 7 STEP 10
W270R459
Use a lever to remove the cover from the output shaft.
W230R452
Lift the planetary carrier out of the brake housing by means of the lifting device 380001578.
STEP 8 STEP 11
W270R460
Loosen locking screws and remove the releasing cover.
84547255A
W230R453
Pull the tapered roller bearing from the planetary carrier.
Issued 11-11
Printed in E.C.
6004-10
STEP 12
STEP 15
W230R454
W230R457
Disengage retaining ring.
Lift the disk package out of the brake housing.
STEP 13
STEP 16
W230R455
Pull off planetary gear.
W230R458
Loosen hexagon screws, remove releasing cover and cup spring.
STEP 14 STEP 17
W230R456
Lift the end plate out of the brake housing.
W230R459
Mount breather valve and press piston out of the brake housing by means of compressed air.
84547255A
Issued 11-11
Printed in E.C.
6004-11
STEP 18
STEP 19
W230R460
If necessary, remove guide ring, back-up rings and grooved rings out of the annular grooves of the brake housing (see arrows). NOTE: For the installation position of the single parts please also refer to the following sketch.
W270R461
Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft
STEP 20
W230R462
Lift the brake housing from the output shaft by means of the lifting device.
84547255A
Issued 11-11
Printed in E.C.
6004-12
STEP 21
W230R463
Use a lever to remove the slide ring seal from the brake housing.
STEP 22
W230R464
Use a lever to remove the slide ring seal from the output shaft.
STEP 23
W230R465
Pull the tapered roller bearing from the output shaft.
84547255A
Issued 11-11
Printed in E.C.
6004-13
Axle Housing
STEP 26
STEP 24
W230R468
Loosen screw neck. W230R554
Secure axle housing with the lifting device and loosen the hexagon screws. Then separate the axle housing from the axle drive housing. NOTE: Pay attention to releasing differential.
STEP 25
W230R467
Loosen the threaded connections and remove the releasing brake tube.
84547255A
Issued 11-11
Printed in E.C.
6004-14
Disassembly axle drive housing
STEP 30
STEP 27
W270R465
W270R462
Secure axle drive housing with the lifting device (S) and loosen the hexagon screws. Then separate the axle drive housing from the axle housing.
Pull the bearing outer ring (see arrow) out of the bearing hole and remove the shim behind.
STEP 31
STEP 28
W270R466
Press the piston out of the bearing housing by means of compressed air. W270R463
STEP 32
Fix axle drive housing to the assembly truck.
STEP 29
W270R467
Lift differential out of the axle drive housing with the lifting device. W270R464
Loosen cylindrical screws and lift the releasing bearing housing with the lifting device. 84547255A
Issued 11-11
Printed in E.C.
6004-15
STEP 33
STEP 36
W270R468
W270R471
Pull the bearing outer ring (see arrow) out of the bearing hole and remove the shim behind.
Pull input flange from the input pinion and use a lever to lift the shaft seal ring behind out of the axle drive housing.
STEP 34 STEP 37
W270R469
Heat slotted nut by means of hot-air blower.
W270R472
NOTE: Slotted nut is secured with Loctite (Type no.: 262).
STEP 35
Use a two-armed puller to press the input pinion out of the axle drive housing and remove the releasing tapered roller bearing.
STEP 38
W270R470
Loosen the slotted nut and remove the shim behind.
W270R473
Remove the spacer and pull the tapered roller bearing from the input pinion.
84547255A
Issued 11-11
Printed in E.C.
6004-16
STEP 39
W270R474
Loosen the threaded connection and remove the releasing oil tube.
STEP 40
W270R475
If necessary pull the internal bearing outer ring out of the axle drive housing and remove the shim behind.
STEP 41
W270R476
If necessary pull the external bearing ring out of the axle drive housing.
84547255A
Issued 11-11
Printed in E.C.
6004-17
Disassembly differentials
STEP 45
Disassembly multi-disk differential lock STEP 42
W270R480
Lift the differential cover from the differential housing by means of the lifting device. W270R477
Remove axial roller cage (arrow).
STEP 46
STEP 43
W270R481
Preload the compression spring by means of the press and disengage the retaining ring. W270R478
Pull both tapered roller bearings from the differential.
STEP 44
Then pull the sliding sleeve out of the differential cover and remove the releasing compression springs.
W270R479
Preload the differential by means of the press and loosen the locking screws.
84547255A
Issued 11-11
Printed in E.C.
6004-18
STEP 47
STEP 49
W270R482
Remove single parts.
W270R484
Remove thrust washer and axle bevel gear from the differential housing.
1 = Disk 2 = Pressure piece 3 = Cage 4 = Lever 5 = Disk carrier 6 = Disk package
STEP 50
STEP 48
W270R485
Force out slotted pins.
STEP 51 W270R483
Loosen hexagon screws and remove the releasing disk.
W270R486
Pull spider shafts and remove the releasing spider gears with the thrust washers from the differential housing.
84547255A
Issued 11-11
Printed in E.C.
6004-19
STEP 52
W270R487
Remove the axle bevel gears and the shims behind.
STEP 53
W270R488
Support the crown wheel and force out the differential housing.
84547255A
Issued 11-11
Printed in E.C.
6004-20
REASSEMBLY Reassembly differentials
STEP 3
Reassembly multi-disk differential lock STEP 1
W270R487
Insert axle bevel gear.
STEP 4 W270R489
Mount two adjusting screws and press the heated crown wheel onto the differential housing until contact is obtained.
STEP 2
W270R491
Insert spider gears with thrust washers into the differential housing and fix them with the spider shaft. NOTE: Thrust washers must be positioned with the tabs (see arrow 1) in the recesses of the differential housing. W270R490
Insert disk and thrust washer into the differential housing.
84547255A
NOTE: Pay attention to radial installation position of the spider shafts (fixing holes, arrow 2).
Issued 11-11
Printed in E.C.
6004-21
STEP 5
Setting of disk package STEP 8 8 7 6 5 4
3
2 1
W270R485
Fix spider shafts with slotted pins (2 pieces / hole). NOTE: Press the slotted pins with 180° offset openings into flush position.
STEP 6
W270R493
Premount single parts according to the adjacent sketch. 1 = Differential cover 2 = Pressure piece 3 = Disk 4 = Cage 5 = Lever 6 = End plate 7 = Outer disks (optional) 8 = Inner disks
STEP 9
W270R484
Mount second axle bevel gear and thrust washer.
STEP 7
W270R494
Preload disk package with an axial force of F = 7 t. Then check the setting dimension “A” = 0.61-0.0078 in (15.5 -0.2 mm) from the mounting face of the differential cover to the plane face of the outer disk (see also below sketch). W270R492
Mount disk and fix it with hexagon screws. Tightening torque.................50 Nm (36.8 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-22
STEP 10
STEP 13
A
W270R495
W270R498
A = Setting dimension = 0.61-0.0078 in (15.5 -0.2 mm).
Mount outer and inner disks.
STEP 11
NOTE: For the number of disks and disk arrangement please refer to the relating spare parts list. ATTENTION: Pay attention to the radial installation position of the disk package, as shown on the adjacent figure.
STEP 14
W270R496
Engage the snap ring (see arrow) into the annular groove of the disk carrier.
STEP 12 W270R499
Insert end plate.
STEP 15
W270R497
Insert the premounted disk carrier onto the axle bevel gear.
W270R500
Mount cage and lever. 84547255A
Issued 11-11
Printed in E.C.
6004-23
STEP 16
STEP 19
W270R501
Insert pressure piece (see arrow) and install disk.
STEP 17
W270R481
Preload the compression springs by means of the press and engage the retaining ring into the annular groove of the sliding sleeve.
STEP 20
W270R502
Insert compression springs into the differential cover. W270R480
STEP 18
Mount two adjusting screws and insert the differential cover by means of the lifting device.
STEP 21
W270R503
Insert sliding sleeve. W270R504
Preload the differential by means of the press and bolt with new locking screws. Tightening torque ............= 400 Nm (295 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-24
STEP 22
Determination of shim thickness to obtain a correct contact pattern STEP 25 The following measuring procedures must be carried out with utmost accuracy. Inaccurate measurements lead to an incorrect contact pattern requiring an additional disassembly and reassembly of input pinion and differential.
STEP 26 W270R505
Heat both tapered roller bearings and insert until contact is obtained. NOTE: Adjust tapered roller bearing after cooling down.
STEP 23
W270R506
Read dimension I from the axle drive housing. Dimension I e.g. ............................13 in (331.25 mm)
STEP 27
W270R477
Insert axial roller cage (see arrow).
Reassembly axle drive housing STEP 24 If crown wheel or input pinion are damaged, both parts must be jointly replaced. In case of a new installation of a complete bevel gear set pay attention to an identical mating number of input pinion and crown wheel.
84547255A
W270R507
Read dimension II (pinion dimension). Dimension II e.g. ........................10.4 in (265.00 mm)
Issued 11-11
Printed in E.C.
6004-25
STEP 28
STEP 30
W270R508
Determine dimension III (bearing width). Dimension III e.g............................ 2.5 in (63.60 mm) CALCULATION EXAMPLE â&#x20AC;&#x153;Aâ&#x20AC;?: Dimension I................................... 13 in (331.25 mm) Dimension II............................... - 10.4 in (265.0 mm) Dimension III................................ - 2.5 in (63.60 mm) Difference = shim...................s = 0.10 in (2.60 mm)
W270R510
Insert the determined shim e.g. s = 0.10 in (2.60 mm) into the housing hole.
STEP 31
Reassembly of input pinion STEP 29
W270R511
Undercool the internal bearing outer ring and bring it into contact position in the housing hole by using the assembly fixture.
STEP 32
W270R509
Undercool the external bearing outer ring and insert it into the axle drive housing until contact is obtained.
W270R512
Heat the tapered roller bearing and insert it into the input pinion until contact is obtained.
84547255A
Issued 11-11
Printed in E.C.
6004-26
STEP 33
STEP 35
W270R513
W270R515
Setting of rolling torque of input pinion bearing 1.0 ... 5.0 Nm (0.7...3.6 pound feet) (without shaft seal ring)
Press the protection plate onto the input flange (see arrow) until contact is obtained.
Insert spacer e.g. s = 0.28 in (7.13 mm). NOTE: According to our experience the necessary rolling torque is obtained when reusing the spacer which has been removed during disassembly e.g. s = 0.28 in (7.13 mm). A later check of the rolling torque, however, is absolutely necessary.
NOTE: Do not fit the shaft seal ring until the contact pattern has been checked (page 31).
STEP 36
STEP 34
W270R516
Insert input flange and fix it by means of disk and slotted nut. Tightening torque ..........= 1200 Nm (885 pound feet) NOTE: Preliminarily mount slotted nut without Loctite. W270R514
Insert the preassembled input pinion into the axle drive housing and insert the heated tapered roller bearing until contact is obtained.
84547255A
ATTENTION: While tightening rotate the input pinion several times in both directions.
Issued 11-11
Printed in E.C.
6004-27
STEP 37
STEP 39
W270R517
Check rolling torque (1.5 ... 5.0 Nm (1.1 ... 3.6 pound feet) without shaft seal ring). NOTE: When installing new bearings try to achieve the upper value of the rolling torque.
W270R519
Mount oil tube. Tightening torque ...........= 100 Nm (73.7 pound feet)
STEP 40
ATTENTION: In case of deviations from the necessary rolling torque correct with a corresponding spacer (STEP 33) as specified below. Insufficient rolling torque - install thinner spacer ring. Excessive rolling torque - install thicker spacer ring.
STEP 38
W270R520
Grease O-rings (see arrows) and insert them into the annular grooves of the piston.
STEP 41
W270R518
Mount threaded connection. Tightening torque............= 100 Nm (73.7 pound feet)
W270R465
Insert piston (see arrow) into the bearing housing until contact is obtained.
84547255A
Issued 11-11
Printed in E.C.
6004-28
Setting Backlash and Bearing Preload Crow wheel marking
-30
-20
-10
0
10
20
Deviation
-0.3
-0.2
-0.1
0
0.1
0.2
Shim Diff. cage side Shim thickness
1.1
1.2
1.3
1.4
1.5
1.6
Shim Crown wheel side Shim thickness
1.7
1.6
1.5
1.4
1.3
1.2
STEP 42
STEP 43
1
3
2
4
W270R521
W270R522
Deviation see crown wheel rear side.
Legend to sketch:
The test dimension “108” is stamped into the crown wheel rear side. If no + or – deviation is indicated, this value corresponds to the actual value ”O” in the table below.
1 = Bearing housing 2 = Shim (crown wheel side) 3 = Shim (diff. carrier side) 4 = Axle housing
According to this value, the required shims are allocated in the table below.
STEP 44
Any + or – deviation of the test dimension caused by production is also marked on the crown wheel rear side (e.g. - 20 or - 10 or 10 or 20) . In accordance with this deviation, the required shims are allocated in the table below.
W270R523
Insert the determined shim e.g. s = 0.055 in (1.4 mm) into the hole of the axle drive housing and reset until contact with the bearing outer ring is obtained.
84547255A
Issued 11-11
Printed in E.C.
6004-29
STEP 45
STEP 47
W270R467
W270R525
Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing.
Place the premounted bearing housing onto the axle drive housing by means of the lifting device.
STEP 46
NOTE: Preliminarily mount the bearing housing without O-ring.
STEP 48
W270R524
Insert the determined shim e.g. s = 0.055 in (1.4 mm) into the bearing housing and reset the bearing outer ring until contact is obtained.
W270R526
Fix the bearing housing by means of cylindrical screws. Tightening torque .............= 50 Nm (36.8 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-30
Leakage test of lock
STEP 51
STEP 49
W270R467
W270R527
After the contact pattern check insert the differential again into the axle drive housing.
Pressurize the lock = 1 bar (14.5 psi), close shut-off valve and remove air line. ATTENTION: No noticeable pressure loss is allowed to occur within 10 sec.
STEP 50
W270R464
By rotating the input flange, roll crown wheel over the input pinion in both directions several times. Then remove the bearing housing again and lift the differential out of the axle drive housing. ATTENTION: In case of any contact pattern deviation, a measuring error was made when determining the shim (STEP 30), which must be corrected by all means.
84547255A
Issued 11-11
Printed in E.C.
6004-31
Reassembly of shaft seal ring (STEP 52 â&#x20AC;Ś 54)
STEP 54
STEP 52
W270R529
Insert input flange and finally tighten by means of disk and slotted nut. W270R470
Loosen slotted nut and pull the input flange from the input pinion.
STEP 53
Tightening torque ..........= 1200 Nm (885 pound feet) ATTENTION: Cover the thread of the slotted nut with Loctite (Type no.: 262).
STEP 55
W270R528
Mount the shaft seal ring with the seal lip showing to the oil chamber.
W270R530
Grease O-ring (see arrow) and insert it into the annular groove of the bearing housing.
NOTE: The exact installation position of the shaft seal ring is obtained when using the specified driver tool. ATTENTION: Wet the outer diameter of the shaft seal ring with spirit directly before installation and fill the space between seal and dust lip with grease.
84547255A
Issued 11-11
Printed in E.C.
6004-32
STEP 56
STEP 58
W270R531
W270R533
Insert the bearing housing by means of the lifting device and finally tighten it with cylindrical screws.
Mount two adjusting screws and bring axle drive housing in contact position with the axle housing by using the lifting device. Then fix the axle drive housing with hexagon screws.
Tightening torque..............= 50 Nm (36.8 pound feet)
STEP 57
Tightening torque ............= 560 Nm (413 pound feet) ATTENTION: After mounting the axle drive housing unbolt the support until contact is obtained.
W270R532
Grease O-rings (see arrows) and insert them on both sides of the axle drive housing.
84547255A
Issued 11-11
Printed in E.C.
6004-33
Reassembly axle housing
STEP 61
STEP 59
W270R536
Tightening torque..............= 36 Nm (26.5 pound feet)
Mount two adjusting screws and bring the axle housing into contact position with the axle drive housing by using the lifting device. Then fix the axle housing by means of hexagon screws.
STEP 60
Tightening torque ............= 560 Nm (413 pound feet)
W270R534
Mount both fittings.
ATTENTION: After assembling the axle housing secure the axle with clamping brackets.
W270R535
Mount brake tube. Tightening torque............= 100 Nm (73.5 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-34
Output and Brake
STEP 64
STEP 62
W230R524
W230R522
Pull in wheel stud into the output shaft until contact is obtained.
STEP 63
Wet O-ring of slide ring seal and locating hole with spirit. Snap new slide ring seal into the output shaft. Then mount new slide ring seal accordingly into the brake housing. NOTE: For the installation position of the seal please also refer to sketch STEP 70.
STEP 65
W230R523
Heat tapered roller bearing and insert it into the output shaft until contact is obtained. W230R525
ATTENTION: The surface of the slide ring seal may not have any grooves, scratches or other types of damage. Take care that the sealing surface is parallel to the housing face. The O-rings must be mounted evenly into the locating hole and must not bulge out of the hole. Risk of injury - Metal rings have extremely sharp edges. Wear protective gloves.
84547255A
Issued 11-11
Printed in E.C.
6004-35
STEP 66
STEP 68
W230R526
W230R460
Insert both bearing outer rings (see arrows) into the brake housing until contact is obtained.
Insert back-up rings and grooved rings into the annular grooves of the brake housing (see arrows).
STEP 67
NOTE: Pay attention to the installation position; please also refer to sketch STEP 70.
STEP 69
W230R462
Insert the premounted brake housing by means of the lifting device over the output shaft until contact is obtained. ATTENTION: Before clamping the seal rings (slide ring seal) to installation dimension, clean the sliding surfaces and apply an oil film. We recommend to use a leather cloth soaked with oil.
W230R527
Clean the annular groove of the brake housing with spirit. Then insert the guide ring into the annular groove (see also the following sketch) and fix it with Loctite (type no.: 415) at its extremities (see arrows). NOTE: The full circumference of the guide ring must be in an exact contact position. ATTENTION: Upon installation the orifice of the guide ring must show upwards (12 oâ&#x20AC;&#x2122;clock).
84547255A
Issued 11-11
Printed in E.C.
6004-36
STEP 70
STEP 72
W270R546
Insert disk and cup spring with the convex side showing upwards into the piston.
STEP 73
W270R461
Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft
W230R531
Insert cover and fix it by means of hexagon screws. Tightening torque ................= 34 Nm (25 pound feet)
STEP 74
STEP 71
W230R457
W230R529
Insert the piston into the brake housing and carefully install with the fixing device until contact is obtained.
84547255A
Mount outer and inner disks. NOTE: For the number of disks and the disk arrangement please refer to the relating spare part list.
Issued 11-11
Printed in E.C.
6004-37
STEP 75
STEP 77 1 2
3
W230R456
Insert end plate.
W270R551
Press stop bolt into the planetary carrier until contact is obtained.
STEP 76
Legend to sketch: 1 = Stop bolt 2 = Cover 3 = Planetary carrier
STEP 78 1
2 3 4
W270R550
Setting of installation dimension 2.25 … 2.27 in (57.25 … 57.79 mm) Measure installation dimension from the mounting face of the brake housing to the front face of the end plate. Installation dimension e.g. ........... 2.26 in (57.50 mm) NOTE: Any deviation from the necessary installation dimension must be corrected with an approppriate outer disk (see spare parts list).
W230R533
Insert the cylindrical roller bearing into the planetary gear – for this purpose press the cylindrical roller bearing through the packaging sleeve until the snap ring engages into the annular groove of the planetary gear. 1 = Cylindrical roller bearing 2 = Packaging sleeve 3 = Snap ring 4 = Planetary gear
84547255A
Issued 11-11
Printed in E.C.
6004-38
STEP 79
STEP 81
1 2
W230R454
W230R535
Heat bearing inner rings and insert the premounted planetary gears with large radius facing the planetary carrier (downwards) until contact is obtained.
Wet front face (contact face bearing inner ring, arrow 1) and profile (teeth, arrow 2) in the output shaft with anti-corrosive agent.
NOTE: Adjust bearing inner rings after cooling down.
STEP 82
Then fix planetary gears by means of retaining rings.
STEP 80
W230R452
W230R534
Align disk package centrally and radially. Then insert the planetary carrier by means of the lifting device into the teeth of the output shaft.
Heat tapered roller bearing and install it to the planetary carrier until contact is obtained.
84547255A
Issued 11-11
Printed in E.C.
6004-39
STEP 83
STEP 85
W230R537
W230R539
Pivot output 90°. Insert disk and fix planetary carrier with new locking screws.
Insert the cover into the output shaft until contact is obtained.
ATTENTION: Tighten locking screws successively with a tightening torque of 200 Nm (147.5 pound feet). Then retighten the locking screws successively with a tightening torque of 500 Nm (368.7 pound feet).
STEP 86
STEP 84
2 W230R540
Determine dimension I, from the mounting face of the brake housing to the front face of the stop bolt.
1
Dimension I ....................................2.3 in (58.60 mm) W230R538
Install O-ring (see arrow 1) to the cover (2). NOTE: Use new cover and O-ring.
84547255A
Issued 11-11
Printed in E.C.
6004-40
STEP 87
STEP 89
W230R541
W230R543
Insert stub shaft into the teeth of the axle bevel gear until contact is obtained.
Measure dimension II, from the front face of the sun gear shaft to the mounting surface of the axle housing.
ATTENTION: Pay attention to the installation position; mount the stub shaft with the long teeth showing to the differential.
Dimension II ...................................2.2 in (56.60 mm) CALCULATION EXAMPLE: Dimension I ...................................2.3 in (58.60 mm) Dimension II ................................ - 2.2 in (56.60 mm) Difference .........................................0.1 in (2.00 mm) Required axial play........................ - 0.4 in (1.00 mm) Difference = shim e.g. ................s = 0.4 in (1.00 mm)
STEP 88
STEP 90
W230R542
Insert the sun gear shaft until contact is obtained.
W230R544
Insert sun gear shaft into the planetary carrier.
84547255A
Issued 11-11
Printed in E.C.
6004-41
STEP 91
STEP 94
W230R545
W230R588
Fix determined shim(s) e.g. s = 0.4 in (1.00 mm) with grease into the sun gear shaft.
Mount two adjusting screws and use the lifting device to 380002303 bring the output into contact position with the axle housing.
STEP 92
Then fix the output by means of hexagon screws. Tightening torque ............= 560 Nm (413 pound feet)
STEP 95
W230R546
Fix O-ring (see arrow) with grease into the countersink of the brake housing.
STEP 93
W230R548
Mount breather (see arrow).
W230R547
Grease O-ring (see arrow) and install it to the axle housing.
84547255A
Issued 11-11
Printed in E.C.
6004-42
BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS.
High Pressure Test STEP 97
STEP 96
Operate the hand pump to increase pressure to 100 bar (1450 psi) maximum. Close connection to hand pump using the shutoff valve. During a 5 minute period, pressure shall not drop more than 2 bar (29 psi).
Low Pressure Test STEP 98 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period pressure shall not drop. W230R589
Connect a hand pump with pressure gauge to the brake port as shown above. Fill the hand pump with hydraulic oil. Build up pressure in the axle internal brake lines then bleed air from the lines. After air is bled, actuate the brakes a minimum of 5 times to a pressure of 100 bar (1450 psi) by operating the hand pump.
STEP 99 Check operability of DHL
W230R590
Build up pressure p = 20 bar max. (290 psi) and close connection to HP pump via shut-off valve. Lock on: When rotating the input flange, both outputs must have the same direction of rotation. Lock off: When rotating the input flange one side has no movement or has the opposite direction of rotation.
84547255A
Issued 11-11
Printed in E.C.
6004
Section 6004 REAR AXLE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6004-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 4 6 6 7 17 35 35 35
Printed in E.C.
6004-3
SPECIFICATIONS Axle supplied with open differentials Overall width ..............................................................................................................................2476 mm (97.4 inch) Track...........................................................................................................................................2250 mm (88.5 inch) Distance flange to flange ...............................................................................................................2314 mm (91 inch) Wheel mounting bolt circle Dia. ....................................................................................................500 mm (19.6 inch) Wheel mounting studs 23 Hub pilot Dia. ................................................................................................................................448 mm (17.6 inch) Input flange joint centerline to be..................................................................................................399 mm (15.7 inch) Axle filled with 20W-40 Oil
SPECIAL TORQUES Bolts Securing Wheel End to Axle Housing......................................................................390 Nm (287.6 pound feet) Nut Securing Input Flange (Apply Loctite 262 to Threads)................................................1200 Nm (885 pound feet) Bolts Securing Differential Ring Gear..................................................................................560 Nm (413 pound feet) Bolts Securing Axle Housing to Center Section ..................................................................560 Nm (413 pound feet) Locknut Securing Planetary Carrier..................................................................................500 Nm (368.7 pound feet)
SPECIAL TOOLS Planetary bearing puller collet set .............................................................................................................380001757 Brake housing seal installer.......................................................................................................................380001574 Differential bearing cone puller collet set...................................................................................................380001569 Differential bearing preload wrench...........................................................................................................380001565 Brake housing inner bearing cup installer .................................................................................................380001572 Brake housing outer bearing cup installer .................................................................................................380001573 Brake housing inner bearing cup installer .................................................................................................380001556 Wear ring installer adapter ........................................................................................................................380001754 Wear ring installer adapter .......................................................................................................................380001755 Pinion depth gauge set..............................................................................................................................380001570 Pinion depth gauge block ..........................................................................................................................380001753 Puller body and screw ...............................................................................................................................380001575 Support bracket .........................................................................................................................................380001576 Slide hammer puller adapter .....................................................................................................................380001545 Slide hammer ............................................................................................................................................380001582 Replacer ....................................................................................................................................................380001552 Magnetic base with indicator .....................................................................................................................380001725 Heat gun ....................................................................................................................................................380001544 Lifting sling.................................................................................................................................................380001579 Engine stand..............................................................................................................................................380001580 Snap ring pliers..........................................................................................................................................380001584 Snap ring pliers..........................................................................................................................................380001583 Snap ring pliers..........................................................................................................................................380001585 Step plate set (includes 380001539, 380001541, and 380001542) ............................................................OEM4288 Step plate ..................................................................................................................................................380001539 Step plate ..................................................................................................................................................380001541 Step plate ..................................................................................................................................................380001542 Hexagonal wrench 4.1 in (105 mm)...........................................................................................................380003004 Lifting devise..............................................................................................................................................380002303 Clamping devise ........................................................................................................................................380001564 Assembly fixture ........................................................................................................................................380100001
84547255A
Issued 11-11
Printed in E.C.
6004-4
GEAR TOOTH CONTACT PATTERNS Ideal Tooth Contact Pattern
Pinion Distance Must Be Increased
BS01D011
BS01D009
COAST SIDE (CONCAVE)
BS01D013 BS01D012
COAST SIDE (CONCAVE)
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)
84547255A
Issued 11-11
Printed in E.C.
6004-5
Pinion Distance Must Be Decreased
BS01D016 BS01D010
DRIVE SIDE (CONVEX)
BS01D015
COAST SIDE (CONCAVE)
84547255A
Issued 11-11
Printed in E.C.
6004-6
LUBRICATION 7
4 6 5 6 7
2
3
1 2 W270R084
1. OIL DRAIN HOLE (AXLE HOUSING) 2. OIL DRAIN HOLE (OUTPUTS) 3. OIL FILLING AND OIL LEVEL CHECK
4. BRAKE BLEEDER 5. BREATHER 6. BRAKE INLET
7. WEAR CHECK FOR MULTIPLE DISK BRAKE
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE A
BS00M071
BD00M234
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired. Wear measurement must be made on both wheel end sides. Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing the plug. Tighten plug to a torque of 50 Nm (40 pound feet).
84547255A
Issued 11-11
Printed in E.C.
6004-7
DISASSEMBLY ATTENTION: The views in the following steps may be different than the machine.
STEP 3
Output and Brake STEP 1
W230R445
Remove the breather valve (see arrow).
STEP 4 W230R551
Fix axle to assembly truck. ATTENTION: Before clamping the axle fully turn in the support. Position axle first onto the two fixtures, secure with clamping brackets and then unbolt the support until contact with the axle is obtained.
STEP 2
BD06G004
Secure the output with the lifting device 380002303 and loosen hexagon screws. Then separate the output assy from the axle housing.
STEP 5
W230R447
Pull stub shaft and sun gear shaft. W230R444
NOTE: Pay attention to potentially releasing shim.
Loosen screw plugs and drain oil from the axle. 84547255A
Issued 11-11
Printed in E.C.
6004-8
STEP 6
STEP 9
W230R448
Fix output to assembly truck.
W230R451
Press planetary carrier with a two-armed puller out of the profile of the output shaft.
STEP 7 STEP 10
W230R449
Use a lever to remove the cover from the output shaft.
W230R452
Lift the planetary carrier out of the brake housing by means of the lifting device 380001578.
STEP 8 STEP 11
W230R450
Loosen locking screws and remove the releasing cover.
84547255A
W230R453
Pull the tapered roller bearing from the planetary carrier.
Issued 11-11
Printed in E.C.
6004-9
STEP 12
STEP 15
W230R454
W230R457
Disengage retaining ring.
Lift the disk package out of the brake housing.
STEP 13
STEP 16
W230R455
Pull off planetary gear.
W230R458
Loosen hexagon screws, remove releasing cover and cup spring.
STEP 14 STEP 17
W230R456
Lift the end plate out of the brake housing.
W230R459
Mount breather valve and press piston out of the brake housing by means of compressed air.
84547255A
Issued 11-11
Printed in E.C.
6004-10
STEP 18
STEP 19
W230R460
If necessary, remove guide ring, back-up rings and grooved rings out of the annular grooves of the brake housing (see arrows). NOTE: For the installation position of the single parts please also refer to the following sketch.
W230R461
Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft
STEP 20
W230R462
Lift the brake housing from the output shaft by means of the lifting device.
84547255A
Issued 11-11
Printed in E.C.
6004-11
STEP 21
W230R463
Use a lever to remove the slide ring seal from the brake housing.
STEP 22
W230R464
Use a lever to remove the slide ring seal from the output shaft.
STEP 23
W230R465
Pull the tapered roller bearing from the output shaft.
84547255A
Issued 11-11
Printed in E.C.
6004-12
Axle Housing
STEP 26
STEP 24
W230R468
Loosen screw neck. W230R554
Secure axle housing with the lifting device and loosen the hexagon screws. Then separate the axle housing from the axle drive housing.
STEP 27
NOTE: Pay attention to releasing differential.
STEP 25
W230R469
Pull the bearing outer ring out of the bearing hole and remove the shim behind. Then remove the O-ring (see arrow).
W230R467
Loosen the threaded connections and remove the releasing brake tube.
84547255A
Issued 11-11
Printed in E.C.
6004-13
Input
STEP 31
STEP 28
W230R558
W230R555
Use the lifting device to lift the differential out of the axle drive housing.
Install holding wrench on input flange. Hold flange using holding wrench, 380001546, and remove lock nut and washer. Remove holding tool from flange.
STEP 32 STEP 29
Remove the input flange from the drive pinion.
STEP 33
W230R556
Pull the bearing outer ring out of the housing hole and remove the shim behind.
W230R559
Remove the shaft seal from the axle drive housing.
STEP 30 Heat lock nut securing flange with a hot air blower to loosen Loctite, approximately 120° C (248° F).
STEP 34
W230R560
Press the input pinion out of the housing.
84547255A
Issued 11-11
Printed in E.C.
6004-14
STEP 35
W230R489
Remove spacer ring and pull the tapered roller bearing from the input pinion.
STEP 36
W230R484
If necessary, force both bearing outer rings out of the axle drive housing.
84547255A
Issued 11-11
Printed in E.C.
6004-15
Differential â&#x20AC;&#x153;Openâ&#x20AC;?
STEP 40
STEP 37
W230R507
W230R504
Remove axle bevel gear with thrust washers from the differential housing.
Pull both tapered roller bearings from the differential.
STEP 41 STEP 38
W230R508 W230R505
Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover.
Force out both slotted pins.
STEP 42
STEP 39
W230R519
W230R506
Force out both differential axles and remove the releasing spider gears with thrust washers from the differential housing.
Preload the differential by means of the press, loosen locking screws and housing cover.
84547255A
Issued 11-11
Printed in E.C.
6004-16
STEP 43
W230R509
Remove the axle bevel gear and the shim behind.
STEP 44
W230R510
Press crown wheel from the differential carrier.
84547255A
Issued 11-11
Printed in E.C.
6004-17
REASSEMBLY Differential â&#x20AC;&#x153;Openâ&#x20AC;?
STEP 48
STEP 45
W230R520
W230R511
Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained.
STEP 46
Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts. NOTE: Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing. Pay attention to radial installation position of the spider shafts (fixing holes, arrow 2).
STEP 49
W230R512
Insert thrust washer into the differential housing.
STEP 47
W230R521
Fix spider shafts (short) with slotted pins. NOTE: Flush mount slotted pins.
W230R513
Insert axle bevel gear. 84547255A
Issued 11-11
Printed in E.C.
6004-18
STEP 50
STEP 53
W230R507
Mount second axle bevel gear.
W230R517
Attach the housing cover and preload the differential with the press.
STEP 51
Then fix the housing cover with hexagon screws. Tightening torque .........= 185 Nm (136.5 pound feet)
STEP 54
W230R515
Fix the thrust washers into the housing cover by means of grease.
STEP 52
W230R518
Heat both tapered roller bearings and insert until contact is obtained. NOTE: Adjust tapered roller bearing after cooling down.
W230R516
Mount two adjusting screws and insert the housing cover until contact with the differential housing is obtained. Preload the differential by means of the press and bolt with new locking screws. Tightening torque.............= 400 Nm (295 pound feet) 84547255A
Issued 11-11
Printed in E.C.
6004-19
Input
STEP 57
STEP 55 1
3 2 BD06G139
W230R572
Find and record the housing dimension â&#x20AC;&#x153;Xâ&#x20AC;?. Dimension X (Example). . . . . 205.30 mm (8.08 inch)
STEP 56
1. MATING NUMBER (MARKED MANUALLY) 2. PINION BASIC DIMENSION (STAMPED) 3. PINION DISTANCE DEVIATION + OR - (MARKED MANUALLY)
Distance deviation is indicated in 1/100 mm. If no distance deviation is indicated the pinion basic dimension is identical with the pinion dimension. Record this as dimension â&#x20AC;&#x153;IIâ&#x20AC;?. Dimension II (Example) 168 -0.05 mm = 167.95 mm . . . . . . . . . (6.614 inch -0.002 inch = 6.612 inch)
STEP 58 Calculation example A: Dimension I Dimension II Results in dimension Y BD06G138
Measure the thickness of the inner bearing and record its measurement, dimension â&#x20AC;&#x153;Iâ&#x20AC;?. Dimension I (Example) . . . . . 36.13 mm (1.422 inch)
Calculation example B:
NOTE: Deduct the thickness of the gauge blocks being used to support the bearing from the overall measurement, IE: overall measurement 106.13 mm (4.178 inch) minus gauge block thickness 70 mm (2.756 inch) will equal dimension I.
Dimension Y
Dimension X
Difference = shim thickness
36.13 mm -------(1.422 inch) 167.95 mm -------(6.612 inch) 204.08 mm ------(8.034 inch)
205.30 mm -------(8.080 inch) 204.08 mm -------(8.034 inch) 1.22 mm ------(0.046 inch)
NOTE: Shims are available in 0.10 mm (0.004 inch), round up or down to the next available shim thickness, s = 1.20 (0.044 inch)
84547255A
Issued 11-11
Printed in E.C.
6004-20
STEP 59
STEP 62
W230R573
Heat the bearing hole to approximately 120° C (248° F) and install the outer bearing until contact is made using the outer bearing cup installer.
STEP 60
BD06G143
Press the inner bearing on the drive pinion shaft.
Drive Pinion Bearing Rolling Torque Adjustment STEP 63
W230R574
Install the shim set determined in Step 58 in the bearing bore on the differential carrier.
STEP 61
BD06G144
Install an 8.18 mm (0.32 inch) thick spacer on the pinion shaft.
W230R575
Undercool the internal bearing outer ring and bring it into contact position in the housing hole by using 380100001 the assembly fixture. 84547255A
Issued 11-11
Printed in E.C.
6004-21
STEP 64
STEP 66
WARNING: Always wear heat protective gloves to prevent burning your hand when handling heated parts. SM121A
W230R577
Install the input flange on the pinion shaft.
STEP 67 W230R576
Heat the pinion shaft outer bearing to 120° C (248° F) in a bearing oven. Wearing heat resistance gloves or mittens, install the bearing on the pinion shaft until contact. NOTE: Prior to mounting the input flange and tightening the nut, allow the bearing to cool to ambient temperature.
Put the washer in place on the pinion shaft.
STEP 68 Install holding wrench, 380001546, on input flange. Hold flange using holding tool and tighten nut to a torque of 1200 Nm (885 pound feet). Remove holding wrench. NOTE: When tightening rotate the pinion shaft in both directions several times.
STEP 65
STEP 69
BD06G146
Press the dust shield on the input flange. W230R578
Check the rolling torque of the drive pinion bearing. The rolling torque should be 1.5 to 4.0 Nm (13.3 to 35.4 lb-inch). If rolling torque is too low, install a thinner spacer (Step 63); if rolling torque is too high, install a thicker spacer (Step 63).
84547255A
Issued 11-11
Printed in E.C.
6004-22
Setting Backlash and Bearing Preload Deviation Value
-0.2
-0.1
0
0.1
Shim 2
0.8
0.9
1.0
1.1
Shim 3
1.2
1.1
1.0
0.9
STEP 70
STEP 71
1
3
2
4
W270R085
Deviation see crown wheel rear side. The test dimension „106“ is stamped into the crown wheel rear side. If no + or – deviation is indicated, this value corresponds to the actual value ”O” in the table below. According to this value, the required shims are allocated in the table below. Any + or – deviation of the test dimension caused by production is also marked on the crown wheel rear side (e.g. - 20 or - 10 or 10 or 20) . In accordance with this deviation, the required shims are allocated in the table below.
W230R501
Legend to sketch: 1 = Axle housing 2 = Shim (crown wheel side) 3 = Shim (diff. carrier side) 4 = Axle housing
STEP 72
W230R495
Insert the determined shim (e.g. s = 1.0 mm) (0.039 inch) into the hole of the axle housing and adjust the bearing outer ring (see arrow) until contact is obtained.
84547255A
Issued 11-11
Printed in E.C.
6004-23
STEP 73
STEP 75
W230R579
W230R580
Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing.
Mount two locating pins and bring the axle housing into contact position with the axle drive housing by means of the lifting device.
STEP 74
Then preliminarily fix the axle housing with 4 hexagon screws. Tightening torque ............= 560 Nm (413 pound feet) NOTE: Preliminarily mount the axle housing without O-ring.
STEP 76
W230R496
Insert the determined shim (e.g. s = 1.0 mm) (0.039 inch) into the hole of the axle housing and adjust the bearing outer ring until contact is obtained. W230R584
Loosen the slotted nut and input flange.
STEP 77
W230R573
Install the shaft seal with the sealing lip towards oil sump using pinion shaft seal. NOTE: Wet the outer diameter of the seal with a solution of 50% water and 50% mineral spirits. Fill the space between the sealing and dust lip with grease.
84547255A
Issued 11-11
Printed in E.C.
6004-24
STEP 78
W230R577
Install the input flange. Install holding wrench, 380001546, on input flange. Apply Loctite No. 262, on the threads of the locknut. Install the washer and locknut by hand. Hold flange using holding tool and tighten nut to a torque of 1200 Nm (885 pound feet). NOTE: Rotate the input pinion several times in both directions when tightening.
84547255A
Issued 11-11
Printed in E.C.
6004-25
Axle Housing
STEP 81
STEP 79
W230R498
Mount fitting. W230R497
Grease O-ring (see arrow) and insert it into the axle housing.
Tightening torque .............= 36 Nm (26.5 pound feet)
STEP 82
STEP 80
W230R499 W230R585
Mount two locating pins and bring the axle housing into contact position with the axle drive housing by using the lifting device.
Grease O-ring and insert it into the annular groove of the brake tube (see arrow).
Then fix the axle housing by means of hexagon screws. Tightening torque.............= 560 Nm (413 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-26
STEP 83
1
W270R086
Mount brake tube with threaded connection and hexagon nut (1). Tightening torque............= 100 Nm (73.7 pound feet)
STEP 84 2
W270R087
Provide screw plug with a new O-ring and fit it (2). Tightening torque..............= 50 Nm (36.8 pound feet)
84547255A
Issued 11-11
Printed in E.C.
6004-27
Output and Brake
STEP 87
STEP 85
W230R524
W230R522
Pull in wheel stud into the output shaft until contact is obtained.
STEP 86
Wet O-ring of slide ring seal and locating hole with spirit. Snap new slide ring seal into the output shaft. Then mount new slide ring seal accordingly into the brake housing. NOTE: For the installation position of the seal please also refer to sketch page 29.
STEP 88
W230R523
Heat tapered roller bearing and insert it into the output shaft until contact is obtained. W230R525
ATTENTION: The surface of the slide ring seal may not have any grooves, scratches or other types of damage. Take care that the sealing surface is parallel to the housing face. The O-rings must be mounted evenly into the locating hole and must not bulge out of the hole. Risk of injury - Metal rings have extremely sharp edges. Wear protective gloves.
84547255A
Issued 11-11
Printed in E.C.
6004-28
STEP 89
STEP 91
W230R526
W230R460
Insert both bearing outer rings (see arrows) into the brake housing until contact is obtained.
Insert back-up rings and grooved rings into the annular grooves of the brake housing (see arrows).
STEP 90
NOTE: Pay attention to the installation position; please also refer to sketch page 29.
STEP 92
W230R462
Insert the premounted brake housing by means of the lifting device over the output shaft until contact is obtained. ATTENTION: Before clamping the seal rings (slide ring seal) to installation dimension, clean the sliding surfaces and apply an oil film. We recommend to use a leather cloth soaked with oil.
W230R527
Clean the annular groove of the brake housing with spirit. Then insert the guide ring into the annular groove (see also the following sketch) and fix it with Loctite (type no.: 415) at its extremities (see arrows). NOTE: The full circumference of the guide ring must be in an exact contact position. ATTENTION: Upon installation the orifice of the guide ring must show upwards (12 oâ&#x20AC;&#x2122;clock).
84547255A
Issued 11-11
Printed in E.C.
6004-29
STEP 93
STEP 95
W230R529
Insert the piston into the brake housing and carefully install with the fixing device until contact is obtained.
STEP 96
W230R461
Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft
W230R530
Insert disk and cup spring with the convex side showing upwards into the piston.
STEP 97
STEP 94
W230R531 W230R528
Flush-mount the slotted pins (6x) into the holes of the piston.
84547255A
Insert cover and fix it by means of hexagon screws. Tightening torque ................= 34 Nm (25 pound feet)
Issued 11-11
Printed in E.C.
6004-30
STEP 98
STEP 100
1 2
W230R457
Mount outer and inner disks. NOTE: For the number of disks and the disk arrangement please refer to the relating spare part list.
STEP 99
W230R532
Press stop bolt into the planetary carrier until contact is obtained. Legend to sketch: 1 = Stop bolt 2 = Planetary carrier
STEP 101 1
2 3 4
W230R456
Insert end plate. W230R533
Insert the cylindrical roller bearing into the planetary gear â&#x20AC;&#x201C; for this purpose press the cylindrical roller bearing through the packaging sleeve until the snap ring engages into the annular groove of the planetary gear. 1 = Cylindrical roller bearing 2 = Packaging sleeve 3 = Snap ring 4 = Planetary gear
84547255A
Issued 11-11
Printed in E.C.
6004-31
STEP 102
STEP 104
1 2
W230R454
W230R535
Heat bearing inner rings and insert the premounted planetary gears with large radius facing the planetary carrier (downwards) until contact is obtained.
Wet front face (contact face bearing inner ring, arrow 1) and profile (teeth, arrow 2) in the output shaft with anti-corrosive agent.
NOTE: Adjust bearing inner rings after cooling down.
STEP 105
Then fix planetary gears by means of retaining rings.
STEP 103
W230R452
W230R534
Heat tapered roller bearing and install it to the planetary carrier until contact is obtained.
Align disk package centrally and radially. Then insert the planetary carrier by means of the lifting device 380001578 into the teeth of the output shaft.
STEP 106
W230R536
Bring planetary carrier into contact position with the cover and the old locking screws which were removed during disassembly. Then remove the locking screws again. 84547255A
Issued 11-11
Printed in E.C.
6004-32
STEP 107
STEP 109
W230R537
W230R539
Pivot output 90°. Insert disk and fix planetary carrier with new locking screws.
Insert the cover into the output shaft until contact is obtained.
ATTENTION: Tighten locking screws successively with a tightening torque of 200 Nm (147.5 pound feet). Then retighten the locking screws successively with a tightening torque of 500 Nm (368.7 pound feet).
STEP 110
STEP 108
2 W230R540
Determine dimension I, from the mounting face of the brake housing to the front face of the stop bolt.
1
Dimension I ................................40.80 mm (1.6 inch) W230R538
Install O-ring (see arrow 1) to the cover (2). NOTE: Use new cover and O-ring.
84547255A
Issued 11-11
Printed in E.C.
6004-33
STEP 111
STEP 113
W230R541
W230R543
Insert stub shaft into the teeth of the axle bevel gear until contact is obtained.
Measure dimension II, from the front face of the sun gear shaft to the mounting surface of the axle housing.
ATTENTION: Pay attention to the installation position; mount the stub shaft with the long teeth showing to the differential.
Dimension II ...............................38.20 mm (1.5 inch) CALCULATION EXAMPLE: Dimension I ...............................40.80 mm (1.6 inch) Dimension II .............................- 38.20 mm (1.5 inch) Difference ...................................2.60 mm (0.10 inch) Required axial play.....................- 1.00 mm (0.4 inch) Difference = shim e.g. ........... s = 1.60 mm(0.06 inch)
STEP 112
STEP 114
W230R542
Insert the sun gear shaft until contact is obtained.
W230R544
Insert sun gear shaft into the planetary carrier.
84547255A
Issued 11-11
Printed in E.C.
6004-34
STEP 115
STEP 118
W230R545
BD06G004
Fix determined shim(s) e.g. s = 1.60 mm (0.06 inch) with grease into the sun gear shaft.
Mount two adjusting screws and use the lifting device to 380002303 bring the output into contact position with the axle housing.
STEP 116
Then fix the output by means of hexagon screws. Tightening torque ............= 560 Nm (413 pound feet)
STEP 119
W230R546
Fix O-ring (see arrow) with grease into the countersink of the brake housing.
STEP 117
W230R548
Mount breather (see arrow).
W230R547
Grease O-ring (see arrow) and install it to the axle housing.
84547255A
Issued 11-11
Printed in E.C.
6004-35
BRAKE HYDRAULICS LEAKAGE TEST IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) PRESSURE IN THE FOLLOWING STEPS.
High Pressure Test STEP 121
STEP 120
Operate the hand pump to increase pressure to 100 bar (1450 psi) maximum. Close connection to hand pump using the shutoff valve. During a 5 minute period, pressure shall not drop more than 2 bar (29 psi).
Low Pressure Test STEP 122 Reduce pressure to 5 bar (72.5 psi) and close the shutoff valve. During a 5 minute period pressure shall not drop. W230R549
Connect a hand pump with pressure gauge to the brake port as shown above. Fill the hand pump with hydraulic oil. Build up pressure in the axle internal brake lines then bleed air from the lines. After air is bled, actuate the brakes a minimum of 5 times to a pressure of 100 bar (1450 psi) by operating the hand pump.
84547255A
Issued 11-11
Printed in E.C.
6004-36
NOTES
84547255A
Issued 11-11
Printed in E.C.
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6005
Section 6005
6005-2
TABLE OF CONTENTS SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING YOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 4 4 6 6 6 8 8 8 8 8 8 8 8 8
Printed in E.C.
6005-3
SPECIAL TORQUES Center, Rear and Front Drive Shaft Bolts......................................................136 to 149 Nm (100 to 110 pound-feet) Lock Nut for Yoke on Front Drive Shaft.........................................................339 to 373 Nm (250 to 275 pound-feet)
84547255A
Issued 11-11
Printed in E.C.
6005-4
FRONT DRIVE SHAFT Removal 1. Remove the cap screws that fasten the center drive shaft to the yoke (16) at the rear of the front drive shaft. Use a prybar to disengage the universal joint from the yoke (16) and move the center drive shaft out of the way. 2. Loosen the lock nut (9) and set screw (8) in the center bearing (10) of the housing (7). 3. Remove the self-locking nut (15) and flat washer (14) that fasten the yoke (16) to the rear of the front drive shaft (1). 4. Make an alignment mark on the yoke (15) 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 (16) 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 penetrating 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 136 to 149 Nm (100 to 110 pound-feet). 4. Apply antiseize compound to the splines on the front drive shaft (1). 5. Install the yoke (16) 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 (15) and flat washer (14) 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 (8) with the slot in the front drive shaft (1). 8. Tighten the set screw (8) until it bottoms out in the slot, loosen the set screw (8) one full turn. 9. Hold the set screw (8) so it will not turn, tighten the jam nut (9). 10. Engage the universal joint of the center drive shaft with the yoke (16). 11. Install the cap screws that fasten the center drive shaft to the yoke (16). Tighten the cap screws to 136 to 149 Nm (100 to 110 pound-feet).
84547255A
Issued 11-11
Printed in E.C.
6005-5
2 2
1
3
6
5 7
4
16 10 11 12
9
14 15
14
8
13 15
14 9
BS07B229
1. 2. 3. 4. 5. 6. 84547255A
FRONT- DRIVE SHAFT CAP SCREW UNIVERSAL JOINT NUT LOCK WASHER BOLT
7. 8. 9. 10. 11. 12.
HOUSING SET SCREW JAM NUT CENTER BEARING ELBOW HOSE
13. 14. 15. 16.
CLAMP FLAT WASHER SELF-LOCKING NUT YOKE
Issued 11-11
Printed in E.C.
6005-6
CENTER BEARING Removal 1. Remove the hardware (14 and 15) that holds the clamp (13) for the lubrication hose (12). 2. Remove the lock nut (9) from the end of the lubrication hose (12). 3. Remove the lubrication hose (12). 4. Remove the cap screws that fastens the center drive shaft to the yoke (16) 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 (9) and set screw (8) in the center bearing (10). 6. Remove the self-locking nut (15) and flat washer (14) that fasten the yoke (16) to the rear of the front drive shaft (1). 7. Make an alignment mark on the yoke (16) and the end of the front drive shaft (1) to make sure that the yoke (16) is installed correctly. 8. Use an acceptable puller and remove the yoke (16) 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 penetrating oil to loosen any rust between the inner race and the front drive shaft.
Installation NOTE: The center bearing (10) and housing (7) are not serviced separately. If the center bearing (10) is worn or damaged or if the housing (7) has cracks, a new housing (7) and center bearing (10) must be used. 1. Apply antiseize compound to the bearing area of the front drive shaft (1). 2. Install the housing (7) so that the lubrication fitting is to the right. 3. Install the bolts (6), lock washers (5), and nuts (4) that hold the housing (7). Tighten the nuts (4) to 150 to 164 Nm (110 to 120 pound-feet). 4. Apply antiseize compound to the splines on the front drive shaft (1). 5. Install the yoke (16) so that the alignment marks are aligned. If a new front drive shaft (1) has been installed. 6. Install the self-locking nut (15) and flat washer (14) that fasten the yoke (16) to the front drive shaft (1). Tighten the self-locking nut (15) to 339 to 373 Nm (250 to 275 pound-feet). 7. Align the set screw (8) with the slot in the front drive shaft (1). 8. Tighten the set screw (8) until it bottoms out in the slot, loosen the set screw (8) one full turn.
10. Remove the nuts (4), lock washers (5), and bolts (6) that hold the housing (7).
9. Hold the set screw (8) so it will not turn, tighten the lock nut (9).
11. Install two longer bolts, approximately 3 inches (75 mm) longer to hold the housing (7) during removal. Use an acceptable puller to remove the housing (7).
10. Engage the universal joint at the front of the center drive shaft with the yoke (16). 11. Install the cap screws that fasten the center drive shaft to the yoke (16). Tighten the cap screws to 136 to 149 Nm (100 to 110 pound-feet). 12. Install the lubrication hose (12). 13. Install the jam nut (9) to end of the lubrication hose (12). 14. Install the hardware (14 and 15) that holds the clamp (12) for the lubrication hose (12). 15. Lubricate the center bearing (10).
84547255A
Issued 11-11
Printed in E.C.
6005-7
2 1 3 4
8 5 7 6 3 2
2
9
3 4 5 2
6
3 BS07B230 BS07B231
CENTER DRIVE SHAFT (TOP ILLUSTRATION) REAR DRIVE SHAFT- (BOTTOM ILLUSTRATION) 1. DRIVE SHAFT 2. CAP SCREW 3. UNIVERSAL JOINT
84547255A
4. YOKE 5. RETAINER 6. SLIDING YOKE
7. SEAL 8. BREATHER 9. PLUG
Issued 11-11
Printed in E.C.
6005-8
CENTER OR REAR DRIVE SHAFT Removal
Installation
1. Remove the cap screws (2) that hold both universal joints (3). 2. Use a prybar to disengage the rear universal joint (3) from the yoke (4). 3. Hold the drive shaft (1) and disengage the front universal joint (3) from the yoke (4) and remove the drive shaft.
1. Lubricate the rear drive shaft (1) with the grease. 2. Engage the front universal joint (3) with the yoke (4) and install the cap screws (2). Tighten the cap screws (2) to 136 to 149 Nm (100 to 110 pound-feet). 3. Engage the rear universal joint (3) with the yoke (4) and install the cap screws (2). Tighten the cap screws to 136 to 149 Nm (100 to 110 pound-feet).
SLIDING YOKE Installation
Removal 1. Make an alignment mark on the sliding yoke (6) and the drive shaft (1) so that the par ts are assembled correctly. 2. Remove the retainer (5) and seal (7) from the sliding yoke (6). 3. Remove the sliding yoke (6). 4. Clean the parts in cleaning solvent. Inspect the splines for damage and wear.
1. Install the retainer (5) and seal (7) on the drive shaft (1). 2. Install the sliding yoke (6) so that the alignment marks are aligned. If a new par t is being installed, the yokes must be parallel. 3. Turn the retainer (5) and seal (7) onto the sliding yoke (6) and tighten the retainer (5). 4. Lubricate the sliding yoke.
UNIVERSAL JOINT Removal 1. Remove the cap screws (2) that fasten the universal joint (3) to the drive shaft (1) 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. 1. Clean the slots in the yoke (4) or the drive sliding yoke (7). 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 136 to 149 Nm (100 to 110 pound-feet). 3. Lubricate universal joints.
84547255A
Issued 11-11
Printed in E.C.
Section 6006
6006
WHEELS AND TIRES
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6006-2
TABLE OF CONTENTS WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 3 4 4 5
Printed in E.C.
6006-3
WHEELS AND BOLTS General Information
Torque Specification
The wheel bolts must be tightened after every 20 hours of operation until the wheel bolts stay tight:
Tighten the wheel bolts to 298 Nm (220 pound-feet) in the sequence shown in Figure. 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 W270C Service Specifications - Normal Work Tire Inflations Tire Type Front Pressure Rear Pressure 26.5 X 25 Bias Ply 3.5 bar (50.0 psi) 2.8 bar (40.0 psi) 26.5 X 25 Radial 4.5 bar (65.0 psi) 3.2 bar (47.0 psi) W300C Service Specifications - Normal Work Tire Inflations Tire Type Front Pressure Rear Pressure 26.5 X 25 Bias Ply 4.5 bar (50.0 psi) 3.2 bar (47.0 psi) 26.5 X 25 Radial 5.0 bar (73 psi) 3.5 bar (50.0 psi)
84547255A
Issued 11-11
Printed in E.C.
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
1. Have a qualified tire mechanic service the split rim wheels used on this machine. 2. The correct tire equipment, especially a tire inflation cage, is required. Using the wrong procedure for a split rim wheel can result in death. IMPORTANT: When installing a Michelin tire, lubricate the tire with a tire mounting lubricant and inflate the tire to 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated on the rim. Then decrease the pressure to the specified pressure.
INSTALLING A WHEEL 1. Make sure the mounting surfaces of the rim and axle flange are clean and free of dirt and grease. 2. Install the wheel, hardened washers and wheel bolts.
4. Tighten the wheel bolts to 298 Nm (220 pound-feet) in the sequence shown in Figure 1. Then tighten the wheel bolts in the same sequence to 640 to 720 Nm (475 to 530 pound-feet).
3. Use a hand wrench (not an impact) to tighten the wheel b olts to pu ll the wheel against the planetary housing. DO NOT use an impact wrench to tighten the wheel bolts.
84547255A
Issued 11-11
Printed in E.C.
6006-5
1
16 8
9 17
20
5
12
13
4
21
22
14
3
11
6 19
18 10
7 2
23
15
W270R011
WHEEL BOLT TORQUE SEQUENCE
84547255A
Issued 11-11
Printed in E.C.
6006-6
NOTES
84547255A
Issued 11-11
Printed in E.C.
Section 6007
6007
TRANSMISSION CONTROL VALVE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
6007-2
TABLE OF CONTENTS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 5 5
Printed in E.C.
6007-3
CONTROL VALVE Disassembly
STEP 4
STEP 1
BD06A010
BD06A007
Mark the installation position of the wiring harness to the valve block.
Loosen and remove the cap screws, remove the cover. Remove the opposite cover.
STEP 5
STEP 2
BD06A011
Remove the wiring harness. BD06A008
Loosen and remove the cap screws that secure the distribution plate and intermediate plate to the valve body, remove the intermediate plate and distribution plate.
STEP 6
STEP 3
BD06A012
Loosen and remove the retaining plate cap screws, remove the retaining plates and solenoids.
BD06A009
Remove the wiring harness retaining clamp. 84547255A
Issued 11-11
Printed in E.C.
6007-4
STEP 7
STEP 9
BD06A013
Loosen and remove two cap screws, install two adjusting screws. Loosen and remove the remaining cap screws.
BD06A015
Remove the components.
STEP 10
STEP 8
BD06A016
BD06A014
Remove the opposite solenoids, housing, and components.
Separate the housing from the valve body by equally loosening the adjusting screws.
84547255A
Issued 11-11
Printed in E.C.
6007-5
Inspection 1. Clean all metal parts in cleaning solvent. 2. Immerse end housings, valve housing, valve plate, and distribution plate in cleaning solvent and agitate cleaning solvent. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to remove foreign matter from interior of housings and plates and to ensure that all bores are clear of foreign matter.
Assembly NOTE: Apply clean engine oil (15W-40) to pistons and springs, orifices, new O-rings, and filter screens before assembly.
STEP 11
3. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. Use compressed air to ensure that orifices are clear of foreign matter. 4. Check filter screens for blockage, rips, or tears. Replace if any of these conditions are seen. 5. Inspect the plates, housings and covers for corrosion, cracks, breaks, chipping or other damage. Check bores in housings for deep scratches, gouges, and other damage. Replace a housing or cover if any of the above conditions are seen. 6. Check pressure regulators for cracks, breaks, or other damage. Check connector contacts for looseness or signs of corrosion. Replace a pressure regulator if any of these conditions are seen. Check resistance of pressure regulators using a multimeter. Replace a pressure regulator if resistance is not 17 to 21 ohms. 7. Check wiring harness connectors for signs of breaks, cracks, or other damage. Check contacts for foreign matter or corrosion. Check harness wiring for signs of broken or cracked insulation and broken or frayed wiring at connection to connectors. Replace wiring harness if any of these conditions are seen. 8. Check springs for cracks, breaks, distortion, or signs of permanent set. Replace a spring if any of these conditions are seen. 9. Inspect pistons for cracks, breaks, chipping, grooves, or other damage. Replace if any of these conditions are seen.
BD06A017
Place the valve body on the bench with the orifices up.
STEP 12
3
2
1
2
1 BD06A018
1. VIBRATION DAMPER 2. PISTONS
3. PRESSURE REDUCING VALVE
Install components in positions shown.
STEP 13
BD06A019
Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch). 84547255A
Issued 11-11
Printed in E.C.
6007-6
STEP 14
STEP 17
BD06A020
BD06A023
Install the adjusting screws, gasket, and housing cover.
Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 15
STEP 18
BD06A021
BD06A024
Tighten the adjusting screws equally until the cover is flush on the valve body.
Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch).
STEP 16
NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.
STEP 19
BD06A022
Push the pistons down through the pressure controller wholes and remove the roll pins.
1 2
1
3 2 BD06A025
1. VIBRATION DAMPER 2. PISTONS
3. MAIN PRESSURE VALVE
Install components in positions shown.
84547255A
Issued 11-11
Printed in E.C.
6007-7
STEP 20
STEP 23
BD06A026
BD06A028
Preload the compression springs of the pistons, install a roll pin of a diameter of 5.0 mm (0.20 inch). Install the adjusting screws, gasket, and housing cover.
Install the wiring harness with connector on side of valve body marking made during disassembly. Connect wiring harness to the solenoids.
STEP 21
STEP 24
BD06A029
Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).
Install the gasket, install the wiring harness plug in the cover. Install the cap screws and torque in a criss cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 22
STEP 25
BD06A023
BD06A027
Install the solenoids and secure them with the retaining plates and cap screws. Torque the cap screws to 5.5 Nm (48.5 pound-inch).
BD06A030
Install the wiring harness retaining clamp.
NOTE: Install the retaining plate with the neck towards valve body, install controllers with connectors as shown.
84547255A
Issued 11-11
Printed in E.C.
6007-8
STEP 26
STEP 28
BD06A031
BD06A033
Install the screens into the bores of the intermediate plate towards the distribution plate.
Install the distribution plate, install the cap screws and torque in a criss cross pattern to 9.5 Nm (84 pound-inch).
STEP 27
STEP 29
BD06A032
Install two adjusting screws. Place the intermediate plate with the screens facing up.
84547255A
BD06A034
Install new o-rings on the plugs, install and torque plugs to 6 Nm (53 pound-inch).
Issued 11-11
Printed in E.C.
SECTION INDEX
BRAKES Section Title
Section Number
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002 Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003 Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
7001 Section 7001 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
7001-2
TABLE OF CONTENTS BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
4 4 4 6 6 6 8 8 8
Printed in E.C.
7001-3
3
4
7
1 5 6
2
W270R003
1. 2. 3. 4.
FRONT AXLE REAR AXLE BRAKE VALVE PARKING BRAKE ACCUMULATOR
5. FRONT ACCUMULATOR 6. REAR ACCUMULATOR 7. BRAKE PUMP
COMPONENT LOCATION ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
7001-4
BRAKE VALVE Removal
Installation
1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine.
1. Install the brake valve (1) in the cab or canopy. Refer to the illustration on page 5.
2. Put blocks on both sides of each tire to prevent machine movement.
2. Remove the plugs from the hydraulic lines and connect the hydraulic lines to the brake valve (1).
3. Make sure the brake accumulators are completely discharged. Push down and release the brake pedals at least 30 times.
3. Stop the vacuum pump and remove.
4. Turn the master disconnect switch to the OFF position. 5. Remove the cab skirts located under the cab or canopy. 6. To release the pressure on the parking brake accumulator, the line at the accumulator must be SLOWLY cracked open. A pan will be needed to catch the hydraulic oil.
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).
84547255A
Issued 11-11
Printed in E.C.
7001-5
2
4
8
3
5
10 6
1
7
9
W270R005
1. 2. 3. 4. 5.
BRAKE VALVE REAR ACCUMULATOR LINE PARKING BRAKE LINE BRAKE PUMP INPUT BRAKE VALVE DISCHARGE
6. 7. 8. 9. 10.
FRONT BRAKE LINE REAR BRAKE LINE FRONT ACCUMULATOR RETURN TO TANK HOSE PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS Removal
Installation
1. Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine. 2. Put blocks on both sides of each tire to prevent machine movement. 3. Make sure the service brake accumulators (1) and the parking brake accumulator (2) are completely discharged. Refer to illustration on page 7. 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. 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).
to
the
parking
brake
7. Stop the vacuum pump and remove. 8. Install the left cab skirt. 9. Turn the master disconnect switch to the ON position. 10. Bleed the brake system. See Section 7002. 11. Refer to Section 7008 and perform the Parking Brake Test Procedure. 12. Check the hydraulic reservoir oil level and add oil as required. See Section 1002 for the correct oil.
10. Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. 11. Disconnect the accumulators (1).
tubes
from
both
brake
12. Loosen the clamp stud (8) on the accumulator clamp (7). 13. Remove the accumulators accumulator clamps (7).
(1)
from
the
14. Install plugs in the tubes. 15. Disconnect the accumulator (2).
hose
from
parking
brake
16. Remove the nut (3), remove the parking brake accumulator (2). 17. Install a plug in the hose.
84547255A
Issued 11-11
Printed in E.C.
7001-7
2 3 4
1
7
5 8 6
W270R004
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
84547255A
Issued 11-11
Printed in E.C.
7001-8
BRAKE PUMP 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 pump (1), mounting bolts (2) and washers (3).
2. Put blocks on both sides of each tire to prevent machine movement.
2. Torque mounting bolts (2) to 149.14 to 169.48 Nm (110 to 125 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).
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.
7. Disconnect the lines from the brake pump (1) and put plugs in each line. 8. Remove the mounting bolts (2) and washers (3) from the brake pump (1) and remove the brake pump (1).
84547255A
Issued 11-11
Printed in E.C.
7001-9
12
5
4
6
8
7 2
11
3
1
10
9
W270R006
1. 2. 3. 4.
BRAKE PUMP MOUNTING BOLT WASHER SUCTION HOSE
5. 6. 7. 8.
BOLT WASHER FLANGE O-RING
9. 10. 11. 12.
HOSE BRAKE PUMP TO BRAKE VALVE PRESSURE HOSE TRANSMISSION HYDRAULIC TANK
BRAKE PUMP ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
7001-10
NOTES
84547255A
Issued 11-11
Printed in E.C.
7002
Section 7002 HYDRAULIC BRAKE TROUBLESHOOTING
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
7002-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Valve Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 5 5 6 7 7 8 9 10 14
Printed in E.C.
7002-3
SPECIFICATIONS Brake pump output ..............................................................................................................42 to 45 L/min at 172 bar (11 to 12 gpm at 2500 psi at 2000 rpm) Accumulator nitrogen charge pressure...........................................................................48 to 59 bar (700 to 850 psi) Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi) Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2845 psi) Brake warning pressure switch (normally closed) opening set point......................106 to 115 bar (1530 to 1670 psi) Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi) Brake light pressure switch (normally open) closing set point.............................. 5 to 6 bar increasing (75 to 85 psi) Modulation pressure front brake cylinders..................................................................80 to 87 bar (1160 to 1260 psi) Modulation pressure rear brake cylinders ..................................................................78 to 85 bar (1130 to 1230 psi)
SPECIAL TOOLS
G 94L95
380001737 NITROGEN CHARGING KIT USED TO CHECK AND CHARGE THE ACCUMULATOR WITH NITROGEN. BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER
84547255A
Issued 11-11
Printed in E.C.
7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM NOTE: The hydraulic brake schematic is included in the hydraulic schematic. Refer to the rear pocket of this manual. 1. Check the oil level in the hydraulic reservoir; add oil as necessary. 2. Push and release the brake pedal many times with the engine stopped to remove all hydraulic pressure from the brake system until there is no pressure on the pedal. 3. Install two 207 bar (3000 psi) pressure gauges to front and rear hydraulic brake accumulator test ports, refer to page 7 for the locations of the test ports. 4. Make sure that the pressure gauge hoses are long enough so the gauges can be read while sitting in the operators seat. NOTE: The gauges can not be connected to the test ports if hydraulic pressure remains in the system. 5. Start the engine. Run the engine at low idle while reading the pressure gauges. The alarms (buzzer, master warning light and brake pressure warning light) should shut off when the accumulator with the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi), approximately 40 seconds at any engine speed. 6. After the alarms stop, run the machine at high idle to finish charging the accumulators. The pressure must increase on both gauges until 190 to 196 bar (2757 to 2843 psi) is reached. This is the accumulator valve cut-out pressure. It is normal for the pressure to drop slightly once the cut-out pressure is reached. 7. With the engine running at high idle, push and release the brake pedal rapidly while reading the drop in pressure on the gauges. The pressure drops may not be equal, but as the lowest pressure reaches 157 to 167 bar (2280 to 2420 psi), the system pressure must start to increase. This is the valve cut in pressure.
8. Stop the engine. Turn the ignition switch to the ON position. Push and release the brake several times while reading the pressure on the gauges. Each push and release of the pedal will result in a slight drop in pressure, but not necessarily equal on the two gauges. As the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi) the brake warning lamp and alarm buzzer must actuate. If the warning lamp and alarm buzzer fail to work, test the low brake pressure warning switches and electrical circuit. If the warning lamp and alarm buzzer actuate at a higher or lower pressure than specified, test the low brake pressure warning switches and replace as needed. 9. As the lowest pressure reaches 106 to 115 bar (1530 to 1670 psi) the brake warning lamp and alarm buzzer must actuate. If the warning lamp and alarm buzzer fail to work, test the low brake pressure warning switches and electrical circuit. If the warning lamp and alarm buzzer actuate at a higher or lower pressure than specified, test the low brake pressure warning switches and replace as needed. 10. After the low brake pressure light activates, press the brake pedal eight more times. 11. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi). 12. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete. 13. If the pressures are not within the required specifications, then the brake system must be bled. 14. After bleeding the brake system, perform the brake system check again.
NOTE: The brake cut-in and cut-out pressures of the brake system charge valve are factory preset and are not adjustable.
15. Continue to slowly push and release the brake pedal several times until the gauge pressure suddenly drops to zero. The last pressure reading before the drop to zero is the nitrogen charge pressure in the accumulator. Test the pressure in both accumulators. If the pressure is below 48 to 59 bar (700 to 850 psi), charge or replace the accumulator(s) (see page 5).
NOTE: If the pressure on one of the pressure gauges is lower than specified, the problem can be a bad accumulator valve.
NOTE: Nominal temperature of 20° C (68° F), colder temperature will reduce pressure, hotter temperature will increase pressure.
84547255A
Issued 11-11
Printed in E.C.
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. 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.
E
C
F
D
B
A 94L95
5. Remove the cap screws and guard from the accumulator. 6. Remove the cap from the accumulator valve stem. 7. Connect valve F to the accumulator valve stem.
NITROGEN CHARGING KIT
8. Make sure that valve D is open. 9. Turn the stem into valve F and read the pressure gauge E. 10. The pressure must be 48 to 59 bar (700 to 850 psi). If the pressure is too low, charge the accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator. 1. Close (turn counterclockwise) valve A and open valve B. Close valves C and D. 2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the accumulator valve stem. 3. Connect the nitrogen charging kit to a dry nitrogen tank. 4. Slowly turn valve A clockwise and read gauge E until the pressure is 48 to 59 bar (700 to 850 psi). Stop turning valve A.
5. If the pressure increases above 59 bar (850 psi), quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure. 6. Connect valve F to the accumulator valve stem. Turn the stem into valve F until the stem stops 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.
84547255A
Issued 11-11
Printed in E.C.
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 quick-attached components, disconnect them machine prior to proceeding.
with from
8. Start the engine and run at low idle. 9. Push the brake pedal all the way down and slowly release for one cycle. 10. Close all four wheel end bleed screws. 11. Fully depress the brake pedal three times in 5 second cycles. 12. With the brake pedal partially depressed, open the bleed screw on the left front axle. Hold the brake pedal in position until the oil is clear (no bubbles). Close the bleed screw. 13. Open the bleed screw on the right front axle. Repeat step 12.
1
14. Open the bleed screw on the left rear axle. Repeat step 12.
BD03A092
1. SAFETY LINK
2. Raise loader arms and install the safety link (1) for safe access to the front axle bleed screws.
15. Open the bleed screw on the right rear axle. Repeat step 12. 16. Replace all bleed screws, caps and plugs. 17. Check the hydraulic fluid and add as necessary.
3. Apply the parking brake. 4. Keep the engine speed at high idle until both brake accumulators are fully charged. NOTE: This will be approximately 30 seconds after the low brake pressure light goes out. 5. Stop the engine. 6. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps). 7. Remove the plastic and rubber caps from each wheel end and slowly open all four bleed screws. NOTE: Attach a hose to the bleed screws to prevent spilling any fluids.
84547255A
Issued 11-11
Printed in E.C.
7002-7
BRAKE MODULATION PRESSURE CHECK
4 3 1
2
W270R008
1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT
Testing the Brake Modulation Pressure 1. Make sure the hydraulic accumulator cut-in and cut-out pressures are correct. Refer to page 4 of this section.
3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
6. Start the engine. 7. Operate the machine at low idle and watch the pressure gauges on the brake accumulators until the gauges rise above 170 bar (2645 psi). 8. Apply and hold the brakes for 10 to 15 seconds.
2. Stop the engine. Pump the brake pedal until there is no pressure in the brake system.
9. Make a note of the pressure on the gauges for the front and rear brakes.
3. Remove the cab skirts to gain access to the brake test ports.
10. The front brake pressure should read 80 to 87 bar (1160 to 1260 psi). This is the modulation pressure for the front axle.
4. Connect two 207 bar (3000 psi) pressure gauges to the front brake test port (1) and the rear brake test port (2). 5. Connect two 207 bar (3000 psi) pressure gauges to the front brake accumulator test port (4) and the rear brake accumulator test port (3).
84547255A
11. The rear brake pressure should read 78 to 85 bar (1130 to 1230 psi). This is the modulation pressure for the rear axle 12. If the pressures are not within the specified range, it will be necessary to adjust the modulation pressures.
Issued 11-11
Printed in E.C.
7002-8
Adjusting the Brake Modulation Pressure NOTE: The adjusting bolt to adjust the modulation pressure is located in the cab, under the brake pedal.
1. Remove the tamper evident cover (1). NOTE: This is a tamper evident cover and it will be necessary to install a new cover after the modulation pressure is adjusted. 2. Remove the locking bolt (2). 3. Turn the adjusting screw (3) to adjust the modulation pressure. NOTE: The rear brake modulation pressure cannot be adjusted separately from the front brake modulation pressure. 4. Repeat steps 5 through 10 in the Testing the Brake Modulation Pressure procedure. 5. Repeat these steps until the brake modulation pressure is within the specified range.
3
2 1 W270R015
1. TAMPER RESISTANT COVER 2. LOCKING BOLT 3. ADJUSTING SCREW
84547255A
Issued 11-11
Printed in E.C.
7002-9
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
4 3 2
1
W270R008
1. FRONT AXLE TEST PORT 2. REAR AXLE TEST PORT
3. FRONT BRAKE ACCUMULATOR TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
NOTE: Prior to doing this procedure make sure that the accumulator pressures are correct. 1. Check the level of the hydraulic fluid in the reservoir, add as needed.
6. Start the engine and let idle until both the front and rear accumulators 3 and 4 are fully charged. The accumulators are fully charged at 190 to 196 bar (2755 to 2842 psi). 7. Stop the engine. 8. Push the brake pedal down slowly, allowing for full piston actuation. NOTE: Depress the brake pedal at the rate of three strokes per minute. 9. Continue pressing the brake pedal down. The low brake pressure light should activate when the pressure reaches 106 to 115 bar (1530 to 1670 psi). After the low brake pressure light activates, press the brake pedal eight more times.
1 W230R407
10. Record the readings on the pressure gauges. The pressure gauges should read at or above 48 to 59 bar (700 to 850 psi).
2. Install the articulation lock (1) before doing this test.
11. If the pressures are at or above 48 to 59 bar (700 to 850 psi), the test is complete.
3. Remove the left side cab skirt to gain access to the brake accumulator test ports.
12. If the pressures are not within the required specifications, then the brake system must be bled.
1. ARTICULATION LOCK
4. Pump the brake pedal until there is no hydraulic pressure in the brake system (approximately 20 pumps).
13. After bleeding the brake system, perform the brake system check again.
5. Connect two 207 bar (3000 psi) pressure gauges to the test ports 3 and 4. 84547255A
Issued 11-11
Printed in E.C.
7002-10
BRAKE PUMP OUTPUT TEST 1. Connect the flowmeter to the brake pump as shown, refer to the illustration below. 2. Make sure the load control of the flowmeter is open. Start the engine. Run the engine at full throttle. Make sure the oil is at operating temperature.
3. Measure the flow at 0 bar (0 psi). Record the flow reading. Slowly close the load valve on the flowmeter and read the flow at 170 bar (2500 psi). Record the flow reading. 4. Divide the flow reading at 170 bar (2500 psi) by the reading at 0 bar (0 psi). Multiply the result by 100. This is the percent efficiency of the pump. If the efficiency of the pump is less than 85%, repair or replace the pump.
5
1 6
2
4 3
W270R009
1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD 2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. TRANSMISSION *: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
84547255A
Issued 11-11
Printed in E.C.
7002-11
NOTES
84547255A
Issued 11-11
Printed in E.C.
7002-12
BRAKE VALVE CONNECTIONS T1-T2. F1-F2. R1-R2-R4. F. P. N. B. X. Xâ&#x20AC;&#x2122;.
Brake Brake pressure switch (F1 plugged) Accumulators Accumulators pressure switch Inlet oil Tank Other services or tank Parking brake Parking pressure switch (plugged)
BRAKE VALVE COMPONENTS 1. 2. 3. 4. 5. 6. 7. 8.
Seal kit Complete pedal support Dust rubber Pedal rubber cover Solenoid 24V Deutsch connector Solenoid + Cartridge valve Brake pressure adjustment Accumulator pressure adjustment Pedal position adjustment
84547255A
Issued 11-11
Printed in E.C.
7002-13
F2 R1
P
F
B
N
X1 X
7
F1 R 4 5
R4
F1
X
T1
F2
T2
3
8 1
8 P
2
B X1 N R1 F
T1 T2
R2
6
W270R014
BRAKE VALVE ASSEMBLY Printed in E.C.
Issued 11-11
84547255A
7002-14 40 Nm
30 Nm 1
50 Nm
15 Nm
1 1
1 1
1
25 Nm
9 Nm
1 1 1 9 Nm
2
1
2 1
10 Nm
2
2 2.4
2
2
2
2
2
2
1
10 Nm
1
2
2
2 10 Nm
9 Nm 1
2
2
55 Nm
44-50 Nm
2
5.6
9-11 Nm
1
6 2
2
25 Nm 2
2
2.3 1.2 45 Nm 2
3 Nm
1.2 2
70 Nm 2
9 Nm
1 1
2 1
2
22 Nm
1
22 Nm
25 Nm
1
1
1 9 Nm 1
1
45 Nm 45 Nm 1
1
1 W270R016
BRAKE VALVE EXPLODED VIEW 84547255A
Issued 11-11
Printed in E.C.
7002-15
SPARE PARTS LIST 1. 2. 3. 4. 5. 6.
Seal kit Complete pedal support Dust rubber Pedal rubber cover Solenoid 24V Deutsch connector Solenoid + Cartridge valve
84547255A
Issued 11-11
Printed in E.C.
7002-16
NOTES
84547255A
Issued 11-11
Printed in E.C.
7003
Section 7003 BRAKE PUMP
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
7003-2
TABLE OF CONTENTS BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84547255A
Issued 11-11
Printed in E.C.
7003-3
BRAKE PUMP Remove
STEP 9
STEP 1 Park the machine on a level surface and lower the loader bucket to the floor. Stop the engine.
STEP 2 Put blocks on both sides of each tire to prevent machine movement.
STEP 3 Turn the master disconnect switch to the OFF position.
STEP 4 Clean the brake pump and lines.
STEP 5 Put identification tags on all lines that are connected to the brake pump.
W270R653
Remove the brake pump-to-brake valve hose (1). Remove the valve tube (2).
STEP 10
STEP 6 Connect a vacuum pump to the hydraulic reservoir. Start the vacuum pump. NOTE: Hydraulic pump suction hose removed for picture clarity.
STEP 7 Drain the hydraulic tank.
STEP 8 Remove the hydraulic pump suction hose (not shown).
W270R654
Attach lifting equipment to the brake pump. Remove the brake pump mounting bolts (1). Remove brake pump.
84547255A
Issued 11-11
Printed in E.C.
7003-4
W270R657
BRAKE PUMP ILLUSTRATION 1. 2. 3. 4. 5.
84547255A
BRAKE PUMP MOUNTING BOLT (2) LOCK WASHER (2) GEAR GASKET
6. 7. 8. 9.
ELBOW CONNECTOR STRAIGHT SUCTION HOSE PRESSURE HOSE
Issued 11-11
Printed in E.C.
7003-5
Install
STEP 13
STEP 11
W270R656
W270R655
Lubricate and install the pump O-ring. NOTE: Hydraulic pump suction hose removed for picture clarity.
Install the brake pump-to-brake valve hose (3). Install the valve tube (2). Install the hydraulic pump suction hose (not shown). Tighten the split, flange clamp bolts (1) to a torque of 73 - 90 N¡m (54 - 66 lb ft).
STEP 14
STEP 12
Stop the vacuum pump and remove.
STEP 15 Turn the master disconnect switch to the ON position.
STEP 16 Bleed the brake system.
STEP 17 Check the hydraulic reservoir oil level and add oil as required.
W270R654
Attach lifting equipment to the brake pump. Install the brake pump. Tighten the brake pump mounting bolts (1) to a torque of 149 - 170 N¡m (110 - 125 lb ft).
84547255A
Issued 11-11
Printed in E.C.
7003-6
NOTES
84547255A
Issued 11-11
Printed in E.C.
7004
Section 7004 BRAKE ACCUMULATORS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 4 4
Printed in E.C.
7004-3
SPECIAL TOOL E
C F
G D
B
A 94L95
380001737 NITROGEN CHARGING KIT
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR 1. Remove cover from accumulator charge port. Loosen the Allen screw in the charge port.
6. Connect valve F to the valve stem on the adapter.
NOTE: Do not turn the Allen screw more than 1/8 of a turn or gas will escape uncontrolled.
7. Turn the T-handle inward on valve F to engage the pin in the valve stem, open valve G.
2. Install adapter on accumulator, use the 380001737 nitrogen charging kit to discharge the accumulator, refer to illustrations above. The tool must be disconnected from the nitrogen tank.
8. Open valve D and check the charge pressure on gauge E.
3. Close valves B, C and D. 4. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise. 5. Turn the T-handle on valve F fully out.
9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem and remove adapter.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR 1. Make sure that the oil side of the accumulator is completely discharged by doing the following: A. Stop the engine. B. Push down and release the brake pedal 21 times to release the pressure. 2. Connect a drain hose to the test connector in each brake circuit to release any pressure in the brake circuit. 3. Close valves B and C on the nitrogen charging kit, refer to the illustration. 4. Turn the stem out of valve F until the stem stops.
5. Remove the cap from the accumulator. Loosen the Allen screw in the charge port. NOTE: Do not turn the Allen screw more than 1/8 of a turn or gas will escape uncontrolled. 6. Connect adapter to accumulator. 7. Connect valve F to the adapter valve stem. 8. Make sure that valve D and G are open. 9. Turn the stem into valve F and read the pressure gauge E. NOTE: See chart below for pressure readings. 10. If the pressure is too low, accumulator with dry nitrogen.
84547255A
Issued 11-11
charge
the
Printed in E.C.
7004-4
CHARGING THE ACCUMULATOR WITH DRY NITROGEN NOTE: Check the pressure in the accumulator according to the instructions in Checking the Nitrogen Charge in the Accumulator. Keep the nitrogen charging kit connected to the accumulator.
6. Connect valve F to the adapter valve stem. Turn the stem into valve F until the stem stops moving and open valve G and D to charge the accumulator.
1. Close (turn counterclockwise) valve A and open valve B. Close valves C, D, and G.
7. After the accumulator stops charging, turn the stem out of valve F until the stem stops moving and close valve G.
2. Turn the stem out of valve F until the stem stops moving. Disconnect valve F from the adapter valve stem. 3. Connect the nitrogen charging kit to a dry nitrogen tank. 4. Slowly turn valve A clockwise and read gauge E until the pressure is equal to charge pressure required for accumulator being charged. Stop turning valve A. 5. If the pressure increases above required pressure, quickly open and close valve D and read gauge E. If the pressure is still too high, close valve A (turn counterclockwise) a small amount and quickly open and close valve D. The pressure shown on gauge E is the charge pressure.
8. Close valve B and disconnect the nitrogen charging kit from the adapter valve stem, remove the adapter. 9. Torque the Allen screw to 20 Nm (15 lb-ft), install the cover on the accumulator valve stem.
TEMPERATURE 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 67.4 BAR 977 PSI 68.1 BAR 987 PSI 68.8 BAR 998 PSI 69.3 BAR 1005 PSI 70.0 BAR 1015 PSI 70.7 BAR 1025 PSI 71.4 BAR 1036 PSI 71.9 BAR 1043 PSI 72.6 BAR 1053 PSI 73.3 BAR 1063 PSI 74.0 BAR 1074 PSI
TEMPERATURE/CHARGE PRESSURE BRAKE ACCUMULATOR
84547255A
Issued 11-11
Printed in E.C.
Section 7008
7008
PARKING BRAKE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
7008-2
TABLE OF CONTENTS PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 4 5
Printed in E.C.
7008-3
PARKING BRAKE Disassembly
STEP 7
STEP 1 Park the machine on a hard level surface and lower the loader bucket to the ground.
STEP 2 Place wheel chocks on each wheel to prevent machine movement.
STEP 3 BD03A185
Loosen the jam nut, turn adjusting bolt counterclockwise until the brake pads are loose.
STEP 8
W230R406
Install the articulation lock.
STEP 4 Place the master disconnect switch in the OFF position.
STEP 5
BD03A186
Pump the brake pedal at least 30 times to discharge the accumulators.
Remove the retainer pin and brake pin.
STEP 9
STEP 6
BD03A187 BD03A184
Remove the two brake pads from the parking brake assembly.
Loosen and remove the cover from the parking brake. 84547255A
Issued 11-11
Printed in E.C.
7008-4
Inspection
STEP 14 Disengage the parking brake.
STEP 10 Clean and inspect all parts for wear and damage. Inspect the brake disc for wear and damage. Replace all parts that are worn or damaged.
NOTE: Hydraulic pressure will not be applied to the parking brake until the parking brake rocker switch is turned off, the service brakes applied and the transmission is put into gear. A. Place the parking brake rocker switch in the OFF position.
Assembly
B. Apply the service brake and put the machine into gear.
STEP 11
C. The parking brake light on the cluster will turn off at this time. Place the transmission back into neutral before proceeding.
STEP 15
BD03A187
Install the two brake pads in the parking brake assembly.
STEP 12 BD0CA185
Turn the adjusting bolt clockwise until both brake pads contact the brake disc, then turn the adjusting bolt counterclockwise one turn. Tighten the jam nut to secure the adjusting bolt.
STEP 16 Install the cover on the parking brake.
STEP 17 BD03A186
Install the brake pins and retainer pins.
STEP 13 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.
84547255A
Perform the Parking Brake Test Procedure as described in this section.
STEP 18 Remove the articulation lock.
STEP 19 Place the master disconnect switch to the ON position.
Issued 11-11
Printed in E.C.
7008-5
PARKING BRAKE TEST PROCEDURE STEP 20
STEP 25
While testing, the machine must be on a clear level surface with the bucket in the travel position. WARNING: Always know the location of all workers in your area. Warn them before you start working the machine. Always keep all other persons away from your area. Serious injury or death can result if you do not follow these instructions. SA015
STEP 21 Start the machine and run the engine at low idle in third gear neutral.
STEP 22 Place the Transmission-Auto switch to the manual position.
W230R430
Use up or down arrow and highlight Service, press the enter key to select the config menu.
STEP 26
STEP 23 Place the Parking Brake switch to the ON position.
STEP 24
W230R431
Press the up or down arrow and high light Calibration, press the enter key.
STEP 27 BD06F141
Press and hold the enter key for 2 to 3 seconds until the instrument cluster monitor display changes to the select screen.
W230R432
Press the up or down arrow and high light Park Brake, press the enter key.
84547255A
Issued 11-11
Printed in E.C.
7008-6
STEP 28
STEP 34 Shift the gear selector to third gear reverse and slowly increase the engine speed to wide open throttle.
STEP 35 Verify that the machine does not move.
STEP 36 Reduce the engine speed to low idle and return the transmission to neutral. W230R433
STEP 37
Press the up or down arrow and high light brake test, press the enter key.
STEP 29
BD06F141
Press the escape switch on the key pad to exit the test mode. W230R434
Monitor will display Test Park Brake if all conditions are met to test the brake, press the enter key.
STEP 38 If any machine movement was detected, the parking brake must be adjusted, see procedures this section.
NOTE: If all conditions are not met to test the brake the monitor will display the condition that needs corrected prior to proceeding.
STEP 30 Monitor will display Test Park Brake Ready.
STEP 31 Shift the gear selector into third gear forward and slowly increase the engine speed to wide open throttle.
STEP 32 Verify that the machine does not move.
STEP 33 Reduce the engine speed to low idle and return the transmission neutral.
84547255A
Issued 11-11
Printed in E.C.
SECTION INDEX
HYDRAULICS Section Title
Section Number
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001 Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002 Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004 Loader Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006 Ride Control Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013 Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8001 Section 8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8001-2
TABLE OF CONTENTS LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JOYSTICK CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 5 7 8 8 9 11 11 12 12 13 14 14 16 16 17 19 19 21 23 23 24 25 25 26 27 27 28 29 29 30 31 31 31
Printed in E.C.
8001-3
LOADER CONTROL VALVE Removal
STEP 5
STEP 1 Park the machine on a level surface. IMPORTANT: If machine is equipped with quick-attached components, disconnect them from machine prior to proceeding.
STEP 2
BD06H198
Relieve the pressure in the ride control accumulator with the manual bleeder valve located on the top of the ride control valve. Remove the plug and turn the valve two turns counter-clockwise.
STEP 6 Loosen the filler cap on the reservoir to release the air pressure in the reservoir. BD03A092
Raise the lift arms and install the safety link on the lift arm cylinder.
STEP 3
STEP 7 Drain the hydraulic reservoir.
STEP 8
Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.
STEP 4 Place the master disconnect switch in the OFF position. BD03A093
Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.
84547255A
Issued 11-11
Printed in E.C.
8001-4
3 4 6 5
2
1 6 W270R025
1. GREEN-BLACK-BLACK 2. RED-BLACK-BLACK
3. YELLOW-BLACK-BLACK 4. ORANGE-BLACK-BLACK
5. HOSE PILOT ACCUMULATOR 6. RED-WHITE-BLACK
HYDRAULIC VALVE PILOT LINE CONNECTIONS
84547255A
Issued 11-11
Printed in E.C.
8001-5
2
1
8 5
7
3
3 6
4
W270R026
1. TUBE TILT LEFT BASE 2. TUBE TILT RIGHT BASE 3. HOSE LIFT CYLINDER
4. TUBE LIFT RIGHT ROD 5. TUBE LIFT LEFT ROD 6. TUBE LIFT LEFT BASE
7. TUBE LIFT RIGHT BASE 8. LOADER VALVE
LOADER CONTROL VALVE LINE CONNECTIONS
84547255A
Issued 11-11
Printed in E.C.
8001-6
STEP 9
STEP 15
Disconnect the hoses from the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding. Install a plug in each hose and a cap on each fitting.
STEP 10 Loosen and remove tilt cylinder lines (1 and 2). Install a plug in each line and a cap on each fitting.
STEP 11 Loosen and remove lines (4 and 5). Install a plug in each line and a cap on each fitting.
STEP 12 Loosen and remove lines (6 and 7). Install a plug in each line and a cap on each fitting.
STEP 13 Loosen and remove supply and return lines. Install a plug in each line and a cap on each fitting.
STEP 14 Attach proper lifting equipment to lift loader control valve.
84547255A
W270R027
Loosen and remove the three bolts, washers and spacer that hold the loader control valve to the valve mounting plate. Remove the loader control valve.
Issued 11-11
Printed in E.C.
8001-7
Installation
STEP 23
IMPORTANT: Before installing the fittings or connecting the tubes to the fittings, install new O-rings on the fittings.
Fill the hydraulic reservoir with oil. Refer to Section 1002 for the correct oil.
STEP 24
STEP 16
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 25 Place the master disconnect switch in the ON position.
STEP 26
W270R027 BD03A092
Install and align the loader control valve with the valve mounting plate.
Raise the loader arms and remove the safety link.
STEP 17
STEP 27
Install the bolts, washers and spacer that fasten the loader control valve to the valve mounting plate. Tighten the bolts.
Run engine at half throttle.
STEP 28
Tighten the left lift cylinder lines (5 and 6).
Slowly and completely extend and retract all cylinders at least 10 times to remove any air from the circuits.
STEP 19
STEP 29
Install and tighten the supply and return lines.
Stop the engine and check for leaks.
STEP 20
STEP 30
Install and tighten right lift cylinder lines (4 and 7).
Install the access cover on the front of the machine.
STEP 21
STEP 31
Install and tighten tilt cylinder lines (1 and 2).
Check the level of the hydraulic oil and add hydraulic oil as required.
STEP 18
STEP 22 Connect the hoses to the remote control valve(s) at the loader control valve. Refer to the illustration on page 4 for color coding.
84547255A
Issued 11-11
Printed in E.C.
8001-8
JOYSTICK CONTROL VALVE Removal
STEP 37
STEP 32 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF. BD06F208
STEP 33
Open and remove the access panel.
Place the master disconnect switch in the OFF position.
STEP 38
STEP 34 Unlatch and open the right hand side access door.
STEP 35 Lift the access door up and remove the access door from the pins.
STEP 36 BD06F209
Remove the front access panel.
STEP 39
BD06F207
Unlatch and open the window on the right hand side.
BD06F210
Disconnect the electrical connectors for the joystick control valve.
STEP 40 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump. 84547255A
Issued 11-11
Printed in E.C.
8001-9
STEP 41
Installation
Put identification tags on each hose and disconnect one at a time from the joystick control valve. Install plugs in the hoses and caps on the fittings.
STEP 45
STEP 42 Loosen and remove the screws and washers holding the hydraulic control tower cover. Remove the cover.
STEP 43 Loosen and remove the screws that fasten the joystick control valve to the hydraulic control tower.
STEP 44 Remove the joystick control valve from the hydraulic control tower.
Install new O-rings on the adapters for the joystick control valve.
STEP 46 Install the joystick control valve and screws in the hydraulic control tower and tighten the screws.
STEP 47 Install the cover over the joystick control valve and install the screws and washers.
STEP 48 Remove the plugs from the hoses and the caps from the fittings and connect the hydraulic hoses to the fittings according to the identification tags. (Refer to illustrations on pages 11 and 12 as necessary.
STEP 49 Turn off the vacuum pump and disconnect from the hydraulic reservoir.
STEP 50
BD06F210
Connect the electrical connectors for the joystick control valve.
STEP 51 Place the master disconnect switch in the ON position.
STEP 52 Start the engine and run the engine at low idle.
STEP 53 Check to see that the joystick control valve works correctly.
84547255A
Issued 11-11
Printed in E.C.
8001-10
STEP 54
STEP 57
Check for hydraulic oil leakage at the joystick control valve.
STEP 55 Check the level of hydraulic oil in the reservoir and add as required.
STEP 56
BD06F208
Install and close the access panel.
STEP 58
BD06F209
Position the access panel on the ROPS cab or the ROPS canopy and install and tighten the screw.
BD06F207
Close the right hand window.
84547255A
Issued 11-11
Printed in E.C.
8001-11
1
7
4
5 6
3
7 6
4 2
7
1 2
3 5
2
2
1 6
3 4
7
7
7
7
1 6
3 4
5
5
W230R021
1. 2. 3. 4. 5. 6. 7.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN
3 LEVER HOSE COLOR CODING
84547255A
W230R022
1. 2. 3. 4. 5. 6. 7.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN
JOYSTICK AND 1 LEVER HOSE COLOR CODING
Issued 11-11
Printed in E.C.
8001-12
1 4
5 6 5
4
3
6
3
1
2
2
1
2
6
3 4
1
2
6
3
5
4
5
W230R023
1. 2. 3. 4. 5. 6.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN
2 LEVER HOSE COLOR CODING
84547255A
W230R020
1. 2. 3. 4. 5. 6.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN
JOYSTICK HOSE COLOR CODING
Issued 11-11
Printed in E.C.
8001-13
HYDRAULIC PUMP
9
17 4 10
5
4
7
5 6
17
6
8
11
1 16 12 14
2
3
18
13 15
W270R028
1. 2. 3. 4. 5.
PUMP MAIN HYDRAULIC MOUNT BOLTS DRAIN HOSE BOLT SPLIT FLANGE
84547255A
6. 7. 8. 9. 10.
TUBE HOSE SUCTION HOSE CASE DRAIN HYDRAULIC TANK CLAMPS
11. 12. 13. 14. 15.
TRANSMISSION LOADER LOAD SENSE HOSE BOLT SPLIT FLANGE LOADER HIGH PRESSURE
16. STEERING PRIORITY MANIFOLD 17. CLAMPS 18. LOADER VALVE
Issued 11-11
Printed in E.C.
8001-14
Removal
STEP 69
NOTE: When disconnecting hydraulic fittings, plug hoses and cap fittings to prevent entry of foreign matter into hydraulic system.
STEP 59
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.
Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.
Installation
STEP 60 Place the master disconnect switch in the OFF position.
STEP 61 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.
STEP 62 Refer to Section 9007 and remove the ROPS cab or ROPS canopy.
STEP 63
NOTE: Install new O-rings where required.
STEP 70 Install new O-ring on hydraulic pump flange. Move pump into position and install in transmission. Install four washers and bolts (2) to secure pump (1) to transmission, tighten the bolts. Disconnect lifting equipment from pump.
STEP 71 Connect pump pressure hose (15) to steering priority manifold (16). Install two split flanges (14). Install four bolts (13). Apply tightening and torquing bolts to 198 to 242 Nm (1752-2142 pound feet).
Remove eight bolts (4) and washers. Remove four split flanges (5). Disconnect tubes (6) with suction hoses (7) from hydraulic pump. Remove and discard O-ring face seals from flange heads of tubes.
STEP 72
STEP 64
Connect load sense hose (12).
Loosen clamps (10). Tag and disconnect suction hoses (7) from hydraulic reservoir and remove from machine.
STEP 74
STEP 65
STEP 75
Tag and disconnect case drain hose (8); remove hose (8). Remove and discard O-ring face seal from fitting.
Install suction hoses (7), tighten clamps (10) to 10 to 11 Nm (90 to 100 pound inches).
STEP 66
Connect drain hose (3).
STEP 73
Install and connect case drain hose (8).
STEP 76
Tag and disconnect load sense hose (12). Remove and discard O-ring face seal from fitting.
Install four split flanges (5). Install eight bolts (4) and washers, tighten bolts (4) to 73.4 to 90.4 Nm (650 to 800 pound inches).
STEP 67
STEP 77
Tag and disconnect drain hose (3). Remove and discard O-ring face seal from fitting.
Refer to Section 9007 and install the ROPS cab or ROPS canopy.
STEP 68
STEP 78
Remove four bolts (13) and washers. Remove two split flanges (14). Tag and disconnect pump pressure hose (15) from steering priority manifold (16). Remove and discard O-ring face seal from flange heads of hose.
Turn off the vacuum pump and disconnect from the hydraulic reservoir.
84547255A
Issued 11-11
Printed in E.C.
8001-15
STEP 79
STEP 81
Place the master disconnect switch in the ON position.
Stop the engine and check for hydraulic oil leakage at the hydraulic pump.
STEP 80
STEP 82
Start the engine and run the engine at low idle for two minutes.
Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.
NOTE: If any unusual vibration is heard coming from the pump, stop the machine immediately and check for obstructions in the pump suction line.
84547255A
Issued 11-11
Printed in E.C.
8001-16
LIFT CYLINDERS Removal
STEP 87
STEP 83 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake. IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.
STEP 84
BD01D709
Relieve the pressure in the ride control accumulator with the manual bleeder valve located at the rear of the front chassis.
Loosen and remove the bolt, washer and spacer that hold the pivot pin for the yoke.
STEP 88
STEP 85 Loosen the filler cap on the hydraulic reservoir to release any pressure.
STEP 86
BD01D711
Use a proper lifting device and secure a strap around the lift cylinder.
STEP 89 W230R479
Tag and disconnect the hoses on each side of the lift cylinder. Install plugs in the hoses and caps on the fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift cylinder.
84547255A
Issued 11-11
Printed in E.C.
8001-17
Installation
STEP 90
STEP 93 Apply antiseize compound to the bores in the front frame and the yoke on the piston rod.
STEP 94
BD01D710
Loosen and remove the bolt, washer and spacer that hold the pivot pin at the closed end of the lift cylinder.
STEP 91 BD01D714
Use a proper lifting device and position the lift cylinder on the machine.
STEP 95
BD01D713
Remove the pivot pin from the closed end of the lift cylinder.
STEP 92 Remove the lift cylinder from the machine BD01D713
Align the closed end of the lift cylinder with the front frame and install the pivot pin.
84547255A
Issued 11-11
Printed in E.C.
8001-18
STEP 96
STEP 99
BD01D710
Align the pivot pin with the front frame and install the spacer, washer and bolt. Tighten the bolt.
STEP 97
BD01D712
Install the pivot pin for the yoke. Stop the engine.
STEP 100
BD01D709 W230R479
Remove the caps and plugs and connect the hoses to the lift cylinder.
STEP 98 If the yoke of the lift cylinder is not aligned with the loader frame, have another person start and run the engine at low idle and use the loader control lever to SLOWLY move the yoke into alignment with the loader frame.
Align the pivot pin with the yoke and install the spacer, washer and bolt. Tighten the bolt.
STEP 101 SLOWLY extend and retract the piston rod three times to remove any air from the lift cylinders.
STEP 102 Lubricate the pivot pins with molydisulfide grease.
STEP 103 Check the level of hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.
84547255A
Issued 11-11
Printed in E.C.
8001-19
BUCKET CYLINDER Removal
STEP 108
STEP 104 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.
STEP 105 With the engine stopped, move the bucket control lever to release pressure in the bucket circuit.
STEP 106 BD01D695
Loosen and remove the two bolts that fasten the mounting bracket to the machine. Remove the mounting bracket.
STEP 109
W230R480
Disconnect the proximity switch connector from the wiring harness connector.
STEP 107 W230R483
Loosen and remove the two bolts that fasten the mounting bracket for the proximity switch to the bucket cylinder. Remove the mounting bracket and switch.
W230R481
Loosen and remove the two bolts that fasten the target bar to the mounting bracket. Remove the target bar.
84547255A
Issued 11-11
Printed in E.C.
8001-20
STEP 110
STEP 113
W230R482
BD01D701
Disconnect the hoses from each side of the bucket cylinder. Install plugs in the hoses and caps on the fittings.
Remove the pivot pin from the rod end of the bucket cylinder.
STEP 111
STEP 114
BD01D704 BD01D700
Use acceptable equipment to hold the bucket cylinder.
STEP 112
Remove the pivot pin from the head end of the bucket cylinder. NOTE: It is not necessary to remove the grease line from the pivot pin unless the pivot pin is to be replaced.
STEP 115
BD01D698
Loosen and remove the bolt, washer and spacer that fasten the pivot pin from both ends of the bucket cylinder.
84547255A
BD01D706
Raise the bucket cylinder and remove the cylinder from the machine.
Issued 11-11
Printed in E.C.
8001-21
Installation
STEP 120
STEP 116 Apply antisieze compound to the bores in the front frame and the bores in the loader arm for the bucket cylinder.
STEP 117
W230R482
Connect the hoses to each side of the bucket cylinder.
STEP 121
Use acceptable lifting equipment to lower the bucket cylinder into position.
If the rod end of the bucket cylinder is not aligned with the bellcrank, have another person start the engine and run the engine at low idle and use the bucket control lever to SLOWLY move the piston rod eye into alignment with the bellcrank.
STEP 118
STEP 122
BD01D706
Install the pivot pin and stop the engine.
STEP 123
BD01D704
Install the pivot pin to the head end of the bucket cylinder. BD01D698
STEP 119 Install the spacer, washer and bolt that fasten the pivot pin to the front frame. Tighten the bolt.
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect the grease line to the pivot pin.
84547255A
Issued 11-11
Printed in E.C.
8001-22
STEP 124
STEP 127
W230R483
W230R480
Install the two bolts that fasten the mounting bracket for the switch to the bucket cylinder.
Connect the proximity switch connector to the wiring harness connector.
STEP 125
STEP 128 See Section 9006 for the adjustment procedure for adjusting the proximity switch.
STEP 129 Start and run the engine at low idle.
STEP 130 SLOWLY extend and retract the piston rod three times to remove any air from the bucket cylinder.
STEP 131 Lubricate the pivot pins with molydisulfide grease. BD01D695
Install the two bolts for the mounting bracket for the target bar.
STEP 126
STEP 132 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.
W230R481
Install the two bolts that fasten the target bar to the mounting bracket.
84547255A
Issued 11-11
Printed in E.C.
8001-23
OIL COOLER Removal
STEP 138
STEP 133 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.
STEP 134 Raise the engine hood.
STEP 135 Place the master disconnect switch in the OFF position. W270R609
Disconnect the top hose and install a plug in the hose and a cap on the fitting.
STEP 136
STEP 139
W270R610
Disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting.
1
STEP 140
W270R118
2
Open the frame (1) of the engine cooling system.
STEP 137
1
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. W270R611
Loosen and remove the bolt (1) and washer (2) that fasten the oil cooler to the cooling frame. Remove the oil cooler from the machine. 84547255A
Issued 11-11
Printed in E.C.
8001-24
Installation
STEP 144
STEP 141
Turn off the vacuum pump and disconnect from the hydraulic reservoir.
STEP 145 2
Place the master disconnect switch in the ON position.
1
STEP 146 Start the engine and run the engine at low idle for two minutes. Stop the engine and check for hydraulic oil leakage at the ports on the oil cooler.
STEP 147 W270R611
Place the oil cooler in position in the cooling frame. Install and tighten the mounting washers (2) and bolts (1).
Check the level of the hydraulic oil in the reservoir and add hydraulic oil as required.
STEP 142
W270R610
Connect the lower hose to the oil cooler to the cooling frame
STEP 143
W270R609
Connect the hose to the top of the oil cooler.
84547255A
Issued 11-11
Printed in E.C.
8001-25
RIDE CONTROL ACCUMULATORS Removal
STEP 151
STEP 148 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.
3
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. W270R030
Disconnect the hoses (3) from the elbow at the top of the ride control accumulators. Install a plug in the hoses and a cap on the fittings.
STEP 149
STEP 152 5 4 2 6
1
W270R031
Loosen and remove the nuts (4) and washers (5) from the U-bolt (6). Remove the U-bolt.
STEP 153 W270R029
Relieve the pressure in the ride control accumulators with the manual bleeder valve (1) located on the top of the ride control valve (2). Remove the plug and turn the valve two turns counter-clockwise.
Loosen and remove the eight bolts that fasten the accumulators bracket to the front frame. Remove the ride control accumulators from the machine.
STEP 150 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.
84547255A
Issued 11-11
Printed in E.C.
8001-26
Installation
STEP 157
STEP 154 Place the ride control accumulators in position on the front frame.
4
STEP 155 Install the eight bolts that fasten the accumulators bracket to the front frame. Tighten the bolts.
STEP 156 W270R033
Remove the caps and plugs and install the hoses (4) on the elbow at the top of the ride control accumulators.
2 3
STEP 158 Turn off and disconnect the vacuum pump from the hydraulic reservoir.
1
STEP 159 W270R032
Install the U-bolt (1), washers (2) and nuts (3). Tighten the nuts.
Tighten the accumulator manual bleeder valve located on the top of the ride control valve to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 5 Nm (44 lb-in).
STEP 160 Refer to Section 8002 Testing the Ride Control for the proper charging of the accumulator to check for leaks.
STEP 161 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.
84547255A
Issued 11-11
Printed in E.C.
8001-27
RIDE CONTROL VALVE Removal
STEP 164
STEP 162 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 163
Loosen the filler cap on the hydraulic reservoir to release the air pressure in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.
STEP 165 Place the master disconnect switch in the OFF position.
STEP 166 Disconnect the electrical connector the ride control valve.
STEP 167 Tag and disconnect the hoses from the ride control valve. Install a plug in the hoses and caps on fittings.
STEP 168 3 4
2 1
W270R034
Loosen and remove the three bolts (3) and washers (4) that fasten the ride control valve to the frame.
W270R029
Relieve the pressure in the ride control accumulators with the manual bleeder valve (1) located on the top of the ride control valve (2). Remove the plug and turn the valve two turns counter-clockwise.
84547255A
STEP 169 Remove the ride control valve from the machine.
STEP 170 Remove and discard all O-rings.
Issued 11-11
Printed in E.C.
8001-28
Installation
STEP 175 Connect the hoses to the ride control valve.
STEP 171 Install the ride control valve in position on the front frame.
STEP 172 2
STEP 176 Connect the electrical connector to the ride control valve.
STEP 177
3
Turn off the vacuum pump and disconnect from the hydraulic reservoir.
1
STEP 178 Place the master disconnect switch in the ON position.
STEP 179 Start and run the engine at low idle for two minutes. W270R036
STEP 180
Install the washers (1) and bolts (2) through the plate (3) into the ride control valve. Tighten the bolts.
Stop the engine and check for hydraulic oil leakage at the ride control valve.
STEP 173
STEP 181 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the hydraulic reservoir.
STEP 182 Refer to Section 8002 and perform the Ride Control Test Procedure.
5 4
W270R036
Tighten the accumulator manual bleeder valve (4) located on the top of the ride control valve (5) to a torque of 3.5 Nm (31 lb-in). Install the plug and torque to 5 Nm (44 lb-in).
STEP 174 Lubricate and install new O-rings.
84547255A
Issued 11-11
Printed in E.C.
8001-29
FAN REVERSING VALVE Removal
STEP 186
STEP 183 Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.
2
1
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 184
W270R038
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 185
Tag and disconnect the fan forward hose (1) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan reverse hose (2) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.
STEP 187
1 3
4
2 3 W270R039
W270R037
Disconnect the electrical connector (1-2) for the fan reversing valve (3).
Tag and disconnect the fan valve return hose (3) from the fan reversing valve. Install a plug in the hose and a cap on the fitting. Tag and disconnect the fan valve supply hose (4) from the fan reversing valve. Install a plug in the hose and a cap on the fitting.
STEP 188 Loosen and remove the nuts, washers and bolts.
STEP 189 Remove the fan reversing valve from the machine.
STEP 190 Remove and discard all O-rings from the fittings.
84547255A
Issued 11-11
Printed in E.C.
8001-30
Installation
STEP 196
STEP 191 Place the fan reversing valve into position on the machine.
1 3
STEP 192 Lubricate and install new O-rings in the fittings.
STEP 193 Install the bolts, washers and nuts. Tighten the nuts.
2
STEP 194
W270R037
Connect the electrical connector for the fan reversing valve.
STEP 197
4
Turn off the vacuum pump and disconnect from the hydraulic reservoir.
STEP 198 Check the level of the hydraulic oil in the reservoir.
3 W270R039
STEP 199
Connect the fan valve supply hose (4) to the fitting on the fan reversing valve. Connect the fan valve return hose (3) to the elbow on the fan reversing valve.
Start the engine and run the engine at low idle for two minutes.
STEP 195
Stop the engine and check for hydraulic oil leakage at the fan reversing valve.
2
1
STEP 200
STEP 201 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.
W270R038
Connect the fan reverse hose (2) to the fitting on the fan reversing valve. Connect the fan forward hose (1) to the fitting on the fan reversing valve.
84547255A
Issued 11-11
Printed in E.C.
8001-31
THERMAL VALVE Removal
Installation
STEP 202
STEP 206
Park the machine on a level surface and lower the bucket to the ground. Stop the engine and apply the parking brake.
Place the thermal valve (5) into position on the machine.
IMPORTANT: With the engine NOT running, pump the brake repeatedly to be sure the brake accumulators have no hydraulic pressure, put the ignition switch in the ON position then move the loader control valve back and forth several times to release any hydraulic pressure in the pilot control circuit, turn ignition switch OFF.
STEP 207 Lubricate and install new O-rings in the fittings.
STEP 208 Install the bolts (8), washers (7) and nuts (6). Tighten the nuts.
STEP 203
STEP 209
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.
Connect the hoses (1-2-3-4) to the thermal valve, remove and discard tags.
STEP 204
Turn off the vacuum pump and disconnect from the hydraulic reservoir.
8
STEP 210
STEP 211 Check the level of the hydraulic oil in the reservoir.
1
2
STEP 212 Start the engine and run the engine at low idle for two minutes.
STEP 213 Stop the engine and check for hydraulic oil leakage at the thermal valve.
5 7
3 6
STEP 214 Check the level of the hydraulic oil in the reservoir and add as required. Tighten the filler cap on the reservoir.
4 W270R040
Tag and disconnect the hoses (1-2-3-4) from the thermal valve (5). Install a plug in the hose and a cap on the fitting.
STEP 205 Remove the nuts (6), washer (7) and mounting bolts (8) from the thermal valve, remove the valve from the machine.
84547255A
Issued 11-11
Printed in E.C.
8001-32
NOTES
84547255A
Issued 11-11
Printed in E.C.
8002
Section 8002 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING, AND PRESSURE CHECKS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8002-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84447255A
Issued 11-11
3 4 5 5 5 5 6 6 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15 16 17 17 18 20 20 20 21
Printed in E.C.
8002-3
SPECIFICATIONS Manufacturer ....................................................................................................................................... Bosch-Rexroth High pressure pump (closest to transmission) .............................................................................220 L/min (58 gpm) Differential pressure ......................................................................................................... 26 ± 1 bar (377 ± 14.5 psi) Nominal displacement .............................................................................................................100 cm3 (6 cubie inch) Implement Limit Pressure.................................................................................248 to 255 bar (3596.9 to 3698.4 psi) Low pressure pump (furthest from transmission) ......................................................................187 L/min (49.5 gpm) Differential pressure ......................................................................................................... 22 ± 1 bar (319 ± 14.5 psi) Nominal displacement ...............................................................................................................85 cm3 (5 cubie inch) Implement Limit Pressure.................................................................................239 to 243 bar (3466.4 to 3524.4 psi) Circuit relief valve pressure setting Auxiliary A and B port.................................................................................................................280 bar (4061 psi) Bucket A port..............................................................................................................................280 bar (4061 psi) Bucket B port..............................................................................................................................280 bar (4061 psi) Hydraulic Controller Pilot supply Pressure ..................................................................29 to 40 bar (420.6 to 580 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.
84547255A
Issued 11-11
Printed in E.C.
8002-4
SPECIAL TOOLS
B877168V
633L95
380001740 FLOWMETER FITTING KIT
380001741 PRESSURE FITTING KIT
B877895M
632L95
380001726 HAND PUMP
380001742 PRESSURE FITTING KIT
B877558M
B785789M
380001731 FLOWMETER
84547255A
380001739 PRESSURE FITTING KIT
Issued 11-11
Printed in E.C.
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?.
No
Fill the hydraulic reservoir with the hydraulic oil specified in Section 1002.
No
See Page 18. Do the flow meter test of the hydraulic pump.
No
Adjust the limit pressure. See page 11 in this section.
Yes Heat the oil in the hydraulic system to operating temperature. Operate the machine to find which circuits have problems.
Problems in All Circuits Replace the return line hydraulic filter. See Section 2002. Do the stall test to see if the engine is good. See Section 8003 and check for contaminated oil. Is the oil contaminated? Yes See Section 8003 and clean or replace the oil.
Problem in All Loader Circuits See Page 11 and check the pressure setting of the limit pressure in the loader control valve. Is the pressure setting correct?
Problem in the Braking Circuit See Section 7002 and check the braking circuit.
84547255A
Issued 11-11
Printed in E.C.
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?
No
The loader control valve is damaged. See Section 8005 and repair the loader control valve
No
See Section 8006 and repair the cylinder.
No
See Section 8005. Disassemble the loader control valve and check for worn or damaged parts.
No
Repair the component as necessary.
No
See the Ride Control Test Procedure page 21 in this section.
Yes Check the cylinder piston packing. Is the packing good? Yes See Page 20. Check and adjust the circuit relief valves. Then check the operation of the circuit again. Does the circuit work correctly? Yes The problem is repaired.
Problem in the Steering Circuit See Section 5002 and check the steering circuit. Is the steering circuit good? Yes See Page 13. Do the Steering Pump Limit Pressure Test and Adjustment
Problem in the Ride Control Lift arms rapidly and continuously sink towards the ground. Yes Check the manual bleed valve for the ride control accumulator to be sure that it is closed.
84547255A
Issued 11-11
Printed in E.C.
8002-7
TESTING AND ADJUSTING THE HIGH PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check
STEP 3
STEP 1
4
1 W230R407
1. ARTICULATION LOCK
3
2
W270R041
Install articulation lock (1).
STEP 2 Make sure that the temperature of the hydraulic oil is at least 54째C to 57째C (129째F to 135째F). The following is the procedure for heating the hydraulic oil. A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. D. View the oil temperature by pressing the down arrow on the key pad to display hydraulic oil temperature. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.
2. TEST PORT G1 (PUMP PRESSURE) 4. TEST PORT (LOAD SENSE)
Connect two 69 bar (1000 psi) test gauges, one to the test port G1 (2) located on the priority valve (3), and one on the pump load-sense pressure tap (4 closest to transmission). IMPORTANT: Do not steer or operate loader controls while the gauges are connected, gauges could be damaged.
STEP 4 Start the engine and run at low idle.
STEP 5 Make sure all of the controls are in the neutral position and record the readings on the test gauges (2) and (4).
STEP 6 Subtract the reading of the test port (4) from the reading of the test port (2).
84547255A
Issued 11-11
Printed in E.C.
8002-8
STEP 7 The difference between the two readings should be 25 to 27 bar (363 to 392 psi).
STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump load-sense pressure.
Adjusting the High Pressure Pump Differential Pressure STEP 9 The load-sense adjusting screw is directly under the priority valve. 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).
84547255A
Issued 11-11
Printed in E.C.
8002-9
TESTING AND ADJUSTING THE LOW PRESSURE PUMP DIFFERENTIAL PRESSURE Pressure Check
STEP 3
STEP 1
4
1 W230R407
1. ARTICULATION LOCK
2
3 W270R042
Install articulation lock (1). 2. TEST PORT G2 (PUMP PRESSURE) 4. TEST PORT (LOAD SENSE)
STEP 2 Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●
To measure the instrument cluster:
oil
temperature
with
IMPORTANT: Do not steer of operate loader controls while the gauges are connected, gauges could be damaged.
STEP 4 Start the engine and run at low idle.
the
A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.
84547255A
Connect two 69 bar (1000 psi) test gauges, one to the test port G2 (2) located on the priority valve (3), and one on the pump load-sense pressure tap (4 furthest from the transmission).
STEP 5 Make sure all of the controls are in the neutral position and record the readings on the test gauges (2) and (4).
STEP 6 Subtract the reading of the test port (4) from the reading of the test port (2).
Issued 11-11
Printed in E.C.
8002-10
STEP 7 The difference between the two readings should be 21 to 23 bar (305 to 333 psi).
STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump differential pressure.
Adjusting the Low Pressure Pump Differential Pressure STEP 9 The differential adjusting screw is directly under the priority valve. Turn the screw clockwise to increase the load-sense pressure. Turning the screw counterclockwise will decrease the differential pressure. NOTE: One turn of the adjustment screw will change the pressure approximately 16 bar (230 psi).
84547255A
Issued 11-11
Printed in E.C.
8002-11
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE Pressure Check
STEP 3
STEP 1
Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●
1
To measure the instrument cluster:
oil
temperature
with
the
A. Press the up or down arrow key. W230R407
1. ARTICULATION LOCK
B. Stop at the info screen with the temperatures that need to be monitored are on. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.
Install articulation lock (1).
STEP 2 STEP 4 Run the engine at full throttle.
STEP 5 Roll the loader bucket back against the stops.
STEP 6 Record the reading on the test gauge.
STEP 7 Reading should be 248 to 255 bar (3597 to 3700 psi).
STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump limit pressure.
1
2 W270R043
1. TEST PORT G1 (LOAD LIMIT)
Connect a 345 bar (5000 psi) test gauge to the test port G1 (1), located on the priority valve (2).
84547255A
Issued 11-11
Printed in E.C.
8002-12
Adjusting the Loader Limit Pressure
STEP 9 The limit adjusting screw (1) is located on the left side of the loader valve (2). Turn the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure.
2
NOTE: One turn of the adjustment screw will change the pressure approximately 35 bar (500 psi).
1
W270R044
84547255A
Issued 11-11
Printed in E.C.
8002-13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE Pressure Check
STEP 3
STEP 1
Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●
1
To measure the instrument cluster:
oil
temperature
with
the
A. Press the up or down arrow key. W230R407
1. ARTICULATION LOCK
B. Stop at the info screen with the temperatures that need to be monitored are on. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.
Install articulation lock (1).
STEP 2 STEP 4 Start the engine and run at full throttle.
STEP 5 Steer hard in either direction over relief pressure.
STEP 6 Record the reading on the test gauge.
STEP 7 Reading should be 239 to 243 bar (3465 to 3525 psi).
STEP 8 If this reading is more or less than specified, it will be necessary to adjust the steering limit pressure.
1
2 W270R043
1. TEST PORT G1 (LOAD LIMIT)
Connect a 345 bar (5000 psi) test gauge to the test port G1 (1), located on the priority valve (2).
84547255A
Issued 11-11
Printed in E.C.
8002-14
Adjusting the Steering Limit Pressure
STEP 9 The steering priority valve is located on the hydraulic pump, the adjusting valve (1) is located on the transmission side of the priority valve. Turning the screw clockwise to increase the limit pressure. Turning the screw counterclockwise will decrease the limit pressure.
1 W270R045
1. STEERING LIMIT VALVE
84547255A
Issued 11-11
Printed in E.C.
8002-15
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE Pressure Check
STEP 3
STEP 1
Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil. A. Start the engine and run at full throttle. B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●
1
To measure the instrument cluster:
oil
temperature
with
the
A. Press the up or down arrow key. W230R407
1. ARTICULATION LOCK
B. Stop at the info screen with the temperatures that need to be monitored are on. After heating oil to operating temperature, lower bucket to the ground, turn off the engine, and relieve all pressure in the hydraulic system.
Install articulation lock (1).
STEP 2 STEP 4 Start the engine and run at full throttle.
STEP 5 Roll the loader bucket back against the stops.
STEP 6 Record the reading on the test gauge.
STEP 7 Reading should be 198 to 202 bar (2870 to 2930 psi).
STEP 8 If this reading is more or less than specified, it will be necessary to adjust the pump cutoff pressure.
1
2 W270R046
1. TEST PORT G2 (PUMP PRESSURE)
Connect two 345 bar (5000 psi) test gauge to the test port G2 (1) located on the priority valve (2).
84547255A
Issued 11-11
Printed in E.C.
8002-16
Adjusting the Loader Pump Cutoff Pressure STEP 9
1
W270R047
The unloading adjuster (1) is the longer of the two adjusters on the loader pump. Turn the screw clockwise to increase the cutoff pressure. Turning the screw counterclockwise will decrease the cutoff pressure. NOTE: The adjusting screw is located just above the steering priority valve on the pump furthest from the transmission.
84547255A
Issued 11-11
Printed in E.C.
8002-17
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE NOTE: This pressure is factory preset and is not adjustable.
STEP 2
Pressure Check
Raise lift arms to the top and turn off the engine. Turn the ignition switch to the “RUN” position and disengage the controller lock-out switch.
STEP 1
STEP 3
Make sure that the temperature of the hydraulic oil is at least 54°C to 57°C (129°F to 135°F). The following is the procedure for heating the hydraulic oil.
Wait for the buzzer to stop then repeatedly put the loader control lever into “FLOAT” position and back to neutral.
A. Start the engine and run at full throttle.
STEP 4
B. Lower the loader bucket to the ground and hold the lift control lever in the FLOAT position. C. Roll the bucket back against the stops and hold. ●
To measure the instrument cluster:
oil
temperature
with
The system should allow a minimum of 10 actuations into float and still cause the lift arms to come down. NOTE: If 10 full actuations cannot be made, an internal hydraulic leak exists.
the
A. Press the up or down arrow key. B. Stop at the info screen with the temperatures that need to be monitored are on.
84547255A
Issued 11-11
Printed in E.C.
8002-18
HIGH PRESSURE PUMP FLOW TEST NOTE: The pump differential pressure must be set before attempting any other tests. Refer to page 3 of this section.
STEP 1 Connect the flow meter (3) by disconnecting the articulation pressure hose (6) to the valve supply tube (12), installing a cap on the fitting at the valve supply tube (12). Refer to illustration on page 19.
STEP 2 Disconnect the load sense hose (7) and install a cap the fitting at the loader valve (13).
STEP 6 Using the temperature gauge on the flow meter, continue to run the engine at high idle until the temperature of the hydraulic oil is at least 52°C to 60°C (125°F to 140°F).
STEP 7 Run the engine at low idle, fully open the flow meter valve.
STEP 8
NOTE: This is the line that returns to the pump compensator valve.
Open the needle valve (8) and operate the engine at 2000 rpm. At 0 bar (0 psi) the flow should be 250 to 255 L/min (66 to 67.4 gpm).
STEP 3
STEP 9
Connect a “T” fitting (10) into the loader control valve inlet hose (6) and to the flow meter inlet hose (11).
Close the flow meter valve slowly and read the flow at 34.5 bar (500 psi) the flow should be 249 to 255 L/min (65.8 to 66.8 gpm).
STEP 4 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).
STEP 5 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.
STEP 10 Close the flow meter valve slowly and read the flow at 2000 psi @ 2000 rpm. The flow should read 244.5 to 247.5 L/min (64.6 to 65.4 gpm).
STEP 11 Continue to close the flow meter valve slowly, at approximately 2900 psi the flow should drop significantly, this will be the low pressure pump destroking.
STEP 12 Continue slowly closing the flow meter valve until 3500 psi is reached. The flow should read between 120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13 If any of the pump flow readings are not within specifications, the pump may be out of calibration and Technical Support Services should be contacted.
84547255A
Issued 11-11
Printed in E.C.
8002-19
1 4
7 2
3
11
5 6 10 9 8 12
13
W270R049
1. HYDRAULIC RETURN MANIFOLD 6. HOSE ARTICULATION PRESSURE 11. FLOW METER INLET HOSE 2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. VALVE TUBE SUPPLY 3. FLOW METER 8. NEEDLE VALVE 13. LOADER VALVE 4. PUMPS 9. UNION 5. PRIORITY VALVE 10. T FITTING NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
84547255A
Issued 11-11
Printed in E.C.
8002-20
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES Pressure Check
STEP 4
STEP 1
Remove the safety strut and lower the bucket to the floor. Shut off the engine. Find an easy place to disconnect the line for the circuit to be tested.
Circuit relief valves are located as shown below.
6
STEP 5
2 4
3 5
Connect the hand pump to the disconnected line that goes to the loader control valve.
STEP 6 Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).
STEP 7 Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.
STEP 8 Compare the reading to the specifications on Page 3.
STEP 9
1
If the pressure is not correct, adjust the circuit relief valve.
Adjustment STEP 1 W270R048
1. 2. 3. 4. 5. 6.
CIRCUIT RELIEF VALVES PUMP LIMIT PRESSURE ADJUSTMENT BUCKET SPOOL LIFT SPOOL AUXILIARY SPOOL LOADER CONTROL VALVE
STEP 2 Raise the lift arms and install the safety link on the lift arm cylinder.
Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).
STEP 2 Check the pressure again. Repeat the adjustment as necessary.
STEP 3 Loosen and remove the bolts and washers that fasten the access cover plate for the loader control valve. Remove the cover plate.
84547255A
Issued 11-11
Printed in E.C.
8002-21
TESTING THE RIDE CONTROL STEP 1
STEP 6
Move the machine to a clear level surface with clearance for full lift arm and bucket movement.
Dump the bucket until it hits the dump stops. Hold the bucket in the dump position for 5 to 10 seconds.
STEP 2 Install the articulation lock, start the machine, activate the parking brake.
STEP 3 With the pilot controller in neutral, set the ride control rocker switch on the right side console to the “Always On” position and observe the switch lamp, the lamp should illuminate.
STEP 4 Set the ride control rocker switch to the “Off” position and observe the switch lamp, the lamp should go out. NOTE: This indicates that the switch is operating correctly and has power, if the switch does not illuminate see section 4002 and troubleshoot the electrical system for the ride control.
STEP 5 Raise the lift arms to the top of their travel and dump the bucket.
NOTE: This will charge the ride control accumulator.
STEP 7 Lower the lift arms and roll the bucket back to a carry position. Do not leave the lift arms or the bucket on their stops, place the pilot control lever in the neutral position.
STEP 8 Set the ride control rocker switch to the “Always On” position. The lift arms should rise 15 to 30 cm (6 to 12 inches) with an empty bucket. NOTE: Test results will be for a machine with a empty factory bucket and no attachments.
STEP 9 If there is little or no lift arm raise, the test may have been done too slowly. The elapsed time between step 6 and step 8 should not exceed six seconds. NOTE: If test was done to slowly repeat in the allotted time.
STEP 10 If test was completed in the allotted time and the lift arms still do not rise, test the nitrogen charge in the accumulator, see section 8013.
84547255A
Issued 11-11
Printed in E.C.
8002-22
NOTES
84547255A
Issued 11-11
Printed in E.C.
8003
Section 8003 CLEANING THE HYDRAULIC SYSTEM
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8003-2
TABLE OF CONTENTS SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Issued 11-11
3 4 4 5 7
Printed in E.C.
8003-3
SPECIAL TOOLS
806128
380001733, fitting kit.
806127
380001727, filter unit, portable.
TR98H032
380001728, vacuum pump.
84547255A
Issued 11-11
Printed in E.C.
8003-4
GENERAL INFORMATION Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1. When you drain the oil or disconnect any line.
1. Cylinder rod seals leak. 2. Control valve spools do not return to neutral. 3. Movement of control valve spools is difficult. 4. Hydraulic oil becomes too hot.
2. When you disassemble a component.
5. Pump gears, housing, and other parts wear rapidly.
3. From normal wear of the hydraulic components.
6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals.
7. Quick failure of components that have been repaired.
5. From a damaged component in the hydraulic system. All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems.
8. Cycle times are slow; machine does not have enough power. If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.
TYPES OF CONTAMINATION There are two types of contamination, microscopic and visible. 1. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. 2. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems:
3. Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: A. Particles of metal or dirt in the oil. B. Air in the oil C. The oil is dark and thick. D. The oil has an odor of burned oil. E. Water in the oil. See page 7.
A. Cylinder rod seal leak. B. Control valve NEUTRAL.
spools
do
not
return
to
C. The hydraulic system has a high operating temperature.
84547255A
Issued 11-11
Printed in E.C.
8003-5
CLEANING THE HYDRAULIC SYSTEM 1. Prepare the portable filter on page 3 by doing the following steps: A. Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. B. Remove the filter element from the portable filter. C. Remove all hydraulic oil from the portable filter. D. Clean the inside of the housing for the filter element. 2. You must know whether the contamination is microscopic or visible. See types of contamination on page 4. 3. If the contamination is microscopic: A. Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If needed, change the hydraulic oil. See Section 1002 for specifications. Change the hydraulic filter. B. Do steps 6 through 35. 4. If the contamination is visible:
8. Using the fitting kit shown on page 3, install the valve in the hole for the drain plug. Make sure that the valve is closed. 9. Stop the vacuum pump. 10. Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug. 11. Disconnect the vacuum pump from the hydraulic reservoir air breather hose. Remove the filler cap. 12. Install the outlet hose for the portable filter in the hydraulic reservoir filler neck. 13. Open the valve that is installed in the hole for the drain plug. 14. Move the switch for the portable filter to the ON position. Start and run the engine at 1500 rpm (r/min). 15. Run the portable filter for 10 minutes. 16. Continue to run the portable filter. Increase the engine speed to full throttle. Heat the oil to operating temperature by doing the following steps:
A. Change the hydraulic oil and hydraulic filter. See Section 1002 for specifications.
A. Hold the blade control lever in the TILT position for five seconds.
B. Do steps 5 through 35.
B. Return the blade control lever NEUTRAL position for five seconds.
5. Check the amount of contamination in the hydraulic system by doing the following steps: A. Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. B. If, in your judgment, the damage to the cylinders was caused by sever contamination and is not the result of normal wear, it is necessary to remove, clean and repair valves, pump, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. 6. Remove the breather from the reservoir and connect the vacuum pump to the opening. Start the vacuum pump. 7. Loosen and remove the drain plug from the reservoir.
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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.
Issued 11-11
Printed in E.C.
8003-6 24. Close the valve that is installed in the hole for the drain plug. 25. Disconnect the inlet hose for the portable filter from the valve. Remove the outlet hose from the reservoir filler neck and replace filler cap.
30. Stop the vacuum pump. Disconnect the vacuum pump from the opening in the reservoir and install the breather. 31. Remove the hydraulic filter elements from the machine.
26. Connect a vacuum pump to the breather hose of the hydraulic reservoir.
32. Install new hydraulic filter elements on the machine.
27. Start the vacuum pump.
33. Start the engine. Check for oil leakage around the new hydraulic filters.
28. Remove the valve from the hole for the drain plug. 29. Install the drain plug.
84547255A
34. Stop the engine. 35. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
Issued 11-11
Printed in E.C.
8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM 1. Start and run the engine at 1500 rpm (r/min). 2. Completely retract the cylinders of all attachments on the machine. Angle the blade to the right, the right cylinder will be fully retracted and the left will be fully extended. Stop the engine. WARNING: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before proceeding to the next step! 39-4
13. Slowly move each control lever in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line. 14. Stop the engine. 15. Connect the system line to the CLOSED end of each cylinder. 16. Connect a suitable drain line to the OPEN end of each cylinder and place the other end in an acceptable container for contaminated oil. 17. Start the engine and run the engine at low idle.
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.
18. Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to release pressure in the hydraulic circuits.
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling.
4. Loosen and remove the filler cap from the reservoir. 5. Drain the hydraulic oil from the reservoir.
19. Support any attachments that will be in the RAISED position.
A. See Section 1002 for capacity specifications.
20. Stop the engine.
B. Have available acceptable equipment to drain the hydraulic oil.
21. Disconnect the drain lines and connect the system lines to the cylinders.
C. Remove the drain plug from the bottom of the reservoir.
22. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
6. Remove the hydraulic filter elements from the machine.
23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the machine.
24. Remove the hydraulic filter elements from the machine.
8. Install the drain plug in the bottom of the reservoir.
25. Install new hydraulic filter elements on the machine.
9. Fill the hydraulic reservoir with hydraulic fluid. See Section 1002 for specifications.
26. Start and run the engine at 1500 rpm (r/min), operate each hydraulic circuit to completely extend and retract the cylinders.
10. Disconnect the line from the OPEN end and CLOSED end of each cylinder. 11. Be sure all control levers are in the NEUTRAL position.
27. Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. See Section 1002 for specifications.
12. Start and run the engine at low idle. IMPORTANT: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13.
84547255A
Issued 11-11
Printed in E.C.
8003-8
NOTES
84547255A
Issued 11-11
Printed in E.C.
8004
Section 8004 HYDRAULIC PUMP
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8004-2
TABLE OF CONTENTS PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PUMP SPECIFICATIONS W270C Manufacturer .................................................................................................................................................. Rexroth High pressure pump (steering pump next to transmission) ..........................................................220 L/min (58 gpm) Nominal displacement ............................................................................................................. 100 cm3 (6 cubic inch) Low pressure pump (loader pump farthermost from transmission) ...........................................187 L/min (49.5 gpm) Nominal displacement ............................................................................................................... 85 cm3 (5 cubic inch) Rotation ................................................................................................. Clockwise as seen from the end of the shaft Special torques Pump end cover bolts ..................................................................................................165 Nm (121.5 pound-feet) Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet) Control piston plug ..............................................................................................................90 Nm (66 pound-feet) W300C Manufacturer .................................................................................................................................................. Rexroth High pressure pump (steering pump next to transmission) ..........................................................220 L/min (58 gpm) Nominal displacement ............................................................................................................. 100 cm3 (6 cubic inch) Low pressure pump (loader pump farthermost from transmission) ..............................................220 L/min (58 gpm) Nominal displacement ............................................................................................................. 100 cm3 (6 cubic inch) Rotation ................................................................................................. Clockwise as seen from the end of the shaft
PREPARING THE EQUIPMENT PUMP FOR USE Do the following procedure any time you install a new or overhauled equipment pump: 1. Start and run the engine at half throttle for three minutes. 2. With the engine running at half throttle, move the bucket control lever into roll back position. Hold the bucket control lever in this position until the bucket stops moving.
4. Repeat Step 3 for three minutes. 5. Increase the engine speed to full throttle and repeat Steps 3 and 4. 6. Stop the engine and check for leaks. 7. Replace the hydraulic filter.
3. Hold the bucket control lever in the roll back position for five seconds. Then put the bucket control lever in the NEUTRAL position for five seconds.
84547255A
Issued 11-11
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EQUIPMENT PUMP 7
9
8
5
6 4
5 4
3
1
10
2
11 13
12 21
22
23
24
20 19
14
17
15
18
16
30 29 15 26
27
28
25
BC06F550
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
84547255A
SNAP RING SEAL MAIN BODY O-RING PLUG CONTROL VALVE CAP SCREW PISTON ROD CONTROL PISTON SHAFT
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
TAPERED BEARING BEARING RACE SHIM SPRING HALF BEARING SWASH PLATE PISTONS RETAINING PLATE BALL CYLINDER
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
PRESSURE PINS BACKUP PLATE SPRING SNAP RING PORT PLATE SHIM TAPERED BEARING BEARING RACE DOWEL PIN END COVER
Issued 11-11
Printed in E.C.
8004-5
Disassembly
STEP 3
STEP 1 Remove all dirt, oil, and grease from the exterior of the equipment pump.
STEP 2
BC06F552
Remove the control valve.
STEP 4
BC06F551
Put alignment marks on the end cover and housing.
BC06F553
Remove the four bolts.
84547255A
Issued 11-11
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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.
84547255A
Use a suitable bearing race puller and pull the bearing race from the end cover. NOTE: Do not damage the sealing surfaces.
Issued 11-11
Printed in E.C.
8004-7
STEP 7
STEP 9
BC06F558
Remove plug, pull control piston using a suitable tool as shown. NOTE: Do not use a magnet to pull the piston.
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.
84547255A
Issued 11-11
Printed in E.C.
8004-8
STEP 11
STEP 14
BC06F560
Remove the bearing and spring.
STEP 12 BC06F563
Use a suitable bearing race puller and pull the bearing race from the housing.
STEP 15
BC06F561
Remove the shaft and bearing.
STEP 13
BC06F564
Remove the shim and plug.
BC06F562
Remove the retaining ring an seal.
84547255A
Issued 11-11
Printed in E.C.
8004-9
Inspection
STEP 19
STEP 16 Clean all parts in cleaning solvent. Be careful not to remove the alignment marks made during disassembly.
STEP 17
BC06F567
Check the bearing surface.
STEP 20
BC06F565
Check for wear on the splines, seal areas for grooves, bearing areas for scaring, and key set.
STEP 18
BC06F568
Check that the retaining plate is free of grooves and that there is no sign of wear.
STEP 21
BC06F566
Check the surface that the pistons contact for grooves and scaring.
BC06F569
Check the sliding surface for scratches or metal deposits, check the tightness of the cup on the piston. NOTE: If a piston needs to be replaced, all of the pistons must be replaced.
84547255A
Issued 11-11
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8004-10
STEP 22
STEP 24
BC06F570
Check the cylinder bores and splines for damage.
STEP 23
BC06F572
Check cylinder surface for grooves, wear, embedded particles. Check flow plate for scratches or wear.
STEP 25
BC06F571
Check ball for grooves and wear.
84547255A
BC06F573
Check mounting surface for the flow plate for damage.
Issued 11-11
Printed in E.C.
8004-11
Assembly
STEP 27
STEP 26
BC06F575
BC06F574
Install the plug in the housing and tighten to 127 Nm (93.5 pound-feet). Install shim and press in the bearing race.
Put the shaft and bearing in the housing.
STEP 28
BC06F576
Press in a new race into the end cover.
84547255A
Issued 11-11
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8004-12
STEP 29
STEP 31
BC06F579
Install the seal and retaining ring.
STEP 32 BC06F577
Install the end cover, 4 bolts and hand tighten.
STEP 30
BC06F578
A bearing pre load of 0.05 mm (0.002 inch) must be obtained, add remove shims from bearing as required.
BC06F580
Put new bearings in the housing. Install the reaction spring.
84547255A
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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.
84547255A
Issued 11-11
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STEP 36
STEP 39
BC06F584
Use a suitable compressor, compress the spring and install the snap ring.
STEP 37
BC06F585
BC06F587
Place the ball onto the pressure pins, install the pistons into the retaining plate.
Hold the pistons in the rotating housing using an O-ring, install the rotating group into the housing, remove the O-ring.
STEP 38
BC06F586
Lubricate the piston and retaining plate with clean oil, install the piston into the rotating housing.
84547255A
Issued 11-11
Printed in E.C.
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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.
84547255A
Issued 11-11
Printed in E.C.
8004-16
STEP 42
STEP 43
BC06F591
Use new O-rings, install and tighten the control valve.
BC06F590
Instal and tighten the four bolts to 165 Nm (121.5 pound-feet).
84547255A
Issued 11-11
Printed in E.C.
Section 8005
8005
LOADER CONTROL VALVE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8005-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 5 6 7 8 12 12 15 15
Printed in E.C.
8005-3
SPECIFICATIONS Manufacturer .................................................................................................................................................. Rexroth Special Torques End plate mounting bolts.....................................................................................................68 Nm (50 pound feet) Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound inches) Allen head plugs...........................................................................................................200 Nm (147.5 pound feet) Allen head locking screw................................................................................................100 Nm (73.7 pound feet) Allen head cover screws (short) ................................................................................. 8.3 Nm (73.4 pound inches) Allen head cover screws (long) .................................................................................. 8.3 Nm (73.4 pound inches) Anticavitation valves.......................................................................................................100 Nm (73.7 pound feet) Combination anticavitation and circuit relief .....................................................................60 Nm (44.2 pound feet) Main relief valve pressure settings (Long Reach and Z-Bar) ............................. 248 to 255 bar (3597 to 3698.5 psi) Circuit relief valve pressure setting Auxiliary A and B port (Long Reach and Z-Bar) ........................................................................290 bar (4206 psi) Bucket A port (Long Reach and Z-Bar) .....................................................................................290 bar (4206 psi) Bucket B port (Long Reach and Z-Bar) .....................................................................................290 bar (4206 psi)
84547255A
Issued 11-11
Printed in E.C.
8005-4
3 2 1 4 8
21
9
10 6
8
6 12
14 5
16
7 13
20 19 14 15
5
11
13 10
18 17 W270R089
1. 2. 3. 4. 5. 6. 7.
STUD WASHER HEXAGON NUT PLATE ANTI-CAVITATION VALVE O-RINGS THROTTLE CHECK VALVE
8. 9. 10. 11. 12. 13. 14.
ANTICAVITATION AND CIRCUIT RELIEF HOUSING 1M6-22 FLOW COMPENSATOR SPOOL HOUSING 2M-22 INTERMEDIATE PLATE O-RINGS PLUG
15. 16. 17. 18. 19. 20. 21.
ANTI-CAVITATION VALVE CHECK VALVE LOCKING PLATE CYLINDER SCREW PRESSURE RELIEFE VALVE FLOW LIMIT VALVE PRESSURE REDUCING VALVE
3 SPOOL VALVE HOUSING CONFIGURATION
84547255A
Issued 11-11
Printed in E.C.
8005-5
36
22
6
23
6
24 32
26 35
24
22
23
22
31 37
6 6
27
36
28
29 6
25 34 33
23
24
30 32
W270R090
6. 22. 23. 24. 25. 26.
O-RINGS THREADED STEEL PIPE FITTING SPRING RETAINER SPRING SPRING COVER
27. 28. 29. 30. 31. 32.
BOLT COVER CAP NUT JAM NUT SPOOL BOLT
33. 34. 35. 36. 37.
COVER ADJUSTING ROD SPOOL LOCKING SCREW SPOOL
3 SPOOL VALVE SPOOL CONFIGURATION
84547255A
Issued 11-11
Printed in E.C.
8005-6
39
38
40 39 W270R091
38. HOUSING
39. ANTICAVITATION AND CIRCUIT RELIEF
40. FLOW COMPENSATOR SPOOL
4 SPOOL MOUNTING CONFIGURATION
84547255A
Issued 11-11
Printed in E.C.
8005-7
36
22
6
24 6
23
35
24
22
23
32
26 22
31 37
6 6
27
36
28
29 6
25 34 33
23
24
30 32
W270R092
6. 22. 23. 24. 25. 26.
O-RINGS THREADED STEEL PIPE FITTING SPRING RETAINER SPRING SPRING COVER
27. 28. 29. 30. 31. 32.
BOLT COVER CAP NUT JAM NUT SPOOL BOLT
33. 34. 35. 36. 37.
COVER ADJUSTING ROD SPOOL LOCKING SCREW SPOOL
4 SPOOL VALVE SPOOL CONFIGURATION
84547255A
Issued 11-11
Printed in E.C.
8005-8
DISSASEMBLY STEP 1
STEP 7
Remove valve from machine, see section 8001.
Remove pressure relief valve (19).
STEP 2
STEP 8
Remove bolts (27), cover (28), springs (24 and 25), and spring retainer (23).
Remove flow limit valve (20).
STEP 9 STEP 3
Remove the check valve (16).
Remove bolts (32), covers (33 and 26), spring (24), and spring retainer (23).
STEP 10
STEP 4 Use wooden dowel or brass drift and push spools (31, 35 and 37) from housing (11). IMPORTANT: Do not force spools from housing, if spool binds work back and forth until spool comes out freely.
Remove locking screw (14).
STEP 11 Remove load sense shuttle check valve (7).
STEP 12
NOTE: Repeat steps 3 and 4 for a spool valve configuration.
Remove pilot pressure reducing valve (21).
STEP 5
Remove the cylinder screw (18) and the locking plate (17).
Remove anticavitation valves (5, 8 and 15). NOTE: Repeat step for a 4 spool anticavitation valves (39).
STEP 6 Remove the flow compensator spool (10). NOTE: Repeat step for a 4 spool for the flow compensator spool (40).
84547255A
STEP 13
STEP 14 Remove the hexagon nut (3) and washers (2) from stud (1), remove plate (4) and intermediate plate (12) from housing (11). NOTE: For 4 spool configuration remove housing (38) from housing (11).
Issued 11-11
Printed in E.C.
8005-9
STEP 15
STEP 17 2 1 2
1
1
1
BS03C025
1. O-RINGS
BS03C027
2. THRUST RINGS
1. O-RINGS
Remove and discard O-rings and thrust rings from pilot pressure reducing valve (21).
2. THRUST RING
Remove and discard O-rings and thrust ring from locking screw (14).
STEP 16 2
STEP 18 1
2 1
1 1
2
BS03C026
1. O-RINGS
2. THRUST RINGS
Remove and discard O-rings and thrust rings from flow limit valve (20).
84547255A
3
1
BS03C028
1. O-RINGS
2. THRUST RING
3. SPOOL SEAL
Remove and discard O-rings, thrust ring, and spool seal from anticavitation valve (5).
Issued 11-11
Printed in E.C.
8005-10
STEP 19
1 2
1 1 2 2 BS03C029
1. O-RINGS
2. THRUST RINGS
Remove and discard O-rings and thrust rings from pressure relief valve (19).
84547255A
Issued 11-11
Printed in E.C.
8005-11
STEP 20
3
2
4
1
1 1
BS03C032
1. O-RINGS
2. THRUST RING
3. SPOOL SEAL
4. LOCK NUT
Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 39).
84547255A
Issued 11-11
Printed in E.C.
8005-12
INSPECTION 1. Discard all O-rings, thrust rings, and spool seals. 2. Clean all parts in cleaning solvent. 3. Check the spools and the spool bores for damage and wear.
4. Check the parts of the pressure relief valve, anticavitation valves, and the anticavitation and circuit relief valves. Use new parts as necessary. Inspect the other parts of the control valve. If any of the parts are damaged, install new parts.
ASSEMBLY STEP 1
3
4 A
2
1
1
See Note
1
BS03C032
1. O-RINGS
2. THRUST RING
3. SPOOL SEAL
4. LOCK NUT
Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 39). Torque relief valve (A) into anticavitation valve to 20 Nm (14.7 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.
84547255A
Issued 11-11
Printed in E.C.
8005-13
STEP 2
1 2
1 1 2 2 BS03C029
1. O-RINGS
2. THRUST RINGS
Install new O-rings and thrust rings on pressure relief valve (19).
84547255A
Issued 11-11
Printed in E.C.
8005-14
STEP 3
STEP 6 2
1 1
1 1
3
1
2 BS03C025
1. O-RINGS
2. THRUST RINGS
BS03C028
1. O-RINGS
2. THRUST RING
3. SPOOL SEAL
Install new O-rings and thrust rings on pilot pressure reducing valve (21).
Install new O-rings, thrust ring, and spool seal on anticavitation valve (5).
STEP 4
STEP 7 Install and torque locking screw (14) to 100 Nm (73.7 pound feet).
2
STEP 8 Install and tighten load sense shuttle check valve (7).
2 1
STEP 9 1
Install and torque pilot pressure reducing valve (21) to 60 Nm (44 pound feet).
STEP 10
Install new O-rings and thrust rings on flow limit valve (20).
Install new O-rings on housing (11). Install plate (4) and intermediate plate (12), stud (1), washers (2) and hexagon nut (3) onto housing (11). Torque nut to 68 Nm (50 pound feet).
STEP 5
STEP 11
BS03C026
1. O-RINGS
2. THRUST RINGS
Install the locking plate (17) and the cylinder screw (18). Torque screw to 68 Nm (50 pound feet).
1
NOTE: Repeat step for a 4 spool configuration for the housing (38).
2
STEP 12
1
Install anticavitation valves (5 and 8) and torque to 100 Nm (73.7 pound feet). NOTE: Repeat step for a 4 spool anticavitation valves (39). BS03C027
1. O-RINGS
2. THRUST RING
Install new O-rings and thrust ring on locking screw (14).
84547255A
STEP 13 Install anticavitation valves (15) and torque to 60 Nm (44.2 pound feet).
Issued 11-11
Printed in E.C.
8005-15
STEP 14
Circuit Relief Pressure Test
Install and torque flow limit valve (20) to 20 to 25 Nm (177 to 221 pound inches).
STEP 1
STEP 15
Connect the hand pump to the port for anticavitation and circuit relief valves (19).
Install the check valve (16). Torque locking screw to 100 Nm (73.7 pound feet).
STEP 16 Lubricate spools with hydraulic oil and push spools (31, 35 and 37) into housing (11).
NOTE: Repeat steps for machines that are configured with a 3 or 4 spool valve.
STEP 2
IMPORTANT: Do not force spools into housing.
Make sure that the hand pump is full of hydraulic oil and that the temperature of the oil is approximately 21°C (70°F).
STEP 17
STEP 3
Install spring retainers (23), springs (24), covers (33 and 26), and bolts (32). Torque bolts to 8.3 Nm (73.4 pound inches).
Operate the handle of the hand pump and read the highest pressure. Repeat this step several times to be sure of the reading.
STEP 18
STEP 4
Install spring retainers (23), spring (24 and 25), cover (28), and bolts (27). Torque bolts to 8.3 Nm (73.4 pound inches).
Compare the reading to the specifications on Page 3.
NOTE: Prior to installation in the machine, circuit reliefs can be tested.
If the pressure is not correct, adjust the circuit relief valve.
STEP 19
Circuit Relief Adjustment
STEP 5
Install valve in machine, see section 8001.
STEP 1 STEP 20 Check loader limit pressure, see section 8002.
Loosen the lock nut. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. NOTE: One turn of the adjusting screw will change the pressure approximately 138 bar (2000 psi).
STEP 2 Check the pressure again. Repeat the adjustment as necessary.
84547255A
Issued 11-11
Printed in E.C.
8005-16
NOTES
84547255A
Issued 11-11
Printed in E.C.
Section 8006
8006
CYLINDERS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8006-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 4 4 4 6 7 7 7 9 11 11 11 12 12 12
Printed in E.C.
8006-3
SPECIFICATIONS W270C
Approximate weight
Lift Cylinder..............................................................................................................................279 kg (616.6 pounds) Bucket Cylinder ....................................................................................................................289.3 kg (637.7 pounds) W300C
Approximate weight
Lift Cylinder..............................................................................................................................294.4 kg (649 pounds) Bucket Cylinder ....................................................................................................................304.1 kg (670.4 pounds)
SPECIAL TORQUES W270C Gland Bolts Bucket Cylinder....................................................................535 to 660 Nm (394.5 to 486.7 pound-feet) Screw in Gland for Lift Cylinders ................................................................420 to 500 Nm (310 to 368.8 pound-feet) W300C Gland Bolts Bucket Cylinder....................................................................535 to 660 Nm (394.5 to 486.7 pound-feet) Screw in Gland for Lift Cylinders ................................................................420 to 500 Nm (310 to 368.8 pound-feet)
SPECIAL TOOLS Torque Multiplier........................................................................................................................................380001732
84547255A
Issued 11-11
Printed in E.C.
8006-4
LIFT CYLINDER Disassembly
Inspection
1. Clean exterior of cylinder. If hoses were removed with cylinder, remove hoses from cylinder.
1. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or other holding equipment. Do not damage tube (1).
2. Check to be sure that piston rod (13) is straight. If piston rod is not straight, replace it with a new piston rod.
3. Use a spanner wrench to loosen and remove the bolt (7, q.ty 8) of gland (4) from tube (1).
3. Shine a light inside tube (1) and check for deep grooves and other damage. If there is any damage to tube, replace with a new tube.
4. Pull piston rod (13) straight out of tube (1) to prevent damage to tube. 5. Fasten piston rod eye or yoke in a vise and put a support under piston rod (13) near piston (15). Put a shop cloth between support and piston rod to prevent damage to piston rod. 6. Remove the lock pin (14). 7. Remove piston (15) from piston rod (13). 8. Remove and discard seal (16), ring (17), and wear ring (18) and O-ring (10) from piston (15). 9. Remove and discard O-ring (11), backup ring (9), O-ring (12), wiper (5), rod seal (6), and bushing (8) from gland (4).
84547255A
4. Remove any small scratches on piston rod (13) or inside tube (1) with emery cloth of medium grit. Use emery cloth with a rotary motion. 5. Inspect bushings (2) in tube eye. Replace as required. 6. Inspect gland (4) for rust. Clean and remove rust as necessary. 7. Inspect gland end of tube (4) for sharp edges that may cut gland O-ring (11) and remove as necessary. 8. Inspect piston (15) for damage and wear. If piston is damaged or worn, replace with a new piston.
Issued 11-11
Printed in E.C.
8006-5
13
14 5
12
6
9 8 7
11 16
19
18 17
4
10 15
3
1
2
3
W230R591
1. 2. 3. 4. 5.
TUBE BUSHING WIPER GLAND WIPER
6. 7. 8. 9. 10.
ROD SEAL BOLT BUSHING BACKUP RING O-RING
11. 12. 13. 14. 15.
O-RING O-RING ROD BOLT PISTON
16. 17. 18. 19.
SEAL RING WEAR RING WASHER
LIFT CYLINDER
84547255A
Issued 11-11
Printed in E.C.
8006-6
Assembly NOTE: If a new gland is being used, put part number of cylinder on new gland. 1. Install bushing (8) in gland (4). 2. Install rod seal (6) in gland (4). Rod seal is to be installed so that lips of seal are toward bushing (8). Rod seal (6) can be difficult to install.
21. Turn the bolt (7, q.ty 8) on gland (4) into tube (1). Tighten gland to a torque of 535 to 660 Nm (394.5 to 486.7 pound-feet). 22. If hoses were removed with cylinder, install new O-rings, if equipped, on hose fittings. Lubricate O-rings with clean oil. Install hoses.
3. Install a new wiper (5) in gland (4). Lips of wiper must be toward outside end of gland (4). 4. Install a new O-ring (12) in groove on OD of gland (4). 5. Install a new backup ring (9) in groove on OD of gland (4). If both sides of backup ring are not flat, side that is not flat must be toward small end of gland (4). 6. Install a new O-ring (11) next to backup ring (9) in groove on outside of gland (4). O-ring must be toward small end of gland. 7. Fasten piston rod (13) eye or yoke in vise. 8. Remove any marks and sharp edges on chamfer at end of piston rod (13). Make sure that piston rod is clean. 9. Lubricate bore of gland (4) and piston rod (13) with clean oil. 10. Push gland (4) onto piston rod (13). If necessary, use a soft hammer to drive gland onto piston rod. 11. Put a support below and near end of piston rod (13). Use a shop cloth between support and the piston rod to prevent damage to piston rod. 12. Start piston (15) onto piston rod (13) and install the lock pin (14) on piston (15). 13. Install a new wear ring (18) in wide groove on outside of piston (15). 14. Install a new ring (17) in the other groove on the outside of the piston (15). 15. Install a new seal (16) on top of ring (17). 16. Fasten tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to tube. 17. Lubricate inside of the tube (1) and piston (15) with clean oil. 18. Push piston (15) straight into tube (1). 19. When the piston (15) is in smooth part of tube (1), start gland (4) into tube. 20. Lubricate O-rings (11 and 12) on gland (4) with clean oil. 84547255A
Issued 11-11
Printed in E.C.
8006-7
BUCKET CYLINDERS Disassembly 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Do not damage the tube (1). 3. Loosen and remove the cap screws (2) and hardened washers (18) from the gland (3) and the tube (1). 4. Pull the piston rod (4) straight out of the tube (1) to prevent damage to the tube (1). 5. Fasten the piston rod eye or yoke in a vise and put a support under the piston rod (4) near the piston (7). Put a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4). 6. Remove the retaining ring (10) that fastens the pin (11) in the piston (7) and piston rod (4). 7. Remove the pin (11) from the piston (7) and the piston rod (4). 8. Turn the piston (7) off the piston rod (4) and remove the piston (7). 9. Remove the gland (3) from the piston rod (4).
Inspection 1. Discard the parts that were removed from the piston and the gland. 2. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying. 3. Check to be sure that the piston rod is straight. If the piston rod is not straight, replace it with a new piston rod. 4. Illuminate the inside of the tube for deep grooves and other damage. If there is any damage to the tube, replace it with a new tube. 5. Remove any small scratches on the piston rod or inside the tube with emery cloth of medium grit. Use the emery cloth with a rotary motion. 6. Inspect the bushings in the piston rod eye or yoke and the tube. Replace as required. 7. Inspect the gland for rust and clean and remove rust as necessary. 8. Inspect the gland end of the tube for sharp edges that will cut the gland O-ring and remove as necessary. 9. Inspect the piston for damage and wear. If the piston is damaged or worn, replace it with a new piston.
10. Remove the seal (6) from the OD of the piston (7). 11. Remove the wear ring (5) from the OD of the piston (7). 12. Remove the backup rings (8) and the O-ring (9) from the ID of the piston (7). 13. Remove the seal (16), backup ring (15), wiper (12), wide seal (13), narrow seal (14), and bushing (17) from the gland (3).
84547255A
Issued 11-11
Printed in E.C.
8006-8
20
19
20
4 11
19 12
13 14
17 8
15
16 9
2
6
18
5 10
3
7
19
1 20 19
20 W230R592
1. 2. 3. 4. 5. 6.
TUBE CAP SCREW GLAND PISTON ROD WEAR RING SEAL
7. 8. 9. 10. 11.
PISTON BACKUP RING O-RING RETAINING RING PIN
12. 13. 14. 15. 16.
WIPER WIDE SEAL NARROW SEAL BACKUP RING SEAL
17. 18. 19. 20.
BUSHING HARDENED WASHER SEAL BUSHING
BUCKET CYLINDER
84547255A
Issued 11-11
Printed in E.C.
8006-9
Assembly NOTE: If a new gland is being used, put the part number of the cylinder on the new gland.
11. Install a new backup ring (8) in the groove in the ID of the piston (7). If both sides of the backup ring (8) are not flat, the side that is not flat must be toward the O-ring (9).
1. Install the bushing (17) in the gland (3), refer to illustration on page 8.
12. Install a new O-ring (9) in the groove in the ID of the piston (7) next to the backup ring (8).
2. Install the wide seal (13) in the gland (3). The wide seal (13) is to be installed so that the lips of the wide seal (13) are toward the bushing (17). The wide seal (13) can be difficult to install.
13. Install the other new backup ring (8) in the groove in the ID of the piston (7) next to the O-ring (9). If both sides of the backup ring (8) are not flat, the side that is not flat must be toward the O-ring (9).
3. Install a new wiper (12) in the gland (3). The lips of the wiper (12) must be toward the outside end of the gland (3). 4. Install the narrow seal (14) in the gland (3). The side of the narrow seal (14) with the groove must be toward the bushing (17). 5. Install a new backup ring (15) in the groove on the outside of the gland (3). If both sides of the backup ring (15) are not flat, the side that is not flat must be toward the small end of the gland (3). 6. Install the seal (16) next to the backup ring (15) in the groove on the outside of the gland (3). The seal (16) must be toward the small end of the gland (3).
14. Lubricate the ID of the piston (7) with clean oil. 15. Start the piston (7) onto the piston rod (4). Turn the piston (7) onto the piston rod (4) until the piston (7) is seated against the shoulder of the piston rod (4). 16. If none of the holes in the piston (7) align with the holes in the piston rod (4), turn the piston (7) counterclockwise until one of the holes in the piston (7) aligns with one of holes in the piston rod (4). Do not turn the piston (7) more than 90 degrees.
7
11
7. Remove any marks and sharp edges on the chamfer at the end of the piston rod (4). Make sure that the piston rod (4) is clean.
10
8. Lubricate the bore of the gland (3) and the piston rod (4) with clean oil. 9. Push the gland (3) onto the piston rod (4). If necessary, use a soft hammer to drive the gland (3) onto the piston rod (4). 10. Put a support below and near the end of the piston rod (4). Use a shop cloth between the support and the piston rod (4) to prevent damage to the piston rod (4).
4 GS98J804 PISTON AND PISTON ROD HOLE ALIGNMENT
17. Install the pin (11) in the piston (7) and the piston rod (4). 18. Install the retaining ring (10) in the pin (11).
84547255A
Issued 11-11
Printed in E.C.
8006-10 19. Install a new wear ring (5) in the wide groove on the OD of the piston (7).
27. Tighten the cap screws (2). Torque to 535 to 660 Nm (394.5 to 486.7 pound-feet).
20. Install a new seal (6) in the groove on the OD of the piston (7). 21. Fasten the tube (1) in an acceptable repair stand or other holding equipment. Be careful to prevent damage to the tube (1). 22. Lubricate the inside of the tube (1) and the outside of the piston (7) with clean oil. 23. Push the piston (7) straight into the tube (1). 24. Lubricate the O-ring (16) on the gland (3) with clean oil. 25. Push the gland into the tube (1) and align the holes in the tube (1). 26. Install the cap screws (2) and hardened washers (18).
84547255A
Issued 11-11
Printed in E.C.
8006-11
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Removal 1. Put piston tube (4) in a press. 2. Use an acceptable driver to press wipers (1) and bushings (2) out of piston tube (4) eye.
3
3. Clean bore for bushings (2) in tube (4) eye.
1
Installation
4
1. Use an acceptable driver to press new bushings (2) into tube (4) eye. Bushings shall be recessed 8 mm (0.315 inch) in tube eye. 2. Use an acceptable driver to install wipers (1) until flush with tube (4) eye. The lips of wipers must be toward outside of bore.
2 1 2
BS01C003
1. WIPER 2. BUSHING
3. PISTON ROD YOKE 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT LIFT CYLINDERS
84547255A
Issued 11-11
Printed in E.C.
8006-12
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Removal
3
1. Put piston rod eye (3) in a press. 2. Use an acceptable driver to press wipers (1) and bushing (2) out of piston rod eye (3). 3. Put tube (4) in a press. 4. Use an acceptable driver to press bushings (2) out of tube (4) eye.
2 1
1
2
5. Clean bore for bushings (2) in piston rod eye (3) and tube (4) eye.
Installation
1
4 2
1. Use an acceptable driver to press new bushings (2) into piston rod eye (3) until recessed 8 mm (0.315 inch). 2. Use an acceptable driver to install wipers (1) until flush with piston rod eye (3). The lips of the wipers (1) must be towards outside of bore.
2
3. Use an acceptable driver to press new bushings (2) into tube (4) eye until recessed 8 mm (0.315 inch). 4. Use an acceptable driver to install wipers (1) until flush with tube (4) eye. The lips of wipers (1) must be towards outside of bore.
1 BS03B201
1. WIPER 2. BUSHING
3. PISTON ROD EYE 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT BUCKET CYLINDERS
84547255A
Issued 11-11
Printed in E.C.
8013
Section 8013 RIDE CONTROL ACCUMULATOR
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8013-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 4 6
Printed in E.C.
8013-3
SPECIFICATIONS Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 7 Ride Control Accumulator Fluid Capacity............................................................................. 3.78 liters (230 cu. inch) Ride Control Accumulator Maximum Operating Pressure..............................................................280 bar (4061 psi)
SPECIAL TOOLS
94L95
380001737 NITROGEN ACCUMULATOR CHARGING KIT
84547255A
B786441M
380001738 GLAND WRENCH
Issued 11-11
Printed in E.C.
8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
E
C F
D
A
B
94L95
380001737 NITROGEN CHARGING KIT
1. Use the 380001737 Nitrogen Charging Kit to discharge the accumulator, refer to the illustration above. The tool must be disconnected from the nitrogen tank. 2. Close valves B, C and D. 3. Adjust the regulator A to the minimum pressure setting by turning the knob counterclockwise. 4. Turn the T-handle on valve F fully out. 5. Remove the guard and valve assembly cap from the accumulator.
7. Turn the T-handle inward on valve F to engage the pin in the valve stem. 8. Open valve D and check the charge pressure on gauge E. 9. To discharge the accumulator, partially open valve B. The accumulator charge will bleed down through the regulator. 10. Once the accumulator is fully discharged, disconnect valve F from the valve stem. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the accumulator.
84547255A
Issued 11-11
Printed in E.C.
8013-5
4
2
1
4
3
5
W230R026
1. CYLINDER 2. PISTON
3. GAS VALVE 4. END CAP
5. FLUID CONNECTION
RIDE CONTROL ACCUMULATOR ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
8013-6
CHARGING THE ACCUMULATOR WITH NITROGEN
1
2
6
5
3
4
GS98N801
1. VALVE C 2. TO NITROGEN TANK 3. VALVE A
4. VALVE B 5. VALVE D 6. TO ACCUMULATOR
NITROGEN CHARGING KIT 380001737
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar (450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration. IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high pressure (10 bar/150 psi and above) applications.
84547255A
Issued 11-11
Printed in E.C.
8013-7 1. Close the shutoff valve A by turning it all the way to the left (counterclockwise), refer to the illustration on page 6. 2. Open valve B by turning it out all the way to the left (counterclockwise). 3. Close valve C by turning it all the way to the right (clockwise). 4. Close the gauge valve D by turning it all the way to the right (clockwise). 5. Connect the charging hose to the nitrogen supply tank. 6. SLOWLY turn valve A clockwise while watching the high pressure gauge. Stop turning valve A when the needle on the gauge reaches 31 bar (450 psi). NOTE: If the needle goes over the needed pressure, quickly open and close valve D and check the pressure setting again. The charging kit is now ready to be installed on the accumulator. 7. Remove the valve cap from the pressure valve on the accumulator. 8. Back off the needle valve on the accumulator end of the charging hose by turning it counterclockwise to the maximum amount. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve. 9. Install the charging hose fitting onto the accumulator pressure valve. 10. Tighten the needle valve by turning it clockwise. Slowly open the gauge valve D and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.
84547255A
11. Open the shutoff valve A on the nitrogen supply tank. While observing the pressure on the gauge, slightly open the needle valve on the accumulator charge hose. By regulating the needle valve, fill the accumulator to pressure according to temperature chart below. Close the needle valve. Close the shutoff valve A on the nitrogen supply tank. TEMPERATURE 10° C 50° F 13° C 55° F 16° C 60° F 18° C 65° F 21° C 70° F 24° C 75° F 27° C 80° F 29° C 85° F 32° C 90° F 35° C 95° F 38° C 100° F
CHARGE PRESSURE 1636 KPA 237 PSI 1655 KPA 240 PSI 1674 KPA 243 PSI 1687 KPA 245 PSI 1706 KPA 248 PSI 1726 KPA 250 PSI 1745 KPA 253 PSI 1758 KPA 255 PSI 1777 KPA 258 PSI 1796 KPA 261 PSI 1815 KPA 263 PSI
TEMPERATURE/CHARGE PRESSURE RIDE CONTROL ACCUMULATOR
12. Close valve B by turning to the right (clockwise). After a few minutes, check the accumulator for leakage. 13. Back off the needle valve on the accumulator end of the charging hose by turning it counterclockwise the maximum amount. This will p re ve n t n itro g e n fro m esca p ing from th e accumulator as the hose is removed. Remove the charging hose from the accumulator pressure valve. 14. Install the valve cap onto the pressure valve on the accumulator. 15. Remove the charging hose from the nitrogen supply tank.
Issued 11-11
Printed in E.C.
8013-8
NOTES
84547255A
Issued 11-11
Printed in E.C.
8014
Section 8014 RIDE CONTROL VALVE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
8014-2
TABLE OF CONTENTS RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 4 4
Printed in E.C.
8014-3
RIDE CONTROL VALVE
5
6
7
4 8
2 1
3
9 10
11
12 BC06A224
1. 2. 3. 4.
Issued 11-11
PLUG CAP SCREW BUSHING SPRING CARRIER
Printed in E.C.
5. 6. 7. 8.
SPRING SPRING SPOOL PLUG
9. 10. 11. 12.
SOLENOID ORFICE POPPET ORFICE
84547255A
8014-4
Dissasembly
Assembly
STEP 1
STEP 1
Remove ride control valve, refer to section 8001.
Install new O-rings.
STEP 2
STEP 2
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
STEP 4
Install and torque accumulator drain screw to 20 Nm (177 lb-in).
Remove the spool (7) from the valve block.
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).
STEP 6
STEP 5
Remove orifice (10), poppet (11), and orifice (12).
STEP 7 Remove accumulator drain screw.
STEP 8 Remove the pressure relief valve.
Inspection 1. Discard all O-rings. 2. Clean all parts in cleaning solvent. 3. Check the spools and the spool bores for damage and wear. 4. Check the parts of the pressure relief valve. If any of the parts are damaged, install new parts.
Install and torque solenoid valve (9) to 12 Nm (106 lb-in).
STEP 6 Install springs (5 &6), spring carrier (4), bushing (3), cap screw (2) onto spool (7) and torque cap screw (2) to 23 Nm (203.5 lb-in).
STEP 7 Install spool (7) into valve block.
STEP 8 Install and torque plug (1) to 420 Nm (309.7 lb-ft).
STEP 9 Install plug (8) and torque to 330 Nm (243.3 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.
84547255A
Issued 11-11
Printed in E.C.
SECTION INDEX
MOUNTED EQUIPMENT Section Title
Section Number
Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant . . . . . . . . . . . . .9002 Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003 Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004 Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006 Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007 Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
COMPONENTS
1. 2. 3. 4. 5.
Rear Axle Brakes Front axle Brakes Parking Brake Brake Valve Parking Brake Accumulator 0.16 Liter (0.17 Quart) 97 BAR (1392 PSI) Precharge 6. Rear Brake Accumulator 3.5 Liter (3.69 Quart) 70 BAR (1015 PSI) Precharge 7. Redundant Accumulator Brake Pressure Switch
CIRCUIT DIAGRAM LEGEND
CIRCUIT COMPONENT
# SHOWS CIRCUIT CROSSING NOT CONNECTED
SHOWS CIRCUIT CONNECTED
COMPONENT NUMBER
LOAD SENSE CHECK VALVE
RESTRICTOR
FILTER OR SCREEN
OIL COOLER
LINE TYPES
8. Low Brake Pressure Warning Switch 9. Brake Declutch 10. Brake Light Pressure Switch 11. Front Brake Accumulator 3.5 Liter (3.69 Quart) 70 BAR (1015 PSI) Precharge 12. Redundant Accumulator Brake Pressure Switch 13. Brake Damping Accumulator 14. Axle Cooler 15. Pilot Control Valve 16. Bucket Cylinder Z BAR 17. Not Used
18. Lift Cylinders 19. Ride Control 20. Ride Control Accumulator 3.78 Liter (4 Quart) 10 BAR (145 PSI) Precharge 21. Pilot Control Accumulator 0.75 Liter (0.79 Quart) 13.8 BAR (200 PSI) Precharge 22. Loader Valve 23. Steering Cylinders 24. Steering Control Valve
25. 26. 27. 28. 29. 30. 31. 32.
Auxiliary Steering Pressure Switch Auxiliary Steering Control Valve Auxiliary Steering Pump Low Pressure Pump Cut Off 280 BAR (4061 PSI) Delta 25 BAR (362 PSI) Priority Valve High Pressure Pump Cut Off 280 BAR (4060 PSI) Delta 29 BAR (420.6 PSI) Brake Pump 100 MSH Strainers
33. Reservoir 34. Reservoir Vent 35. Filter 10 Micron Media Bypass 3.4 BAR (49.3 PSI) Warning Switch 2.7 BAR (39 PSI) 36. Oil Cooler Thermal Valve 37. Oil Cooler 38. Oil Cooler Fan 39. Fan Reversing and Variable Valve 40. Steering Back Pressure Valve 10 BAR (145 PSI)
CONVERSION INFORMATION 1 bar = 14.5 pounds per square inch (PSI) 1 liter per minute = 264 gallons per minute
HYDRAULIC SCHEMATIC W270C WHEEL LOADER
41. Steering Control Valve PVG 32 42. LS Joystick Steering Valve
COMPONENTS
1. 2. 3. 4. 5.
Rear Axle Brakes Front axle Brakes Parking Brake Brake Valve Parking Brake Accumulator 0.16 Liter (0.17 Quart) 97 BAR (1392 PSI) Precharge 6. Rear Brake Accumulator 3.5 Liter (3.69 Quart) 70 BAR (1015 PSI) Precharge 7. Redundant Accumulator Brake Pressure Switch
CIRCUIT DIAGRAM LEGEND
CIRCUIT COMPONENT
# SHOWS CIRCUIT CROSSING NOT CONNECTED
SHOWS CIRCUIT CONNECTED
COMPONENT NUMBER
LOAD SENSE CHECK VALVE
RESTRICTOR
FILTER OR SCREEN
OIL COOLER
LINE TYPES
8. Low Brake Pressure Warning Switch 9. Brake Declutch 10. Brake Light Pressure Switch 11. Front Brake Accumulator 3.5 Liter (3.69 Quart) 70 BAR (1015 PSI) Precharge 12. Redundant Accumulator Brake Pressure Switch 13. Brake Damping Accumulator 14. Axle Cooler 15. Pilot Control Valve 16. Bucket Cylinder Z BAR 17. Not Used
18. Lift Cylinders 19. Ride Control 20. Ride Control Accumulator 3.78 Liter (4 Quart) 10 BAR (145 PSI) Precharge 21. Pilot Control Accumulator 0.75 Liter (0.79 Quart) 13.8 BAR (200 PSI) Precharge 22. Loader Valve 23. Steering Cylinders 24. Steering Control Valve
25. 26. 27. 28. 29. 30. 31. 32.
Auxiliary Steering Pressure Switch Auxiliary Steering Control Valve Auxiliary Steering Pump Low Pressure Pump Cut Off 280 BAR (4061 PSI) Delta 25 BAR (362 PSI) Priority Valve High Pressure Pump Cut Off 280 BAR (4060 PSI) Delta 29 BAR (420.6 PSI) Brake Pump 100 MSH Strainers
33. Reservoir 34. Reservoir Vent 35. Filter 10 Micron Media Bypass 3.4 BAR (49.3 PSI) Warning Switch 2.7 BAR (39 PSI) 36. Oil Cooler Thermal Valve 37. Oil Cooler 38. Oil Cooler Fan 39. Fan Reversing and Variable Valve 40. Steering Back Pressure Valve 10 BAR (145 PSI)
CONVERSION INFORMATION 1 bar = 14.5 pounds per square inch (PSI) 1 liter per minute = 264 gallons per minute
HYDRAULIC SCHEMATIC W300C WHEEL LOADER
41. Steering Control Valve PVG 32 42. LS Joystick Steering Valve
9002
Section 9002 AIR CONDITIONING TROUBLESHOOTING AND SYSTEM CHECKS FOR SYSTEMS WITH HFC-134A REFRIGERANT
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
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
Printed in E.C.
9002-3
SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable, and easiest to work with of the refrigerants now used in air conditioner systems. Refrigerant HFC-134a does not contain any chlorofluorocarbons (CFCâ&#x20AC;&#x2122;s) which are harmful to the earthâ&#x20AC;&#x2122;s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury.
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.
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.
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.
84547255A
Issued 11-11
Printed in E.C.
9002-4
299L7C
BELT TENSION TOOL 380001325
A22094
REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION, 380001326
A22090 109L7
ELECTRONIC LEAK DETECTOR 380001327 SAFETY GOGGLES CAS-10073-3
84547255A
Issued 11-11
Printed in E.C.
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.
1
2
3 5 4
208L95
1. EXPANSION VALVE 2. EVAPORATOR
84547255A
3. COMPRESSOR 4. CONDENSER
5. RECEIVER-DRIER
Issued 11-11
Printed in E.C.
9002-6
TROUBLESHOOTING Perform a visual inspection of the machine. Check the following and correct as necessary: 1. - Obtain service history if possible.
5. - Are there heavy accumulations of oil, or oily dust around the fittings, indicating refrigerant leakage? 6. - Are air ducts undamaged, sealed properly and in position?
2. - Is compressor drive belt in place and tensioned? 3. - Are grille screens, fan blades, condenser, air filter, and evaporator unobstructed?
7. - Condensate drain hoses and check valves present and unobstructed?
4. - Are there any sharp bends or kinks in the hoses?
Problem: No Cooling Compressor Runs
No
Mechanical - See Mechanical Compressor Check Page 8 Electrical - See Blower and Compressor Clutch Check Page 9
Yes Internal System Problem See Pressure Testing, Page 13
84547255A
Issued 11-11
Printed in E.C.
9002-7
Problem: Not Enough Cooling
Problem: Erratic Cooling
MECHANICAL HEATER
See Mechanical Compressor Check Page 8.
Make sure the heater control is OFF and that there is no coolant flow through the heater core. ELECTRICAL See Blower and Compressor Clutch Check - Blower Motor Check, Blower Switch Check and Compressor Clutch Check on Page 9. SEAL Make sure the sealing material is correctly in place. INTERNAL SYSTEM PROBLEMS See Pressure Testing, Page 13. MECHANICAL See Mechanical Compressor Check page 8. See Evaporator Heater Core Check Page 12.
Problem: System Makes Noise
ELECTRICAL See Blower and Compressor Clutch Check on Page 9. MECHANICAL See Mechanical Compressor Check Page 8. See Blower Motor Check Page 9. REFRIGERANT See Cab Temperature Check Page 10. ELECTRICAL See Compressor Clutch Check Page 9. INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.
INTERNAL SYSTEM PROBLEM See Pressure Testing, Page 13.
84547255A
Issued 11-11
Printed in E.C.
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.
84547255A
Issued 11-11
Printed in E.C.
9002-9
Blower and Compressor Clutch Check NOTE: Check supply voltage with compressor lead plugged in and engaged. Voltage drops will not be apparent without current flow. Compressor Clutch
1. If there is electrical system voltage to the clutch, check for excessive voltage drop in the ground circuit, then see Section 9004 and replace the compressor.
Low and High Pressure Switches
1. See Section 4002 and check the high and low pressure switches.
Blower Fuse (10 amp)
1. Check for damaged blower fuse.
Blower Fan Switch
1. Check switch operation. Switch must give four different blower speeds: OFF, Low, High, and Purge. 2. Check for loose connections or broken wires. Repair or replace as necessary. 3. Check resistor board.
Blower Motor
1. Check the wiring to the blower motor. Make repairs or replace items as necessary. 2. Check motor ground wire. Make sure motor ground wire is making good contact with mounting bracket.
1. With key in ON position, turn switch to maximum cold. Compressor clutch must engage.
Temperature Control Switch
84547255A
NOTE: Blower must be operating, since electrical power to temperature control switch is received from blower switch. 2. Turn the blower off. Disconnect the wires from the temperature control. Using an ohmmeter, check the continuity between switch terminals. If continuity is not present when switch is on maximum cold, replace switch.
Issued 11-11
Printed in E.C.
9002-10
Cab Temperature Check Air Louvers
1. Make sure louvers and recirculation vents are fully open for most efficient air conditioning operation. Defrost louvers must be closed. 2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses become very hot. Check temperature by slowly reaching for hose and touching briefly several times with finger tips, increasing the duration with each touch. Air Conditioning
1. Feel the air conditioning hoses. The high pressure hoses (small line) must be warmer than the low pressure hose (large line). 2. If no temperature difference, the system is low on refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and run the compressor for five minutes to make temperature stable. Refer to page 12. 2. Duct temperature must be below 25° C (72° F) if the system is operating at maximum efficiency. Duct Temperature
Temperature Sensing Probe Check
84547255A
NOTE: Ambient temperature must be 27 to 43° C (80 to 110° F). 3. If temperature is above 25° C (72° F), system is low on refrigerant, there is a restriction in the system, compressor is not working correctly, or air ducts are not sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON and temperature control switch turned fully clockwise. 2. Remove the temperature sensing probe from the evaporator. Refer to Section 9004. 3. Put the end of the temperature sensing probe in a container with ice and water. 4. When the sensing tube has cooled to the temperature of the ice and water mixture, the temperature control switch should interrupt the current flow to the compressor. Check for current at the control switch terminals as on previous page. If current is not interrupted then replace the control switch.
Issued 11-11
Printed in E.C.
9002-11
Visual and Leak Check Compressor Hoses
1. Make sure that all hose connections are tight. 2. Check hoses for bends or cracks. Replace all hoses that have damage.
1. Shut off the engine. WARNING: When refrigerant comes in contact with an open flame, it can form dangerous gas. Never breathe these fumes. 2. Use electronic leak detector 380001327 to inspect all connections. Use instructions from manufacturer of leak finding tool. 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.
Condenser
84547255A
1. Make sure the condenser is clean and the seals are in place. Make sure condenser fans run when temperature control switch is ON.
Issued 11-11
Printed in E.C.
9002-12
Evaporator/Heater Core Check Make sure heater valve is closed
Evaporator/Heater Core
Evaporator/Heater Core
1. See Section 9004 for access to the evaporator/heater core. 2. Inspect the fins on the evaporator/heater core. All the fins that have bends or damage must be made straight. 3. Inspect the evaporator/heater core for restrictions. If the core is dry, use compressed air or a brush and vacuum cleaner. If the core is wet or filled with mud, flush the core with water using a hose without pressure. Make sure the water drains freely from the evaporator/heater core. DO NOT USE STEAM. WARNING: Do not steam clean any air conditioning systems parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode.
Evaporator/Heater Core Sealing
1. See Section 9004 for access to the evaporator/heater core. 2. Make sure seals are in place so blower will pull air only through the evaporator/heater core and not around the evaporator/heater core.
Filters
1. Make sure the filters are clean.
84547255A
Issued 11-11
Printed in E.C.
9002-13
PRESSURE TESTING Manifold Gauge Set NOTE: The gauge set is not accurate enough to optimize an existing charge of HFC-134a. The best use of the gauge set is to determine whether undercharge or overcharge exists, and then evacuate, reclaim and recharge system with the recommended quantity (charge) of HFC-134a. The manifold gauge set is the most important tool used to service the air conditioning system. The manifold gauge set is used to measure the high and low pressures of the system, as a tool to troubleshoot for correct refrigerant charge quantity, system diagnosis, and operating efficiency. The manifold gauge set can read both the high (discharge) and low (suction) sides at the same time, since pressure must be compared in order to make a diagnosis of system operation.
During normal operation the low pressure gauge must always indicate from 10 to 35 psi (0.7 to 2.4 bar) after the system has run 10 to 15 minutes. HIGH PRESSURE GAUGE - The high pressure gauge is used to indicate pressures in the high side of the system. The gauge must indicate from 0 to 400 psi (0 to 27.6 bar) minimum. During normal operation, the high pressure gauge will normally indicate from 120 to 310 psi (8.3 to 21.4 bar). See pressure-temperature chart on page 14.
Pressure Test Connection Connect the manifold gauge set into the air conditioning system as shown. Make sure that both valves in the manifold gauge set are closed.
LOW PRESSURE GAUGE - The low pressure gauge is a compound gauge. It is best used to judge evacuation effectiveness. A vacuum reading indicates a system malfunction. For this reason, it is necessary to use a compound gauge that will indicate both pressure and vacuum.
84547255A
Issued 11-11
Printed in E.C.
9002-14
PRESSURE-TEMPERATURE CHART AIR LOUVER (BEHIND SEAT) MAXIMUM TEMP. TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION 째F (째C) psi (bar) psi (bar) 째F (째C) AMBIENT
NORMAL LOW
NORMAL HIGH
80 (27)
9 to 12
145 to 165
(0.62 to 0.83)
(10 to 11.53)
11 to 15
190 to 210
(0.76 to 1.04)
(13.10 to 14.48)
16 to 18
210 to 230
(1.10 to 1.24)
(14.48 to 15.86)
17 to 19
235 to 255
(1.17 to 1.31)
(16.2 to 17.58)
20 to 21
260 to 280
(1.38 to 1.45)
(17.93 to 19.31)
22 to 24
290 to 310
(1.93 to 2.14)
(20 to 21.37)
90 (32) 95 (35) 100 (38) 105 (41) 110 (43)
The pressure-temperature chart is based on the following conditions: NOTE: High humidity will cause higher air louver temperatures and dramatic increase in suction pressure. The table shown represents readings taken in low relative humidity. Adjust the chart according to local conditions.
55 (14) 61 (18) 63 (20) 66 (22) 68 (23) 72 (25)
2. All panels and access doors installed and closed. 3. Cab filters clean and installed. 4. Heater valve at engine closed. 5. Measurements taken 15 minutes after startup.
1. Engine at 1500 RPM, no load, fan speed & temperature control at max setting, A/C switch ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART PROBLEM
LOW PRESSURE GAUGE
HIGH PRESSURE GAUGE
SEE PAGE
NO COOLING
VERY LOW
VERY LOW
16
NO COOLING
HIGH
HIGH
17
NOT ENOUGH COOLING
NORMAL TO HIGH
NORMAL
19
NOT ENOUGH COOLING
LOW
LOW
20
NOT ENOUGH COOLING
HIGH
LOW
22
NOT ENOUGH COOLING
HIGH
HIGH
23
INTERMITTENT COOLING
NORMAL
NORMAL
24
NOISE IN SYSTEM
NORMAL TO HIGH
HIGH
25
84547255A
Issued 11-11
Printed in E.C.
9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS STEP 1
STEP 4
Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.
Connect the hose from the high pressure gauge to the port on the discharge hose.
WARNING: Do not steam clean any air conditioning system parts while the system is charged. The heat will cause the refrigerant to rise to a pressure that could cause the system to explode. SM104A
WARNING: Always wear safety goggles when working with liquid refrigerant. Liquid refrigerant in your eyes could cause blindness. SM105A
STEP 5
STEP 2
Make sure the charging station manifold gauge valves are in the closed position.
Connect the hoses from the test gauges to the service ports by turning the knurled knobs on the depressors.
STEP 6
STEP 3 Connect the hose from the low pressure gauge to the port on the suction hose.
84547255A
Start the engine and run at 1500 RPM maximum speed. Operate the air conditioner system at maximum cooling setting and blower speed for 15 minutes with the cab door open. Observe the test gauges and check the chart on page 13 against the gauge readings.
Issued 11-11
Printed in E.C.
9002-16
PROBLEM: NO COOLING
VERY LOW
VERY LOW
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Indication of No Refrigerant or Low Refrigerant Charge: 1. Leak test the system, see Page 11. It may be necessary to add refrigerant. See Section 9003. 2. Evacuate and reclaim remaining refrigerant from system. See Section 9003. 3. Repair system leaks as needed. Follow the given repair procedure. A. Discharge air from evaporator warm. B. Compressor does not run, or cycles off rapidly after start-up. (A/C warning light in cab should illuminate).
Yes
4. Check level of oil in compressor - possible for compressor to have an oil loss. 5. Remove air and moisture from the system. Replace Receiver-Drier. See Section 9004. 6. Charge system with new refrigerant. See Section 9003. 7. Continue performance test for other possible problems.
84547255A
Issued 11-11
Printed in E.C.
9002-17
HIGH
HIGH
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Indication of Large Quantity of Air in System: 1. Evacuate and reclaim refrigerant from system. See Section 9003. 2. Replace receiver-drier. Discharge air from evaporator warm
Yes
3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.
Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine fan belt and proper condenser fan operation. 2. Check to see that condenser is clean and unobstructed and that the fins are straight. 3. Check system for too much refrigerant. Evacuate, reclaim and recharge refrigerant until gauge pressure is normal. See Section 9003. A. Liquid line (between evaporator and condenser) is very hot. B. Discharge air from evaporator warm.
4. Remove and check condenser for restrictions caused by oil or reduced heat transfer. A. Remove refrigerant from the system. See Section 9003. B. Use compressed air condenser.
to
remove oil from
C. Replace receiver-drier. D. Remove moisture and charge the system. See section 9003. 5. Continue the performance test for other possible problems.
84547255A
Issued 11-11
Printed in E.C.
9002-18
Expansion Valve Malfunctioning - Indications: A. Discharge air from heater/evaporator warm. B. Much condensation on suction hose at compressor. C. Much condensation outlet.
on
See Section 9004 and replace the expansion valve.
evaporator
Refrigerant Contamination: 1. See table below and check stable saturation pressures at given temperature to determine if contamination exists. A. Measure pressure from gauge on reclamation unit. B. Measure temperature from refrigerant in reclamation tank. If refrigerant has been in reclamation unit for some time, use ambient temperature. The numbers in the table represent the boiling point for HFC-134a.
Refrigerant Contamination
C. Pressure readings below range given in chart indicate contaminated refrigerant. IMPORTANT: Do not use contaminated refrigerant or mix with uncontaminated refrigerant. Dispose of in accordance with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart Temperature 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)
84547255A
Issued 11-11
Printed in E.C.
9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO SLIGHTLY HIGH
NORMAL
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Air in the System - Indications: 1. Test system for leaks. See page 11. Possible leak has let air enter; check compressor seal carefully. 2. Discharge system of refrigerant. See Section 9003. A. Suction line warm to your hand.
3. Repair system leak as necessary.
B. Discharge air from heater/evaporator only a little cool.
4. Replace receiver-drier. 5. Check compressor oil level. 6. Remove air and moisture from the system. See Section 9003. 7. Charge system with new refrigerant. See Section 9003.
84547255A
Issued 11-11
Printed in E.C.
9002-20
LOW
LO W
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Not Enough Refrigerant - Indications: 1. Leak test system - system has a loss of refrigerant. NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7 to 29.5 grams) of refrigerant between seasons. A. If leak is found, go to Step 2. B. If no leak is found, go to Step 6. 2. Discharge refrigerant from system. See Section 9003. A. Discharge air from evaporator cool or warm - not cold.
3. Repair system leaks as needed. 4. Check oil level in compressor - It is possible for compressor to lose oil. 5. Remove air and moisture from the system. Replace Receiver-Drier. See Section 9004. 6. Charge system with new refrigerant. See Section 9003.
High Side Restriction - Indications: A. Discharge air from heater/evaporator only a little cool. B. Condensation receiver-drier.
or
frost
on
C. Liquid line to receiver-drier cool, with frost or condensation. NOTE: The frost will form downstream from or at the point of the restriction
84547255A
1. Discharge refrigerant from system-restriction in receiver-drier or liquid line must be removed. 2. Remove and replace part with restriction. 3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.
Issued 11-11
Printed in E.C.
9002-21
Expansion Valve Not Operating - Indications: A. Discharge air from evaporator warm or cool - not cold. B. Condensation or frost on expansion valve outlet. C. Inlet end of expansion valve is warm.
84547255A
1. Expansion valve outlet with condensation or frost is an indication of a restriction in the expansion valve. Replace expansion valve. See Section 9004. 2. Inlet end of expansion valve is warm (not hot), indicating expansion valve is not completely open. If the valve is stuck closed, there will be little or no flow of refrigerant through the valve. Replace expansion valve. See Section 9004.
Issued 11-11
Printed in E.C.
9002-22
HIGH
LOW
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Compressor Turning But Not Pumping Properly - Indications: 1. Discharge refrigerant from system. See Section 9003. 2. Remove the compressor from the machine. See Section 9004. 3. Remove and replace compressor because there is indication of internal leak in compressor. A. System is fully charged.
4. Replace compressor.
B. Cool discharge air from evaporator.
5. Replace receiver-drier if: A. System has been opened before. B. Receiver-drier has been used two or more years. See Section 9004 for receiver-drier replacement. 6. Charge the system with refrigerant. See Section 9003.
Expansion Valve Stuck Open Expansion Valve Stuck Open
84547255A
1. Replace expansion valve. See Section 9004.
Issued 11-11
Printed in E.C.
9002-23
HIGH
HIGH
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and proper condenser fan operation. 2. Check to see that condenser is clean and that the fins are straight. 3. Check system for too much refrigerant. A. Remove refrigerant from system until gauge pressure is below normal. See Section 9003. A. Liquid line very hot. B. Discharge air from evaporator warm.
B. Add refrigerant until gauge pressures are normal. See Section 9003. C. If there is still a problem, do step 4. 4. Remove and inspect condenser for restrictions caused by oil or reduced heat transfer. A. Discharge refrigerant from system. See Section 9003. B. Use compressed air to remove oil from condenser. C. Replace receiver-drier. See Section 9004.
Air in the System - Indications: 1. Discharge refrigerant from system. See Section 9003. 2. Replace receiver-drier. Warm discharge air from evaporator.
3. Remove air and moisture from the system. See Section 9003. 4. Charge system with new refrigerant. See Section 9003.
84547255A
Issued 11-11
Printed in E.C.
9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL
NORMAL
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Moisture in the System - Indications: 1. Discharge system of refrigerant. If too much moisture enters the orifice of the expansion valve, the freezing of this moisture can stop refrigerant flow. See Section 9003.
Cooling is acceptable during cool part of day but not acceptable during hot part of day.
2. Replace receiver-drier. The moisture removing material could be full to capacity with moisture. See Section 9004. 3. Remove air and moisture from the system. See Section 9003. NOTE: The time needed to remove a large amount of moisture will be two to three hours minimum. 4. Charge system with new refrigerant. See Section 9003.
84547255A
Issued 11-11
Printed in E.C.
9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL TO HIGH
HIGH
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
476L7
Too Much Refrigerant in System - Indications: A. Cool discharge air from heater/evaporator. B. Compressor makes noise.
84547255A
1. Remove refrigerant from system until gauge readings are below normal. See Section 9003. 2. Add new refrigerant until gauge readings are normal. See Section 9003.
Issued 11-11
Printed in E.C.
9002-26
TUBE CONNECTIONS TORQUE CHART TUBING SIZE
3/8 inch
1/2 inch
5/8 inch
THREAD SIZE
M10 -1.25
5/8-18
3/4-18 OR 3/4-16
7/8-18 OR 7/8-14
1-14
STEEL TO STEEL
31-36 Nm
31-36 Nm
40-46 Nm
45-52 Nm
45-52 Nm
ALUMINUM TO BRASS
10-14 Nm
10-14 Nm
24-30 Nm
30-37 Nm
45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used. IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator since these connections are easily distorted.
84547255A
Issued 11-11
Printed in E.C.
9003
Section 9003 AIR CONDITIONER SYSTEM SERVICE
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
9003-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 5 7 10
Printed in E.C.
9003-3
SPECIFICATIONS Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)
SPECIAL TOOLS
A22094
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING STATION 380001326
84547255A
109L7
SAFETY GOGGLES CAS-10073-3
Issued 11-11
Printed in E.C.
9003-4
SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be RECOVERED and RECYCLED when removed from a system during servicing. Refrigerant HFC-134a is the most stable and easiest to work with of the refrigerants now used in air conditioning systems. Refrigerant HFC-134a does not contain chlorofluorocarbons (CFCâ&#x20AC;&#x2122;s) which are harmful to the Earthâ&#x20AC;&#x2122;s ozone layer. Safety procedures must be followed when working with refrigerant HFC-134a to prevent possible personal injury.
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.
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.
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.
84547255A
Issued 11-11
Printed in E.C.
9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY Recovered refrigerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it.
STEP 3
If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD03A213
Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports on the suction and pressure hoses.
STEP 2 A22107
Make certain the refrigerant tank gas and liquid valves are open.
BD03B001
With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports. Connect the hose from the low pressure gauge to the port on the suction hose. Turn in valve depressor. Connect the hose from the high pressure gauge to the port on the discharge hose. Turn in valve depressor.
84547255A
Issued 11-11
Printed in E.C.
9003-6
STEP 5
STEP 7
A22112
A22110
Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the recovery start switch.
Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely.
The compressor will shut OFF automatically when recovery is complete. Wait for 5 minutes and observe the manifold pressure gauges for a pressure rise. If pressure rises above 0 psi (0 bar), depress the hold/cont switch. Then wait for the compressor to automatically shut OFF.
STEP 8
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil equal to the amount in the reservoir.
STEP 9 A22108
Drain the oil separator of the A/C system oil. Open the air purge valve long enough to let some of the compressor discharge pressure back into the separator.
BD03A213
Remove the hoses from the service ports and install the caps.
84547255A
Issued 11-11
Printed in E.C.
9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING IMPORTANT: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system. A. The system has been opened for service before. B. Receiver-drier has operated two or more years. C. Disassembly of compressor shows small particles of moisture removing material (gold or brown particles).
Air and moisture are removed from the system by a vacuum pump. A vacuum pump is the only equipment made to lower the pressure enough to change the moisture to vapor that can be removed from the system. NOTE: Refer to the vacuum pump manufacturer’s user manual for additional information.
STEP 11
D. Large system leak (broken hose, break in line). E. Too much air or moisture in system. F. Removal of compressor caused the system to be open (uncapped) longer than 5 minutes.
STEP 10 A22113
Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the vacuum key. Program a minimum of 45 minutes and press the Enter key. The display will flash once indicating the programmed data has been accepted.
STEP 12 BD03B001
With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports as follows: 1. Connect the hose from the low pressure gauge to the port on the suction hose. 2. Connect the hose from the high pressure gauge to the port on the discharge hose. 3. Turn in both thumbscrews to depress the service valves. Removal of air and moisture from the system is necessary after the refrigerant has been removed after the system has been opened for maintenance. Air enters the system when the system is opened. Air has moisture that must be removed to prevent damage to the system components.
A22115
Press the Charge key. “Program” and “Charge” will appear on the display.
NOTE: The pump on the reclamation unit will not pull a sufficient vacuum to remove air and moisture.
84547255A
Issued 11-11
Printed in E.C.
9003-8
STEP 13
STEP 16
A22113
A22123
Program 3.5 lbs and press the enter key. The display will flash once indicating the programmed data has been accepted.
Press the Vacuum key. “Automatic” will appear on the display. Vacuum will appear on the display and after a slight delay, the vacuum pump will start. The display will show the amount of time programmed and begin a countdown to zero.
STEP 14
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.
STEP 17
STEP 15
A22113 A22107
Open the red (vapor) and blue (liquid) valves on the tank.
84547255A
Press the charge key to begin refrigerant charging. “Automatic” and “Charge” will appear on the display. The display shows the programmed amount and counts down to zero as charging proceeds. When charging is completed, the display shows “CPL”.
Issued 11-11
Printed in E.C.
9003-9
STEP 18
STEP 21
A22114
BD03B001
Completely close the high and low pressure manifold valves.
Stop the engine, close any open valves and carefully remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual before performing Step 19 to avoid damaging the recovery unit. The pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the valves accidently open or if either or both valves are opened while the A/C system is operating.
STEP 22
STEP 19 Start the engine and run at 1500 RPM. Operate the air conditioner system at maximum cooling setting and blower speed with the doors and windows open. NOTE: The compressor will not operate if the system pressure is too low or too high. The pressure indicator lamp will illuminate when the relay is actuated by a low or high pressure and the compressor clutch will disengage. To restart the compressor, the air conditioner control or blower switch must be turned to the OFF position and then to the ON position.
BD03B213
Install the caps on the service ports on the suction and discharge hoses.
STEP 20
A22117
Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system. See chart on Page 9002-9 for temperature and pressure variations.
84547255A
Issued 11-11
Printed in E.C.
9003-10
PRESSURE - TEMPERATURE CHART AMBIENT NORMAL LOW NORMAL HIGH TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION psi (bar) 째F (째C) psi (bar)
AIR LOUVER MAXIMUM TEMP. 째F (째C)
80 (27)
9 to 12 (0.62 to 0.83)
145 to 165 (10 to 11.5)
55 (14)
90 (32)
11 to 15 (0.76 to 1.04)
190 to 210 (13.1 to 14.5)
61 (18)
95 (35)
16 to 18 (1.10 to 1.24)
210 to 230 (14.5 to 15.8)
63 (20)
100 (38)
17 to 19 (1.17 to 1.31)
235 to 255 (16.2 to 17.6)
66 (22)
105 (41)
20 to 21 (1.38 to 1.45)
260 to 280 (17.9 to 19.3)
68 (23)
110 (43)
22 to 24 (1.93 to 2.14)
290 to 310 (20 to 21.4)
72 (25)
The pressure-temperature chart is based on the following conditions: 1. Engine operating at 1500 RPM 2. No engine load 3. Fan speed control in maximum position and all louvers open.
5. Both cab doors open 6. All panels and access doors installed and closed. 7. Cab filters clean and installed. 8. Heater valve at engine closed. 9. Measurements taken 15 minutes after start-up.
4. Cab temperature control set to maximum cooling.
84547255A
Issued 11-11
Printed in E.C.
REMOVAL AND INSTALLATION OF AIR CONDITIONING AND HEATER COMPONENTS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 4 5 5 6 8 9 14 19 19 20
Printed in E.C.
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 (CFCâ&#x20AC;&#x2122;s) which are harmful to the earthâ&#x20AC;&#x2122;s ozone layer. Safety procedures must be followed when working with Refrigerant HFC-134a to prevent possible personal injury. 1. Always wear safety goggles when doing any service work near an air conditioner system. Liquid refrigerant getting into the eyes can cause serious injury. Do the following if you get refrigerant near or in your eyes: A. Flush your eyes with water for 15 minutes.
3. Keep refrigerant containers in the correct upright position. Always keep refrigerant containers away from heat and sunlight. The pressure in a container will increase with heat. 4. Always reclaim refrigerant from the system if you are going to weld or steam clean near the air conditioner system. 5. Always check the temperature and pressure of the air conditioner system before reclaiming refrigerant and when you test the system. 6. Dangerous gas can form when refrigerant comes in contact with an open flame. Never permit fumes to be inhaled. 7. Never leak test with compressed air or flame testers. Tests have indicated that compressed mixtures of HFC-134a and air can form a combustible gas. 8. Always reclaim refrigerant from the system before removing any air conditioning component.
B. See a physician immediately. 2. A drop of liquid refrigerant on your skin may cause frostbite. Open the fittings carefully and slowly when it is necessary to service the air conditioner system. Your skin must be treated for frostbite or a physician must be seen if you get refrigerant on your skin.
84547255A
Issued 11-11
Printed in E.C.
9004-4
SPECIAL TOOLS
A22094
REFRIGERANT RECOVERY, RECYCLING AND CHARGING STATION 380001326
84547255A
BS03H012
SAFETY GOGGLES CAS-10073-3
Issued 11-11
Printed in E.C.
9004-5
COMPRESSOR Removal
STEP 4
STEP 1 Place the master disconnect switch in the OFF position.
STEP 2 Discharge the air conditioning system according to the instructions in Section 9003.
STEP 3 BD06F117
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.
W270R591
Remove the fan belt.
84547255A
Issued 11-11
Printed in E.C.
9004-6
Installation
STEP 5
STEP 8 Place the compressor into position on the machine.
STEP 9
BD06F117
Disconnect the compressor clutch wire from the engine harness assembly.
STEP 6 BD06F117
Install the three bolts to mount the compressor.
STEP 10
BD06F117
Loosen and remove the three compressor mounting bolts.
STEP 7 Remove the compressor from the machine.
84547255A
BD06F117
Connect the compressor clutch wire to the engine harness assembly.
Issued 11-11
Printed in E.C.
9004-7
STEP 11
STEP 12 Carefully remove the protective cap, install a new O-ring, and connect the low pressure line to the suction port on the compressor.
STEP 13 Install the belt.
STEP 14 Install the protective shield.
STEP 15 BD06F117
Charge the air conditioning system according to the instructions in Section 9003.
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.
84547255A
Issued 11-11
Printed in E.C.
9004-8
EXPANSION VALVE, EVAPORATOR/HEATER CORE, HEATER VALVE, BLOWERS 3
6
5
7
4 2 1 8
9
10
18 17 12
14
11
13
16
15
BS06G118
1. 2. 3. 4. 5. 6.
84547255A
EVAPORATOR UPPER BOX PPE COVER PPE SOLENOID DRIVER UPPER BOX BOLT
7. 8. 9. 10. 11. 12.
WASHER GROMMET HEATER CORE HEATER VALVE 24V THERMOSTAT LOWER BOX
13. 14. 15. 16. 17. 18.
LOWER BOX PPE EXPANSION VALVE BLOWER RECIRCULATING VAIN RECIRCULATING MOTOR RESISTOR BLOWER MOTOR
Issued 11-11
Printed in E.C.
9004-9
Removal
STEP 21
STEP 16 Park the machine on a level surface and lower the bucket to the floor.
STEP 17 If changing any air conditioning components, discharge the air conditioning system according to the instructions in Section 9003.
STEP 18 BD06G202
Remove the four bolts that fasten the operatorâ&#x20AC;&#x2122;s seat to the upper box, remove the seat from the machine.
STEP 22
W270R571
If changing the heater core, put a 37 liter (10 gallon) container below radiator drain. Remove radiator cap. Remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.
BD06G212
Open the cover on the cooler.
STEP 23
STEP 19 Place the master disconnect in the OFF position.
STEP 20 Disconnect the wiring harness from the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option).
BD06G213
Remove the four screws securing the air vent, remove the vent cover.
84547255A
Issued 11-11
Printed in E.C.
9004-10
STEP 24
STEP 28 Place the air selector on the control panel to outside air. NOTE: In step 29 and 32 the upper box is shown removed for clarity only, these steps must be done prior to removing the upper box.
STEP 29
BD06G214
Remove the three screws securing the cooler to the cab, remove the cooler.
STEP 25 Fold the rubber mat over to gain access to the upper box mounting bolts.
BD06G217
G o i n g t h r o u g h t h e i n s i d e f i l t er a re a f e e l t he recirculating vain to make sure is is in the outside air, “closed”, position.
STEP 26
STEP 30
BD06G215
Remove the six bolts securing the upper box.
STEP 27
BD06G218
The above photo shows that the recirculating vain is not in the outside air “closed” position.
STEP 31
BD06G216
Remove two screws, one on each side of the upper box, securing the upper box to the lower box. BD06G240
Use a screw driver and disconnect the linkage. 84547255A
Issued 11-11
Printed in E.C.
9004-11
STEP 32
STEP 35
BD06G219
Close the vain so the upper cover can be removed.
BD06G203
Disconnect the solenoid driver.
STEP 33 Remove the upper box up and rest it against the console.
STEP 36
NOTE: The wiring harness for the HVAC system goes through the upper cover, by resting the cover against the console the wiring harness will not need to be removed.
STEP 34
BD06G236
Remove the upper PPE from the heater and air conditioning cores. NOTE: If testing on the electrical components are required the solenoid driver can be reconnected once the upper PPE is removed.
BD06G220
Pull the wiring harness loose from the upper PPE.
84547255A
Issued 11-11
Printed in E.C.
9004-12 NOTE: If replacing the heater control valve, heater core, air conditioning expansion valve, air conditioning evaporator core do steps 37 through 46, if replacing electrical components go to step 47.
STEP 39
STEP 37
BD06G206
Remove the thermostat probe and clamp from the evaporator core.
STEP 40 BD06G204
Remove the right side cab skirt.
STEP 38 2
3
1
BD06G237
Disconnect the electrical connectors from the thermostat control.
STEP 41 BD06G205
1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES
Fasten identification tags on the hoses. Disconnect the hoses for the heater core and evaporator core, install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater control valve.
84547255A
Issued 11-11
Printed in E.C.
9004-13
STEP 42
STEP 48
Pull the heater core and evaporator core from the lower box PPE.
STEP 43 Remove the expansion valve from the evaporator core.
STEP 44 Remove and discard the O-rings from the openings in the expansion valve.
STEP 45 Remove the screws from the heater core and remove the control valve.
STEP 46 Remove and discard the O-rings from the heater control valve.
STEP 47
BD06G208
Disconnect the electrical connector for the recirculating vain motor, disconnect the linkage from the vain. Remove the mounting screws and remove the motor.
STEP 49 1
2
3
1 3 2 BD06G209 BD06G207
1. RESISTORS 2. RESISTOR CONNECTOR 3. BLOWER MOTOR CONNECTOR
Remove the fans from the lower PPE, disconnect the electrical connectors. Remove the two mounting screws for the resistor, remove the resistor.
84547255A
1. FAN SPEED AND A/C SWITCH 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH 3. THERMOSTAT
Remove the switch panel from the console. Disconnect the electrical connectors and remove switches as required.
Issued 11-11
Printed in E.C.
9004-14
Installation
STEP 52
STEP 50 1
2
1 3 3 2
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
Install the resistor, install the two mounting screws and tighten. Install the fans in the lower PPE, connect the electrical connectors.
STEP 53 Install new O-rings on the heater control valve.
STEP 51
STEP 54 Install the control valve, install and tighten the screws to the heater core.
STEP 55 Install new O-rings on the openings of the expansion valve.
STEP 56 Install the heater core and evaporator core into the lower box PPE. BD06G208
STEP 57
Install the motor and install the mounting screws and tighten. Connect the electrical connector for the recirculating vain motor, connect the linkage to the vain.
BD06G236
Connect the electrical connectors to the heater control valve.
84547255A
Issued 11-11
Printed in E.C.
9004-15
STEP 58
STEP 60 3
2
1
BD06G237
Connect the electrical connectors to the thermostat control.
STEP 59
BD06G205
1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES
Remove the plugs from the hoses and the caps from the fittings. Install new O-rings in the evaporator fittings, connect the heater and evaporator hoses. Remove and discard identification tags that were used during disassemble.
STEP 61
BD06G206
Install the thermostat probe coil and clamp to the evaporator core â&#x20AC;&#x153;coldâ&#x20AC;? tube.
BD06G204
Install the right side cab skirt.
STEP 62
BD06G238
Install the upper PPE on the heater and air conditioning cores. 84547255A
Issued 11-11
Printed in E.C.
9004-16
STEP 63
STEP 66
BD06G210. BD06G203
Connect the solenoid driver.
Make sure that the recirculating vain is in the closed position. IMPORTANT: This photo shows it in the open position and the upper box will not go back into position without damaging the recirculating vain.
STEP 64
STEP 67
BD06G239
Push the wiring harness into the preformed notches in the upper PPE.
STEP 65 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 68
BD06G216
Install two screws, one on each side of the upper box securing the upper box to the lower box.
84547255A
Issued 11-11
Printed in E.C.
9004-17
STEP 69
STEP 73
BD06G242
BD06G214
Install the insolation panel in the center of the upper box.
Install and tighten the three screws securing the cooler to the cab.
STEP 70
STEP 74
BD06G215
BD06G213
Install and tighten the six bolts securing the upper box.
Install the vent cover, install and tighten the four screws securing the air vent.
STEP 71
STEP 75
BD06G243
Install the right rear floor mat into the cab, if machine is equipped with air ride seat make sure to pull the wiring up above the mat for the seat.
BD06G202
Install and torque the four bolts to 73 to 87 Nm (55 to 65 pound-feet).
STEP 72 Install the remainder of the floor mat.
84547255A
Issued 11-11
Printed in E.C.
9004-18
STEP 76
STEP 78
Connect the wiring connector to the operatorâ&#x20AC;&#x2122;s seat (if equipped with air seat option).
Charge the air conditioning system according to the instructions in Section 9003.
STEP 77 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.
84547255A
Issued 11-11
Printed in E.C.
9004-19
CONDENSER AND RECIEVER DRIER Removal
STEP 83
STEP 79 Park the machine on a level surface and lower the bucket to the ground.
STEP 80
W270R597
Fasten identification tags on the hoses and disconnect the hoses from the condenser.
1
STEP 84 Install plugs in the hoses and caps on the fittings. W270R118
STEP 85
Raise the hood using controls located behind the access cover. Open the frame (1) of the engine cooling system.
1 2
STEP 81 Place the master disconnect switch in the OFF position.
STEP 82 Discharge the air conditioning system according to the instructions in Section 9003.
3
W270R598
Loosen the bolts that fasten the condenser to the frame cooling (1) and remove the bolts (2), washers (3) and condenser.
84547255A
Issued 11-11
Printed in E.C.
9004-20
Installation
STEP 86
STEP 89 Put the condenser in position on the bracket.
STEP 90 1 2
3
W270R598
Install the washer (3) and bolts (2) that fasten the condenser to the frame cooling (1) and tighten the bolts. W270R599
Fasten identification tags on the hoses and disconnect the hoses from the receiver drier.
STEP 91
STEP 87 Install plugs in the hoses and caps on the fittings.
STEP 88
W270R597
W270R600
Remove the plugs from the hoses and the caps from the fittings. Install new O-rings and connect the hoses to the fittings. Remove and discard identification tags that were used during disassemble.
Disconnect the trinary switch, remove the mounting bolt, remove the receiver drier and bracket. 84547255A
Issued 11-11
Printed in E.C.
9004-21
STEP 92
STEP 94
Pivot the condenser down and close the cover.
STEP 93
W270R599 W270R600
Mount the receiver drier and bracket, install and tighten the mounting bolt.
Remove plugs from the hoses and caps from the fittings, install new O-rings and connect the hoses to the fittings, connect the trinary switch. Remove and discard identification tags that were used during disassemble.
STEP 95 Charge the air conditioning system according to the instructions in Section 9003.
STEP 96 Place the master disconnect switch in the ON position.
84547255A
Issued 11-11
Printed in E.C.
9004-22
NOTES
84547255A
Issued 11-11
Printed in E.C.
Section 9006
9006
LOADER
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
9006-2
TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 3 3 3 4 5 8 10
Printed in E.C.
9006-3
SPECIFICATIONS Special Torques Bolts for the Bucket Teeth .......................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH Replacement of the Tooth Points 3
1. Use a hammer and punch to drive the retaining pin (1) for the tooth point (2) out of the tooth shank (3), refer to the illustration on this page.
2
5
4
1
2. Remove the tooth point (2). 3. Install a new tooth point (2) on the tooth shank (3). 4. Install the retaining pin (1) into the tooth point (2) and tooth shank (3). Make sure the shoulder on the retaining pin is toward the cutting edge. Use a hammer to hit the retaining pin (1) until the retaining pin (1) is even with the outside of the tooth shank (3).
7 8
3 2
Replacement of the Bucket Teeth
6 10
1
1. Loosen and remove the nuts (4), hardened washers (5), and bolts (6) from the bucket teeth.
9
NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off.
7
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).
1. 2. 3. 4. 5.
RETAINING RING TOOTH POINT TOOTH SHANK NUT HARDENED WASHER
6. 7. 8. 9. 10.
BOLT CUTTING EDGE PLOW BOLT NUT CORNER TOOTH
BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner Teeth 1. Loosen and remove the nuts (9) and bolts (8) from the bucket corner teeth (10). NOTE: If wear of the bolt or nut makes removal difficult, the bolt or nut can be cut off. 2. Remove the corner tooth (10). 3. Install the new corner tooth (10) on the bucket cutting edge (7). 4. Use new nuts (9) and bolts (8) for the corner tooth being installed. 5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to 1090 pound-feet). 84547255A
Issued 11-11
Printed in E.C.
9006-4
RETURN TO DIG ADJUSTMENT
2 6 1
3 4
5
BS01C083
1. TARGET MOUNTING BRACKET 2. BUCKET CYLINDER
3. TARGET BAR 4. PROXIMITY SWITCH MOUNTING BRACKET
5. PROXIMITY SWITCH 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION
IMPORTANT: Before adjusting the return-to-dig, make sure that the target bar on the bucket linkage is not damaged. Slowly roll back and dump the bucket and make sure that the target bar stays the same distance from the switch. The switch mounting bracket protects the switch. Make sure the target bar cannot touch the switch when the bucket is dumped. 1. Park the machine on a level surface. Raise the lift arms until they are approximately horizontal and dump the bucket. Lower the bucket until the bucket edge is on the ground. 2. Apply the parking brake and stop the engine. 3. Loosen the bolts holding the target mounting bracket (1) to the tilt cylinder eye. Align the target mounting bracket (1) parallel to the tilt cylinder (2). Tighten the bolts, refer to the illustration on this page. 4. Loosen the bolts holding the proximity switch mounting bracket (4) to the tilt cylinder (2). Position the proximity switch (5) parallel to the target bar (3) and tighten the bolts. 5. Adjust the proximity switch (5) out towards the target bar (3), until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. Torque the jam nut to 6.7 Âą 0.6 Nm (5 Âą 0.5 pound-feet). NOTE: The proximity switch (5) must not protrude past the proximity switch guard (6). 6. Start the engine, position the bucket to the correct digging angle and stop the engine.
7. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). Slide the target bar (3) towards the proximity switch (5) until the face of the proximity switch (5) is completely covered. 8. Align the target bar (3) parallel to the tilt cylinder (2) and tighten the bolts. 9. Turn the ignition switch to the ON position. Do NOT start the engine. 10. Place the bucket control lever in the ROLLBACK position. 11. Loosen the bolts holding the target bar (3) to the target mounting bracket (1). 12. Slide the target bar (3) slowly away from the proximity switch (5), until the control lever returns to the center position. Tighten the bolts holding the target bar (3). 13. Check to make sure that the 3.2 to 5.0 mm (1/8 to 3/16 inch) gap is still maintained. 14. Start the engine. 15. Place the detent switch in the ON position and place the return to travel/float detent switch to the TRAVEL position. 16. Raise the lift arms approximately horizontal, and put the bucket in the fully dumped position. 17. Place the loader control lever in the ROLLBACK position, and verify that the electromagnet holds it in that position until the end of the target bar (3) passes in front of the proximity switch (5). 18. Lower the lift arms and verify that the bucket is at the correct digging angle.
84547255A
Issued 11-11
Printed in E.C.
9006-5
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
5 6
4
3 1
2
BS01C081
1. TARGET MOUNTING PLATE 2. HEIGHT CONTROL TARGET
3. PROXIMITY SWITCH 4. LIFT ARM
5. RETURN TO TRAVEL TARGET 6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
1. Park the machine on a level surface. 2. Start the engine and apply the parking brake. 3. Lower the lift arms and place the bucket flat on the ground. 4. Stop the engine.
6. Adjust the proximity switch (3) out towards the return to travel target (5) until an air gap of 3.2 to 5.0 mm (1/8 to 3/16 inch) is obtained. 7. Lock the proximity switch (3) in this position with the jam nut. Torque the jam nut to 6.7 ± 0.6 Nm (5 ± 0.5 pound-feet).
NOTE: To avoid damage to the proximity switch (3), it must be adjusted back to clear everything on the lift arm as it passes. Refer to the illustration on this page. WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operators compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine. CSM105
5. Position the return to travel target (5) opposite the proximity switch (3) and tighten it to the target mounting plate (1).
84547255A
Issued 11-11
Printed in E.C.
9006-6
2 A
3 B
1
BS01C082
1. HEIGHT CONTROL TARGET
2. RETURN TO TRAVEL TARGET
3. TARGET MOUNTING PLATE
MACHINE
A
APPROXIMATE RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT
B
APPROXIMATE RESULTING HEIGHT CONTROL HINGE PIN HEIGHT
W270C Z-Bar
67.0 mm (2.6 in)
540.0 mm (21.3 in)
75.0 mm (3.0 in)
4140.0 mm (163.0 in)
W270C Long Reach
50.0 mm (2.0 in)
693.0 mm (27.3 in)
60.0 mm (2.4 in)
4140.0 mm (163.0 in)
W300C Z-Bar
59.0 mm (2.3 in)
653.5 mm (25.7 in)
76.0 mm (3.0 in)
4220.0 mm (166.0 in)
W300C Long Reach
46.0 mm (1.8 in)
694.0 mm (27.3 in)
65.0 mm (2.6 in)
4220.0 mm (166.0 in)
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 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.
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.
11. Check to make sure the proximity switch (3) and all of the mounting bolts are tight. Refer to the illustration on page 5.
9. Tighten the height control target (1). 10. Position the return to travel target (2) using the table above.
84547255A
12. Start the engine. 13. Place the detent switch in the ON position, and set the return to travel/float detent switch to the return to travel position.
Issued 11-11
Printed in E.C.
9006-7 14. Place the loader control lever in the raise position and verify that the electromagnet holds it in that position until the height control target (2) passes in front of the proximity switch (3). Refer to the illustration on page 5. 15. With the lift arms still raised, place the loader control lever in the lower position and verify that the electromagnet holds it in that position until the return to travel target (5) passes in front of the proximity switch (3). Refer to the illustration on page 5. 16. Repeat steps 8 through 15 until the desired heights are reached. 17. Lower the bucket to the ground and stop the engine.
84547255A
Issued 11-11
Printed in E.C.
9006-8
REMOVING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) 1. Park the machine on a level surface and apply the parking brake. Roll the bucket all the way forward and lower the bucket to the floor. Stop the engine.
17. Remove from pivot pin (9) the hoses grease (26 and 27). Loosen and remove the bolt (19), flat washer (20) and spacer (21) that fasten the pivot pin (9) to the front frame.
2. Loosen the filler plug in the reservoir to release the air in the reservoir.
18. Raise the loader frame slightly. Use an acceptable driver and drive the pivot pin (9) out of the front frame. Do not lose the washers (18) and wipers (22) between the front frame and the loader frame (2).
3. Fasten a chain hoist to the cross member (1) of the loader frame (2), refer to the illustration on page 9. 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).
19. Remove the proximity switch cover Left-hand side of the machine only.
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.
(30).
30 32
6. Repeat Steps 4 and 5 for the left lift cylinder (8). 7. Start the engine. Roll the bucket back and lower the bucket so that the bucket is flat on the floor and fasten the chain hoist to a lift cylinder (4 or 8). 8. Raise the lift cylinder (4 or 8) slightly and remove the driver.
31
9. Repeat steps 7 and 8 for the other lift cylinder (4 or 8). 10. Connect the chain hoist to the bucket cylinder (8). 11. Loosen and remove the bolt (15), flat washer (16), and spacer (17) that fasten the pivot pin (7) for the piston rod eye of the bucket cylinder (8) to the bell crank (11). 12. Use an acceptable driver and drive the pivot pin (7) out of the piston rod eye of the bucket cylinder (8). 13. Raise the bucket cylinder (8) and use a chain or other acceptable holding equipment to hold the bucket cylinder (8) in place. 14. If the machine is equipped with auxiliary hydraulics, disconnect the two hoses from the tubes at the bracket on the right side of the loader frame (2). Install caps on the hoses and plugs in the tube fittings.
W230R083
20. Disconnect the electrical connector (31), remove the lock nut from the proximity switch (32) and remove the proximity switch (32) from the machine. Left-hand side of the machine only. 21. Repeat Steps 17 and 18 for the other pivot pin (9). 22. Raise the loader frame (2) out of the front frame. Carefully move the machine out of the loader frame (2).
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).
84547255A
Issued 11-11
Printed in E.C.
9006-9
28 29 26 6
27
8 22
18
9
5
9 21
29
20
17
1 7
5
19
22
25 10 16 15
3
4 12
13 14
2
11
24
23 W270R001
1. 2. 3. 4. 5. 6. 7. 8.
CROSS MEMBER LOADER FRAME PIVOT PIN 10.8 in (276 mm) LIFT CYLINDER PIVOT PIN 13.5 in (343 mm) BUCKET CYLINDER PIVOT PIN 11.6 in (295 mm) LIFT CYLINDER
9. 10. 11. 12. 13. 14. 15. 16.
PIVOT PIN 12.9 in (329 mm) PIVOT PIN 18.5 in (472 mm) BELL CRANK BOLT WASHER SPACER BOLT WASHER
17. 18. 19. 20. 21. 22. 23. 24.
SPACER WASHER BOLT WASHER SPACER WIPER DUMP LINK PIVOT PIN 11.6 in (295 mm)
25. 26. 27. 28. 29.
TUBE GREASE HOSE GREASE HOSE GREASE HOSE GREASE PIVOT PIN 10.4 in (266 mm)
LOADER FRAME ILLUSTRATION
84547255A
Issued 11-11
Printed in E.C.
9006-10
INSTALLING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) 1. Apply antiseize compound to the inner bores and outer bores for the pivot pins of the front frame, refer to the illustration on page 9. 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) that fasten the loader frame (2) to the front frame. 5. Start the pivot pins (9) 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) all the way. 7. Install the bolt (19), washer (20) and spacer (21) that fasten the pivot pins (9). Tighten the bolt. Install on the pivot pin (9) the hoses grease (26 and 27). 8. Install the proximity switch and cover. Left-hand side of the machine only. 9. Disconnect the chain hoist from the loader frame (2). 10. If the machine is equipped with front lamps, hold the front lamps in place and install the cap screws and lock washers that fasten the front lamps to the front frame. Tighten the cap screws. 11. If the machine is equipped with auxiliary hydraulics, remove the plugs from the tube fittings and the caps from the hoses. Connect the hoses to the tubes. 12. Connect the chain hoist to the bucket cylinder (6) and lower the bucket cylinder (6). 13. Start the engine and run the engine at low idle. 14. Have another person help you at this time. Move the bucket control lever as required to align the piston rod eye of the bucket cylinder (6) with the bell crank (11). Stop the engine. IMPORTANT: D o n o t u s e y o u r f i n g e r s t o check the alignment of the cylinder rod. Personal injury can be the result. 48-88
15. Install the pivot pin (7) in the bell crank (11) and the piston rod eye of the bucket cylinder (6). 16. Install the bolt (15), washer (16), and spacer (17) that fasten the pivot pin (7). Tighten the bolt.
84547255A
17. Disconnect the chain hoist from the bucket cylinder (6). 18. Fasten the chain hoist to one of the lift cylinders (4 or 8). 19. Raise the piston rod yoke of the lift cylinder (4 or 8) so the piston rod yoke is aligned with the loader frame (2). 20. Install a driver in the piston rod yoke and the loader frame (2). 21. Repeat Steps 18, 19, and 20 for the other lift cylinder (4 or 8). 22. Disconnect the chain hoist from the lift cylinder (4 or 8). 23. Start the engine. Raise the loader frame and roll the bucket all the way forward. Lower the bucket to the floor. Stop the engine. 24. Fasten the chain hoist to the cross member (1) of the loader frame (2). 25. Start the engine and run the engine at low idle. 26. Have another person help you at this time. Move the lift control lever as required to align the piston rod yoke of one of the lift cylinders (4 or 8) with the loader frame (2). IMPORTANT: D o n o t u s e y o u r f i n g e r s t o check the alignment of the cylinder rod. Personal injury can be the result. 48-88
27. Remove the driver and install the pivot pin (3). 28. Install the bolt (12), washer (13), and spacer(14) that fasten the pivot pin (3). Tighten the bolt. 29. Repeat Steps 26, 27, and 28 for the other lift cylinder (4 or 8). Stop the engine. 30. Lubricate the pivot pins with molydisulfide grease. 31. Disconnect the chain hoist from the cross member (1) of the loader frame (2). 32. Tighten the filler plug in the reservoir. 33. If the machine is equipped with auxiliary hydraulics, start the engine and run the engine at low idle. 34. Slowly extend and retract the clam cylinders four times to remove air from the auxiliary circuit. 35. Stop the engine, check the level of the oil in the reservoir, and check for leaks. Add oil to the reservoir as required. Issued 11-11
Printed in E.C.
Section 9007
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF)
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84547255A
Issued 11-11
3 3 4 4 9
Printed in E.C.
9007-3
ROLLOVER PROTECTIVE STRUCTURE (ROPS) CAB STRUCTURAL FRAME (CSF) Attention
The Rollover Protective Structure (ROPS) or Cab Structural Frame (CSF) is a special safety component of your machine.
After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site operation: ●
The ROPS or CSF structure MUST be replaced.
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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.
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All damaged parts MUST be replaced.
DO NOT attach any device to the ROPS or CSF for pulling purposes. The ROPS or CSF is a certified structural support and any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS or CSF MUST be replaced so that it will provide the same protection as a new ROPS or CSF.
DO NOT WELD, ATTEMPT TO STRAIGHTEN OR REPAIR THE ROPS OR CAB STRUCTURAL FRAME.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY After every 500 hours of operation or every six months, whichever comes first, do the following: 1. Check the torque on the CSF cab or ROPS canopy mounting bolts; torque should be 773 to 854 Nm (570 to 630 lb-ft). If necessary, tighten the bolts to the correct torque. 2. Check that seat belt mounting hardware is tight and seat belt is not cut or frayed. Check the torque on operators seat mounting bolts; torque should be 73 to 87 Nm (54 to 64 lb-ft). If necessary, tighten the bolts to the correct torque. Replace parts that are worn or damaged. WARNING: Grade 8 hardware is used to mount and anchor the ROPS. Parts used for replacement must be those shown in the parts catalog. 47-27A
84547255A
WARNING: Do not install attachments that will make the total weight of the machine more than the weight shown in the maximum gross vehicle weight section of the ROPS serial number plate. 47-26 WARNING: Do not change the ROPS in any way. Changes made to the ROPS which are not authorized, such as welding, drilling or cutting will make the ROPS weaker and decrease your protection. Replace the ROPS if it becomes damaged in any way. DO NOT TRY TO MAKE REPAIRS TO THE ROPS. 47-25
Issued 11-11
Printed in E.C.
9007-4
CSF CAB AND ROPS CANOPY Removal
STEP 4
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.
STEP 2
W270R571
If machine is equipped with a heater, put a 40 liters (10 Gallons) container below radiator drain. Remove cap and drain coolant into container. Install cap after coolant has drained.
STEP 5
W230R406
Put articulation lock in LOCKED position.
STEP 3 Put battery disconnect switch in OFF position.
BD06G191
Remove skirting under each side and front of cab.
84547255A
Issued 11-11
Printed in E.C.
9007-5
STEP 6
STEP 9 3
2
1
BD06G186
BD06G205
1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES
Remove the ducts from the machine.
STEP 7
If machine is equipped with a heater disconnect heater hoses (3), if machine is equipped with air conditioning discharge the air conditioning system, see section 9003, and disconnect the air conditioning hoses (2), cap and plug lines and fittings.
STEP 10
BD06G189
At RH rear, bottom of cab, disconnect ground strap from rear chassis.
STEP 8 BD06G193
Disconnect throttle connector and the air duct.
BD06G194
If machine is equipped with windshield washers, identify, tag, and disconnect front and rear windshield washer nozzle hoses from supply hoses.
84547255A
Issued 11-11
Printed in E.C.
9007-6
STEP 11
STEP 14
BD06F209
BD06G192
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.
Remove the front access panel.
STEP 15
STEP 12
BD06F210
Disconnect the electrical connectors for the remote control valve. BD06F207
Unlatch and open the window on the right hand side.
STEP 13
STEP 16 Loosen the filler cap on the reservoir to release any air in the reservoir. Connect a vacuum pump to the hydraulic reservoir, turn on the pump.
STEP 17 Put identification tags on each hose and disconnect one at a time from the remote control valve. Install plugs in the hoses and caps on the fittings to prevent entry of foreign matter into hydraulic system.
STEP 18 Push the hoses out of the bottom of the cab with the rubber gromment. BD06F208
Open and remove the access panel.
84547255A
Issued 11-11
Printed in E.C.
9007-7
STEP 19
STEP 22
BD06G187
BD06G184
Disconnect the electrical connectors, push connectors out of the bottom of the cab with the rubber gromment
Install lifting eyes in threaded holes at top of the cab.
STEP 23 Connect lifting equipment to cab at lifting eyes. Take up all slack in lifting equipment.
STEP 20
STEP 24 Remove nuts, bolts, and washers securing cab to rear chassis.
STEP 25
BD06G188
Raise floor mat up and away from brake pedal to gain access to mounting hardware.
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.
STEP 21
BD06G185
Remove hardware securing brake valve to cab floor. Let brake valve rest on the frame.
84547255A
Issued 11-11
Printed in E.C.
9007-8
1 2
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BC06G031
1. NUT 2. WASHER 3. RUBBER MOUNT
84547255A
4. RUBBER MOUNT 5. WASHER 6. BOLT
Issued 11-11
Printed in E.C.
9007-9
Installation
STEP 32
STEP 26 Check rubber mounts (3 an 4) for deterioration, tears, deformation, or other damage; replace rubber mounts as necessary.
STEP 27
BD06G188
Position floor mat.
STEP 33
BD01D388
Position cab over rear chassis then put wood blocks under brake valve. Slowly lower cab onto rear chassis making sure that brake valve is positioned so that brake pedal enters into cab. Remove wood blocks as cab is lowered onto brake valve.
STEP 28 Install washers, bolts, and nuts to secure cab to rear chassis. Tighten bolts to a torque of 773 to 854 Nm (570 to 630 pound feet)
STEP 29
BD06G192
Remove plugs from hoses and caps from fittings. Connect hoses to steering control valve following tags installed during removal. Remove and discard tags.
Disconnect lifting equipment from cab.
STEP 34
STEP 30 Remove lifting eyes.
STEP 31
BD06G193
Connect throttle connector and mount air duct.
BD06G185
Align mounting holes in brake valve with associated holes in cab or canopy floor. Install hardware to secure brake valve to floor. 84547255A
Issued 11-11
Printed in E.C.
9007-10
STEP 35
STEP 37
BD06G186
Install the ducts on the machine.
BD06G194
If machine is equipped with windshield washers, connect front and rear windshield washer nozzle hoses following tags installed during removal. Remove and discard tags.
STEP 36
STEP 38 3
2
1 BD06G189
At RH rear, bottom of cab, connect ground strap to rear chassis. BD06G205
1. TRANSMISSION FILTER 2. AIR CONDITIONING HOSES 3. HEATER HOSES
If machine is equipped with a heater, remove plugs from hoses and caps from fittings, connect heater hoses (3), if machine is equipped with air conditioning, remove plugs from hoses and caps from fittings, connect air conditioning hoses (2), charge the air conditioning system, see section 9003.
STEP 39 Remove plugs from hoses and caps from fittings. Connect hoses to joystick and two-lever controller and install in hose mounting grommet halves as shown on pages 11 and 12.
84547255A
Issued 11-11
Printed in E.C.
9007-11
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W230R021
1. 2. 3. 4. 5. 6. 7.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN
3 LEVER HOSE COLOR CODING
84547255A
W230R022
1. 2. 3. 4. 5. 6. 7.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN RED WHITE GREEN
JOYSTICK AND 1 LEVER HOSE COLOR CODING
Issued 11-11
Printed in E.C.
9007-12
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W230R023
1. 2. 3. 4. 5. 6.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN
2 LEVER HOSE COLOR CODING
84547255A
W230R020
1. 2. 3. 4. 5. 6.
PILOT TANK HOSE PILOT PRESSURE HOSE RED BLACK GREEN ORANGE BLACK GREEN YELLOW BLACK GREEN GREEN BLACK GREEN
JOYSTICK HOSE COLOR CODING
Issued 11-11
Printed in E.C.
9007-13
STEP 40
STEP 43
BD06F210
Connect the electrical connectors for the remote control valve.
STEP 41
BD06F208
Install and close the access panel.
STEP 44
BD06F209
Place the access panel into position, install and tighten the screw.
STEP 42
BD06F207
Close the right hand window.
STEP 45
BD06G187
Connect wiring harness connectors.
84547255A
BD06G191
Install skirting under each side and front of cab.
Issued 11-11
Printed in E.C.
9007-14
STEP 46
STEP 49 Start engine and run engine at low idle. Run engine at operating temperature for approximately five minutes to completely mix Ethylene Glycol and water. When coolant is at operating temperature, stop engine. When engine has cooled, check coolant level at reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.
STEP 50 Put articulation lock in OPERATING position.
W270R571
If machine is equipped with a heater and coolant was drained, check that coolant drain cap is tight.
STEP 47 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 56.8 liters (15 U.S. Gallons). Install radiator cap. Fill coolant reservoir up to FULL mark on reservoir.
STEP 48 Put battery disconnect switch in ON position.
84547255A
Issued 11-11
Printed in E.C.
Section 9010
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
84547255A
Copyright © 2011 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued November, 2011
9010
CAB GLASS INSTALLATION
9010-2
TABLE OF CONTENTS PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84547255A
Issued 11-11
Printed in E.C.
9010-3
PREPARATION FOR GLASS REPLACEMENT 1. Remove all of the damaged glass section and the silicone sealant from the window frame 2. Remove all the adhesive from the window frame. 3. The window frame recesses must be free of oil and dust. Clean the frame with rubbing alcohol with a clean rag. Do not reuse the rag.
5. Clean the new glass section. Apply a 25 mm (1 inch) wide band of glass primer (349-110) to the black ceramic painted edges of the window. 6. When replacing a front window section, a silicone forming tool is needed, refer to Figure 2. Use the template and instructions provided to make the tool.
4. Apply a 25 mm (1 inch) wide band of metal primer (349-108) to the window recesses.
GLASS INSTALLATION NOTE: Once the adhesive is applied, the glass must be installed within 5 minutes. If the glass is not installed within the 5 minute period, the adhesive must be removed and applied again. 1. Apply a 10 mm (3/8 inch) diameter bead of adhesive (345-135) to the primed surface approximately 12 mm (1/2 inch) from edge. 2. The adhesive may be applied either to the primed glass or to the primed metal frame. DO NOT apply the adhesive to both the glass and the frame.
3. For front glass installations install a glass spacer 12 mm (1/2 inch) from each corner on bottom edge of each glass section, refer to Figure 3. 4. Install the glass. The glass edges must not contact the metal frame at any point. 5. For front glass installations position the glass to maintain a uniform 3 mm (1/8 inch) gap between front and front side glass sections.
NOTE: When replacing two or more sections of the front glass apply extra adhesive in corners, refer to Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS 1. Clean the edges of the front center and front side windows. Use glass cleaning primer. 2. Apply masking tape to the inside edge of each glass section next to the gap. 3. Apply the polyester tape on top of the masking tape across the inside side gap. Do not push the tape into the gap. 4. Apply masking tape to the outside edge of each glass section. Align the edge of the tape with edge of glass on both sections. 5. The tape must be smooth to get the best result when using the silicone forming tool.
84547255A
6. Fill the joint with the clear silicone sealant (114328A1), refer to Figure 1. The silicone must completely penetrate and fill the gap between the glass sections. The sealant must extend at least 1.5 mm (1/16 inch) above the outside surface of the glass section for the length of the gap. Be sure the sealant fills against the adhesive at each end of the joint. 7. Remove the polyester tape from the inside joint. 8. Remove the extra silicone from the outside joint by carefully sliding the forming tool down the length of the joint. The tool must remain in contact with the glass sections during this process. Refer to Figure 2 for forming tool template.
Issued 11-11
Printed in E.C.
9010-4
1
9. Remove all the silicone from the forming tool immediately after use.
2
10. Remove the outside tape from the glass sections. 11. Remove the extra silicone sealant from the inside joint by carefully sliding the forming tool down the length of the joint. 12. Remove all the silicone from the forming tool immediately after use.
3
13. Remove the inside joint masking tape.
4 498L93
1. FRONT RH SIDE GLASS 2. FRONT CENTER GLASS
3. SILICONE BEFORE SMOOTHING 4. SILICONE AFTER SMOOTHING
FIGURE 1. SILICONE APPLICATION
NOTE: Make the forming tool from 10 mm (3/8 inch) plexiglass, or wood. Sand all radius and edges smooth.
14. If two or more glass sections are being replaced, use the procedure on the second joint. 15. Apply the gray silicone sealant above the front center, front side or rear windows for additional leak protection. 16. Apply the gray silicone sealant (345-174) down approximately 50 mm (2 inches) from the top on each front side window replaced, refer to Figure 3. 17. Apply the gray silicone sealant (345-174) down approximately 50 mm (2 inches) from the top edge of the rear glass, if replaced.
6 MM (1/2 INCH) R
120°
120°
4 MM (3/16 INCH) R 496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE 84547255A
Issued 11-11
Printed in E.C.
9010-5
5
2 1 3 4
6 2
1
497L93
1. SIDE GLASS ADHESIVE 2. CENTER GLASS ADHESIVE
4. RIGHT HAND SIDE GLASS SPACER LOCATIONS 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES) FROM TOP OF FRONT SIDE GLASS 3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF CENTER AND SIDE PANELS CENTER GLASS FIGURE 3 SILICONE APPLICATION
NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set. 84547255A
Issued 11-11
Printed in E.C.
9010-6
NOTES
84547255A
Issued 11-11
Printed in E.C.